Adhesives Mag logo
search
cart
facebook twitter linkedin youtube
  • Sign In
  • Create Account
  • Sign Out
  • My Account
Adhesives Mag logo
  • NEW PRODUCTS
  • NEWS
    • Adhesives & Sealants Headlines
    • Mergers/Acquisitions
    • Events Calendar
    • Market Trends
  • TOPICS
    • Finished Adhesives and Sealants
    • Pressure-Sensitive Adhesives (PSAs)
    • Coatings
    • Raw Materials and Chemicals
    • Materials Handling/Processing
    • Meter/Mix/Dispense
    • Curing
    • Testing/Quality Control
    • Packaging of Adhesives & Sealants
    • Converting/Packaging
    • Composites
    • Sustainability
  • COLUMNS
    • European Perspectives
    • Strategic Solutions
    • Supply Chain Strategies
    • Tape Talk
  • TOP 20
  • MULTIMEDIA
    • Videos
    • Podcasts
    • Webinars
    • eBooks
  • EXPLORE
    • Adhesives in Action
    • Blog
    • ASI Store
    • Industry Links
    • Market Research
    • Classifieds
  • DIRECTORIES
    • Buyers' Guide
    • Global Adhesives & Sealants Directory
    • Raw Materials, Chemicals, Polymers and Additives Handbook
    • Equipment Handbook
    • Distributor Directory
  • EMAGAZINE
    • EMAGAZINE
    • ARCHIVE ISSUES
    • ADVERTISE
      • Custom Content & Marketing Services
    • CONTACT
  • SIGN UP!
Finished Adhesives and SealantsMeter/Mix/DispenseEnd User Features

Mixing Two-Component Fluids in Exacting Proportions

A new static mixing method can completely mix 2K adhesives and improve material performance when compared to traditional techniques.

By Anthony Martucci
static mixing method
A new line of square static 2K fluid mixers provides optimum mixing of two-component adhesives and other fluids in shorter lengths than spherical and other mixing geometries.
adhesive mixing method
static mixing method
adhesive mixing method
October 3, 2016

Construction and automotive repair often require controlled blends of adhesives and sealants. Reliable and efficient applications can depend on precise and repeatable placement of epoxies and other two-component (2K) adhesives and sealants for such tasks as concrete anchoring, crack injection, foam insulation, seam sealers, bumper repair, windshield installation, and sound deadening. Before 2K adhesives can be applied, however, they must be properly mixed; this mixing process cannot be taken for granted. Studies have shown that poorly mixed 2K adhesives can suffer a loss in adhesion strength, resulting in compromised long-term durability and reliability. Similarly, 2K sealants are often processed in a similar manner and the mixing process is critical for optimum results.

Fortunately, a significant advance was made recently in the state of fluid mixing dynamics. A patented 2K fluid mixing approach was developed by combining knowledge of fluid dynamics with computer-aided modeling and analysis. The new static mixing method provides complete mixing of 2K adhesives in a shorter length than earlier 2K mixer techniques. It yields excellent flow rates with thorough mixing of the two fluid components and 30% less retained fluid volume compared to previous disposable mixers.

Applying Adhesives with Static Mixers

Static mixers work with 2K cartridges and dispensers to apply a mixed adhesive or sealant in a precise ratio on demand where needed. Ideally, a 2K mixer will blend the two fluid components into one homogeneous fluid in the shortest distance possible―and with the least material waste. A short mixing time implies a mechanically short structure to perform the mixing of the fluid components, and the new 2K mixing method is based on an innovative flow path that achieves complete mixing of two fluid components, including adhesives and sealants, in a relatively short fluid path length.

This novel disposable static mixer is an improvement on existing square geometry when compared to earlier 2K fluid mixers with spiral geometries. It is designed to attach to most large-volume (≥ 200 mL) commercial 2K dispensing cartridges and systems and can handle many different fluids, including sealants and adhesives, for a range of industries, such as automotive, aerospace, construction, electronics, and maintenance, repair, and operations (MRO). The short length means that effective mixing can be achieved while at the same time providing the capability to position the fluid mixer/dispenser closer to the work surface.

The Role of Research

The new fluid mixing solution was developed through an understanding of fluid dynamics. The mixing of two fluids is complex and tends to be nonlinear in nature, as the aggregate viscosities of the fluids change during the mixing process and the viscosity of the final solution changes as it begins its curing process. Nonlinear behavior occurs at the interfaces of the two fluids but, by means of techniques such as fluid stretching, it is possible to analyze and model these nonlinear dynamics of the two mixing fluids.

Fluid mixing can occur in different ways, such as by random mixing, chaotic mixing and laminar mixing. In random mixing, random fluid structures are produced by the instabilities of the two moving fluids; in chaotic mixing, laminar flows can produce complex distributions of the two fluid components. The fluid motions change as functions of space and time, with inhomogeneous mixing effects such as fluid stretching occurring as fluids flow at different rates as a function of a given change in time, Dt. Because stretching is inhomogeneous, the challenge in developing an efficient mixing structure is to achieve a homogeneous solution of the two fluid components in the shortest mixing distance and time possible. Mathematical analysis allows the use of probability density functions to predict the mixing rates expected from different mixing geometries for given viscosities of fluid components, and a great deal of research has been performed on fluid mixing in this area, such as with models for the mixing of water in oil emulsions to better understand the fluid dynamics of 2K component fluids. The new mixer design approach uses laminar mixing because this method requires less energy to achieve a given mix quality.

Proprietary software also contributed to the development of the new 2K square disposable static mixer. The software, which required two years to develop, was used to analyze a large number of different mixing geometries for their resulting flow patterns when mixing two fluid components of similar viscosities. The computer analysis consisted of selecting an input pattern, such as D-shaped inlets, and then studying the flow patterns and flow rates produced by different mixing geometries. Hundreds of different fluid path angles and openings were simulated and analyzed, and then fabricated into prototype mixing structures to test actual flow rates and mixing effectiveness.

When evaluated by a customer needing to dispense a 2K adhesive with a battery-powered dispenser system, the new static mixer design yielded impressive results. The customer’s goals were to achieve improved flow rates in order to apply more adhesive in less time with less applied force. From an actual application, it was learned that the effectiveness of the new mixer design resulted in considerably shorter cure time for the adhesive. The new mixing geometry achieved a cure time of 90 min, vs. two hours for a conventional static mixer.

The new mixing approach was incorporated into a square mixer about one-third the length of a spiral mixer currently being used for this application. In comparison, the new mixer resulted in much less retained fluid within the square mixer compared to the longer, spiral mixer.

The new mixing geometry has been implemented in a line of commercial mixer products.* These mixers are produced with different numbers of wedge elements, depending upon desired mixer length and volume capacity, from nine to 41 mixing elements and housing lengths from 2.9-8.1 in. This choice of lengths provides some working flexibility, in being closer to the work surface with shorter mixers and having greater mixing efficacy with longer mixers. The new mixers are about 20% shorter than comparable square mixers currently on the market.

The retained volume of material for these new mixers is extremely low, and dependent upon mixer length, with only 1.6-10 mL retained fluid volume for the longest mixer. The mixer is designed with barbed or stepped outlets and bell-shaped or integral nut inlets for use with many different dispensing systems. It is well-suited for use with all industry-standard dispensers (manual, pneumatic or battery powered) for ease of fluid application in hard-to-reach surfaces. In addition, it provides the mixing quality demanded of various critical applications, including in medical product assembly. It is suitable for mixing such 2K fluids as epoxies, urethanes, silicones, and hybrids, and can be used for applying adhesives, seals, bonding, undercoats, and gaskets.

The impact of such an advance in two-component fluid mixing should not be overlooked. The improvements in curing time and the reduced waste of adhesive or sealing materials can mean higher yields and reduced costs in high-volume applications. In addition, the improved homogenous adhesives produced by such a mixer will contribute to the improved quality of assembled products, in addition to the improved quality of many other applications requiring mixing of 2K fluids.  ASI


For more information, phone (800) 556-3484 or (401) 431-7000, fax (401) 431-7079, or visit http://nordsonefd.com.

KEYWORDS: adhesives in assembly dispensing static mixers

Share This Story

Looking for a reprint of this article?
From high-res PDFs to custom plaques, order your copy today!

Anthony Martucci is a Product Line Manager at Nordson EFD.

Recommended Content

JOIN TODAY
to unlock your recommendations.

Already have an account? Sign In

  • mouse in hole

    Using Foam Sealants for Pest Prevention

    According to the National Pest Management Association,...
    Adhesives and Sealants Topics
    By: Kevin Corcoran
  • linked network nodes

    Using the Power of AI for Adhesive and Sealant Formulation

    With the help of software solutions, adhesive formulators...
    Raw Materials and Chemicals
    By: Karen Parker
  • top20-hero.jpg

    2024 ASI Top 20: Leading Global Manufacturers of Adhesives and Sealants

    ASI's annual ranking of the top 20 global adhesive and...
    Pressure-Sensitive Adhesives (PSAs)
Manage My Account
  • eMagazine Issues
  • eNewsletter
  • Online Registration
  • Manage My Preferences
  • Subscription Customer Service

More Videos

Popular Stories

Picture of three men and one woman cutting a ribbon

H.B. Fuller Opens Adhesives and Sealants Facility in UAE

Picture of Noelle Sieradzki

Mactac Announces Changes to Leadership Team

Aerial view of Bostik manufacturing facility

Bostik Invests in Added Capacity at Massachusetts Manufacturing Plant

ASI Top 20 website

Events

January 1, 2030

Webinar Sponsorship Information

For webinar sponsorship information, visit www.bnpevents.com/webinars or email webinars@bnpmedia.com.

View All Submit An Event

Products

Structural Adhesives: Properties, Characterization and Applications

Structural Adhesives: Properties, Characterization and Applications

See More Products

ASI CASE EBOOK

Related Articles

  • Dr. Dave

    The two-component epoxy we're using in a metal assembly operation on small parts doesn't cure fast enough. Can you help?

    See More
  • Two-Component Dispensing Solution for Adhesives and Sealants

    Two-Component Dispensing Solution for Adhesives and Sealants

    See More
  • Mixing controls

    Dispensing Systems for Dosing Two-Component Silicones

    See More

Related Products

See More Products
  • 9781574447170.jpg

    Sealants in Construction, Second Edition

  • biomedical.jpg

    Adhesion in Pharmaceutical, Biomedical, and Dental Fields

  • advances-in-structural-adhe.gif

    Advances in Structural Adhesive Bonding

See More Products

Related Directories

  • Re Mixers Inc.

    Re Mixers, Inc. manufactures Xemex nozzles, a revolutionary new static mixer providing optimal mixing with 75% less adhesive waste. Made in the USA, Xemex nozzles offer the most sustainable and reliable solution for your most critical processes. Contact us to learn more about all of our dispensing solutions.
  • Ashby Cross Co. Inc.

    Since 1974, Ashby Cross has offered and manufactured a full line of multi-component adhesive dispensing equipment. Our adhesive dispensing equipment is built to handle epoxy, polyurethanes, silicones, acrylics, adhesive and structural bonding materials. These materials are used in various applications such as potting, encapsulation, coating, resin transfer molding (RTM), doming, and sealing operations. Adhesive dispensing equipment and 2K consumables for two-component adhesives.
  • medmix US Inc.

    A technology and innovation leader for cartridge-based metering, static mixing, and dispensing solutions for two-component adhesives, sealants, and coatings. Offers a full line of manual, pneumatic, and battery-driven dispensing tools for one- and two-component materials.
×

Keep the info flowing with our eNewsletters!

Get the latest industry updates tailored your way.

JOIN TODAY!
  • RESOURCES
    • Advertise
    • Contact Us
    • Directories
    • Store
    • Want More
  • SIGN UP TODAY
    • Create Account
    • eMagazine
    • eNewsletters
    • Customer Service
    • Manage Preferences
  • SERVICES
    • Marketing Services
    • Reprints
    • Market Research
    • List Rental
    • Survey & Sample
  • STAY CONNECTED
    • LinkedIn
    • Facebook
    • Youtube
    • X (Twitter)
  • PRIVACY
    • PRIVACY POLICY
    • TERMS & CONDITIONS
    • DO NOT SELL MY PERSONAL INFORMATION
    • PRIVACY REQUEST
    • ACCESSIBILITY

Copyright ©2025. All Rights Reserved BNP Media.

Design, CMS, Hosting & Web Development :: ePublishing