Endoscope Image Pickup Assembly With Resin-Based Focal Alignment
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Solution Overview
Problem
Current manufacturing methods for endoscope image pickup apparatuses face challenges in reducing the diameter of the optical portion at the distal end while maintaining high performance and efficiency, particularly in aligning the image-forming plane with the light receiving surface effectively.
Innovation Solution
A method involving the stacking of multiple optical devices, precise measurement of the image-forming plane, adjustment of the interval between the optical and image pickup members using a transparent resin, and curing to fix the assembly, ensuring the image-forming plane aligns with the light receiving surface, thereby achieving a compact and high-performance image pickup apparatus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the diameter of the image pickup apparatus is reduced to achieve a less-invasive endoscope, then the invasiveness is reduced, but the alignment precision between the image-forming plane and light receiving surface deteriorates
Solution Approach 1:
The patent applies preliminary action by pre-forming a resin layer with a specific thickness between the optical member and image pickup member before final assembly. This resin layer is formed with controlled thickness (e.g., 5-20 μm) to pre-establish the correct optical interval, ensuring that when the components are stacked, the image-forming plane automatically aligns with the light receiving surface. This preliminary preparation of the resin layer thickness resolves the alignment precision issue that would otherwise occur when reducing the apparatus diameter.
2Reliability
If multiple optical devices are stacked to improve optical performance, then the image quality is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent merges multiple optical devices (lenses, filters, etc.) into a single stacked optical member assembly. By stacking these optical devices together with a resin layer and curing them as an integrated unit, the patent simplifies the manufacturing process compared to assembling each optical device separately. This merging approach maintains high image quality through optimized optical paths while reducing manufacturing complexity by treating the stacked optical devices as one combined component.
Solution Approach 2:
The patent uses a resin material as a composite bonding medium between the optical member and image pickup member. This resin layer serves multiple functions: it bonds the stacked optical devices together, maintains the precise interval between components, and corrects optical aberrations. The use of this composite resin material simplifies manufacturing by replacing multiple separate adjustment and bonding operations with a single material that performs multiple functions simultaneously.
3Manufacturing precision
If the interval between optical member and image pickup member is adjusted for precise alignment, then the alignment precision is improved, but the manufacturing time increases
Solution Approach 1:
The patent applies preliminary action by pre-forming the resin layer with a controlled thickness that corresponds to the required optical interval before final assembly. This pre-formed resin layer eliminates the need for time-consuming iterative adjustments of the interval between the optical member and image pickup member. The thickness is controlled during the resin formation step itself, allowing precise alignment to be achieved without extending the manufacturing process.
Solution Approach 2:
The patent employs a self-aligning mechanism where the pre-formed resin layer automatically positions the optical member and image pickup member at the correct interval when stacked. The resin layer's controlled thickness acts as a self-contained positioning feature that does not require external adjustment mechanisms or manual intervention. This self-service approach to interval control significantly reduces manufacturing time while maintaining high alignment precision.
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
This approach results in a smaller, less-invasive endoscope with high performance, enabling efficient manufacturing and effective alignment of the image-forming plane with the light receiving surface, enhancing the overall image quality and manufacturing efficiency.
Implementation Method 1
fixing the optical member and the image pickup member in a state of the adjusted interval by performing curing processing on a transparent resin disposed to fill an optical path between the optical member and the image pickup member
Data Source
AI summary
A manufacturing method of an image pickup apparatus for endoscope includes manufacturing an optical member in which a plurality of optical devices are stacked, and an image pickup member including an image pickup device having a light receiving surface, measuring a position of an image-forming plane on which an object image, light of which is focused by the optical member, is formed, and fixing the optical member and the image pickup member in a state where an interval is adjusted so that a measured position of the image-forming plane becomes a position of the light receiving surface by performing curing processing on a transparent resin disposed to fill an optical path between the optical member and the image pickup member.