Static Mixer for Uniform Melt Temperature in Particle Forming
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Solution Overview
Problem
Forming particles with uniform shape and temperature is challenging due to non-uniform temperature profiles in the melt as it travels through feed pipes, leading to inconsistent particle shape and quality concerns in consumer products.
Innovation Solution
Incorporating a static mixer between the batch mixer and the distributor, which disrupts the flow and mixes the precursor material uniformly by utilizing energy loss, ensuring a temperature variation of less than 10 °C across the feed pipe cross-section, and using a rotating distributor with apertures to deposit the material on a conveyor for cooling into uniform particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heat is applied to the feed pipe from outside, then the temperature of the boundary layer and melt flowing proximal the boundary layer is raised, but the temperature of the melt at the centerline remains relatively cooler, resulting in non-uniform temperature profile
Solution Approach 1:
A static mixer is introduced as an intermediary device in the feed pipe to redistribute the melt flow. The static mixer elements act as mediators that disrupt the boundary layer and promote mixing between the heated peripheral melt and the cooler central melt, achieving more uniform temperature distribution without direct contact heating
Solution Approach 2:
The patent replaces thermal conduction heating (which creates non-uniform temperature profiles) with mechanical mixing action through the static mixer. The mechanical disruption of flow patterns substitutes for the inadequate thermal diffusion, achieving temperature uniformity through flow redistribution rather than heat transfer
2Use of energy by moving object
If the melt has non-uniform temperature across the dispensing apparatus, then heating energy can be reduced, but the particles formed have non-uniform shape
Solution Approach 1:
The static mixer performs preliminary mixing action on the melt before it reaches the dispensing apparatus. By pre-distributing the temperature uniformity upstream, the system eliminates the need for excessive heating energy at the dispensing point while ensuring uniform particle shape formation
3Stability of the object's composition
If a batch mixer is used to provide desired residence time for mixing and reaction, then uniform temperature and mixing can be achieved, but it is challenging to maintain and establish the desired temperature of the melt within the batch mixer
Solution Approach 1:
The static mixer enables continuous mixing and temperature equalization action throughout the melt flow in the feed pipe. This continuous mixing action complements the batch mixing process, ensuring that temperature uniformity is maintained and established throughout the melt from the batch mixer through the dispensing apparatus
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 static mixer ensures more uniform temperature and shape of particles, reducing variability and enhancing the perceived quality of the product by maintaining consistent particle dimensions and shape across packages.
Implementation Method 1
In transit, heat conduction through the wall of the feed pipe can result in cooling of the melt
Implementation Method 2
depositing the precursor material on to the moving conveyor and cooling the precursor material to form a plurality of particles
Data Source
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AI summary
An apparatus and process for forming particles. The apparatus and process employs an intermediate mixer downstream of a batch mixer.