Endoscope Optical Unit Bonding Sheet Partial Curing
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Solution Overview
Problem
Existing optical units for endoscopes face challenges in size reduction, particularly in diameter minimization for minimally invasive procedures, and conventional bonding methods result in suboptimal surface accuracy and light scattering due to adhesive protrusions into optical path spaces.
Innovation Solution
A manufacturing method involving a curable resin film bonding sheet with partial curing and mirror-finishing processes to create optical flat surfaces, allowing for precise lamination and cutting of optical elements without adhesive protrusions, resulting in an optical unit with improved surface accuracy and reduced light scattering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional bonding methods using adhesive sheets are used to bond optical elements, then the optical elements can be bonded together, but adhesive protrusions occur into the optical path space causing light scattering and degraded optical quality
Solution Approach 1:
The patent applies preliminary action by performing curing treatment on the bonding sheet before lamination. The bonding sheet is cured in advance to form a hardened layer that prevents adhesive protrusions during the bonding process, thereby eliminating light scattering and ensuring high surface accuracy in the optical path region.
Solution Approach 2:
The bonding sheet is divided into two functional regions: a cured region that contacts the optical path space and provides an optically flat surface, and an uncured region that bonds the optical elements. This segmentation allows each region to fulfill its specific function without interfering with the other.
2Length of moving object
If the diameter size of the optical unit is reduced for minimally invasive procedures, then low invasion is achieved, but manufacturing precision and optical quality become more difficult to maintain
Solution Approach 1:
By curing the bonding sheet before lamination, the patent ensures that even in miniaturized optical units, the optical path region maintains high surface accuracy. The pre-cured bonding sheet provides a stable, protrusion-free bonding interface that is critical for maintaining optical quality in small-diameter endoscopes.
3Strength
If a bonding sheet is used to bond element wafers, then bonding is achieved, but the surface of the bonding sheet in the optical path region is not optically flat causing light scattering
Solution Approach 1:
The bonding sheet is segmented into a cured region and an uncured region. The cured region provides an optically flat surface that prevents light scattering, while the uncured region maintains bonding capability. This segmentation resolves the contradiction between achieving strong bonding and maintaining optical flatness.
Solution Approach 2:
Different regions of the bonding sheet are given different properties: the center region is cured to provide optical flatness, while the peripheral region remains uncured to provide bonding strength. This local differentiation of properties allows both bonding strength and optical flatness to be achieved simultaneously.
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 method enables the production of thin, reliable optical units with excellent optical properties, facilitating easier manufacturing and enhanced image quality by eliminating adhesive protrusions and ensuring optical flat surfaces within the optical path.
Implementation Method 1
a partial curing process of performing curing treatment on a predetermined region of the bonding sheet; a curing process of performing curing treatment on an uncured region of the bonding sheet in the laminated wafer
Implementation Method 2
a mirror-finishing process of processing a surface of the predetermined region into an optical flat surface
Data Source
AI summary
A manufacturing method of an optical unit for endoscope includes: a process of crimping a bonding sheet including a curable resin film to a release substrate having a release surface which is an optical flat surface; a mirror-finishing process of performing a partial curing treatment on a predetermined region of the bonding sheet to process the predetermined region into an optical flat surface; a process of fabricating a laminated wafer by laminating a first element wafer including a first optical element and a second element wafer including a second optical element, with the bonding sheet being arranged between the first element wafer and the second element wafer; a curing process of performing a curing treatment on an uncured region of the bonding sheet; and a process of cutting the laminated wafer and segmenting the laminated wafer into optical units.