Elastically Expanding Static Mixer Insert for Cost Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing housed-elements static mixers are expensive, require specialized skills for manufacturing and assembly, and are not readily serviceable due to their complex design and securement methods.
Innovation Solution
A static mixer design featuring a housing with a hollow, elastically expansive insert that has deflectors projecting inwardly into the fluid flow path, eliminating the need for separate fasteners or securement methods by using frictional engagement between the insert and the housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If housed-elements static mixers use precision-engineered mixer elements secured with fasteners, brackets, or collars, then mixing precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the mixer element and housing into a single integrated structure where the housing itself forms the mixing chamber with integrated baffles and flow paths. This eliminates separate mixer elements that need to be secured with fasteners, brackets, or collars, thereby reducing device complexity while maintaining mixing precision through the integrated design.
Solution Approach 2:
The housing serves multiple functions simultaneously: it provides structural support, defines the fluid flow path, creates the mixing chamber, and incorporates the mixing baffles as integral features. This multi-functionality eliminates the need for separate precision-engineered mixer elements, reducing both device complexity and manufacturing cost while achieving effective mixing.
2Strength
If housed-elements static mixers use welded or mechanically secured mixer elements, then structural strength is improved, but ease of manufacture and assembly deteriorates
Solution Approach 1:
The integrated housing design combines what were previously separate components (housing and mixer elements) into a single manufacturable structure. This eliminates the need for welding or mechanical assembly operations, allowing the entire mixer to be manufactured as one piece through processes like injection molding or CNC machining, significantly improving ease of manufacture while maintaining structural integrity.
3Reliability
If housed-elements static mixers use separate hold-down devices for securing mixer elements, then reliability is improved, but ease of repair deteriorates
Solution Approach 1:
The integrated design eliminates separate hold-down devices by incorporating the mixing features directly into the housing structure. This monolithic construction means there are no separate components to fail or require replacement, improving reliability while simultaneously making the device easier to repair or replace as a single unit rather than disassembling multiple secured components.
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 reduces manufacturing and assembly costs, simplifies the serviceability of the static mixer, and maintains effective fluid mixing without moving parts.
Implementation Method 1
The hollow insert extends longitudinally through the fluid flow path between the inlet and the outlet, is elastically expansive to exert outwardly directed pressure against the continuous inner surface
Implementation Method 2
Each deflector projects inwardly into the fluid flow path. More specifically, each deflector projects angularly upward toward the inlet.
Data Source
AI summary
A static mixer for liquids or gases includes a housing having a continuous inner surface defining a fluid flow path for liquids or gases, an inlet to the fluid flow path, and an outlet from the fluid flow path, and an insert extending longitudinally through the fluid flow path between the inlet and the outlet. The insert is elastically expansive to exert outwardly directed pressure against the continuous inner surface of the housing. In one embodiment, the insert is hollow and has deflectors dispersed therethroughout and each projecting inwardly into the fluid flow path. In another embodiment, the insert includes a helical deflector extending inwardly into the fluid flow path from the continuous inner surface, and helically about a longitudinal axis of the housing.