Disposable Optical Assembly for Single-Use Endoscopes
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Solution Overview
Problem
The high cost of imaging optics has limited the feasibility of single-use endoscopes and imaging catheters, as they need to provide images comparable to reusable devices while being inexpensive enough for single-use, which is not economically viable with current technology.
Innovation Solution
The development of optical assemblies featuring a lens barrel with stacked optical elements, including plastic injection-molded lenses and a compressible gasket forming an airtight seal, along with a multi-element lens configuration using different materials for improved image quality and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional imaging optics are used in single-use devices, then image quality can be maintained, but manufacturing cost becomes prohibitively high
Solution Approach 1:
The patent applies this principle by designing the optical assembly specifically for single-use disposal rather than reuse. The entire optical assembly including lens barrel, optical elements, and sealing components is configured as a disposable unit that is discarded after one use, eliminating the need for expensive reusable-grade optics while maintaining adequate image quality for the intended application
Solution Approach 2:
The patent changes the parameter of optical element material from traditional glass to injection-molded plastic. This material substitution significantly reduces manufacturing cost while the multi-element lens design compensates to maintain acceptable optical performance for single-use imaging applications
2Ease of manufacture
If plastic injection-molded lenses are used, then manufacturing cost is reduced, but image quality may deteriorate
Solution Approach 1:
The patent divides the optical system into multiple discrete lens elements rather than using a single element. This segmentation allows each plastic injection-molded lens to have simpler, more manufacturable surfaces while the combination of multiple elements achieves the necessary overall optical performance through cumulative refraction and aberration correction
Solution Approach 2:
The patent uses composite construction by combining multiple plastic lens elements with different optical properties (different refractive indices and Abbe numbers) to achieve superior image quality compared to single-element designs. The multi-element configuration allows correction of chromatic and spherical aberrations that would be difficult to correct in single plastic lenses
3Reliability
If a seal is formed between the lens and lens barrel, then hermetic sealing is achieved, but assembly complexity increases
Solution Approach 1:
The patent employs a flexible O-ring gasket made of elastomeric material to create the hermetic seal between the lens barrel and the optical assembly. This flexible sealing element can be compressed during assembly to form a reliable seal, and the O-ring's elasticity allows for tolerance compensation and easy installation without requiring precision-machined sealing surfaces
Solution Approach 2:
The patent combines the sealing function with the mechanical retention function by integrating the O-ring gasket into the lens barrel structure where it simultaneously provides hermetic sealing and helps retain the optical elements in position. This merging of functions reduces the number of separate components and simplifies the overall assembly process
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The optical assemblies provide improved image contrast and transmission at a lower manufacturing cost, making them suitable for single-use medical devices while maintaining image quality comparable to reusable devices.
Implementation Method 1
A compressible gasket is situated within the lens barrel at the distal rim, and a lens is situated within the lens barrel and in contact with the compressible gasket such that the compressible gasket forms a seal between the distal rim of the lens barrel and the lens
Data Source
AI summary
Optical assemblies for use in medical or other devices so as to image an object under examination onto an image sensor include a plurality of lens elements that can be retained in lens barrel. The lens elements and the lens barrel can be sealed with a compressible gasket. In one example, at least one lens element is made of an injection-moldable plastic and at least one lens element is made of a relatively dispersive optical glass. A lens barrel diameter or lens diameter can be selected to permit access to the object under examination with surgical or other tools. Aperture plates can be situated so as to reduce flare in the object image.