Single-Part Static Mixer Insert for Low Pressure Loss
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Solution Overview
Problem
Conventional mixer inserts are complex and costly to manufacture, face stability issues due to size limitations, and have suboptimal mixing efficiency and pressure loss, particularly in injection molding processes.
Innovation Solution
A single-part mixer insert design with intersecting and adjoining webs, manufactured via injection molding, which maintains high mixing efficiency and low flow resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If mixer inserts are assembled from two part mixing inserts, then mixing performance can be improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges two separate part mixing inserts into a single integrated mixer insert. The mixing insert comprises a first mixing element and a second mixing element that are directly connected to each other, eliminating the need for separate assembly operations. This integration maintains the enhanced mixing performance while significantly simplifying manufacturing and eliminating assembly complexity.
2Volume of moving object
If mixer insert size is reduced, then application flexibility improves, but structural stability deteriorates
Solution Approach 1:
The patent employs curved transition regions between the first and second mixing elements, replacing sharp corners with rounded surfaces. This curvature design maintains structural integrity and stability even as the overall mixer insert size is reduced, allowing for compact dimensions without compromising the mechanical strength and structural composition of the component.
3Manufacturing precision
If web dimensions are reduced for smaller mixer inserts, then manufacturing precision improves, but demolding reliability deteriorates
Solution Approach 1:
The patent introduces rounded transition regions and curved surfaces in the web structures, eliminating sharp corners and straight edges. This curvature design prevents stress concentration during demolding and allows for reliable ejection of the molded part from the injection mold, even when web dimensions are reduced to achieve smaller mixer insert sizes while maintaining manufacturing precision.
4Ease of manufacture
If single-part mixer insert design is used, then manufacturing cost decreases, but mixing efficiency may worsen
Solution Approach 1:
The patent divides the single mixing insert into two distinct mixing elements with different orientations. The first mixing element has a first orientation and the second mixing element has a second orientation that differs from the first. This segmentation within a unified single-part structure maintains high mixing efficiency by creating multiple mixing zones while keeping manufacturing costs low through integrated production.
Solution Approach 2:
The patent employs asymmetric web arrangements where the web patterns in the first mixing element differ from those in the second mixing element. This asymmetry creates varied flow paths and mixing characteristics in different sections of the insert, maintaining high mixing efficiency despite the simplified single-part construction that reduces manufacturing costs.
Data Source
AI summary
A mixer insert for a static mixer, includes mixing elements that are arranged behind one another along a longitudinal central axis. The mixing elements have a web arrangement including a plurality of intersecting or mutually adjoining webs. The mixing elements have web arrangements that are rotated by an angle of rotation with respect to one another. The mixer insert is configured as a single-part component.