Abstract:
A mixing apparatus includes a housing having an inner chamber, an inlet, and an outlet; an outlet conduit having a first and second end, the second end providing communication between the inner chamber and the outlet; and one or more dispersion members configured to mix one or more fluids, the one or more dispersion members extending between the outlet conduit and the housing. The dispersion members include a plate having a first and second side, a first opening in the plate for receiving an outlet conduit of the mixing device, and a plurality of second openings in the plate. The plurality of second openings has a first and second side. The first and second sides of the plurality of second openings have chamfered edges.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional of U.S. application Ser. No. 13/422,785 filed Mar. 16, 2012, which is hereby incorporated herein by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     The present disclosure relates generally to a mixing apparatus, and more particularly, to mixing and diluting chemicals for the water and wastewater treatment industry, as well as, a mixer for the addition of a chemical solution to water flows for water treatment, for example, in individual residential water systems. 
     BACKGROUND 
     Currently available mixing devices, some of which use an impeller style mixer, may cause shearing or breaking of polymer chains in the chemicals being diluted or mixed by the mixing device. In addition, the currently used mixing devices may fail to allow the polymer chains to fully open before the mixed and diluted chemical is used. If the polymer chains of a chemical are sheared, broken, or not fully open prior to introduction into the process in which they are being used, then the diluted chemical will not be as effective. 
     The present disclosure contemplates a new and improved mixing apparatus and method that overcome the current limitations. 
     SUMMARY 
     In one aspect provided herein, is a novel mixing apparatus including a housing, an outlet conduit, and one or more dispersion plates. The housing has an inner chamber, an inlet, and an outlet. The outlet conduit has a first end and a second end and the second end of the outlet conduit providing fluid communication between the housing&#39;s inner chamber and the outlet. The one or more dispersion plates are configured to mix one or more fluids and the one or more dispersion plates extend between the outlet conduit and the housing. 
     In another aspect provided herein, is a dispersion plate of a mixing apparatus. The dispersion plate includes a plate having a first side and a second side, a first opening in the plate, and a plurality of second openings in the plate. The first opening is for receiving an outlet conduit of the mixing device. The plurality of second openings has a first side and a second side and the first and second sides have chamfered edges. 
     In yet another aspect of the present invention provided herein, is a method of mixing and diluting a concentrated fluid in a mixing device. The method includes delivering the concentrated fluid into a stream of dilution fluid outside a housing of the mixing device. The concentrated fluid and the dilution fluid are supplied into the housing through an inlet. The concentrated fluid and the dilution fluid are mixed in an inner chamber of the housing, wherein the mixing includes passing the concentrated fluid and the dilution fluid through a plurality of first openings in one or more dispersion members in the inner chamber of the housing to blend the concentrated fluid and the dilution fluid to form a mixed fluid. The mixed fluid is discharged through an outlet conduit from the inner chamber of the housing to an outlet of the housing, wherein a pressure of the concentrated fluid and the dilution fluid at the inlet forces the mixed fluid out of the housing through the outlet conduit and the outlet. 
     These, and other embodiments, objects, features and advantages of this invention will become apparent from the following detailed description of the various aspects of the invention taken in conjunction with the accompanying drawings and are considered a part of the claimed invention. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and together with the detailed description herein, serve to explain the principles of the invention. The drawings are only for purposes of illustrating preferred embodiments and are not to be construed as limiting the invention. 
         FIG. 1  is a side view of a mixing apparatus, in accordance with one or more aspects of the present invention; 
         FIG. 2  is a top view of the mixing apparatus of  FIG. 1 , in accordance with one or more aspects of the present invention; 
         FIG. 3  is a cross-sectional view of the mixing apparatus taken along line  3 - 3  in  FIG. 2 , in accordance with one or more aspects of the present invention; 
         FIG. 4  is a top view of a dispersion plate in the mixing apparatus of  FIGS. 1-3 , in accordance with one or more aspects of the present invention; 
         FIG. 5  is a cross-sectional view of the dispersion plate of  FIG. 4  taken along line  5 - 5  in  FIG. 4 , in accordance with one or more aspects of the present invention; 
         FIG. 6  is a perspective view of a cap, in accordance with one or more aspects of the present invention; 
         FIG. 7  is a cross-section view of the cap of  FIG. 6  taken along line  7 - 7  in  FIG. 6 , in accordance with one or more aspects of the present invention; 
         FIG. 8  is an enlarged cross-section view of one chamfered opening in the dispersion plate of  FIGS. 4-5 , in accordance with one or more aspects of the present invention; and 
         FIG. 9  is an enlarged cross-section view of one chamfered opening in the cap of  FIGS. 6-7 , in accordance with one or more aspects of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to the drawings, wherein like reference numerals are used to indicate like or analogous components or steps throughout the several views, and with particular reference to  FIGS. 1-3 , there is illustrated an exemplary mixing apparatus  10 . As best seen in  FIGS. 1-3 , mixing apparatus  10  includes a housing  12  having an inner chamber  14 , an outlet conduit  32 , an inlet  20 , an outlet  30 , and one or more dispersion plates  40 . The housing  12 , inner chamber  14 , and outlet conduit  32  are illustrated as cylindrical tubes in the depicted embodiments, however alternative shapes are contemplated. In the depicted embodiment the inlet  20  is on a side (e.g., axial or longitudinal side) of housing  12  near a top  31  of housing  12  and outlet  30  is on the top  31  of housing  12 , although other arrangements have been contemplated. Referring now to  FIG. 3 , the one or more dispersion plates  40  are evenly spaced apart along the inner chamber  32  and extend (e.g., substantially perpendicular) between the housing  12  and the outlet conduit  32 . The bottom of the outlet conduit  32  is spaced apart from a bottom  39  of inner chamber  14  and extends from bottom  39  of inner chamber  32  of housing  12  and out of top  31  of inner chamber  32  of housing  12  by outlet  30 . The outlet conduit  32  may have a cap  36  on bottom  39  of outlet conduit  32 . 
       FIGS. 4 and 5  illustrate dispersion members  40 . As best seen in  FIG. 4 , dispersion plates  40  have a plate  42 , a first opening  44 , and a plurality of second openings  46 . The first opening  44  may be of a size and shaped to fit around the outer circumference of outlet conduit  32  and inhibit the flow of inlet fluid  16  between first opening  44  and the outside of outlet conduit  32  (e.g., if the outlet conduit  32  is a 1″ pipe having an outer diameter of 1.315″ then the first opening  44  would be machined to about 1.320″ in diameter). In the illustrated embodiment, the outer circumference of dispersion plates  40  engages the inner circumference of housing  12  and inhibits the flow of inlet fluid  16  between the inner circumference of housing  12  and the outer circumference of dispersion plates  40 . In the depicted embodiment, plurality of openings  46  are located across plate  42  in two rings, an inner ring  50  and an outer ring  52 . Other configurations for plurality of openings  46  across plate  42  are also contemplated. As illustrated in the depicted embodiment plurality of openings  46  has twenty openings and the twenty openings each have a diameter of about ¼″. It is also contemplated that plurality of openings  46  may range from about 10 to 50 and the diameter of the openings would vary with number of openings such that the more openings the smaller the diameter and the fewer openings the larger the diameter. Although plurality of openings  46  are shown as round, other shapes are also contemplated. 
     As depicted in  FIG. 5 , plurality of openings  46  are bounded by chamfered edges  48  on both sides of plate  42 . The angles of chamfered edges  48  may range from about 30 degrees to 60 degrees. Preferably the angles of chamfered edges  48  on both sides of plate  42  are about 45 degrees to reduce the possibility of shearing the polymers in the chemicals being mixed and diluted. The angles of chamfered edges  48  are described in greater detail hereinafter. In addition, chamfered edges  48  create a current in the fluids within inner chamber  14  to induce mixing of the chemical within the dilution fluid which enables full activation of the polymers in the chemical. The current in the fluids is formed by a vortex that is created within, and immediately adjacent to, plurality of openings  46  as the fluids pass through dispersion plates  40 . It is also contemplated that only the top side  54  of plate  42  has chamfered edges and the chamfered top edges may range from about 30 to 60 degrees. The angle for chamfered edges  48  on only the top side  54  of plate  42  may preferably be 45 degrees. It is further contemplated that only the bottom side  56  of plate  42  has chamfered edges and the chamfered bottom edges may range from about 30 to 60 degrees. The angle for chamfered edges  48  on only the bottom side  56  of plate  42  may preferably be 45 degrees. 
     As illustrated in  FIGS. 6 and 7 , a cap  34  may include one or more openings  36 , which a fluid  16  passes through to enter outlet conduit  32 , and a second opening  37 . The second opening  37  provides the attachment means for securing cap  34  to outlet conduit  32 . The cap  34  may be secured to outlet conduit  32  at second opening  37  by attachment means know in the art (e.g., with an adhesive, such as polyvinyl chloride cement). In the illustrated embodiment, the one or more openings  36  are located equally spaced apart around the outer surface of cap  34 . It is also contemplated that one or more openings  36  may be located anywhere on cap  34 , including a bottom  39  of cap  34 . Referring now to  FIG. 7 , one or more openings  36  in cap  34  may have chamfered edges  38  to reduce the possibility of shearing the polymers in the chemicals being mixed and diluted. The angles of chamfered edges  38  may range from about 30 degrees to 60 degrees. Preferably the angles of chamfered edges  38  on both sides of cap  34  are about 45 degrees. The angles of chamfered edges  38  are described in greater detail hereinafter. The cap  34  is a cylinder in the illustrated embodiments, however other shapes are also contemplated. 
     As best seen in  FIG. 8 , the angles of chamfered edges  48  of dispersion plates  42  are created relative to a top side  54  of dispersion plates  42  and a bottom side  56  of dispersion plates  42 . An angle  58  is created relative to top side  54  of and into dispersion plates  42  and may range from about 30 degrees to 60 degrees. Preferably angle  58  is about 45 degrees. An angle  60  is created relative to the bottom side  56  of and into dispersion plates  42  and may range from about 30 degrees to 60 degrees. Preferably angle  60  is about 45 degrees. Referring now to  FIG. 9 , the angles of chamfered edges  38  of cap  34  are created relative to an outer surface  62  of cap  34  and an inner surface  64  of cap  34 . An angle  66  is created relative to outer surface  62  of and into cap  34  and may range from about 30 degrees to 60 degrees. Preferably angle  66  is about 45 degrees. An angle  68  is created relative to the inside surface  64  of and into cap  34  and may range from about 30 to 60 degrees. Preferably angle  68  is about 45 degrees. 
     Referring now to  FIGS. 1-9 , a chemical is injected or otherwise added to a dilution fluid prior to entering mixing apparatus  10 . Although not described above, the chemical mixed with the dilution fluid per the method now being described could be, for example, polymer emulsions. The dilution fluid is typically water, but other dilution fluids known in the art may also be used. Once the chemical is injected into the dilution fluid, a blended fluid  16  is created. The blended fluid  16  flows into housing  12  under pressure (e.g., generally the pressure of the water entering the system which is typically “street” pressure of about 50-70 psi and should not exceed about 100 psi due to the construction materials) of mixing apparatus  10  at inlet  20 . As blended fluid  16  enters housing  12  the blended fluid  16  flows into inner chamber  14  and fills inner chamber  14  around outlet conduit  32 . As blended fluid  16  continues to fill inner chamber  14  the pressure from blended fluid  16  entering housing  12  at inlet  20  forces blended fluid  16  to flow through plurality of openings  46  in one or more dispersion plates  40 . In the depicted embodiment, eight dispersion plates  40  are shown, although other numbers of dispersion plates  40  are also contemplated. 
     The plurality of openings  46  in each adjacent dispersion plate  40  are offset (e.g., axially or longitudinally relative to housing  12 ) from plurality of openings  46  in the prior dispersion plate  40  to inhibit blended fluid  16  from flowing straight down through plurality of openings  46  in each of dispersion plates  40  without inducing any mixing. As blended fluid  16  flows through each of the offset dispersion plates  40 , blended fluid  16  flows through the plurality of openings  46  of one of dispersion plates  40  then contacts the surface of the subsequent dispersion plate  40  changing the flow pattern of blended fluid  16  and creating a current or flow to mix blended fluid  16 . As blended fluid  16  passes through each of dispersion plates  40  the current created by blended fluid  16  interacting with dispersion plates  40  induces additional mixing of blended fluid  16 . 
     After blended fluid  16  passes through each of dispersion plates  40  and reaches bottom  39  of inner chamber  14 , blended fluid  16  then may pass through one or more openings  36  in cap  34  to enter outlet conduit  32 . Once blended fluid  16  enters cap  34  and outlet conduit  32  mixing by dispersion plates  40  is substantially completed and blended fluid  16  is now mixed and diluted creating an outlet fluid  18 . Outlet fluid  18  travels up through outlet conduit  32  due to the pressure of the fluids entering at inlet  20 . Outlet fluid  18  then passes out of housing  12  at outlet  30  and is ready for use. The mixed and diluted outlet fluid  18  may be used for wastewater treatment, such as in the dewatering processes. For example, the dewatering process may mix outlet fluid  18  with wastewater sludge to encourage coagulation, flocculation, and separation of solids from the sludge water. As the water pressure of the fluids at inlet  20  provides the necessary pressure to move and mix blended fluid  16  and outlet fluid  18  through mixing apparatus  10 , mixing apparatus  10  does not require additional energy to mix the chemicals and dilution fluid and no moving parts are needed for the mixing process. The flow rate of the fluids at inlet  20  may be controlled by a valve which in turn controls the pressure exerted on the fluids as they pass through mixing apparatus  10 . 
     Alternatively, mixing apparatus  10  could be used in individual residential water systems to remove contaminants, for example sulfur or water hardness, from the water before it is dispersed throughout the residence for use. The incoming water would be mixed with a chemical, such as hydrogen peroxide, to form blended fluid  16  as described above. As the blended fluid  16  passes through dispersion plates  40 , as described above, the chemical oxidizes the contaminants in the water thereby removing the contaminants before the water is dispersed throughout the home for use. Once the blended fluid  16  has reached the bottom  39  of inner chamber  14  it enters cap  34  and creates outlet fluid  18 , as described above, which then exits through outlet conduit  32  at outlet  30  and may then pass into the pipes of the residence for distribution as needed. 
     The invention has been described with reference to the preferred embodiments as well as several alternative embodiments. It will be understood that the architectural and operational embodiments described herein are exemplary of a plurality of possible arrangements to provide the same general features, characteristics, and general system operation. Modifications and alterations will occur to others upon a reading and understanding of the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations.