Laser Welding Disposable Diagnostic Test Elements
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Solution Overview
Problem
Existing methods for manufacturing disposable diagnostic test elements are limited by the use of adhesive tapes, which increase production costs and require specific adhesive compounds, and are restricted to simple 'black' and 'clear' layer configurations in laser welding techniques.
Innovation Solution
The method involves laser welding of layered structures with an absorbing layer and a transparent layer, where a coating on one layer absorbs and/or scatters laser radiation, allowing for specific sample interaction and eliminating the need for adhesives by forming a strong weld without impeding the connection or sealing ability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive tapes are used to combine layers in diagnostic test elements, then layer bonding is achieved, but production costs increase and specific adhesive compounds are required
Solution Approach 1:
The patent removes adhesive tapes from the manufacturing process entirely, replacing them with laser welding technology. This extraction eliminates the need for adhesive compounds and their associated costs while maintaining layer bonding capability through direct thermal fusion of the layers at the weld interface.
Solution Approach 2:
The patent substitutes the mechanical adhesive bonding system with a thermal laser welding system. Instead of using chemical adhesives to bond layers, the invention uses laser-induced thermal energy to melt and fuse the layers together, creating a strong mechanical bond without requiring any adhesive substances.
2Ease of manufacture
If laser welding is used on simple 'black' and 'clear' layer configurations, then welding is achieved, but complexity is limited
Solution Approach 1:
The patent applies local quality by introducing a reflective coating only in specific regions where optical interaction is needed, while other regions maintain their original laser absorption or transparency properties. This allows different parts of the same layer structure to have different optical characteristics, enabling complex multi-functional designs beyond simple black-and-clear configurations.
Solution Approach 2:
The patent uses composite material structures by combining layers with different optical properties (transparent, absorbing, and reflective coatings) to create a multi-functional assembly. The reflective coating is integrated as a functional layer that works in conjunction with the base layers to achieve both welding and optical interaction capabilities in a single structure.
3Adaptability or versatility
If a coating absorbs and/or scatters laser radiation, then specific sample interaction is enabled, but weld area coverage is reduced
Solution Approach 1:
The patent segments the layer structure by applying reflective coating only in specific localized regions rather than uniformly across the entire surface. This segmentation allows the coating to provide sample interaction functionality where needed while leaving other areas uncovered for proper laser welding, thus resolving the conflict between functional capability and manufacturing precision.
Solution Approach 2:
The patent implements local quality by strategically positioning the reflective coating to cover only the areas requiring optical interaction with the sample. This localized application ensures that the coating's radiation-absorbing and scattering properties are utilized where functionally necessary, while maintaining adequate laser radiation transmission and absorption in the weld areas for successful bonding.
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 reduces material expenditure, enhances production efficiency, and integrates specific interaction with body fluid samples while maintaining weld strength and sealing ability, enabling the creation of reliable diagnostic test elements.
Implementation Method 1
one of the layers is an absorbing layer configured to absorb radiation from a laser beam
Implementation Method 2
at least one of the other layers is a transparent layer permeable for the laser radiation
Implementation Method 3
a coating is provided to one of the layers and covers a weld area at least in part and absorbs and/or scatters laser radiation at least in part
Implementation Method 4
a coating is provided to one of the layers and covers a weld area at least in part and absorbs and/or scatters laser radiation at least in part
Implementation Method 5
directing the laser beam in a weld area through the at least one transparent layer and against the absorbing layer to fuse the transparent and the absorbing layers together
Data Source
AI summary
Methods are provided for manufacturing disposable diagnostic test elements via laser welding, where the methods include providing, in a stacked or layered arrangement, a base layer, a cover layer, and optionally an intermediate layer, where one of the layers is an absorbing layer and at least one other of the layers is a transparent layer, and where one of the layers includes a coating adapted to interact with a body fluid sample when conducting a test on the resulting test element; directing a laser beam in a weld area through the at least one transparent layer and against the absorbing layer; and fusing the transparent and the absorbing layers together to form the test element, where the coating covers the weld area at least in part and absorbs and/or scatters radiation from the laser beam at least in part. Disposable diagnostic test elements also are provided.