Welded Reagent Container Assembly Without Connecting Frame

Solution Overview

Problem

The existing methods for producing reagent container assemblies are cumbersome and costly, requiring a separate connecting frame that increases space and complexity, and are not efficient for handling and storage due to the need for pre-assembled, partially filled containers.

Innovation Solution

A process involving the assembly and permanent welding of plastic reagent containers using ultrasonic or laser welding to form a reagent container assembly without a connecting frame, allowing for efficient production, reduced space usage, and flexible filling and calibration of reagents.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If a connecting frame is used to assemble reagent containers, then the structural stability is improved, but the device complexity and space requirements increase

Engineering Contradiction:

Improvestructural stabilityVSAvoiddevice complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The patent removes the connecting frame from the system entirely. Instead of using a separate frame structure to hold and connect reagent containers, the invention directly joins the containers to each other through welding, eliminating the need for this intermediate structural component and reducing overall device complexity.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent merges the functions of the connecting frame and container support into the container joints themselves. By welding containers directly to each other, the joint structure simultaneously provides both connection and support functions, eliminating the need for separate frame elements.

Inventive Principle:

Principle #5Merging (Combining)

2Stability of the object's composition

If a connecting frame is used to assemble reagent containers, then the structural stability is improved, but the space requirements increase

Engineering Contradiction:

Improvestructural stabilityVSAvoidspace requirements

Core Design Contradiction:

Stability of the object's compositionVSArea of stationary object

Solution Approach 1:

The patent removes the connecting frame from the system entirely. Instead of using a separate frame structure to hold and connect reagent containers, the invention directly joins the containers to each other through welding, eliminating the need for this intermediate structural component and reducing overall device complexity.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent merges the functions of the connecting frame and container support into the container joints themselves. By welding containers directly to each other, the joint structure simultaneously provides both connection and support functions, eliminating the need for separate frame elements.

Inventive Principle:

Principle #5Merging (Combining)

3Productivity

If reagent containers are pre-assembled and partially filled, then the handling efficiency is improved, but the manufacturing complexity and cost increase

Engineering Contradiction:

Improvehandling efficiencyVSAvoidmanufacturing complexity

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent performs the welding operation during the final assembly stage, after containers are filled with reagents. This allows containers to be manufactured and filled separately (simplifying manufacturing), then efficiently assembled at the end through welding, achieving both manufacturing simplicity and assembly efficiency.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces mechanical connection methods (such as frames, clips, or mechanical joints) with welding processes (ultrasonic, laser, or friction welding). This substitution enables direct bonding of containers without complex mechanical assembly fixtures or procedures, reducing manufacturing complexity while maintaining assembly efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Strength

If welding is used to join reagent containers, then the joint strength is improved, but the risk of damaging reagents increases

Engineering Contradiction:

Improvejoint strengthVSAvoidreagent damage risk

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent segments the welding process into localized zones at the container joints, concentrating thermal and mechanical energy only where needed for bonding. This segmentation prevents heat and stress from propagating to the reagent contents, thereby protecting reagents from damage while achieving strong joints.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs non-contact or low-contact welding methods (such as laser welding or friction welding) that minimize direct mechanical stress on containers. These methods generate heat through controlled means rather than direct mechanical force, reducing the risk of thermal damage to reagents while maintaining joint strength.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 and handling of reagent container assemblies by eliminating the need for a connecting frame, reducing costs and space requirements, while ensuring stable and leak-proof joints that do not damage or alter the reagents during the welding process.

Implementation Method 1

at least two of the reagent containers are joined together by at least one welding process

Methodology Applied

Scientific EffectUltrasonic welding: Ultrasonic Vibration

Implementation Method 2

using ultrasonic or laser welding to form a reagent container assembly

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Implementation Method 3

joining the reagent containers to form the reagent container assembly such that at least two of the reagent containers are joined together by at least one welding process

Methodology Applied

Scientific EffectThermal heating: Heating

Data Source

PatentUS9149979B2Method for producing a reagent container assembly and reagent container assembly

Publication Date: 2015.10.06 ROCHE DIAGNOSTICS OPERATIONS INC

AI summary

Embodiments directed to a process for producing a reagent container assembly made of plastic and a reagent container assembly are disclosed. The process may comprise: assembling a group of particular reagent containers, and joining the reagent containers to form the reagent container assembly where at least two of the reagent containers are permanently joined together by at least one welding process.