Universal Endoscope Tip Camera Assembly for Lower-Cost Manufacturing
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Solution Overview
Problem
The manufacturing costs of single-use endoscopes are high due to the need for diverse components and complex supply-chains, especially when producing procedure-specialized endoscopes in various sizes, and there is a desire to reduce these costs while maintaining efficiency and quality.
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 used across different endoscope types, along with separate lighting modules for varying configurations, and a simplified assembly process that reduces design and supply-chain costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If diverse components and complex supply-chains are used for procedure-specialized endoscopes in various sizes, then the quality and functionality of endoscopes are maintained, but manufacturing costs increase
Solution Approach 1:
The patent implements a universal camera module design that can be used across multiple endoscope types and sizes. The camera module features standardized mounting surfaces, electrical connections, and mechanical interfaces that allow it to function in different endoscope configurations without modification, thereby reducing supply-chain complexity while maintaining quality and functionality
Solution Approach 2:
The patent segments the endoscope system into modular components, with the camera module as a distinct, separable unit. This segmentation allows the camera module to be independently manufactured, tested, and assembled into different endoscope types, simplifying the overall supply-chain while preserving the specialized functionality of each endoscope variant
2Adaptability or versatility
If diverse components are used for different endoscope sizes, then the functionality for specific procedures is optimized, but manufacturing costs and inventory management complexity increase
Solution Approach 1:
The universal camera module is designed with standardized interfaces and mounting mechanisms that enable it to be adapted to different endoscope sizes and procedural requirements without requiring custom components for each variant, thereby reducing manufacturing costs while maintaining procedure-specific functionality through configuration rather than component variation
Solution Approach 2:
The patent utilizes parameter changes in the mounting and positioning mechanisms of the camera module to adapt it to different endoscope sizes. By adjusting positional parameters, orientation angles, and mounting depths rather than changing the fundamental camera module design, the system achieves procedure-specific optimization without increasing manufacturing complexity
3Reliability
If custom camera modules are designed for each endoscope type, then the optimal performance for each procedure is achieved, but design time and supply-chain costs increase
Solution Approach 1:
The patent establishes a universal camera module design that eliminates the need for custom design iterations for each endoscope type. The standardized module maintains optimal performance across different procedures through consistent optical and electronic design, while significantly reducing design time by avoiding repetitive customization efforts
4Adaptability or versatility
If separate lighting modules are used for different configurations, then the lighting needs for various endoscope sizes are met, but assembly complexity increases
Solution Approach 1:
The patent separates the lighting function into independent lighting modules that can be selectively assembled with the universal camera module based on specific procedural needs. This segmentation allows for flexible configuration of lighting capabilities while keeping the assembly process standardized and manageable through modular attachment procedures
Data Source
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AI summary
An endoscope including a positioning interface or handle; an insertion tube extending distally from the positioning interface or handle; 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, 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. A transition piece includes a transition piece working channel having a distal working channel portion and a proximal working channel portion offset from a middle portion working channel.