Rotating Surface Mixing Apparatus for Uniform Dispersion
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Solution Overview
Problem
Current methods for mixing and dispersing a dispersed phase in a medium are inefficient, particularly in achieving uniform distribution and high surface area contact between nano and micro objects and the medium, which is crucial for effective mass transfer and composite formation.
Innovation Solution
The use of rotating surfaces with atomizing apparatuses and interfacial dispersion devices that generate aerosolized constituents, which are deposited into a receptive medium, followed by shear and extensional flow deformation to form thin films and projectiles, enhancing dispersion through recirculation and collection processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional mixing methods are used, then the process is simple, but the dispersion uniformity and surface area contact are insufficient
Solution Approach 1:
The mixing process is segmented into distinct functional zones: a high-shear mixing zone with rotating elements for initial dispersion, a circulation zone for continuous flow, and a discharge zone. This segmentation allows each zone to perform its specific function optimally, achieving uniform dispersion through progressive breakdown and redistribution of the dispersed phase
Solution Approach 2:
The mixing apparatus employs rotating mixing elements with variable speeds, where the rotor rotates at a different speed than the stator, creating dynamic high-shear zones. The circulation system also introduces dynamic flow patterns that continuously renew the mixing interface, enhancing dispersion uniformity while managing system complexity through controlled motion
2Productivity
If conventional mixing methods are used, then the equipment is simple, but the mass transfer efficiency is low
Solution Approach 1:
The system maintains continuous mass transfer through a circulation loop that continuously pumps the mixture from the discharge zone back to the mixing zone. This continuous circulation ensures that fresh medium is constantly exposed to the dispersed phase, maximizing mass transfer efficiency without requiring excessively complex batch processing systems
Solution Approach 2:
A hydraulic circulation system with pumps and piping is integrated to maintain continuous flow through the mixing apparatus. The hydraulic system enables controlled circulation rates and pressure management, enhancing mass transfer efficiency while keeping the overall system design manageable through standardized fluid handling components
3Manufacturing precision
If high shear mixing is applied, then the dispersion quality improves, but the energy consumption increases
Solution Approach 1:
High shear mixing is applied locally in specific zones where the rotor and stator interact, rather than throughout the entire mixing volume. This localized high-shear application achieves effective dispersion at the critical interface while minimizing energy consumption in regions where intense mixing is not required, optimizing the balance between dispersion quality and energy use
4Manufacturing precision
If recirculation is implemented, then the dispersion uniformity improves, but the processing time increases
Solution Approach 1:
The circulation system is designed to maintain optimal flow conditions and prevent settling or separation during the recirculation process. By preliminarily establishing continuous motion and uniform distribution patterns before discharge, the system achieves high dispersion uniformity in a single pass through the circulation loop, reducing the need for extended processing times
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
This approach ensures efficient dispersion and distribution of nano and micro objects within the medium, increasing surface area contact and promoting effective mass transfer, leading to improved composite formation and properties.
Implementation Method 1
Aerosolized constituents of the dispersed phase are deposited into a receptive medium spun on to a rotating surface to form a thin film
Implementation Method 2
apparatuses and methods for mixing and dispersing a dispersed phase in a medium... generate aerosolized constituents
Implementation Method 3
followed by shear and extensional flow deformation to form thin films and projectiles, enhancing dispersion
Data Source
AI summary
A method for mixing and dispersing an internal phase and an external phase in a liquid compound. The method includes preparing the compound by combining the internal phase of the compound and the external phase of the compound, the external phase of the compound being a liquid, forming a film of the compound by depositing a first volume of the liquid compound on a rotating surface and collecting the film as a dispersed liquid compound on a collection surface.