Static Mixer Insert with Concave-Convex Segments
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Solution Overview
Problem
Existing static mixers suffer from poor mixing and heat transfer efficiency due to inefficient fluid flow patterns, and they are often complex and costly to construct.
Innovation Solution
The design of a static mixer insert with a series of concave and convex surface portions and notches within a circular tube, which induces turbulent flow and radial fluid movement, enhancing mixing and heat transfer efficiency while being simple to construct from readily available materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional static mixer designs with central hubs and vanes are used, then structural support is provided, but mixing efficiency and heat transfer efficiency are poor for a given pressure drop
Solution Approach 1:
The insert is divided into multiple segments (first segment, second segment, third segment) arranged radially around the tube. Each segment has independent leading and trailing edges, creating multiple flow paths that enhance mixing efficiency while distributing pressure drop across segments rather than concentrating it in a single hub structure.
Solution Approach 2:
The insert surfaces incorporate concave and convex curvature portions instead of flat surfaces. The concave leading edges and convex trailing edges create controlled flow separation and reattachment patterns that enhance turbulent mixing and heat transfer while maintaining lower pressure drop compared to sharp-edged traditional vanes.
2Productivity
If complex static mixer structures are used to improve mixing efficiency, then mixing performance increases, but construction complexity and cost increase
Solution Approach 1:
The insert design serves multiple functions simultaneously: the segmented structure provides both flow division for mixing and structural support without requiring a central hub; the concave-convex surface geometry provides both flow control for enhanced mixing and heat transfer. This multi-functionality eliminates the need for separate central support structures and complex assembly procedures.
Solution Approach 2:
Instead of using a central hub with outward-extending vanes (traditional approach), the invention inverts the approach by placing multiple independent segments around the tube periphery, eliminating the central hub entirely. This inversion simplifies construction by using readily available circular tube sections and standard fabrication techniques without requiring complex central support structures.
3Productivity
If turbulent flow patterns are induced to enhance mixing and heat transfer, then convective heat transfer increases, but pressure drop increases
Solution Approach 1:
The insert creates localized turbulent flow regions at the concave leading edges and convex trailing edges of each segment, rather than inducing turbulence throughout the entire flow path. This localized turbulence generation enhances heat transfer and mixing only where needed, minimizing overall pressure drop while maintaining high convective heat transfer coefficients in critical regions.
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 insert significantly improves mixing and heat transfer efficiency with minimal pressure drop, favoring disturbed and turbulent flow patterns that increase convective heat transfer and mixing, particularly in fluids like gas and low viscosity mixtures.
Implementation Method 1
The design of a static mixer insert with a series of concave and convex surface portions and notches within a circular tube, which induces turbulent flow and radial fluid movement, enhancing mixing and heat transfer efficiency
Implementation Method 2
favoring disturbed and turbulent flow patterns that increase convective heat transfer and mixing
Data Source
AI summary
There is provided an insert (110) for a static mixer (100), wherein the static mixer includes the insert and a tube (102). In use, the insert is within the tube. The insert has a first surface (120) including a first leading edge (122) and a first trailing edge (124) joined by a first longitudinal edge (126) and a second longitudinal edge (128). The first surface has a first concave surface portion (130) at or adjacent the first leading edge and a first convex surface portion (132) at or adjacent the first trailing edge.