Segmented Cutting Tools for Narrow Capillary Channels
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Solution Overview
Problem
Current processes for producing analytical devices, particularly test strips with capillary elements, face challenges in achieving narrow capillary widths below 2 mm due to limitations in cutting tools, leading to reduced capillary activity, adhesive residuals, and tool damage, as well as inaccuracies in positioning and variable divisor ratios.
Innovation Solution
A continuous process using at least two independent cutting tools to form the contour of the capillary channel, allowing for precise control of capillary width and divisor ratios, and enabling the production of capillary elements with widths less than 1.5 mm, while avoiding the squeezing of spacer material between cutting edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a rotary cutting tool with opposing blades is used to cut capillary elements, then the cutting process can be performed, but the minimum width of the capillary element increases and capillary activity is reduced
Solution Approach 1:
The cutting tool is divided into two separate cutting elements instead of one tool with opposing blades. Each cutting element independently cuts one side of the capillary channel, allowing precise control of cut depth and position without the interference of opposing blades that would otherwise limit minimum width and damage the capillary structure.
2Strength
If the thickness of adhesive tapes is increased to provide structural support, then the strength of the capillary element is improved, but the minimum width of the capillary element producible by cutting increases
Solution Approach 1:
The cutting process parameters are changed to accommodate thicker adhesive tapes while maintaining narrow capillary widths. The segmented cutting elements can be adjusted in depth and position to precisely control the cut, allowing the use of thicker adhesive tapes for structural support without increasing the minimum producible capillary width.
3Ease of manufacture
If a rotary cutting tool is used to cut thin capillary elements, then cutting can be performed, but cutting tool damage occurs due to pressure from pushed-aside material
Solution Approach 1:
By segmenting the cutting tool into two separate cutting elements, each element cuts only one side of the capillary channel. This eliminates the problem of opposing blades where material gets pushed between them, causing excessive pressure and tool damage. Each cutting element operates independently with adequate clearance, preventing material compression and tool destruction.
4Productivity
If continuous cutting processes are used for mass production, then productivity is improved, but positioning accuracy of capillary elements decreases
Solution Approach 1:
The system incorporates feedback mechanisms to monitor and adjust the positioning of the cutting elements relative to the carrier layer during continuous operation. This allows the high-speed continuous cutting process to maintain precise positioning accuracy by real-time correction of any deviations in the cutting path or material feed.
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 enables the production of analytical devices with improved capillary properties, reduced residual adhesive, and precise control over capillary dimensions, enhancing the manufacturing yield and accuracy of capillary elements.
Implementation Method 1
a) providing at least one carrier layer; b) providing at least one spacer layer; c) applying the spacer layer on top of the carrier layer
Implementation Method 2
d) providing at least one cover layer; e) applying the cover layer on top of the spacer layer
Implementation Method 3
the cutting step is performed by using at least two cutting tools, the cutting tools complementing one another to form a contour of the capillary channel
Data Source
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AI summary
A process for the production of at least one analytical device (112) is disclosed. The analytical device (112) has at least one capillary element (136). The process comprises the following steps: a) providing at least one carrier layer (120); b) providing at least one spacer layer (122); c) applying the spacer layer (122) on top of the carrier layer (120); d) providing at least one cover layer (124); e) applying the cover layer (124) on top of the spacer layer (122). The process further comprises at least one cutting step, wherein at least one capillary channel (140) of the capillary element (136) is cut out from the spacer layer (122). The cutting step is performed by using at least two cutting tools (170, 172, 174), the cutting tools (170, 172, 174) complementing one another to form a contour (196) of the capillary channel (140).