Rotor-Stator Mixer Particle Size Breakup Design
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Solution Overview
Problem
Current rotor/stator type mixers lack a comprehensive performance estimation method and scale-up approach that can be applied universally across different forms and circulation modes, leading to inefficiencies in particle size breakup and emulsification processes, particularly in large-scale manufacturing.
Innovation Solution
The introduction of a total energy dissipation rate index (εa) that accounts for both form-dependent and running condition-dependent factors, allowing for the design and optimization of mixers to achieve higher performance by adjusting shearing stress and flow rates, and enabling the manufacture of high-quality products like pharmaceuticals and food items.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a rotor/stator type mixer is used for particle size breakup and emulsification, then mixing performance is improved, but there is no comprehensive performance estimation method and scale-up approach applicable universally across different forms and circulation modes
Solution Approach 1:
The patent introduces a dimensionless performance evaluation index that transforms the performance estimation from being specific to individual mixer configurations into a universal parameter-based evaluation system. By changing the evaluation parameters to dimensionless forms, the method can be applied across different mixer forms and circulation modes while maintaining accuracy in particle size breakup prediction
Solution Approach 2:
The patent creates a universal performance estimation method that functions across multiple mixer types and circulation modes. The dimensionless index serves as a multi-functional tool that can evaluate both internal and external circulation modes, as well as different mixer geometries, providing a single unified approach rather than separate methods for each configuration
2Manufacturing precision
If the gap between rotor and stator is reduced to increase shearing stress, then particle size breakup is improved, but energy consumption increases
Solution Approach 1:
The patent uses dimensionless parameters to characterize the relationship between gap size, shearing stress, and energy consumption. By transforming the problem into dimensionless form, the optimal gap can be determined as a parameter ratio rather than a fixed value, allowing energy-efficient design across different scales while maintaining particle size breakup performance
Solution Approach 2:
The patent suggests that excessive reduction of the gap beyond a certain point does not proportionally improve particle size breakup. The dimensionless analysis identifies an optimal range where further gap reduction yields diminishing returns while continuously increasing energy consumption, allowing for partial action rather than excessive gap minimization
3Manufacturing precision
If the rotor speed is increased to improve emulsification, then mixing performance is improved, but processing time and energy consumption increase
Solution Approach 1:
The patent analyzes the periodic nature of fluid passage through the rotor-stator gap and uses dimensionless frequency parameters to optimize the mixing process. By matching the periodic action of fluid elements with the rotor rotation, the method achieves efficient emulsification at lower speeds, reducing both processing time and energy consumption compared to continuous high-speed operation
Solution Approach 2:
The patent introduces dynamic similarity parameters that allow the mixing process to be optimized for different operating conditions. Rather than using a fixed high rotor speed, the dimensionless approach enables dynamic adjustment of speed based on the specific emulsification requirements, fluid properties, and scale, achieving optimal performance with reduced energy input and processing time
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 enables the design of high-performance mixers that consistently produce desirable particle sizes and emulsification effects across various scales, reducing processing time and energy consumption while ensuring product quality and hygiene.
Implementation Method 1
by taking advantage of the high shearing stress that may be produced in the neighborhood of the gap between the rotor 3 rotating at high speeds and the stator 2 in its fixed position
Implementation Method 2
the particle size breakup effect for the resulting liquid drop diameters may be promoted by the energy dissipation rate for the turbulent flow
Implementation Method 3
may be affected by the frequency with which the liquid being processed is subjected to the shearing stress (shearing frequency)
Data Source
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AI summary
In general, a particle size breakup apparatus is disclosed herein. More particularly, the present invention proposes a rotor/stator type mixer that implements the particle size breakup apparatus and includes a stator having a plurality of openings formed thereon and a rotor disposed on the inside of the stator and spaced away form the stator with a specific gap, wherein the mixer can improve the shearing stress applied to a fluid to be processed and exhibit the higher performance and wherein the mixer can change and/or adjust the shearing stress applied to the fluid to be processed and change and/or adjust the rate at which the fluid to be processed is allowed to flow in accordance with the changed and/or adjusted shearing stress. The rotor, which is disposed inwardly of the stator having the plurality of openings formed thereon so that it can be spaced away from the stator with the specific gap, has a rotor peripheral wall that faces opposite the inside of the stator peripheral wall and is disposed inwardly radially of the peripheral wall of the stator having the plurality of openings formed thereon so that it can be spaced away from the stator with the specific gap. In addition, the rotor has a plurality of openings formed thereon.