Static Mixer Segmentation for Residual Volume Reduction
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Solution Overview
Problem
Existing static mixers face challenges in achieving thorough mixing of two-component materials without increasing the residual volume or design complexity, particularly when reduced in length to minimize material loss.
Innovation Solution
A static mixer design featuring a mixing element with a separating wall and flow obstructions that ensures uniform supply and optimal mixing by allowing partial flows to combine and enter entry openings, reducing the mixer's length while maintaining effective mixing, and incorporating a meandering pattern and thickened segments to adjust the accessible volume and prevent undue forerunning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the length of the static mixer is reduced to minimize material loss, then the residual volume is reduced, but the mixing quality deteriorates and design complexity increases
Solution Approach 1:
The mixing element is divided into multiple mixing sections with alternating flow directions. Each section contains flow obstructions that segment the material streams, forcing repeated separation and recombination of components. This segmentation enables effective mixing within a compact length by creating multiple mixing zones rather than relying on a single long mixing path.
Solution Approach 2:
The patent introduces a transverse dimension to the mixing process through flow obstructions that deflect materials in alternating directions perpendicular to the main flow axis. This dimensional approach creates a three-dimensional mixing pattern within a short axial length, allowing thorough mixing without extending the mixer length and thereby reducing residual volume.
2Loss of substance
If the length of the static mixer is reduced to minimize material loss, then the residual volume is reduced, but the design complexity increases
Solution Approach 1:
The mixing element is divided into multiple mixing sections with alternating flow directions. Each section contains flow obstructions that segment the material streams, forcing repeated separation and recombination of components. This segmentation enables effective mixing within a compact length by creating multiple mixing zones rather than relying on a single long mixing path.
Solution Approach 2:
The patent systematically varies geometric parameters including the number of mixing sections, positions and shapes of flow obstructions, and angles of deflection to optimize mixing performance. By adjusting these parameters, the design achieves effective mixing in a compact form without requiring excessively complex structures, balancing performance with manufacturability.
3Manufacturing precision
If conventional mixing designs are used to ensure thorough mixing, then mixing quality is maintained, but the mixer length increases and production costs increase
Solution Approach 1:
The mixing element is divided into multiple mixing sections with alternating flow directions. Each section contains flow obstructions that segment the material streams, forcing repeated separation and recombination of components. This segmentation enables effective mixing within a compact length by creating multiple mixing zones rather than relying on a single long mixing path.
Solution Approach 2:
The patent systematically varies geometric parameters including the number of mixing sections, positions and shapes of flow obstructions, and angles of deflection to optimize mixing performance. By adjusting these parameters, the design achieves effective mixing in a compact form without requiring excessively complex structures, balancing performance with manufacturability.
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
This design enhances mixing efficiency, reduces residual volume, and simplifies the mixer's design, allowing for a shorter length without compromising mixing quality, thus reducing production costs and effort.
Implementation Method 1
at least one flow obstruction disposed between the upstream end of the mixing element and the output surface for deflecting the components or at least partial flows of the components
Implementation Method 2
a separating wall disposed between the output surface and the upstream end of the mixing element for separating the components leaving the outlets
Data Source
Figure 1a~1b
Figure 2
Figure 3a~3b
AI summary
The present invention relates to a static mixer (10) for mixing together at least two components. The static mixer (10) comprises: - a mixer housing (12); - a mixing element (14) having an upstream end (16) with at least two entry openings (20a, 20b, 20c) and a downstream end (18), the mixing element (14) being arranged at least partly within the mixer housing (12); - a mixing head (22) having at least two inlets (24a, 24b) provided at an input side (26) and at least two outlets (28a, 28b) provided at an output surface (30), wherein each of the at least two inlets (24a, 24b) is in fluid communication with one of the at least two outlets (28a, 28b); and - a separating wall (32) disposed between the output surface (30) and the upstream end (16) of the mixing element (14) for separating the components leaving the outlets (28a, 28b). The separating wall (32) comprises a free downstream edge (33) which is disposed with respect to at least one of the entry openings (20a, 20b, 20c) so as to allow at least partial flows of the components separated by the separating wall (32) to combine after exceeding the downstream edge (33) and to jointly enter said at least one of the entry openings (20a, 20b, 20c).