Static Mixer Baffle Elements Disrupting Flow Recirculation

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Solution Overview

Problem

Conventional wafer-style static mixers rely on back-mixing and flow recirculation, resulting in transient flow characteristics and uneven chemical concentrations, which complicates the mixing process.

Innovation Solution

The design incorporates symmetric baffle elements with perimeter openings that disrupt recirculation, promoting turbulent dispersion and maintaining a tight residence time distribution, while allowing for efficient additive dispersion and reduced pressure loss.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If conventional wafer-style static mixers rely on back-mixing and flow recirculation, then mixing is achieved, but transient flow characteristics and wide residence time distribution occur

Engineering Contradiction:

Improvemixing effectivenessVSAvoidflow characteristics stability

Core Design Contradiction:

Quantity of substanceVSStability of the object's composition

Solution Approach 1:

The baffle element is segmented into multiple sections (first section, second section, third section) with different geometric configurations. Each section creates specific flow patterns that collectively achieve mixing while maintaining stable flow characteristics. The segmentation allows the mixer to break down the complex mixing task into manageable flow manipulation steps.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The baffle element employs asymmetric geometry where the first section has a different configuration than the second and third sections. This asymmetry creates controlled flow disruption and prevents symmetric recirculation patterns, leading to more stable flow characteristics while still achieving effective mixing through the asymmetric flow paths.

Inventive Principle:

Principle #4Asymmetry

2Quantity of substance

If conventional static mixers use back-mixing mechanisms, then mixing occurs, but elevated chemical concentrations accumulate on the discharge side

Engineering Contradiction:

Improvemixing effectivenessVSAvoidchemical concentration uniformity

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The design extracts and eliminates the recirculation zone that causes back-mixing and concentration accumulation. By positioning the baffle element to disrupt recirculation flows and prevent them from returning to the discharge side, the harmful back-mixing effect is removed while mixing is still achieved through the baffle-induced flow disruption in the forward direction.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of relying on back-mixing mechanisms that cause concentration accumulation, the invention inverts the approach by using forward-flow disruption and turbulence. The baffle element creates mixing through chaotic advection and flow splitting in the forward direction, eliminating the need for recirculation-based mixing that leads to concentration non-uniformity.

Inventive Principle:

Principle #13The other way round (Inversion)

3Stability of the object's composition

If symmetric baffle elements with perimeter openings are used to disrupt recirculation, then turbulent dispersion and tight residence time distribution are achieved, but pressure loss increases

Engineering Contradiction:

Improveresidence time distributionVSAvoidpressure loss

Core Design Contradiction:

Stability of the object's compositionVSLoss of energy

Solution Approach 1:

The baffle element has different geometric properties in different sections to optimize performance locally. The first section has a configuration optimized for flow disruption, while the second and third sections have configurations optimized for maintaining flow stability. This local differentiation allows tight residence time distribution to be achieved without excessive pressure loss across the entire element.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The perimeter openings provide partial recirculation disruption rather than complete blockage. This partial action is sufficient to achieve tight residence time distribution and turbulent dispersion while allowing enough flow through the openings to minimize pressure loss. The openings prevent full recirculation zones from forming without creating excessive flow resistance.

Inventive Principle:

Principle #16Partial or excessive action

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 design enhances mixing efficiency by reducing back-mixing effects and recirculation, ensuring consistent chemical distribution and improved flow characteristics.

Implementation Method 1

promoting turbulent dispersion

Methodology Applied

Scientific EffectTurbulence: Turbulence

Data Source

PatentUS20240173681A1Baffle Elements and Static Mixers Including Baffles Elements

Publication Date: 2024.05.30 KOFLO CORP

AI summary

Static mixers include: (i) a base member having a perimeter wall that defines an open interior space; and (ii) at least one baffle section located within the open interior space. The baffle section(s) may include a surface that extends between an outer perimeter side or outer perimeter region and an inner edge or inner region. The outer perimeter side or outer perimeter region defines at least one outer perimeter fluid passageway or perimeter open space that allows fluid flow through the static mixer. In some examples, the inner region of the baffle section may be angled forward from the outer perimeter region in the direction of fluid flow through the mixer. Additionally, in some examples, the static mixer may include two baffle sections, e.g., baffle sections that are spaced apart and/or mirror images of one another.