Static Mixer Exchange Elements for Complete Cross-Section Mixing

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Solution Overview

Problem

Conventional static mixers allow regions where one or more components flow unaffected, hindering complete mixing within the cross section of the mixer.

Innovation Solution

A static mixer design with mixing bodies and exchange elements that include deflection elements to redirect flows transverse to the longitudinal axis, preventing unaffected flow regions and ensuring complete mixing by using a mixer housing with specific inlet and outlet configurations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional mixing bodies are used in static mixers, then the structure is simple and easy to manufacture, but regions of unaffected flow occur adjacent to the mixer housing, preventing complete mixing

Engineering Contradiction:

Improveease of manufactureVSAvoidmixing completeness

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The mixing body is divided into multiple functional elements: input wall, deflection element with openings, output walls, and lateral outlets. This segmentation allows each element to perform a specific function in directing and mixing the streams, eliminating dead zones while maintaining manufacturability through modular design

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the mixing body have different functions: the deflection element creates specific flow patterns in certain areas, the input wall separates streams at the inlet, and the output walls direct flow at outlets. This localized functional differentiation ensures complete mixing throughout the cross-section while keeping the overall structure manufacturable

Inventive Principle:

Principle #3Local quality

2Duration of action of stationary object

If mixing bodies are arranged one after another along the longitudinal axis, then the mixing process is continuous, but unaffected flow regions persist through the static mixer, hindering complete mixing

Engineering Contradiction:

Improvemixing durationVSAvoidmixing completeness

Core Design Contradiction:

Duration of action of stationary objectVSManufacturing precision

Solution Approach 1:

The deflection element is positioned upstream within each mixing body to pre-direct the flow streams before they reach the outlets. This preliminary flow redirection ensures that even after multiple mixing bodies in series, no unaffected regions develop, maintaining complete mixing throughout the extended mixing duration

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The series arrangement of mixing bodies with the specific deflection element configuration maintains continuous effective mixing action throughout the static mixer. Each mixing body contributes to the mixing process without creating dead zones, ensuring that the useful mixing action continues uniformly along the longitudinal axis

Inventive Principle:

Principle #20Continuity of useful 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

The design ensures thorough mixing of components by prohibiting unaffected flow regions, enhancing the overall mixing efficiency and completeness of the mixing process.

Implementation Method 1

the further deflection element is positioned and sized to prevent that the stream of the components exiting the first lateral outlet flows through the exchange element in the direction of the longitudinal axis and to deflect the stream in a direction transverse to the longitudinal axis

Methodology Applied

Scientific EffectFluid deflection:

Implementation Method 2

a first inlet and a second inlet; a first and a second lateral outlet and an intermediate outlet disposed between the first and the second lateral outlet; an input wall separating the first inlet and the second inlet and extending in the direction of the longitudinal axis

Methodology Applied

Scientific EffectGeometric flow separation and recombination:

Data Source

PatentUS12434206B2Static mixer for mixing at least two components with an exchange element

Publication Date: 2025.10.07 MEDMIX SWITZERLAND AG

AI summary

A static mixer includes a mixer housing, a mixing element including mixing bodies arranged one after another along a longitudinal axis so as to be capable of repeated separation and recombination of components, each of the mixing bodies including a first and second inlets, first and second lateral outlets and an intermediate outlet disposed between the first and the second lateral outlet, an input wall separating the first and second inlets, a deflection element arranged downstream of and adjacent to the input wall, first and second output walls arranged downstream of and adjacent to the deflection element, the first output wall separating the first lateral outlet and the intermediate outlet and the second output wall separating the intermediate outlet and the second lateral outlet.