Positive Displacement Mixer for Homogeneous Small-Batch Mixing
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Solution Overview
Problem
Current mixing technologies face challenges in producing customized, small-batch products efficiently, particularly in achieving homogeneity and minimizing material loss and contamination, especially when dealing with high viscosity and immiscible fluids, and require specific packaging dimensions and headspace, which limits scalability and throughput.
Innovation Solution
A positive displacement mixer utilizing three or more positive displacement elements that mix materials through a 'split-and-recombine' principle, employing laminar flow to achieve homogeneity, allowing for self-cleaning and efficient mixing of small volumes without washouts, and accommodating various packaging shapes and sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional mixing equipment is used for small batches, then mixing capacity is sufficient, but homogeneity is difficult to achieve and material loss increases
Solution Approach 1:
The mixing system is segmented into multiple independently controllable mixing zones or chambers, allowing materials to be mixed in stages. This segmentation enables better control over the mixing process for small batches, achieving homogeneity while minimizing material loss through controlled transfer between zones.
Solution Approach 2:
The mixing equipment employs dynamic adjustment capabilities where mixing parameters (speed, time, intensity) can be changed during the mixing process. This dynamic control allows optimization for small batch sizes while maintaining homogeneity and reducing material loss through adaptive process control.
2Productivity
If traditional mixing equipment is used for small batches, then mixing capacity is sufficient, but washouts are required between batches of different compositions
Solution Approach 1:
The design extracts or separates the mixing chambers in a way that allows easy removal or isolation of individual mixing zones. This enables quick cleaning or replacement of specific chambers without requiring complete disassembly or washout of the entire system, thereby maintaining productivity while reducing cleaning complexity.
Solution Approach 2:
The system incorporates design features that facilitate easy discarding of residual materials and recovering of cleaning resources. This may include self-draining chambers, accessible cleaning ports, or modular components that can be quickly cleaned and reused, reducing both time and complexity of washout procedures between batches.
3Adaptability or versatility
If small batch mixing is performed, then customization is enabled, but higher loss and more washouts are needed compared to mass production
Solution Approach 1:
The mixing system is designed with universal features that allow it to handle multiple product types and batch sizes using the same core mechanism. This multi-functionality enables customization for different products while minimizing material loss through consistent, optimized mixing processes that work efficiently across various applications.
Solution Approach 2:
The system allows for parameter changes (volume, composition, mixing intensity) to be adjusted for customization without fundamentally changing the mixing process. This enables small batch customization while maintaining efficient mixing that minimizes material loss, as the core mixing mechanism remains optimized for the task.
4Adaptability or versatility
If small batch mixing is performed, then customization is enabled, but higher loss and more washouts are needed compared to mass production
Solution Approach 1:
The system performs preliminary actions such as pre-positioning of materials, pre-setting of mixing parameters, or pre-cleaning of chambers before each small batch mixing operation. This preliminary preparation enables quick customization for different products while maintaining high throughput by minimizing setup time and avoiding extensive washout procedures between batches.
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 ensures minimal material loss and contamination, achieves efficient mixing of high viscosity and immiscible fluids, and allows for flexible packaging, maintaining product integrity and density without aeration or foaming, thereby enhancing scalability and throughput.
Implementation Method 1
mixing the one or more materials using laminar flow by a mixing method selected from the group consisting of Method A, Method B, Method C
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A positive displacement mixer (1) and method for mixing a product that mixes at least two materials into a homogenous product. The positive displacement mixer (1) has at least one positive displacement element having a length, a primary compartment (23), and a moving element (13), and two or more minor positive displacement elements each having a length, a minor compartment (21, 22), and a moving element (11, 12). The primary compartment (23) and the minor compartments (21, 22) are fluidly connected and during mixing the primary compartment (23) and minor compartments (21, 22) are closed to the atmosphere.