Analysis Tape Label Transfer Using Vacuum Rollers
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Solution Overview
Problem
Existing methods for producing analysis tapes for fluid samples face challenges with low throughput, high production costs, and significant rejects due to labeling tolerances and complex construction, which affect the quality and reproducibility of diagnostic aids.
Innovation Solution
A method using a laminate tape with a diagnostic functional layer, where diagnostic aids like test fields and lancets are transferred to a carrier tape via a vacuum roller, allowing for high-speed application with precise positioning and reduced waste, enabling increased throughput and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If stamping and removing a stamping grid is used to subdivide the multitrack label tape, then the test labels can be transferred to the transport tape, but the throughput is restricted and labeling tolerances exceed maximum tolerances at high tape speeds
Solution Approach 1:
The invention extracts the stamping grid removal step from the labeling process. Instead of stamping and removing a grid to create individual test labels, the patent uses a continuous multitrack label tape that is directly transferred to the transport tape, eliminating the intermediate stamping and grid removal operations that bottleneck throughput and compromise precision at high speeds.
Solution Approach 2:
The multitrack label tape is prepared in advance with multiple test labels already formed and positioned, eliminating the need for on-the-fly stamping and grid removal operations during the labeling process, thus enabling high-speed transfer while maintaining precision.
2Manufacturing precision
If stamping and removing a stamping grid is used to subdivide the multitrack label tape, then test labels can be transferred, but large amounts of rejects arise during labeling
Solution Approach 1:
The invention removes the stamping and grid removal operations that cause rejects. By using a pre-formed multitrack label tape with integrated test labels, the process eliminates the source of defects associated with stamping operations, significantly reducing the reject rate while maintaining high labeling quality.
Solution Approach 2:
Instead of creating test labels through stamping operations that can fail, the patent uses a pre-formed multitrack label tape that serves as a master copy, transferring complete test labels directly to the transport tape without the intermediate stamping step that generates rejects.
3Productivity
If high tape speeds are used to increase productivity, then throughput improves, but labeling tolerances exceed maximum tolerances
Solution Approach 1:
The test labels are pre-formed and positioned on the multitrack label tape before transfer, so that at high tape speeds during transfer, the labels are already in their final positions requiring no additional stamping or adjustment, enabling high throughput while maintaining precision.
Solution Approach 2:
The patent replaces the mechanical stamping and grid removal process with a direct transfer mechanism that moves pre-formed test labels from the multitrack label tape to the transport tape, eliminating mechanical positioning errors that occur at high speeds during stamping operations.
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
The method achieves high-quality analysis tapes with increased throughput and reduced production costs by utilizing a vacuum roller for precise and efficient transfer of diagnostic aids, maintaining quality while enhancing production efficiency.
Implementation Method 1
a vacuum roller for precise transfer
Data Source
AI summary
A method for producing an analysis tape for fluid samples, in particular body fluids, is proposed. The method comprises providing a laminate tape having a laminate carrier tape and at least one diagnostic functional layer, and cutting the laminate tape in such a way that a diagnostic auxiliary label arises; transferring the diagnostic auxiliary label to a vacuum roller; and transferring the diagnostic auxiliary label to a carrier tape. In general, at least one vacuum roller is used for the transfer of the diagnostic auxiliary label to the carrier tape. The cutting of the diagnostic functional layer is effected in such a way that a free end of the diagnostic functional layer is lifted off from the laminate carrier tape by guiding the laminate carrier tape around a cutting edge with a small radius, wherein the diagnostic functional layer is cut at a predetermined distance from the lifted off free end by means of a cutting device.