Stacked Mixing Elements with Interconnected Holes for Fluid Homogeneity
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Solution Overview
Problem
Existing mixing devices face limitations in achieving significant mixing effects in a small space, require high power due to increased pressure drop at higher fluid flow rates, and have inefficient washing operations due to fluid residue accumulation in static mixers, while dynamic mixers like agitation blades only mix fluid in specific areas around the blades.
Innovation Solution
A mixing unit with stacked disc-shaped mixing elements and cover plates that allow fluid to flow through interconnected first through holes, enhancing mixing by repeated flow in and out, increasing the cross-sectional area for higher fluid flow rates, and facilitating easy disassembly for cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If fluid flow rate is increased in existing static mixers, then mixing capacity is improved, but pressure drop increases and power consumption increases
Solution Approach 1:
The mixing device is divided into multiple mixing elements stacked in series, each containing a pattern of holes. This segmentation allows fluid to be divided into multiple streams that mix progressively through successive elements, achieving effective mixing at lower flow rates without excessive pressure drop
Solution Approach 2:
The invention transitions from planar mixing surfaces to three-dimensional stacked mixing elements with holes arranged in specific patterns. This dimensional change creates multiple flow paths and mixing zones throughout the stack, improving mixing efficiency while maintaining acceptable pressure drop characteristics
2Productivity
If fluid flow rate is increased in existing static mixers, then mixing capacity is improved, but device complexity and space requirements increase
Solution Approach 1:
The mixing function is segmented into multiple identical or variations of mixing elements that can be stacked. Each element performs a portion of the mixing task, and the modular design simplifies manufacturing and assembly while achieving the required mixing capacity
Solution Approach 2:
The mixing elements are designed with universal applicability - the same basic element design can be used in various configurations and positions within the stack. This universality reduces the number of unique parts needed and simplifies the overall device design
3Reliability
If static mixing devices are used, then no movable components are needed, but washing operation becomes time-consuming due to residue accumulation in compartments
Solution Approach 1:
The mixing function is extracted from enclosed compartments to open-hole structures. Fluid flows through the holes rather than being contained within compartments, eliminating dead spaces where residue would accumulate and making the device easier to clean
Solution Approach 2:
The mixing elements incorporate patterns of holes that allow fluid to pass through while maintaining structural integrity. This porous-like structure prevents residue accumulation by eliminating enclosed spaces, facilitating easier washing operations
4Productivity
If agitation blades are used for dynamic mixing, then significant mixing effects are achieved, but mixing is limited to areas around the blades only
Solution Approach 1:
The invention extends mixing from a two-dimensional blade surface to a three-dimensional stacked structure. Multiple mixing elements stacked in series create mixing zones throughout the volume, expanding the effective mixing area beyond what a single blade can achieve
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 solution achieves enhanced mixing effects with reduced power consumption and simplified maintenance by allowing fluid to flow complexly through interconnected holes, effectively mixing larger volumes of fluid and improving reaction efficiency in reaction devices.
Implementation Method 1
the fluid is mixed by being dispersed, reversed and combined, and is further mixed by eddying flow, turbulent flow, collision and the like produced in each compartment
Implementation Method 2
the fluid is mixed by being dispersed, reversed and combined, and is further mixed by eddying flow, turbulent flow, collision and the like produced in each compartment
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
A mixing unit, a mixing device, an agitation impeller and a pump mixer can mix a large amount of fluid while having significant mixing effects in a small space. There are also provided a mixing system that uses the pump mixer and achieves a continuous operation and a reaction device that uses the mixing unit and achieves an efficient operation. The mixing unit (1) includes: a stacked member (2) in which a plurality of mixing elements (21) are stacked; and a first plate (3) and a second plate (4) between which the stacked member (2) is sandwiched and which are arranged opposite each other. In the mixing unit (1), the mixing elements (21) have a plurality of first through holes (22), the second plate (4) has an opening portion (41) communicating with at least one of the first through holes (22) in the mixing elements (21) and the mixing elements (21) are arranged such that part or all of the first through holes (22) in one of the mixing elements (21) communicate with a first through hole (22) in the adjacent mixing element (21) to allow fluid to be passed in a direction in which the mixing elements (21) extend.