Reconfigurable Mixing Baffle for Static Mixer
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Solution Overview
Problem
The manufacturing of static mixers with high numbers of intersecting blades is complex, costly, and time-consuming due to the difficulty in molding undercuts and achieving precise tolerances, which complicates assembly and increases the length of the mixer.
Innovation Solution
A reconfigurable mixing baffle with moveable elements that change configuration upon insertion into a tubular conduit, forming a lattice structure with undercuts, allowing for molding as a unitary stack and reducing assembly complexity by using deformable materials or living hinges for pivotal movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mixing baffles with a high number of intersecting blades are used to mix mass fluid flow more rapidly, then mixing efficiency is improved, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The mixing baffle employs moveable mixing elements that can pivot between a first configuration for manufacturing and a second configuration for mixing operations. This dynamic reconfiguration allows the baffle to achieve complex lattice structures with high numbers of intersecting blades during mixing while maintaining simple geometries during manufacturing, thus resolving the contradiction between mixing efficiency and manufacturing ease.
Solution Approach 2:
The mixing elements change their geometric parameters (orientation, position, and configuration) based on the operational mode. During manufacturing, elements are in a first configuration with simplified geometry, while during mixing operations, they pivot to a second configuration forming complex intersecting blade patterns. This parameter change enables the same component to satisfy both manufacturing simplicity and mixing efficiency requirements.
2Length of stationary object
If mixing baffles with a high number of intersecting blades are used to shorten the static mixer length, then device compactness is improved, but manufacturing precision requirements increase
Solution Approach 1:
The moveable mixing elements pivot to their final mixing configuration automatically upon insertion into the conduit, eliminating the need for precision machining of complex geometries during manufacturing. The elements self-adjust to the correct angles and positions through their pivotal mechanism, reducing tolerance requirements while achieving the compact mixer length through the formed lattice structure.
Solution Approach 2:
The mixing baffle is divided into multiple separate mixing elements that can be manufactured individually with standard tolerances and then assembled through pivotal connections. This segmentation allows each element to be manufactured with reasonable precision rather than requiring the entire complex lattice structure to be molded with tight tolerances, thus reducing overall manufacturing precision requirements while achieving compact mixer length.
3Adaptability or versatility
If mixing baffles are molded separately rather than as a unitary stack, then adaptability to different configurations is improved, but assembly complexity and time increase
Solution Approach 1:
Multiple mixing baffles are molded as a single unitary stack with the mixing elements in their first configuration, then the entire stack is inserted into the conduit where all elements simultaneously pivot to their second configuration. This merging approach maintains the adaptability of having multiple baffles while eliminating the complexity of assembling separate components, as the unitary stack is inserted and reconfigured as one piece.
Solution Approach 2:
The mixing elements are pre-positioned in their first configuration during molding, which is the configuration that is easiest to manufacture. The pivotal movement to the second configuration occurs automatically upon insertion into the conduit, performing the reconfiguration action in advance of actual mixing operations. This preliminary positioning simplifies manufacturing while maintaining the ability to achieve the required mixing configuration.
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 enables efficient mixing over a shorter length, simplifies manufacturing and assembly, and ensures a reliable frictional fit within the conduit, reducing tolerance inconsistencies and manufacturing costs.
Implementation Method 1
Each of the first set of moveable mixing elements is sized to elastically deform or otherwise move from the first configuration to the second configuration when positioned in a tubular conduit
Implementation Method 2
Each of the first set of moveable mixing elements includes an inner end connected to the mixing element support structure and a chamfered outer end configured to frictionally engage the tubular conduit
Data Source
AI summary
A mixing baffle for mixing a fluid flow includes a longitudinal support structure and a first set of moveable mixing elements integrally molded with and extending from the longitudinal support structure. The first set of moveable mixing elements are molded in a first configuration and deform to a second configuration. The first set of moveable mixing elements may deform when the mixing baffle is inserted into a conduit. A static mixer for mixing a fluid includes a conduit and the mixing baffle inserted in the conduit.