Endoscope Optical Waveguide Assembly for Small-Diameter Fiber Alignment
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Solution Overview
Problem
The existing methods for producing endoscopes with small diameters face challenges in arranging and aligning light guide elements due to the lack of reliable guide segments, leading to high production costs, skill-intensive processes, and high rejection rates, as traditional soldering methods fail to provide a strong and reproducible adhesion, especially in small diameters ≤4 mm.
Innovation Solution
The method involves forming a guide segment directly on the outer surface of the inner shaft using additive manufacturing processes like laser build-up welding, eliminating the need for additional connecting materials and simplifying the production process by creating a durable and strong connection between the inner shaft and the guide segment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional soldering methods are used to attach guide segments to inner shafts, then the process is simple and familiar, but adhesion is insufficient especially in small diameters ≤4 mm leading to high rejection rates
Solution Approach 1:
The patent replaces the mechanical soldering process with a laser-based additive manufacturing process. The laser builds up material layer by layer to form the guide segment directly on the inner shaft, eliminating the need for separate soldering steps and providing superior adhesion through direct material deposition and fusion.
Solution Approach 2:
The patent changes the fundamental parameters of the attachment process by transitioning from thermal soldering to laser-induced material deposition. The laser parameters (power, speed, focal point) are precisely controlled to achieve optimal adhesion strength, particularly for small diameter inner shafts where traditional methods fail.
2Manufacturing precision
If guide segments are produced using multi-stage processes with soldering and machining, then the guide segments can be formed with required precision, but the production complexity and time increase significantly
Solution Approach 1:
The patent merges multiple separate manufacturing operations (soldering, machining, shaping) into a single additive manufacturing process. The laser simultaneously performs attachment, shaping, and sizing operations, eliminating the need for multiple process stages and reducing overall production complexity.
Solution Approach 2:
The additive manufacturing process performs preliminary shaping and sizing of the guide segment during the deposition process itself, rather than requiring subsequent machining operations. The guide segment is formed in its final shape directly during material deposition, eliminating post-processing steps.
3Ease of manufacture
If brass is used as guide segment material for ease of soldering and machining, then the guide segments are easy to manufacture, but biocompatibility issues arise due to allergen classification
Solution Approach 1:
The patent changes the material parameter from brass to biocompatible materials such as titanium or titanium alloys. The additive manufacturing process using laser deposition is particularly suited for these materials, as they can be directly deposited with excellent adhesion and can be formed into the required shapes without traditional machining.
Solution Approach 2:
The patent replaces mechanical machining processes with laser-based additive manufacturing. This substitution enables the use of biocompatible materials like titanium that are difficult to machine but can be easily deposited layer by layer using laser fusion, thereby eliminating biocompatibility issues while maintaining manufacturing capability.
4Device complexity
If guide segments are not used in small diameter endoscopes due to adhesion problems, then production complexity is reduced, but alignment and arrangement of light guide elements cannot be ensured
Solution Approach 1:
The patent replaces traditional mechanical attachment methods with laser additive manufacturing, enabling the successful use of guide segments in small diameter endoscopes (≤4 mm). The direct material deposition and fusion process creates sufficient adhesion strength even in confined spaces, allowing guide segments to be effectively used for precise alignment of light guide elements.
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 enables a quick, safe, and reliable arrangement of guide segments on endoscopes with small diameters, reducing production complexity and increasing reproducibility, allowing for the first-time successful formation of guide segments on endoscopes with outer diameters ≤4 mm, thereby improving the alignment and arrangement of light guide elements.
Implementation Method 1
forming a guide segment directly on the outer surface of the inner shaft by an additive manufacturing process, in particular by laser build-up welding
Implementation Method 2
laser build-up welding
Data Source
Figure 1~2
Figure 3~4
AI summary
1. The invention relates to a method for manufacturing an endoscope (02) with a fiber optic device, comprising the following steps: - providing an inner shaft (03) for receiving an imaging optic (S1); - arranging a guide segment (09) for aligning the inner shaft (03) in an outer shaft (04) and/or for guiding fiber optic elements (06) of the fiber optic device on the outer surface (11) of the inner shaft (03), in particular in a distal end section (01) of the outer shaft (04); - arranging the fiber optic elements (06) on the outer surface (11) of the inner shaft (03; S3); - inserting the inner shaft (03) together with the fiber optic elements (06) into the outer shaft (04) with a radially outer surface (12) of the guide segment (09) against an inner surface (13) of the outer shaft (04; S4);- Attaching the inner shaft (03) and the light guide elements (06) to the outer shaft (04), at least in the distal end section (01) of the inner shaft (03) and outer shaft (04; S5), wherein it is provided that the guide segment (09) is formed directly on the outer surface (11) of the inner shaft (03) by an additive manufacturing process (S2).;