Open-Shell Shearing Tools for Dissolver Mixing
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Solution Overview
Problem
Conventional dissolvers with high-speed agitator discs often lead to overheating and unwanted bubble formation in mixtures, particularly in food products, which negatively affects taste and texture.
Innovation Solution
A dissolver design featuring open-shell shearing tools that break up particles at gaps, allowing for effective recirculation at lower rotational speeds, preventing overheating and bubble formation, and suitable for dispersing and homogenizing foods and other materials like paints and paper production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the agitator discs rotate quickly to achieve good recirculation, then the mixing efficiency is improved, but the material is heated and bubbles are formed
Solution Approach 1:
The dissolver divides the mixing function into multiple shearing tools arranged on the holder, each creating localized shear zones. This segmentation allows recirculation to be achieved through distributed particle breakdown rather than relying on high-speed rotation of a single agitator, thereby reducing overall heat generation while maintaining mixing effectiveness.
Solution Approach 2:
The invention changes the operational parameters by using open-shell shearing tools that create gaps for particle breakdown. This design enables effective recirculation at lower rotational speeds compared to conventional solid agitator discs, directly addressing the temperature issue while maintaining productivity.
2Productivity
If the agitator discs rotate quickly to achieve good recirculation, then the mixing efficiency is improved, but unwanted bubble formation occurs
Solution Approach 1:
The multiple shearing tools on the holder create distributed mixing zones that gently recirculate material without the intense vortex formation caused by high-speed single-disc agitators. This segmented approach achieves recirculation while minimizing bubble entrainment.
Solution Approach 2:
By changing the agitator design from solid discs to open-shell shearing tools with gaps, the invention enables effective recirculation at lower rotational speeds, directly reducing the energy input that causes bubble formation while maintaining mixing productivity.
3Device complexity
If conventional solid agitator discs are used, then structural simplicity is maintained, but particle breakdown and recirculation are insufficient at low speeds
Solution Approach 1:
The holder is equipped with multiple shearing tools that segment the particle breakdown function across several locations. This segmentation provides effective particle size reduction and recirculation at low speeds, overcoming the limitation of simple solid discs while maintaining reasonable structural complexity.
Solution Approach 2:
The open-shell shearing tools create localized high-shear zones at the gaps where particles are broken up. This local quality enhancement provides intense particle breakdown exactly where needed, achieving high productivity without requiring high overall rotational speeds or complex multi-component agitators.
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 dissolver achieves good mixing results without overheating or bubble formation, enabling efficient processing of larger mix volumes with reduced energy consumption and potentially reducing a two-stage process to one stage.
Implementation Method 1
several shearing tools (14) arranged on a surface (13) of the holder (12) and extending away from the surface, the shearing tools being designed as open shells on or towards a side facing away from the surface, the outer surfaces of which enclose gaps with the surface
Data Source
Figure 1
Figure 2~4
Figure 5~6
AI summary
The dissolver (1) has a mixing tank (2) in which a mixture (3) is provided, and a holder (12) that is arranged in the tank and rotates relative to the tank at a rotation axis (11). Multiple shearing tools (14) are arranged on and extend away from an upper surface (13) of the holder. A drive (10) i.e. electric motor, rotates the holder at the rotation axis. The shearing tools are formed as cups that are open to a side turned away from the upper surface of the holder. Outer surface area of each tool is embedded at the upper surface of the holder to form a gap (19).