Static Spray Mixer Groove Inclination Atomization
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Solution Overview
Problem
Existing static spray mixers for mixing and spraying flowable components are complex and costly, with complicated installations that are not cost-effective for single-use applications, particularly when handling high-viscosity materials like polyurethane or epoxy resins.
Innovation Solution
A static spray mixer design featuring a tubular mixer housing with a one-piece mixing element and atomization sleeve, where grooves on the outer or inner surface form flow channels with varying inclinations to optimize atomization, allowing for efficient mixing and spraying of components with a simpler, cost-effective structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex multi-component structure with separate nozzle body, atomizer element, cap, and retaining nut is used, then reliable atomization function is achieved, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent combines the nozzle body, atomizer element, and cap into a single integrated atomization sleeve component. The flow channels are directly formed in the atomization sleeve, eliminating the need for separate components and their associated connections. This merging maintains the atomization function while significantly reducing device complexity and the number of parts.
Solution Approach 2:
The atomization sleeve serves multiple functions simultaneously: it acts as the nozzle body, contains the flow channels for atomization medium, provides the atomizer surface with grooves, and eliminates the need for separate retaining structures. This multi-functionality reduces the overall device complexity while maintaining reliable atomization.
2Reliability
If multiple separate components with threading and retaining nuts are used, then functional reliability is improved, but ease of manufacture and installation deteriorate
Solution Approach 1:
By integrating multiple functional elements into a single atomization sleeve, the patent eliminates complex threading operations and assembly steps. The flow channels and atomizer grooves are formed directly in the sleeve, simplifying manufacturing to a single casting or machining operation rather than multiple component fabrication and assembly steps.
3Ease of manufacture
If flow channels with constant inclination are used, then manufacturing simplicity is maintained, but atomization uniformity and reproducibility deteriorate
Solution Approach 1:
The patent applies different groove inclinations at different locations along the flow channels. The grooves have varying angles that are optimized for specific regions of the flow, creating locally optimized atomization conditions. This local quality variation improves overall atomization uniformity and reproducibility while the entire channel system remains integrated in a single component.
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 design achieves uniform and stable atomization with higher reproducibility, reducing complexity and manufacturing costs while maintaining high-quality mixing and atomization, enabling efficient processing of high-viscosity materials.
Implementation Method 1
the mixed components are atomized at the outlet of the mixer by the action of a medium such as air and can then be applied to the desired substrate in the form of a spray jet or spray mist
Implementation Method 2
Each flow channel has a respective changing inclination toward the longitudinal axis in the direction of flow
Data Source
AI summary
A static spray mixer for the mixing and spraying of at least two flowable components is proposed having a tubular mixer housing (2) which extends in the direction of a longitudinal axis (A) up to a distal end (21) which has an outlet opening (22) for the components, having at least one mixing element (3) arranged in the mixer housing (2) for the mixing of the components as well as having an atomization sleeve (4) which has an inner surface which surrounds the mixer housing (2) in its end region, wherein the atomization sleeve (4) has an inlet channel (41) for a pressurized atomization medium, wherein a plurality of grooves (5) are provided in the outer surface of the mixer housing (2) or in the inner surface of the atomization sleeve (4) which respectively extend toward the distal end and which form separate flow channels (51) between the atomization sleeve (4) and the mixer housing (2) through which the atomization medium can flow from the inlet channel (41) of the atomization sleeve (4) to the distal end (21) of the mixer housing (2). Each flow channel has a respective changing inclination toward the longitudinal axis (A) in the direction of flow.