String-Based Polymer Plug Applicator for Automated Sample Container Closure
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Solution Overview
Problem
Current laboratory automation systems face challenges in efficiently and cost-effectively closing sample containers of varying sizes and shapes due to the limited diameter range of existing caps and plugs, requiring complex and expensive mechanisms for handling and alignment.
Innovation Solution
An applicator assembly using a string of polymer-based material that can be stored in a magazine and inserted into sample containers, with a drive system and separator to form a plug by separating the end piece from the string, allowing for automated and efficient closure of containers of different sizes and shapes without the need for complex alignment mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If individual caps and plugs are used for sample containers, then the closure can be applied to specific types of containers, but the system requires complicated and expensive mechanisms for handling and alignment
Solution Approach 1:
The system segments the closure process by using a continuous string material that is fed through a magazine and cut to individual lengths, eliminating the need to handle pre-formed individual caps and plugs. This segmentation approach simplifies the handling mechanism while maintaining adaptability to different container types through adjustable cutting and insertion parameters
Solution Approach 2:
The string-based closure system serves multiple functions: it can close various types of sample containers (different diameters and shapes), provide sealing protection, and be integrated with automated handling systems. The single string material replaces multiple specialized cap and plug types, achieving universality across different container configurations
2Ease of manufacture
If caps and plugs are supplied in bulk packages, then storage and handling is simplified, but decollation and alignment require complicated and expensive mechanisms
Solution Approach 1:
The system extracts the individual closure units from bulk packages by feeding continuous string material through a magazine and separating individual segments only at the point of use. This eliminates the need for complex decollation mechanisms while maintaining the benefits of bulk storage in the magazine
Solution Approach 2:
The string material self-aligns as it is fed from the magazine through the insertion device, eliminating the need for external alignment mechanisms. The continuous feed mechanism naturally positions each segment for insertion without requiring complex alignment devices
3Manufacturing precision
If specialized devices like re-capper robots are used, then precise closure application is achieved, but production costs increase
Solution Approach 1:
The system uses inexpensive string material that is fed continuously and cut to individual lengths, replacing expensive specialized closure components. The simple magazine and cutting mechanism achieves precise closure application without requiring costly re-capper robots or specialized handling devices
Data Source
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Figure 5A~5B
AI summary
An applicator assembly (100) for closing a sample container (500) with a plug (16) is proposed. The applicator assembly comprises a magazine (102) configured to store a string (10) comprising polymer-based material, an insertion device (104) configured to insert an end piece (12) of the string at least partly into an opening (502) of the sample container (500), and a drive system (106) configured to supply at least a part of the string (10) from the magazine (102) to the insertion device (104). The applicator assembly further comprises a separator (108) configured to separate the end piece (12) from the string, such that the end piece (12) forms a plug (16) closing the sample container (500).