Scope distal end seal

Abstract

The present disclosure provides for sealing a distal component of a scope to form a distal cap assembly, thereby eliminating the need for adhesives and potting often used in conventional distal cap assemblies. Specifically, the present disclosure provides a spline structure configured to hold the distal tip component in a predetermined position. The spline structure, along with the distal tip component, is inserted into a mold, and the spline structure, along with the distal tip component, is sealed (e.g., in a polymer using a hot melt or the like) to form the distal cap. The distal cap locks the distal tip component within the spline structure, protecting the distal tip component from moisture and relative movement. Advantageously, the present sealing technique and distal cap assembly are faster to manufacture and have less room for error than conventional methods.

Description

[Technical Field]

[0001] The present disclosure relates generally to the distal end of a scope. In particular, but not exclusively, the present disclosure relates to sealing components at the distal end of a scope, such as an endoscope. [Background technology]

[0002] Modern endoscopes include several components (e.g., lights, cameras, etc.) at the distal tip. Often, these components are packaged or fitted within a distal cap assembly. A typical distal cap assembly is manufactured using a plastic molded cap into which all distal components are inserted. Once inserted, the components are locked into place using adhesives and potting. This increases the likelihood of manufacturing defects due to the complexity and size of the distal cap assembly and the number of individual components. Furthermore, the curing time of the adhesives typically increases manufacturing time. Therefore, there is a need for an improved distal cap assembly. Summary of the Invention

[0003] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to necessarily identify key features or essential features of the claimed subject matter, nor is it intended as an aid in determining the scope of the claimed subject matter.

[0004] The present disclosure provides a method of manufacturing a distal cap assembly for a scope, which can include providing a spline structure, fitting a plurality of distal tip components into the spline structure, inserting the spline structure and the plurality of distal tip components into a mold, and injecting a sealing material into the mold to seal the spline structure and the distal tip components and form a distal tip capsule.

[0005] In some embodiments, the method provides that the spline structure comprises a plurality of channels, each of the plurality of channels configured to receive a corresponding one of the plurality of distal tip components. In some embodiments, the method provides that the spline structure comprises at least one lumen connecting a proximal end of the spline structure to the plurality of channels. In some embodiments, the method provides that at least one of the plurality of distal tip components is an image sensor. In some embodiments, the method provides that at least one of the plurality of distal tip components comprises a lead routed through the at least one lumen and coupled to the image sensor. In some embodiments, the method provides that at least another one of the plurality of distal tip components is a light emitting diode (LED). In some embodiments, the method provides that at least another one of the plurality of distal tip components comprises a lead routed through the at least one lumen and coupled to the LED, and the encapsulating material is at least partially transparent to wavelengths of light emitted by the light emitting diode. In some embodiments, the method provides that the image sensor is a charge coupled device (CCD) sensor or a complimentary metal-oxide semiconductor (CMOS) sensor. In some embodiments, the method includes printing, depositing, or printing and depositing multiple layers of spline structure material using a three-dimensional (3D) printer to form the spline structure. In some embodiments, the method provides that the spline structure comprises a raised ring disposed between a proximal end of the spline structure and a distal end of the spline structure. In some embodiments, the method provides that the distal end capsule completely encapsulates at least one of the multiple distal end components. In some embodiments, the method provides that a distal-most end of at least one of the distal end components is flush with a distal-most end of the distal end capsule.In some embodiments, the method provides that the encapsulation material is a polymer. In some embodiments, the method provides that injecting the encapsulation material into the mold is part of a hot melt process.

[0006] The present disclosure also provides a distal cap assembly. In some implementations, the distal cap assembly is manufactured according to the methods described herein. In some embodiments, the present disclosure provides a distal cap assembly comprising: a spline structure; a plurality of distal end components disposed within the spline structure; and a distal end capsule sealing the spline structure and the distal end components, the distal end capsule being formed of a sealing material using a hot melt injection process.

[0007] In some embodiments, the distal cap assembly provides that the spline structure comprises a plurality of channels, each of the plurality of channels configured to receive a corresponding one of the plurality of distal tip components. In some embodiments, the distal cap assembly provides that the spline structure comprises at least one lumen connecting a proximal end of the spline structure to the plurality of channels. In some embodiments, the distal cap assembly provides that at least one of the plurality of distal tip components is an image sensor. In some embodiments, the distal cap assembly provides that at least one of the plurality of distal tip components comprises a lead routed through the at least one lumen and coupled to the image sensor. In some embodiments, the distal cap assembly provides that at least another one of the plurality of distal tip components is a light emitting diode (LED). In some embodiments, the distal cap assembly provides that at least another one of the plurality of distal tip components comprises a lead routed through the at least one lumen and coupled to the LED, and the encapsulating material is at least partially transparent to wavelengths of light emitted by the light emitting diode. In some embodiments, the distal cap assembly provides that the image sensor is a charge-coupled device (CCD) sensor or a complementary metal-oxide semiconductor (CMOS) sensor. In some embodiments, the distal cap assembly provides that the spline structure includes a raised ring disposed between a proximal end of the spline structure and a distal end of the spline structure. In some embodiments, the distal cap assembly provides that the distal tip capsule completely encapsulates at least one of the plurality of distal tip components. In some embodiments, the distal cap assembly provides that a distal-most end of at least one of the distal tip components is flush with a distal-most end of the distal tip capsule. In some embodiments, the distal cap assembly provides that the sealing material is a polymer.

[0008] The present disclosure provides an endoscope comprising: a proximal end having at least one electrical connector; a distal end having a plurality of distal tip components; an outer lumen joining the proximal end and the distal end; and at least one lead disposed within the outer lumen, the at least one lead electrically coupling the at least one electrical connector to the plurality of distal tip components; the distal end comprising a cap assembly comprising: a spline structure having the plurality of distal tip components disposed within the spline structure; and a distal tip capsule sealing the spline structure and the distal tip components, the distal tip capsule being formed of a sealing material using a hot melt injection process.

[0009] In some embodiments, the endoscope provides that the spline structure comprises a plurality of channels, each of the plurality of channels configured to receive a corresponding one of the plurality of distal tip components. In some embodiments, the endoscope provides that the spline structure comprises at least one distal lumen connecting a proximal end of the spline structure to the plurality of channels. In some embodiments, the endoscope provides that at least one of the plurality of distal tip components is an image sensor, at least one lead is routed through the at least one distal lumen, and at least another of the plurality of distal tip components is a light emitting diode (LED), and the sealing material is at least partially transparent to wavelengths of light emitted by the light emitting diode. In some embodiments, the endoscope provides that the spline structure comprises a raised ring disposed between the proximal end of the spline structure and the distal end of the spline structure, the outer lumen abutting a first side of the raised ring proximal to the proximal end of the spline structure, and the distal tip capsule abutting a second side of the raised ring proximal to the distal end of the spline structure. In some embodiments, the endoscope provides that the distal tip capsule completely seals at least one of the plurality of distal tip components, and the distal-most end of at least one of the distal tip components is flush with the distal-most end of the distal tip capsule.

[0010] To easily identify the discussion of any particular element or operation, the most significant digit(s) in a reference number refers to the figure number in which that element is first introduced. [Brief explanation of the drawings]

[0011] [Figure 1] 1 illustrates aspects of the present subject matter, according to one embodiment. [Figure 2] 1 illustrates aspects of the present subject matter, according to one embodiment. [Figure 3] 1 illustrates aspects of the present subject matter, according to one embodiment. [Figure 4] 1 illustrates aspects of the present subject matter, according to one embodiment. [Figure 5A] 1 illustrates aspects of the present subject matter, according to one embodiment. [Figure 5B] 1 illustrates aspects of the present subject matter, according to one embodiment. [Figure 5C] 1 illustrates aspects of the present subject matter, according to one embodiment. [Figure 6A] 1 illustrates aspects of the present subject matter, according to one embodiment. [Figure 6B] 1 illustrates aspects of the present subject matter, according to one embodiment. [Figure 6C] 1 illustrates aspects of the present subject matter, according to one embodiment. [Figure 6D] 1 illustrates aspects of the present subject matter, according to one embodiment. [Figure 6E] 1 illustrates aspects of the present subject matter, according to one embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0012] The present disclosure provides for sealing a distal component of a scope to form a distal cap assembly, thereby eliminating the need for adhesives and potting often used in conventional distal cap assemblies. Specifically, the present disclosure provides a spline structure configured to hold the distal tip component in a predetermined position. The spline structure, along with the distal tip component, is inserted into a mold, and the spline structure, along with the distal tip component, is sealed (e.g., in a polymer using a hot melt or the like) to form the distal cap. The distal cap locks the distal tip component within the spline structure, protecting the distal tip component from moisture and relative movement. Advantageously, the present sealing technique and distal cap assembly are faster to manufacture and have less room for error than conventional methods.

[0013] The foregoing has outlined broadly the features and technical advantages of the present disclosure in order that the following detailed description of the disclosure may be better understood. It should be appreciated by those skilled in the art that the disclosed embodiments may readily be utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present disclosure. The novel features of the present disclosure, both as to its organization and method of operation, together with further objects and advantages, will be better understood from the following description when considered in connection with the accompanying drawings. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure.

[0014] FIG. 1 illustrates a completed distal cap assembly 100 according to some embodiments of the present disclosure. Generally, the distal cap assembly 100 may form the distal end of any of a variety of endoscopes, such as, for example, a gastroscope, colonoscope, bronchoscope, laryngoscope, cystoscope, duodenoscope, enteroscope, ureteroscope, hysteroscope, etc. As illustrated, the distal cap assembly 100 of FIG. 1 illustrates a spline structure 200 (see FIG. 2 ) within which various components are disposed (see FIG. 5A ) and sealed as described herein. In particular, the distal cap assembly 100 includes several distal tip components 102 a, 102 b, 104, 102 c, and 102 d that are disposed within the spline structure 200 and sealed within material that forms a distal tip capsule 106. In such an embodiment, distal tip components 102a-102d may be any of a variety of components that may include any combination of cameras, lighting elements (e.g., fiber optic cables, light emitting diodes (LEDs), etc.), sensing devices, etc. Additionally, distal cap assembly 100 includes a working channel 104. It should be noted that while distal cap assembly 100 shows only a single working channel 104, multiple working channels 104 may be provided.

[0015] Some of the distal tip components (e.g., 102a, etc.) can have electrical connections 108 routed to the proximal end of the scope (not shown) and coupled to the distal tip components. The electrical connections 108 can ultimately couple to electronics within the scope in which the spline structure 200 and distal cap assembly 100 are provided, or can be coupled to a hub or additional electrical connector at the proximal end of the scope and configured to provide electrical connection between a controller (e.g., an image acquisition unit, a computer, etc.) and the distal tip components (e.g., distal tip component 102a, etc.).

[0016] The distal cap assembly 100 can be sized based on the type of scope with which the distal cap assembly 100 will be paired. For example, the distal cap assembly 100 can have an outer diameter of 2 millimeters (mm), 15 mm, 2 mm to 15 mm, or any other size that may be suitable for use with a scope as described herein.

[0017] 2 illustrates a spline structure 200 according to some embodiments of the present disclosure. As can be seen, the spline structure 200 includes component channels 202a, 202b, 202c, and 202d, often simply referred to as "channels." The spline structure 200 further includes component access ports 204a and 204b and the working channel 104. The component channels 202a, 202b, 202c, and 202d can be configured and arranged to hold particular ones of the distal end components 102a, 102b, 102c, and 102d. For example, if the distal end component 102b is a camera, the component channel 202b can be configured and arranged to fit the dimensions of the camera and securely hold the camera during the sealing process (described in more detail below). As another example, if distal end components 102a and 102c are LEDs, component channels 202a and 202c can be configured and arranged to fit the dimensions of the LEDs and to securely hold the LEDs during the sealing process.

[0018] It should be noted that while component channels 202a, 202b, 202c, and 202d are shown as square or rectangular in shape, they may be any shape or size configured to hold the corresponding distal end components 102a, 102b, 102c, and 102d. For example, if one of the distal end components (e.g., distal end components 102a and / or 102b) is a fiber optic cable, the associated component channel(s) (e.g., component channels 202a and / or 202b) may be circular or oval in shape to securely hold the fiber optic cable during the sealing process.

[0019] The spline structure 200 further includes component access ports 204a and 204b. Generally, the component access ports 204a and 204b can be arranged to allow electrical connections (e.g., signal wires, conductors, cables, etc.) from the distal tip components to be routed through the spline structure 200. As mentioned above, these electrical connections (e.g., electrical connection 108) can ultimately couple to electronics within a scope in which the spline structure 200 and distal cap assembly 100 are provided, or can be coupled to a hub or electrical connection at the proximal end of the scope and configured to provide electrical connection between a controller (e.g., an image acquisition unit, computer, etc.) and the distal tip components.

[0020] It is important to note that the spline structure 200 includes a channel (e.g., 202a, 202b, 202c, and 202d) for each corresponding distal tip component sealed within the distal cap assembly 100. Furthermore, the channels are molded to hold the distal tip components in position relative to one another during the sealing process without the need for potting or other fastening materials or mechanisms. Furthermore, the spline structure 200 and channels allow the distal tip components to be held in position (e.g., without adhesives and / or potting) while inserted into a mold for sealing, as described herein. This provides an advantage over conventional distal cap assemblies in that the distal tip components are held in position (e.g., relative to one another, relative to the distal cap assembly, etc.) with less material and processing. Therefore, manufacturing time can be shortened, reducing the cost of the manufacturing process.

[0021] 3 illustrates a mold 300, according to some embodiments of the present disclosure. The mold 300 includes a lower half 302 and an upper half 304, and is arranged and configured such that the spline structure 200 is inserted into a cavity 306 formed when the lower half 302 and the upper half 304 are positioned adjacent to one another, thereby forming the cavity 306 for a larger cavity into which the spline structure 200 can be inserted, disposed, positioned, or mated.

[0022] Mold 300 further includes support structure 308, which may be configured to receive a clamp or other support structure to hold mold 300 (e.g., bottom half 302 and top half 304) in a stable position during the injection process. In addition, mold 300 includes an injection port 310 through which a sealing material may be injected to surround and seal spline structure 200 and distal end components (e.g., 102a, etc.) to form distal end capsule 106.

[0023] FIG. 4 illustrates a method 400 according to some embodiments of the present disclosure. The method 400 can be performed to form the distal end capsule 106, as outlined herein. In general, the method 400 can be performed to form any distal end capsule. However, for convenience and clarity, the method 400 will be described with reference to the distal cap assembly 100 of FIG. 1, the spline structure 200 of FIG. 2, and the mold 300 of FIG. 3. However, this is not intended to be limiting.

[0024] The method 400 may begin at block 402. In block 402, "Prepare a Spline Structure," a spline structure may be provided. For example, spline structure 200 may be provided. The provided spline structure may include a component channel and at least one working channel. Proceeding to block 404, "Fit a Plurality of Distal End Components into the Spline Structure," a plurality of distal end components may be fitted into the component channels of the spline structure. For example, distal end components 102a, 102b, 102c, and 102d may be fitted into component channels 202a, 202b, 202c, and 202d, respectively.

[0025] This is more clearly shown in Figure 5A, which illustrates spline structure 200 with distal end components "fitted" into multiple channels of spline structure 200. For example, distal end components 102a, 102b, 102c, and 102d are shown fitted or disposed in corresponding ones of component channels 202a, 202b, 202c, and 202d (not numbered in this view for clarity). Similarly, electrical connections 108 are shown coupled to the distal end components and routed through corresponding component access ports 204a and 204b (not numbered in this view for clarity).

[0026] Proceeding to block 406, "Insert spline structure and multiple distal end components into mold," the spline structure may be inserted into the mold. For example, the spline structure 200, including the distal end component 102a, may be inserted into the mold 300. This is more clearly shown in Figures 5B and 5C, which show the spline structure 200 inserted into the mold 300.

[0027] 5C shows a perspective version of the top half 304 of the mold 300, showing the injection port 310 in more detail. The injection port 310 can be positioned and configured to receive a sealing injector (described in more detail below) that can inject a sealing material into the cavity 306 to surround the spline structure 200, the distal end component 102a, etc., to form the distal end capsule 106.

[0028] Proceeding to block 408 "Inject sealing material into mold to seal the splined structure and distal tip components and form a distal tip capsule," a sealing material is injected into the mold cavity to seal the splined structure and distal tip components and form a distal tip capsule. For example, the sealing material may be injected into cavity 306 through injection port 310 to form distal tip capsule 106, which surrounds and seals splined structure 200 and distal tip components 102a, 102b, 102c, and 102d. Additionally, the sealing material may form the distal or forward end of the scope in which distal cap assembly 100 is configured, including the distal end of working channel 104.

[0029] 6A-6E show a prototype distal end capsule 602 formed in accordance with an embodiment of the present disclosure. Figure 6A shows a spline 604 inserted into a mold 606. Mold 606 includes 608 and 610, shown positioned together to form a cavity (not shown) into which spline 604 is inserted. Also shown in this figure is an injection port 612.

[0030] 6B shows mold 606 with sealing injector 614 installed in injection port 612 (which is obscured by sealing injector 614). A sealing material can be injected into the cavity to seal and surround splines 604 and form distal end capsule 602.

[0031] 6C shows a view from the distal end of distal end capsule 602. As can be seen, distal end capsule 602 includes working channel 616 and distal end components 618a, 618b, and 618c.

[0032] 6D illustrates a side view of distal end capsule 602, showing distal end capsule 602 formed around the distal end of spline 604 and sealing distal end components 618a, 618b, and 618c. As can be seen, distal end capsule 602 can include a distal-most surface 620 and a sub-distal surface 622. Sub-distal surface 622 can be slightly angled or at an angle relative to distal-most surface 620. For example, sub-distal surface 622 can be at an angle of 25 to 50 degrees relative to distal-most surface 620.

[0033] FIG. 6E shows another side view of distal end capsule 602, showing distal end capsule 602 formed around the distal end of spline 604 and sealing distal end components 618a, 618b, and 618c (not shown) and working channel 616.

[0034] Terms used in this specification should be given their ordinary meaning in the relevant art or as indicated by their use in context, except that if an explicit definition is provided, that meaning will control.

[0035] References herein to "one embodiment" or "an embodiment" do not necessarily refer to the same embodiment, although they may. Throughout this description and the claims, the terms "comprise," "comprising," and the like, should be construed in an inclusive sense, i.e., "including, but not limited to," rather than an exclusive or exhaustive sense, unless the context clearly requires otherwise. Words using the singular or plural also include the plural or singular, respectively, unless expressly limited to the singular or plural. In addition, the words "herein," "above," "below," and words of similar import, when used in this application, refer to this application as a whole, not any particular portion of this application. When a claim uses the word "or" in connection with a list of two or more items, the word includes the following interpretations of that word, unless expressly limited to one or the other: any of the items in the list, all of the items in the list, and all of any combination of the items in the list. Any terms not expressly defined herein have their conventional meanings as commonly understood by those of ordinary skill in the art.

Claims

1. 1. A method of manufacturing a distal cap assembly for a scope, comprising: providing a spline structure; fitting a plurality of distal end components into the spline structure; inserting the spline structure and the plurality of distal end components into a mold; injecting a sealing material into the mold to seal the spline structure and the distal tip component to form a distal tip capsule; A method comprising:

2. The method of claim 1 , wherein the spline structure comprises a plurality of channels, each of the plurality of channels configured to receive a corresponding one of the plurality of distal end components.

3. The method of claim 2 , wherein the spline structure comprises at least one lumen connecting a proximal end of the spline structure to the plurality of channels.

4. The method of claim 3 , wherein at least one of the plurality of distal end components is an image sensor.

5. The method of claim 4 , wherein the at least one of the plurality of distal end components comprises a lead routed through the at least one lumen and coupled to the image sensor.

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

7. 7. The method of claim 6, wherein the at least another one of the plurality of distal tip components comprises a lead wire routed through the at least one lumen and coupled to the LED, and the encapsulating material is at least partially transparent to wavelengths of light emitted by the light emitting diode.

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

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

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

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

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

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

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

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

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