Static Mixer Without Sidewalls for High Pressure Fluid Mixing
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Solution Overview
Problem
Current static mixers with sidewalls face issues such as fluid trapping, reduced flow rates, increased material waste, and limitations in baffle geometry and size due to sidewalls, which hinder effective mixing and lead to premature failure of downstream baffles under high fluid pressures.
Innovation Solution
A static mixer design without continuous sidewalls, featuring tapered mixing elements with alternating baffle widths and heights that act as a wedge within the mixing conduit, distributing pressure evenly and allowing for more complex geometries and smaller sizes, enabling efficient fluid mixing without sidewall constraints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If sidewalls are added to mixing baffles to provide structural support and transmit forces, then the strength and stability of the mixing element is improved, but fluid trapping occurs, flow rate is reduced, and material waste increases
Solution Approach 1:
The patent removes the sidewalls from the mixing baffles, extracting the harmful structural element that caused fluid trapping and flow rate reduction. The mixing baffles are designed to function without continuous sidewalls, allowing fluid to flow freely while still providing necessary structural support through the baffle geometry itself.
Solution Approach 2:
The mixing element is divided into multiple discrete mixing baffles spaced along the mixing conduit. Each baffle is a separate component that provides localized mixing and force distribution without requiring continuous sidewalls to connect them, enabling structural support without the harmful effects of enclosed sidewalls.
2Reliability
If sidewalls are added to mixing baffles to withstand elevated fluid pressures, then the reliability of the mixing element is improved, but the mixing conduit size must be increased and material waste increases
Solution Approach 1:
The patent eliminates the sidewalls that consumed additional material and increased mixing conduit size. The mixing baffles are designed to withstand pressure without the encumbrance of sidewalls, reducing material usage while maintaining or improving pressure resistance through optimized baffle geometry and spacing.
Solution Approach 2:
The patent changes the structural parameters of the mixing element by removing sidewalls and adjusting baffle geometry. This allows the mixing element to achieve adequate pressure resistance with less material, reducing material waste and allowing for smaller mixing conduit dimensions.
3Strength
If sidewalls are added to mixing baffles to provide stability, then the manufacturing strength is improved, but the complexity of baffle geometry is limited and smaller mixer sizes cannot be produced
Solution Approach 1:
The patent removes the constraint of sidewalls that limited baffle geometry design. Without sidewalls, the mixing baffles can be formed with more complex and varied geometries using injection molding, enabling better mixing performance and allowing for smaller mixer sizes while maintaining manufacturing strength through proper baffle design.
Solution Approach 2:
The patent changes the geometric parameters of the mixing baffles by eliminating sidewall constraints. This enables the use of more complex baffle geometries, including varied panel configurations and orientations, that can be effectively manufactured through injection molding without the limiting presence of sidewalls.
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 fluid mixing efficiency, reduces material usage, and allows for the production of smaller, more effective static mixers capable of handling high pressures without premature baffle failure, while enabling the use of complex geometries and smaller sizes.
Implementation Method 1
tapered mixing elements with alternating baffle widths and heights that act as a wedge within the mixing conduit, distributing pressure evenly
Data Source
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AI summary
A static mixer 10 for mixing a flow of two or more fluids is disclosed. The static mixer 10 includes a mixing conduit 20 that defines a mixing passage, and a mixing element 100,200 configured to be received by the mixing passage that includes at least two mixing baffles 101, 201. Each of the at least two mixing baffles 101, 201 comprises a plurality panels that are configured to divide and mix the fluid as the fluid flows through the mixing passage. No continuous sidewalls extend between the at least two mixing baffles, and the mixing element is tapered along a longitudinal direction.