Endoscope Window Overmoulding for Hermetic Bezel Sealing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for affixing windows on endoscopes, particularly using sapphire discs, are complex, costly, and prone to errors due to manual processes, with hermeticity tests being incomplete and parts requiring gold plating, leading to high costs and potential window detachment.
Innovation Solution
The use of amorphous metal overmoulding to create a bezel around the window edges, providing a hermetic seal and secure attachment, eliminating the need for soldering and gluing, and ensuring the window cannot fall out, with amorphous metals like zirconium or copper alloys being used for this process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering and gluing processes are used to affix the window, then hermetic seal and secure attachment are achieved, but the process complexity and manufacturing costs increase significantly
Solution Approach 1:
The patent combines the attachment and hermetic sealing functions into a single integrated process. The amorphous metal is molded directly onto the window edge in one operation, simultaneously providing mechanical attachment and hermetic seal, eliminating the need for separate soldering and gluing steps.
Solution Approach 2:
The patent replaces the complex thermal processes of soldering and gluing with a cold-forming molding process. The amorphous metal is shaped directly onto the window edge through molding, substituting the need for heat-based joining methods and associated flux agents.
2Reliability
If gold plating is applied to the window and socket for soldering, then hermetic connection is improved, but manufacturing costs double
Solution Approach 1:
The patent extracts and eliminates the gold plating step from the manufacturing process. By using amorphous metal molding that directly attaches to the uncoated window edge, the method removes the requirement for expensive gold plating on both the window and socket surfaces.
Solution Approach 2:
The patent uses a cost-effective amorphous metal material that provides sufficient hermetic sealing without requiring expensive gold plating. The amorphous metal itself serves as both the attachment medium and sealing material, replacing the need for costly precious metal coatings.
3Reliability
If manual soldering process is used, then hermetic seal can be achieved, but validation and quality control become difficult
Solution Approach 1:
The patent replaces manual soldering operations with an automated molding process. The amorphous metal is molded directly onto the window edge using a mold, providing consistent, repeatable results that are easier to validate and control quality-wise compared to manual soldering.
Solution Approach 2:
The patent performs the hermetic sealing action during the molding process itself, before final assembly. The amorphous metal is shaped and attached in one preliminary operation, making the hermetic seal inherent to the manufacturing process rather than a subsequent validation step.
4Reliability
If flux agents are used during soldering, then hermetic connection is achieved, but cleaning of particles and flux residues becomes difficult
Solution Approach 1:
The patent replaces the chemical flux-based soldering process with a mechanical molding process. By forming the amorphous metal directly onto the window edge without thermal soldering, the method eliminates the need for flux agents and the associated cleaning of flux residues and particles.
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 method reduces costs, minimizes errors, and ensures a reliable hermetic seal without the need for gold plating, as amorphous metals provide a strong, secure attachment and simplified quality control.
Implementation Method 1
creating a bezel for the window by overmoulding the lateral edge of the window with amorphous metal
Data Source
AI summary
A method of affixing a window on an endoscope. The method including positioning the window on or in an end part of the endoscope and creating a bezel for the window by overmoulding a lateral edge of the window with amorphous metal.