Multilayer article formed by adhesive ablation

• US 20060134387A1
• Filed: 12/20/2004
• Published: 06/22/2006
• Est. Priority Date: 12/20/2004
• Status: Abandoned Application

• Current Assignee: Ortho-Clinical Diagnostics Incorporated (The Carlyle Group LP (Corporate Private Equity))
• Original Assignee: Ortho-Clinical Diagnostics Incorporated (The Carlyle Group LP (Corporate Private Equity))
• Inventors: Stockschlaeder, James, Gottermeier, William, Wigent, Joseph
• Application Number:
  US11/016,793
• Publication Number:
  US 20060134387A1
• Time in Patent Office: Days
• US Class Current: 428/173
• CPC Class Codes: B01L 3/5027 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 B01L3/5023 takes precedence; micromixers B01F33/30; microreactors for synthesis B01J19/0093; microcapillary devices in general B81B1/00
• CPC Class Codes: B32B 37/1284 Application of adhesive
• CPC Class Codes: G01N 27/307 Disposable laminated or multilayered electrodes G01N27/3272 takes precedence
• CPC Class Codes: G01N 27/333 Ion-selective electrodes or membranes glass electrodes G01N27/36
• CPC Class Codes: Y10T 428/2462 with partial filling of valleys on outer surface

Abstract

A method of manufacturing a multilayer laminated article includes: providing a first layer having a major surface; providing a second layer having a major surface that faces the major surface of the first layer; providing an adhesive layer such that the adhesive extends to at least one sidewall, which is perpendicular to the major surface; removing a length of the adhesive layer from the sidewall back in a direction away from the sidewall, whereby the adhesive is recessed from the at least one sidewall; and laminating the first and second layer with the adhesive disposed there between. In a preferred embodiment, the adhesive is removed by laser ablation. In another preferred embodiment, the article is a potentiometric test element used in a diagnostic analyzer.

Claims

1. A method of manufacturing a multilayer laminated article comprising:

providing a first layer having a major surface;

providing a second layer having a major surface that faces the major surface of the first layer;

providing an adhesive layer such that the adhesive extends to at least one sidewall, which is perpendicular to the major surface;

removing a length of the adhesive layer from the sidewall back in a direction away from the sidewall, whereby the adhesive is recessed from the at least one sidewall; and

laminating the first and second layer with the adhesive disposed there between.

2. A method as claimed in claim 1, wherein the adhesive layer extends to all four sidewalls, and the adhesive is removed from the four sidewalls back in a direction away from the sidewalls, whereby the adhesive is recessed from the four sidewalls.

3. A method as claimed in claim 1, wherein the adhesive is removed in the range of from 0.010 to 0.090 inches as measured from the edge of the sidewall.

4. A method of manufacturing according to claim 1, wherein the adhesive is removed before the laminating.

5. A method of manufacturing according to claim 1, wherein the adhesive is removed after the laminating.

6. A method of manufacturing according to claim 1, wherein the removing the length of adhesive is performed by mechanical cutting or laser ablation.

7. A method of manufacturing according to claim 6, wherein the adhesive is removed by laser ablation.

8. A method according to claim 7, wherein the laser is a CO₂ laser.

27. A method of reducing downtime on an apparatus comprising:

inserting the article according to claim 1 into the apparatus; and

transporting the article through the apparatus, whereby the recessed adhesive does not contact the apparatus.

28. A method according to claim 27, wherein the article is a potentiometric test element used on a diagnostic analyzer and the apparatus is a test element handler of diagnostic analyzer.

9. A method of manufacturing a multilayer laminated article comprising:

providing a first layer having a major surface;

providing a second layer having a major surface that faces the major surface of the first layer;

providing an adhesive layer such that the adhesive extends to at least one sidewall, which is perpendicular to the major surface;

laser ablating a length of the adhesive layer from the sidewall back in a direction away from the sidewall, whereby the adhesive is recessed from the at least one sidewall; and

laminating the first and second layer with the adhesive disposed there between.

10. A method as claimed in claim 9, wherein the adhesive layer extends to all four sidewalls, and the adhesive is laser ablated from the four sidewalls back in a direction away from the sidewalls, whereby the adhesive is recessed from the four sidewalls.

11. A method according to claim 9, wherein the laser is a CO₂ laser.

12. A multilayer laminated article comprising:

at least two layers each having a major surface that faces the major surface of the other layer; and

an adhesive disposed at least partially between the at least two layers, wherein the adhesive extends in a direction to at least one sidewall but the adhesive is recessed from the at least one sidewall, wherein said article is made by a process comprising;

providing a first layer having a major surface;

providing a second layer having a major surface that faces the major surface of the first layer;

providing an adhesive layer such that the adhesive extends to at least one sidewall, which is perpendicular to the major surface;

removing a length of the adhesive layer from the sidewall back in a direction away from the sidewall, whereby the adhesive is recessed from the at least one sidewall; and

laminating the first and second layer with the adhesive disposed there between.

13. A multilayer laminated article as claimed in claim 12, wherein the amount of recess is sufficient to prevent the adhesive from extending or flowing beyond the sidewall when the article is being handled by a machine during manufacturing of the article or while the article is in use.

14. A multilayer article as claimed in claim 12, wherein the recess is in the amount of in the range of from 0.010 to 0.090 inches as measured from the edge of the sidewall.

15. A method of manufacturing a potentiometric test element comprising the steps of:

providing a cover web having a lengthwise ribbon of fibers disposed therein to form an ion junction bridge;

applying an adhesive layer to the cover web, wherein the adhesive layer covers at least a part of the width of the cover web that includes the ribbon of fibers;

forming one or more apertures in the cover web and adhesive;

removing a portion of the adhesive in a region where the sidewalls of the test element will be formed;

applying ion-selective electrodes to the cover web;

applying one or more further webs over the ion-selective electrodes;

laminating the layers form a composite laminate;

cutting individual elements in the region of the adhesive removal to form individual test elements having sidewalls formed by the cut, whereby the adhesive is recessed from the sidewalls by virtue of the adhesive removal.

16. A method as claimed in claim 15, wherein the adhesive layer covers the entire width of the cover web, and the adhesive is removed from the edges of the cover web and in the region where the sidewalls of the test element will be formed, whereby the adhesive is recessed from the sidewalls by virtue of the adhesive removal.

17. A method as claimed in claim 15, wherein the adhesive is removed in the range of from 0.010 to 0.090 inches as measured from the edge of the sidewall.

18. A method of manufacturing according to claim 15, wherein the adhesive is removed before the laminating.

19. A method of manufacturing according to claim 15, wherein the adhesive is removed after the laminating.

20. A method of manufacturing according to claim 15, wherein the removing the length of adhesive is performed by mechanical cutting or laser ablation.

21. A method of manufacturing according to claim 20, wherein the adhesive is removed by laser ablation.

22. A method according to claim 21, wherein the laser is a CO₂ laser.

23. A method of manufacturing a potentiometric test element comprising the steps of:

providing a cover web having a lengthwise ribbon of fibers disposed therein to form an ion junction bridge;

applying an adhesive layer to the cover web, wherein the adhesive layer covers at least a part of the width of the cover web that includes the ribbon of fibers;

forming one or more apertures in the cover web and adhesive;

laser ablating a portion of the adhesive in a region where the sidewalls of the test element will be formed;

applying ion-selective electrodes to the cover web;

applying one or more further webs over the ion-selective electrodes;

laminating the layers form a composite laminate;

cutting individual elements in the region of the laser ablation to form individual test elements having sidewalls formed by the cut, whereby the adhesive is recessed from the sidewalls by virtue of the laser ablation.

24. A method as claimed in claim 23, wherein the adhesive layer covers the entire width of the cover web, and the adhesive is laser ablated from the edges of the cover web and in the region where the sidewalls of the test element will be formed, whereby the adhesive is recessed from the sidewalls by virtue of the adhesive removal.

25. A potentiometric test element for use in a diagnostic analyzer comprising:

two major surfaces and sidewalls;

a cover layer having therein at least two access apertures, the first cover layer forming the first major surface of the element;

an ion-junction bridge formed from a sheet of fibers disposed in the first cover layer, wherein the bridge is accessible by the two access apertures;

an adhesive layer disposed on the major surface of the cover layer which is opposite the first major surface and beneath the sheet of fibers;

two ion-selective electrodes each arranged such that the ion-junction bridge extends between the electrodes; and

a first additional layer disposed on the opposite side of the first major surface formed by the cover layer, said electrodes being disposed within said first additional layer;

wherein the adhesive layer extends in a direction to at least one sidewall but is recessed from the at least one sidewall, wherein the test element is formed by a process comprising the steps of;

providing a cover web having a lengthwise ribbon of fibers disposed therein to form an ion junction bridge;

applying an adhesive layer to the plastic strip, wherein the adhesive layer covers at least a part of the width of the cover web that includes the ribbon of fibers;

forming one or more apertures in the cover web;

laser ablating a portion of the adhesive in a region where the sidewall of the test element will be formed;

applying ion-selective electrodes to the cover web;

applying one or more further webs over the ion-selective electrodes;

laminating the layers form a composite laminate;

cutting individual elements in the region of the laser ablation to form individual test elements having sidewalls formed by the cut, whereby the adhesive is recessed from the sidewall by virtue of the laser ablation.

26. A potentiometric test element as claimed in claim 25, further comprising a second additional layer disposed on the first additional layer opposite the cover layer.