Two-Part Material Mixing for On-Demand Sealant Activation
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Solution Overview
Problem
The limited shelf life of premixed sealants leads to waste and inefficiency, as they expire before being fully used, resulting in excess disposal and resource wastage.
Innovation Solution
A material mixing system comprising a pump system, mixing system, and controller that allows for the precise mixing of base and activator parts in a container based on the desired amount of compounded material needed, extending the usable life of the sealants by mixing only what is required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If premixed sealant is stored in frozen form, then the sealant can be stored for a short period of time (43 days), but the sealant expires and must be disposed of, resulting in waste
Solution Approach 1:
The sealant system is divided into separate base sealant and activator components that are stored independently. The base sealant has an extended shelf life when stored alone, and only becomes active when mixed with the activator at the point of use, preventing waste from expired premixed sealant.
Solution Approach 2:
The base sealant is prepared and stored in advance in a stable, inactive state with extended shelf life. The activator is separately prepared and stored. Both components are ready for use but do not react until the moment of mixing, allowing optimal utilization of material before application.
2Ease of manufacture
If a fixed amount of sealant is mixed in advance, then the mixing process is simplified, but the excess sealant must be disposed of when the required amount is not used
Solution Approach 1:
The mixing system is designed to be dynamic and adjustable, allowing the operator to control the exact amount of base sealant and activator mixed based on the specific requirements of each application, thereby minimizing waste while maintaining ease of use.
Solution Approach 2:
The system allows adjustment of mixing parameters (amounts of base sealant and activator) to match the exact requirements of each application. This flexibility enables optimized material usage without compromising the simplicity of the mixing process.
3Productivity
If sealant is mixed in larger quantities to reduce frequent mixing, then the mixing frequency is reduced, but the unused sealant expires and must be disposed of
Solution Approach 1:
By keeping base sealant and activator separate and only mixing them when needed, the system eliminates waste from premature mixing. The base sealant can be stored in larger quantities with extended shelf life, and only the required amount is activated and mixed at the point of use.
Solution Approach 2:
The system allows operators to mix exactly the amount needed for each task, providing flexibility to match production requirements without being constrained by pre-determined batch sizes, thus eliminating waste from over-mixing.
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 approach reduces waste by allowing customized mixing of sealants, ensuring only the necessary amount is produced, thereby minimizing excess disposal and optimizing resource utilization.
Implementation Method 1
a pump system, which operates to pump the base part and the activator part for the compounded material into the container
Implementation Method 2
a mixing system, which operates to mix the base part and the activator part for the compounded material in the container
Data Source
AI summary
A method, apparatus, and system for mixing a compounded material. A first selected amount of a base part for the compounded material and a second selected amount of an activator part for the compounded material to form a total amount of the compounded material is determined. The first selected amount of the base part is pumped by a pump system from a set of base part sources connected to the pump system into a container. The second selected amount of the activator part is pumped by the pump system from a set of activator part sources connected to the pump system into a container. The base part and the activator part in the container are mixed by a mixing system for a predetermined amount of time that is sufficient to activate the compounded material for use.