Static Mixing Device with Cavity Slits for Low-Energy Emulsions
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Solution Overview
Problem
Conventional dynamic mixing apparatuses require high operating pressures and rotational speeds, leading to energy inefficiencies, dimensional instabilities, and increased costs, while also posing challenges in maintaining effective dispersive mixing without causing unwanted heating or wear.
Innovation Solution
A mixing device with two confronting surfaces featuring cavities that create slits for fluid flow, allowing for contraction and expansion, which achieves dispersive mixing under low pressure drops and can operate in both static and dynamic modes, reducing power input and maintaining efficient mixing performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional dynamic mixing apparatuses operate at high rotational speeds and pressures, then dispersive mixing performance is improved, but energy consumption increases and dimensional instabilities occur
Solution Approach 1:
The patent inverts the conventional approach by using a static mixer instead of a dynamic rotating mixer. The static mixer uses fixed cavities and slits to create dispersive mixing through pressure-driven flow, eliminating the need for high rotational speeds and reducing energy consumption while maintaining mixing performance.
Solution Approach 2:
The patent replaces the mechanical rotating system with a pressure-driven flow system. Instead of using rotational mechanical energy to achieve mixing, the system uses pressure differential to drive fluid through cavities and slits, substituting mechanical rotation with pressure-driven flow for dispersive mixing.
2Manufacturing precision
If conventional homogenisers use high pressure, then droplet size reduction is improved, but unwanted heating occurs
Solution Approach 1:
The patent replaces high-pressure mechanical homogenization with a controlled pressure-driven flow through static cavities and slits. This substitution reduces the mechanical energy dissipation that causes heating while still achieving effective droplet size reduction through the geometric constraints of the flow path.
Solution Approach 2:
The patent changes the operating parameters by using moderate pressure differentials combined with specific cavity and slit geometries (depths, widths, lengths) to achieve droplet size reduction without the extreme pressures that cause heating in conventional homogenizers.
3Manufacturing precision
If conventional mixers use closely spaced confronting surfaces, then dispersive mixing is improved, but wear and mechanical complexity increase
Solution Approach 1:
The patent inverts the conventional dynamic mixer design by using a static configuration with fixed cavities and slits. This eliminates the need for closely spaced rotating surfaces and their associated wear problems, while still achieving dispersive mixing through the pressure-driven flow geometry.
Solution Approach 2:
The patent extracts the mixing function from the rotating mechanical system and embeds it in the static geometry of cavities and slits. This separation removes the wear-prone rotating components while retaining the dispersive mixing capability through the fixed structural features.
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 device effectively produces fine emulsions with small droplet sizes at lower operating pressures, comparable to conventional high-pressure homogenizers, while minimizing energy consumption and mechanical complexity, and can handle a wide range of fluid mixtures efficiently.
Implementation Method 1
the modes, rates and times of mixing of the composition by, for example, the application of shear and/or extensional forces
Implementation Method 2
the fluids are pressed through the slits and subsequently expand in a wider cavity
Data Source
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AI summary
Provided is a mixing apparatus which can efficiently mix two fluids, for example to create emulsions, which using a relatively low energy input. This objective is met by a mixing device comprising two confronting surfaces (1, 2) having cavities (3, 4) in the surfaces, (1, 2) and wherein the two confronting surfaces are located such that a least three narrow slits (cf. 7, 8, 81) are formed to provide subsequent contraction and expansion of the flow. Especially when the apparatus is run in a static mode, only a low energy input is required, while still providing favourable mixing conditions.