Laser-Markable Sample Tube via Wet-on-Wet Injection Molding
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Solution Overview
Problem
Conventional test tubes require multiple process steps and materials for creating a writable area, making them inefficient and costly to produce, and may suffer from material property inconsistencies that can lead to handling issues.
Innovation Solution
A test tube produced using wet-on-wet injection molding with a single piece design, where a polymer with an additive forms a writable area that changes color upon irradiation, allowing for a one-step manufacturing process and consistent material properties throughout the tube.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a writable area is attached to the sample tube in a second step (multi-component process), then the sample tube can be labeled, but the production process becomes complex and time-consuming
Solution Approach 1:
The patent combines the tube body and writable area into a single integrated component manufactured in one injection molding process. The writable area is formed as an integral part of the tube during the same manufacturing cycle, eliminating the need for separate attachment steps. This merging of components directly resolves the technical contradiction by simplifying the manufacturing process while maintaining the labeling function.
Solution Approach 2:
The injection molding process is designed to simultaneously produce both the structural tube body and the functional writable area with laser-markable properties. The single process performs multiple functions: creating the tube geometry, forming the writable area, and incorporating the necessary material properties for laser marking, thereby reducing process complexity.
2Productivity
If multiple process steps are used to create a writable area, then labeling is achieved, but production time and costs increase
Solution Approach 1:
The patent merges the production of the tube body and writable area into a single injection molding cycle. Both components are formed simultaneously in one process step, eliminating the time required for separate attachment operations. This directly improves productivity by reducing the total manufacturing cycle time while maintaining complete labeling functionality.
Solution Approach 2:
The writable area is prepared and integrated into the tube body during the initial molding process rather than being added later. The laser-markable material is incorporated into the tube structure upfront, allowing the labeling surface to be ready for use immediately after ejection without requiring subsequent processing steps.
3Reliability
If different materials are used for the tube body and writable area, then labeling function is achieved, but material property consistency deteriorates
Solution Approach 1:
The patent uses the same base polymer material for both the tube body and writable area, ensuring uniform material properties throughout the entire component. The writable area contains additional laser-markable additives, but the fundamental polymer matrix remains consistent, guaranteeing homogeneous mechanical and thermal properties across the whole tube for reliable handling and storage.
Solution Approach 2:
The writable area is formed as a composite region within the homogeneous polymer matrix, incorporating laser-markable additives while maintaining compatibility with the base material. This composite approach allows the writable area to have specialized optical properties for laser marking while the overall material consistency is preserved, ensuring reliable handling and storage characteristics.
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 of test tubes, reduces manufacturing costs, and ensures consistent material properties, enhancing handling and storage by integrating a writable area that changes color under irradiation, while maintaining airtight closure options.
Implementation Method 1
the additive can include color pigments that change color upon irradiation, or the additive itself can change color due to the thermal energy exerted during laser irradiation
Implementation Method 2
the writable area is irradiated, and the irradiated area then changes color
Implementation Method 3
The two materials flow into one another and merge. This 'free' flow creates gradients of the transparent and colored components in the transition zone
Data Source
Figure 1
AI summary
The invention relates to a sample tube comprising an inscribable region, in particular to a sample tube on which the colour of the inscribable region changes under irradiation. The invention also relates to a method for producing a sample tube of this type.