Light Guide Test Sensor Ultrasonic Welding Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing optical test sensors for determining analyte concentration in biological fluids face contamination issues due to residual biological fluids from previous samples, leading to inaccurate readings, and traditional manufacturing methods for test sensors are labor-intensive and time-consuming.
Innovation Solution
The development of an optic light guide test sensor comprising a light guide, a reagent-coated membrane, and a mesh layer, where the light guide has protrusions to facilitate sample collection and ultrasonic welding is used for efficient manufacturing, allowing for easy attachment and cutting of the reagent-coated membrane and mesh layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional manufacturing techniques are used to cut and bond the reagent-coated membrane strip and mesh layer strip, then the test sensor can be manufactured, but the manufacturing process becomes time-consuming and labor-intensive
Solution Approach 1:
The patent combines multiple manufacturing operations (cutting and bonding) into a single integrated ultrasonic welding process. The ultrasonic welding tool simultaneously performs both cutting of the strips and bonding of the membrane to the light guide in one continuous operation, eliminating the need for separate cutting and bonding steps that characterize traditional manufacturing techniques
Solution Approach 2:
The patent replaces traditional mechanical cutting and bonding tools with ultrasonic welding technology. Instead of using separate mechanical cutters and adhesives or thermal bonding equipment, the system uses ultrasonic vibrations to both cut the strips and bond them together through friction-generated heat and mechanical interlocking, significantly streamlining the manufacturing process
2Ease of operation
If the optical instrument is exposed to biological fluid samples, then the testing function is enabled, but contamination occurs leading to reduced accuracy of test results
Solution Approach 1:
The patent extracts the optical components (light guide and optics) from direct contact with the biological fluid sample. The light guide is positioned such that it transmits light through or near the sample without the optics themselves being exposed to the fluid, thereby preventing contamination while maintaining the optical measurement function
Solution Approach 2:
The patent introduces an intermediary structure (the light guide and its positioning relative to the sample) that allows optical measurement without direct contact between optics and biological fluid. The light guide acts as a mediator that transmits light through the sample or close proximity while preventing fluid from reaching the optical components
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 solution effectively isolates the optics from biological fluids, improving test accuracy and simplifying the manufacturing process by using ultrasonic welding to bond and cut the reagent-coated membrane and mesh layer efficiently.
Implementation Method 1
Ultrasonic welding melts the protrusions to attach and cut the strip of reagent-coated membrane to the plurality of light guides
Implementation Method 2
Ultrasonic welding melts the protrusions to attach and cut the strip of reagent-coated membrane to the plurality of light guides
Implementation Method 3
The light guide has an input end and an output end
Data Source
AI summary
An optic light guide test sensor comprises a light guide, a reagent-coated membrane, and a mesh layer. The reagent-coated membrane and the mesh layer are attached to the light guide at an output end of the light guide. The light guide test sensor is adapted to be used to test the level of an analyte in a biological fluid sample when used with a readhead. A method of manufacturing the light guide test sensor involves providing a plurality of light guides, providing a strip of reagent-coated membrane, and providing a strip of mesh layer. The reagent-coated membrane and mesh layer are attached to the light guides by ultrasonic welding. The reagent-coated membrane and mesh layer may also be attached to the light guides by adhesive.