WO2020185202A1

WO2020185202A1 - Active mixing system

Info

Publication number: WO2020185202A1
Application number: PCT/US2019/021538
Authority: WO
Inventors: Thomas R. Tudor; David W. Groat
Original assignee: Nordson Corporation
Priority date: 2019-03-11
Filing date: 2019-03-11
Publication date: 2020-09-17

Abstract

Active mixing system and method for mixing first and second material are described. The system includes a mixing body (50) defining a mixing chamber (210) extending therethrough along a longitudinal direction (1), a first input (150B, 210A, 210B) configured to receive the first material, a second input (150B, 210A, 210B) configured to receive the second material, and at least one output (240A, 240B) configured to emit a mixture comprising the first and second materials. The second input (150B, 210A, 210B) is disposed between the first input (150B, 210A, 210B) and the at least one output (240A, 240B) along the longitudinal direction (1). The active mixing system (10) also includes an active mixer (212) extending through the mixing chamber (210), where the active mixer (212) is configured to mix the first and second materials, and a motor (18) attached to the active mixer (212), where the motor (18) is configured to rotate the active mixer (212).

Description

ACTIVE MIXING SYSTEM

TECHNICAL FIELD

[0001] This disclosure generally relates to active mixing systems, and more particularly to mixing systems utilizing actively rotating mixing elements to mix two materials into mixture and dispense the mixture into one or more cartridges.

BACKGROUND

[0002] In many industrial applications, and in particular in the aerospace industry, various types of mixtures are used that are comprised of multiple components, where each of these components are initially produce separately. Then, the separate components are mixed and dispensed into a cartridge, which will cure after mixing if they are not immediately placed into refrigeration. As such, during nonoperational for periods of time, the mixture can cure within the machinery, requiring a user to at least partially disassemble the machinery to clean the machinery before an upcoming mixing operation. Alternatively, the user must disassembly and clean the machinery after each mixing operation has ceased and the mixing machinery will be unused for an extended period of time, such as overnight. As such, previous mixing machines require costly labor to maintain and operate and cause lengthy delays in mixing operations.

[0003] As a result, there is a need for an active mixing system that does not require the disassembly and maintenance time of previous mixers to regularly clean out cured mixture.

SUMMARY

[0004] An embodiment of the present disclosure is an active mixing system for mixing a first material and a second material. The system includes a mixing body defining a mixing chamber extending therethrough along a longitudinal direction, a first input configured to receive the first material, a second input configured to receive the second material, and at least one output configured to emit a mixture comprising the first and second materials. The second input is disposed between the first input and the at least one output along the longitudinal direction. The active mixing system also includes an active mixer extending through the mixing chamber, where the active mixer is configured to mix the first and second materials, and a motor attached to the active mixer, where the motor is configured to rotate the active mixer.

[0005] Another embodiment of the present disclosure is a method of mixing a first material and a second material in an active mixing system. The method includes providing the first material to a mixing chamber through a first input and providing the second material to the mixing chamber through a second input that is spaced from the first input in a longitudinal direction. The method also includes rotating an active mixer that extends through the mixing chamber along the longitudinal direction so as to mix the first material and the second material into a mixture. The method further includes dispensing the mixture into a cartridge, and freezing the cartridge and the mixture contained therein.

[0006] A further embodiment of the present disclosure is an active mixing system for mixing a first material and a second material. The system includes a mixing body defining a mixing chamber extending therethrough along a longitudinal direction, a first input configured to receive the first material, a second input configured to receive the second material, and at least one output configured to emit a mixture comprising the first and second materials. The second input is disposed between the first input and the at least one output along the longitudinal direction. The active mixing system also includes an active mixer extending through the mixing chamber, where the active mixer is configured to mix the first and second materials, and a motor attached to the active mixer, where the motor is configured to rotate the active mixer so as to mix the first and second material. Additionally, the active mixing system includes a first valve releasably attached to the mixing body and configured to selectively provide the first material to the mixing chamber through the first input, and a second valve releasably to the mixing body and configured to selectively provide the second material to the mixing chamber through the second input. The active mixing system further includes a first cover configured to create a fluidic seal over the first input when the first valve is detached from the mixing body, and a second cover configured to create a fluidic seal over the second input when the second valve is detached from the mixing body.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The foregoing summary, as well as the following detailed description, will be better understood when read in conjunction with the appended drawings. The drawings show illustrative embodiments of the disclosure. It should be understood, however, that the application is not limited to the precise arrangements and instrumentalities shown. [0008] FIG. 1 is a perspective view of an active mixing system according to an embodiment of the present disclosure, with first and second valves attached to the mixing body;

[0009] FIG. 2 is an alternative perspective view of the active mixing system shown in

FIG. 1;

[0010] FIG. 3A is a cross-sectional view of the active mixing system shown in FIG. 1, taken along line 3A-3A shown in FIG. 2;

[0011] FIG. 3B is a cross-sectional view of the active mixing system shown in FIG. 1, taken along line 3B-3B shown in FIG. 2;

[0012] FIG. 4 is a perspective view of the active mixing system shown in FIG. 1, with the first and second valves detached and first and second covers attached;

[0013] FIG. 5A is a cross-sectional view of the active mixing system shown in FIG. 4, taken along line 5A-5A shown in FIG. 4;

[0014] FIG. 5B is a cross-sectional view of the active mixing system shown in FIG. 4, taken along line 5B-5B shown in FIG. 4;

[0015] FIG. 6 is an enlarged view of a portion of the cross-sectional view shown in FIG. 5B;

[0016] FIG. 7 is a perspective view of the mixing body of the active mixing system shown in FIG. 4 detached from the base and motor;

[0017] FIG. 8 is a schematic diagram of a controller of the active mixing system and components to which it is in signal connection; and

[0018] FIG. 9 is a process flow diagram of a method of mixing a first material and a second material according to an embodiment of the present disclosure.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0019] Described herein is an active mixing system 10 including a base 14, a motor 18, and a mixing body 50 releasably connected to the base 14 and the motor 18. The mixing body 50 is configured to receive a first material from a first valve 100 and a second material from a second valve 150, mix the first and second materials into a mixture using an active mixer 212, and dispense the mixture into at least one cartridge (not shown). Certain terminology is used to describe the active mixing system 10 in the following description for convenience only and is not limiting. The words“right,”“left,”“lower,” and“upper” designate directions in the drawings to which reference is made. The words“inner” and “outer” refer to directions toward and away from, respectively, the geometric center of the description to describe the active mixing system 10 and related parts thereof. The words “forward” and“rearward” refer to directions in a longitudinal direction 1 and a direction opposite the longitudinal direction 1 along the active mixing system 10 and related parts thereof. The terminology includes the above-listed words, derivatives thereof, and words of similar import.

[0020] Unless otherwise specified herein, the terms“longitudinal,”“lateral,” and “vertical” are used to describe the orthogonal directional components of various components of the active mixing system 10, as designated by the longitudinal direction 1, lateral direction 2, and vertical direction 3. It should be appreciated that while the longitudinal and lateral directions 1 and 2 are illustrated as extending along a horizontal plane, and the vertical direction 3 is illustrated as extending along a vertical plane, the planes that encompass the various directions may differ during use.

[0021] Referring to FIGS. 1-3B, an active mixing system 10 for mixing a first material and a second material into a mixture, and subsequently dispensing the mixture into a cartridge (not shown) is depicted. The first material and the second material can each be either of the constituent materials comprising a two-part poly sulphide sealant, though other materials and resulting mixtures are contemplated. The active mixing system 10 includes a base 14, a motor 18 mounted to the base 14, and a removable assembly 22 releasably attached to each of the motor 18 and the base 14, as will be described further below. The removable assembly 22 can include, among other components, a mixing body 50. The base 14 can be configured to support the mixing body 50 and the motor 18. To attach to the mixing body 50, the base 14 can include a first support block 26 extending upwards from the base 14 along the vertical direction 3. The first support block 26 can comprise a plurality of discrete parts, including a base 26a and a cap 26b releasably attached to the base 26a. The first support block 26 can define a gap 27 between the base 26a and the cap 26b that extends through the entirety of the first support block 26 along the longitudinal direction 1. The gap 27 can be sized to receive a portion of the mixing body 50, in particular a portion of the mixing section 58 of the mixing body 50, which will be described further below. When the mixing body 50 is positioned within the gap 27, the mixing body 50 may be secured to the base 14 via direct contact between the base 26a and the mixing body 50, as well as between the cap 26b and the mixing body 50.

[0022] At least one fastener can extend through the cap 26b and the base 26a so as to secure the cap 26b to the base 26a. In the depicted embodiment, the fasteners take the form of first and second thumb screws 28a, 28b, though other types and quantities of fasteners are contemplated. Thumb screws can be particularly advantageous in a power mixing operation utilizing the active mixing system 10, as thumb screws can reliably and releasably secure components together, while allowing manual loosening and tightening by an operator of the active mixing system 10 without using separate tools. As shown, the first thumb screw 28a can be spaced from the second thumb screw 28b in the lateral direction 2, though other configurations are contemplated. To disengage the mixing body 50 from the base 14, the operator of the active mixing system 10 can manually rotate the first and second thumb screws 28a, 28b until the first and second thumb screws 28a, 28b can be removed from the first support block 26. This allows the cap 26b to be disengaged from the base 26a, and thus the mixing body 50 to be removed from the gap 27. Alternatively, the operator may simply loosen the first and second thumb screws 28a, 28b, which can provide enough clearance between the cap 26b and the base 26a for the operator to slide the mixing body 50 out of the gap 27. Though the first support block 26 as described above is specifically described for securing the mixing body 50 to the base 14, other mechanisms for attaching the mixing body 50 to the base 14 can alternatively be utilized.

[0023] In addition to the first support block 26, the active mixing system 10 can also include a second support block 30 spaced from the first support block 26 along the longitudinal direction 1. The second support block 30 can extend from the base 14 along the vertical direction 3. The second support block 30 can define a cavity 32 that can be sized to receive a portion of the mixing body 50, in particular the seal section 54, which will be discussed further below. Though the cavity 32 is shown as having a particular shape, which in the depicted embodiment can be substantially a rectangular prism, the shape and size of the cavity 32 may differ based upon the shape and size of the portion of the particular mixing body 50 that it is intended to receive. Though the second support block 30 may be similarly shaped to the base 26a of the first support block 26, the second support block 30 may not include a cap or any other structure to secure the mixing body 50 to the second support block 30. As such, the second support block 30 can simply serve as a vertical support that holds a portion of the mixing body 50, and the mixing body 50 can be removed from engagement with the second support block 30 without disengaging or removing any features of the active mixing system 10. However, it is contemplated that the second support block 30 can include a cap similar to the cap 26b of the first support block 26 for securing the mixing body 50 to the second support block 30, or any other type of fastening mechanism for securing the mixing body 50 to the second support block 30.

[0024] As stated above, the active mixing system 10 can also include a motor 18 for rotating an active mixer 212. The motor 18 can be a continuous duty motor that is electric powered (AC or DC), air powered, fluid powered, etc., or any other type of motor capable of rotating the active mixer 212. In the depicted embodiment, the motor 18 is shown as attached to the base 14 through a plurality of fasteners 38. However, the motor 18 can be attached to the base 14 through an alternative fastening mechanism that allows the motor 18 to be releasably or permanently coupled to the base 14. The active mixing system 10 can also include a stabilization piece 34 attached to the base 14 and defining a cavity that a portion of the motor 18 can extend through. The stabilization piece 34 can extend over and around a portion of the motor 18 so as to limit vibration or movement of the portion of the motor 18 that extends through the stabilization piece 34 during operation of the motor 18.

[0025] Referring to FIG. 8, the motor 18 can be connected to a controller 12 through a signal connection 260a, where the signal connection can comprise a wired and/or wireless connection. The controller 12 can be configured to control operation of the motor 18, either automatically or in response to user input. The controller 12 can comprise any suitable computing device configured to host a software application for monitoring and controlling various operations of the active mixing system 10, including the motor 18 and other components as will be described below. It will be understood that the controller 12 can include any appropriate computing device, examples of which include a processor, a desktop computing device, a server computing device, or a portable computing device, such as a laptop, tablet, or smart phone. Specifically, the controller 12 can include a memory and a human-machine interface (HMI) device. The memory can be volatile (such as some types of RAM), non-volatile (such as ROM, flash memory, etc.), or a combination thereof. The controller 12 can include additional storage (e.g., removable storage and/or non-removable storage) including, but not limited to, tape, flash memory, smart cards, CD-ROM, digital versatile disks (DVD) or other optical storage, magnetic tape, magnetic disk storage or other magnetic storage devices, universal serial bus (USB) compatible memory, or any other medium which can be used to store information and which can be accessed by the controller 12. The HMI device can include inputs that provide the ability to control the controller 12, via, for example, buttons, soft keys, a mouse, voice actuated controls, a touch screen, movement of the controller 12, visual cues (e.g., moving a hand in front of a camera on the controller 12), or the like. The HMI device can provide outputs, via a graphical user interface, including visual information, such as the visual indication of the rotational speed of the motor 18, temperature of the mixture, etc., as well as acceptable ranges for various parameters via a display. Other outputs can include audio information (e.g., via speaker), mechanical output (e.g., via a vibrating mechanism), or a combination thereof. In various configurations, the HMI device can include a display, a touch screen, a keyboard, a mouse, a motion detector, a speaker, a microphone, a camera, or any combination thereof. The HMI device can further include any suitable device for inputting biometric information, such as, for example, fingerprint information, retinal information, voice information, and/or facial characteristic information, for instance, so as to require specific biometric information for accessing the controller 12.

[0026] Continuing with FIGS. 1-3B, the removable assembly 22, and particularly the mixing body 50, will be discussed in greater detail. The mixing body 50 includes a seal section 54 at one end, a dispense section 62 at the opposite end along the longitudinal direction 1, and a mixing section 58 connected to both the seal section 54 and the dispense section 62 and extending from the seal section 54 to the dispense section 62. The dispense section 62 can include a first dispense portion 62a and a second dispense portion 62b offset from the first dispense portion 62a, where each of the first and second dispense portions 62a, 62b will be discussed further below. Each of the seal section 54, mixing section 58, and dispense section 62 can be integrally or releasably attached to each other. In the depicted embodiment, the seal section 54 is integrally attached to the mixing section 58, and the mixing section 58 is releasably attached to the dispense section 62. The active mixing system 10 can include at least one fastener that releasably attaches the mixing section 58 to the dispense section 62. In the depicted embodiment, the at least one fastener includes first and second thumb screws 60a, 60b, though other types of fasteners are also contemplated. Additionally, devices other than fasteners can be utilized to releasably secure the dispense section 62 to the mixing section 58, such as clamps, press-fit engagement, dovetail slots, etc.

[0027] The mixing section 58 of the mixing body 50 can define a mixing chamber 210 that extends along the longitudinal direction 1 through the mixing section 58. The mixing section 58 can define a first input 210a that extends through the mixing section 58 from its outer surface to the mixing chamber 210, and is configured to receive the first material therethrough. The mixing section 58 of the mixing body 50 can also define a second input 210b that extends through the mixing section 58 from its outer surface to the mixing chamber 210, and is configured to receive the second material therethrough. The dispense section 62 can define at least one output configured to emit a mixture that comprises the first and second materials, where the mixture can be a substantially homogenous combination of the first and second materials. In the depicted embodiment, the dispense section 62 includes a first output 240a and a second output 240b, though other embodiments are contemplated. The second input 210b is positioned between the first input 210a and the at least one output along the longitudinal direction 1. Additionally, the first and second inputs 210a, 210b can be rotationally offset from each other. In the depicted embodiment, the first input 210a is oriented along a plane that is parallel to the longitudinal and lateral directions 1, 2, while the second input 210b is oriented along a plane that is parallel to the lateral and vertical directions 2, 3. Though one specific relative rotational orientation of the first and second inputs 210a, 210b is described, this can differ as desired. The effects of this relative positioning of the first and second inputs 210a, 210b will be described further below.

[0028] To mix the first and second materials, the active mixing system 10 can include an active mixer 212 that extends through the mixing chamber 210 along the longitudinal direction 1. The active mixer 212 is configured to receive a torque produced by the motor 18, such that the active mixer 212 rotates within the mixing chamber 210. The active mixer 212 can be configured to rotate in one or both of a clockwise direction or a counterclockwise direction, which may be controllable by the operator of the active mixing system 10 or may be a preset setting in the controller 12. The active mixer 212 can comprise a longitudinal arrangement of mixing baffles as it extends through the mixing chamber, where the collection of mixing baffles can comprise multiple types of mixing baffles that are each configured to interact with the first and second materials differently. In the depicted embodiment, the active mixer 212 can include a plurality of left-handed mixing baffles 216 and a plurality of right-handed mixing baffles 220, where each of the left-handed mixing baffles 216 and the right-handed mixing baffles 220 are configured to interact with and mix the first and second materials differently. This combination of differently designed left and right-handed mixing baffles 216, 220 in the active mixer 212 can ensure that the first and second materials are mixed to produce a mixture that is as homogenous and streak-free as possible. However, in other embodiments the active mixer 212 can include more than two types of mixing baffles, such as three types, four types, etc.

[0029] The active mixer 212 shown in the present Figures begins with two left- handed mixing baffles 216 attached to each other in a row at the end of the active mixer 212 adjacent the seal section 54. By directly connecting two left-handed mixing baffles 216 to each other adjacent the seal section 54, and particularly between the first input 210a and the seal section 54 along the longitudinal direction 1, rotation of the active mixer 212 draws the first material and/or the second material away from the seal section 54. By minimizing the amount of the first and second material that comes into contact with the seal section 54, leaking of the first and second material out of the mixing chamber 210 through the seal section 54 can be effectively prevented, and wear on the components disposed within the seal section 54 can be limited, thus prolonging the useful life of these components. Extending from the two left-handed mixing baffles 216, the active mixer 212 can comprise an alternating arrangement of left-handed mixing baffles 216 and right-handed mixing baffles 220. For example, the active mixer 212 comprises two left-handed mixing baffles 216 connected to a single right-handed mixing baffle 220, followed by a left-handed mixing baffle 216, followed by a right-handed mixing baffle 220, and so on. However, other arrangements of the left-handed mixing baffles 216 and right-handed mixing baffles 220 are contemplated. When rotating, this alternating arrangement of oppositely-oriented mixing baffles can function to effectively mix the first and second materials to produce the mixture and draw the ensuing mixture through the mixing chamber 210 along the longitudinal direction 1 and to the dispense section 62.

[0030] As noted previously, the dispense section 62 can include a first dispense portion 62a and a second dispense portion 62b offset from the first dispense portion 62a. In the depicted embodiment, the first and second dispense portions 62a, 62b are spaced apart and aligned along the lateral direction 2, though other relative positions for the first and second dispense portions 62a, 62b are contemplated. For example, the first and second dispense portions 62a, 62b can be spaced apart vertically, extend parallel to each other, etc.

[0031] The first dispense portion 62a can define a first outlet channel 224a that extends from the mixing chamber 210 to the first output 240a, where the first outlet channel 224a is configured to direct the mixed mixture from the mixing chamber 210 to the first output 240a. The first output 240a is configured to be releasably connected to a cartridge (not shown), such that the mixture can flow through the first output 240a to fill the cartridge. The first output 240a can define an MPT connection, though other types of connections are contemplated. To control the flow of mixture through the first output 240a so as to allow for changing cartridges when one has been fully filled, for example, the first dispense portion 62a can include a first valve 248a, where the first valve 248a is configure to selectively block or allow the flow of mixture through the first outlet channel 224a to the first output 240a. In one embodiment, the first valve 248a is in fluid communication with a pressurized air source 256. The pressurized air source 256 can comprise any pressurized air source capable of providing air that is clean and relatively dry at a pressure of at least 80 psi, though lower pressures are also contemplated. The controller 12 can direct the pressurized air source 256 through a signal connection 260d, which can be a wired and/or wireless connection, to selectively provide air to the first valve 248a through a first air input 244a so as to block or allow the flow of the mixture. However, valves other than a pneumatically actuated valve are contemplated for use in the first dispense portion 62a.

[0032] Similarly, the second dispense portion 62b can define a second outlet channel 224b that extends from the mixing chamber 210 to the second output 240b, where the second outlet channel 224b is configured to direct the mixed mixture from the mixing chamber 210 to the second output 240b. The second output 240b is configured to be releasably connected to a cartridge (not shown), such that the mixture can flow through the second output 240b to fill the cartridge. The second output 240b can define an MPT connection, though other types of connections are contemplated. To control the flow of mixture through the second output 240b so as to allow for changing cartridges when one has been fully filled, for example, the second dispense portion 62b can include a second valve 248b, where the second valve 248b is configure to selectively block or allow the flow of mixture through the second outlet channel 224b to the second output 240b. In one embodiment, the second valve 248b is in fluid communication with the pressurized air source 256. The controller 12 can direct the pressurized air source 256 to selectively provide air to the second valve 248b through a second air input 244b so as to block or allow the flow of the mixture. However, valves other than a pneumatically actuated valve are contemplated for use in the second dispense portion 62b. Further, though the first and second dispense portions 62a, 62b and their corresponding components are described as being substantially similar, the first and second dispense portions 62a, 62b can differ as desired. Additionally, though the active mixing system 10 has been described as including two dispense portions 62a, 62b, and likewise two outputs 240a, 240b, the dispense section 62 can include more or less than two outputs. For example, in other embodiments the dispense section 62 can include one output, three outputs, four outputs, etc., and optionally a corresponding number of dispense sections.

[0033] Now referring to FIG. 6, at the end of the active mixer 212, the last mixing baffle, which can be either of the left-handed mixing baffles 216 or the right-handed mixing baffles 220, can include a magnetic element 228 attached thereto. As the active mixer 212 rotates, the magnetic element 228 can rotate as well. In one embodiment, the magnetic element 228 is a magnetic ball, though other types of magnetic elements are contemplated. The dispense section 62 can include a magnetic switch 232 attached thereto, where the magnetic switch 232 is configured to detect a rotational position of the magnetic element 228. The magnetic switch 232 can provide the rotational position of the magnetic element 228 to the controller 12 through a signal connection 260b, which can comprise a wired and/or a wireless connection. The magnetic switch 232 can be attached to the dispense section 62 such that the magnetic switch 232 does not come into contact with the mixture. The magnetic element 228 and the magnetic switch 232 allow an operator of the active mixing system 10 to monitor rotation of the active mixer 212 without disassembling the mixing body 50. If the magnetic switch 232 detects that the magnetic element 228 is no longer rotating, it can be indicative of a problem within the mixing body 50, such as a blockage of cured mixture, a broken part, etc. As a result, the operator will only be required to take the active mixing system 10 out of operation and disassemble a portion of the mixing body 50 when a problem actually occurs, thus saving time and money. Additionally, the dispense section 62 can include a temperature sensor 236 configured to detect a temperature of the mixture within the mixing body 50. The temperature sensor 236 can transmit the detected temperature to the controller 12 through a signal connection 260c, which can comprise a wired and/or wireless connection. The temperature sensor 236 can be utilized to determine whether the mixing body 50, and particular the mixture contained therein, has been brought up to a temperature sufficiently high to perform a mixing operation after removal from a freezer, where the freezing of the mixing body 50 will be described further below. For example, for certain mixtures, the mixing body 50 must be brought up to about 65-70 degrees Fahrenheit for optimal mixing to occur.

[0034] Continuing with FIGS. 1-3B, at the opposite end of the mixing body 50, the active mixing system 10 can include a shaft 200 that extends from the motor 18 to the removable assembly 22, and is operatively attached to the active mixer 212. The shaft 200 can function to transfer torque produced by the motor 18 to the active mixer 212. The shaft 200 can extend along the longitudinal direction 1 through the seal section 54. To prevent the first and second material from migrating out of the mixing section 58 and into the seal section 54, a first seal 204 can be positioned within the seal section 54 and disposed around the shaft 200 so as to provide a fluidic seal between the seal section 54 and the mixing section 58. In the event that the first seal 204 fails or becomes damaged, the active mixing system 10 can include a second seal 208 spaced from the first seal 204 along the longitudinal direction 1. Like the first seal 204, the second seal 208 can be disposed around the shaft 200 and create a fluidic seal within the seal section 54 to prevent longitudinal migration of the first or second materials in the event that the first seal 204 becomes damaged.

[0035] The active mixing system 10 can include a first valve 100 attached to the mixing body 50 and configured to selectively provide the first material to the mixing chamber 210 through the first input 210a. The first valve 100 can include a channel 112 that extends therethrough and a material input 126 that is configured to receive the first material from a material source (not shown) and provide the first material to the channel 112. A needle 108 can be disposed within the channel 112, where the needle 108 is configured to linearly translate through the channel 112 so as to selectively block the first material from flowing through the first input 210a. A piston 116 can be attached at an end of the needle 108, where actuation of the piston 116 is configured to translate the needle 108 within the channel 112.

To actuate the piston 116, the first valve 100 can include a first air input 122a that provides pressurized air to the upper side of the piston 116 and a second air input 122b that provides pressurized air to the bottom side of the piston 116. Each of the first and second air inputs 122a, 122b can be in fluid communication with the pressurized air source 256, so that the controller 12 can selectively direct the pressurized air source 256 to provide pressurized air to the first air input 122a or the second air input 122b. When the pressurized air source 256 provides air to the first air input 122a, and likewise to the upper side of the piston 116, the piston 116 translates the needle 108 such that the needle 108 blocks the first material from entering the mixing chamber 210 through the first input 210a. In contrast, when the pressurized air source 256 provides air to the second air input 122a, and likewise to the bottom side of the piston 116, the piston 116 translates the needle 108 such that the needle 108 allows the first material to flow into the mixing chamber 210 through the first input 210a.

[0036] The active mixing system 10 can also include a second valve 150 attached to the mixing body 50 and configured to selectively provide the second material to the mixing chamber 210 through the second input 210b. The second valve 150 can include a channel 162 that extends therethrough and a material input 176 that is configured to receive the second material from a material source (not shown) and provide the second material to the channel 162. A needle 158 can be disposed within the channel 162, where the needle 158 is configured to linearly translate through the channel 162 so as to selectively block the second material from flowing through the second input 210b. A piston 166 can be attached to one end of the needle 158, where actuation of the piston 166 is configured to translate the needle 158 within the channel 162. To actuate the piston 166, the second valve 150 can include a first air input 172a that provides pressurized air to the upper side of the piston 166 and a second air input 172b that provides pressurized air to the bottom side of the piston 166. Each of the first and second air inputs 172a, 172b can be in fluid communication with the pressurized air source 256, so that the controller 12 can selectively provide pressurized air to the first air input 172a or the second air input 172b. When the pressurized air source 256 provides air to the first air input 172a, and likewise to the upper side of the piston 166, the piston 166 translates the needle 158 such that the needle 158 blocks the second material from entering the mixing chamber 210 through the second input 210b. In contrast, when the pressurized air source 256 provides air to the second air input 122a, and likewise to the bottom side of the piston 166, the piston 166 translates the needle 158 such that the needle 158 allows the second material to flow into the mixing chamber 210 through the second input 210b. Though the first and second valves 100, 150 are each described as pneumatically- actuated valves, each of the first and second valves 100, 150 can be alternatively configured as desired.

[0037] In the depicted embodiment, the first valve 100 is larger than the second valve 150. As such, the first valve 100 may also be referred to as the larger valve and the second valve 150 can be referred to as the smaller valve. The first valve 100 can be configured to selectively provide the first material to the mixing chamber 210 at a first flow rate, while the second valve 150 can be configured to selectively provide the second material to the mixing chamber 210 at a second flow rate. In one embodiment, the second flow rate is less than the first flow rate. However, in other embodiments the first and second flow rates can be substantially equal, or the first flow rate can be less than the second flow rate. This difference between the first and second flow rates can be reflective of the intended ratio of first material to second material in the resulting mixture.

[0038] Each of the first and second valves 100, 150 can be releasably connected to the mixing body 50. For example, the first valve 100 can be attached to the mixing body 50 by at least one fastener. In the depicted embodiment, the at least one fastener includes a first thumb screw 104a and a second thumb screw 104b. Though thumb screws are specifically shown, the first valve 100 can be attached to the mixing body 50 through other means, such as clamps, press-fit engagement, dovetail slots, etc. Similarly, the second valve 150 can be attached to the mixing body 50 by at least one fastener. In the depicted embodiment, the at least one fastener includes a first thumb screw 154a and a second thumb screw 154b. Though thumb screws are specifically shown, the second valve 150 can be attached to the mixing body 50 through other means, such as clamps, press-fit engagement, dovetail slots, etc.

Thumb screws can be particularly advantageous for attaching the first and second valves 100, 150 to the mixing body 50, as attaching and detaching the first and second valves 100, 150 to and from the mixing body 50 using thumb screws can be performed manually by an operator of the active mixing system 10 without the use of any separate tools.

[0039] In operation, the active operation of the active mixing system 10 can begin when the controller 12 instructs the motor 18 to begin rotating the active mixer 212. The first and second materials can then be provided to the first and second valves 100, 150 from respective material sources (not shown), and the controller 12 can selectively actuate the first and second valves 100, 150 to provide the first and second materials to the mixing chamber 210. After the first and second materials enter the mixing chamber 210 and come into contact with the active mixer 212, the first and second materials can be forced along the longitudinal direction 1 by the active mixer 212 as the active mixer 212 simultaneously mixes the first and second materials to produce the substantially homogenous mixture. After the mixture reaches the end of the mixing chamber 210, the mixture can flow through the first and second portions 62a, 62b of the dispense section 62 to the first and second outputs 240a, 240b. The controller 12 can selectively close and open the first and second valves 248a, 248b of the first and second portions 62a, 62b of the dispense section 62, respectively, so as to control the flow of the mixture to cartridges attached to each of the first and second outputs 240a, 240b. By controlling the first and second valves 248a, 248b, the controller 12 can prevent mixture from flowing out of the first and second outputs 240a, 240b when a cartridge has been filed by one of the respective first and second outputs 240a, 240b and a new cartridge is being attached, or when a mixing operation is being paused.

[0040] Conventionally, when a mixing operation is paused for an extended period of time, such as at the end of a working shift, prior mixing systems must be disassembled and fully cleaned before being used again. This is because the mixture produced by the mixing system can cure within the mixing system, which negatively impacts future mixing operations. Such cleaning and disassembly can be costly and time consuming for the operator of the mixing system. However, the removable assembly 22 of the active mixing system 10 can be easily detached from the base 14 and the motor 18 by the operator and quickly frozen. In one embodiment, the removable assembly 22 is deep frozen at a temperature of about -30° F. This can be done without performing any further cleaning or disassembly on the removable assembly 22 so as to halt mixture curing within the removable assembly 22. Specifically, the removable assembly 22 includes the mixing body 50 and the active mixer 212, which, along with the first and second valves 100, 150, define all of the components of the active mixing system 10 that come into contact with the first and second materials or their resulting mixture. By refrigerating or freezing the removable assembly 22 with a quantity of mixture still contained therein, the curing of the mixture can be stopped.

As a result, the removable assembly 22 can be removed from refrigeration at a later time, brought up to room temperature, such as in a warm water bath, and reattached to the motor 18 and base 14, and mixing of the first and second materials can be resumed. This eliminates most of the time required to disassemble the active mixing system 10 and clean each of its constituent components.

[0041] To remove the removable assembly 22 from the remaining components of the active mixing system 10, the operator must simply perform a minimal number of manual detachments, each of which can require no external tools. Each of the below described detachments can be done in any order, and need not be limited to the order in which they are described. To detach the removable assembly 22 from the base 14, the operator can manually rotate the first and second thumb screws 28a, 28b to loosen or detach the cap 26b of the first support block 26 from the base 26a. The operator can also disengage the motor 18 from a coupling that couples motor 18 to the shaft 200. In one embodiment, the coupling is a hex keyed shaft coupling, though other types of couplings can be utilized. After these steps have been completed, the removable assembly 22 and the active mixer 212 can be simultaneously detached from the base 14 and the motor 18.

[0042] Before or after the removable assembly 22 is detached from the base 14 and the motor 18, the first and second valves 100, 150 must be removed from the removable assembly 22 before the removable assembly 22 is placed in refrigeration. To achieve this, first and second thumb screws 104a, 104b are manually loosened by the operator of the active mixing system 10 sufficiently so that that the first valve 100 can be detached from the removable assembly 22. Likewise, the first and second thumb screws 154a, 154b can be manually loosened by the operator sufficiently so that the second valve 150 can be detached from the removable assembly 22. The first and second valves 100, 150 can be detached from the removable assembly in any order.

[0043] However, once the first and second valves 100, 150 have been detached from the removable assembly 22, the first and second inputs 210a, 210b are left exposed, which can result in the first and second material leaking out of the mixing body 50. Referring to FIGS. 4-5B and 7, the active mixing system 10 can include a first cover 252a that is configured to attach to the mixing body 50 and create a fluidic seal over the first input 210a when the first valve 100 is detached from the mixing body 50. The first cover 252a can be configured as a plate that has a substantially rectangular shape, though other shapes are contemplated. To attach the first cover 252a to the mixing body 50, the operator can dispose the first and second thumb screws 104a, 104b through corresponding apertures in the first cover 252a as well as the mixing body 50, and rotate the first and second thumb screws 104a, 104b until the first cover 252a is firmly secured to the mixing body 50 and a fluidic seal is created over the first input 210a. As shown in FIG. 5 A, the first cover 252a can extend over, and not through, the first input 210a, though it is contemplated that in other embodiments a cover can be provided having an extension that extends through the first input 210a for additional sealing. [0044] The active mixing system 10 can also include a second cover 252b that is configured to attach to the mixing body 50 and create a fluidic seal over the second input 210b when the second valve 150 is detached from the mixing body 50. The second cover 252b can be configured as a plate that has a substantially rectangular shape, though other shapes are contemplated. To attach the second cover 252b to the mixing body 50, the operator can dispose the first and second thumb screws 154a, 154b through corresponding apertures in the second cover 252b as well as the mixing body 50, and turn the first and second thumb screws 154a, 154b until the second cover 252b is firmly secured to the mixing body 50 and a fluidic seal is created over the second input 210b. As shown in FIG. 5B, the second cover 252b can extend over, and not through, the second input 210b, though it is contemplated that in other embodiments a cover can be provided having an extension that extends through the second input 210b for additional sealing. Though first and second covers 252a, 252b are specifically described for sealing the first and second inputs 210a, 210b, it is contemplated that other devices can be utilized to seal the first and second inputs 210a, 210b. The complete removable assembly 22 with the first and second valves 100, 150 detached and the first and second covers 252a, 252b attached is shown in FIG. 7. The assembly shown in FIG. 7 is the collection of components from the active mixing system 10 that will be refrigerated together.

[0045] Now referring to FIG. 9, a method 300 of mixing the first material and the second material will be described. In step 302, the first material can be provided to the mixing chamber 210 through the first input 210a. The first material is provided to the mixing chamber 210 through the controller 12 selectively actuating the needle 108 within the first valve 100 by controlling air provided to the first valve 100 from the pressurized air source 256. In step 306, the second material can be provided to the mixing chamber 210 through the second input 210b. The second material is provided to the mixing chamber 210 through the controller 12 selectively actuating needle 158 within the second valve 150 by controlling air provided to the second valve 150 from the pressurized air source 256. Then in step 310, the controller 12 can direct the motor 18 to rotate the active mixer 212 within the mixing chamber 210 so as to mix the first material and second material into a mixture. Each of the steps 302, 306, 310 can be performed in the order described above, or any other order as desired. In particular, the active mixer 212 may begin rotating before either of the first or second materials are provided to the mixing chamber 210 so that the active mixer 212 can begin mixing the first and second materials immediately upon their introduction to the mixing chamber 210.

[0046] In step 314, once the mixture has been fully mixed and moved through the mixing chamber 210, the mixture can be dispensed into a cartridge. As the dispense section 62 includes first and second dispense portions 62a, 62b with corresponding first and second outputs 240a, 240b, respectively, the depicted active mixing system 10 can be configured to dispense the mixture into two cartridges, either simultaneously or in quick succession.

However, as noted above, the dispense section 62 can be alternatively configured to include various other numbers of dispense portions and outputs, and likewise be configured to dispense the mixture into various numbers of cartridges. In step 318, while the mixing process is ongoing the rotational position of the active mixer 212 can be sensed. In particular, the magnetic switch 232 can sense the position of the magnetic element 228 that is attached to the active mixer 212. In step 322, the temperature sensor 236 can sense the temperature of the mixture disposed in the mixing chamber 210. This step can be performed throughout the mixing operation, but in particular can be performed before the mixing operation begins so as to ensure that the active mixing system 10 has been sufficiently brought up to temperature.

[0047] After the cartridge has been filled, in step 326 the cartridge is detached from the active mixing system 10, and the cartridge and the mixture contained therein are frozen. By freezing the cartridge, curing of the mixture within the cartridge can be slowed or effectively stopped. Because of this, the first and second materials can be mixed before either of the first or second materials are provided to the end user, and thus the end user can be provided with a cartridge of the mixture ready for application. Step 326, in addition to detaching a cartridge from the active mixing system 10, can include attaching a new empty cartridge to the active mixing system 10 for filling.

[0048] After a mixing operation has been completed or a substantial pause in the mixing operation will occur, the removable assembly 22 can be detached from the base 14 and the motor 18. To accomplish this, the operator of the active mixing system 10 can perform step 330, in which that operator detaches the first valve 100 from the mixing body 50. This step can involve manually loosening the first and second thumb screws 104a, 104b sufficiently so as to release the first valve 100 from the removable assembly 22, particularly the mixing body 50. In step 334, the operator of the active mixing system 10 can detach the second valve 150 from the mixing body 50. As for the first valve 100, this can involve manually loosening the first and second thumb screws 154a, 154b sufficiently so as to release the second valve 150 from the removable assembly 22, particularly the mixing body 50. At this stage, the first and second inputs 210a, 210b are exposed, which may allow the first and second material to leak out of the mixing body. To prevent this, in step 338, the first cover 252a is attached to the mixing body 50 so as to create a fluidic seal over the first input 210a. This can be done by inserting the first and second thumb screws 104a, 104b through corresponding apertures in the first cover 252a and the mixing body 50 and sufficiently tightening the first and second thumb screws 104a, 104b to create the fluidic seal over the first input 210a. Additionally, in step 342, the second cover 252b is attached to the mixing body 50 so as to create a fluidic seal over the second input 210b. This can be done by inserting the first and second thumb screws 154a, 154b through corresponding apertures in the second cover 252b and the mixing body 50 and sufficiently tightening the first and second thumb screws 154a, 154b to create the fluidic seal over the second input 150b.

[0049] Method 300 can also include step 346, in which the active mixer 212 is detached from the motor 18 that is configured to rotate the active mixer 212. This step can be performed by decoupling the motor 18 from a coupling, such as a hex keyed shaft coupling, that operatively connects the motor 18 to the shaft 200, and thus the active mixer 212. Also, method 300 can include step 350, in which the mixing body 50 is detached from the base 14 that supports the motor 18 and the mixing body 50. This step can be performed by manually loosening the first and second thumb screws 28a, 28b sufficiently so as to loosen the cap 26b from the base 26a of the first support block 26 and the mixing body 50 can be detached from the base 14. Alternatively, the first and second thumb screws 28a, 28b can be loosened to such an extent that the cap 26b is completely detached from the base 26a. Then, once the entirety of the removable assembly 22 is detached from the base 14 and the motor 18, which includes detaching the mixing body 50 from the base 14 and the active mixer 212 from the motor 18, detaching the first and second valves 100, 150 from the mixing body 50, and attaching the first and second covers 252a, 252b to the mixing body 50, step 354 can be performed. In step 354, the mixing body 50 and the active mixer 212 can be frozen to slow or stop the mixture from curing within the mixing body 50. When the operator wants to resume mixing using the active mixing system 10, the operator can simply remove the removable assembly 22 from freezing, bring the removable assembly 22 back up to temperature, and attach the removable assembly 22 to the base 14 and the motor 18. [0050] The active mixing system 10 provides several advantages over known mixing systems. By locating the first input 210a upstream from the second input 210b, the components of the seal section 54 will only be exposed to quantities of the first material, which can be less abrasive than the second material and thus less destructive to the first and second seals 204, 208. To further this goal, beginning the active mixer 212 with two mixing baffles having the same orientation at the end of the active mixer 212 adjacent the seal section 54 aids in drawing the first material away from the seal section 54. As such, the lifespan of the first and second seals 204, 208 can be lengthened. Additionally, the ability to easily and manually remove the removable assembly 22 from the base 14 and the motor 18 allows the removable assembly 22 to be quickly frozen after a mixing operation has been completed to stop mixture curing, which prevents the operator from having to undergo costly and time intensive cleaning and disassembly operations to prepare the active mixing system 10 for the next mixing operation. This advantage can be amplified by using the various sets of thumb screws described above to attach the various components of the active mixing system 10 to each other.

[0051] While various inventive aspects, concepts and features of the inventions may be described and illustrated herein as embodied in combination in the exemplary

embodiments, these various aspects, concepts and features may be used in many alternative embodiments, either individually or in various combinations and sub-combinations thereof. Unless expressly excluded herein all such combinations and sub-combinations are intended to be within the scope of the present inventions. Still further, while various alternative embodiments as to the various aspects, concepts, and features of the inventions— such as alternative materials, structures, configurations, methods, circuits, devices and components, software, hardware, control logic, alternatives as to form, fit and function, and so on— may be described herein, such descriptions are not intended to be a complete or exhaustive list of available alternative embodiments, whether presently known or later developed.

Additionally, even though some features, concepts or aspects of the inventions may be described herein as being a preferred arrangement or method, such description is not intended to suggest that such feature is required or necessary unless expressly so stated. Still further, exemplary or representative values and ranges may be included to assist in understanding the present disclosure; however, such values and ranges are not to be construed in a limiting sense and are intended to be critical values or ranges only if so expressly stated. Moreover, while various aspects, features, and concepts may be expressly identified herein as being inventive or forming part of an invention, such identification is not intended to be exclusive, but rather there may be inventive aspects, concepts, and features that are fully described herein without being expressly identified as such or as part of a specific invention, the scope of the inventions instead being set forth in the appended claims or the claims of related or continuing applications. Descriptions of exemplary methods or processes are not limited to inclusion of all steps as being required in all cases, nor is the order that the steps are presented to be construed as required or necessary unless expressly so stated.

[0052] While the invention is described herein using a limited number of embodiments, these specific embodiments are not intended to limit the scope of the invention as otherwise described and claimed herein. The precise arrangement of various elements and order of the steps of articles and methods described herein are not to be considered limiting. For instance, although the steps of the methods are described with reference to sequential series of reference signs and progression of the blocks in the figures, the method can be implemented in a particular order as desired.

Claims

What is claimed is:

1. An active mixing system for mixing a first material and a second material, the system comprising:

a mixing body defining a mixing chamber extending therethrough along a

longitudinal direction, a first input configured to receive the first material, a second input configured to receive the second material, and at least one output configured to emit a mixture comprising the first and second materials, wherein the second input is disposed between the first input and the at least one output along the longitudinal direction;

an active mixer extending through the mixing chamber, wherein the active mixer is configured to mix the first and second materials; and

a motor attached to the active mixer, wherein the motor is configured to rotate the active mixer.

2. The active mixing system of claim 1, further comprising:

a first valve attached to the mixing body and configured to selectively provide the first material to the mixing chamber through the first input; and

a second valve attached to the mixing body and configured to selectively provide the second material to the mixing chamber through the second input.

3. The active mixing system of claim 2, wherein the first valve is configured to selectively provide the first material at a first flow rate and the second valve is configured to selectively provide the second material at a second flow rate that is less than the first flow rate.

4. The active mixing system of claim 1, further comprising:

a base configured to support the mixing body and the motor,

wherein the mixing body and the active mixer are configured to be simultaneously detached from the base and the motor, respectively.

5. The active mixing system of claim 1, wherein at least a portion of the active mixer comprises alternating left-handed mixing baffles and right-handed mixing baffles.

6. The active mixing system of claim 5, wherein the mixing body defines a seal section including at least one seal disposed around a shaft that operatively connects to the motor and the active mixer.

7. The active mixing system of claim 6, wherein the at least one seal includes a first seal and a second seal spaced from the first seal along the longitudinal direction.

8. The active mixing system of claim 6, wherein the active mixer includes two of the left-handed mixing baffles directly connected to each other between the first input and the seal section along the longitudinal direction, wherein the two left-handed mixing baffles are configured to draw the first and second material away from the seal section.

9. The active mixing system of claim 1, wherein the at least one output includes a first output and a second output spaced from the first output, wherein each of the first and second outputs is configured to provide the mixture to a cartridge.

10. The active mixing system of claim 1, wherein the active mixer includes a magnetic element, the active mixing system further comprising:

a magnetic switch configured to detect a rotational position of the magnetic element.

11. The active mixing system of claim 10, wherein the magnetic switch is fluidly isolated from the mixing chamber.

12. The active mixing system of claim 1, wherein the mixing body further comprises a temperature sensor configured to detect a temperature of the mixture within the mixing chamber.

13. A method of mixing a first material and a second material in an active mixing system, the method comprising:

providing the first material to a mixing chamber through a first input;

providing the second material to the mixing chamber through a second input that is spaced from the first input in a longitudinal direction;

rotating an active mixer that extends through the mixing chamber along the longitudinal direction so as to mix the first material and the second material into a mixture; dispensing the mixture into a cartridge; and

freezing the cartridge and the mixture contained therein.

14. The method of claim 13, wherein providing the first material to the mixing chamber includes providing the first material at a first flow rate, and providing the second material to the mixing chamber includes providing the second material at a second flow rate that is less than the first flow rate.

15. The method of claim 13, wherein the mixing chamber is defined by a mixing body, and wherein providing the first material to the mixing chamber includes selectively providing the first material from a first valve attached to the mixing body and providing the second material to the mixing chamber includes providing the second material from a second valve attached to the mixing body.

16. The method of claim 15, further comprising:

detaching the active mixer from a motor that is configured to rotate the active mixer; detaching the mixing body from a base that supports the motor and the mixing body; and

freezing the mixing body and the active mixer.

17. The method of claim 15, further comprising:

detaching the first valve from the mixing body;

detaching the second valve from the mixing body;

attaching a first cover to the mixing body so as to create a fluidic seal over the first input; and

attaching a second cover to the mixing body so as to create a fluidic seal over the second input.

18. The method of claim 13, wherein dispensing the mixture into the cartridge includes dispensing the mixture into a first cartridge through a first outlet and dispensing the mixture into a second cartridge through a second outlet spaced from the first outlet.

19. The method of claim 13, further comprising:

sensing a rotational position of the active mixer.

20. The method of claim 13, further comprising:

sensing a temperature of the mixture disposed in the mixing chamber.

21. An active mixing system for mixing a first material and a second material, the system comprising: a mixing body defining a mixing chamber extending therethrough along a longitudinal direction, a first input configured to receive the first material, a second input configured to receive the second material, and at least one output configured to emit a mixture comprising the first and second materials, wherein the second input is disposed between the first input and the at least one output along the longitudinal direction;

an active mixer extending through the mixing chamber, wherein the active mixer is configured to mix the first and second materials;

a motor attached to the active mixer, wherein the motor is configured to rotate the active mixer so as to mix the first and second material;

a first valve releasably attached to the mixing body and configured to selectively provide the first material to the mixing chamber through the first input;

a second valve releasably to the mixing body and configured to selectively provide the second material to the mixing chamber through the second input;

a first cover configured to create a fluidic seal over the first input when the first valve is detached from the mixing body; and

a second cover configured to create a fluidic seal over the second input when the second valve is detached from the mixing body.

22. The active mixing system of claim 21, further comprising:

at least one first fastener configured to releasably attach the first valve to the mixing body; and

at least one second fastener configured to releasably attach the second valve to the mixing body.

23. The active mixing system of claim 22, wherein each of the at least one first fastener and the at least one second fastener includes at least one thumb screw.

24. The active mixing system of claim 21, further comprising:

a base configured to support the mixing body and the motor, wherein the mixing body and the active mixer are configured to be simultaneously detached from the base and the motor, respectively.

25. The active mixing system of claim 24, further comprising:

at least one fastener configured to releasably attach the mixing body to the base.

26. The active mixing system of claim 25, wherein the at least one fastener includes at least one thumb screw.

27. The active mixing system of claim 21, wherein the active mixer includes a magnetic element, the active mixing system further comprising:

28. The active mixing system of claim 27, wherein the magnetic switch is fluidly isolated from the mixing chamber.

29. The active mixing system of claim 21, wherein the mixing body further comprises a temperature sensor configured to detect a temperature of the mixture within the mixing chamber.

30. The active mixing system of claim 21, wherein the second input is disposed between the first input and the at least one output along the longitudinal direction.