Static Spray Mixer with Integrated Grooves
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing static mixers for mixing and spraying flowable components are complex and costly, with intricate structures that complicate installation and are not cost-effective for single-use applications, particularly when used for high-viscosity materials like sealing compounds or two-component adhesives.
Innovation Solution
A simplified static spray mixer design featuring a tubular one-piece mixer housing with a mixing element and an atomization sleeve, where the atomization sleeve is connected thread-free, and grooves on the mixer housing or sleeve allow for efficient atomization using a pressurized medium, reducing complexity and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex multi-component structure with threaded connections and retaining nuts is used, then reliable atomization and mixing can be achieved, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent combines multiple separate components (mixer housing, atomizer, retaining nut, cap) into a single integrated mixer housing with integrated atomization features. The atomization channels are formed directly within the mixer housing structure, eliminating the need for separate atomizer components and their associated fastening mechanisms.
Solution Approach 2:
The mixer housing serves multiple functions simultaneously: it contains the mixing elements, provides structural support, and incorporates integrated atomization channels. This multi-functional design replaces what previously required separate specialized components for each function.
2Reliability
If multiple separate components with threaded connections are used, then functional reliability is maintained, but ease of manufacture and installation deteriorate
Solution Approach 1:
The patent merges multiple manufactured components into a single molded housing structure, transforming a multi-step assembly process involving threading and fastening into a single manufacturing operation that produces an integrated component with built-in atomization channels.
3Device complexity
If a simple one-piece mixer housing with integrated atomization channels is used, then device complexity and manufacturing cost are reduced, but the number of components and assembly steps must be minimized
Solution Approach 1:
The integration of atomization channels directly into the mixer housing creates a single-component design that can be manufactured as one piece, eliminating assembly steps and enabling fully automated manufacturing processes while maintaining functional reliability.
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 efficient mixing and atomization of components with a significantly simpler structure, enabling cost-effective and automated manufacturing, and improved atomization efficiency with a reduced number of components and no need for screw connections, making it more economical and easier to install.
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
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
Data Source
AI summary
A static spray mixer is proposed for the mixing and spraying of at least two flowable components, having a tubular, one-piece 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 (41) for a pressurized atomization medium. A plurality of grooves are provided in the outer surface of the mixer housing (2) or in the inner surface of the atomization sleeve (4) which respectively extend in the direction of the longitudinal axis (A) and through which the atomization medium can flow from the inlet (41) of the atomization sleeve (4) to the distal end (21) of the mixer housing (2).