Simulation and visualization of flow in a new miniature mixer for multiphase polymer systems

Abstract

A newly designed mixer, the Alberta polymer asymmetric minimixer (APAM), was compared to the MiniMAX molder with flow simulation and flow visualization techniques to evaluate the performance of the mixers. The APAM has a unique, asymmetric design consisting of a varying clearance between the rotor blade tips and the cup wall, which enables the material to be squeezed, stretched, and kneaded in high-shear and converging zones. Flow simulation showed that substantial folding and axial movement occurred in this mixer and that the pressure and velocity profiles exhibited high values at the rotor tip with the smallest rotor tip/cup clearance. In contrast, the MiniMAX molder had very simple flow patterns, which were insufficient to induce good dispersive and distributive mixing. These results concurred with those from an earlier work that studied the structure of blends and nanocomposites processed in the APAM compared to other polymer processing equipment.

Melt Mixing of Polycarbonate with Multi‐Walled Carbon Nanotubes in Miniature Mixers

“…This combined flow is important to break up the CNT agglomerates and to disperse them into the PC matrix. Re‐orientation occurs when the materials squeeze through the smaller gaps, especially in the smallest clearance where substantial recirculation is seen,17,41 helping distributive mixing.…”

Structure–Properties Relationships in Thermoplastic Polyurethane Elastomer Nanocomposites: Interactions between Polymer Phases and Nanofillers

“…The motor then turns the rotor at the desired rotation per minute (rpm) to perform the mixing operation. The small clearances, combined with a range of rotation speeds, allow a shear rates ranging from 1 to 550 · s −1 …”

“…The small clearances, combined with a range of rotation speeds, allow a shear rates ranging from 1 to 550 Á s À1 . [54] …”

Numerical simulation of flow of rubber compounds in partially filled internal mixer

“…A substantial amount of simulation work on internal mixer has been conducted by various researchers. [10][11][12][13][14][15][16][17][18][19][20][21][22][23] Bai and Sundararaj 10 studied the transient temperature development due to viscous dissipation inside an internal batch mixer, using 3D nonisothermal CFD modeling. Salahudeen et al 14 performed simulation work on an miniature internal mixer to compare the mixing efficiency of various rotor geometries such as cam, Banbury rotors, and roller.…”

“…A substantial amount of simulation work on internal mixer has been conducted by various researchers . Bai and Sundararaj studied the transient temperature development due to viscous dissipation inside an internal batch mixer, using 3D nonisothermal CFD modeling.…”