Rigid PCB Camera Head with External Pins
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Solution Overview
Problem
The challenge in developing small diameter camera heads for medical endoscopes and industrial borescopes lies in reducing the diameter further while addressing obstacles such as flexible PCB substrates, internal wiring complexity, assembly difficulties, and integrating illumination while maintaining minimal dimensions.
Innovation Solution
A video camera head design utilizing at least two rigid printed circuit boards (PCBs) mechanically supported by external pins, with electrically conducting pins facilitating power and signal transfer between PCBs, allowing for reduced diameter and simplified assembly, and incorporating an objective optical system and illumination means.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If flexible PCB substrates are used to reduce diameter, then the camera head diameter is reduced, but assembly complexity and manufacturing difficulty increase
Solution Approach 1:
The camera head is divided into multiple rigid PCB layers (first PCB, second PCB, third PCB) arranged in parallel planes, with each layer containing specific components. This segmentation allows each layer to be manufactured and assembled separately, then combined using external pins, reducing overall assembly complexity while maintaining a reduced diameter.
Solution Approach 2:
The patent transitions from using flexible PCB substrates (2D planar structure) to rigid PCBs arranged in parallel planes (3D stacked structure). This dimensional change allows the camera head to achieve a reduced diameter through vertical stacking while using rigid components that are easier to manufacture and assemble in mass production.
2Reliability
If internal wiring is used to connect components, then electrical connections are achieved, but assembly difficulty and manufacturing complexity increase
Solution Approach 1:
The patent extracts the electrical connection function from complex internal wiring by using external pins that protrude from the perimeters of the PCBs. These external pins provide simple electrical connections between layers without requiring complex internal wiring, significantly easing manufacturing while maintaining reliable electrical connections.
Solution Approach 2:
The external pins serve multiple functions: mechanical support for positioning PCBs relative to each other, electrical connection for power and signal transfer, and structural integration. This multi-functionality eliminates the need for separate wiring components, simplifying assembly and manufacturing.
3Illumination intensity
If illumination means are integrated into the camera head, then adequate illumination is achieved, but current transfer difficulty increases while maintaining minimal dimensions
Solution Approach 1:
The patent merges the illumination means with the rigid PCB structure, integrating the light source directly into the camera head assembly. This combination allows adequate illumination to be provided while the rigid PCB and external pin structure provide simple, reliable current transfer paths, avoiding the complexity of flexible wiring for power delivery.
4Ease of manufacture
If external pins are used to support PCBs, then assembly is simplified and mass production is enabled, but the pins must be integrated into the PCB perimeters
Solution Approach 1:
The external pins are pre-integrated into the perimeters of the PCBs during PCB manufacturing, before the PCBs are assembled together. This preliminary action ensures precise positioning and integration of the pins, enabling simple assembly in the final step while maintaining high manufacturing precision through pre-fabrication.
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 design effectively reduces the camera head's diameter, simplifies assembly, and enables adequate current transfer for illumination, making it suitable for mass production and maintaining minimal dimensions.
Implementation Method 1
The external pins are made of an electrically conducting material. Electrical power is conducted from the bottom PCB to electronic components or illumination means mounted on the other PCBs of the at least two PCBs and signals from a solid state sensor chip mounted on one of the other PCBs of the at least two PCBs to the bottom PCB
Data Source
AI summary
Disclosed is a video camera head comprised of at least two rigid printed circuit boards (PCBs) arranged in parallel planes. The at least two PCBs are mechanically supported one above the other by at least two external pins attached to the perimeters of the PCBs. The external pins fit into grooves cut into the edges of the PCBs. Several embodiments of the video camera head are described.