Interlocking Multi-Rotor Mixer for Polymer Temperature Control
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Solution Overview
Problem
Existing mixers for polymer processing, particularly in the rubber industry, face inefficiencies in mixing performance and temperature control, leading to suboptimal mixing quality and throughput.
Innovation Solution
The mixer employs multiple interlocking rotors within a mixing chamber, allowing for enhanced mixing performance through increased engagement areas and improved temperature control, with features like internal temperature sensors and dispensing devices to enhance mixing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If two rotors are arranged in the mixing chamber, then the device complexity is low, but the mixing performance and engagement area are insufficient
Solution Approach 1:
The mixing chamber is segmented by introducing more than two rotors, each responsible for specific zones. This segmentation increases the total engagement area and improves mixing performance by distributing the mixing workload across multiple rotors, directly resolving the contradiction between mixing performance and device complexity
Solution Approach 2:
The patent transitions from a conventional two-rotor configuration to a multi-rotor arrangement where rotors are positioned at different heights and angular positions within the mixing chamber. This dimensional expansion creates multiple engagement areas simultaneously, increasing overall mixing effectiveness without proportionally increasing complexity
2Area of stationary object
If more than two rotors are arranged in the mixing chamber, then the engagement area and mixing performance are improved, but the device complexity increases
Solution Approach 1:
Multiple rotors are merged into a coordinated system where each rotor contributes to the overall mixing action. The rotors work synergistically with interlocking teeth that engage across rotor boundaries, creating a unified mixing mechanism that achieves large engagement area without linearly increasing system complexity
Solution Approach 2:
Each rotor in the multi-rotor system is designed with universal functionality, featuring interlocking teeth that can engage with adjacent rotors and perform mixing functions in multiple zones. This multi-functionality allows each rotor to contribute to several engagement areas, increasing total effective area without proportionally increasing the number of components
3Manufacturing precision
If conventional mixing is used, then the device structure is simple, but the temperature control and mixing quality are suboptimal
Solution Approach 1:
Temperature sensors are installed within the mixing chamber to provide real-time feedback on mixing temperature. This feedback enables precise temperature control during the mixing process, ensuring optimal mixing quality while managing the increased structural complexity through intelligent monitoring and control
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution achieves higher mixing quality and throughput while reducing material loss and operational costs, enabling better temperature control and incorporation of additives.
Implementation Method 1
the mixing material is mixed by rotating the rotors
Implementation Method 2
The addition of one or more components, in particular a polymer, can be carried out via a plunger that presses the components into the mixing chamber
Implementation Method 3
mixture components, for example powdery components, can accumulate on the lower rotor during filling
Data Source
AI summary
A mixer (1) for mixing a mixing material (13) in polymer processing comprises a mixing chamber (2) and more than two rotors (6a-6d) arranged in the mixing chamber (2). In particular, the rotors (6a-6d) can be configured to interlock.