Rotating Surface Mixing Apparatus for Nanoparticle Dispersion
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Solution Overview
Problem
Existing mixing technologies face challenges in achieving homogeneous dispersion of particles, particularly nanoparticles, due to agglomeration issues, which require high shear stresses exceeding the binding energy of particle aggregates, and are inefficient in viscous media.
Innovation Solution
The apparatus employs high shear, cavitation, and impacting forces using rotating surfaces with designed profiles to disperse substances, generating high shear stresses and cavitation, effectively breaking down particle agglomerations and achieving complete dispersion in both low and high viscosity liquids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional high shear mixing is used to disperse particles, then particle dispersion is achieved, but high shear stresses exceeding binding energy are required and mixing efficiency is poor in viscous media
Solution Approach 1:
The patent combines multiple mixing mechanisms (high shear mixing, cavitation, and impacting forces) into a single integrated mixing device. The rotor combines all these forces to achieve superior particle dispersion without requiring excessively high shear stresses, resolving the contradiction between dispersion quality and power requirements
Solution Approach 2:
The patent utilizes cavitation (a form of mechanical vibration and shock) to break down particle agglomerates. The cavitation effect generates micro-jets and shock waves that effectively disperse particles in viscous media without requiring sustained high shear stresses, thus improving dispersion quality while reducing power requirements
2Manufacturing precision
If high shear stresses are applied to break down particle agglomerations, then particle dispersion is improved, but energy consumption increases
Solution Approach 1:
By merging cavitation, impacting forces, and high shear mixing into a single rotor system, the patent achieves effective particle dispersion through multiple mechanisms working simultaneously. This combination allows the system to reach the required dispersion quality with lower overall energy consumption compared to conventional high shear mixing alone
Solution Approach 2:
The cavitation effect operates in a periodic manner through the rotation of the rotor, creating intermittent shock waves and micro-jets that progressively break down agglomerates. This periodic action is more energy-efficient than continuous high shear stress application, as the cavitation events occur in cycles rather than requiring sustained maximum power
3Ease of operation
If conventional mixing equipment is used, then mixing operation is simple, but homogeneous dispersion of nanoparticles is not achieved due to agglomeration
Solution Approach 1:
The patent integrates multiple sophisticated mixing mechanisms (high shear, cavitation, impacting) into a single rotor that operates with simple rotational motion. This allows the complex dispersion process to be achieved through a simple operational action, maintaining ease of operation while dramatically improving homogeneous dispersion quality
Solution Approach 2:
The patent replaces conventional simple mechanical mixing with a multi-mechanism system that incorporates cavitation (acoustic/mechanical vibration) and impacting forces in addition to high shear mixing. This substitution enables effective nanoparticle dispersion while maintaining simple operational procedures through the single rotational motion of the rotor
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 achieves superior dispersion quality compared to conventional high shear mixing, as demonstrated by complete dispersion of nanoparticles in various polymer matrices, even at lower rotation speeds and viscosities, with improved mixing efficiency and reduced agglomeration.
Implementation Method 1
The profile of at least one of the first surface and the second surface comprises alternate curved surfaces... designed or configured to mix and disperse the two or more substances flowing through the mixing gap together using one or more of high shear, cavitation and impacting forces
Implementation Method 2
designed or configured to mix and disperse the two or more substances flowing through the mixing gap together using one or more of high shear, cavitation and impacting forces
Implementation Method 3
designed or configured to mix and disperse the two or more substances flowing through the mixing gap together using one or more of high shear, cavitation and impacting forces
Data Source
AI summary
An apparatus for mixing two or more substances, the apparatus comprising: (a) a first surface, the first surface having a first profile, (b) a second surface spaced apart from the first surface, the second surface having a second profile, (c) a mixing gap formed between the first and second profiles of the first surface and the second surface, and (d) at least one input channel in liquid communication with the mixing gap, to feed the mixing gap with the two or more substances to be mixed.