Static Mixer Element Segmented Bar Stability
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Solution Overview
Problem
Static mixers with small wall thicknesses face manufacturing challenges due to high internal tool pressures, leading to instability and increased pressure loss, especially when handling viscous materials.
Innovation Solution
Connecting installation bodies via a common bar element increases stability while minimizing pressure loss by optimizing the mixing element's structure, allowing for a longer mixer length and improved mixing quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If installation bodies are connected via a common bar element, then stability and resistance to break increase, but pressure loss increases
Solution Approach 1:
The common bar element is segmented into multiple individual bar elements, where each bar element connects only two adjacent installation bodies. This segmentation reduces the total volume of bar elements taking up mixing space compared to a single continuous bar element, thereby reducing pressure loss while maintaining the stability benefits of connected installation bodies.
Solution Approach 2:
Different connection approaches are applied at different locations: bar elements connect installation bodies at their interfaces, providing localized stability where needed, while leaving the mixing space in the central region unobstructed. This local application of connection structures optimizes the balance between stability and pressure loss.
2Length of stationary object
If wall thickness is reduced to enable longer mixer length, then mixing quality improves, but manufacturing becomes difficult due to high internal tool pressures
Solution Approach 1:
The mixer is segmented into multiple installation bodies connected by bar elements. This segmentation allows the injection molding process to build up the structure in manageable sections, with the bar elements serving as connection points that also facilitate polymer melt flow between sections during manufacturing, reducing the required internal tool pressures.
Solution Approach 2:
The bar elements serve as intermediaries that facilitate the injection molding process by providing pathways for polymer melt flow between installation bodies. This intermediary structure enables the manufacturing of thin-walled components by maintaining manageable internal pressures during the injection process.
3Stability of the object's composition
If bar elements connect multiple installation bodies, then structural stability increases, but mixing space is taken up reducing mixing efficiency
Solution Approach 1:
The connection structure is segmented into multiple discrete bar elements rather than a continuous structure. This segmentation minimizes the total volume occupied by connection elements while maintaining structural stability, as each bar element only connects two adjacent installation bodies rather than spanning the entire mixer length.
Data Source
AI summary
A mixing element for a static mixer for installation into a tubular mixer housing has a longitudinal axis along which a plurality of installation bodies are arranged behind one another. A first installation body has a first wall element which extends in the direction of the longitudinal axis and a first side wall and a second side wall which is arranged opposite the first side wall. A deflection element is arranged adjacent to the first wall element and has a deflection surface extending in the transverse direction to the wall element at both sides of the wall element. A first opening is provided in the deflection surface at the side which faces the first side wall of the first wall element.