Mixer insert, static mixer and production method

Abstract

A mixer insert (1) for a static mixer, comprising a plurality of mixing elements (3, 3a, 3b, 3c, 3d, etc.) which are disposed one behind the other along a longitudinal axis (L) and preferably immediately adjoin each other and each comprise a plurality of crossing rods (8, 9; 10, 11), at least two mixing elements consecutive along the longitudinal axis (L) among the plurality of mixing elements (3, 3a, 3b; 3b, 3c; 3c, 3d; etc.) being turned relative to each other by a twist angle of preferably 90 with respect to the longitudinal axis (L), the mixer insert (1) being composed of multiple separate mixer-insert parts (2, 2a, 2b) which each extend along the longitudinal axis and which are disposed adjacent to each other perpendicular to the longitudinal axis (L), each mixer-insert part (2, 2a, 2b) having a plurality of mixing-element parts (14, 14a, 14b, 14c, 14d, etc.; 15, 15a, 15b, 15c, 15d, etc.) which are disposed one behind the other along the longitudinal axis (L) and are integrally connected to each other along the longitudinal axis (L) and immediately adjoin each other, and that the mixing-element parts (14, 15; 14a, 15a; 14b, 15b; 14c, 15c, 14d, 15d; etc.) of the mixer-insert parts (2, 2a, 2b) that are disposed next to each other perpendicular to the longitudinal axis form one of the mixing elements (3, 3a, 3b, 3c, 3d, etc.), and that at least two of the mixing-element parts (14, 14a, 14b, 14c, 14d, etc.; 15, 15a, 15b, 15c, 15d, etc.) of the mixer-insert parts (2, 2a, 2b) that immediately adjoin each other along the longitudinal axis (L) are turned relative to each other by the twist angle with respect to the longitudinal axis (L).

Claims

1. A mixer insert (1) for a static mixer, comprising a plurality of mixing elements (3, 3a, 3b, 3c, 3d, etc.) which are disposed one behind the other along a longitudinal axis (L) and each comprise a plurality of crossing rods (8, 9; 10, 11), at least two mixing elements consecutive along the longitudinal axis (L) among the plurality of mixing elements (3, 3a, 3b; 3b, 3c; 3c, 3d; etc.) being turned relative to each other by a twist angle, the mixer insert (1) being composed of multiple separate mixer-insert parts (2, 2a, 2b) which each extend along the longitudinal axis and which are disposed adjacent to each other perpendicular to the longitudinal axis (L), each mixer-insert part (2, 2a, 2b) having a plurality of mixing-element parts (14, 14a, 14b, 14c, 14d, etc.; 15, 15a, 15b, 15c, 15d, etc.) which are disposed one behind the other along the longitudinal axis (L) and are integrally connected to each other along the longitudinal axis (L), and wherein the mixing-element parts (14, 15; 14a, 15a; 14b, 15b; 14c, 15c, 14d, 15d; etc.) of the mixer-insert parts (2, 2a, 2b) that are disposed next to each other perpendicular to the longitudinal axis form one of the mixing elements (3, 3a, 3b, 3c, 3d, etc.), the mixing-element parts (14, 14a, 14b, 14c, 14d, etc.; 15, 15a, 15b, 15c, 15d, etc.) of at least one of the mixer-insert parts (2, 2a, 2b) each having crossing rods (8, 9, 10, 11), wherein the mixing-element parts (14, 14a, 14b, 14c, 14d, etc.; 15, 15a, 15b, 15c, 15d, etc.) of each mixer-insert part (2, 2a, 2b) immediately adjoin each other and at least two of the mixing-element parts (14, 14a, 14b, 14c, 14d, etc.; 15, 15a, 15b, 15c, 15d, etc.) of the mixer-insert parts (2, 2a, 2b) that immediately adjoin each other along the longitudinal axis (L) are turned relative to each other by the twist angle with respect to the longitudinal axis (L).

2. The mixer insert according to claim 1, wherein the mixing elements (3, 3a, 3b, 3c, 3d, etc.) and/or the mixing-element parts (14, 14a, 14b, 14c, 14d, etc.; 15, 15a, 15b, 15c, 15d, etc.) are turned by the twist angle with respect to the longitudinal axis (L) in an alternating manner along the longitudinal axis (L).

3. The mixer insert according to claim 1, wherein the mixer-insert parts (2, 2a, 2b) mesh with each other in a form-fitting fashion perpendicular to the longitudinal axis (L) in such a manner that the mixer-insert parts (2, 2a, 2b) are secured against relative displacement along the longitudinal axis.

4. The mixer insert according to claim 1, wherein the mixing-element parts (14, 14a, 14b, 14c, 14d, etc.; 15, 15a, 15b, 15c, 15d, etc.) of at least one of the mixer-insert parts (2, 2a, 2b) have rod portions and rod portions of mixing-element parts (14, 15; 14a, 15a; 14b, 15b; 14c, 15c; 14d, 15d, etc.) adjacent to each other perpendicular to the longitudinal axis (L) come together to form the crossing rods (8, 9, 10, 11) of the mixing elements (3, 3a, 3b, 3c, 3d, etc.).

5. The mixer insert according to claim 1, wherein a portion of the rod portions and/or rods (8, 9; 10, 11) of mixing-element parts (14, 15; 14a, 15a; 14b, 15b; 14c, 15c; 14d, 15d; etc.) disposed axially next to each other immediately adjoin each other.

6. The mixer insert according to claim 1, wherein rods (8, 9; 10, 11) of the mixing-element parts (14, 15; 14a, 15a; 14b, 15b; 14c, 15c; 14d, 15d; etc.) adjacent to each other perpendicular to the longitudinal axis (L) extend parallel to each other.

7. The mixer insert according to claim 1, wherein mixing-element parts that adjoin each other along the longitudinal axis (L) among the mixing-element parts (14, 14a, 14b, 14c, 14d, etc.; 15, 15a, 15b, 15c, 15d, etc.) of at least one of the mixer-insert parts (2, 2a, 2b) integrally merge with each other at free ends of the respective crossing rods (8, 9, 10, 11) and/or wherein some of the rods (8, 9, 10, 11) of the mixing-element parts of one of the mixer-insert parts and some of the rods of the mixing-element parts of the other one of the mixer-insert parts have free ends in the direction of the longitudinal axis, the respective free rod ends of the mixing-element parts adjoining each other along the longitudinal axis of mixer-insert parts adjacent to each other perpendicular to the longitudinal axis (L) are in contact with each other in the assembled state.

8. The mixer insert according to claim 7, wherein the free ends of parallel rods and/or rod portions of the mixing-element parts (14, 14a, 14b, 14c, 14d, etc.; 15, 15a, 15b, 15c, 15d, etc.) that point in the same direction and adjoin a common mixing-element part adjacent along the longitudinal axis (L) among the mixing-element parts (14, 14a, 14b, 14c, 14d, etc.; 15, 15a, 15b, 15c, 15d, etc.) are spaced apart, a clearance being maintained perpendicular to the longitudinal center axis (L).

9. The mixer insert according to claim 1, wherein the mixer-insert parts (2, 2a, 2b) that are adjacent to each other perpendicular to the longitudinal axis (L) are identical.

10. The mixer insert according to claim 1, wherein to form one of the mixing elements (3, 3a, 3b, 3c, 3d, etc.), the mixing-element parts (14, 15; 14a, 15a; 14b, 15b; 14c, 15c; 14d, 15d; etc.) of the mixer-insert parts (2, 2a, 2b) that are each adjacent to each other perpendicular to the longitudinal axis (L) are in contact with each other at a separating plane (T.sub.1, T.sub.2), which accommodates the longitudinal axis (L), and wherein the separating planes (T.sub.1, T.sub.2) of two mixing elements (3; 3a, 3b; 3b, 3c; 3c, 3d; etc.) disposed next to each other along the longitudinal axis (L) are turned relative to each other by 90 with respect to the longitudinal axis (L), all separating planes (T.sub.1, T.sub.2) being turned relative to each other by 90 in an alternating manner.

11. The mixer insert according to claim 1, wherein at least one of the mixer-insert parts (2, 2a, 2b) has a pair (16) of mixing-element parts each pair (16) comprising a first mixing-element part and a second mixing-element part (14; 14a, 14b; 14b, 14c; 14c, 14d; 15; 15a, 15b; 15b, 15c; 15c, 15d; etc.) which are turned relative to each other by 90 with respect to the longitudinal axis, and wherein the first mixing-element part (14a) has multiple rods (8, 9) which are disposed one behind the other along a first transverse axis (Q.sub.1) extending perpendicular to the longitudinal axis (L), rods (10, 11) that are adjacent to each other along the first transverse axis (Q.sub.1) crossing each other and defining at least one first opening (12) which is open in the direction of the first transverse axis (Q.sub.1), and wherein the second mixing-element part (14b) has multiple rods (10, 11) disposed one behind the other along a second transverse axis (Q.sub.2) extending perpendicular to the longitudinal axis (L) and perpendicular to the first transverse axis (Q.sub.1), rods (10, 11) that are adjacent to each other along the second transverse axis (Q.sub.2) crossing each other and defining at least one second opening (13) open in the direction of the second transverse axis (Q.sub.2).

12. The mixer insert according to claim 11, wherein the rods (8, 9) of the first mixing-element part (14a) and the rods (10, 11) of the second mixing-element part (14b) adjoin each other at no more than two parallel connecting lines (V.sub.1, V.sub.2) extending along the first and/or second transverse axis (Q.sub.1, Q.sub.2).

13. The mixer insert according to claim 11, wherein the first mixing-element part (14a) does not have any pairs of crossing rods (8, 9; 10, 11) that are adjacent along the second transverse axis (Q.sub.2) and/or wherein the second mixing-element part (14b) does not have any pairs of crossing rods (8, 9; 10, 11) that are adjacent along the first transverse axis (Q.sub.1).

14. The mixer insert according to claim 1, wherein the rods (8, 9; 10, 11) of the mixing elements (3, 3a, 3b, 3c, 3d, etc.) are each disposed in two groups (6, 7), and wherein the rods (8, 9; 10, 11) within a first group (6, 7) of the two groups are oriented parallel to each other and the rods (8, 9; 10, 11) of a second group of the two groups (6, 7) cross the rods (8, 9; 10, 11) of the first group (6, 7), and wherein the mixing elements (3, 3a, 3b, 3c, 3d, etc.) have a circular, oval, polygonal, rectangular, or square cross-sectional circumferential contour.

15. Mixer insert according to claim 1, wherein the mixing-element parts (14, 14a, 14b, 14c, 14d, etc.; 15, 15a, 15b, 15c, 15d, etc.) of the mixer-insert parts (2, 2a, 2b) have the same extension along the longitudinal axis (L), thus allowing two of the mixer-insert parts (2, 2a, 2b) to be inserted into each other perpendicular to the longitudinal axis (L) without one of the mixer-insert parts (2, 2a, 2b) bending perpendicular to the longitudinal axis (L).

16. A static mixer comprising a tubular container and a mixer insert (1) according to claim 1 disposed therein.

17. A method for producing a mixer insert according to claim 1, comprising the steps of: providing at least two mixer-insert parts (2, 2a, 2b) which are injection-molded and extend along a longitudinal axis and each have a plurality of integrally interconnected mixing-element parts (14, 14a, 14b, 14c, 14d; etc. 15, 15a, 15b, 15c, 15d, etc.) disposed one behind the other along the longitudinal axis (L) and immediately adjoining each other, of which at least two immediately adjoining mixing-element parts (14, 14a, 14b, 14c, 14d; etc. 15, 15a, 15b, 15c, 15d, etc.) are turned relative to each other by a twist angle, joining the mixer-insert parts (2, 2a, 2b) in at least one assembly direction, which extends perpendicular to the longitudinal axis (L), in such a manner that the mixing-element parts (14, 15; 14a, 15a; 14b, 15b; 14c, 15c; 14d, 15d; etc.) that are disposed next to each other perpendicular to the longitudinal axis of the mixer-insert parts (2, 2a, 2b) come together to form one of the mixer inserts (3, 3a, 3b, 3c, 3d, etc.), of which at least two mixing elements (3; 3a, 3b; 3b, 3c; 3c, 3d; etc.) disposed next to each other along the longitudinal axis (L) are turned 90 relative to each other by the twist angle.

18. The mixer insert according to claim 1, wherein the twist angle is 90.

19. The mixer insert according to claim 1, wherein the plurality of mixing elements immediately adjoin each other.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1a: shows a side view of a preferred embodiment of a mixer insert according to the invention;

(2) FIG. 1b: shows a top view of the mixer insert of FIG. 1a,

(3) FIG. 2: shows a view, turned about the longitudinal axis in relation to FIG. 1a, of the mixer insert of FIGS. 1a and 1b;

(4) FIG. 3 and FIG. 4: show different perspective views of a mixer-insert part for forming or assembling the mixer insert of FIGS. 1a and 1b;

(5) FIG. 5: shows a perspective view of two mixer-insert parts during assembly into a mixer insert according to FIGS. 1a to 2;

(6) FIG. 6: shows a perspective view of an injection-molding tool section for producing a mixer-insert part according to FIGS. 3 and 4 or 5.

(7) In the figures, similar elements and elements having similar functions are denoted by similar reference signs.

DETAILED DESCRIPTION

(8) In FIGS. 1a, 1b and 2, a preferred embodiment of a mixer insert 1 according to the invention for producing a static mixer is shown. In the embodiment shown, the mixer insert 1 is made of plastic, specifically by plastic injection-molding. The mixer insert 1 is composed of multiple parts and, in the embodiment shown, comprises two identical mixer-insert parts 2, which are illustrated in perspective views in FIGS. 3, 4 and 5.

(9) To produce a static mixer, the (assembled) mixer insert 1 simply has to be inserted, along its longitudinal extension, into a preferably tubular container.

(10) As can be seen in FIG. 1, the mixer insert 1 has a circumferential contour with a circular cross-section and has an overall circular-cylindrical contour. The mixer insert 1 comprises a plurality of mixing elements 3a, 3b, 3c, 3d, etc., which are disposed one behind the other along a longitudinal axis L (the longitudinal center axis in this case). In the embodiment shown, mixing elements 3a, 3b; 3b, 3c; 3c, 3d; etc. adjoining each other or consecutive along the longitudinal axis are alternately turned relative to each other by a twist angle, in this case an angle of (preferably) 90, for example, with respect to the der longitudinal axis, which means that crossing axes 4a, 4b and 5a, 5b, 5c, 5d, which are to be explained later, of adjacent mixing elements 3a, 3b and of mixing elements 3a, 3b turned relative to each other by 90, respectively, extend not only at a right angle to the longitudinal axis L but also at right angles to each other. The same applies to openings, which are to be explained later, of the mixing elements 3a, 3b turned relative to each other.

(11) Each mixing element 3a, 3b, 3c, 3d comprises two groups 6, 7 of rods, rods 8 of one group 6 (within group 6) being oriented parallel to each other, as are rods 9 of the other group 7 (within group 7), the rods 8, 9 of the two groups 6, 7 crossing each other, specifically on the aforementioned crossing axes 4a, 4b, 5a, 5b, 5c, 5d that extend perpendicular to the longitudinal axis L. Overall, it becomes clear that the rods 8, 9 of some of the mixing elements 3b, 3d, etc. extend substantially (diagonally) in the direction of the longitudinal axis L and rods 10, 11 (cf. FIG. 2) of mixing elements turned relative thereto by 90 extend diagonally perpendicular to the longitudinal axis L. In other word, the rods 8, 9, in terms of their longitudinal extension, i.e. from their respective first axial end to their second axial end, extend along a main direction of extension H.sub.1, with which they form an angle of 45 in this case, for example. The main direction of extension H.sub.1 extends parallel to the longitudinal axis L. The rods 10, 11 of the adjacent mixing element extend, in terms of their respective longitudinal extension, along a second main direction of extension H.sub.2, with which they form an angle of 45 in this case, for example, the second main direction of extension H.sub.2 extending perpendicular to the first main direction of extension H.sub.1 and perpendicular to the longitudinal axis L and parallel to a transverse axis Q.sub.1, which will be explained later.

(12) In the specific embodiment, each mixing element 3a, 3b, 3c, 3d comprises a total of six rods consecutive perpendicular to the longitudinal axis L, though this number may vary; at minimum, there are two adjacent rods, but three, four, five, six or even more than six rods can also be realized.

(13) As can also be seen from FIG. 1a, the crossing rods 8, 9 and 10, 11 define openings 12, 13, respectively, the openings 12, 13 of mixing elements turned relative to each other by 90 each having an angle of 90 to each other with respect to their respective longitudinal extension oriented perpendicular to the longitudinal axis L.

(14) As mentioned, the mixer insert 1 illustrated in FIGS. 1a to 2 is composed of a total of two mixer-insert parts 2 of the kind illustrated in FIGS. 3 and 4. Alternative embodiments having more than two mixer-insert parts can also be realized. In the case at hand, the mixer-insert parts 2 and 2a, 2b (cf. FIG. 2 and FIG. 5) for forming the mixer insert 1 are identical.

(15) FIG. 4 particularly clearly shows the structure of such a one-part mixer-insert part 2, which is preferably injection-molded in this case. A mixer-insert part 2 comprises multiple mixing-element parts 14a, 14b, 14c, 14d, etc., which are disposed one behind the other along the longitudinal axis L. In the assembled state of the mixer insert 1, as becomes clear in particular in FIG. 5, each mixing-element part 14a, 14b, 14c, 14d is assigned a mixing-element part 15a, 15b, 15c, 15d of another mixer-insert part 2, said mixing element part being adjacent perpendicular to the longitudinal axis L and mirror-symmetric to a respective separating plane, the mixing-element parts 14a, 15a; 14b, 15b; 14c, 15c; 14d, 15d; etc. opposite each other perpendicular to the longitudinal axis L coming together to form a mixing element 3a, 3b, 3c, 3d.

(16) Specifically, in the embodiment shown, two mixer-insert parts 2a, 2b, which are identical by way of example, are moved toward each other perpendicular to the longitudinal axis L of the finished mixer insert 1 in a direction of relative movement M (assembly direction), the mixing element parts 14a to 14d and 15a to 15d meshing with each other in the manner of a toothing because of their specific disposition in the case at hand and thus forming a form-fitting connection between the mixer-insert parts 2a, 2b in the assembled state of the mixer insert 1, said connection reliably preventing relative movement of the mixer-insert parts 2a, 2b along the longitudinal axis L.

(17) In FIG. 4, a possible structure of a preferred embodiment of a mixer-insert part 2 is shown in detail. In the embodiment shown, the mixer-insert part 2 comprises multiple pairs 16 of mixing-element parts 14a, 14b that adjoin each other in the direction of the longitudinal axis L and are integral with each other and are turned relative to each other by 90 with respect to the longitudinal axis L. A first mixing-element part 14a of the pair 16 comprises multiple rods 10, 11 which extend along a transverse axis Q.sub.1 extending perpendicular to the longitudinal axis L, the rods 10, 11, as explained above in reference to the mixer insert 1, being disposed in two groups in this case as well, the rods 10 of one of the groups (within the group) being oriented parallel, as are the rods 11 of the other group, and the rods 10, 11 of the different groups crossing each other, specifically along crossing axes 4a, 4b which extend parallel to the first transverse axis Q.sub.1. Openings 13 which are defined by the rods 10, 11 and through which one can look in the direction of the first transverse axis Q.sub.1 also extend in the direction of the first transverse axis Q.sub.1 or parallel thereto. The structure of the other mixing-element part 14b of the pair 16 is turned by exactly 90 thereto. Multiple rods 8, 9 are disposed one behind the other along a second transverse axis Q.sub.2 extending perpendicular to the longitudinal axis L and perpendicular to the first transverse axis Q.sub.1, the rods 8, 9 being divided into two groups of rods 8, 9, the rods 8 of one of the groups extending parallel to each other and the rods 9 of the other group 7 extending parallel to each other, the rods 8, 9 of the groups 6, 7 crossing each other, specifically along crossing axes 5a, 5b that extend parallel to the second transverse axis Q.sub.2, as do the longitudinal extensions of openings 12 defined by the rods 8, 9.

(18) As can be seen, the first mixing-element part 15a of the pair 16 does not have any adjacent pairs of crossing rods in the direction of the second transverse axis Q.sub.2, and neither does the second mixing-element part 14b in the direction of the first transverse axis Q.sub.1. As a result, two mixing-element parts that are disposed next to each other touch only along two connecting lines V.sub.1 and V.sub.2 extending parallel to the second transverse axis Q.sub.2 and on parallel connecting lines V.sub.1, V.sub.2 extending perpendicular thereto and parallel to the first transverse axis Q.sub.1, V.sub.1 and V.sub.2 not being illustrated for the sake of clear illustration. Accordingly, there are rods that have free ends 17 to which no rods of an immediately adjoining mixing-element part of the same mixer-insert part 2 adjoin in the direction of the longitudinal axis L.

(19) As is also apparent from FIG. 4, each two mixing-element parts 14a, 14b; 14b, 14c; 14c, 14d etc. that are turned relative to each other by 90 define two different separating planes T.sub.1, T.sub.2 which are turned relative to each other by 90 and both accommodate the longitudinal axis L (the longitudinal center axis in this case) in the specific embodiment and at which the respective mixing-element parts of a mixer-insert part 2 come into contact with the mixing-element parts of another mixer-insert part 2 that are adjacent or opposite perpendicular to the longitudinal axis L.

(20) This is also apparent from FIG. 5, in particular. There, a separating plane T.sub.1 is delineated that accommodates the longitudinal axis L of the mixer insert 1 in the assembled state. Spoken with reference to the drawing plane, the bottom-right outermost or end-side mixing-element parts of the adjacent mixer-insert parts 2a, 2b meet at this separating plane T.sub.1. The mixing-element parts proximate along the longitudinal axis L meet at a separating plane T.sub.2, which is disposed at a right angle to separating plane T.sub.1 in this case and which is also traversed by the longitudinal axis L.

(21) With regard to the position of the separating planes T.sub.1 and T.sub.2, reference is again made to FIG. 4. As can be seen, the first transverse axis Q.sub.1 is perpendicular to the plane extension of the first separating plane T.sub.1. Analogously, the second transverse axis Q.sub.2 is perpendicular to the plane extension of the second separating plane T.sub.2. As is further apparent from FIG. 4, the first separating planes T.sub.1 are framed between two radial planes R.sub.1 that are parallel to each other and perpendicular to the first separating plane T.sub.1 and defined by two opposite front sides of two mixing-element parts. Likewise, the second separating planes T.sub.2 are axially disposed between two radial planes R.sub.1 defined by two mixing-element parts. In terms of their plane extension, the radial planes R.sub.1 are perpendicular to both the first and the second separating planes T.sub.1 and T.sub.2 and are orthogonally traversed by the longitudinal axis L.

(22) Finally, reference is made to FIG. 6. It shows a section of a mixer-insert part 2 comprising two mixing-element parts 14a, 14b which are turned relative to each other by 90 and are formed and disposed as described above. Also shown is an injection-molding tool 18 having multiple molds for producing the mixer-insert part 2 by injection molding.

REFERENCE SIGNS

(23) 1 mixer insert 2, 2a, 2b mixer-insert parts 3, 3a, 3b, 3c, 3d, etc. mixing elements 4, 4a, 4b, etc. crossing axes 5, 5a, 5b, 5c, 5d, etc. crossing axes 6 group 7 group 8 rods 9 rods 10 rods 11 rods 12 openings 13 openings 14, 14a, 14b, 14c, 14d, etc. mixing-element parts 15, 15a, 15b, 15c, 15d, etc. mixing-element parts 16 pair of mixing-element parts 17 free ends 18 tool L longitudinal axis Q.sub.1 first transverse axis Q.sub.2 second transverse axis M relative assembly direction/direction of relative movement H.sub.1 main direction of extension H.sub.2 main direction of extension T.sub.1 separating plane T.sub.2 separating plane R.sub.1 radial plane