Unitary Static Mixer with Integral Undercuts

Solution Overview

Problem

Current static mixers require separate manufacturing of housing and mixing elements, leading to high mold costs and geometric limitations due to the injection molding process, which hinders efficient production and design flexibility.

Innovation Solution

A single, unitary body static mixer with integrally formed convolutions and undercuts, manufactured through blow molding, roto-molding, or urethane casting, eliminating the need for injection molding and allowing for complex geometries that enhance fluid mixing efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If separate injection molding is used for housing and mixing elements, then manufacturing precision can be achieved, but device complexity and mold costs increase

Engineering Contradiction:

Improvemixing element geometry precisionVSAvoidnumber of separate parts

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent combines the housing and mixing elements into a single unitary body that is injection molded as one piece. The mixing elements are formed directly within the housing cavity during the same molding process, eliminating the need for separate manufacturing and assembly of mixing elements. This integration reduces device complexity while maintaining manufacturing precision through the molding process itself.

Inventive Principle:

Principle #5Merging (Combining)

2Manufacturing precision

If separate injection molding is used for housing and mixing elements, then manufacturing precision can be achieved, but production costs increase due to high mold requirements

Engineering Contradiction:

Improvemixing element geometry precisionVSAvoidmold cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent combines the housing and mixing elements into a single unitary body that is injection molded as one piece. The mixing elements are formed directly within the housing cavity during the same molding process, eliminating the need for separate manufacturing and assembly of mixing elements. This integration reduces device complexity while maintaining manufacturing precision through the molding process itself.

Inventive Principle:

Principle #5Merging (Combining)

3Productivity

If injection molding is used for separate parts, then manufacturing efficiency can be achieved, but geometric flexibility is limited

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidmixing element geometry flexibility

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The patent combines the housing and mixing elements into a single unitary body that is injection molded as one piece. The mixing elements are formed directly within the housing cavity during the same molding process, eliminating the need for separate manufacturing and assembly of mixing elements. This integration reduces device complexity while maintaining manufacturing precision through the molding process itself.

Inventive Principle:

Principle #5Merging (Combining)

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 unitary body design reduces production costs and geometric constraints, enabling efficient and effective fluid mixing by creating continuous swirl patterns that direct fluid flow in multiple directions, improving mixing efficiency without the limitations of traditional injection molding.

Implementation Method 1

The inner wall includes a plurality of integrally formed convolutions... creating continuous swirl patterns that direct fluid flow in multiple directions

Methodology Applied

Scientific EffectVortex flow: Vortex Ring

Data Source

PatentUS10092887B2Static mixers and methods for using and making the same

Publication Date: 2018.10.09 NORDSON CORP

AI summary

A static mixer for mixing a mass fluid flow includes an elongate body including an open proximal end, an open distal end and an inner wall. At least a portion of the inner wall includes a plurality of undercuts formed therein to define a convoluted conduit. The conduit extends along a central axis between the proximal end and the distal end. A portion of the undercuts defines a center-to-perimeter flow portion within the conduit. A portion of the undercuts defines a perimeter-to-center flow portion within the conduit.