Electrophoresis Gel Cassette Sealing via Segmented Welding
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Solution Overview
Problem
Existing methods for manufacturing electrophoresis gel cassettes face issues with gel leakage and the 'smiling effect' due to uneven gel swelling, which affects electrophoresis results, and are often complex and costly to produce.
Innovation Solution
A method involving simple plastic moulding to form unassembled electrophoresis gel cassettes with convex and concave edges for alignment, followed by welding and cutting to create a smooth surface, preventing leakage and eliminating the smiling effect by using bottom and top protrusions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional welding methods with thickened edges and slot-shaped openings are used, then structural stability is improved, but manufacturing complexity increases
Solution Approach 1:
The back plate is divided into multiple welding sections (first welding section and second welding section) with different structural features. The first welding section has a smooth peripheral surface for sealing, while the second welding section has protrusions for structural support. This segmentation allows each section to be optimized independently, reducing overall manufacturing complexity while maintaining structural stability.
Solution Approach 2:
Different regions of the back plate are given different local qualities: the first welding section has a smooth, flat peripheral surface optimized for sealing, while the second welding section has protrusions optimized for structural support. This local differentiation eliminates the need for complex thickened edges throughout the entire plate, simplifying manufacturing while maintaining both stability and sealing performance.
2Manufacturing precision
If gel fixation sites are added to prevent smiling effect, then electrophoresis accuracy is improved, but gel leakage risk increases
Solution Approach 1:
Protrusions are added only in the second welding section away from the gel injection hole, while the first welding section maintains a smooth peripheral surface near the injection hole. This local differentiation allows the protrusions to prevent the smiling effect and improve electrophoresis accuracy, while the smooth surface in the critical area prevents gel leakage during injection.
Solution Approach 2:
The welding sections are segmented into two functional zones: one zone (first welding section) optimized for gel injection with smooth surfaces to prevent leakage, and another zone (second welding section) optimized for structural support with protrusions to prevent smiling effect. This segmentation resolves the contradiction by allowing both functions to coexist in different locations.
3Manufacturing precision
If high precision alignment methods are used, then assembly accuracy is improved, but production time increases
Solution Approach 1:
The protrusions in the second welding section serve a dual function: they provide structural support to prevent the smiling effect and simultaneously act as self-aligning features during assembly. When the front plate is placed on the back plate, the protrusions naturally guide the plates into correct alignment, eliminating the need for complex external alignment tools or procedures and reducing production time while maintaining assembly accuracy.
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 method reduces production costs and time, ensures precise alignment without high precision, and prevents gel leakage and the smiling effect, resulting in consistent electrophoresis results.
Implementation Method 1
the gel will absorb the buffer and result in inflation
Implementation Method 2
Welding is instead performed along the raised lateral edges 34, 35 and the bottom, thickened edge 23
Data Source
AI summary
An improved method for forming a unassembled electrophoresis gel cassette, including following steps: a first injecting step for forming a first plate, and a second injecting step for forming a second plate, in which a plurality of bottom protrusions and/or a plurality of top protrusions are concurrently formed; an engaging step for engaging the convex edges and the concave edges of the two left spacers and the two right spacers when in accommodation; a bonding step for bonding the first plate and the second plate; and a cutting step of cutting off the part lines and the demoulding angles of the bottom sides of the first plate and the second plate in one process to form a smooth and flat peripheral surface.