Static Mixer With Nozzle-Driven Mixing Without Moving Parts

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Solution Overview

Problem

Conventional static mixers for 2-component materials require additional energy inputs through external dynamic mixing systems, leading to increased energy expenditure and maintenance costs, and lack solutions that do not use movable components.

Innovation Solution

A static mixer design that includes a port, mixing chamber, and an impact plate within the chamber, where a nozzle accelerates the starting material to impact the plate, achieving mixing and activation without external energy input, using a nozzle with a narrowing diameter to generate an accelerated jet.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If additional dynamic mixing systems or high-pressure impact mixing systems are used, then mixing capability is improved, but energy expenditure increases

Engineering Contradiction:

Improvemixing capabilityVSAvoidenergy expenditure

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The system uses the kinetic energy of the injected material itself to drive the mixing process. The material jet impacts the impact plate, generating mixing action without requiring external energy input from motors or dynamic mixing systems. The mixing chamber design allows the material flow to self-generate the mixing effect through its own motion and impact.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces external mechanical mixing systems (motors, dynamic mixing heads, high-pressure impact systems) with a passive mixing mechanism. The mixing action is achieved through the natural impact of the material jet against the impact plate and the resulting flow patterns in the mixing chamber, eliminating the need for additional mechanical energy input devices.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If additional dynamic mixing systems are used, then mixing capability is improved, but maintenance expenditure increases

Engineering Contradiction:

Improvemixing capabilityVSAvoidmaintenance expenditure

Core Design Contradiction:

ProductivityVSEase of repair

Solution Approach 1:

The mixing system operates without external mechanical components that would require maintenance. The passive mixing mechanism uses only the material flow and impact plate, which have no moving parts, motors, or complex mechanical systems that would generate maintenance requirements or operational complexity.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

By replacing dynamic mixing systems with a passive impact-based mixing mechanism, the patent eliminates motors, moving mixing elements, and complex mechanical assemblies that would require maintenance. The simplified system with only static components (mixing chamber, impact plate, nozzle) significantly reduces maintenance expenditure and operational complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If movable mixing elements are used, then mixing efficiency is improved, but device complexity increases

Engineering Contradiction:

Improvemixing efficiencyVSAvoiddevice complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The mixing action is generated self-generated by the material flow itself impacting the impact plate and creating mixing patterns in the chamber. No external motors, moving mixing elements, or complex mechanical systems are required. The system uses the kinetic energy of the injected material to create the mixing effect passively.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces movable mixing elements (motors, dynamic mixing heads, driven mixing chambers) with a static mixing chamber and impact plate configuration. The mixing action is achieved through the impact of the material jet and the resulting flow patterns, eliminating all moving mechanical components and significantly reducing device complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 static mixer efficiently mixes and activates 2-component materials like polyurethane foam without movable components, reducing energy and maintenance costs while maintaining mixing efficiency.

Implementation Method 1

A first nozzle is arranged between the port and the mixing chamber, wherein the mixing chamber is adapted to mix and/or activate an accelerated jet of the at least one component

Methodology Applied

Scientific EffectFluid acceleration through nozzle: Bernoulli Effect

Implementation Method 2

the accelerated jet impacts the impact plate

Methodology Applied

Scientific EffectImpact force: Impact Force

Data Source

PatentUS20250296055A1Static Mixer

Publication Date: 2025.09.25 ATLAS COPCO IAS GMBH

AI summary

A static mixer for mixing and/or activating at least one component is provided. The static mixer comprises a port for receiving a starting material containing at least the one component, a mixing chamber arranged downstream of the port, and an impact plate within the mixing chamber. A first nozzle is arranged between the port and the mixing chamber, wherein the mixing chamber is adapted to mix and/or activate an accelerated jet of the at least one component, and provide, wherein the accelerated jet impacts the impact plate.