Endoscope Image Pickup Unit With Notch-Filled Resin Bonding
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Solution Overview
Problem
Existing image pickup units in endoscopes face challenges in downsizing and maintaining mechanical strength while ensuring efficient manufacturing processes.
Innovation Solution
The image pickup unit is designed with a stacked optical unit bonded to an image sensor using a single application of resin that fills notches in the side surfaces and bonds the optical unit and image sensor, enhancing mechanical strength and allowing for efficient manufacturing by integrating resin application and curing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a wafer-level stacked optical unit is used to downsize the image pickup unit, then the diameter is reduced, but the mechanical strength is insufficient
Solution Approach 1:
The patent applies resin to fill notches formed on the side surfaces of the optical unit before bonding the image sensor to the optical unit. This preliminary filling of notches with resin reinforces the optical unit's structure prior to the bonding process, preventing breakage during subsequent handling and assembly operations.
2Productivity
If resin is applied to bond the image sensor and fill notches in separate steps, then the manufacturing process becomes complex, but using a single resin application improves productivity
Solution Approach 1:
The patent combines the resin application for filling notches and the resin application for bonding the image sensor into a single resin application step. The resin is applied to simultaneously perform both functions: filling the notches on the side surfaces and creating the bonding layer between the image sensor and optical unit. This eliminates the need for separate resin application and curing steps, thereby improving manufacturing productivity.
Solution Approach 2:
The resin material serves multiple functions simultaneously: it fills the notches to provide mechanical reinforcement, acts as an adhesive to bond the image sensor to the optical unit, and provides structural support. This multi-functionality of the resin eliminates the need for separate materials and processing steps for each function.
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 solution achieves a compact image pickup unit with improved mechanical strength and high productivity, reducing the risk of damage and enabling efficient assembly through a streamlined manufacturing process.
Implementation Method 1
resin which includes a first region between the light-receiving surface and the exit surface, the first region bonding the optical unit and the image sensor to each other, and a second region filling the notch of the optical unit
Implementation Method 2
the first region bonding the optical unit and the image sensor to each other
Data Source
AI summary
An image pickup unit includes: an optical unit which includes a plurality of stacked optical elements and in which at least corners of four side surfaces have a notch being notched from an exit surface toward an incidence surface; an image sensor including a light-receiving surface; and resin which includes a first region between the light-receiving surface and the exit surface, the first region bonding the optical unit and the image sensor to each other, and a second region filling the notch of the optical unit, and which does not include an interface between the first region and the second region.