Static Mixer Inlet Element with Separate Passages

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing static mixers face challenges in ensuring that components reach the mixing element in the desired ratio and minimizing pressure loss, particularly when dealing with varying mixing ratios, which can lead to uneven mixing and material waste.

Innovation Solution

A mixing element design featuring separate inlet passages for each component, with a connection element that allows for a significant cross-sectional area ratio difference, ensuring that components enter the mixing element in the correct ratio and minimizing pressure loss through a helical or bar element configuration that maintains low internal tool pressures during injection molding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If separate inlet passages are provided for each component, then the components can enter the mixing element in the desired ratio, but the device complexity increases

Engineering Contradiction:

Improvemixing ratio precisionVSAvoidinlet passage configuration

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The inlet element is divided into separate inlet passages for each component, allowing independent control of flow rates and ensuring precise mixing ratios. Each passage can be optimized for its specific component while maintaining overall system functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connection element acts as an intermediary structure that receives components from separate inlet passages and delivers them to the mixing element. This intermediary allows the mixing element to receive components in the desired ratio without requiring complex valve or control mechanisms at the mixing point.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If the cross-sectional area ratio of inlet passages is significantly different, then components with varying ratios can be mixed, but pressure loss increases

Engineering Contradiction:

Improvemixing ratio rangeVSAvoidpressure loss

Core Design Contradiction:

Adaptability or versatilityVSLoss of energy

Solution Approach 1:

The connection element is designed with locally optimized cross-sectional areas that match the flow requirements of each component. The geometry is tailored to minimize pressure losses while maintaining the ability to handle significantly different flow ratios, allowing versatile mixing without excessive energy loss.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The inlet passages and connection element are designed with specific cross-sectional area ratios that optimize flow distribution. By carefully selecting geometric parameters, the system can accommodate varying mixing ratios while keeping pressure losses within acceptable limits through streamlined flow paths.

Inventive Principle:

Principle #35Parameter changes

3Volume of moving object

If wall thicknesses are reduced to less than 1 mm, then the mixer can be made more compact, but manufacturing difficulty increases

Engineering Contradiction:

Improvemixer sizeVSAvoidinjection molding feasibility

Core Design Contradiction:

Volume of moving objectVSEase of manufacture

Solution Approach 1:

Bar elements are incorporated into the injection molding tool to guide and support the polymer melt flow during the molding process. This preliminary structural support enables the formation of thin-walled sections (less than 1 mm) without causing manufacturing defects or tool failures, allowing compact mixer designs to be manufactured reliably.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The bar elements act as intermediary support structures during injection molding, facilitating the formation of thin-walled sections. These temporary structural elements enable the creation of compact mixers with walls thinner than 1 mm by preventing collapse and ensuring proper material distribution during the molding process.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Ease of manufacture

If bar elements are added to maintain internal tool pressures, then manufacturing feasibility improves, but device complexity increases

Engineering Contradiction:

Improveinjection molding feasibilityVSAvoidstructure composition

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The bar elements serve multiple functions: they act as structural support during injection molding, guide polymer melt flow to maintain internal tool pressures below 1000 bar, and can remain as functional parts of the final mixer structure. This multi-functionality justifies the added structural elements by eliminating the need for separate molding support structures or pressure control mechanisms.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS10293311B2Mixing element for a static mixer

Publication Date: 2019.05.21 MEDMIX SWITZERLAND AG

AI summary

A mixing element for a static mixer for installation into a tubular mixer housing has a longitudinal axis along which at least one first and one second installation body are arranged behind one another. An inlet element is provided which is arranged upstream of the first installation body, wherein the inlet element and the first installation body are connected to one another via a connection element. The inlet element has a body which can be sealingly taken up at the peripheral side in the mixer housing. The body has a first inlet passage and a second inlet passage, wherein the first inlet passage has a first entry opening and a first exit opening, wherein the second inlet passage has a second entry opening and a second exit opening so that the corresponding component can be conducted through the corresponding inlet passage.