Rotor-Stator Gas Liquid Mixing for Faster Gas Dissolution
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Solution Overview
Problem
Traditional methods for mixing gases into liquids, such as ozone into water for semiconductor cleaning, are passive and inefficient, leading to incomplete dissolution and reduced cleaning effectiveness due to large gas bubbles remaining in the fluid.
Innovation Solution
A fluid mixing system with a magnetically levitated rotor and stator configuration, featuring an uneven surface in the mixing chamber, which generates turbulent flow by rotating relative to the stator, enhancing gas dissolution into the liquid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If gas is released into a tank bottom portion and allowed to rise as bubbles, then the gas dissolves into the liquid through contact, but the process is slow and incomplete with large gas bubbles remaining in the fluid
Solution Approach 1:
The patent introduces a rotor that rotates within the stator to create dynamic turbulent flow in the mixing chamber. This dynamic motion actively mixes the gas and liquid phases, transforming the slow passive diffusion process into an efficient active mixing process that rapidly achieves homogeneous distribution of gas throughout the liquid.
Solution Approach 2:
The rotating rotor with uneven outer surface generates mechanical turbulence and vortex flow patterns in the liquid. This mechanical agitation increases the interfacial area between gas bubbles and liquid, accelerates mass transfer, and prevents large bubble formation by continuously breaking up gas pockets into finer bubbles that dissolve more rapidly.
2Quantity of substance
If gas is released as large bubbles into the liquid, then the gas rises through the tank, but the contact time between gas and liquid is insufficient leading to incomplete dissolution
Solution Approach 1:
The rotor-stator configuration creates continuous dynamic motion that extends the effective contact time between gas and liquid. By inducing turbulent eddies and recirculation patterns, the system ensures that gas bubbles remain suspended and in contact with liquid for extended periods, dramatically improving dissolution efficiency within a compact mixing chamber.
Solution Approach 2:
The rotating rotor breaks up large gas bubbles into numerous smaller bubbles through mechanical shear forces. This segmentation increases the total surface area of gas-liquid interface, allowing for more simultaneous dissolution sites and reducing the time required for complete gas dissolution.
3Productivity
If a passive mixing process is used, then the system structure is simple, but the mixing efficiency is low and cleaning effectiveness is reduced
Solution Approach 1:
The patent replaces traditional mechanical stirring mechanisms with a magnetically levitated rotor system. The rotor is suspended by magnetic fields from the stator, eliminating mechanical contact and bearing requirements. This substitution maintains structural simplicity while enabling efficient active mixing through controlled rotational motion.
Solution Approach 2:
The rotor-stator assembly serves multiple functions simultaneously: it generates turbulent flow for mixing, creates vortex patterns for enhanced mass transfer, and can be controlled to vary mixing intensity. This multi-functionality achieves high mixing efficiency without requiring multiple separate components or complex mechanical drive systems.
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 system effectively increases the concentration of dissolved gas in the liquid, improving cleaning efficiency and reducing the amount of cleaning fluid needed by actively mixing gases into liquids, resulting in a more homogeneous and effective cleaning solution.
Implementation Method 1
The rotor may be configured to rotate relative to the stator. The rotor may be configured to float within the stator on magnetic bearings.
Implementation Method 2
which generates turbulent flow by rotating relative to the stator, enhancing gas dissolution into the liquid
Data Source
AI summary
A fluid mixing system may include a fluid inlet, a gas inlet, a common outlet, and a mixing chamber. The mixing chamber may be defined between a stator and a magnetically levitated rotor. The rotor may be configured to rotate relative to the stator. The mixing chamber may include an uneven surface. The mixing chamber may operatively couple the fluid inlet and the gas inlet to the common outlet.