SK cast micro-static mixer used for the injection molding

ZERRU's casting process creates seamless connections between mixer elements, eliminating potential dead zones and leak points that exist in traditional welded or assembled mixers. The pressure drop calculation for the mixer is based on hydraulic diameter, considering void fraction and friction coefficient, resulting in minimal pressure drop when used in pipelines. Under higher system pressures, the pressure drop generated by the static mixer can even be considered negligible.

Applications with Specialty Materials & Emerging Technologies

1.1 Fiber-Reinforced Composites

Fiber orientation is a critical factor affecting the mechanical properties of injection-molded fiber-reinforced composite parts. Zhuonuo's cast micro-static mixer can successfully mix the polymer and randomize fiber orientation. Its unique flow channel design achieves uniform mixing while maintaining low shear stress, preventing excessive shear that would otherwise damage fiber length.

1.2 Supercritical Fluid Micro-foaming

In the micro-foaming injection molding process, supercritical fluid (e.g., nitrogen or carbon dioxide) must be injected at the nozzle. ZERRU's cast micro-static mixer ensures instantaneous and uniform mixing of the fluid with the polymer melt, forming a homogeneous solution – a core technological requirement for successful micro-foaming. Patent literature confirms that the configuration of a static mixer within a mixing-type self-locking nozzle assembly is a key technical pathway for achieving supercritical fluid-assisted microcellular injection molding.

1.3 Liquid Silicone Rubber (LSR) Molding

 

Liquid Silicone Rubber (LSR) typically consists of two components (A/B) that must be uniformly mixed immediately before injection. A pneumatic shut-off nozzle equipped with ZERRU's cast micro-static mixer both prevents drooling of low-viscosity LSR and ensures thorough mixing of the two components. The product is suitable for a wide range of processes, including liquid-liquid, liquid-gas, liquid-solid, and gas-gas mixing, emulsification, neutralization, absorption, extraction, reaction, and enhanced heat transfer.

Selection Criteria & Technical Advantages

2.1 The Critical Role of Proper Sizing and Selection

ZERRU's cast micro-static mixer is not a "one-size-fits-all" solution. Its effectiveness is highly dependent on proper design and selection for the specific application. Influencing factors include not only the injection molding machine's size and clamping force but also the specific molded part and the plastic material used. The company offers customized design services based on customer requirements, ensuring the mixer perfectly matches the specific process. The additional pressure loss introduced by the mixing nozzle should not exceed 10–15% of the injection pressure.

Static mixers can be applied to various processes including liquid-liquid, liquid-gas, liquid-solid, and gas-gas mixing, emulsification, neutralization, absorption, extraction, reaction, and enhanced heat transfer. They can operate across a wide viscosity range and under different flow regimes (laminar, transitional, turbulent), for both batch and continuous operations:

• Liquid-Liquid Mixing: From laminar to turbulent flow, fluids with viscosities up to 10,000 cP (10 Mpa·s) can be effectively mixed, achieving dispersed droplets as small as 1–2μm with uniform size distribution.

• Liquid-Gas Mixing: The static mixer allows for continuous renewal and full contact of the liquid-gas phase interface.

• Liquid-Solid Mixing: Under turbulent conditions, small quantities of solid particles or powder can be effectively and forcibly dispersed within the liquid.

• Gas-Gas Mixing: Suitable for mixing cold/hot gases or different gas components.

• Enhanced Heat Transfer: For gas cooling or heating, the heat transfer coefficient can be increased up to 8 times; for heating viscous liquids, it can be increased up to 5 times.