Surgical Image Sensor Holder Alignment
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Solution Overview
Problem
Existing endoscope designs face challenges in maintaining the stable positioning and secure alignment of image sensors, which affects the imaging quality.
Innovation Solution
A holder for the image sensor is designed with a circuit board to which the image sensor is soldered, ensuring permanent positioning and alignment. The holder includes a sleeve for the image sensor and circuit board, with a cover member that provides additional stability through adhesive filling of gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the image sensor is mounted using conventional methods (e.g., glued to a deflecting prism), then the assembly process is simpler, but the stable positioning and secure alignment of the image sensor deteriorate
Solution Approach 1:
The holder is divided into distinct functional segments: a support structure for mechanical support, a circuit board for electrical connections, and a cover member for protection and alignment. This segmentation allows each component to perform its specific function optimally while maintaining overall system reliability.
Solution Approach 2:
The image sensor is pre-soldered to the circuit board before assembly into the holder. This preliminary action ensures precise alignment and secure positioning of the image sensor relative to the optical system, eliminating the need for complex alignment mechanisms during final assembly.
2Manufacturing precision
If the image sensor is permanently fixed to the circuit board, then the imaging quality improves due to stable positioning, but the ease of repair deteriorates
Solution Approach 1:
The holder assembly separates the image sensor-circuit board unit from the support structure and cover member. This segmentation allows the image sensor to be permanently fixed to the circuit board for precision, while the entire unit can be accessed as a module for repair or replacement.
Solution Approach 2:
The image sensor and circuit board can be extracted as a functional unit from the holder for repair or replacement. The cover member is designed to be removable, providing access to the soldered connection without requiring destruction of the permanent bond between the image sensor and circuit board.
3Reliability
If a cover member with adhesive filling is used to secure positioning, then the reliability of the holder improves, but the manufacturing complexity increases
Solution Approach 1:
The support structure and cover member are prepared with predetermined positioning features and adhesive application areas before final assembly. This preliminary preparation ensures that when the image sensor-circuit board unit is inserted, the adhesive is already in position to provide secure fixation, simplifying the manufacturing process while maintaining reliability.
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 solution ensures the image sensor remains fixed relative to the optical system, improving imaging quality and maintaining alignment throughout the service life of the endoscope.
Implementation Method 1
the image sensor is connected, such as being soldered, on its rear side to a circuit board for the image sensor
Implementation Method 2
the interspace between the cover member and the rear side of the circuit board can be filled with an adhesive
Data Source
AI summary
A holder for a surgical instrument, where the holder includes: an image sensor, the image sensor having a photo-sensitive layer and a rear side facing away from the photo-sensitive layer; and a circuit board, a first side of the circuit board being connected to the rear side of the image sensor. The holder may have a cover member having a first side arranged on a second side of the circuit board, the second side of the circuit board facing away from the image sensor. The cover member may be configured to form an interspace between the first side of the cover member and the second side of the circuit board, and the interspace may be filled with an adhesive.