Modular Endoscope Distal Tip Camera Module Testing
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Solution Overview
Problem
Reusable endoscopes are complex, expensive, and difficult to sterilize, while single-use endoscopes are costly to produce and discard entirely if defects are found, lacking quality control and assembly flexibility.
Innovation Solution
A modular distal tip unit design with a separate camera module that can be tested and approved independently, allowing for easier quality control and reduced waste by enabling the replacement of defective modules rather than entire endoscopes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single-use endoscope is used, then sterilization issues are eliminated, but quality control and assembly flexibility are reduced
Solution Approach 1:
The endoscope is divided into modular components: a reusable handle unit and a disposable distal tip unit containing the camera module. This segmentation allows the disposable portion to be pre-tested and quality-controlled during manufacturing, while eliminating sterilization requirements for the entire device. The modular design enables independent quality assurance of critical components before final assembly.
2Reliability
If a single-use endoscope is used, then cross-contamination risk is reduced, but waste increases when defects are found
Solution Approach 1:
By segmenting the endoscope into a reusable handle and a disposable distal tip, the system allows defective disposable units to be replaced without discarding the expensive handle unit. This reduces overall waste when defects are detected during testing or use.
Solution Approach 2:
The disposable distal tip unit undergoes complete quality control testing including liquid-tightness tests and functionality checks before leaving the manufacturing facility. This preliminary action identifies and isolates defective units early, preventing them from reaching clinical use and ensuring only tested units are deployed, thereby reducing waste from field failures.
3Manufacturing precision
If the entire endoscope is tested for liquid-tightness after assembly, then quality is ensured, but assembly complexity increases and defective units cannot be corrected
Solution Approach 1:
The disposable distal tip unit is manufactured and tested as a separate module before final assembly with the handle. This segmentation allows liquid-tightness testing to be performed on the modular unit independently, simplifying the overall assembly process and enabling replacement of only defective modules rather than entire endoscopes.
4Ease of manufacture
If reusable endoscope components are used, then cost is reduced, but sterilization difficulty and complexity increase
Solution Approach 1:
The distal tip unit containing the camera module is designed as a disposable component that is discarded after a single use. This eliminates the need for complex sterilization processes while maintaining low production costs through standardized manufacturing of the disposable unit, avoiding the high reprocessing costs associated with reusable endoscopes.
Data Source
AI summary
An endoscope including a handle or interface and an insertion cord configured to be inserted into a patient's body cavity and including a modular distal tip unit. The modular distal tip unit includes a main body connected to a remainder of the insertion cord; and a camera module configured to be accommodated and inserted in a receptacle formed in the main body, the camera module including a non-cylindrical housing defining an internal space in which at least a light emitting device and an imaging device are accommodated.