Analytical Aid Injection Molding Integration

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Solution Overview

Problem

The existing methods for producing analytical aids for detecting analytes in samples, such as body fluids, are complex and costly, particularly in integrating test chemistry into small structures within analytical magazines, which requires adhesive application and precise coating of surfaces, making the process inefficient and prone to errors.

Innovation Solution

A method where the test element with applied test chemistry is integrated into the housing part during a shaping process, such as injection molding, allowing direct connection without adhesives, and enabling the production of multiple analytical aids in a single magazine with simplified manufacturing steps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If adhesive application and precise coating of surfaces are used to integrate test chemistry into small structures, then the analytical aids can be assembled, but the production process becomes complex and costly

Engineering Contradiction:

Improveintegration reliabilityVSAvoidproduction process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The housing part and test element are merged into a single integrated component through injection molding. The test element is inserted into the injection mold cavity, and housing material is injected to directly form both the housing structure and the test element in one process, eliminating the need for separate adhesive application and surface coating steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The test element is prepared and inserted into the injection mold cavity before the housing material is injected. This preliminary positioning allows the housing material to directly bond with the test element during the molding process, ensuring proper integration without requiring subsequent adhesive application or surface preparation steps.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If adhesive application and precise coating of surfaces are used to integrate test chemistry into small structures, then the analytical aids can be assembled, but the manufacturing cost increases

Engineering Contradiction:

Improveintegration reliabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The injection molding process itself performs the integration function that would otherwise require separate adhesive application and surface coating operations. The housing material automatically bonds to the test element during molding, making the system self-sufficient and eliminating the need for additional manufacturing steps and materials.

Inventive Principle:

Principle #25Self-service

3Productivity

If multiple analytical aids are produced in a single magazine using the new method, then productivity increases, but the shaping process must accommodate multiple components

Engineering Contradiction:

Improveproduction efficiencyVSAvoidshaping process complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The magazine is divided into multiple injection mold cavities, with each cavity producing a separate analytical aid. Multiple test elements are positioned in different cavities simultaneously, and housing material is injected to form multiple analytical aids in parallel, increasing production efficiency while maintaining manageable process complexity through modular cavity design.

Inventive Principle:

Principle #1Segmentation

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

This approach simplifies the production process, reduces costs, and enhances the reliability of analytical aids by eliminating the need for adhesives and complex surface coatings, while maintaining the integrity of the test chemistry and improving the precision of the analytical aids.

Implementation Method 1

producing at least one housing part (114) of the housing (120) by means of at least one shaping process, in particular by means of at least one injection molding process, with the test element (122) being connected to the housing part (114) during the shaping process

Methodology Applied

Scientific EffectInjection molding:

Data Source

PatentEP2977004B1Analytical aid

Publication Date: 2019.10.02 F HOFFMANN LA ROCHE & CO AG

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AI summary

A method for producing an analytical aid (112) for the detection of at least one analyte in a sample, in particular a body fluid, is proposed. The analytical aid (112) comprises at least one housing (120) and at least one test element (122) with at least one test chemistry (134). The method comprises the following steps: a) providing the test element (122); and b) producing at least one housing part (114) of the housing (120) by means of at least one forming process, wherein during the forming process the test element (122) is joined to the housing part (114), and wherein several analytical aids (112) are produced, the method being carried out such that the analytical aids (112) are contained in an analytical magazine (110).