Laminated Optical Member for Ultra-Small Endoscope
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing endoscope designs face challenges in minimizing diameter for insertion into ultra-small lumens, such as blood vessels or bronchioles, while maintaining effective image pickup and optical functionality.
Innovation Solution
The design incorporates a laminated optical member with an emitting surface larger than the incident surface, featuring frame-shaped fixed areas with varying widths around optical path areas, and an image pickup member with a central axis deviation towards the external electrode, allowing for a compact structure without increasing the outer dimension in the optical axis direction. This configuration is achieved through a manufacturing method that includes dicing the laminated optical wafer with specific cutting sequences to prevent peeling and ensure high joining strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the diameter of the endoscope is reduced to minimize invasion, then the endoscope can be inserted into ultra-small diameter lumens such as blood vessels or bronchioles, but the optical functionality and image pickup effectiveness deteriorate
Solution Approach 1:
The patent embeds multiple optical members (lens, aperture stop, infrared cut filter) within a compact laminated structure at the distal end of the endoscope. The optical members are arranged in a nested configuration where the aperture stop is positioned within the lens structure, and the infrared cut filter is integrated into the same laminated assembly, maximizing space utilization while maintaining optical performance in an ultra-small diameter endoscope
Solution Approach 2:
The patent transitions from a conventional single-layer optical design to a multi-layer laminated structure. The optical members are arranged in multiple layers along the optical axis direction, with the lens forming a first optical path area and the infrared cut filter forming a second optical path area. This dimensional arrangement allows independent optimization of each optical function within the constrained radial space of an ultra-small diameter endoscope
2Reliability
If the emitting surface is made larger than the incident surface, then the optical performance is improved, but the outer dimension in the optical axis direction increases
Solution Approach 1:
The patent employs an asymmetric optical design where the emitting surface of the lens is intentionally made larger than the incident surface. The lens has an incident surface facing the subject and an emitting surface that is optically coupled to the image pickup device, with the emitting surface diameter being larger than the incident surface diameter. This asymmetric configuration optimizes light extraction efficiency and image quality while the overall length is controlled through the laminated structure arrangement
Solution Approach 2:
The patent optimizes the diameter ratio between the emitting surface and incident surface of the lens. By carefully controlling this geometric parameter, the design achieves improved optical performance through better light collection and reduced vignetting effects, while maintaining compatibility with the ultra-small diameter endoscope form factor through precise parameter selection
3Strength
If the fixed areas are made frame-shaped with varying widths, then the joining strength is improved and peeling is prevented, but the manufacturing complexity increases
Solution Approach 1:
The patent implements frame-shaped fixed areas with non-uniform width distribution around the optical path areas. The fixed areas have a first width in a first direction and a second width in a second direction perpendicular to the first direction, with the first width being greater than the second width. This local variation in geometric parameters provides enhanced joining strength and peeling prevention at critical locations while maintaining manufacturability through standard lamination processes
Solution Approach 2:
The asymmetric frame-shaped fixed area design provides different width dimensions in different directions to optimize the joining strength distribution. The larger first width provides enhanced mechanical interlocking in the direction where peeling stress is most likely to occur, while the smaller second width maintains adequate joining strength in the perpendicular direction without excessive material usage
4Productivity
If multiple image pickup apparatuses with different specifications are manufactured simultaneously, then the productivity is improved, but the manufacturing precision deteriorates
Solution Approach 1:
The patent designs the optical members and image pickup device as modular laminated units that can be manufactured as arrays on wafers. Multiple image pickup apparatuses with different specifications can be produced simultaneously by arranging different combinations of optical members and image pickup devices in the laminated structure, then separating them through dicing or other separation processes after bulk manufacturing
Solution Approach 2:
The patent creates a universal laminated optical member design that can serve multiple product specifications. The optical members are designed with standardized interfaces and mounting structures that allow the same basic laminated unit to be configured for different endoscope applications by varying the specific optical parameters, aperture sizes, or image pickup device types while maintaining the same fundamental manufacturing process
Data Source
AI summary
An image pickup apparatus includes an image pickup member and a laminated optical member that is fixed in frame-shaped fixed areas around respective optical path areas. The fixed areas include a first area and a second area. A width of the first area is greater than a width of the second area. In the laminated optical member, an optical surface central axis deviates from an optical axis toward the first area. In the image pickup member, an image pickup surface central axis that is a central axis of a first main surface deviates from the optical axis.