Universal Camera Assembly for Multi-Size Endoscope Tip Production
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacturing of single-use endoscopes is hindered by the need for diverse and complex supply-chains due to varying sizes and types, leading to increased costs and inventory management challenges.
Innovation Solution
A universal camera module design with fixed dimensions is used across a range of endoscopes, allowing a single camera module to be mass-produced and reducing the need for multiple designs and tooling, while separate lighting modules can be adapted for different endoscope sizes, and the assembly process is simplified by independent alignment of camera and lighting modules within the tip housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If diverse camera modules are designed for different endoscope sizes and types, then each endoscope can have optimized performance, but manufacturing costs and supply-chain complexity increase
Solution Approach 1:
The patent implements a universal camera module design with standardized dimensions and mounting interfaces that can be used across multiple endoscope types and sizes. The camera module housing includes alignment features and mounting structures that accommodate different endoscope configurations without requiring custom camera modules for each variant, thereby simplifying the supply chain while maintaining performance optimization through proper module selection.
2Adaptability or versatility
If multiple camera module designs are maintained for different endoscope types, then each type can have customized features, but inventory costs and manufacturing complexity increase
Solution Approach 1:
The universal camera module design allows a single standardized module to serve multiple endoscope types. The module's standardized housing, alignment features, and mounting interfaces enable it to be adapted to different endoscope configurations without requiring separate inventory for each type, thereby reducing inventory investment while preserving customization capabilities.
Solution Approach 2:
The patent separates the camera module into a standardized, interchangeable component that can be independently selected and assembled. This segmentation allows the camera module to be decoupled from the specific endoscope type, enabling a shared inventory of universal modules while maintaining the ability to customize the overall endoscope system through different combinations of standardized components.
3Manufacturing precision
If separate tooling and injection molds are created for each endoscope type, then each can be precisely manufactured, but manufacturing costs and setup time increase
Solution Approach 1:
The universal camera module is designed with standardized dimensions and features that can be produced using a single set of injection molds and tooling. This universality allows the same manufacturing equipment to produce camera modules for all endoscope types, eliminating the need for separate tooling for each variant and thereby reducing manufacturing costs while maintaining precision through standardized production processes.
4Ease of operation
If camera and lighting modules are integrated into a single unified design, then assembly is simplified, but flexibility to adapt to different endoscope sizes is reduced
Solution Approach 1:
The patent separates the camera module and lighting module into distinct, independent components. The camera module has its own standardized housing and mounting features, while the lighting module is a separate assembly. This segmentation allows each module to be optimized and assembled independently, simplifying the overall assembly process while maintaining the flexibility to adapt different module combinations to various endoscope sizes and types.
Data Source
Figure 1~6
Figure 7~8
Figure 9~10
AI summary
A method of making endoscope tip assemblies including a lighting module including a body having a longitudinal bed and a transverse wall, a light emitting diode supported at a distal end of the longitudinal bed, and lighting wires electrically connected to the light emitting diode and extending through the insertion tube to the positioning interface or handle; a universal camera module comprising an image sensor, a circuit board electrically connected to the image sensor, a sensor holder, and a sensor housing affixed to the sensor holder, the image sensor housed in the sensor housing, and the sensor holder extending proximally from the image sensor. The same universal camera module can be used to make different tip assemblies for different endoscopes.