Static Mixing Tools for Dry Building Materials

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Solution Overview

Problem

Conventional plastering machines and mortar mixing pumps are ineffective in processing dry building materials like insulating plaster compositions containing airgel particles, leading to comminution of particles, increased bulk density, and thermal conductivity, as well as excessive wear due to high shearing forces and abrasion.

Innovation Solution

A device with a mixing tube equipped with static mixing tools that gently process dry building materials by dividing and recombining the material flow, ensuring good wetting and reducing wear, complemented by a shaft with dynamic mixing tools that interact with the static tools to enhance mixing and reduce abrasion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional plastering machines or mortar mixing pumps are used to process dry building materials containing airgel particles, then mixing and conveying can be achieved, but the high shearing forces cause comminution of airgel particles leading to increased bulk density and thermal conductivity

Engineering Contradiction:

Improvemixing and conveying capabilityVSAvoidparticle integrity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent replaces high-shear mechanical mixing systems with a low-shear mixing system that uses a slowly rotating shaft with gentle mixing elements. This substitution reduces the mechanical stress on airgel particles while still achieving effective mixing of the dry building materials with binding agents.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the operating parameters of the mixing system by using lower rotation speeds and lower shear forces. The mixing shaft rotates at controlled low speeds, and the mixing elements are designed to provide gentle agitation rather than high-intensity mixing, thereby preserving particle integrity while maintaining productivity.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If high-pressure mixing (e.g., 8 bar) is applied to process airgel-containing compositions, then mixing efficiency is improved, but thermal conductivity increases by a factor of about 2, nullifying thermal insulation advantages

Engineering Contradiction:

Improvemixing efficiencyVSAvoidthermal conductivity

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The patent fundamentally changes the pressure parameter from high-pressure (8 bar) to low-pressure operation. The mixing system operates at significantly reduced pressures that are sufficient for effective mixing without compressing or damaging the airgel particles, thereby maintaining low thermal conductivity while achieving good mixing efficiency.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If conventional mixing devices with integrated conveying units (e.g., worm pump) are used, then continuous processing is achieved, but increased abrasion and wear occur on the screw jacket and other components

Engineering Contradiction:

Improvecontinuous processing capabilityVSAvoidcomponent wear

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent replaces high-shear mechanical conveying and mixing systems with a low-shear system that reduces friction and abrasion. The gently rotating mixing shaft and low-stress conveying mechanism minimize contact wear on the screw jacket and other components, extending equipment lifespan while maintaining continuous processing capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 prevents comminution of airgel particles, maintains low thermal conductivity, and reduces wear by ensuring gentle processing and efficient wetting of dry building materials, thereby preserving the thermal insulation properties and extending equipment lifespan.

Implementation Method 1

a part or section of the mixing tube has static mixing tools which extend radially inwards from an inner peripheral surface of the mixing tube... divide and recombine the material flow

Methodology Applied

Scientific EffectMaterial flow division and recombination:

Implementation Method 2

a shaft with mixing tools that can be driven by an electric motor is arranged in the mixing tube... interact with the static tools to enhance mixing

Methodology Applied

Scientific EffectDynamic-static mixing interaction:

Implementation Method 3

ensuring good wetting and reducing wear, complemented by a shaft with dynamic mixing tools that interact with the static tools to enhance mixing and reduce abrasion

Methodology Applied

Scientific EffectWetting: Wetting

Data Source

PatentEP2933079B1Device for making dry building materials that are difficult to wet

Publication Date: 2018.08.22 STO SE & CO KGAA

Figure 1
Figure 2a
Figure 2b

AI summary

The invention relates to a device for mixing dry building materials that are difficult to wet, in particular an insulating plaster composition containing aerogel particles. The device comprises a filling funnel (1) for filling at least one dry building material and a one- or multi-part mixing tube (2) connected to the filling funnel (1), which has at least one connection (3) for a mixing liquid, in particular for water, wherein a shaft (4) driven by an electric motor with mixing tools (5, 6) is arranged in the mixing tube (2). According to the invention, a part (7) or section of the mixing tube (2) has static mixing tools (8) which extend radially inwards from an inner circumferential surface (9) of the mixing tube (2).