Abstract:
A collider mixer includes a collider mixer element of cylindrical shape. Partitions form cylindrical channels around the collider mixer element. An input port is coupled to a first channel and an output port is coupled to a last channel. Exactly one inter-partition passage is formed in each of the partitions and a mixing chamber with a cylindrical inner surface holds the mixer element such that outer edges of the partitions seal against the inner surface of the mixing chamber, forming the channels. Fluids enter the input port and splits. A first portion of the fluids flow one direction through each channel and a remaining second portion of the fluids flow in an opposite direction through the same channel. The first portion of the fluids and the second portion of the fluids meet and collide at the inter-partition passages, then pass through the inter-partition passage to an adjacent channel.

Description:
FIELD 
       [0001]    This invention relates to the field of mixing fluids and more particularly to a system for mixing fluids that set quickly. 
       BACKGROUND 
       [0002]    Many fluids need to be mixed well before applying, for example, when spraying on a surface for rigidity or for affixing the surface to another surface in which the fluids are multiple parts of an adhesive. Many such fluids are very viscous (thick). For example, a resin and a catalyst are often very viscous, especially the resin. Likewise, a typical adhesive and hardener such as a two part epoxy is also viscous. A mix of polyurea and isocyanate as a catalyzer are often mixed before applying. 
         [0003]    The properties and applications for such materials and many other fluid materials require that the materials be mixed just before application. For many materials, mixing before application is possible due to both the reaction during mixing and the amount of time before the mixture sets (e.g. hardens). For example, some epoxy adhesives set on the order of one hour after being mixed. Many of these materials are mixed in batches before applying. 
         [0004]    The properties and applications for some materials require that the fluids be mixed almost instantaneously before application to the target surface. In some cases, setting completes within several seconds of mixing. If such fluids are mixed in a batch, the batch would set before application is complete. In some cases, the mixing of the fluids causes a reaction as with polyurethane/urea foams (commonly known as polyurethane foam. The reaction of, for example, isocyanates and water forms carbamic acid that quickly decomposes, splitting off carbon dioxide and leaving behind an amine. In such, the carbon dioxide provides the foaming action. If this mixing is performed in a batch, the foam would occur in the mixing vat, requiring large amounts of space to contain the foam. 
         [0005]    Some prior spray gun systems mixed two or more fluids within the spray gun just before forcing the combined fluid out of a nozzle. Such in-line mixing works for certain fluids, especially low viscosity fluids that readily mix, perhaps in the nozzle, but mixing some fluids in this manner results in uneven mixing, especially high viscosity fluids, resulting in almost separate streams of each fluid exiting the nozzle and mixing partially at the target surface. 
         [0006]    Some prior mixing systems such as disclosed in U.S. Pat. No. 7,744,019 to Merchant, include a turbulent flow chamber of considerable length. These mixers repeatedly split the materials, and then fold the mix onto itself. In U.S. Pat. No. 7,744,019, the spiral mixer is a reversely flighted segmented pattern with each segment being reversely flighted from adjacent segments. This pattern allows homogenous mixing of a catalyst and resin as they pass through a mixing tube. This reference discloses that the tube and spiral mixer are preferably made of an inexpensive plastic so that after spraying, catalyzed resin both can be discarded, as some of the catalyst and resin will set (harden) within the tube and mixer. Due to the length of travel of the fluids, some of the fluids that mix very at an early point in these types of mixers often begin to set before exiting the mixer, causing clogs and wear downstream in the mixer and nozzle. 
         [0007]    What is needed is a system that will properly mix two or more fluids in a minimal distance, hence reducing time. 
       SUMMARY 
       [0008]    In one embodiment, a collider mixer is disclosed including a collider mixer element that has a plurality of partitions. The partitions form channels around the collider mixer element between an input port that is fluidly coupled to a first channel and an output port that is fluidly coupled to a last channel. Inter-partition passages are formed in each of the partitions for passing the fluid from one channel to an adjacent channel. A mixing chamber surrounds the partitions of the collider mixer such that outer edges of the partitions abut inside walls of the mixing chamber, enclosing the channels. Fluids entering the input port split and a first portion of the fluids flow in one direction through each channel and a remaining second portion of the fluids flow in an opposite direction through the channel The first portion of the fluids and the second portion of the fluids meet and collide at the inter-partition passages, where the fluids recombine and pass through the inter-partition passage to an adjacent channel. 
         [0009]    In another embodiment, a method of mixing two or more fluids is disclosed including (a) partially pre-mixing the fluids then (b) 
         [0010]    splitting the fluids into two separate flows of the fluids, a first flow and a second flow. The first flow is collided with the second flow which is repeated as many times as needed to mix the fluids to the desired level of mixing. 
         [0011]    In another embodiment, a collider mixer is disclosed including a collider mixer element having a cylindrical shape and having plurality of cylindrical partitions. The cylindrical partitions form cylindrical channels around the collider mixer element. An input port is fluidly coupled to a first cylindrical channel and an output port is fluidly coupled to a last cylindrical channel. Exactly one inter-partition passage is formed/cut in each of the partitions and a mixing chamber that has a cylindrical inner surface matching an outer cylindrical surface of the cylindrical partitions holds the mixing chamber such that outer edges of the cylindrical partitions seal with the inner surface of the mixing chamber, thereby enclosing the cylindrical channels. Fluids enter the input port and split. A first portion of the fluids flow one direction through each cylindrical channel and a remaining second portion of the fluids flow in an opposite direction through the same cylindrical channel. The first portion of the fluids and the second portion of the fluids meet and collide at the inter-partition passages, where the first portion of the fluids recombine with the second portion of the fluids and then pass through the inter-partition passage to an adjacent cylindrical channel. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]    The invention can be best understood by those having ordinary skill in the art by reference to the following detailed description when considered in conjunction with the accompanying drawings in which: 
           [0013]      FIG. 1  illustrates a perspective view of an collider apparatus for mixing with the collider mixing element shown removed from the housing. 
           [0014]      FIG. 2  illustrates a perspective view of the collider apparatus for mixing with the collider mixing element shown within the housing. 
           [0015]      FIG. 3  illustrates a cutaway view of the collider apparatus for mixing with the collider mixing element shown removed from the housing. 
           [0016]      FIG. 4  illustrates a cutaway view of the collider apparatus for mixing with the collider mixing element shown within the housing. 
           [0017]      FIG. 5  illustrates a plan view of the collider apparatus for mixing with the collider mixing element shown removed from the housing. 
           [0018]      FIG. 6  illustrates a plan view of the collider apparatus for mixing from the exit end. 
           [0019]      FIG. 7  illustrates a plan view of the collider apparatus for mixing from the fluid entry end. 
       
    
    
     DETAILED DESCRIPTION 
       [0020]    Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Throughout the following detailed description, the same reference numerals refer to the same elements in all figures. 
         [0021]    Throughout this description, the collider mixer apparatus is described mixing two fluids such as a resin and a catalyst or an adhesive and a catalyzer, etc., for example purposes only as it is fully anticipated that any number of fluids are mixed by the collider mixer apparatus having two or more input orifices. 
         [0022]    Referring to  FIG. 1 , a perspective view of a collider apparatus for mixing with the collider mixing element  10  is shown removed from the housing  40 . The collider mixing element  10  fits snuggly within the mixing chamber  44  of the housing  40 , such that the partitions  18  interface with the inside wall  46  of the mixing chamber  44 . In such an arrangement, fluids entering into the collider mixing element  10  through an input orifice  14  are forced to separate and travel in opposing directions in channels formed around the perimeter of the collider mixing element  10  between successive partitions  18  to the opposite side of the collider mixing element  10  where the separated flows of fluids collide, forcing the fluids to comingle and mix, then traveling through the inter-partition passages  16  into an adjacent partition passage  16  between adjacent partitions  18  where the above steps are repeated until the fluids, now being well mixed, exit through an exit orifice  34  (see  FIG. 3 ), through the exit bore  30  and into a downstream device such as a nozzle (not shown) that is mounted over the exit surface  32  and fastened by, for example, a fastener (not shown) threaded to the threads around the outer surface of the mixing chamber  44 . 
         [0023]    The opposing side of the collider mixing element  10  has similar inter-partition passages  16  so that, on one side of the collider mixing element  10 , inter-partition passages  16  permit passage of fluid between odd partitions  18  and on the opposite side of the collider mixing element  10 , inter-partition passages  16  permit passage of fluid between even partitions  18 . In this way, the combined fluids enter the collider mixing element  10  through an input orifice  14  and approximately half of the fluids go around the collider mixing element  10  in a clockwise direction and the remainder of the fluids go around the collider mixing element  10  in a counterclockwise direction, meeting on the distal opposite side of the collider mixing element  10  where the two flows (clockwise flow and counterclockwise flow) collide and mix. The mixed/blended flows then transition through the inter-partition passage  16  (on the opposite side, not visible in  FIG. 1 , see  FIGS. 3 and 4 ), again splitting and circumnavigating the collider mixing element  10 , etc. The collision between the two flows (clockwise flow and counterclockwise flow) mixes the two or more input materials. In the exemplary collider mixing element  10  shown, the fluids collide seven times before exiting through the exit orifice  34 . 
         [0024]    Note that any length, dimension, and/or number of partitions  18  are anticipated providing any required number of collisions as to provide the needed degree of mixing. Also, although in the embodiments shown, the inter-partition passages  16  on alternating partitions  18  are located approximately 180 degrees apart around the collider mixing element  10 , any arrangement of inter-partition passages  16  is anticipated. For example, it is equally anticipated that the second inter-partition passages  16  is positioned at approximately 150 degrees around the collider mixing element  10 . In this way, the fluid traveling in one direction around the collider mixing element  10  must travel further than the fluid traveling in the opposite direction around the collider mixing element  10  and, therefore, different portions of the fluids will mix at the collision. 
         [0025]    Also note that, although the spacing between partitions  18  is shown as being the same between all partitions  18 , any spacing between partitions  18  is equally anticipated, forming larger or smaller channels between certain partitions  18  affects flow rates and collision actions. 
         [0026]    Also note that, although the outer shape of the collider mixer  10  and the inner shape of the mixing chamber  44  are substantially cylindrical, any shape is anticipated. 
         [0027]    Holes  50  bored through the base  44  of the housing  40  are provided for attaching to an up-stream device  80  (see  FIG. 3 ) that, for example, controls the flow of the fluids under pressure, etc. Fasteners  60  provide access to check valves  62 / 64  (see  FIGS. 3 and 4 ). 
         [0028]    Referring to  FIG. 2 , a perspective view of the collider apparatus for mixing with the collider mixing element  10  is shown within the housing  40 . The inside walls  46  of the mixing chamber  44  prevents a majority of the fluids from passing over the partitions  18 , except where the inter-partition passages  16  allow the fluid to transition over the partitions  18 , transitioning between adjacent channels. The fasteners  60 / 66  are explained with  FIG. 3 . 
         [0029]    In use, a down-stream device such as a nozzle is removably affixed over the exit surface  32  by, for example, a threaded fastener that holds the down-stream device (not shown) in contact with the exit surface  32 , thereby receiving the mixed fluids from the exit bore  30 . For cleaning, the down-stream device is removed and the collider mixing element  10  is removed from the mixing chamber  44 , providing access to most surfaces for cleaning, for example, with solvents and air streams. 
         [0030]    Referring to  FIGS. 3 and 4 , a cutaway view of the collider apparatus for mixing in which the collider mixing element  10  shown removed from the housing  44  in  FIG. 3 , and a cutaway view of the collider apparatus for mixing in which the collider mixing element  10  is shown within the housing  44  in  FIG. 4 . 
         [0031]    In these views, the sequencing of inter-partition passages  16  is clear, showing the upper inter-partition passages  16  on odd number partitions  18  (from the left) and the lower inter-partition passages  16  on even number partitions  18 . Again, adjacent inter-partition passages  16  are shown offset from each other by  180  degrees as an example, and any offset is anticipated. 
         [0032]    Although two fluids are shown being mixed as an example, any number of fluids is anticipated. The fluids are provided under pressure from an up-stream device  80  such as a dispensing gun or other valve assembly for control of the flow of the fluids. The fluids preferably pass through check valves  60 / 62 / 64  to prevent any of the fluids from back-flowing into the up-stream device  80 , potentially clogging that device  80 . In this example, the check valve comprises a spring  62  that biases a ball  64  against a surface of the up-stream device  80 , such that, fluid pressure from the up-stream device  80  works against the spring  62 , thereby allowing flow from the up-stream device  80  into the housing  40 , while pressure on the fluids within the housing  40  work with the spring  62 , preventing flow of fluids from the housing  40  back into the up-stream device  80 . Removable fasteners  60  hold the spring  62  in place and are removed for cleaning of the housing  40 , springs  62 , and balls  64 . 
         [0033]    Although generally required only for production, cover screws  66  and set screws  70  seal production holes used during manufacture. During manufacturing, in some embodiments, the first input channels  72  are formed by drilling from where the cover screws  66  are shown, before the cover screws  66  are installed. Likewise, the second input channels  74  are formed by drilling from where the set screws  70  are shown, before the set screws  70  are installed. 
         [0034]    A first fluid flows from the up-stream device  80  around the upper ball  64 , through the upper first channel  72 , through the upper second channel  74  and into a space between a back surface of the collider mixing element  10  and an inner-most surface of the mixing chamber  40 . A second fluid flows from the up-stream device  80  around the lower ball  64 , through the lower first channel  72 , through the lower second channel  74  and into the same space between a back surface of the collider mixing element  10  and an inner-most surface of the mixing chamber  40 . The first fluid and the second fluid partially mix in the space between a back surface of the collider mixing element  10  and an inner-most surface of the mixing chamber  40  before entering the collider mixing element  10  through a mixer channel  17 , then out the input orifice  14 , splitting and traveling between the first two partitions  18 , etc. 
         [0035]    Referring to  FIG. 5 , a plan view of the collider apparatus for mixing with the collider mixing element  10  is shown removed from the housing  40 , as is done for cleaning. The threads on the outside surface of the mixing chamber  44  are shown as an example for attaching a downstream device having mating threads, though any form of attachment is anticipated, with or without threads. 
         [0036]    Referring to  FIG. 6 , a plan view of the collider apparatus for mixing from the downstream device end is shown. The input channels  74  are visible within the mixing chamber  44 . 
         [0037]    Referring to  FIG. 7 , a plan view of the collider apparatus for mixing from the upstream device  80  end is shown. The check valve balls  64  and the set screws  70  are visible. 
         [0038]    Note that various aspects of the disclosed embodiments, various specific shapes, sizes, and appendages are shown that relate to one specific method of manufacturing the collider mixer, but such disclosure is not provided to limit the claims in any way as other methods of manufacturing are equally anticipated. 
         [0039]    Equivalent elements can be substituted for the ones set forth above such that they perform in substantially the same manner in substantially the same way for achieving substantially the same result. 
         [0040]    It is believed that the system and method as described and many of its attendant advantages will be understood by the foregoing description. It is also believed that it will be apparent that various changes may be made in the form, construction and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages. The form herein before described being merely exemplary and explanatory embodiment thereof. It is the intention of the following claims to encompass and include such changes.