Endoscope Tip Windows With Multi-Inlet Transparent Moulding
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Solution Overview
Problem
The existing two-component two-stage injection moulding process for endoscope tip housings faces challenges in achieving homogeneous filling of transparent windows due to complex shapes and potential contamination from opaque material, leading to deteriorated optical quality.
Innovation Solution
A method involving a moulding tool with multiple inlets for separate volumes of transparent and opaque polymer materials, ensuring controlled flow and integration of transparent windows with opaque parts to prevent stray light and improve optical quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If transparent polymer material is injected into the moulding tool via a single inlet to form complex-shaped transparent windows, then the manufacturing process is simplified, but the filling homogeneity and optical quality deteriorate
Solution Approach 1:
The single inlet for transparent polymer material is divided into multiple inlets (first inlet and second inlet). The first inlet directs material to the first cavity while the second inlet directs material to the second cavity, enabling independent control of material flow to each cavity and achieving homogeneous filling of complex-shaped transparent windows
2Stability of the object's composition
If transparent polymer material is injected after opaque polymer material in the two-stage process, then the transparent windows can be formed with proper structural integration, but contamination from opaque material dissolving into transparent material occurs in narrow passages
Solution Approach 1:
The narrow passages containing opaque polymer material are completely removed from the moulding tool between the first and second stages. This extraction eliminates the source of contamination, preventing opaque material from dissolving into the transparent polymer material during the second injection stage
Solution Approach 2:
The opaque polymer material is injected and solidified in the first stage, and the narrow passages are removed before the transparent polymer material is injected in the second stage. This preliminary removal action prevents contamination before it can occur
3Productivity
If the complex-shaped transparent windows are moulded with insufficient material flow control, then the manufacturing process is faster, but the optical properties such as surface smoothness and transparency homogeneity deteriorate
Solution Approach 1:
Different inlets are provided with different flow control characteristics suited to the local requirements of each cavity. The first inlet and second inlet can be configured with different sizes, positions, or flow restriction features to optimize material flow distribution and ensure homogeneous filling and smooth surfaces in each specific cavity
Data Source
AI summary
Transparent windows (5, 6) of a housing of a tip part of an insertion endoscope are moulded by: Providing a moulding tool. Introducing in the moulding tool a first polymer material. Allowing the first polymer material to set to form a first housing part. Introducing in the moulding tool at least one second polymer material, where the second polymer material is different from the first polymer material and transparent. Allowing the second polymer material to set to form a combined housing component (4) with the first housing part. Removing the combined housing component (4) from the moulding tool. At least second polymer material is injected into the moulding tool via a plurality of inlets (Inlw) to form a plurality of volumes of the second polymer material.