Endoscope Tip Part Adhesive Bonding Method
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Solution Overview
Problem
Existing endoscope tip parts face challenges with electrical insulation, liquid ingress, and miniaturization, particularly due to difficulties in adhering materials with low surface energy and the limitations of ultraviolet-curing polymers which affect light quality and increase manufacturing costs.
Innovation Solution
A method for manufacturing a tip part that eliminates the need for a separate mould by using a thinner exterior housing with tighter tolerances, injecting adhesive through a capillary action to avoid contact with light sources, and employing an adhesive spacing to ensure liquid tightness and reduce operator skill requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ultraviolet-curing polymer adhesive is used to secure the lens barrel, then the adhesive provides strong bonding and sealing, but the adhesive may flow onto the light emitting surface and the curing process is slow and expensive
Solution Approach 1:
The patent extracts the harmful element (ultraviolet-curing polymer adhesive) from the system by replacing it with a different adhesive type that cures without UV light, eliminating the slow and expensive curing process while maintaining bonding strength
Solution Approach 2:
The patent changes the chemical parameters of the adhesive system by selecting an adhesive with different curing characteristics (non-UV curing), thereby improving manufacturing efficiency and reducing costs while maintaining adequate bonding strength
2Reliability
If adhesive is injected to seal the tip part, then liquid tightness is improved, but adhesive may flow onto the light emitting surface and affect light quality
Solution Approach 1:
The patent applies preliminary action by positioning the light source before adhesive injection, allowing the light source to be secured in place first, then preventing adhesive flow onto its surface through controlled injection timing and positioning
Solution Approach 2:
The patent introduces an intermediary barrier (adhesive barrier or positioning structure) between the injected adhesive and the light emitting surface, preventing direct contact while allowing the adhesive to fulfill its sealing function
3Device complexity
If a separate mould is used to manufacture the tip part, then assembly is simplified, but the circumference size increases and automation becomes more difficult
Solution Approach 1:
The patent merges the housing structure with the mould structure by making the housing itself the mould, eliminating the need for a separate mould component and reducing overall circumference while enabling direct injection molding and automation
Solution Approach 2:
The housing structure serves multiple functions: it provides structural enclosure, acts as the mould for adhesive injection, and enables automated manufacturing, replacing what would traditionally require separate dedicated mould and housing components
4Manufacturing precision
If operator skill is increased to control adhesive injection, then adhesive placement precision is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent implements self-service by designing the housing with built-in features (adhesive barrier, positioning structures, controlled injection channels) that automatically ensure precise adhesive placement without requiring operator skill or intervention
Solution Approach 2:
The patent replaces the manual mechanical control system (operator skill) with an automated system built into the housing structure that provides precise adhesive placement through engineered features rather than human expertise
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 reduces the risk of adhesive flow onto light sources, maintains desired light properties, enhances liquid tightness, and allows for a smaller circumference, enabling miniaturization and automation of the endoscope tip part production.
Implementation Method 1
employing an adhesive spacing to ensure liquid tightness
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3b
AI summary
A method for manufacture of a tip part for an endoscope, said method comprising the steps of: - providing a camera assembly with an image sensor, a lens barrel positioned at a distal end of the camera assembly, and a circuit board positioned at a proximal end of the camera assembly, - providing an exterior housing comprising a circumferential wall enclosing a spacing, the exterior housing further comprising a distal end wall, the distal end wall being integral with the circumferential wall and having an opening, - inserting the lens barrel of the camera assembly in the spacing of the exterior housing so that a distal end of the lens barrel extends into the opening, and so that an axially extending adhesive spacing is provided between the opening and the lens barrel along a circumference of the lens barrel, a radial extent of the adhesive spacing gradually being reduced in a direction towards the spacing of the exterior housing - injecting an adhesive into the adhesive spacing, - allowing or causing the adhesive to harden so as to adhere the lens barrel to the distal end wall of the exterior housing.