Segmented Static Mixer for Viscous Material Mixing
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Solution Overview
Problem
Existing static mixers for two-component materials, particularly in the building industry, face challenges in reducing residual volume and improving flow and mixing efficiency, leading to complex designs and increased manufacturing costs due to large diameters and complex molds required for large static mixers.
Innovation Solution
A static mixer design featuring a mixer housing, mixing element, and mixer inlet section formed as separate elements, with a plug element and counter plug element for a rotationally fixed connection, reducing the distance between components and allowing for a more efficient flow path, thereby minimizing residual volume and enhancing mixing results.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the diameter of the static mixer is increased to handle highly viscous materials, then the mixing capability is improved, but the residual volume increases and manufacturing complexity increases
Solution Approach 1:
The static mixer is divided into multiple mixing sections with progressively smaller diameters. The first mixing section has a larger diameter to accommodate highly viscous materials, while subsequent sections have reduced diameters to minimize residual volume. This segmentation allows the mixer to handle viscous materials effectively while reducing waste in the later stages of mixing.
2Productivity
If the diameter of the static mixer is increased to handle highly viscous materials, then the mixing capability is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The mixer is segmented into multiple sections with varying diameters, each performing a specific mixing function. This modular segmentation simplifies the overall design by breaking down the complex function of mixing viscous materials into manageable stages, reducing manufacturing complexity while maintaining mixing capability.
Solution Approach 2:
Instead of increasing the diameter uniformly throughout the mixer, the design transitions to a multi-dimensional approach by varying the diameter along the axial length of the mixer. This creates a tapered or stepped structure that reduces residual volume and simplifies manufacturing while preserving the ability to handle highly viscous materials in the initial mixing section.
3Loss of substance
If the length of the static mixer is reduced to minimize residual volume, then the residual volume decreases, but the mixing efficiency deteriorates
Solution Approach 1:
The mixer length is optimized by segmenting the mixing process into distinct sections. Each section contributes to the overall mixing efficiency while the total length is controlled to minimize residual volume. The segmented design ensures that mixing occurs progressively through multiple stages rather than requiring a single long mixing zone.
Solution Approach 2:
The design compensates for reduced length by utilizing radial dimension variations through tapered or stepped sections. This allows the mixer to achieve effective mixing in a more compact axial length by creating complex flow patterns through diameter changes, thereby reducing residual volume without sacrificing mixing efficiency.
4Loss of substance
If a complex design is implemented to reduce residual volume, then the residual volume decreases, but the manufacturing cost and difficulty increase
Solution Approach 1:
The mixer is designed as a segmented structure with standardized sections that can be manufactured using conventional molding techniques. This segmentation allows each section to be produced independently with simpler tooling requirements, reducing manufacturing complexity and cost while achieving the goal of minimized residual volume through the progressive diameter reduction.
Data Source
AI summary
A static mixer for mixing together at least two components includes a mixer housing, a mixing element arranged at least partly within the mixer housing, and a mixer inlet section having at least two inlets at an input side and at least two outlets at an output surface.