Static mixer and a method of manufacture thereof

An injection molding system including a static mixer configured in a melt channel thereof, the static mixer comprising:

• a mixer body (500);
• a first flow face (504) configured at an end of said mixer body (500);
• a second flow face (505) configured at an opposite end of said mixer body (500) from said first flow face (504);
• an outer surface (501) configured around the mixer body (500) between the ends thereof;
• a plurality of first passageways (512) configured in said mixer body (500);
• a plurality of second passageways (514) configured in said mixer body (500);
• said plurality of first and second passageways (512, 514) configured to extend along substantially straight longitudinal axes;
• said plurality of first and second passageways (512, 514) being arranged into a first and a second array, respectively, said arrays being intermeshed and interconnected to configure a plurality of mixing portals (516) between said first and second passageways (512, 514);
• said first and second arrays of passageways (512, 514) including:
• a first subset of passageways (546, 549) each passageway of which extend between the flow faces (504, 505) with a corresponding plurality of fluid portals (518, 520) being configured along each flow face (504, 505);
• a second subset of passageways (547, 550) each passageway of which extend about half way through the mixer body (500) from the first flow face (504), without opening to the outer surface (501) of the mixer body (500), with a corresponding plurality of fluid portals (518, 520) being configured along the first flow face (504);
• a third subset of passageways (548, 551) each passageway of which extend about half way through the mixer body (500) from the second flow face (505), without opening to the outer surface (501) of the mixer body (500), with a corresponding plurality of fluid portals (518, 520) being configured along the second flow face (505);
• an end of each passageway of said second and third subset (547, 550), (548, 551) being enclosed within said mixer body (500) and having a mixing portal (516) defined therebetween;
• whereby said plurality of intermeshed and interconnected first and second passageways (512, 514) provide a convoluted flow path between said flow faces (504, 505).