Static Mixer Connector With Separate Channels
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Solution Overview
Problem
The existing static mixer designs face challenges in injection molding, requiring complex tools and leading to uneven cooling times, contamination risks, and assembly errors due to complicated geometries and flow paths, especially for thin-walled components with long lengths.
Innovation Solution
A static mixer with an intermediate piece that connects to a dispensing cartridge or device, featuring separate channels for each component and coding means for correct positioning, simplifying the injection molding process and reducing contamination risks through distinct inlet openings and alignment elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the static mixer and connector are produced as a single component using injection molding, then the assembly is simplified, but the injection molding process becomes difficult requiring complicated tools and long cooling times
Solution Approach 1:
The invention divides the previously integrated static mixer and connector into two separate components: the static mixer (with mixing elements) and the connector (with channels). This segmentation allows each component to be molded independently with simpler tools, avoiding the need for complex multi-cavity molds and long cooling cycles required for the integrated design.
2Productivity
If the static mixer is designed as a thin-walled component with long length, then the mixing efficiency is improved, but the cooling time becomes excessively long causing production delays
Solution Approach 1:
By separating the thin-walled static mixer from the thicker connector, the mixer can be molded and cooled quickly due to its thin walls, while the connector is molded separately with its own cooling cycle. This eliminates the need to wait for the entire integrated component to cool, significantly reducing cycle time.
Solution Approach 2:
The connector acts as an intermediary component that connects to the static mixer after both are separately molded. This mediator approach allows independent optimization of each component's manufacturing process, enabling the thin-walled mixer to be produced rapidly without being constrained by the connector's cooling requirements.
3Reliability
If separate channels for components are provided in the connector, then contamination is prevented, but the injection molding requires cores for channel formation increasing tool complexity
Solution Approach 1:
The connector is designed with separate channels for different components, and by molding the connector separately from the static mixer, simpler molding tools without complex core mechanisms are required. The separate channel structure is achieved through the connector's geometry rather than complex mold cores.
4Manufacturing precision
If the mixer remains in the mold until the connector is fully cooled, then dimensional stability is ensured, but the mixer occupies mold space unnecessarily long reducing productivity
Solution Approach 1:
By dividing the component into mixer and connector that are molded separately, each can be removed from its own mold once cooled. The mixer does not need to remain in the connector's mold, allowing the connector mold to be reused immediately for the next production cycle, significantly increasing productivity.
Data Source
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AI summary
An intermediate piece (4) for connecting a static mixer (1) to a discharge cartridge or a multi-component discharge device comprises a first channel (30) for a first component and a second channel (40) for a second component, wherein the first channel (30) runs through the intermediate piece separately from the second channel (40). A first inlet opening (31) is provided, which opens into the first channel (30), as well as a second inlet opening (41), which opens into the second channel (40), wherein the first inlet opening (31) includes an element (16, 60) such that the first inlet opening (31) can be aligned in a suitable position relative to the discharge cartridge by means of the element (16, 60).