CN111761824A - 制造用于分析液体的比色杯的方法 - Google Patents

制造用于分析液体的比色杯的方法 Download PDF

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Publication number
CN111761824A
CN111761824A CN202010332893.5A CN202010332893A CN111761824A CN 111761824 A CN111761824 A CN 111761824A CN 202010332893 A CN202010332893 A CN 202010332893A CN 111761824 A CN111761824 A CN 111761824A
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China
Prior art keywords
cuvette
welding
laser
cuvette portion
window portion
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CN202010332893.5A
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English (en)
Inventor
F·内梅特
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77 Elektronika Muszeripari Kft
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77 Elektronika Muszeripari Kft
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Publication date
Application filed by 77 Elektronika Muszeripari Kft filed Critical 77 Elektronika Muszeripari Kft
Priority to CN202010332893.5A priority Critical patent/CN111761824A/zh
Priority to HU2000257A priority patent/HUP2000257A1/hu
Publication of CN111761824A publication Critical patent/CN111761824A/zh
Priority to PCT/HU2021/050025 priority patent/WO2021214500A2/en
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    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01L—CHEMICAL OR PHYSICAL LABORATORY APPARATUS FOR GENERAL USE
    • B01L3/00—Containers or dishes for laboratory use, e.g. laboratory glassware; Droppers
    • B01L3/50—Containers for the purpose of retaining a material to be analysed, e.g. test tubes
    • B01L3/502—Containers for the purpose of retaining a material to be analysed, e.g. test tubes with fluid transport, e.g. in multi-compartment structures
    • B01L3/5027—Containers for the purpose of retaining a material to be analysed, e.g. test tubes with fluid transport, e.g. in multi-compartment structures by integrated microfluidic structures, i.e. dimensions of channels and chambers are such that surface tension forces are important, e.g. lab-on-a-chip
    • B01L3/502707—Containers for the purpose of retaining a material to be analysed, e.g. test tubes with fluid transport, e.g. in multi-compartment structures by integrated microfluidic structures, i.e. dimensions of channels and chambers are such that surface tension forces are important, e.g. lab-on-a-chip characterised by the manufacture of the container or its components
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

本发明涉及一种用于制造用于分析液体的比色杯的方法，该方法包括进行焊接以将比色杯部分固定在一起。在该方法期间，执行以下步骤：将包括透明的上窗口部分(11)的上比色杯部分(10)和包括透明的下窗口部分的下比色杯部分装配在一起，从而在所述上窗口部分(11)和所述下窗口部分之间形成分析空间，其中在装配在一起的位置，所述上比色杯部分(10)和所述下比色杯部分沿至少一条外围闭合焊接路径相互接触，随后沿焊接路径以防泄漏的方式将所述上比色杯部分(10)和所述下比色杯部分焊接在一起。

Description

制造用于分析液体的比色杯的方法
发明领域
本发明涉及一种用于分析各种液体的比色杯的制造方法，例如一种用于尿液光学分析的比色杯。
背景技术
对于液体(例如尿液)的分析，有许多现有技术的比色杯设计。为了光学分析的目的，通常使用浅比色杯，其使得能够分析(优选地通过显微或数字图像处理方法)填充到一个位于另一个下方的透明窗口部分之间的分析空间中的液体。为了允许简单的制造方法，这些容器由平行邻接的上部和下部组成。容器包括用于填充待液体的入口孔，和当液体被填充时空气从容器逸出的出口孔。
例如，在US 7016033 B2、US 2001/0039056 A1、US 2005/0170522 A1、EP 0134627A2、EP 1188483 A2、WO 99/44743中，以及属于本申请人的WO 2008/050165 A1中公开了适用于材料分析并且特别是液体分析的容器。
发明内容
现有技术解决方案的缺点在于，这些技术解决方案没有提供以简单、安全和有效的方式来制造适合于上述目的的比色杯的解决方案。本发明主要适合于根据以上提到的现有技术文献制造比色杯，但是通过应用适当的修改，根据本发明的方法当然也可以用于制造不同的比色杯。
本发明的另一个目的是提供一种生产方法，该方法允许在超声波焊接的情况下以及在激光焊接的情况下提供有效、防漏和简单的生产方法。本发明的又一个目的是最大程度地减少或消除现有技术制造方法的缺点。
通过根据权利要求1的方法实现了根据本发明的目的。在从属权利要求中定义了本发明的优选实施方式。
附图说明
下面参考附图通过示例描述本发明的优选实施方式，其中：
图1是根据本发明的比色杯的俯视图，该比色杯是通过超声波焊接工艺制成的；
图2是根据图1的比色杯的侧视图；
图3是根据图1的比色杯的下部的空间俯视图；
图4是沿着图1中的虚线所示的平面截取的截面图，示出了超声波焊接工艺的开始；
图5是图4的圆圈部分的放大图；
图6以焊接在一起的状态示出了图4的剖视图；
图7是图6的圆圈部分的放大图；
图8是根据本发明的比色杯的俯视图，该比色杯是通过激光焊接工艺制成的；
图9是根据图8的比色杯的下部的空间俯视图；
图10以焊接在一起的状态示出了沿图8所示的截面截取的截面；并且
图11是图10的圆圈部分的放大图。
具体实施方式
根据本发明的比色杯，优选用于尿液分析的比色杯，被设计用于对其中所充入的液体进行光学分析。在这方面，以下描述主要基于WO 2008/050165A1中公开的比色杯。光学分析优选在照明下借助显微镜进行。在分析之前，将装满的容器离心，从而使尿液沉积物沉淀在容器底部透明下窗部分的内抛光表面上。容器的应用之一是对由这种沉积物产生的图像进行数字分析。
比色杯优选由透明的(高度透明的)聚碳酸酯颗粒原料制成，其通过注射成型加工。由于比色杯的透明度(澄清度)也会影响要装入其中的液体的分析，因此保持比色杯的澄清度很重要。因此，优选在密闭系统中将颗粒储存、干燥并运输至注射成型设备。例如，系统中空气过滤器的细度为0.3微米，即大于污染物的颗粒不能进入原料颗粒之间，而较小的颗粒在所应用的放大倍数下不会干扰分析。
这种封闭式原料制备系统的优点是，由于采用了过滤器，因此不必安装在洁净室中。但是，工艺的后续步骤必须在至少符合ISO 8等级要求的洁净室中进行，并且必须定期检查空气质量。使用本身已知的空气处理单元维护洁净室。
比色杯半体优选通过注射成型制造。它们的具体尺寸必须保持在严格的公差范围内，以便可以执行工艺过程的后续步骤，并且成品比色杯能够充分发挥作用。为此，宜采用高精度注塑工具和电动注塑机。根据我们的经验，液压或混合注塑机不太适合提供如此严格的公差范围。
完成的比色杯半体从注射成型工具上取下，然后优选由机器人运输到装配台。然后，机器人通过在装配台上形成的凹槽将两个半体相互安装。比色杯半体通过相互配合的锥面保持在一起。
比色杯半体的防漏接头必须满足许多条件：足够的机械强度、防漏密封、最小变形、尺寸稳定性、表面清洁度以及液体的无气泡填充。
根据附图的比色杯包括上比色杯部分10和下比色杯部分20。图1所示的上比色杯部分10形成有设计用于光学分析的透明的上窗口部分11。为了提高光学分析的精度，上窗口部分11的两面都具有抛光面。此外，在上比色杯部分10中，有一个从圆锥形凹口开始的入口孔，和一个出口孔，设计用于当液体被注入时从容器中排出空气。
图2示出了根据图1的比色杯的侧视图，其中上比色杯部分10和下比色杯部分20被焊接在一起。
图3示出了示例性比色杯的下比色杯部分20的空间俯视图。下比色杯部分20还装配有透明的下窗口部分21，该下窗口部分在两侧均被抛光。根据本发明，下窗口部分21的厚度小于0.6mm，这导致图像清晰度的显着改善。这样，可以确保改善对尿液样品中沉淀物颗粒的识别。如图所示，在下比色杯部分20中形成有通道，该通道的功能在WO 2008/050165A1中进行了详细说明。
图3清楚地示出了熔化边缘22，该熔化边缘22被下比色杯部分20的凸缘内的壁包围。所述熔化边缘22被设计用于邻接围绕上比色杯部分10的边缘延伸的突出部分。熔化边缘22的高度优选地为大约0.25mm，其侧面相互之间的夹角约为60°。
图4示出了图1中用虚线表示的横截面。在图5中以放大的视图示出了该截面的圈出的细节。在这些图中，可以很容易看到在焊接之前处于组装状态的熔化边缘22。在这种状态下，熔化边缘22的顶部边缘线抵靠上比色杯部分10的相对放置的平坦表面。
在图6和7中，以焊接在一起的状态示出了图4和5中所示的横截面和放大的细节。在这种状态下，熔化边缘22的顶部和上比色杯部分10的相对的表面区域处于熔融(融合在一起)状态，从而提供了防漏接头。围绕熔化边缘22的狭槽和包围上比色杯部分10的熔化表面部分的凸缘突起也有助于防漏密封，该上比色杯部分的壁彼此相对放置。焊缝在图6和7中用黑点表示。
因此，为了制造比色杯，将包括透明上窗口部分11的上比色杯部分10和包括透明下窗口部分21的下比色杯部分20装配在一起，从而在上窗口部分11和下窗口部分21之间形成分析空间。在装配在一起的位置，上比色杯部分10和下比色杯部分20沿着至少一个外围闭合的焊接路径彼此接触。图中所示的实施方式包括单个焊接路径，但为了提供更安全的密封，当然可以包括多个焊接路径。上比色杯部分10和下比色杯部分20沿着焊接路径以防漏的方式焊接在一起。
根据图1至图7，可以优选地应用超声波焊接，在超声波焊接过程中，熔化边缘22熔化并凝结在上比色杯部分10的外围突起的表面上。可以实现成本低廉的防漏焊接接头。
更优选地，基于相对距离进行超声波焊接，在超声波焊接过程中，当达到预定的触发压力时，即此时，设置在焊接头末端的超声波发生器开始以给定的频率和振幅振动，并且在经过预定距离后焊接过程结束。超声波发生器会振动直到预设的相对距离结束。在此期间，首先使熔化边缘22熔化，然后焊接头将两个比色杯半体完全压在一起，达到预先设定的冷却时间，在此期间熔化的材料凝固。冷却时间优选在0.5至0.6s之间。
预定触发压力优选在80至100N之间，并且预定距离优选在0.08至0.2mm之间。
在特别优选的实施方式中，沿着预定距离的第一部分施加第一焊接压力，并且沿着该距离的其余部分施加第二焊接压力，该第二焊接压力比第一焊接压力大至少10％。第一焊接压力例如优选为90-150N，而第二焊接压力优选为100-200N。相对距离可以对应于两个力进行划分，即，根据预设，优选地当已经覆盖了优选地在0.04和0.12mm之间的部分距离时，焊工从较小的值改变为较大的值。这允许在焊接过程开始时小心地处理熔化边缘22，并且如果需要的话，可以在焊接的第二阶段中施加更大的压缩力。当然，焊接过程也可以通过施加单一力值来进行。
在焊接过程中，焊头优选以30至40kHz之间的频率振动，更优选地以35kHz的频率振动，并且振幅在21.4至34.1μm之间。
在完成焊接过程之后，将上比色杯部分10和下比色杯部分20压在一起，直到在焊接过程中熔化的材料再次凝固。
如图8-11所示，作为超声波焊接的替代方法，也可以使用激光焊接。在图8中，示出了处于焊接在一起状态的这种比色杯的俯视图。当然，该图仅示出了上比色杯部分10，因为图9所示的下比色杯部分20被上比色杯部分10所遮挡。
采用激光焊接时，具有平坦接触面的焊接区域23优选用于提供防漏接头。在激光焊接过程中，即在形成焊缝期间，上比色杯部分10和下比色杯部分20沿着该焊接区域23无间隙地压在一起。产生这种焊接的基本条件是两个接触表面必须几何上准确且干净。
如在图9中可以看到的，下比色杯部分20设置有定位构件24，该定位构件在所示的优选实施方式中被实现为圆对称圆锥形构件。如图10所示，该构件适合于装配在上比色杯部分10的相应凹部中，从而使得这些部分在横向方向上相对于彼此适当地定位。图11是图10的圆圈部分的放大图，表示焊接区域23。
在进行激光焊接的情况下，关于将激光的能量集中在用于产生防漏焊缝的焊接区域23上，基本上存在三种替代方案。
根据第一替代方案，将吸收剂材料(即，适于吸收激光的材料)施加到焊接区域23的表面。该吸收剂材料优选地施加到在焊接期间位于底部的比色杯部分，该比色杯部分可以是两个比色杯部分中的任何一个。根据我们的实验，在这种情况下，可以通过施加波长在780至1100nm之间，优选波长为980nm的激光来获得最佳焊接质量。在整个焊接过程中，必须将两个比色杯半体压在一起。
施加的吸收剂材料可以是例如选自Crysta-Lyn Chemical Company的Clearweld产品线的吸收剂液体，即LD 100，LD 200或LD 900族，优选产品代码为LD 940的液体。该液体略带绿色，但在焊接过程中变为水色透明。激光焊接过程中产生的热量集中在吸收剂液体覆盖的表面区域，从而降低了被焊接部件内部的应力。
根据从上方进行焊接的第二替代方案，吸收剂材料分布在位于底部的比色杯部分的材料中。在这种情况下，激光穿透位于顶部的比色杯部分10，并且聚焦在焊接区域23上的激光束加热位于底部的比色杯部分的材料。根据我们的实验，在这种替代方案的情况下，可以通过施加波长在900至1100nm之间，优选波长为980nm的激光来获得最佳焊接质量。
在该变型中，例如可以使用由Crysta-Lyn Chemical Company制造的粉末型添加剂LWA267，或由GRAFE Color Batch GmbH制造的添加剂。在这种情况下，注塑机必须具有两个注塑单元。其中一个单元适于注射成型比色杯的上半部分，而另一个单元适于注射成型比色杯的下半部分，其中添加了吸收剂添加剂。
作为第三替代方案，也可以采用完全无吸收体的激光焊接工艺。在这种情况下，压在一起的比色杯部分的焊接区域23本身形成一个具有不同衍射指数的区域，该区域适合于集中激光束的加热效果。在这种情况下，使用波长比上述情况长得多的激光，即波长在1800和2200nm之间，优选波长为1940nm的激光，获得最佳质量的焊接。
在所有三种焊接替代方案中，两个比色杯半体在给定压力下(优选借助玻璃板)被压缩，而接缝由焊接头沿焊接区域23形成。
当然，本发明不限于通过示例示出的实施方式，而是在权利要求的范围内可以进行进一步的修改和变更。比色杯不仅可以用于尿液的光学分析，还可以用于其他液体的光学分析。

Claims (11)

1.一种用于制造用于分析液体的比色杯的方法，所述方法包括应用焊接以将比色杯部分固定在一起，其特征在于，所述方法包括以下步骤：
将包括透明的上窗口部分(11)的上比色杯部分(10)和包括透明的下窗口部分(21)的下比色杯部分(20)装配在一起，从而在所述上窗口部分(11)和所述下窗口部分(21)之间形成分析空间，其中在装配在一起的位置，所述上比色杯部分(10)和所述下比色杯部分(20)沿至少一条周向的闭合焊接路径相互接触，随后
沿焊接路径以防泄漏的方式将所述上比色杯部分(10)和所述下比色杯部分(20)焊接在一起。
2.根据权利要求1所述的方法，其特征在于，所述方法应用超声波焊接。
3.根据权利要求2所述的方法，其特征在于，所述方法基于相对距离应用超声波焊接，包括以下步骤：当达到预定触发压力时，利用焊头启动焊接过程，以及在覆盖预定距离后完成焊接过程。
4.根据权利要求3所述的方法，其特征在于，所述预定触发压力在80至100N之间，并且所述预定距离在0.08至0.2mm之间。
5.根据权利要求3所述的方法，其特征在于，在完成焊接过程之后，将所述上比色杯部分(10)和所述下比色杯部分(20)压在一起，直到在所述焊接过程中熔化的材料凝固为止。
6.根据权利要求3所述的方法，其特征在于，在所述焊接过程中，以30至40kHz之间的频率和21.4至34.1μm的振幅使所述焊头振动。
7.根据权利要求3所述的方法，其特征在于，沿所述预定距离的第一部分施加第一焊接压力，并沿所述距离的剩余部分施加第二焊接压力，所述第二焊接压力比所述第一焊接压力大至少10％。
8.根据权利要求1所述的方法，其特征在于，所述方法应用激光焊接，其中沿具有平坦接触表面的焊接区域(23)无间隙地将所述上比色杯部分(10)和所述下比色杯部分(20)压在一起。
9.根据权利要求8所述的方法，其特征在于，在所述焊接过程之前，将吸收剂材料施加到位于底部的比色杯部分处的所述焊接区域(23)，并且将波长在780-1100nm之间的激光用于所述焊接过程。
10.根据权利要求8所述的方法，其特征在于，将部分由用于所述焊接过程的吸收剂材料制成的比色杯部分作为下比色杯部分应用，并将波长在900到1100nm之间的激光用于所述焊接过程。
11.根据权利要求8所述的方法，其特征在于，利用波长在1800至2200nm之间的激光进行无吸收剂的激光焊接。
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