Static Mixer with Additive Manufactured Elements for HPLC
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Solution Overview
Problem
Conventional static mixers are inadequate for achieving thorough and homogeneous mixing of solvents in high-performance liquid chromatography (HPLC) applications, leading to incomplete mixing, excessive baseline noise, and poor peak shapes due to their inefficiencies in handling fluids with varying viscosities and flow rates.
Innovation Solution
A static mixer device featuring a housing with metal frits and mixer elements fabricated using laser additive manufacturing technology, which provides improved mixing efficiency and reduced size, incorporating interconnected porosity and varying diameters to enhance fluid flow patterns and mixing performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional static mixers are used for solvent mixing in HPLC, then the device structure is simple, but the mixing efficiency is insufficient leading to incomplete mixing and poor peak shapes
Solution Approach 1:
The static mixer is divided into multiple mixing elements (e.g., 3-5 elements) stacked in series within the housing, each element contributing to progressive mixing. This segmentation allows thorough mixing through multiple stages while keeping each individual element relatively simple in structure.
Solution Approach 2:
Different regions of the mixing elements have different geometric features optimized for specific mixing functions. The elements incorporate varying angles, offsets, and configurations in different sections to create localized flow patterns that enhance overall mixing efficiency without requiring complete redesign of the entire structure.
2Volume of moving object
If conventional static mixers are used, then the device is easier to manufacture with traditional methods, but the mixer size is larger and mixing is less thorough
Solution Approach 1:
Multiple mixing elements are nested within a compact cylindrical housing, with each element stacked vertically in series. This nesting arrangement maximizes the mixing path length and mixing thoroughness within a minimal volume, allowing the mixer to achieve effective mixing in a compact footprint suitable for HPLC systems.
Solution Approach 2:
The mixing elements incorporate three-dimensional geometric features including helical patterns, angled surfaces, and offset configurations that create complex flow paths within the limited axial space. This dimensional complexity enhances mixing efficiency without proportionally increasing the mixer volume.
3Adaptability or versatility
If conventional mixing elements are used, then the manufacturing process is traditional, but the mixing performance varies with fluid viscosity and flow rate
Solution Approach 1:
The mixing elements are designed with specific geometric parameters (angles, offsets, element spacing) that can be optimized for different fluid viscosities and flow rates. By adjusting these parameters during design, the mixer adapts to various HPLC conditions without requiring physical modification, maintaining ease of manufacture through standardized production methods.
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 solution achieves more thorough mixing over smaller volumes, reducing ripple amplitudes in HPLC signals and improving peak shapes, while also simplifying manufacturing and reducing the mixer's size, thus enhancing the overall performance and precision of HPLC processes.
Implementation Method 1
improve the mixing of fluids in a high-performance liquid chromatography (HPLC) system
Implementation Method 2
each of the metal frits extending across a cross-sectional dimension of the opening and having interconnected porosity
Data Source
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AI summary
A static mixer device 100 comprising a housing 110 having a proximal end 111, a distal end 112, and an opening 115 extending between the proximal and distal ends. In certain embodiments, a plurality of metal frits 120 is positioned within the opening of the housing, each of the metal frits extending across a cross-sectional dimension of the opening and having interconnected porosity. In other embodiments, one or more mixer elements fabricated using laser additive manufacturing technology and having novel configurations are positioned within the opening of the housing. In yet other embodiments, the housing comprises multiple openings having different diameters from each other, with each opening either extending through the housing with a constant diameter or with one or more of the openings having a varying diameter.