Spectacle distal end encapsulation

Abstract

The present disclosure provides for a distal component to encapsulate a sight glass to form a distal cap assembly that eliminates the need for adhesives and potting typically used in conventional distal cap assemblies. In particular, the present disclosure provides a keyway structure configured to retain the distal end member in a predetermined arrangement. The keyway structure is inserted into a mold along with the distal end member, and the keyway structure is encapsulated (e.g., in a polymer with hot melt or the like) along with the distal end member to form a distal cap. The distal cap locks the distal end member in the keyway structure and protects the distal end member from moisture and relative movement. The packaging technology and the far-side cap assembly have the advantages that compared with an existing method, the packaging technology and the far-side cap assembly are fast to manufacture, and the error possibility is small.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 2022, filed on August 19, 2022, entitled “SCOPE DISTALEND ENCAPSULATION”. 63 / 399,552, which is incorporated herein by reference. Technical Field

[0002] The present disclosure relates generally to distal ends of scopes. In particular, but not exclusively, the present disclosure relates to packaging components at the distal end of a scope, such as an endoscope. Background of the Invention

[0003] Modern endoscopes include multiple components at the distal end (e.g., lights, cameras, etc.). Typically, these components are packaged or assembled into a distal cap assembly. The distal cap assembly is generally manufactured using a plastic molded cap into which all distal components are inserted. Once inserted, the components are locked in place using adhesives and potting. Due to the complexity and size of the distal cap assembly and the number of independent components, this increases the probability of manufacturing defects. In addition, manufacturing time is typically increased due to adhesive curing time. Therefore, there is a need for improving the distal cap assembly. Summary of the invention

[0004] This Summary is provided to introduce some concepts in a simplified form that are further described in the Detailed Description below. This Summary is not intended to necessarily identify key features or essential features of the claimed subject matter, nor is it intended to be an aid in determining the scope of the claimed subject matter.

[0005] The present disclosure provides a method for manufacturing a distal cap assembly of a scope. The method may include: providing a keyway structure; fitting a plurality of distal end components into the keyway structure; inserting the keyway structure and the plurality of distal end components into a mold; and injecting an encapsulating material into the mold to encapsulate the keyway structure and the distal end components to form a distal end capsule.

[0006] In some embodiments, the method provides: wherein the keyway structure includes a plurality of slots, each of the plurality of slots being configured to receive a respective one of a plurality of distal end components. According to some embodiments, the method provides: wherein the keyway structure includes at least one lumen, the at least one lumen connecting the proximal end of the keyway structure to the plurality of slots. In some embodiments, the method provides: wherein at least one of the plurality of distal end components is an image sensor. According to some embodiments, the method provides: wherein at least one of the plurality of distal end components includes a lead wire that is guided through at least one lumen and is coupled to the image sensor. In some embodiments, the method provides: wherein at least another of the plurality of distal end components is a light emitting diode (LED). According to some embodiments, the method provides: wherein at least another of the plurality of distal end components includes a lead wire that is guided through at least one lumen and is coupled to the LED, and wherein the encapsulation material is at least partially transmissive to the wavelength of light emitted by the light emitting diode. In some embodiments, the method provides: wherein the image sensor is a charge coupled device (CCD) sensor or a complementary metal oxide semiconductor (CMOS) sensor. According to some embodiments, the method includes printing, depositing, or printing and depositing multiple layers of keyway structure material with a three-dimensional (3D) printer to form a keyway structure. In some embodiments, the method provides: wherein the keyway structure includes a raised ring, which is disposed between the proximal end of the keyway structure and the distal end of the keyway structure. According to some embodiments, the method provides: wherein the distal end capsule completely encapsulates at least one of a plurality of distal end components. In some embodiments, the method provides: wherein the distal-most end of at least one of the distal end components is flush with the distal-most end of the distal end capsule. According to some embodiments, the method provides: wherein the encapsulation material is a polymer. In some embodiments, the method provides: wherein injecting the encapsulation material into the mold is part of a hot melt process.

[0007] The present disclosure also provides a distal cap assembly. In some embodiments, the distal cap assembly is manufactured according to the method described herein. According to some embodiments, the present disclosure provides a distal cap assembly, which includes: a keyway structure; a plurality of distal end components, which are arranged in the keyway structure; and a distal end capsule, which encapsulates the keyway structure and the distal end component, wherein the distal end capsule is formed with an encapsulation material using a hot melt injection process.

[0008] In some embodiments, the distal cap assembly provides: wherein the keyway structure includes a plurality of slots, each of the plurality of slots being configured to receive a respective one of the plurality of distal end components. According to some embodiments, the distal cap assembly provides: wherein the keyway structure includes at least one lumen, the at least one lumen connecting the proximal end of the keyway structure to the plurality of slots. In some embodiments, the distal cap assembly provides: wherein at least one of the plurality of distal end components is an image sensor. According to some embodiments, the distal cap assembly provides: wherein at least one of the plurality of distal end components includes a lead wire that is guided through at least one lumen and is coupled to the image sensor. In some embodiments, the distal cap assembly provides: wherein at least another of the plurality of distal end components is a light emitting diode (LED). According to some embodiments, the distal cap assembly provides: wherein at least another of the plurality of distal end components includes a lead wire that is guided through at least one lumen and is coupled to the LED, and wherein the encapsulation material is at least partially transmissive to the wavelength of light emitted by the light emitting diode. In some embodiments, the distal cap assembly provides: wherein the image sensor is a charge coupled device (CCD) sensor or a complementary metal oxide semiconductor (CMOS) sensor. According to some embodiments, the distal cap assembly provides: wherein the keyway structure includes a raised ring, which is disposed between the proximal end of the keyway structure and the distal end of the keyway structure. In some embodiments, the distal cap assembly provides: wherein the distal end capsule completely encapsulates at least one of the plurality of distal end components. According to some embodiments, the distal cap assembly provides: wherein the distal-most end of at least one of the distal end components is flush with the distal-most end of the distal end capsule. In some embodiments, the distal cap assembly provides: wherein the encapsulation material is a polymer.

[0009] The present disclosure provides an endoscope, which includes: a proximal end, which includes at least one electrical connector; a distal end, which includes a plurality of distal end components; an outer lumen, which connects the proximal end and the distal end; at least one lead, which is arranged in the outer lumen, and the at least one lead electrically connects at least one electrical connector to the plurality of distal end components; wherein the distal end includes a cap assembly, which includes: a keyway structure, wherein the plurality of distal end components are arranged in the keyway structure; and a distal end capsule, which encapsulates the keyway structure and the distal end components, wherein the distal end capsule is formed with a packaging material using a hot melt injection process.

[0010] In some embodiments, the endoscope provides: wherein the keyway structure includes a plurality of slots, each of the plurality of slots being configured to receive a respective one of a plurality of distal end components. According to some embodiments, the endoscope provides: wherein the keyway structure includes at least one distal lumen, the at least one distal lumen connecting a proximal end of the keyway structure to the plurality of slots. In some embodiments, the endoscope provides: wherein at least one of the plurality of distal end components is an image sensor, and wherein at least one lead is guided through the at least one distal lumen; and wherein at least another of the plurality of distal end components is a light emitting diode (LED), and wherein the encapsulation material is at least partially transmissive to a wavelength of light emitted by the light emitting diode. According to some embodiments, the endoscope provides: wherein the keyway structure includes a raised ring disposed between a proximal end of the keyway structure and a distal end of the keyway structure, and wherein the outer lumen abuts a first side of the raised ring, the first side being adjacent to the proximal end of the keyway structure, and wherein the distal end capsule abuts a second side of the raised ring, the second side being adjacent to the distal end of the keyway structure. In some embodiments, the endoscope provides wherein the distal tip balloon completely encapsulates at least one of the plurality of distal tip components, and wherein a distal-most end of the at least one of the distal tip components is flush with a distal-most end of the distal tip balloon. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] To easily identify the discussion of any particular element or act, the most significant digit(s) in a reference numeral refers to the figure number in which the element is first introduced.

[0012] Figure 1 One aspect of the subject matter is shown according to one embodiment.

[0013] Figure 2 One aspect of the subject matter is shown according to one embodiment.

[0014] Figure 3 One aspect of the subject matter is shown according to one embodiment.

[0015] Figure 4 One aspect of the subject matter is shown according to one embodiment.

[0016] Figure 5A One aspect of the subject matter is shown according to one embodiment.

[0017] Figure 5B One aspect of the subject matter is shown according to one embodiment.

[0018] Figure 5C One aspect of the subject matter is shown according to one embodiment.

[0019] Fig. 6AOne aspect of the subject matter is shown according to one embodiment.

[0020] Figure 6B One aspect of the subject matter is shown according to one embodiment.

[0021] Figure 6C One aspect of the subject matter is shown according to one embodiment.

[0022] Fig.6D One aspect of the subject matter is shown according to one embodiment.

[0023] Fig. 6E One aspect of the subject matter is shown according to one embodiment. DETAILED DESCRIPTION

[0024] The present disclosure provides a distal component for encapsulating a scope to form a distal cap assembly, which eliminates the need for adhesives and potting commonly used in conventional distal cap assemblies. In particular, the present disclosure provides a keyway structure configured to maintain the distal end component in a predetermined arrangement. The keyway structure is inserted into a mold together with the distal end component, and the keyway structure is encapsulated together with the distal end component (e.g., encapsulated in a polymer using hot melt, etc.) to form a distal cap. The distal cap locks the distal end component in the keyway structure and protects the distal end component from moisture and relative movement. As a benefit, compared to conventional methods, the packaging technology of the present invention and the distal cap assembly are manufactured faster and provide less room for error.

[0025] The foregoing has broadly outlined the features and technical advantages of the present disclosure so that the following specific embodiments of the present disclosure can be better understood. It should be understood by those skilled in the art that the disclosed embodiments can be easily implemented as a basis for modifying or designing other structures, which are used to perform the same purpose of the present disclosure. When considered in conjunction with the accompanying drawings, the novel features of the present disclosure (with respect to its organization and method of operation) and other objects and advantages will be better understood according to the following specific embodiments. However, it should be clearly understood that each of the drawings is provided only for the purpose of illustration and description, and is not intended to be a definition of the scope of the present disclosure.

[0026] Figure 1 According to some embodiments of the present disclosure, a complete distal cap assembly 100 is shown. Generally speaking, the distal cap assembly 100 can form the distal end of any of a variety of endoscopes (such as, for example, a gastroscope, a colonoscope, a bronchoscope, a laryngoscope, a cystoscope, a duodenoscope, an enteroscope, a ureteroscope, a hysteroscope, etc.). As shown, Figure 1 The distal cap assembly 100 shows a keyway structure 200 (see Figure 2 ), wherein the various components are arranged in a keyway structure 200 (see Figure 5A) and packaged as described herein. In particular, the distal cap assembly 100 includes a plurality of distal end components 102a, 102b, 104, 102c and 102d, which are disposed in the keyway structure 200 and packaged in a material to form a distal end capsule 106. In such examples, the distal end components 102a to 102d may be any of a variety of components, which may include any combination of cameras, lighting elements (e.g., fiber optic cables, light emitting diodes (LEDs), etc.), sensing devices, etc. In addition, the distal cap assembly 100 includes a working slot 104. It should be noted that although the distal cap assembly 100 only shows a single working slot 104, a plurality of working slots 104 may be provided.

[0027] Some of the distal end components (e.g., 102a, etc.) may have an electrical connection 108 that is coupled to the distal end components that lead to the proximal end of the scope (not shown). The electrical connection 108 may ultimately be coupled to the electronics in the scope, and the keyway structure 200 and the distal cap assembly 100 should provide or be coupled to a hub or other electrical connector at the proximal end of the scope and be configured to provide an electrical connection between a controller (e.g., an image acquisition unit, a computer, etc.) and the distal end components (e.g., distal end components 102a, etc.).

[0028] The size of the distal cap assembly 100 can be set based on the type of the scope with which the distal cap assembly 100 is paired. For example, the distal cap assembly 100 can have an outer diameter of 2 millimeters (mm), 15 mm, between 2 mm and 15 mm, or other sizes suitable for use with a scope as described herein.

[0029] Figure 2 A keyway structure 200 is shown according to some embodiments of the present disclosure. As can be seen, the keyway structure 200 includes component slots 202a, 202b, 202c, and 202d, often referred to simply as "slots." The keyway structure 200 also includes component entry ports 204a and 204b and a working slot 104. The component slots 202a, 202b, 202c, and 202d may be configured and arranged to hold a particular one of the distal end components 102a, 102b, 102c, and 102d. For example, where the distal end component 102b is a camera, the component slot 202b may be configured and arranged to fit the size of the camera and to securely hold the camera during the packaging process (described in more detail below). As another example, where the distal end components 102a and 102c are LEDs, the component slots 202a and 202c may be configured and arranged to fit the size of these LEDs and to securely hold these LEDs during the packaging process.

[0030] It should be noted that although the component grooves 202a, 202b, 202c and 202d are shown as square or rectangular shapes, they can be any shape or size configured to hold the corresponding distal end components 102a, 102b, 102c and 102d. For example, in the case where multiple distal end components (e.g., distal end components 102a and / or 102b, etc.) are optical fiber cables, then the relevant component grooves (e.g., component grooves 202a and / or 202b) can be circular or oval in shape to securely hold these optical fiber cables during the packaging process.

[0031] The keyway structure 200 also includes component access ports 204a and 204b. Generally speaking, the component access ports 204a and 204b can be arranged to allow electrical connections (e.g., signal wires, conductors, cables, etc.) to be guided from the distal end components through the keyway structure 200. As mentioned, these electrical connections (e.g., electrical connection 108) can ultimately be connected to the electronics in the scope, and the keyway structure 200 and the distal cap assembly 100 should provide or be connected to a hub or electrical connection at the proximal end of the scope and be configured to provide an electrical connection between a controller (e.g., an image acquisition unit, a computer, etc.) and the distal end components.

[0032] It is noteworthy that the keyway structure 200 includes a groove (e.g., 202a, 202b, 202c, and 202d) for each corresponding distal end component that will be packaged in the distal cap assembly 100. In addition, the shape of the groove is set to maintain the distal end components in a proper position relative to each other during the packaging process without potting or other fixing materials or mechanisms. In addition, the keyway structure 200 and the groove provide that when inserted into the mold for packaging as described herein, the distal end components are maintained in a proper position (e.g., without adhesive and / or potting). Relative to conventional distal cap assemblies, this provides the advantage that the distal end components are maintained in a proper position (e.g., relative to each other, relative to the distal cap assembly, etc.) with less material and processing. Therefore, manufacturing time can be shortened and the cost of the manufacturing process can be reduced.

[0033] Figure 3 According to some embodiments of the present disclosure, a mold 300 is shown. The mold 300 includes a lower half 302 and an upper half 304, and is arranged and configured to insert the keyway structure 200 into a cavity 306; when the lower half 302 and the upper half 304 are positioned adjacent to each other, the cavity 306 is formed, so that the cavity 306 is a larger cavity, wherein the keyway structure 200 can be inserted, arranged, positioned or assembled in the larger cavity.

[0034] The mold 300 also includes a support structure 308 (which can be configured to receive a clamp) or other support structure to hold the mold 300 (e.g., the lower half 302 and the upper half 304) in a stable position during the injection process. In addition, the mold 300 includes an injection port 310, and the encapsulation material can be injected into the injection port 310 to surround and encapsulate the keyway structure 200 and the distal end component (e.g., 102a, etc.) to form the distal end capsule 106.

[0035] Figure 4 Method 400 is shown according to some embodiments of the present disclosure. Method 400 may be implemented to form distal tip balloon 106, as outlined herein. In general, method 400 may be implemented to form any distal tip balloon. However, for purposes of convenience and clarity, method 400 is referred to as Figure 1 The distal cap assembly 100, Figure 2 The keyway structure 200 and Figure 3 However, this is not intended to be limiting.

[0036] Method 400 may begin at block 402. At block 402, "Provide a keyway structure," a keyway structure may be provided. For example, keyway structure 200 may be provided. The provided keyway structure will include a component slot and at least one working slot. Continuing to block 404, "Assemble a plurality of distal end components into the keyway structure," a plurality of distal end components may be assembled into the component slots of the keyway structure. For example, distal end components 102a, 102b, 102c, and 102d may be assembled into component slots 202a, 202b, 202c, and 202d, respectively.

[0037] This is more clearly shown in Figure 5A middle, Figure 5A A keyway structure 200 is shown in which the distal end components "fit" into a plurality of slots of the keyway structure 200. For example, the distal end components 102a, 102b, 102c, and 102d are shown as fitting or positioned in respective ones of the component slots 202a, 202b, 202c, and 202d (not labeled in this figure for purposes of clarity). Likewise, the electrical connection 108 is shown coupled to the distal end components and directed through respective component entry ports 204a and 204b (not labeled in this figure for purposes of clarity).

[0038] Continuing to block 406, "INSERT KEYWAY STRUCTURE AND PLURAL DISTAL END COMPONENTS INTO MOLD", the keyway structure can be inserted into the mold. For example, the keyway structure 200 (including the distal end component 102a) can be inserted into the mold 300. This is more clearly shown in FIG. Figure 5B and Figure 5C middle, Figure 5B and Figure 5CA keyway structure 200 is shown inserted into a mold 300 .

[0039] Figure 5C A perspective view of the upper half 304 of the mold 300 is shown, with the injection port 310 shown in more detail. The injection port 310 can be arranged and configured to receive a potting syringe (described in more detail below), with which potting material can be injected into the cavity 306 to surround the keyway structure 200 and the distal end component 102a, etc., so that the distal end balloon 106 is formed.

[0040] Continuing to block 408, "Injecting encapsulating material into mold to encapsulate keyway structure and distal end component to form distal end capsule", encapsulating material is injected into the cavity of the mold to encapsulate keyway structure and distal end component to form distal end capsule. For example, encapsulating material can be injected into cavity 306 through injection port 310 to form distal end capsule 106, which surrounds and encapsulates keyway structure 200 and distal end components 102a, 102b, 102c and 102d. In addition, the encapsulating material can form the distal or forward end of the scope (including the distal end of the working slot 104), and the distal cap assembly 100 is configured for the distal or forward end.

[0041] FIG. 6A to FIG. 6E A prototype distal end balloon 602 formed in accordance with examples of the present disclosure is shown. Fig. 6A Keyway 604 is shown inserted into mold 606. Mold 606 includes 608 and 610, which are shown placed together to form a cavity (not shown) into which keyway 604 is inserted. In addition, injection port 612 is shown in this figure.

[0042] Figure 6B Mold 606 is shown with encapsulating syringe 614 mounted in injection port 612 (obscured by encapsulating syringe 614). Encapsulating material may be injected into the cavity to encapsulate and surround keyway 604, thereby forming distal end balloon 602.

[0043] Figure 6C Shown is a view of the distal end of the distal end balloon 602. As can be seen, the distal end balloon 602 includes a working slot 616 and distal end components 618a, 618b and 618c.

[0044] Fig.6DA side view of the distal end capsule 602 is shown, showing the distal end capsule 602; the distal end capsule 602 is formed around the distal end of the keyway 604, thereby encapsulating the distal end components 618a, 618b and 618c. As can be seen, the distal end capsule 602 can include a distal-most side 620 and a secondary distal side 622. The secondary distal side 622 can be slightly inclined, or can be at a certain angle to the distal-most side 620. For example, the secondary distal side 622 can be at an angle of between 25 degrees and 50 degrees to the distal-most side 620.

[0045] Fig. 6E Another side view of the distal end capsule 602 is shown, illustrating the distal end capsule 602; the distal end capsule 602 is formed around the distal end of the keyway 604, thereby encapsulating the distal end components 618a, 618b and 618c (not shown) and the working groove 616.

[0046] Terms used herein should be given their ordinary meaning in the relevant art, or the meaning indicated by their usage in context; however, where an explicit definition is provided, that meaning shall control.

[0047] Herein, references to "one embodiment" or "an embodiment" do not necessarily refer to the same embodiment, but they may refer to the same embodiment. Unless the context clearly requires otherwise, throughout the detailed description and claims, the words "comprise", "comprising", etc. should be understood in an inclusive sense rather than an exclusive or exhaustive sense; that is, to be understood in the sense of "including but not limited to". Words using the singular or plural also include the plural or singular, respectively, unless expressly limited to a single or multiple. In addition, when used in this application, the words "herein", "above", "below" and words of similar meaning refer to the application as a whole, not to any particular part of the application. When the claims use the word "or" to refer to a list of two or more items, the word covers all the following interpretations of the word: any one of the items in the list, all the items in the list, and any combination of the items in the list, unless expressly limited to one or the other. Any term not expressly defined herein has its conventional meaning, as commonly understood by a person skilled in the relevant art.

Claims

1. A method for manufacturing a distal cap assembly of a scope, the method comprising: Provide keyway structure; assembling a plurality of distal end components in the keyway structure; inserting the keyway structure and the plurality of distal end components into a mold; and An encapsulating material is injected into the mold to encapsulate the keyway structure and the distal end component to form a distal end capsule. 2 . The method of claim 1 , wherein the keyway structure comprises a plurality of slots, each of the plurality of slots being configured to receive a respective one of the plurality of distal end components. 3 . The method of claim 2 , wherein the keyway structure includes at least one lumen connecting a proximal end of the keyway structure to the plurality of slots. The method of claim 3 , wherein at least one of the plurality of distal tip components is an image sensor. 5 . The method of claim 4 , wherein the at least one of the plurality of distal tip components comprises a lead wire routed through the at least one lumen and coupled to the image sensor.

6. The method of claim 5, wherein at least another one of the plurality of distal end components is a light emitting diode (LED).

7. A method according to claim 6, wherein at least another one of the plurality of distal end components includes a lead wire that is guided through the at least one lumen and connected to the LED, and wherein the encapsulation material is at least partially transmissive to the wavelength of light emitted by the light emitting diode.

8. The method according to any one of claims 4 to 7, wherein the image sensor is a charge coupled device (CCD) sensor or a complementary metal oxide semiconductor (CMOS) sensor.

9. The method according to any one of claims 1 to 8, comprising printing, depositing, or printing and depositing multiple layers of keyway structure material with a three-dimensional (3D) printer to form the keyway structure.

10. The method of any one of claims 1 to 9, wherein the keyway structure includes a raised ring disposed between the proximal end of the keyway structure and the distal end of the keyway structure.

11. The method of any one of claims 1 to 10, wherein the distal tip balloon completely encapsulates at least one of the plurality of distal tip components.

12. The method of any one of claims 1 to 11, wherein a distal-most end of at least one of the distal tip components is flush with a distal-most end of the distal tip balloon.

13. The method of any one of claims 1 to 12, wherein the encapsulating material is a polymer.

14. The method according to any one of claims 1 to 13, wherein injecting encapsulating material into the mould is part of a hot melt process.

15. A distal cap assembly manufactured by the method according to any one of claims 1 to 14.

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