Static Mixer Element Depth Reduction via Web Segmentation
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Solution Overview
Problem
Existing static mixers for highly viscous fluids, such as polymer melts, face challenges in achieving effective mixing while minimizing pressure loss and residence time, often requiring increased mixer volume or diameter, which can lead to higher costs and difficulties in switching between polymer production processes.
Innovation Solution
A mixing element design featuring crossbars with multiple webs extending at right angles, where the thickness of the crossbar is optimized in relation to the webs' thickness and opening angle, and the arrangement of mixing elements allows for reduced pressure loss and smaller overall depth, maintaining or improving mixing efficiency without increasing residence time or volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional mixing elements with crossbars and webs are used to mix highly viscous fluids, then mixing function is achieved, but installation depth and mixer volume increase
Solution Approach 1:
The mixing element is divided into multiple individual webs instead of using traditional crossbars with attached webs. Each web is a separate structural element that can be independently positioned and optimized, allowing for more efficient space utilization and reduced installation depth while maintaining mixing effectiveness.
Solution Approach 2:
The patent optimizes the spatial arrangement of webs by controlling their opening angles and positional relationships in three-dimensional space. By carefully designing the angular distribution and depth positioning of multiple webs, the mixing function is maintained while reducing the overall installation depth of the mixer.
2Loss of energy
If mixer volume or diameter is increased to reduce pressure loss, then pressure loss decreases, but equipment cost and complexity increase
Solution Approach 1:
Different regions of the mixing element have locally optimized web configurations. The opening angles, web thicknesses, and positional arrangements vary at different locations along the flow path, creating locally optimal conditions for reducing pressure loss without requiring an overall increase in mixer volume.
Solution Approach 2:
The patent systematically varies key geometric parameters including opening angles (specifically optimized to 60-120 degrees), web thickness ratios, and positional coordinates of multiple webs. These parameter optimizations create a flow path that minimizes pressure loss while maintaining compact mixer dimensions.
3Productivity
If residence time is reduced to improve production efficiency, then productivity increases, but mixing quality may deteriorate
Solution Approach 1:
The multiple webs are arranged to create continuous mixing action throughout the fluid path. As the highly viscous fluid flows through the mixing element, it continuously interacts with multiple webs at different positions and angles, ensuring effective mixing is maintained even with reduced residence time.
Solution Approach 2:
The mixing element employs a composite geometric structure combining multiple webs with different opening angles, thicknesses, and positions. This composite configuration creates diverse flow patterns and mixing mechanisms that occur simultaneously, achieving thorough mixing in shorter residence times.
Data Source
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AI summary
The invention relates to mixing elements with a reduced structural depth for static mixers, to static mixers comprising at least two mixing elements with a reduced structural depth, and to a method for mixing fluids using a mixing element with a reduced structural depth or a static mixer comprising at least two mixing elements with a reduced structural depth. In the mixing elements, the thickness of the transverse strut at its thickest point is maximally 0.9 to 1.1 times the thickness of the webs multiplied by the cosine of half the opening angle O divided by the sine of the whole opening angle O.