Biological Analysis Card Welding With Profiled Heating Blocks
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Solution Overview
Problem
Existing biological analysis cards, such as the 'FilmArray®' card, are complex and costly to produce, prone to leaks, and cannot efficiently analyze multiple dilutions or different biological samples without mixing, particularly in endotoxin detection tests due to thickness and sealing issues.
Innovation Solution
A method involving a heating block with a complementary profile to the plate rim, welding thermoplastic films to both faces and rim segments of the plate, ensuring precise fluid separation and channel isolation, allowing for multiple sample analyses without mixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional multi-layer bonding method is used to assemble analysis card, then structural integrity is improved, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent merges the plate and base into a single integrated structure where the base is formed directly as part of the plate assembly. This eliminates the need for separate bonding operations between multiple layers, reducing assembly complexity while maintaining structural integrity through the unified design.
Solution Approach 2:
The base structure serves multiple functions simultaneously: it provides structural support, defines fluid pathways, and integrates with the plate as a single assembly. This multi-functionality reduces the number of separate components needed, simplifying the overall device while maintaining strength.
2Ease of manufacture
If traditional sealing method is used for thick plate, then manufacturing simplicity is improved, but reliability of fluid separation deteriorates due to leakage risk
Solution Approach 1:
The sealing system is segmented into multiple independent sealing elements positioned at critical locations around the plate perimeter. Each sealing element independently prevents leakage in its specific zone, ensuring reliable fluid separation even in thick plate configurations without requiring complex sealing mechanisms.
3Device complexity
If FilmArray configuration is used with single duct, then device complexity is reduced, but adaptability for multiple sample analyses is limited
Solution Approach 1:
The fluid delivery system is segmented into multiple independent ducts, each capable of delivering biological samples to different wells on the plate. This segmentation enables simultaneous analysis of multiple samples or dilutions through separate fluid pathways, maintaining relative simplicity while significantly enhancing versatility.
Solution Approach 2:
The patent transitions from a single-duct vertical arrangement to a multi-duct horizontal arrangement around the plate perimeter. This dimensional change allows multiple samples to be delivered in parallel across different spatial locations, enabling simultaneous multi-sample analysis without substantially increasing complexity.
4Measurement precision
If plate thickness is increased for endotoxin detection, then measurement precision for detection sensitivity is improved, but device complexity and sealing difficulty increase
Solution Approach 1:
The sealing system is divided into multiple discrete sealing elements distributed around the thick plate perimeter. Each element independently addresses sealing at specific locations, making the overall sealing process simpler and more reliable despite the increased plate thickness required for endotoxin detection sensitivity.
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 enables rapid, cost-effective production of analysis cards with enhanced fluid pathway separation, facilitating simultaneous analysis of multiple biological samples or dilutions without mixing, thus improving analysis accuracy and reducing production costs.
Implementation Method 1
a heating block configured to perform the welding step c), said heating block comprising a support and a heating element, a first part of the heating element protruding from the support at least during the application of the heating block
Implementation Method 2
a welding step c) comprising welding the two films of the reception space to the plate
Data Source
AI summary
The invention relates to a method for manufacturing a biological analysis card (1) comprising:—a step a) of providing a base (2) formed of:—at least two films (3) placed one on top of the other;—a receiving space (4) formed between the two films (3); —ducts (5) leading to the receiving space (4);—a step b) of placing a plate (9) in the receiving space (4), the plate (9) comprising:—a first face (10a) and a second face connected by an edge (11) having a profile;—a plurality of wells (12) opening onto at least the first face (10a) or the second face;—a plurality of channels (13) fluidly connecting the wells (12);—a welding step c) for welding the two films (3) in the receiving space (4) to the plate (9) and a film (3) to segments of the edge (11) of the plate (9) by applying a heating block to the film (3) against the edge (11) on the side of the first face (10a).