Dynamic Rotor-Stator Mixing for Viscous Fluid Temperature Control
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Solution Overview
Problem
Existing mixing devices for viscous fluids, particularly molten polymers, suffer from poor mixing efficiency, temperature non-uniformity, and excessive heat generation, leading to degradation and increased costs due to the need for additional pumps and complex designs that create dead zones.
Innovation Solution
A dynamic mixing device with a stator and rotor within a mixing chamber, featuring temperature control channels and rotational mixing to achieve simultaneous mixing and tempering, utilizing shearing forces and temperature control fluid to maintain uniform fluid properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If external temperature control is used on the housing, then the device structure is simple, but temperature uniformity deteriorates due to temperature gradients and limited heat transfer surface
Solution Approach 1:
The patent combines the temperature control function with the mixing elements themselves. The stator and rotor are equipped with temperature control channels that allow temperature control fluid to flow directly through them, merging the structural mixing components with the thermal control system. This eliminates the need for separate external temperature control of the housing and enables direct heat exchange with the fluid.
Solution Approach 2:
The patent introduces a temperature control fluid as an intermediary substance that flows through channels in the stator and rotor. This fluid acts as a mediator to transfer heat directly to or from the mixed fluid, enabling precise temperature control and uniform heat distribution throughout the mixing chamber without relying on external housing control.
2Productivity
If dynamic mixing with rotor and stator is used, then mixing efficiency is improved, but fluid temperature increases excessively causing degradation
Solution Approach 1:
The patent converts the harmful effect of heat generation during dynamic mixing into a beneficial controlled process. By incorporating temperature control channels in the stator and rotor, the system can actively remove excess heat generated by mixing through circulating temperature control fluid, thereby preventing fluid degradation while maintaining efficient mixing performance.
Solution Approach 2:
The patent changes the thermal parameters of the mixing system by introducing active temperature control through fluid circulation in the stator and rotor channels. This allows dynamic adjustment of temperature during the mixing process, enabling the system to maintain optimal temperature ranges even during high-intensity mixing that would otherwise cause excessive heating and degradation.
3Device complexity
If static mixers with web plates are used, then no moving parts are required, but mixing effect is poor requiring large installation space
Solution Approach 1:
The patent transitions from static mixing elements to a dynamic mixing system with a rotating rotor and stationary stator. The rotor can rotate to actively mix the fluid, providing superior mixing efficiency in a compact configuration. The stator with its temperature control channels remains stationary, combining dynamic mixing action with thermal control functionality.
4Ease of manufacture
If scraping motion is performed during mixing, then deposits are removed, but additional mixing effect is minimal and product quality may be compromised
Solution Approach 1:
The patent extracts the cleaning function from the normal mixing operation. The temperature control fluid circulating through the stator and rotor channels continuously removes deposits through thermal action and fluid flow, separating the cleaning function from mechanical scraping. This allows deposits to be removed during normal operation without compromising product quality or requiring separate cleaning cycles.
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 device ensures thorough mixing and uniform temperature distribution, reducing the risk of degradation and eliminating the need for additional pumps, while maintaining consistent fluid quality for high-quality product production.
Implementation Method 1
utilizing shearing forces and temperature control fluid to maintain uniform fluid properties
Implementation Method 2
at least one temperature control channel (7) is formed in the stator (5) and/or in the rotor (6) through which a temperature control fluid (8) can flow for temperature control of the stator (5) and/or the rotor (6)
Implementation Method 3
the fluid is heated considerably by the dynamic mixing process
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present disclosure relates to a dynamic mixing device (1) for a fluid (2), in particular for a viscous medium, having a mixing chamber (4) formed by a housing (3), having a stator (5) and having a rotor (6), wherein the stator (5) and the rotor (6) are arranged at least partially within the mixing chamber (4), wherein the stator (5) is connected to the housing (3) and/or is formed by means of the housing (3), wherein the rotor (6) is rotatable about an axis of rotation (D), wherein at least one free space is formed by means of the rotor (6), into which free space the stator (5) projects at least partially in the direction of the axis of rotation (D), wherein the stator (5) and/or the rotor (6) has at least one temperature control channel (7) through which a temperature control fluid (8) can flow for temperature control of the stator (5) and/or the rotor (6).The present disclosure further relates to an extruder (16) having such a mixing device (1), as well as to a method for operating a dynamic mixing device (1) for a fluid (2) and/or an extruder (16) having the dynamic mixing device (1).