Abstract:
The mixer insert ( 2 ) for a static mixer ( 1 ) extends in one longitudinal direction (L), the mixer insert ( 2 ) having a multitude of elements ( 2   e ) running transverse to the longitudinal direction (L) and at least two longitudinal supports ( 2   f ) running in longitudinal direction (L), and the static mixer insert ( 2 ) consisting of a multitude of base elements ( 2   a   , 2   b   , 2   c   , 2   d ) arranged alongside one another in longitudinal direction (L), each base element ( 2   a   , 2   b   , 2   c   , 2   d ) comprising a longitudinal support ( 2   f ), and the base elements ( 2   a   , 2   b   , 2   c   , 2   d ) and their longitudinal supports ( 2   f ) being arranged relative to one another such that a longitudinal support ( 2   f ) running over the entire length of the mixer insert ( 2 ) is present, and base elements ( 2   a   , 2   b   , 2   c   , 2   d ) arranged alongside one another are bonded to one another in a fixed manner at least via the longitudinal supports ( 2   f ).

Description:
FIELD OF THE INVENTION 
     The invention relates to a mixer insert for a static mixer and methods of manufacture therefore. 
     BACKGROUND OF THE INVENTION 
     The document EP 0727249 discloses a static mixer for the mixing of highly viscous media. The static mixer includes a tube and also a mixer insert arranged within the tube. The mixer insert is also termed a mixing element. A disadvantage of this mixer is the fact that the manufacture of the mixer insert is very complicated and thus costly. A disadvantage is moreover the fact that the mixer insert has ribs at its periphery extending in the longitudinal direction to the tube wall which serve to reinforce the mixer in the axial direction against the pressure drop forces which likewise occur in the axial direction along which a medium to be mixed can flow in the axial direction unhindered through the boundary regions in which the longitudinal ribs extend which considerably reduces the mixing quality of the mixer. 
     SUMMARY OF THE INVENTION 
     It is the object of the present invention to propose an economically more advantageous mixer insert, a more advantageous static mixer and also a more advantageous method for the manufacture of a mixer insert. 
     This object is satisfied in a mixer insert for a static mixer wherein the mixer insert extends in a longitudinal direction and wherein the mixer insert has a plurality of bars extending transverse to the longitudinal direction as well as at least two longitudinal supports extending in the longitudinal direction, characterized in that the static mixer insert consists of a plurality of basic elements arranged lying next to one another in the longitudinal direction, with each basic elements including a longitudinal support and wherein the basic elements and their longitudinal supports are mutually arranged such that a longitudinal support extending over the total length of the mixer insert is formed, with basic elements arranged lying next to one another being firmly connected together at least via the longitudinal supports. 
     The object is in particular satisfied with a mixer insert for a static mixer wherein the mixer insert extends in a longitudinal direction and wherein the mixer insert has a plurality of bars extending transverse to the longitudinal direction as well as at least two longitudinal supports extending in the longitudinal direction, and wherein the static mixer insert consists of a plurality of basic elements arranged lying next to one another in the longitudinal direction, with each basic elements including a longitudinal support and wherein the basic elements and their longitudinal supports are mutually arranged such that a longitudinal support extending over the total length of the mixer insert is formed, with basic elements arranged lying next to one another being firmly connected together at least via the longitudinal supports. 
     The object is, moreover, preferably satisfied with a method of manufacturing a mixer insert wherein basic elements of an easily fusible material are produced, wherein a plurality of basic elements are arranged mutually contacting one another and lying next to one another in a longitudinal direction, wherein the basic elements are thereafter clad, wherein the basic elements are thereafter removed by melting so that hollow cavities are formed by the no longer present basic elements, and wherein a liquid material, which subsequently solidifies, is supplied to the hollow cavities such that a monolithic mixer insert arises which essentially has the form determined by the basic elements. 
     A metal, a casting resin or a plastic, in particular a thermo-setting plastic is preferably used as a liquid material which subsequently solidifies. 
     In a preferred embodiment the longitudinal supports of the mixer inserts are arranged extending within the flow cross-section and are preferably spaced with respect to the outer contour of the mixer insert. 
     The mixer insert of the invention has the advantage that it can be manufactured at favorable cost. The basic elements can in particular be manufactured at favorable cost and with simple tools. Moreover, the mixer insert can be manufactured at favorable cost in a multitude of different designs. The mixer insert has a plurality of longitudinal supports extending in the longitudinal direction which endows the mixer insert with a high strength. Since these longitudinal supports preferably extend within, i.e. removed from, the periphery of the flow cross-section of the tube wall and since no mixing element bars have to be removed for the execution of these longitudinal supports, no material can flow unhindered within the mixer construction and also not along the tube wall and thus negatively influence the mixing result. These longitudinal supports, together with a suitable choice of material, permit the thickness of the mixing element bars to be reduced to a minimum with a high strength, to maximize the empty volume of the mixing elements and to thereby minimize the flow resistance. The mixer insert is thus also not deformed even at high pressure drops. The basic elements lying alongside one another are firmly connected together in an advantageous design at least via the longitudinal supports which contact one another, for example by adhesive bonding, soldering or welding. In a further advantageous embodiment the mixer insert is designed as a monolithic component and thus has a high strength, in particular in the longitudinal direction. The term “monolithic component” will be understood to mean a component that has no weakened points due to joints, for example soldered connections. The monolithic component consists preferably of a metallic casting alloy with high strength values, or a plastic such as a thermoplastic, or a thermo-setting plastic, or a ceramic, and is formed of a single piece. 
     If the monolithic mixer insert consists of metal, then it is as a rule a precision cast part which is preferably cast using a lost wax process. The hollow form manufactured by the lost wax process has longitudinal supports extending in the longitudinal direction which are connected to the transversely extending bars in such a way that the melt that is introduced is reliably supplied to all hollow cavities of the hollow mould. The mixer insert can however, for example, also be manufactured by means of a metal powder injection-casting process. In this process a green part is manufactured by means of injection molding from a mixture of metal powder and organic substances. Thereafter, the organic substances are largely thermally removed and the green part, in which the metallic components still stick to one another, is densely sintered to an end form. The mixer insert could, however, also be manufactured as a ceramic part. For use in chemical reactors, the parts can be additionally coated with catalytically active layers, or ceramic compositions can be doped with catalytically active components. 
     In a preferred design, the mixer insert is arranged in a container with projecting supports, with the longitudinal supports of the mixer insert lying on the supports of the container so that the forces acting on the mixer insert are transmitted to the container at defined positions. This arrangement likewise reduces the danger that the mixer insert could be deformed. This arrangement has, moreover, the advantage that all connection points have a common form which is favorable flow-wise because the starting parts can, for example, be cast from an easily fusible material such as wax by means of a tool, the mixer insert can be removed in simple manner from the container, its open structure can be more simply and quickly cleaned and for example can be controlled well, or indeed replaced. 
     The mixer insert in accordance with the invention has moreover the advantage that it does not have any significant flow obstacles such as large, bulky or misshapen welding points to which the fluids, in particular viscous fluids, could stick during the throw-flow. In this way it is precluded that fluids dwell for a long time at the same point and could indeed decompose, for example with temperature-sensitive polymers. 
     The invention will now be explained in more detail with reference to embodiments. The figures show: 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
         FIG. 1  a perspective view of a basic element; 
         FIG. 2  a perspective view of the opposite side of the basic element of  FIG. 1 ; 
         FIG. 3  a side view of the basic element of  FIG. 1 ; 
         FIG. 4  a plan view of the basic element of  FIG. 2 ; 
         FIG. 5  a perspective view of two basic elements lying against one another; 
         FIG. 6  a monolithic mixer insert including four basic elements; 
         FIG. 7  a mixer insert including four connected basic elements; 
         FIG. 8  a longitudinal section through a static mixer; 
         FIG. 9  a side view of the mixer in accordance with  FIG. 8  from the direction of viewing A and B; 
         FIG. 10  a further side view of a mixer from the direction of viewing A. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  shows a basic element  2   a  having four longitudinal supports  2   f  extending in the longitudinal direction L, with each longitudinal support having, at each of its two end portions, a respective contact surface  2   g  extending perpendicular to the longitudinal direction L and also forming a point of contact  2   g  to a basic element  2   a  arranged lying next to it. All longitudinal supports  2   f  are of the same length. The basic element  2   a  has a plurality of bars  2   e  extending transverse to the longitudinal direction L. 
       FIG. 2  shows the opposite side of the basic element  2   a  shown in  FIG. 1 . The same reference numerals represent the same elements. 
       FIG. 3  shows the basic element  2   a  shown in  FIG. 2  in a side view. The bars  2   e  extend with respect to the longitudinal direction L at an angle α of less than 90 degrees, that is to say transverse to the longitudinal direction L, preferably at an angle α in the range between 10 degrees and 80 degrees. The basic element  2   a  has five connecting webs  2   n  which extend perpendicular to the longitudinal direction L and into which bars  2   e  open and through which the bars  2   e  are mutually held together (with the exception of the outermost short boundary bars which are only held at one side). In an advantageous embodiment the connection webs  2   n  can also form contact surfaces  2   f , as shown in  FIGS. 1 and 3 . It is evident from the view selected in  FIG. 3  that the connection webs  2   n  disposed at the bottom form contact surfaces  2   f  in the illustrated embodiment, whereas the connection webs  2   n  arranged at the top do not form contact surfaces  2   f . The contact surfaces  2   f  of the connection webs  2   n  and also the contact surfaces  2   f  of the longitudinal supports  2   f  preferably extend in a common plane as shown in  FIG. 3 . This arrangement has the advantage that the basic elements  2   a  can be simply arranged above one another or next to one another. The longitudinal support  2   f  could, as indicated in  FIG. 3  at the left, also be provided with connection points  2   p ,  2   o . The same connection points  2   p ,  2   o , or in a similar embodiment, could also be present in the connection webs  2   n.    
     The longitudinal supports  2   f  are preferably directly connected to the connection web  2   n , as shown. The longitudinal supports  2   f  could, however, also only be connected to the bars  2   e . The illustrated basic element  2   a  has four longitudinal supports  2   f , which are arranged spaced apart in a square. The basic element  2   a  should have at least two longitudinal supports  2   f  and can thus, for example, also have three, five or even more longitudinal supports  2   f.    
     The contact or support surfaces  2   g  of the longitudinal supports  2   f  and/or the contact or support surfaces  2   g  of the connection webs  2   n  are preferably arranged in such a way that, as shown in  FIGS. 5 ,  6  and  7 , a plurality of basic elements  2   a ,  2   b ,  2   c ,  2   d  can be arranged lying next to one another in the longitudinal direction L, with the basic elements  2   a ,  2   b ,  2   c ,  2   d  also being in mutual contact via the contact surfaces  2   f . If the mixer insert  2  is formed as a metallic monolithic component, or of a curing casting resin such as a thermo-setting plastic, then the longitudinal supports  2   f  serve as supply passages for the liquid metal or for the casting resin and the support surfaces  2   g  form passage openings for the liquid metal. The longitudinal supports  2   f , the bars  2   e  and the contact surfaces  2   f  are in this arrangement disposed such that all hollow cavities can be filled with the liquid metal. In an advantageous embodiment, all basic elements  2   a ,  2   b ,  2   c ,  2   d  have the same shape. In  FIG. 5  the two basic elements  2   a ,  2   b  arranged next to one another in the longitudinal direction are mutually symmetrically arranged with respect to a plane extending perpendicular to the longitudinal direction L so that the basic elements  2   a ,  2   b  are in mutual contact both at the contact surfaces  2   f  of the longitudinal supports  2   f , and also at the contact surfaces  2   f  of the connecting webs  2   n . The basic elements  2   a ,  2   b  could however, depending on the mixing task that is intended, also be arranged next to one another in a plurality of different mutual alignments and numbers of bars  2   e  such that at least the contact surfaces  2   f  of neighboring longitudinal supports  2   f  in the longitudinal direction come to lie on one another. A plurality of basic elements  2   a ,  2   b ,  2   c ,  2   d  can be disposed lying next to one another in the longitudinal direction L and respectively contacting one another. Moreover, each basic element  2   a ,  2   b ,  2   c ,  2   d  can be arranged in a plurality of possible positions. Depending on the requirement, the mixer insert can thus be designed in a multitude of embodiments by a corresponding mutual arrangement of the basic elements  2   a ,  2   b ,  2   c ,  2   d.    
     The basic elements  2   a ,  2   b ,  2   c ,  2   d  are, for example, manufactured of wax. The simple geometrical shape of the basic elements  2   a ,  2   b ,  2   c ,  2   d  makes it possible to manufacture them at favorable cost, for example with a simple two-part tool. 
     The mixer insert  2  is preferably manufactured by a lost-wax casting process, also termed a precision casting process (English: “Investment Casting”). For this purpose, the basic elements  2   a ,  2   b ,  2   c ,  2   d  are first manufactured of an easily fusible material such as wax. Thereafter, a plurality of basic elements  2   a ,  2   b ,  2   c ,  2   d  are arranged mutually touching one another in a longitudinal direction L. The basic elements  2   a ,  2   b ,  2   c ,  2   d  are thereafter clad with a material. Following this, a heating step takes place during which the basic elements  2   a ,  2   b ,  2   c ,  2   d  are removed by melting so that hollow cavities are formed by the no longer present basic elements  2   a ,  2   b ,  2   c ,  2   d . These hollow cavities are filled with a material, in particular a ceramic material, a thermo-setting casting resin, or a liquid metal, so that a monolithic, preferably metallic mixer insert  2  arises which has substantially the specific form determined by the basic elements  2   a ,  2   b ,  2   c ,  2   d.    
       FIG. 6  shows a mixer insert  2  manufactured in this wax, the shape of which is determined by four basic elements  2   a ,  2   b ,  2   c ,  2   d . The four basic elements  2   a ,  2   b ,  2   c ,  2   d  originally consisting of wax now form a common, single, monolithic metal component. Connection points  2   h  have formed during the casting at the previous contact surfaces  2   f  which is why the basic elements  2   a ,  2   b ,  2   c ,  2   d  are now firmly connected to one another via these mutual connection points  2   h . The basic elements  2   a ,  2   b ,  2   c ,  2   d  are preferably designed in such a way and arranged in such a way that, as shown in  FIG. 6 , longitudinal supports  2   f  are formed which extend over the full length of the mixer insert  2 . 
     The basic elements  2   a ,  2   b ,  2   c ,  2   d  can be mutually arranged in the most diverse manner and can also be arranged next to one another in the longitudinal direction as shown in  FIG. 6  so that the basic elements  2   a ,  2   b  and  2   c ,  2   d  are respectively aligned in the same way with respect to the longitudinal direction L or are mutually rotated relative to one another by an integral multiple of 90 degrees. 
       FIG. 4  shows a plan view of the basic element  2   a  in accordance with  FIG. 2 . The basic element  2   a  or the mixer insert  2  includes a plurality of basic elements  2   a ,  2   b ,  2   c ,  2   d  arranged next to one another in the longitudinal direction L, has a cross-sectional area  2   k  and preferably a circularly extending outer contour  2   l . In a preferred embodiment the longitudinal supports  2   f  extend within the cross-sectional area  2   k  and spaced apart relative to the outer contour  2   l . The longitudinal supports  2   f  could, however, also be arranged such that they form part of the outer contour  2   l  from the view in accordance with  FIG. 4 . Since the mixer insert  2  is preferably designed as a monolithic metallic component, the outer contour  2   l  can be simply machined if it does not correspond to the desired requirements after the casting of the mixer insert  2  or does not have the desired outer contour  2   l . Thus, it is for example very simple and possible at favorable cost to provide a mixer insert  2  with a circular or cylindrical outer contour  2   l  by subsequent machining. 
     The mixer insert  2  is preferably introduced into a tubular container  3 . The container  3  could, however, also have a different cross-sectional shape, for example rectangular or square. The outer contour  2   l  of the mixer insert  2  is thus preferably machined such that a gap of narrow width results between the mixer insert  2  and the container wall  3 . In this way the longitudinal flow which is not subjected to mixing can be considerably reduced. The mixer insert  2  can be machined in such a way that the outer contour  2   l  has a predeterminable gap width, in particular also a very small gap to the inner wall of the container  3 . 
       FIG. 7  shows a mixer insert  2  consisting of four basic elements  2   a ,  2   b ,  2   c ,  2   d  which are fixedly connected together at their points of contact  2   g . The basic elements  2   a ,  2   b ,  2   c ,  2   d  consist of a solid material, for example of metal, plastic (thermoplastic, thermo-setting plastic) or ceramic. The basic elements  2   a ,  2   b ,  2   c ,  2   d  are, for example, firmly connected to one another by adhesive bonding, soldering or welding via their common points of contact  2   g . It can prove advantageous to provide the longitudinal supports  2   f  with connection points, such as projections  2   p  and recesses  2   o , as shown to the left in  FIG. 3 . These connection points enable basic elements  2   a ,  2   b ,  2   c ,  2   d  to be arranged relative to one another in a precisely defined position. 
     In a further advantageous embodiment, the longitudinal supports  2   f  can also be designed as hollow cylinders, within which a clamping device such as a clamping screw is arranged in such a way that, for example in the mixer insert  2  of  FIG. 7 , it contacts against the outwardly facing contact surfaces  2   f  of the basic elements  2   a  and  2   d  and thereby exerts a pressing force on all basic elements  2   a ,  2   b ,  2   c ,  2   d  and holds these together. The ends  2   g  of the longitudinal supports  2   f  are so respectively shaped in a mixer, at the inlet side for the entry element and at the outlet side for the outlet element by machining, or already as a cast part, such that no disturbances or dead zones can arise flow-wise. 
       FIG. 8  shows in a longitudinal section a static mixing apparatus  1  including a tubular container  3 , in which the mixer insert  2  shown in  FIG. 6  or  7  is arranged. The pressure container  3  preferably has, at its inner side, supports  3   a  projecting into the inner space against which the mixer insert  2  lies. The projecting supports  3   a  have a flow favorable shape so that no throughflowing material can stick to them.  FIG. 8  shows two embodiments of connections of the supports  3   a  to the pressure container  3 . The embodiment at the top designated with A includes a sleeve  3   b  which can be inserted into the pressure container  3 , with the support  3   a  being firmly connected to the sleeve  3   b . A further only partly illustrated sleeve  3   c  is releasably connected to the container  3  and serves for the fixing and release of the sleeve  3   b . In the embodiment shown at the bottom designated with B the support  3   a  is fixedly connected to the pressure container  3 . The supports  3   a  are preferably arranged, as shown in  FIGS. 8 and 9 , in such a way that the longitudinal supports  2   f  contact the supports  3   a . The longitudinal supports  2   f  thus serve, on the one hand, for the force transmission in the longitudinal direction L within the mixer insert  2  and, on the other hand, for the transmission of the forces acting on the mixer insert  2  to the container  3 . This arrangement has the advantage that the mixer insert  2  can be removed from the container  3  and thus, for example, be checked or exchanged. The mixer insert  2  in accordance with the invention has the further advantage that it forms a self-supporting structure which can also take up large forces acting in the longitudinal direction L. the mixer insert  2  in accordance with the invention is thus very robust and is in particular also suited for the mixing of viscid media. The arrangement in accordance with  FIG. 8  moreover has the advantage that the longitudinal force is essentially directed via the supports  3   a  to the pressure container  3  which has the consequence that the pressure container  3  only has to be designed at this point in such a way that the longitudinal forces can be taken up. At the remaining points, the pressure container  3  is preferably only exposed to small longitudinal forces. 
       FIG. 9  shows a side view of the mixing apparatus  1  shown in  FIG. 8  from the direction of viewing A and B respectively. In the upper half, the sleeve  3   c  insertable into the container  3  can be seen, with the support  3   a  being held by the sleeve  3   b  as shown in  FIG. 8 . In the lower half it is evident that the support  3   a  is fixedly connected to the wall of the container  3 . The mixer insert  2  can in particular be removed in simple manner from the container  3  and inserted again, in particular with the above illustrated embodiment illustrated at the top. In a preferred design the mixer insert  2  and also the inner diameter of the container  3  has a circular shape. These could, for example, also be of rectangular or square design. 
       FIG. 10  shows in a side view from the direction of viewing B a further embodiment of a mixing apparatus  1  which, in distinction to the embodiment shown in.  FIG. 9 , has a support  3   a  which is designed to extend throughout, that is to say which is connected at both ends to the insertable sleeve  3   c . This throughgoing support  3   a  could also be fixedly connected to the container  3 .