Static Mixer Segments with Deflector Plates for Multi-Component Waste Reduction
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Solution Overview
Problem
Static mixers used for multi-component materials often leave significant amounts of material unused, leading to wastage and increased costs, particularly in applications like dentistry where materials are used sparingly.
Innovation Solution
A static mixer design featuring multiple elongate inlets and outlets arranged in series with angled passages and deflector plates to efficiently mix and direct part flows, minimizing waste by ensuring thorough mixing and uniform exit speeds of all components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional static mixers are used to mix multi-component material, then mixing function is provided, but significant amounts of material remain unused in the mixer leading to wastage and increased costs
Solution Approach 1:
The static mixer is divided into multiple mixing segments arranged in series, where each segment contains multiple passages that subdivide and recombine material flows. This segmentation allows for more complete utilization of the mixer volume, reducing dead zones where material would otherwise remain trapped and unused.
Solution Approach 2:
The outlets of mixing segments are arranged at angles (at least 45°, preferably 90°) relative to the inlets, creating a three-dimensional flow pattern that enhances mixing efficiency and ensures more complete material utilization throughout the mixer length, minimizing residual material.
2Manufacturing precision
If multiple mixing segments are used to achieve thorough mixing, then mixing quality improves, but the volume of material remaining in the mixer increases
Solution Approach 1:
Deflector plates are strategically positioned within specific passages at defined locations (inlet regions, outlet regions, or central parts) to locally redirect flow patterns. This localized flow control ensures thorough mixing in critical areas while maintaining efficient material progression through the mixer, reducing overall residual volume.
Solution Approach 2:
The mixer design uses multiple identical or similar passages arranged in parallel within mixing segments, allowing for standardized manufacturing while achieving comprehensive mixing through the replicated flow paths, ensuring consistent material utilization across all segments.
3Loss of substance
If deflector plates are added to passages to improve mixing and reduce waste, then material utilization improves, but device complexity increases
Solution Approach 1:
The deflector plates modify flow parameters (direction, velocity distribution) within existing passages rather than requiring fundamental structural changes. By adjusting flow patterns through these plates, the design achieves better material utilization with minimal additional complexity.
Solution Approach 2:
The deflector plates are designed as simple, easily manufacturable components that can be integrated into the mixing segments. Their simple geometry allows for cost-effective production and potential replacement if needed, balancing the added complexity with practical manufacturing considerations.
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 design enhances mixing efficiency, reduces material waste, and ensures consistent bonding strength by evenly distributing and slowing down faster-flowing components, thereby minimizing unused material within the mixer.
Implementation Method 1
the at least one deflector plate is configured to deflect at least some of said outer flow component of the part flow of the multi-component material in the region of the elongate inlet and/or in the region of the elongate outlet away from the direction of flow directed at least substantially in the direction of the longitudinal axis
Implementation Method 2
the respective passages are configured to form flow paths that direct a part flow of the multi-component material from the elongate inlet to the elongate outlet of the mixing segment
Implementation Method 3
the static mixers comprise several mixing segments arranged one after the other that repeatedly divide and re-combine part flows of the multi-component material to thoroughly mix the multi-component material
Data Source
Figure 1
Figure 2
Figure 3a
AI summary
The present invention relates to a static mixer comprising a plurality of mixing segments for mixing a multi-component material. The static mixer (2) comprises: a plurality of mixing segments (12, 12') arranged in series one after another along a longitudinal axis (A) of the static mixer (2); wherein at least some of the plurality of mixing segments (12, 12') comprise at least three elongate inlets (13) arranged at least substantially in parallel to one another and at least three elongate outlets (14) arranged at least substantially in parallel to one another, with a respective elongate inlet (13) being connected to a respective elongate outlet (14) via a respective passage (15), wherein the elongate outlets (14) are arranged such that an elongate extent thereof is rotated by an angle of rotation of at least 45° about the longitudinal axis (A) with respect to an elongate extent of the elongate inlets (13); wherein the elongate outlets (14) of one mixing segment (12, 12') are arranged next to the elongate inlets (13) of the next mixing segment (12, 12') of the series; wherein the respective passages (15) are configured to form flow paths that direct a part flow of the multi-component material (M, M') from the elongate inlet (13) to the elongate outlet (14) of the mixing segment (12, 12'); and wherein at least some of the passages (15) of the mixing segment (12, 12') comprise at least one deflector plate (26, 26') arranged in the flow path, preferably in a central part of said passage (15), in a region of the elongate inlet (13) and/or in a region of the elongate outlet (14). The plurality of mixing elements is formed from a plastic.