Prism-Shaped Static Mixer Element for Dental Applications
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Solution Overview
Problem
Existing static mixers with helical mixing elements or longitudinally and transversely arranged mixing chambers face issues with thermal stress and tool damage due to delicate designs, leading to inefficient cooling and production disruptions, especially in mass injection molding.
Innovation Solution
A mixing element with prism-shaped flow-influencing elements, such as orthodiagonal quadrilaterals or rhombuses, arranged perpendicular to the central part, forming diamond-shaped mixing chambers that create backpressure for optimal mixing while allowing economical injection molding and easy temperature control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If delicate tool sections are used to form mixing chambers with complex cavities and openings, then mixing performance is improved, but tool reliability deteriorates due to thermal stress and bursting
Solution Approach 1:
The mixing element is divided into multiple individual mixing chambers arranged in series, each chamber being a simple prism shape. This segmentation allows each chamber to be structurally simple and robust while collectively achieving complex mixing functionality through their arrangement along the flow path.
Solution Approach 2:
Instead of creating complex internal cavities within a single monolithic tool section, the invention inverts the approach by using multiple simple prism-shaped chambers whose external arrangement creates the mixing effect. This eliminates the need for delicate internal cavities that are prone to bursting under thermal stress.
2Manufacturing precision
If complex mixing chamber geometries are implemented, then mixing performance is improved, but ease of manufacture deteriorates due to difficult cooling and production delays
Solution Approach 1:
The mixing element consists of multiple discrete prism-shaped mixing chambers that can be independently manufactured and assembled. This segmentation simplifies the manufacturing of each individual chamber, making cooling easier and more efficient while maintaining overall mixing performance through the series arrangement.
Solution Approach 2:
The invention uses simple prism shapes with flat surfaces and straight edges rather than complex curved geometries. This simplifies manufacturing, allows for easier cooling channel integration, and enables more efficient production cycles while achieving effective mixing through the geometric arrangement of the prisms.
3Manufacturing precision
If longer mixing elements are used to achieve thorough mixing, then mixing performance is improved, but device complexity increases leading to unnecessary shearing and restricted field of vision
Solution Approach 1:
The mixing element is segmented into multiple compact prism chambers arranged in series, achieving thorough mixing within a short overall length. This segmented approach maximizes mixing efficiency per unit length while minimizing the total longitudinal extension, thereby reducing unnecessary shearing and maintaining a clear field of vision during dental application.
Solution Approach 2:
Instead of extending the mixing element longitudinally, the invention achieves thorough mixing by utilizing transverse arrangements of the prism chambers and multiple flow paths within a compact structure. This dimensional optimization reduces the longitudinal footprint while maintaining effective mixing performance.
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 provides efficient mixing of low to high-viscosity components, reduces shearing, and minimizes tool damage, ensuring continuous production with improved thermal management.
Implementation Method 1
forming diamond-shaped mixing chambers that create backpressure for optimal mixing
Implementation Method 2
divide, swirl, and recombine the respective components
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
The invention relates to a mixing element (1) for a static mixer (0), in particular a dental static mixer, for mixing low- to high-viscosity components, comprising a planar central part (10) which extends along a longitudinal axis L and has a front face (10A) and a rear face (10B) located opposite the front face (10A), wherein arranged on the front face (10A) and/or on the rear face (10B) of the central part (10) are at least two flow-influencing elements (101A, 102A, 101B, 102B) which each surround at least one through-opening (101.1, 101.2, 102.1, 102.2) located in the central part (10) and which are each in the form of prism lateral surfaces that are substantially perpendicular to the front face (10A) and/or the rear face (10B), in particular prism lateral surfaces based on an orthodiagonal quadrilateral, pairs of which elements overlap or are connected to one another at a lateral edge (1011A/1023A, 1011B/1023B). The invention also relates to a static mixer (0), in particular a dental static mixer, comprising the mixing element, and to the use thereof for mixing low- to high-viscosity components.