Insertable Container Headspace Control for Reblending Gap Fillers
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Solution Overview
Problem
Thermal gap fillers and other flowable materials suffer from phase separation during storage, leading to reduced quality and processability due to air entrainment during manual or mechanical reblending, limiting their usable life and increasing reject rates.
Innovation Solution
A method involving a receiving container with a removable lid and an insertable insert that reduces the air-filled head space by 30-70%, followed by controlled rotation about one or two axes to reblend separated phases, minimizing air introduction and maintaining material quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the flowable material is stirred by hand or by machine to restore homogeneity, then the separated phases are reblended, but air is introduced into the material matrix which reduces thermal conductivity
Solution Approach 1:
The receiving container is divided into two functional zones using an insert: a head space region for air containment and a material region for reblending. The insert physically segments the container volume to control where air can exist during the reblending process, allowing phases to be mixed while minimizing air entrainment in the material matrix.
Solution Approach 2:
The head space volume is reduced by inserting an insert into the container, changing the geometric parameter of the available air volume. This parameter change limits the amount of air that can be introduced during rotation-based reblending, thereby preserving thermal conductivity while still allowing effective mixing of separated phases.
2Duration of action of moving object
If the material is stored for extended periods, then more time is available for processing, but phase separation occurs which impairs functionality
Solution Approach 1:
The insert is placed in the container before the reblending process begins, preliminarily configuring the internal geometry to prevent air entrainment during mixing. This preliminary setup enables extended storage followed by effective reblending, as the insert is already in position to control air exposure when the material is eventually mixed again.
3Ease of operation
If the head space volume is large, then there is more room for material movement during mixing, but more air is available to be introduced into the material
Solution Approach 1:
The insert creates a localized air-containing zone (head space) separated from the material region. This local quality differentiation allows air to exist in one specific area (the head space above the material) while the material itself remains free of air entrainment, enabling both sufficient movement space and protection from air contamination.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Effectively reblends separated phases with minimal air entrainment, preserving material properties and extending its usable life while reducing reject rates.
Implementation Method 1
rotating the receiving container about at least one axis of rotation during a time interval ΔT to effect reblending of the phases of the flowable material
Implementation Method 2
individual phases of the material separate from each other. Thus, it is usually observed that a liquid phase separates from the rest of the material matrix and settles on it
Data Source
Figure 1
AI summary
The invention relates to a method of reblending at least two phases (3, 4) of a flowable material (2), wherein the flowable material (2) is disposed in a receiving container (1), and wherein the receiving container (1) comprises a receiving volume (5) for the flowable material (2) and a removable lid (7) by means of which the receiving volume (5) is sealingly closable, and wherein an air-filled head space (8) exists within the receiving volume (5) between the flowable material (2) received in the receiving volume (5) and the lid (7), the method comprising the steps of: - insertion of an insert (9) into the air-filled head space (8) of the receiving volume (5), such that the volume of the head space (8) is reduced, - closure of the receiving volume (5) by means of the lid (7), - rotating the receiving container (1) about at least one axis of rotation during a time interval ΔT to effect reblending of the phases (3, 4) of the flowable material (2), - removing the lid (7) and removing the insert (9). The invention further relates to the use of a receiving container (1) having an insertable insert (9) in such a method.