Endoscope tip with universal camera assembly

Abstract

A method of manufacturing an endoscope tip assembly, the endoscope tip assembly comprising: an illumination module, a lighting module including a body having a longitudinal base and a transverse wall, a light emitting diode supported at a distal end of the longitudinal base, and a lighting wire electrically connected to the light emitting diode and extending through the insertion tube to the positioning interface or handle; a universal camera module includes an image sensor, a circuit board electrically connected to the image sensor, a sensor holder, and a sensor housing fixed to the sensor holder, the image sensor being housed in the sensor housing, and the sensor holder extending proximally from the image sensor. The same universal camera module may be used to fabricate different tip assemblies for different endoscopes.

Description

[0001] Cross - Reference to Related Applications

[0002] None.

[0003] This application relates to U.S. Patent Application No. (Case No. 1271) and U.S. Patent Application No. (Case No. 1272). Technical Field

[0004] This disclosure relates to an endoscope tip assembly, an endoscope having the tip assembly, a method for manufacturing the tip assembly, and a manufacturing system for the tip assembly. Background Art

[0005] Endoscopes are well - known devices used in the medical field for visually examining a patient's internal body. An endoscope typically includes a handle or positioning interface and an insertion cord that extends distally therefrom. The insertion cord includes an insertion tube, a bending section, and a distal tip. The distal tip includes a housing that houses a camera assembly, and the camera assembly includes an image sensor. The following commonly - owned U.S. patents and publications (incorporated herein by reference) disclose examples of endoscopes having various distal tips: U.S. Patent Nos. 11,291,352; 11,311,184; 11,432,714; 11,642,010; and U.S. Patent Publication Nos. 20200281445; 20200288953; 20200405137; 20210068640; 20210068641; 20220061645; 20220175226; and 20230054149.

[0006] Disposable endoscopes optimize the workflow and reduce costs while saving patient lives and improving patient care. Disposable endoscopes optimize the workflow and reduce costs because they are available for use as needed without the traditional high capital and maintenance budgets required for reusable endoscopes. For example, the use of sterilization and storage facilities is avoided, there is no need to maintain evidence of sterilization, and there is no need to transport the endoscope from the sterilization and storage facilities to the location where the endoscope is needed, and these transports are sometimes carried out at night or on weekends. Disposable endoscopes save patient lives and improve patient care because they are easily accessible and do not pose a risk of cross - contamination. This also reduces the incidence of readmission. Although disposable endoscopes are discarded after a single use by a patient (a patient can perform one or more procedures in a treatment room), for reusable endoscopes, due to material cleaning, CO2 emissions during the cleaning process, and the use of disposable personal protective equipment by personnel involved in the transport and sterilization of reusable endoscopes, their environmental impact can be similar to that of disposable endoscopes. To further reduce the environmental impact, the endoscopes according to this disclosure are mainly made of polymer materials.

[0007] Both reusable and disposable (i.e., single-use) endoscopes include surgical endoscopes, such as arthroscopes, bronchoscopes, choledochoscopes, colonoscopes, cystoscopes, duodenoscopes, gastroscopes, laparoscopes, ureteroscopes, etc. To manufacture surgical endoscopes, a supply chain for producing various components (such as image sensors, light sources, control wires, working channel tubes, etc.) is necessary. When endoscopes are produced in different sizes, the product composition and inventory investment of the supply chain further increase, adding to the product mix.

[0008] To further increase the benefits of disposable endoscopes, it is desirable to reduce the manufacturing cost. SUMMARY OF THE INVENTION <U+ <U+

[0009] The present invention provides a universal camera module design. Regardless of the size, particularly the outer diameter, of the distal end head housing and the endoscope, the size and design of the universal camera module remain unchanged. <U+ <U+

[0010] The universal camera module design can be used and implemented on a wide range of endoscopes with or without a working channel, thereby allowing a single camera module to be mass-produced and used on a series of endoscopes. Only a single type of injection mold and tooling are required. Thus, the universal camera module design reduces design and supply chain costs, including work-in-progress inventory. In addition, for different endoscope types, since the size of the universal camera module is already fixed, it takes less time to design the camera compartment in the end head housing. Similarly, since the same universal camera module and components are used, the time spent on electronic implementation (e.g., image processing) of the universal camera module in new endoscopes is significantly reduced. <U+ <U+

[0011] This is achieved by providing an end head housing and a universal camera module having a geometry that provides surfaces for guiding and fixing the universal camera module in both the smallest outer diameter endoscope and the largest outer diameter endoscope. In addition, by separating the camera module and the lighting module into separate modules (including separate printed circuit boards (PCBs) and separate wiring), the design also allows different lighting configurations to be used depending on the size and type of the endoscope. In larger endoscopes and where more free space is available, more or larger light-emitting diodes (LEDs) can be used. Optical fibers and light guides can also be used in the lighting module. <U+ <U+

[0012] The first aspect of the invention disclosed herein is to reduce manufacturing costs by designing endoscopes (including surgical endoscopes) with common parts. Using common parts simplifies the supply chain, thereby reducing inventory costs, such as the cost of maintaining large inventories and the obsolescence cost due to product improvements. <U+ <U+

[0013] In an embodiment according to the first aspect, a system is provided that includes: two copies of a general camera module; a first illumination module; a second illumination module; a first end head housing without a working channel; and a second end head housing that includes a working channel, wherein the size and configuration of the first end head housing are determined to receive one copy of the general camera module and the first illumination module, and wherein the size and configuration of the second end head housing are determined to receive the second copy of the general camera module and the second illumination module, and wherein the first end head housing, the general camera module, and the first illumination module form a first end head assembly, and wherein the second end head housing, the general camera module, and the second illumination module form a second end head assembly.

[0014] In another embodiment according to the first aspect, an endoscope includes: a positioning interface or a handle; an insertion tube that extends distally from the positioning interface or the handle; an illumination module that includes a body having a longitudinal base and a transverse wall, a light-emitting diode supported at a distal end of the longitudinal base, and an illumination wire electrically connected to the light-emitting diode and extending through the insertion tube to the positioning interface or the handle; a general camera module that includes an image sensor, a circuit board electrically connected to the image sensor, a sensor holder, and a sensor housing fixed to the sensor holder, the image sensor being received in the sensor housing, and the sensor holder extending proximally from the image sensor; a camera module wire electrically connected to the circuit board that is electrically connected to the image sensor, the camera module wire extending through the insertion tube to the positioning interface or the handle; and an end head housing that encloses the illumination module and the general camera module.

[0015] A second aspect of the invention disclosed herein is to provide a method of manufacturing an endoscope that simplifies the assembly process.

[0016] In an embodiment according to the second aspect, the method includes: assembling a first copy of the general camera module and a second copy of the general camera module, the first copy being identical to the second copy; assembling a first illumination module; assembling a second illumination module different from the first illumination module; providing a first end head housing; providing a second end head housing different from the first end head housing; inserting one copy of the general camera module and the first illumination module into the first end head housing to form a first end head assembly; and inserting the second copy of the general camera module and the second illumination module into the second end head housing to form a second end head assembly.

[0017] A third aspect is to provide an endoscope that has an improved working channel tube connection at the end head of the endoscope.

[0018] In an embodiment according to a third aspect, the endoscope includes an end head assembly, the end head assembly including: a lighting module including a light-emitting diode; a general camera module including an image sensor, a circuit board electrically connected to the image sensor, and a sensor housing in which the image sensor is received; and an end head housing surrounding the lighting module and the general camera module, the end head housing including a working channel, a distal portion, a transition member, and a middle section portion positioned between the distal portion and the transition member, the middle section portion being opaque, the distal portion being transparent, the working channel including a middle section working channel and a transition member working channel, wherein the middle section portion includes the middle section working channel, and wherein the transition member includes the transition member working channel, the transition member working channel including a distal working channel portion distal to a proximal working channel portion, the proximal working channel portion being offset from the middle section working channel. The end head housing may further include a proximal portion, in which case the middle section portion is positioned between the distal portion and the proximal portion, with a separate transition member fixed to the proximal portion. The proximal portion may be transparent and integrally molded with the middle section portion and the distal portion.

[0019] In a variant of this embodiment, the middle section working channel includes a longitudinal axis WCA, and the proximal working channel portion includes a longitudinal axis TPA(p) parallel to the longitudinal axis of the middle section working channel.

[0020] In another variant, the end head housing includes a camera module cavity, the transition member includes a distal protrusion and a proximal joint surface fitting in the camera module cavity, and the middle section portion includes a distal joint surface adhesively bonded to the proximal joint surface to form a joint, with the distal protrusion extending distally of the joint.

[0021] In another variant, the middle section portion includes a circumferential wall having an arcuate portion, a distal joint surface, the transition member includes a proximal joint surface and a circumferential wall portion positioned in front of the transition member working channel, the distal joint surface adhesively bonded to the proximal joint surface to form a joint, and the arcuate portion extends beyond the joint.

[0022] As used herein, "front" refers to the side of the general camera module opposite the lighting module, and "rear" refers to the side of the general camera module adjacent to the lighting module and adjacent to the working channel (if present). The term front may substitute for the term top or upper, and the term rear may substitute for the term bottom or lower.

[0023] One or more of these objects can be achieved by aspects of the present invention described in the following embodiments, variants, and examples.

[0024] Those skilled in the art will understand that any one or more of the above aspects and embodiments of the present disclosure can be combined with any one or more of the other aspects and embodiments of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The present invention will be described in more detail below with reference to the following drawings. The drawings illustrate embodiments, variations, and examples of the present invention to assist in the understanding of those of ordinary skill in the art and should not be construed as limiting the scope of the present invention.

[0026] Figure 1 is a perspective view of a visualization system including an endoscope and a video processor connectable to the endoscope;

[0027] Figure 2 is a perspective view of an embodiment of a general camera module;

[0028] Figure 3 is a perspective view of a first embodiment of an illumination module;

[0029] Figure 4 is a perspective view of a first embodiment of a tip assembly, the tip assembly including a first embodiment of a tip housing and including Figure 3 the illumination module of Figure 2 and the general camera module of

[0030] Figure 5 is a perspective view of a second embodiment of an illumination module;

[0031] Figure 6 is a perspective view of a second embodiment of a tip assembly, the tip assembly including a second embodiment of a tip housing and including Figure 5 the illumination module of Figure 2 and the general camera module of

[0032] Figure 7 is Figure 2 a perspective view of an embodiment of a general camera module of

[0033] Figure 8 is Figure 3 a perspective view of an embodiment of an illumination module of

[0034] Figure 9 is Figure 3 the illumination module of Figure 2 and a side view of the general camera module of

[0035] Figure 10 is Figure 4 a side view of a first embodiment of a tip assembly of

[0036] Figure 11 is Figure 4 a perspective view of a tip assembly of

[0037] Figure 12 is Figure 4 a cross-sectional perspective view of the end component;

[0038] Figure 13 is a proximal view of the first embodiment of the end housing;

[0039] Figure 14 is a proximal view of the second embodiment of the end housing;

[0040] Figure 15 is a proximal perspective view of the second embodiment of the end housing;

[0041] Figure 16 is Figure 6 a perspective view of the end component;

[0042] Figure 17 is Figure 6 a cross-sectional perspective view of the end component;

[0043] Figure 18 is a lateral cross-sectional view of the first embodiment of the transition member of the second embodiment of the end housing;

[0044] Figure 19 and Figure 20 is a perspective view of the component of the second embodiment of the end housing;

[0045] Figure 21 and Figure 22 is a perspective view of the component of another example of the second embodiment of the end housing;

[0046] Figure 23 and Figure 24 is a perspective view of the second lighting module;

[0047] Figure 25 is a flowchart depicting an embodiment of a method of manufacturing an endoscope using Figures 2 to 23 a general camera module and a lighting module;

[0048] Figure 26 is a schematic diagram of an optical waveguide; and

[0049] Figure 27 and Figure 28 is a view of an example of a video processor. Detailed Description

[0050] Figure 1An embodiment of a visualization system 10 including a video processor 11 and an endoscope 20 is shown. The endoscope includes a general camera module. The endoscope 20 includes a handle 21 that includes a housing 22 and a manipulation actuator 25 (illustrated as a rotatable control lever or wheel). The wire rope 23 includes a connector 24 that can be received by one of the connector sockets of the video processor 11 to establish electronic communication between the corresponding medical device interface of the video processor 11 and the endoscope 20. The endoscope 20 also includes an insertion cord 30 that includes an insertion tube 31, a bending section 32, and a tip assembly 33. In this embodiment, the endoscope 20 includes a working channel 40. A tool 41 is shown extending through the insertion cord 30, the working channel 40, and protruding from the tip assembly 33. The manipulation wire 42 (shown in Figure 22 is operably connected to the manipulation actuator 25 and is configured to manipulate the tip assembly 33. Embodiments of the video processor 11 are described with reference to Figure 26 and Figure 27 .

[0051] A general camera module and a system for reducing manufacturing costs will now be described with reference to Figures 2 to 6 . Figures 2 to 6 Two embodiments of the tip assembly 33 are shown, both of which include a general camera module 100 ( Figure 2 ), which includes a sensor holder 200 and a sensor housing 300. Figure 3 and Figure 5 show embodiments of the lighting module 400, denoted by reference numerals 400a and 400b for the first lighting module and the second lighting module, respectively. Figure 4 and Figure 6 show embodiments of the tip assembly 33, denoted by reference numerals 33a and 33b, each of which includes a general camera module 100. The first tip assembly 33a includes a first lighting module 400a and a first tip housing 500a, and the second tip assembly 33b includes a second lighting module 400b and a second tip housing 500b that is different from the first tip housing 500a. The first lighting module 400a and the second lighting module 400b are variants of the lighting module 400, and the first tip housing 500a and the second tip housing 500b are variants of the tip housing 500. As shown, assembling the tip assembly with different lighting modules and tip housings using the same general camera module 100 design simplifies the design and manufacturing while reducing work-in-progress and supply chain inventory. The components of the parts or sub-assemblies represented by reference numerals 100, 200, 300, 400, and 500 will now be described in the order starting with reference numerals 102, 202, 302, 402, and 502, respectively.

[0052] In some embodiments, when the sensor housing is assembled in an endoscope head housing with or without a working channel, the front surface of the sensor housing 300 may abut the proximal inner surface of the endoscope head housing 500a, 500b, thereby restricting movement in the proximal-distal direction. The front surface may be a surface located at the distal end of the endoscope head housing and transverse to the longitudinal extent of the endoscope head housing. The front distal surface and the rear distal surface of the sensor housing 300 abut the corresponding front distal inner surface and rear distal inner surface of the endoscope head housing, thereby restricting the forward and backward movement of the distal end of the sensor housing 300. To restrict the lateral movement of the sensor housing 300, the guiding or aligning surfaces of the "wings" on each side of the sensor housing 300 abut the corresponding guiding or aligning surfaces in the endoscope head housing 500a, 500b. The endoscope head housing with and without a working channel is different in terms of how to support the proximal end of the sensor housing 300 and how to restrict the rotational movement of the sensor housing 300, as illustrated with reference to Figure 7 as described.

[0053] The dimensions of the universal camera module 100, particularly the external dimensions, may be fixed such that the universal camera module 100 can be used with endoscope head housings of different sizes with and without a working channel. Advantageously, the fixed dimensions enable the use of the same camera module on a wide range of endoscopes, thereby allowing a single camera module to be mass-produced and used on a series of endoscopes or more broadly on insertion-type visualization devices (including endotracheal tubes). Therefore, manufacturing the universal camera module 100 requires a set of injection molds and tools. In addition, for different types of endoscopes, since the dimensions of the universal camera module are already fixed, the time required for designing the camera compartment lumen in the endoscope head housing is less. Similarly, since the same universal camera module and components are used, the time spent on the electronic implementation (e.g., image processing) of the universal camera module in a new endoscope is significantly reduced.

[0054] Figure 7 is a perspective view of an embodiment of the universal camera module 100, which includes a sensor holder 200 and a sensor housing 300 fixed at the joint 118. The universal camera module 100 is very small. In some embodiments, the universal camera module 100 is approximately the size of a rice grain, and its cross-section is at most less than 2 mm, potentially less than 1.5 mm. In an endoscope without a working channel, the cross-section of the endoscope head housing 500 may be at most 3 mm, preferably less than 2.8 mm, and more preferably less than 2.7 mm. Obviously, assembling multiple parts into such a small-scale universal camera module 100 benefits from an innovative assembly method. Such a method (described below) is also beneficial in the case where the universal camera module 100 is mainly made of plastic parts (except for electronic components such as image sensors, circuit boards, and LEDs) to manufacture a disposable endoscope head assembly.

[0055] In this embodiment, the general camera module 100 includes a circuit board 103 electrically connected to an image sensor and a camera module wire 111. The camera module wire 111 can form a cable assembly 110 together with an optional shroud and / or cover. Optionally, a circuit board 104 can be electrically connected to the circuit board 103. The use of the circuit board 104 facilitates soldering of the camera module wire 111 prior to assembling the general camera module 100 by enabling simple soldering or connection of two flat surfaces of the circuit boards 103, 104. As Figure 9 shown, this embodiment of the general camera module 100 further includes an image sensor 102, an electrical shield 112, and a cable cover 113. The cable assembly 110 includes the camera module wire 111, the electrical shield 112, and the cable cover 113. Each joint 118 is preferably formed by adhesive bonding. The circuit board 103 can include a flexible printed circuit board. The image sensor 102 can be electrically connected to the circuit board 103, the circuit board 104, and the camera module wire 111, and then these components are assembled onto a sensor holder 200. Then, the image sensor 102 is placed in a sensor cavity of the sensor housing 300, after which the sensor holder 200 can be fixed to the sensor housing 300.

[0056] The sensor holder 200 includes a cable holder 202 that includes an outer surface 203 and a recess 204. The recess 204 is optionally a through hole. The cable holder 202 is connected to a longitudinal base 206 that includes a base surface to which a circuit board can be attached. The camera module wire 111 passes through the recess 204. At the distal end of the longitudinal base 206, the distal surface forms a joint 118 with an opposing surface of the sensor housing 300.

[0057] The sensor housing 300 includes a circumferential wall 302 that defines a sensor cavity 304, a lens 306( Figure 12as shown) and the image sensor 102 are received in the sensor cavity, and the lens 306 is positioned distally to the image sensor 102. The circumferential wall 302 has an outer surface 310. The sensor housing 300 is opaque to prevent stray light from entering the sensor cavity 304, which would otherwise potentially distort the desired image captured by the image sensor 102. The arm 340 extends proximally, and the wing 320 extends laterally from the circumferential wall 302. Alignment surfaces 312 are provided on the outer surface 310 and / or the arm 340 and / or the wing 320, denoted as surfaces 312a, 312p, 312la, and 312r, which contact the opposing alignment surfaces of the end housings 500, 500a, 500b. More than one rear alignment surface 312p and front alignment surface 312a may be provided. The alignment surfaces 312r, 312la prevent rotational movement and may be referred to as "anti-rotation" surfaces. As shown, the anti-rotation surfaces are surfaces of the wing. Alternatively, they may be surfaces of the sensor holder. The sensor holder may include the wing 320. The sensor holder and the sensor housing may include the wing 320. The front alignment surface 312a is a part of the outer surface 310. The alignment surface 312 abuts the corresponding surface of the end housing 500 to limit the forward and backward movement and rotational movement of the general camera module 100 in the end housings 500, 500a, 500b. As shown, the anti-rotation surface 312r is the rear surface of the wing 320. Alternatively, the anti-rotation surface 312r may be the rear surface of the arm 340. The anti-rotation surface 312la may be the lateral surface of the wing 320 or the arm 340 and is arranged to abut the alignment surface 512rb of the end housing 500b (as Figure 14 shown).

[0058] In one variant, two rear alignment surfaces 312r and one front alignment surface 312a are provided. In this variant, the end housing 500a may be cantilevered on the anti-rotation surface 312r proximal to the front alignment surface 312a so as to accurately align and place the sensor housing 300 in the end housing 500a in a simple and thus economical manner.

[0059] The arm 340 may extend through a hole or recess / cutout 103r in the circuit board 103. Either or both of the sensor holder 200 and the sensor housing 300 may include one or more of the arms 340, which extend to form a joint 118 with a portion of the circuit board 103 located therebetween. Three arms 340 are preferred because three arms provide sufficient structural support while requiring less space than more than three arms. The circuit board 103 may include a flexible circuit board that is electrically connected to a rigid circuit board fixed to the image sensor 102.

[0060] Now refer to Figure 8, the first lighting module 400a includes a body 402, which includes a proximal transverse wall 404 and a longitudinal base 406 extending distally from the proximal transverse wall 404. The proximal transverse wall 404 includes a cable recess 408 configured to receive the cable assembly 110 (for the camera) or its wires and / or the cable holder 203. At the distal end, the longitudinal base 406 supports a light-emitting diode (LED) 414 electrically connected to a circuit board 412. The lighting wire 416 electrically connects the LED 414 to a power source at the handle or at the video processor via the circuit board 412 to power the LED. The proximal transverse wall 404 also includes a cable recess 410 configured to receive the lighting wire 416 passing therethrough. As shown, the cable recess 408 is a notch, and the cable recess 410 is a through-hole separated from the cable recess 408 by an intermediate portion 418 of the transverse wall 404, and the longitudinal base 406 extends longitudinally along a plane passing through the intermediate portion of the transverse wall 404. The cable holder 203 can be longitudinally translated into the cable recess 408 or can slide through the open end of the notch. Alternatively, the cable recess 408 can be a through-hole, so the cable holder 203 can be longitudinally translated into the cable recess 408.

[0061] The first lighting module 400a can be electrically isolated from the general camera module 100 at the tip assembly. Electrical isolation means that there is no electrical connection between the first lighting module 400a and the general camera module 100. The isolation also enables independent control of the light intensity, which can vary in different endoscopes without the need to change the camera module, thus having universality. The lighting can be optimized for each endoscope by selecting different light emitters and modifying the configuration of the light emitters, for example, by optimizing the size, color, light intensity, position, and orientation. Some endoscopes can include light emitters that emit light at different frequencies. The light emitters can include LEDs and / or optical fibers that extend through the insertion cord and receive light from a source located at the handle or a separate light source. Optionally, the lighting wire can be connected to the circuit board 103 or 104.

[0062] Figure 9 An embodiment shows how the general camera module 100 and the first lighting module 400a are aligned before being inserted into the tip housing 500a. The general camera module 100 is not necessarily fixed to the first lighting module 400a, so it can be longitudinally moved in the front-rear direction and / or rotatably moved relative to the first lighting module 400a such that the alignment of the general camera module 100 in the tip housing 500a is independent of the alignment of the first lighting module 400a in the tip housing 500a.

[0063] Figure 9An observation window 502 and an illumination window 504 are also shown, which can be part of the end head housing 500a. The observation window 502 and the illumination window 504 can be molded as an integral part with the end head housing 500a to form a sealed housing of the general camera module 100. During assembly, when the LED 414 abuts against the illumination window 504, the first illumination module 400a stops moving distally. Alternatively, the light guide can extend proximally from the illumination window 504, in which case, when the LED 414 abuts against the light guide, the first illumination module 400a stops moving distally. More generally, the light emitted by the light source is received by the light receiving surface and emitted by the distal surface of the illumination window, and the light receiving surface can be the proximal surface of the light guide or the proximal surface of the illumination window. Refer to Figure 26 Example light guides are discussed. Alternatively, the observation window 502 and the illumination window 504 can be attached to the sensor housing 300 or the end head housing 500a.

[0064] Now refer to Figure 10 and Figure 11 , the end head housing 500a includes a distal portion 510, a middle section portion 512, and a proximal portion 514. The proximal portion 514 and the distal portion 510 can be transparent, while the middle section portion 512 can be opaque. The distal portion 510 includes the observation window 502 and the illumination window 504, and the observation window and the illumination window are separated by an intermediate opaque wall 528, which is part of the middle section portion 512. The transparent portions allow light to pass through. Passing light at the proximal portion 514 helps with the ultraviolet curing of the ultraviolet-curing adhesive, simplifies manufacturing, and thus reduces costs. Passing light at the distal portion 510 allows the image sensor 102 to capture images and allows the LED 414 to provide illumination. The middle section portion 512 includes a circumferential wall 518, which has an outer wall surface 519 and an inner wall surface 520 (see Figure 12 ), and the inner wall surface forms a camera module cavity 522, which includes a sensor module cavity 524 and an LED cavity 526. The middle section portion 512 is molded with an intermediate wall 528. The circumferential wall 518 can be shaped as a cylinder, however, non-circular cross-sections are allowable. The sensor module cavity 524 is positioned on one side of the intermediate wall 528, and the LED cavity 526 is positioned on the other side of the intermediate wall 528.

[0065] Once the general camera module 100 and the first illumination module 400a are positioned and aligned in the first end housing 500a, an adhesive is inserted into the inner cavity to adhesively bond the general camera module 100, the first illumination module 400a, and the first end housing 500a to each other (or to adhesively bond the general camera module 100, the second illumination module 400b, and the second end housing 500b to each other), thereby allowing the general camera module 100 and the corresponding illumination module to be inserted into the corresponding end housing by relative movement between the general camera module 100 and the illumination module, such that the positioning of the general camera module 100 is independent of the positioning of the illumination module. This provides the following advantages: compared with the case where the general camera module 100 is fixed to the illumination module before being inserted into the end housing, the above method cuts off the assembly chain tolerance, and there is less variation in the assembly of the end assembly. The assembly chain includes a plurality of assembly steps performed in sequence. Typically, each step has a variation or tolerance, and performing these steps in sequence increases the variation of the final assembly because the variation of each step increases the variation of the immediately subsequent step. Cutting off the assembly tolerance chain makes the sequence of steps that are dependent on each other shorter, thus making the assembly of the end assembly more precise and less variable, thereby improving quality and performance.

[0066] Figure 12 is a cross-sectional perspective view of the end assembly 33a, in which the general camera module 100 is positioned in the end housing 500a. The longitudinal base 206 of the sensor holder 200 may include a distal base portion 206d that is offset relative to the proximal base portion 206p. Similarly, the longitudinal base 406 of the illumination module 400 may include a distal base portion 406d that is offset relative to the proximal base portion 406p. In this case, the offset means that the distal portion is shifted backward from the proximal portion while the two portions extend longitudinally in parallel. This offset creates a step 420, which creates space for the rear side 404p of the transverse wall 404, thereby allowing the camera module to be smaller. Accordingly, the rear side 404p is offset forward relative to the distal base portion 406d.

[0067] Now refer to Figure 13, the end housing 500a includes at least three alignment surfaces, denoted as 512a, 512p, and 512r, which can abut the alignment surfaces 312a, 312p, and 312r of the sensor housing 300. The rear alignment surface 512p is the intermediate surface of the intermediate wall 528. The alignment surface 512r can be referred to as an anti-rotation surface and is the surface of the intermediate wall 528 positioned adjacent to the circumferential wall 518. The anti-rotation surface 512r can extend forward along a transverse plane (transverse to the front-rear plane). The front alignment surface 512a is the front portion of the inner surface 520 of the middle section 512 of the end housing 500a. As described above, the alignment surfaces of the end housing 500a abut the alignment surfaces of the general camera module 100 to allow the general camera module 100 to be fixed in place independently of the first lighting module 400a. Alternatively, the general camera module 100 can be mounted onto the first lighting module 400a such that the alignment surfaces allow the general camera module 100 and the first lighting module 400a to be fixed in the exact desired positions.

[0068] In a variant of the present embodiment, the at least three alignment surfaces consist of two anti-rotation surfaces 512r and one front alignment surface 512a.

[0069] In another variant of the present embodiment, the at least three alignment surfaces consist of two anti-rotation surfaces 512r and two front alignment surfaces 512a, with one of the front alignment surfaces positioned distally from the other.

[0070] In another variant of the present embodiment, the at least three alignment surfaces consist of two anti-rotation surfaces 512r, two front alignment surfaces 512a, and at least one rear alignment surface 512p.

[0071] In yet another variant of the present embodiment, the at least three alignment surfaces consist of two anti-rotation surfaces 512r, one front alignment surface 512a, and one rear alignment surface 512p. The alignment surfaces 512a and 512p are positioned distally from the two anti-rotation surfaces 512r.

[0072] More generally, the anti-rotation surfaces can be a pair of surfaces positioned on opposite (lateral) sides of the general camera module. Even more generally, only one anti-rotation surface can be provided. Examples of anti-rotation surfaces can be the surfaces of protrusions that fit into longitudinal slots of the end housing. Another example of an anti-rotation surface can be the surfaces of longitudinal slots into which protrusions of the end housing fit. The protrusions and slots of the general camera module can include curved surfaces and can be positioned in the sensor housing or sensor holder.

[0073] Reference will now be made to Figures 14 to 24Discuss the second embodiment of the end component, denoted by 33b. The part of the end component 33b with the suffix "b" is functionally equivalent to the corresponding part of the end component 33a with the same prefix. Thus, the sensor housing 500a is functionally equivalent to the sensor housing 500b, however, the sensor housing 500b provides additional functions. Figure 14 is a proximal view of the end housing 500b, Figure 15 is a proximal perspective view of the middle section 512 of the end housing 500b. The end housing 500b includes at least three alignment surfaces 512b, denoted as 512ab, 512pb, and 512rb. The alignment surface 512rb is configured to prevent the general camera module 100 from rotating and is oriented differently from the alignment surface 512r (these alignment surfaces can be referred to as "anti-rotation" surfaces). As shown, the alignment surfaces 512rb are oriented to face each other and are adjacent to the lateral surface 312la of the wing portion 340. Additionally, the end housing 500b includes a working channel 600 that forms part of the working channel 40. Thus, the general camera module 100 includes a first pair of anti-rotation surfaces 312r and a second pair of anti-rotation surfaces 312la, the end housing 500a includes a pair of anti-rotation surfaces 512r, and the end housing 500b includes a pair of anti-rotation surfaces 512rb.

[0074] The end housing 500b includes a working channel wall 604, an outer surface 606 of the working channel wall, and an inner surface 608 of the working channel wall. At the rear side of the end housing 500b, the inner surface 608 of the working channel wall overlaps with the wall surface 519b at the housing portion 610. The end housing 500b further includes an intermediate wall 528b and a circumferential wall 518b that has an outer wall surface 519b and an inner wall surface 520b, and the inner wall surface together with the outer surface 606 of the working channel wall forms a camera module cavity 522b, which includes a sensor module cavity 524b and an LED cavity 526b. The circumferential wall 518b can be shaped as a cylinder, however, a non-circular cross-section is allowable. The intermediate wall 528b is connected to the circumferential wall 518b and the working channel wall 604 and extends between them.

[0075] As Figure 15 shown, the circumferential wall 518b may include a front notch 612 and one or more inlet notches 618d. The inlet notches 618d match or align with the inlet notches 618p to form an inlet hole 618 suitable for inserting a liquid adhesive.

[0076] As Figure 16 and Figure 17As shown, the end housing 500b further includes a distal portion 510b, a middle portion 512b, and a proximal portion 514b. The proximal portion 514b may be referred to as a "transition piece". The proximal portion 514b and the transition piece 512b may be transparent, while the middle portion 512b may be opaque. The distal portion 510b includes an observation window 502b and an illumination window 504b, which are separated by an intermediate opaque wall 528b that is part of the middle portion 512b. The distal portion 510b may be molded as a one-piece part with the middle portion 512b. Passing light at the proximal portion 514b facilitates the ultraviolet curing of the ultraviolet-curable adhesive, simplifies manufacturing, and thus reduces costs. Passing light at the distal portion 510b allows the image sensor 102 to capture images and allows the LED 414 to provide illumination. The middle portion 512b is molded with an intermediate wall 528b. The sensor module cavity 524b is positioned on one side of the intermediate wall 528b, and the LED cavity 526b is positioned on the other side of the intermediate wall 528b. Alternatively, the end housing may further include a proximal portion, in which case the middle portion is positioned between the distal portion and the proximal portion, and a separate transition piece is fixed to the proximal portion. The proximal portion may be transparent and integrally molded with the middle portion (as in the end housing 500a shown in Figure 12 ), and then the transition piece is fixed to the proximal portion.

[0077] In one example, the transition piece may be adhesively bonded to the middle portion of the end housing, or in another example, adhesively bonded to the proximal portion of the end housing. The transition piece may also be ultrasonically bonded, such as by melting.

[0078] As described above, the end housing 500b includes at least three alignment surfaces 512. In a variant of the present embodiment, the at least three alignment surfaces 512 are composed of two alignment surfaces 512rb and a front alignment surface 512ab. Alternatively, the at least three alignment surfaces 512 are composed of two alignment surfaces 512rb and a rear alignment surface 512pb.

[0079] In another variant of the present embodiment, the at least three alignment surfaces 512 are composed of two alignment surfaces 512rb and two front alignment surfaces 512ab, with one of the front alignment surfaces positioned distally of the other.

[0080] In another variant of the present embodiment, the at least three alignment surfaces 12 are composed of two alignment surfaces 512rb, two front alignment surfaces 512ab, and at least one rear alignment surface 512pb.

[0081] In yet another variant of the present embodiment, the at least three alignment surfaces 512 are composed of two alignment surfaces 512rb, one front alignment surface 512ab, and one rear alignment surface 512pb.

[0082] The working channel 600 includes a distal working channel portion or a mid-section working channel or the working channel 620 of the mid-section portion, and a transition member working channel 622. Figure 16 The longitudinal axis LA and the inlet hole 618 are shown. The inlet hole 618 is shown to be located at the junction of the mid-section portion 512b and the transition member 514b. Figure 17 Also shown are a working channel axis WCA that is not concentric with the longitudinal axis LA, and a distal transition member axis TPA(d) that is not parallel to the working channel axis WCA. Figure 17 An elliptical CS representing the cross-section of the working channel 600 is provided to show the position of the longitudinal axis LA relative to the working channel axis WCA.

[0083] The transition member working channel 622 includes a distal working channel portion 624, a proximal working channel portion 626, and a wiring channel 632 formed between the circumferential wall 630 and the working channel wall 634. The proximal working channel portion 626 is offset from the mid-section portion working channel 620, and their axes are parallel or non-parallel. The proximal working channel portion 626 includes a working channel wall 634 sized to receive a working channel tube 640. The distal transition member axis TPA(d) is the longitudinal axis of the distal working channel portion 624. The proximal end of the transition member axis TPA(p) is closer to the front channel 628 than its distal end. In other words, the proximal working channel portion 626 of the transition member is offset from the mid-section portion working channel 620. The transition member working channel 622 may include a distal transition member axis angle that is large enough such that the longitudinal projection of the camera module cavity 522b covers the working channel overlap portion 628 of the proximal working channel portion 626. A dashed line extending proximally from the inner surface 608 of the working channel wall is shown to better illustrate the working channel overlap portion 628.

[0084] By angling the working channel 622 of the transition piece, the perimeter and cross-section of the end cap 500b at its proximal end can be reduced relative to its distal end. Thus, the end cap 500b can include a distal cross-section that is smaller than the proximal cross-section. Additionally, the transition piece with an angled working channel portion allows the working channel tube to be installed in a stress-free state, facilitating assembly. Angling the working channel 622 of the transition piece makes assembly easier because the working channel tube can be installed straight onto the transition piece in its unbent natural state. An alternative is to angle the working channel tube itself, but bending an elastic / resilient working channel tube has the problem that the tube tends to return to its original unbent state. Attempting to install an angled tube that is trying to force itself back to its unbent state can be difficult, especially when attempting to achieve a flush fit into the middle working channel portion 620 of the end cap to provide as smooth a transition as possible for the tool to pass through. Additionally, after installing the working channel tube, the force attempting to return the tube to its unbent state may cause the working channel tube to become disengaged from the end cap, resulting in misalignment or even leakage between the working channel tube and the end cap.

[0085] The working channel tube 640 can be bent proximally in the end cap 500b such that its longitudinal axis is closer to or parallel to the longitudinal axis LA. The proximal working channel portion 626 can be angled at a proximal transition piece axis (TPA(p)) angle that is different from the distal transition piece axis angle. For example, the proximal transition piece axis angle can be less than the distal transition piece axis angle. This will allow for a smaller amount of bending of the working channel tube 640. The angles of the proximal transition piece axis TPA(p) and the distal transition piece axis TPA(d) are measured relative to the working channel axis WCA.

[0086] In Figures 18 to 20 In another example shown, the bending of the working channel tube is incorporated within the end cap 500b. There is an offset between the working channel axis WCA and the proximal transition piece axis TPA(p) that is parallel to the working channel axis WCA. The proximal transition piece axis TPA(p) is positioned between the front channel 632 and the working channel axis WCA. It should be noted that at least Figures 17 to 20 are drawn to scale, although not always to the same scale, for example to emphasize structural details. The transition piece 514b includes a distal protrusion 642 that mates into the proximal end of the middle section 512b, which will be described in more detail below.

[0087] The working channel tube 640 can be inserted into the proximal working channel portion 626. For this purpose, the diameter of the proximal working channel portion is larger than the diameter of the distal working channel portion 624, and thus the working channel tube is adhesively bonded to the transition piece 514b. The sizes of these diameters are determined to provide a seamless inner surface between the working channel tube 640 and the distal working channel portion 624. Therefore, the diameter of the proximal working channel portion 626 can be larger than the diameter of the distal working channel portion 624 by twice the wall thickness of the working channel tube 640.

[0088] Figure 19 The entrance notch 618d and the distal joint surface 636d are shown. By injecting an adhesive into the entrance hole 618, the distal joint surface will be adhesively bonded to the proximal joint surface 636p of the transition piece 514b. Figure 20 The entrance notch 618p and the proximal joint surface 636p are shown. The transition piece 514b includes a distal protrusion 642, which is formed by a part of the circumferential wall 630 (denoted by the reference numeral 646) and a front wall portion 648 located at the distal end of the transition piece 514b. The contour of the front wall portion 648 is determined to fit the working channel wall 604. The thickness of the circumferential wall portion 646 is reduced relative to the thickness at the proximal end of the transition piece, but the thickness of the front pin 644 is the same as that at the proximal end. The pin 644 has a shape matching the notch 612 and fits into the notch 612. The longitudinal groove 650 extends along the rear side of the front pin 644. The longitudinal groove 652 extends along the front side of the working channel wall 634. The grooves 650 and 652 are aligned to provide additional space along the front-rear plane for the wire. Thus, the distal protrusion 642 is formed. In this example, the transition piece 514b may include a pair of control wire holes, which are positioned adjacent to the position where the circumferential wall portion 646 abuts the front wall portion 648. In this example, the transition piece 514b may further include a control wire groove 674, which extends between the pair of control wire holes located between the front wall portion 648 and the longitudinal groove 652.

[0089] In a variant of this example, the notch 612 and the front pin 644 are omitted. Depending on the size of the end head housing 500b, the longitudinal groove 650 may also be omitted. If the size is large enough to allow the wire to pass through without the longitudinal groove 650, then this groove can be omitted, and the circumferential wall portion 646 can thus be an arc-shaped portion extending from one side to the other. Alternatively, a front cut may divide the circumferential wall portion 646 into two parts with a wire channel therebetween.

[0090] Figure 21 and Figure 22The following example of the end housing 500b as shown will further illustrate the manipulation wire groove 674 and the manipulation wire holes. In this example, the intermediate section 512b includes a notch 660 in the circumferential wall 518b, which causes the arcuate portion 662 of the circumferential wall 518b to extend proximally and extend beyond the distal end of the transition member 514b to fix the transition member 514b to the intermediate section 512b. The bending of the working channel tube is also included in the end housing 500b. There is an offset between the working channel axis WCA and the proximal transition member axis TPA(p). The inlet notch 618d is located at the junction of the arcuate portion 662 and the uncut portion of the circumferential wall 518b. There is no notch 612 in the circumferential wall 518b. The inlet notch 618d is located in the plane of the proximal joint surface 636p. There is also a portion 646 of the circumferential wall 630, but there is no front pin 644. In this example, the longitudinal groove 650 is omitted, and the circumferential wall portion 646 is shown as an arcuate portion extending from one side to the other. Alternatively, a front cut may divide the circumferential wall portion 646 into two portions with a wire channel therebetween.

[0091] The wall surface 672 of the transverse wall 670 extends between the portion 646 of the circumferential wall 630 and the arcuate manipulation wire groove 674 adjacent to the working channel wall 634. At the end of the arcuate manipulation wire groove 674, a pair of manipulation wire holes 676 are located in the transverse wall 670. The circumferential wall 630 includes a notch 678.

[0092] The bending section 32 includes segments, which include a distal segment 700 and an intermediate segment 710. These segments are interconnected by a movable hinge 712, and the movable hinge forms an integral part with the segments. The movable hinge 712 is a flexible polymer strip, which imparts at least some bending characteristics to the bending section. The range of motion of the bending section can be defined by the shape of the segments. The distal segment 700 includes a wall 702 having a notch 704. The distal arcuate portion 706 of the wall 702 fits into the notch 678. An inlet hole 708 is provided to allow the insertion of a liquid adhesive to bond the distal segment 700 to the insert 514b. Generally, compared with the case where the parts are only adhesively bonded, the cooperation of the notch and the remaining part enables the parts to be interlocked in a more secure manner. The interlock can be beneficial for increasing strength, especially when the wall thickness is very small. Alternatively, the interlock notch can be omitted.

[0093] The intermediate segment 710 includes manipulation wire holes 714, which are concentric with the manipulation wire holes 676 in the assembled state of the transition member and the bending section. As Figure 22As shown, the control wire 42 includes an intermediate portion 42a located in the arcuate control wire groove 674 and a longitudinal portion 42b extending from the intermediate portion 42a to the handle. To assemble the end head 33b, the control wire 42 passes through the control wire hole 676 and then through the control wire hole 714, after which the longitudinal portion 42b passes through the insertion tube 31 and is directly or indirectly connected to the control actuator 25. In this way, the bending section 32 is attached to the end head assembly 33b and can be steered via the control actuator 25.

[0094] Figure 23 and Figure 24 are two views of the second lighting module 400b. The second lighting module 400b includes a body 402b that includes a proximal transverse wall 404b and a longitudinal base 406b extending distally from the proximal transverse wall 404b. The proximal transverse wall 404b includes a cable recess 408b that is configured to receive the cable assembly 110 or its wires and / or the cable holder 203. At the distal end, the longitudinal base 406b supports the LED 414 electrically connected to the circuit board 412b. The lighting wire 416 electrically connects the LED 414 to a power source at the handle or at the video processor via the circuit board 412b to power the LED. The proximal transverse wall 404b also includes a cable recess 410b ( Figure 24 ) that is configured to receive the lighting wire 416 passing therethrough. As shown, the cable recess 408b is a notch, the cable recess 410b is a through hole separated from the cable recess 408b by an intermediate portion 418b of the transverse wall 404b, and the longitudinal base 406b extends longitudinally along a plane passing through the intermediate portion of the transverse wall 404b. The cable holder 203 can be longitudinally translated into the cable recess 408b or can slide through the open end of the notch. Alternatively, the cable recess 408b can be a through hole, so the cable holder 203 can be longitudinally translated into the cable recess 408b. The dashed line indicates the lighting window 504.

[0095] The second lighting module 400b can be electrically isolated from the general camera module 100 at the end head assembly.

[0096] Reference Figure 24, the second illumination module 400b further includes four legs 720 extending rearward from the longitudinal base 406b. Each leg 720 has an arcuate surface 722 that faces the longitudinal axis LA and is shaped to have a profile matching the shape of the working channel wall 604. The opposite surface of each leg 720 has an arcuate surface 724 that faces the circumferential wall 518b and is shaped to have a profile matching the shape of the inner wall surface 520b of the circumferential wall 518b. The longitudinal base 406b includes a cutout 726 sized to receive a portion of the general-purpose camera module 100, thereby forming a compact subassembly that includes the general-purpose camera module 100 and the second illumination module 400b, and the cross-section of this subassembly is reduced compared to the case without the cutout 726. Alternatively, instead of completely eliminating it via the cutout, the thickness of the section corresponding to the cutout 726 can be reduced. For clarity, a cutout refers to a shape with a portion removed. Thus, the longitudinal base 406b would be of a generally rectangular shape without the cutout.

[0097] Reference will now be made to Figure 25 the flowchart 800 in Figures 2 to 6 to describe a method of manufacturing an endoscope for the system depicted in

[0098] In 802, assemble a first copy of the general-purpose camera module 100 and a second copy of the general-purpose camera module 100, the first copy being identical to the second copy;

[0099] In 804, assemble the first illumination module 400a;

[0100] In 806, assemble a second illumination module 400b different from the first illumination module 400a;

[0101] In 808, provide the first end head housing 500a;

[0102] In 810, provide a second end head housing 500b different from the first end head housing 500a;

[0103] In ⑧12, insert the first copy of the general-purpose camera module 100 into the first end head housing 500a; [[ID=q6]]

[0104] In 814, insert the first illumination module 400a into the first end head housing 500a;

[0105] In 816, adhesively bond the first copy of the general-purpose camera module 100, the first illumination module 400a, and the first end head housing 500a to each other;

[0106] At 820, a second copy of the general camera module 100 is inserted into the second end head housing 500b;

[0107] At 822, the second illumination module 400b is inserted into the second end head housing 500b; and

[0108] At 824, the second copy of the general camera module 100, the second illumination module 400b, and the second end head housing 500b are adhesively bonded to each other.

[0109] The general camera module 100 and the illumination modules 400a, 400b can be assembled in any order at any time before the general camera module is installed on the end head housing. The end head housing can be provided at any time before the sub - assemblies are inserted into it. The general camera module 100 and the illumination modules 400a, 400b can be simultaneously inserted into the end head housings 500a, 500b respectively, and then the general camera module 100 can be pushed until it stops translating distally due to contact with the housing. The illumination modules 400a, 400b can be pushed until the LED emission surfaces are adjacent to the illumination window or the light guide. The movement of the illumination modules 400a, 400b into place is independent of the movement of the general camera module 100 into its insertion position. After insertion, the general camera module 100 can be adhesively fixed to the distal ends of the end head housings 500a, 500b, after which the illumination modules 400a, 400b are inserted into the end head housings 500a, 500b. Then, the general camera module 100, the illumination modules 400a, 400b, and the end head housings 500a, 500b can be adhesively bonded to each other by inserting glue through the proximal ends of the end head housings 500a, 500b.

[0110] In a variant of this embodiment, the second end head housing 500b includes a working channel outlet, and the first end head housing 500a does not have a working channel outlet.

[0111] In another variant of the above - described embodiment of the method of manufacturing an endoscope, the general camera module includes a first housing alignment feature and a second housing alignment feature different from the first housing alignment feature. The first housing alignment feature abuts an alignment surface of the first end head housing to align the general camera module in the first end head housing, and the second housing alignment feature abuts an alignment surface of the second end head housing to align the general camera module in the second end head housing.

[0112] The first illumination module 400a can be inserted into the first end head housing 500a simultaneously with the general camera module 100. When the LED 414 abuts against the illumination window 504, the illumination modules 400a, 400b stop moving distally. Alternatively, an optical waveguide can be provided, in which case, when the LED 414 abuts against the optical waveguide, the illumination modules 400a, 400b stop moving distally. When the front end of the general camera module 100 abuts against the viewing window 502, the general camera module 100 can stop moving distally.

[0113] Now referring to Figure 26 , an optical waveguide 840 is inserted between the LED 414 and the illumination window 504. The optical waveguide 840 and the illumination window 504 can be molded as an integral part and can be molded together with the end head housing 500. As is well known in the art, the LED 414 includes a substrate 414a having a light emitting surface 414b and a pair of electrical contacts 414c. The light emitting surface 414b faces the light receiving surface of the optical waveguide 840. The optical waveguide 840 is shaped and potentially coated to provide total internal reflection and shapes the light emitted by the LED 414 into a desired light pattern based on the position of the optical waveguide 840 and the general camera module 100 to illuminate a desired field of view of the general camera module 100. Light travels through the optical waveguide 840 and into the illumination window 504 without a transition therebetween, so the optical waveguide can be considered to extend through the illumination window 504, and the light emitting surface of the optical waveguide 840 is thus the outer surface of the illumination window 504. It can be seen that the optical waveguide in this example is a truncated pyramid having a generally rectangular cross section, which has been found to be useful for the rectangular image sensor 102. Alternatively, the optical waveguide can be a separate part adhesively bonded to the illumination window 504.

[0114] The above-described embodiments of the method of manufacturing an endoscope can further include passing the camera module wire 111 and / or the cable assembly 110 and the illumination wire 416 through the insertion tube 31 of the endoscope 20.

[0115] Now an endoscope according to a second aspect manufactured according to the method described with reference to Figure 25 above will be described. In one embodiment, the endoscope includes:

[0116] - a positioning interface or handle 21;

[0117] - an insertion tube 31 extending distally from the positioning interface or handle 21;

[0118] - Lighting modules 400a, 400b, which include: a body 402 including longitudinal bases 406, 406b and transverse walls 404, 404b; light-emitting diodes 414 supported at distal ends of the longitudinal bases 406, 406b; and lighting wires 416 electrically connected to the light-emitting diodes 414 and extending through an insertion tube 31 to a positioning interface or a handle 21;

[0119] - A general camera module 100, which includes an image sensor 102, a circuit board 103 electrically connected to the image sensor 102, a sensor holder 200, and a sensor housing 300 fixed to the sensor holder 200. The image sensor 102 is received in the sensor housing 300, and the sensor holder 200 extends proximally from the image sensor 102;

[0120] - End housings 500a, 500b, which include: sensor module cavities 524, 524b configured to receive the distal ends of the sensor housing 300; and LED cavities 526, 526b configured to receive the LEDs of the lighting modules 400a, 400b. The general camera module 100, the lighting modules 400a, 400b, and the end housings 500a, 500b are adhesively bonded; and - Camera module wires 111 electrically connected to the circuit board 103 and extending through the insertion tube 31 to the positioning interface or the handle 21.

[0121] The general camera module 100 and the lighting modules 400a, 400b can be adhesively bonded to the end housings 500a, 500b individually. Additionally, they can also be adhesively bonded to each other after stopping moving distally and being in their final positions, and adhesively bonded to the end housings 500a, 500b.

[0122] Figure 27 and Figure 28 Two embodiments of a video processor 11 are shown, denoted by reference numerals 11a and 11b. The video processor 11 includes a cable socket 850 to which a video connector 24 ( Figure 1 shown) of the endoscope 20 can be connected to establish signal communication between the image sensor 102 and the video processor 11 via a cable 23 and wires 111. The video processor 11 is configured to cause a display to present images and / or videos captured by the image sensor 102, thereby allowing an operator to "see" the body cavity into which the endoscope 20 is inserted.

[0123] The video processor 11 includes a housing 852, one or more medical device interfaces connected to a cable socket 850, and video processing circuitry (not shown). Variants of the video processor 11 may be provided. For example, it may not be desirable to provide a display screen with a touch screen (e.g., the video processor 11a including the display screen 854), or it may be desirable to omit the display screen entirely (e.g., the video processor 11b). Omitting the display screen may facilitate taking advantage of evolving video display technologies, thereby increasing resolution and reducing costs. Providing interchangeable medical device interfaces allows for the adoption of evolving image sensor and endoscope technologies, and thus using an existing or future-developed external video display may allow for the presentation of higher resolution or otherwise improved video. Using an external video display may also leverage existing capital investments.

[0124] The video processor 11a includes a housing 852, a display screen 854, and one or more medical device interfaces connected to a cable socket 850.

[0125] In all embodiments and their variants, the endoscope may be disposable and may not be intended for cleaning and reuse. Alternatively, in all embodiments, the endoscope may be reusable. In some variants of the present embodiment, the endoscope and the video processor include wireless transceivers for exchanging image data and configuration data. The endoscope may include a battery for powering the image sensor and the light source (such as a light-emitting diode (LED)).

[0126] The video processing circuitry of the video processor is operable to receive image data, present a graphical user interface to allow a user to manipulate the image data with a touch screen, and optionally output a video signal to allow remote viewing of the image presented on the touch screen. A separate, potentially remote, display screen may also be connected to the endoscope via the video processor, which may include or omit the display screen. For example, the medical device interface includes circuitry for accommodating signals from the image sensor. Thus, a particular type of endoscope is matched with a corresponding medical device interface, and the video processor is thus able to use different endoscopes or other medical device technologies. In other words, the video processor or monitor is customized to work with a particular endoscope technology. The medical device interface may also include an isolation amplifier for electrically isolating the video signal, and a power output connector for providing power to the endoscope for the image sensor and the LED. The medical device interface may also include a serial-to-parallel converter circuit for deserializing the video signal of the endoscope that generates a serial signal (such as a serial analog video signal). The medical device interface may also include a configuration connector for outputting image sensor configuration parameters, such as image inversion, clock, shutter speed, etc.

[0127] A positioning interface or interfaces are used to control the position of the insertion cord 30. The handle 21 is an example of a positioning interface, and these terms may be used interchangeably unless otherwise specified. The positioning interface is also used to provide a steering controller (e.g., a knob, a joystick, a button, etc.) to steer the field of view of the camera. Alternatively, a different positioning interface that is connected to the insertion cord and detachably connected to the robotic arm may be provided. Thus, the insertion cord extends from the robotic arm, and the invasive medical device may be detached from the robotic arm. The robotic arm responds to signals (including voice commands from an operator) to rotate, translate, or otherwise position the proximal end of the insertion cord as if the operator were doing so manually. The positioning interface may include a control actuator, including a manual control actuator. Alternatively or additionally, the control actuator may be provided within or on the robotic arm, or through a robotic system including the robotic arm, potentially reducing the cost of the invasive medical device. Example control actuators include single-axis actuators, including linear motion actuators. The linear motion actuator may include a threaded rod coupled to a threaded nut portion in which a motor rotates the rod to translate the nut portion.

[0128] The following clauses are further variations and examples of the embodiments described with reference to the accompanying drawings.

[0129] 1. A method of manufacturing an endoscope, the method comprising: assembling a first copy of a general camera module (100) and a second copy of the general camera module (100), the first copy being identical to the second copy; assembling a first lighting module (400a); assembling a second lighting module (400b) different from the first lighting module (400a); providing a first end head housing (500a); providing a second end head housing (500b) different from the first end head housing (500a); inserting the first copy of the general camera module (100) and the first lighting module (400a) into the first end head housing (500a) to form a first end head assembly (33a); and inserting the second copy of the general camera module (100) and the second lighting module (400b) into the second end head housing (500b) to form a second end head assembly (33b).

[0130] 2. The method as described in Clause 1, wherein the general camera module (100) includes a first anti-rotation surface (312r) and a second anti-rotation surface (312la) different from these first anti-rotation surfaces (312r), wherein the first end housing (500a) includes a first end housing anti-rotation surface (512r), and the second end housing (500b) includes a second end housing anti-rotation surface (512la), and wherein: inserting a first copy of the general camera module (100) includes translating the first copy of the general camera module (100) to be adjacent to these first anti-rotation surfaces (312r) and these first end housing anti-rotation surfaces (512r), and inserting a second copy of the general camera module (100) includes translating the second copy of the general camera module (100) to be adjacent to these second anti-rotation surfaces (312la) and these second end housing anti-rotation surfaces (512la).

[0131] 3. The method as described in Clause 2, wherein the general camera module (100) includes longitudinally extending wings (320), and wherein these wings (320) include these first anti-rotation surfaces (312r) and second anti-rotation surfaces (312la).

[0132] 4. The method as described in Clause 3, wherein these first anti-rotation surfaces (312r) are the rear surfaces of these wings (320), and these second anti-rotation surfaces (312la) are the lateral surfaces of these wings (320).

[0133] 5. The method as described in Clause 4, wherein these wings (320) extend laterally from the circumferential wall (302) of the sensor housing (300).

[0134] 6. The method as described in any one of Clauses 1 to 5, further comprising inserting an image sensor (102) into the proximal end of the sensor housing (300), and adhesively bonding the sensor holder (200) and the sensor housing (300) to the image sensor (102) accommodated in the sensor housing (300).

[0135] 7. The method as described in Clause 6, wherein the camera housing (300) and / or the sensor holder (200) includes arms (340), these arms extending between the camera housing (300) and the sensor holder (200) around a part of a circuit board (103) electrically connected to the image sensor (102), the method further comprising adhesively bonding these arms (340) to the camera housing (300) and / or the sensor holder (200) to fix the sensor holder (200) and the camera housing (300) to each other.

[0136] 8. The method as described in clause 6, wherein the circuit board (103) is electrically connected to the camera module wire (111), and wherein the first lighting module (400a) includes a light-emitting diode (414) and a lighting wire (416) electrically connected to the light-emitting diode (414), and the method further includes passing the camera module wires (111) and the lighting wires (416) through the insertion tube of the endoscope (20).

[0137] 9. The method as described in clause 8, wherein the first lighting module (400a) is electrically isolated from the general camera module (100) at the first end assembly (33a).

[0138] 10. The method as described in any one of clauses 1 to 9, wherein the first end housing (500a) includes a lighting window (504) and a light receiving surface (504p), and wherein inserting the first copy of the general camera module (100) and the first lighting module (400a) into the first end housing (500a) to form the first end assembly (33a) includes: stopping the distal translation of the first lighting module (400a) when the light-emitting diode (414) of the first lighting module (400a) abuts the light receiving surface (504p), and stopping the distal translation of the general camera module (100) when the general camera module (100) abuts the proximally facing surface of the first end housing (500a), and the stopping of the distal translation of the first lighting module (400a) and the stopping of the distal translation of the general camera module (100) occur sequentially.

[0139] 11. The method as described in any one of clauses 1 to 10, wherein the second end housing (500b) includes a working channel (600), and the first end housing (500a) does not have a working channel.

[0140] 12. The method as described in clause 11, wherein the second end housing (500b) includes a middle section (512b) and a transition section (514b), the transition section (514b) includes a distal portion (624) having a longitudinal axis and a proximal portion (626) having a longitudinal axis offset from the longitudinal axis of the distal portion (624), and the method further includes inserting the distal end of a working channel tube (640) into the proximal portion (626).

[0141] 13. The method as described in clause 12, the method further includes adhesively bonding the transition section (514b) to the middle section (512b).

[0142] 14. The method according to any one of the preceding clauses, wherein the first lighting module (400a) includes a body (402), the body includes a longitudinal base (406) and a transverse wall (404), the longitudinal base (406) includes a distal base portion (406d), a proximal base portion (406p), and a step (420) that longitudinally offsets the distal base portion (406d) and the proximal base portion (406p), the transverse wall (404) includes a rear portion (404p) that extends rearward from the proximal base portion (406p) and includes cable recesses (410, 410b), the transverse wall (404) further includes a cable recess (408) positioned in front of the proximal base portion (406p), wherein the sensor holder (200) includes a cable holder (202), and wherein the method further includes positioning the cable holder (202) at least partially in the cable recess (408).

[0143] 15. The method according to any one of the preceding clauses, the method further comprising: attaching the first end assembly (33a) to the first bending section (32), attaching the first bending section (32) to the first insertion tube (31), and attaching the first insertion tube (31) to the first handle or positioning interface (21) to assemble the first endoscope (20), and attaching the second end assembly (33b) to the second bending section (32), attaching the second bending section (32) to the second insertion tube (31), and attaching the second insertion tube (31) to the second handle or positioning interface (21) to assemble the second endoscope (20).

[0144] 16. An endoscope (20) manufactured by the method according to any one of clauses 1 to 15 and according to any one of the following clauses.

[0145] 21. An endoscope (20) includes: a positioning interface or handle (21); an insertion tube extending distally from the positioning interface or handle (21); an illumination module (400, 400a, 400b) including: a body (402) including a longitudinal base (406) and a transverse wall (404); a light-emitting diode (414) supported at a distal end of the longitudinal base (406); and an illumination wire (416) electrically connected to the light-emitting diode (414); a general camera module (100) including an image sensor (102), a circuit board electrically connected to the image sensor (102), a sensor holder, and a sensor housing fixed to the sensor holder, the image sensor (102) being received in the sensor housing and the sensor holder extending proximally from the image sensor (102); camera module wires (111) electrically connected to the circuit board (103) which is electrically connected to the image sensor (102); and a tip housing (500, 500a, 500b) surrounding the illumination module (400, 400a, 400b) and the general camera module (100).

[0146] 22. The endoscope (20) according to clause 21, wherein the illumination wires extend through the insertion tube to the positioning interface or handle (21), and wherein the camera module wires extend through the insertion tube to the positioning interface or handle (21).

[0147] 23. The endoscope (20) according to clause 21, wherein the longitudinal base (406) includes a distal base portion (206d), a proximal base portion (206p), and a step (420) that longitudinally offsets the distal base portion (206d) and the proximal base portion (206p).

[0148] 24. The endoscope (20) according to clause 21, wherein the longitudinal base (406) includes a distal base portion (406d), a proximal base portion (406p), and a step (420) that longitudinally offsets the distal base portion (406d) and the proximal base portion (406p), the transverse wall (404) includes a rear portion (404p) extending rearward from the proximal base portion (406p) and cable recesses (410, 410b), and the illumination wires (416) extend through the cable recesses (410, 410b).

[0149] 25. The endoscope (20) as described in clause 34, wherein the transverse wall (404) further includes a cable recess (408) positioned in front of the proximal base portion (406p), wherein the sensor holder (200) includes a cable holder (202), wherein the cable holder (202) is at least partially positioned in the cable recess (408), and wherein the camera module wires extend through the cable recess (408).

[0150] 26. The endoscope (20) as described in any one of clauses 21 to 25, wherein the general camera module (100) is electrically isolated from the lighting module (400a, 400b) at the end head housing (33a, 33b).

[0151] 27. The endoscope (20) as described in any one of clauses 21 to 26, wherein the sensor housing (300) includes a circumferential wall (302) and wings (320) extending laterally from the circumferential wall (302), the wings (320) including a first anti-rotation surface (312r) and a second anti-rotation surface (312la) different from the first anti-rotation surfaces (312r), the end head housing (500a, 500b) including a first end head housing anti-rotation surface (512r) or a second end head housing anti-rotation surface (512rb), the first anti-rotation surfaces (312r) adjacent to the first end head housing anti-rotation surfaces (512r), or the second anti-rotation surfaces (312r) adjacent to the second end head housing anti-rotation surfaces (512la).

[0152] 28. The endoscope (20) as described in clause 27, wherein the image sensor (102) is positioned in the proximal end of the sensor housing (300), and the sensor holder (200) is adhesively bonded to the sensor housing (300).

[0153] 29. The endoscope (20) as described in clause 27, wherein the image sensor (102) is positioned in the proximal end of the sensor housing (300), wherein the distal end of the circuit board (103) is attached to the image sensor (102) and includes a recess (103r), the sensor housing (300) and / or the sensor holder (200) includes an arm (340) extending between the sensor housing (300) and / or the sensor holder (200), and wherein the arms (340) pass through the recesses (103r) and fix the sensor holder (200) and the camera housing (300) to each other.

[0154] 30. The endoscope (20) as described in clause 29, wherein the arms (340) extend proximally from the wings (320).

[0155] 31. The endoscope (20) as described in any one of the foregoing clauses, wherein the end head housing (500b) includes a working channel (600), a middle section (512b), and a transition section (514b), the working channel (600) extends through the middle section (512b) and the transition section (514b), the transition section (514b) includes a distal portion having a longitudinal axis and a proximal portion (626) having a longitudinal axis offset from the longitudinal axis of the distal portion (624), and the endoscope (20) further includes a working channel tube (640) fixed to the proximal portion.

[0156] 32. The endoscope (20) as described in clause 31, wherein the end head housing (500, 500a, 500b) includes a camera module cavity (522, 522b), wherein the transition member includes a distal protrusion (642) and a proximal joint surface (636p) fitted in the camera module cavity (522, 522b), and wherein the middle section (512b) includes a distal joint surface (636d), the distal joint surface is adhesively bonded to the proximal joint surface (636p) to form a joint (118), and wherein the distal protrusion (642) extends distally of the joint (118).

[0157] 33. The endoscope (20) as described in clause 31, wherein the middle section (512b) includes a proximal joint surface (636p), wherein the middle section (512b) includes a circumferential wall (518b), the circumferential wall includes an arcuate portion (662), wherein the transition member includes a distal joint surface (636p) and a circumferential wall portion (646) positioned in front of the working channel (622) of the transition member, wherein the distal joint surface (636d) is adhesively bonded to the proximal joint surface (636p) to form a joint (118), and wherein the arcuate portion (662) extends beyond the joint (118).

[0158] 34. The endoscope (20) as described in clause 31, wherein the middle section (512b) includes a proximal joint surface (636p), wherein the transition member (514b) includes a distal joint surface (636p), wherein the distal joint surface (636d) is adhesively bonded to the proximal joint surface (636p) to form a joint (118), and wherein the transition member (514b) includes an arcuate manipulation wire groove (674) positioned distally of the proximal working channel portion (626).

[0159] 41. An endoscope (20) comprising: a positioning interface or handle (21); an insertion tube extending distally from the positioning interface or handle (21); an illumination module (400b) including a light emitting diode (414); a general camera module (100) including an image sensor (102), a circuit board electrically connected to the image sensor (102), and a sensor housing in which the image sensor (102) is received; and a tip housing (500b) surrounding the illumination module (400b) and the general camera module (100), the tip housing (500b) including a working channel (600), a distal portion (510b), a transition member (514b), and a middle portion (512b) positioned between the distal portion (510b) and the transition member (514b), the middle portion (512b) being opaque, the distal portion (510b) being transparent, the working channel (600) including a middle portion working channel (620) and a transition member working channel (622), wherein the middle portion (512b) includes the middle portion working channel (620), and wherein the transition member (514b) includes the transition member working channel (622), the transition member working channel (622) including a distal working channel portion (624) distal to a proximal working channel portion (626), the proximal working channel portion (626) being offset from the middle portion working channel (620).

[0160] 42. The endoscope (20) of clause 41, wherein the middle portion working channel (620) includes a longitudinal axis (WCA), and wherein the proximal working channel portion (626) includes a longitudinal axis (TPA(p)) parallel to the longitudinal axis of the middle portion working channel (620).

[0161] 43. The endoscope (20) of clause 42, wherein the transition member (514b) is transparent and adhesively bonded to the middle portion.

[0162] 44. The endoscope (20) of clause 41, wherein the tip housing includes a camera module cavity (522b), wherein the transition member includes a distal protrusion (642) and a proximal joint surface (636p) fitting in the camera module cavity (522b), and wherein the middle portion (512b) includes a distal joint surface (636d) adhesively bonded to the proximal joint surface (636p) to form a joint (118), wherein the distal protrusion (642) extends distally of the joint (118).

[0163] 45. The endoscope (20) as described in clause 41, wherein the middle section (512b) includes a proximal joint surface (636p), wherein the middle section (512b) includes a circumferential wall (518b), the circumferential wall including an arcuate portion (662), wherein the transition piece includes a distal joint surface (636p) and a circumferential wall portion (646) positioned in front of the working channel (622) of the transition piece, wherein the distal joint surface (636d) is adhesively bonded to the proximal joint surface (636p) to form a joint (118), and wherein the arcuate portion (662) extends beyond the joint (118).

[0164] 46. The endoscope (20) as described in clause 41, wherein the middle section (512b) includes a proximal joint surface (636p), wherein the transition piece (514b) includes a distal joint surface (636p), wherein the distal joint surface (636d) is adhesively bonded to the proximal joint surface (636p) to form a joint (118), and wherein the transition piece (514b) includes an arcuate manipulation wire groove (674) positioned distal to the proximal working channel portion (626).

[0165] 47. The endoscope (20) as described in clause 41, wherein these illumination wires (616) extend through the insertion tube (31) to the positioning interface or the handle (21), and wherein these camera module wires (111) extend through the insertion tube (31) to the positioning interface or the handle (21).

[0166] 48. The endoscope (20) as described in clause 41, wherein the longitudinal base (406) includes a distal base portion (206d), a proximal base portion (206p), and a step (420) that longitudinally offsets the distal base portion (206d) and the proximal base portion (206p).

[0167] 49. The endoscope (20) as described in clause 41, wherein the longitudinal base (406) includes a distal base portion (406d), a proximal base portion (406p), and a step (420) that longitudinally offsets the distal base portion (406d) and the proximal base portion (406p), the transverse wall (404) includes a rear portion (404p) extending rearward from the proximal base portion (406p) and a cable recess (410b), and these illumination wires (416) pass through the cable recess (410b).

[0168] 50. The endoscope (20) as described in clause 49, wherein the transverse wall (404) further includes a cable recess (408) positioned in front of the proximal base portion (406p), wherein the sensor holder (200) includes a cable holder (202), wherein the cable holder (202) is at least partially positioned in the cable recess (408), and wherein the camera module wires extend through the cable recess (408).

[0169] 51. The endoscope (20) as described in any one of clauses 41 to 50, wherein the general camera module (100) is electrically isolated from the lighting module (400b) at the first end assembly (33b).

[0170] 52. The endoscope (20) as described in any one of clauses 41 to 50, wherein the sensor housing includes a circumferential wall (302) and wings (320) extending laterally from the circumferential wall (302), the wings (320) include anti-rotation surfaces (312la), the end housing (500b) includes end housing anti-rotation surfaces (512rb), and the anti-rotation surfaces (312la) are adjacent to the end housing anti-rotation surfaces (512la).

[0171] 53. The endoscope (20) as described in clause 52, wherein the image sensor (102) is positioned in the proximal end of the sensor housing (300), and the sensor holder (200) is adhesively bonded to the sensor housing (300).

[0172] 54. The endoscope (20) as described in clause 52, wherein the image sensor (102) is positioned in the proximal end of the sensor housing (300), wherein the distal end of the circuit board (103) is attached to the image sensor (102) and includes a recess (103r), the sensor housing (300) and / or the sensor holder (200) includes an arm (340) extending between the sensor housing (300) and / or the sensor holder (200), and wherein the arms (340) pass through the recesses (103r) and fix the sensor holder (200) and the camera housing (300) to each other.

[0173] 55. The endoscope (20) as described in clause 54, wherein the arms (340) extend proximally from the wings (320).

[0174] Bill of materials:

[0175] 10 Visualization system

[0176] 11, 11a, 11b Video processor

[0177] 20 Endoscope

[0178] 21 Handle or positioning interface

[0179] 22 Housing

[0180] 23 Cable rope

[0181] 24 Connector

[0182] 25 Manipulation actuator

[0183] 30 Insertion cord

[0184] 31 Insertion tube

[0185] 32 Bending section

[0186] 33, 33a, 33b Tip assembly

[0187] 40 Working channel

[0188] 41 Tool

[0189] 42 Control wire

[0190] 42a Intermediate part

[0191] 42b Longitudinal part

[0192] 100 Universal camera module

[0193] 102 Image sensor

[0194] 103 Circuit board

[0195] 103r Recess

[0196] 104 Circuit board

[0197] 110 Cable assembly

[0198] 111 Camera module wire

[0199] 112 Electrical shield

[0200] 113 Cable cover

[0201] 118 Connector

[0202] 200 Sensor holder

[0203] 202 Cable holder[[ID=...]]

[0204] 203 Outer surface

[0205] 204 Recess

[0206] 206 Longitudinal base

[0207] 206d Distal portion of longitudinal base

[0208] 206p Proximal portion of longitudinal base

[0209] 300 sensor housing

[0210] 302 circumferential wall

[0211] 304 sensor cavity

[0212] 306 lens

[0213] 312, 312a, 312ap alignment surfaces

[0214] 312la, 312r alignment / anti-rotation surfaces

[0215] 320 Wing

[0216] 340 Arm

[0217] 400, 400a, 400b lighting modules

[0218] 402, 402b body

[0219] 404, 404b transverse wall

[0220] 404p rear side of the transverse wall

[0221] 406, 406b vertical base

[0222] 406d Distal portion of longitudinal base

[0223] 406p proximal portion of longitudinal base

[0224] 408, 408b Cable recess

[0225] 410, 410b Cable recess

[0226] 412, 412b circuit boards

[0227] 414 Light-emitting diodes (LEDs)

[0228] 414a base plate

[0229] 414b Light emitting surface

[0230] 414c electrical contacts

[0231] 416 Lighting Wire

[0232] 418 middle part

[0233] 420 steps End caps 500a, 500b

[0234] Observation window 502

[0235] Illumination window 504

[0236] Light receiving surface 504p

[0237] Distal portions 510, 510b

[0238] Middle portions 512, 512b

[0239] Alignment surfaces 512a, 512p

[0240] Alignment surfaces 512ab, 512pb

[0241] Anti-rotation surfaces 512r, 512rb

[0242] Proximal portion / transition member 514, 514b

[0243] Circumferential walls 518, 518b

[0244] Outer surfaces of circumferential walls 519, 519b

[0245] Inner surfaces of circumferential walls 520, 520b

[0246] Camera module cavities 522, 522b

[0247] Sensor module cavities 524, 524b

[0248] LED cavities 526, 526b

[0249] Intermediate walls 528, 528b

[0250] Working channel 600

[0251] Working channel wall 604

[0252] Outer surface of working channel wall 606

[0253] Inner surface of working channel wall 608

[0254] Housing portion 610

[0255] Front notch 612 Hole 618

[0256] Inlet notch 618d

[0257] Inlet notch 618p

[0258] Working channel of middle portion 620

[0259] Working channel of the transition piece 622

[0260] Distal working channel portion of the transition piece 624 Proximal working channel portion of the transition piece 626 Front channel 628

[0261] Circumferential wall 630

[0262] Wiring channel of the transition piece 632

[0263] Working channel wall 634

[0264] Distal joint surface 636d

[0265] Proximal joint surface 636p

[0266] Working channel tube 640

[0267] Distal protrusion 642

[0268] Front pin 644

[0269] Portion of the circumferential wall 646

[0270] Front wall portion 648

[0271] Longitudinal groove 650

[0272] Longitudinal groove 652

[0273] Arc portion 662

[0274] Transverse wall 670

[0275] Wall surface 672

[0276] Manipulation wire groove 674

[0277] Manipulation wire hole 676

[0278] Notch 678

[0279] Distal segment 700

[0280] Wall 702

[0281] Notch 704

[0282] Distal arc portion of the wall 706

[0283] Entrance hole 708

[0284] Intermediate segment 710

[0285] Moving hinge 712

[0286] 714 Control wire hole

[0287] 720 Leg

[0288] 722 Arc surface

[0289] 724 Arc surface

[0290] 726 Notch

[0291] 800 Flow chart

[0292] 840 Optical waveguide

[0293] 850 Cable socket

[0294] 852 Housing

[0295] 854 Display screen

[0296] Elliptical cross-section of the CS working channel

[0297] LA Longitudinal axis

[0298] TPA(d) Distal transition piece axis

[0299] WCA Working channel axis

Claims

1. A method of manufacturing an endoscope, the method comprising: assembling a first copy of a general camera module (100) and a second copy of the general camera module (100), the first copy being identical to the second copy; assembling a first lighting module (400a); assembling a second lighting module (400b) different from the first lighting module (400a); providing a first end head housing (500a); providing a second end head housing (500b) different from the first end head housing (500a); inserting the first copy of the general camera module (100) and the first lighting module (400a) into the first end head housing (500a) to form a first end head assembly (33a); and inserting the second copy of the general camera module (100) and the second lighting module (400b) into the second end head housing (500b) to form a second end head assembly (33b).

2. The method according to claim 1, wherein The general camera module (100) includes a first anti-rotation surface (312r) and a second anti-rotation surface (312la) different from the first anti-rotation surfaces (312r), wherein the first end head housing (500a) includes a first end head housing anti-rotation surface (512r), and the second end head housing (500b) includes a second end head housing anti-rotation surface (512rb), and wherein: inserting the first copy of the general camera module (100) includes translating the first copy of the general camera module (100) to abut the first anti-rotation surfaces (312r) and the first end head housing anti-rotation surfaces (512r), and inserting the second copy of the general camera module (100) includes translating the second copy of the general camera module (100) to abut the second anti-rotation surfaces (312la) and the second end head housing anti-rotation surfaces (512rb).

3. The method according to claim 2, wherein The general camera module (100) includes longitudinally extending wings (320), and wherein the wings (320) include the first anti-rotation surfaces (312r) and the second anti-rotation surfaces (312la).

4. The method according to claim 3, wherein, The first anti-rotation surfaces (312r) are the rear surfaces of the wings (320), and the second anti-rotation surfaces (312la) are the lateral surfaces of the wings (320).

5. The method according to claim 4, wherein, The wings (320) extend laterally from a circumferential wall (302) of the sensor housing (300).

6. The method according to any one of claims 1 to 5, further comprising inserting an image sensor (102) into a proximal end of the sensor housing (300), and adhesively bonding the sensor holder (200) and the sensor housing (300) to the image sensor (102) received in the sensor housing (300).

7. The method according to claim 6, wherein, The camera housing (300) and / or the sensor holder (200) includes arms (340) that extend between the camera housing (300) and the sensor holder (200) around a portion of a circuit board (103) electrically connected to the image sensor (102), and the method further includes adhesively bonding the arms (340) to the camera housing (300) and / or the sensor holder (200) to fix the sensor holder (200) and the camera housing (300) to each other.

8. The method according to claim 6, wherein, The circuit board (103) is electrically connected to camera module wires (111), and wherein the first illumination module (400a) includes a light emitting diode (414) and illumination wires (416) electrically connected to the light emitting diode (414), and the method further includes passing the camera module wires (111) and the illumination wires (416) through an insertion tube of the endoscope (20).

9. The method according to claim 8, wherein The first illumination module (400a) is electrically isolated from the general camera module (100) at the first end assembly (33a).

10. The method according to any one of claims 1 to 9, wherein, The first end housing (500a) includes an illumination window (504) and a light receiving surface (504p), and wherein inserting a first copy of the general camera module (100) and the first illumination module (400a) into the first end housing (500a) to form the first end assembly (33a) includes: stopping translating the first illumination module (400a) distally when the light emitting diode (414) of the first illumination module (400a) abuts the light receiving surface (504p), and stopping translating the general camera module (100) distally when the general camera module (100) abuts a proximally facing surface of the first end housing (500a), and the stopping translating the first illumination module (400a) and the stopping translating the general camera module (100) occur in sequence.

11. The method according to any one of claims 1 to 10, wherein, The second end housing (500b) includes a working channel (600), and the first end housing (500a) does not have a working channel.

12. The method according to claim 11, wherein, The second end housing (500b) includes a middle section (512b) and a transition section (514b), the transition section (514b) includes a distal portion (624) having a longitudinal axis and a proximal portion (626) having a longitudinal axis offset from the longitudinal axis of the distal portion (624), and the method further includes inserting a distal end of a working channel tube (640) into the proximal portion (626).

13. The method of claim 12, the method further includes adhesively bonding the transition section (514b) to the middle section (512b).

14. The method according to any one of the preceding claims, wherein, The first lighting module (400a) includes a body (402) that includes a longitudinal base (406) and a transverse wall (404). The longitudinal base (406) includes a distal base portion (406d), a proximal base portion (406p), and a step (420) that longitudinally offsets the distal base portion (406d) and the proximal base portion (406p). The transverse wall (404) includes a rear portion (404p) that extends rearward from the proximal base portion (406p) and includes cable recesses (410, 410b). The transverse wall (404) further includes a cable recess (408) positioned in front of the proximal base portion (406p). Wherein, the sensor holder (200) includes a cable holder (202), and wherein the method further includes at least partially positioning the cable holder (202) in the cable recess (408).

15. The method according to any one of the preceding claims, the method further comprising: attaching the first end assembly (33a) to the first curved section (32), attaching the first curved section (32) to the first insertion tube (31), and attaching the first insertion tube (31) to the first handle or positioning interface (21) to assemble the first endoscope (20), and attaching the second end assembly (33b) to the second curved section (32), attaching the second curved section (32) to the second insertion tube (31), and attaching the second insertion tube (31) to the second handle or positioning interface (21) to assemble the second endoscope (20).

Images