Plastic Static Spray Mixer for Uniform Multicomponent Plastic Application
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Solution Overview
Problem
Existing technologies face challenges in achieving uniform and continuous application of viscous multicomponent plastics onto substrates, often requiring heating of components or varying pressures which can be laborious and inconsistent.
Innovation Solution
A device comprising a dosing valve and a static spray mixer with a plastic mixing element, where the mixer housing and mixing element are made of plastic, allowing for efficient mixing and atomization of the multicomponent plastic, enabling homogeneous and uniform application without the need for heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If components are heated beforehand to achieve uniform application of viscous multicomponent plastic, then the application quality improves, but the operational complexity and labor requirements increase
Solution Approach 1:
The patent changes the material parameter of the mixing element from metal to plastic, which has different thermal properties. The plastic mixing element does not conduct heat as readily as metal, allowing the viscous multicomponent plastic to be mixed and applied without preliminary heating, thus achieving uniform application while avoiding the complexity of heating systems
Solution Approach 2:
The patent replaces the thermal field approach (heating components before mixing) with a mechanical field approach (using the plastic mixing element's geometry and flow dynamics to achieve uniform mixing at ambient temperature), thereby eliminating the need for heating equipment and reducing operational complexity
2Manufacturing precision
If pressure is varied to improve application quality of viscous multicomponent plastic, then the spray characteristics improve, but the process stability deteriorates
Solution Approach 1:
The patent changes the material parameter of the mixing element to plastic, which alters the flow characteristics and pressure distribution within the mixer. This enables consistent spray quality to be achieved through optimized plastic material properties and mixer geometry rather than through active pressure variation, thereby maintaining process stability
3Productivity
If a one-piece plastic mixing element is used, then the mixing efficiency and compactness improve, but the manufacturing complexity of the mixing element increases
Solution Approach 1:
The patent extracts the mixing element as a separate, standalone component that can be manufactured independently using injection molding technology. This allows the complex one-piece plastic mixing element to be produced efficiently through specialized manufacturing processes, decoupling the manufacturing complexity from the assembly process and enabling high mixing efficiency without compromising overall ease of manufacture
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 device effectively sprays viscous multicomponent plastics onto substrates with improved homogeneity and layer thickness, maintaining performance over a longer period and reducing operational complexity.
Implementation Method 1
An atomization sleeve is disposed on the distal end of the mixer housing. The atomization sleeve has an inlet for a pressurized atomizing medium. This atomizing medium can be compressed air, for example. The atomization makes it possible to apply the mixture of the two components emerging from the outlet nozzle to the substrate in the form of a spray jet or spray mist
Implementation Method 2
a dosing valve which can be controlled by compressed air as pressure medium and has a first valve inlet for a first component, a second valve inlet for a second component and a valve outlet
Data Source
AI summary
The invention relates to a device for applying a multicomponent plastic to a substrate and a method of using same, the device comprising: a dosing valve which can be controlled by compressed air as pressure medium and has a first valve inlet for a first component, a second valve inlet for a second component and a valve outlet; a static spray mixer comprising a tubular mixer housing extending along a longitudinal axis and having a valve-side end and a distal end, a mixing element disposed within the mixer housing for producing a component mixture, and an atomization sleeve disposed on the distal end of the mixer housing and having an inlet for a pressurized atomizing medium wherein the mixer housing and the mixing element are made of plastic and the mixing element is a one-piece component that is inserted into the mixer housing.