Endoscope Optical Module Groove Design for Resin Curing
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Solution Overview
Problem
In the manufacturing of optical modules for endoscopes, it is challenging to effectively fix optical fibers to ferrules using transparent resin, as it is difficult to ensure sufficient curing due to the small size and complexity of the components, which can lead to reduced reliability and transmission efficiency.
Innovation Solution
The optical module design includes a ferrule with a groove that communicates with the insertion hole, allowing for the injection of transparent resin from the side surface, ensuring complete curing and preventing air bubbles, with a specific geometry that prevents resin overflow into the groove and maintains mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If transparent resin is injected into the groove from the side surface opening to fix the optical fiber, then the curing completeness and reliability are improved, but the risk of resin overflow into the groove and causing light interference increases
Solution Approach 1:
The groove depth is designed with non-uniform distribution: deeper at the bottom to ensure complete resin curing and fixation reliability, and shallower near the side surface opening to prevent resin overflow into the groove. This local variation in groove depth resolves the contradiction between ensuring thorough curing and preventing light interference.
Solution Approach 2:
The groove geometry is pre-designed with controlled depth variations before resin injection, establishing depth limits that prevent resin from overflowing into the groove. This preliminary structural design ensures that even when resin is injected to achieve complete curing, it cannot exceed the predetermined depth boundary and cause light interference.
2Reliability
If the groove depth is increased to ensure complete resin curing, then the fixation reliability is improved, but the risk of resin overflow and light interference increases
Solution Approach 1:
The groove exhibits local quality variation in depth: the bottom portion has greater depth to accommodate complete resin curing, while the upper portion near the opening has reduced depth to act as a containment barrier. This spatially differentiated groove structure simultaneously achieves thorough curing and prevents overflow.
Solution Approach 2:
The varied-depth groove structure acts as an intermediary mechanism between the resin injection process and the optical fiber fixation. It mediates by allowing sufficient resin volume for complete curing at the bottom while the shallower upper section serves as a physical barrier preventing overflow into the optical path.
3Object-affected harmful factors
If the groove is made shallower to prevent resin overflow, then light interference is reduced, but the curing completeness and fixation reliability deteriorate
Solution Approach 1:
The groove depth is optimized with local quality differentiation: sufficient depth at the bottom ensures complete resin curing and reliable fixation, while the shallower upper section near the opening prevents resin overflow and light interference. This non-uniform depth distribution resolves the contradiction between curing completeness and preventing overflow.
4Ease of manufacture
If uniform groove depth is used throughout, then manufacturing simplicity is maintained, but either curing completeness or overflow prevention cannot be optimally achieved
Solution Approach 1:
The groove is designed with local quality variation in depth rather than uniform depth throughout. This allows the bottom portion to be deeper for complete curing while the upper portion is shallower to prevent overflow, achieving optimal fixation reliability without significantly complicating the manufacturing 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
This design enhances the reliability and transmission efficiency of the optical module by ensuring proper fixation of the optical fiber and preventing light interference, while maintaining mechanical strength and high transmission efficiency.
Implementation Method 1
By injecting a transparent resin into the groove from an opening of the groove on a side surface and by curing the transparent resin, it is possible to efficiently manufacture an optical module having high reliability.
Data Source
AI summary
An optical module for endoscope includes a light emitting element, an optical fiber, a ferrule to which the light emitting element is bonded, a wiring board to which the ferrule is bonded, and a resin disposed between the ferrule and the wiring board, wherein the ferrule has a first principal surface made of a transparent material, a second principal surface, and a side surface, the second principal surface has an opening of an insertion hole, the second principal surface has an opening of a groove communicating with the insertion hole, the side surface has an opening of the groove, and a first distance between the opening of the groove on the side surface and the first principal surface is greater than a second distance between the bottom surface of the insertion hole and the first principal surface.