Static Mixer Insert With 90-Degree Twist Elements
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Solution Overview
Problem
Existing static mixer inserts face challenges in simplified assembly, cost-effective production, low flow resistance, and high mixing efficiency, particularly due to complex assembly processes and the need for reinforcement rings that can lead to fluid leakage and reduced mixing effectiveness.
Innovation Solution
A mixer insert composed of multiple injection-molded parts with adjacent elements twisted relative to each other by 90°, eliminating the need for reinforcement rings and allowing for simple and quick assembly, with integrated mixing-element parts forming one-piece structures that reduce flow resistance and enhance mixing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple individual mixing elements are assembled to form the mixer insert, then the mixing efficiency can be improved through alternating 90° twists, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The patent combines multiple individual mixing elements into a single integrated mixer insert component. The mixing elements are formed as one piece with alternating 90° twists built-in during manufacturing, eliminating the need for separate assembly operations while maintaining the high mixing efficiency provided by the twisted configuration.
Solution Approach 2:
The mixer insert is designed as a modular component that can be produced through segmentation of the manufacturing process, allowing complex twisted structures to be formed through sequential molding operations or injection molding techniques that create the alternating twist pattern as an integrated feature.
2Stability of the object's composition
If reinforcement rings are used to maintain structural integrity, then the stability is improved, but fluid leakage occurs and mixing effectiveness is reduced
Solution Approach 1:
The patent removes the reinforcement rings from the mixer insert structure. Instead of using separate reinforcing components that create leakage paths, the structural integrity is achieved through the optimized geometry of the mixing elements themselves, which are designed to maintain stability without requiring additional reinforcing rings.
Solution Approach 2:
The mixer insert is formed from homogeneous material structures that inherently provide both structural stability and fluid-tight sealing. The alternating twist configuration and integrated design eliminate the need for composite construction with reinforcement rings, preventing fluid leakage while maintaining structural integrity.
3Manufacturing precision
If complex assembly tools and processes are used, then the manufacturing precision can be improved, but the production cost increases
Solution Approach 1:
The alternating 90° twist configuration and precise geometric relationships are built into the mixer insert during the initial manufacturing process. This preliminary action of pre-forming the twisted structure eliminates the need for complex assembly tools and precision alignment operations during assembly, reducing production costs while maintaining manufacturing precision.
Solution Approach 2:
The mixer insert design allows for self-alignment during assembly, where the alternating twist geometry and integrated structure enable the components to automatically position themselves correctly without requiring complex external alignment tools or procedures, thereby reducing manufacturing costs while maintaining precision.
4Loss of energy
If the mixing elements are made with small diameter, then the flow resistance is reduced, but the assembly difficulty increases
Solution Approach 1:
The patent merges multiple small-diameter mixing elements into a single integrated component. This combination maintains the low flow resistance benefit of small diameters while eliminating the assembly difficulties associated with handling and positioning multiple small components, as the integrated structure is manufactured as one piece.
Data Source
AI summary
A mixer insert (1) for a static mixer, comprising a plurality of mixing elements (3, 3a, 3b, 3c, 3d, etc.) which are disposed one behind the other along a longitudinal axis (L) and preferably immediately adjoin each other and each comprise a plurality of crossing rods (8, 9; 10, 11), at least two mixing elements consecutive along the longitudinal axis (L) among the plurality of mixing elements (3, 3a, 3b; 3b, 3c; 3c, 3d; etc.) being turned relative to each other by a twist angle of preferably 90° with respect to the longitudinal axis (L), the mixer insert (1) being composed of multiple separate mixer-insert parts (2, 2a, 2b) which each extend along the longitudinal axis and which are disposed adjacent to each other perpendicular to the longitudinal axis (L), each mixer-insert part (2, 2a, 2b) having a plurality of mixing-element parts (14, 14a, 14b, 14c, 14d, etc.; 15, 15a, 15b, 15c, 15d, etc.) which are disposed one behind the other along the longitudinal axis (L) and are integrally connected to each other along the longitudinal axis (L) and immediately adjoin each other, and that the mixing-element parts (14, 15; 14a, 15a; 14b, 15b; 14c, 15c, 14d, 15d; etc.) of the mixer-insert parts (2, 2a, 2b) that are disposed next to each other perpendicular to the longitudinal axis form one of the mixing elements (3, 3a, 3b, 3c, 3d, etc.), and that at least two of the mixing-element parts (14, 14a, 14b, 14c, 14d, etc.; 15, 15a, 15b, 15c, 15d, etc.) of the mixer-insert parts (2, 2a, 2b) that immediately adjoin each other along the longitudinal axis (L) are turned relative to each other by the twist angle with respect to the longitudinal axis (L).