The present invention relates to a distal end unit of an endoscope that includes an image pickup unit in an interior, and the endoscope.
Conventionally, in a medical field or an industrial field, an endoscope has been widely used, for observing sites for which it is difficult to directly perform visual observation, for example, for observing an interior of a living body or a structural object. The endoscope is formed such that the endoscope can be introduced from an exterior of the living body or the structural object to the interior, and is configured such that the endoscope can form an optical image or can pick up the optical image.
In the endoscope, a distal end portion provided at a distal end of an insertion portion is mainly made up of a distal end unit in which various functional components are provided in a rigid distal end frame. As the distal end frame of the distal end unit, in recent years, a distal end frame using a technique for a molded interconnect device (MID) has been proposed. For example, International Publication No. 2015/082328 discloses an endoscope head (the distal end unit of the endoscope) including a head body (distal end frame) constituted by a MID element in which a plurality of conduction paths are formed, at least one electronic device to which electric power is supplied through the conduction paths, and a camera module (image pickup unit).
A distal end unit of an endoscope according to an aspect of the present invention includes: an image pickup unit including an optical unit and an image pickup device that are integrally formed, the optical unit being constituted by a lens stack body, the image pickup unit being made using a wafer level optics technique; a distal end frame having a columnar shape, a distal end surface of the distal end frame and a part of an outer circumference surface of the distal end frame forming an external shape of a distal end portion of an insertion portion, the distal end frame being constituted by a resin molded article; an image pickup unit containing room containing the image pickup unit in an interior of the distal end frame, the image pickup unit containing room including a first opening portion and a second opening portion that are continuously formed, the first opening portion being positioned on the distal end surface of the distal end frame, the second opening portion being positioned on a side surface of the distal end frame; and a filler having light blocking property, the image pickup unit containing room being filled with the filler so that the filler covers an outer circumference of the image pickup unit, the filler forming the external shape of the distal end portion with the distal end frame.
Further, an endoscope according to an aspect of the present invention includes a distal end unit including: an image pickup unit including an optical unit and an image pickup device that are integrally formed, the optical unit being constituted by a lens stack body, the image pickup remit being made using a wafer level optics technique; a distal end frame having a columnar shape, a distal end surface of the distal end frame and a part of an outer circumference surface of the distal end frame forming an external shape of a distal end portion of an insertion portion, the distal end frame being constituted by a resin molded article; an image pickup unit containing room containing the image pickup unit in an interior of the distal end frame, the image pickup unit containing room including a first opening portion and a second opening portion that are continuously formed, the first opening portion being positioned on the distal end surface of the distal end frame, the second opening portion being positioned on a side surface of the distal end frame; and a filler having light blocking property, the image pickup unit containing room being filled with the filler so that the filler covers an outer circumference of the image pickup unit, the filler forming the external shape of the distal end portion with the distal end frame, and the insertion portion in which the distal end unit is provided.
Embodiments of the present invention will be described below with reference to the drawings.
An endoscope 1 shown in
The insertion portion 2 is a tubular member in which a distal end portion 6, a bending portion 7 and a flexible tube portion 8 are provided so as to be continuous in an order from a distal end side and that has flexibility.
As shown in
As shown in
For example, the bending portion 7 is a mechanism configured to actively bend in two bending directions of an upward direction and a downward direction (UP-DOWN). Note that an upward direction, a downward direction, a right direction and a left direction for the insertion portion 2 and the like are conveniently defined so as to correspond to an upward direction, a downward direction, a right direction and a left direction in an endoscope image that is picked up by the image pickup unit 25 in the embodiment.
The flexible tube portion 8 is a tubular member having flexibility and configured to be passively flexible. The light guide 26, the treatment instrument channel 27 and the like are inserted into an interior of the flexible tube portion 8, in addition to various cables 28 that are electrically connected to the image pickup unit 25 and the like.
The operation portion 3 is configured to include a bend preventing portion 9 that is connected to the flexible tube portion 8 so as to cover a proximal end of the flexible tube portion 8, and a grasping portion 10 that is provided so as to be continuous with a proximal end side of the bend preventing portion 9 and that can be grasped by user's hand.
A treatment instrument insertion portion 11 that communicates with a proximal end side of the treatment instrument channel 27 is provided on a distal end side of the grasping portion 10. Further, an operation lever 13 for performing a bending operation of the bending portion 7 and operation switches 14 to which various functions of the endoscope 1 are assigned are provided on a proximal end side of the grasping portion 10.
For example, the universal cable 4 is a composite cable that allows insertion of the various cables 28, the light guide 26 and the like in an interior thereof and that allows insertion of an air/water feeding tube (not illustrated) and the like in the interior thereof. The various cables 28 extend from the distal end portion 6 of the insertion portion 2, and a distal end side of the air/water feeding tube is connected to the treatment instrument channel 27.
The endoscope connector 5 is configured to include an electric connector portion 16 for connecting the various cables 28 to a video processor (not illustrated) that is an external apparatus, a light source connector portion 17 for connecting the light guide 26 to a light source apparatus (not illustrated) that is an external apparatus, and an air/water feeding plug 18 for connecting the air/water feeding tube to an air/water feeding apparatus (not illustrated) that is an external apparatus.
Next, a configuration of the distal end portion 6 will be more specifically described with reference to
The distal end portion 6 in the embodiment is mainly made up of a distal end unit 35. In the distal end unit 35, various functional components such as an image pickup unit 25 are provided in a rigid distal end frame 36 constituted by a molded interconnect device (MID) and having a roughly circular columnar shape.
In the embodiment, the image pickup unit 25 is provided in the distal end frame 36 as a functional component. As shown in
For example, the distal end frame 36 includes a distal end frame body 37 formed by injection molding using a resin material and having a roughly columnar shape (more specifically, a roughly circular columnar shape in the embodiment). In the distal end frame body 37, a distal end surface and a part of an outer circumference surface are exposed on a surface of the distal end portion 6, and directly form an external shape of the distal end portion 6. Therefore, as the resin material composing the distal end frame body 37, a material having not only compatibility with the MID technique but also biological compatibility is selected. In the embodiment, the distal end frame body 37 means a resin portion formed by injection molding, for example, and various wiring patterns and the like (described later) are formed on a surface of the distal end frame body 37 by metal patterns using the MID technique, so that the distal end frame 36 is provided.
In the distal end frame body 37, an image pickup unit containing room 40, a light source containing room 41 and a channel holding room 42 are formed. The image pickup unit containing room 40 serves as a containing room that contains the image pickup unit 25 that is an optical functional component. The light source containing room 41 serves as containing room that contains a distal end side of the light guide as a light source that is an optical functional component. The channel holding room 42 is a room for holding a distal end side of the treatment instrument channel 27.
A stepped portion is formed on an outer circumference of the distal end frame body 37, such that an outer diameter on the proximal end side is smaller than an outer diameter on the distal end side, and a smaller-diameter region on the proximal end side that is formed by the stepped portion is set as a fitting portion 43 that is connected to the bending portion 7 by fitting.
Furthermore, a cutout portion is provided on the fitting portion 43, and a plane formed by the cutout portion is set as a cable connection surface 45 for connecting various cables.
The image pickup unit containing room 40 is configured by a concave portion having a roughly rectangular shape with a first opening portion 40a and a second opening portion 40b. The first opening portion 40a is provided on the distal end surface of the distal end frame body 37, and the second opening portion 40b is provided on one side of the distal end frame body 37.
In other words, the first opening portion 40a positioned on the distal end surface of the distal end frame body 37 (the distal end frame 36) and the second opening portion 40b positioned on the side surface of the distal end frame body 37 are continuously formed in the image pickup unit containing room 40 in the embodiment.
As side surfaces that extend in a direction of an insertion axis O, the image pickup unit containing room 40 in the embodiment includes a first side surface 40c and a second side surface 40d that are provided so as to be continuous with the first opening portion 40a and the second opening portion 40b respectively, and a third side surface 40e that is provided so as to be continuous with the first opening portion 40a and that is provided so as to be continuous with the first side surface 40c and the second side surface 40d.
Further, the image pickup unit containing room 40 includes a proximal end surface that is provided so as to be continuous with proximal ends of the first to third side surfaces 40c, 40d, 40e and a proximal end of the second opening portion 40b, and the proximal end surface is set as a mounting surface 40f for mounting the image pickup unit 25.
On the mounting surface 40f, a plurality of (for example, four) first lands 50a are provided as metal patterns. The image pickup device 33 is electrically connected to each first land 50a by an electrically conductive material. Note that solder, an electrically conductive adhesive or the like can be suitably used as the electrically conductive material for electrically connecting the image pickup device 33 to the each first land 50a.
Furthermore, wiring patterns 50b as metal patterns are connected to the respective first lands 50a. Each wiring pattern 50b extends from the mounting surface 40f to the cable connection surface 45 through the side surface of the distal end frame body 37.
For example, as shown in
In the embodiment, the communication groove 46 is provided so as to be continuous with the proximal end of the second opening portion 40b. Further, each wiring pattern 50b extending from the side of the mounting surface 40f is arranged in the communication groove 46. Consequently, in the side portion of the distal end frame body 37, each wiring pattern 50b is arranged inside an inner circumference surface of the distal end frame body 37.
On the cable connection surface 45, second lands 50c as metal patterns are provided on proximal ends of the respective wiring patterns 50b. Further, signal cables 28 inserted into the insertion portion 2 are electrically connected to the respective second lands 50c by an electrically conductive material.
Each first land 50a, each wiring pattern 50b and each second land 50c are formed by the MID technique, and for example, are formed by activating a resin surface forming the distal end frame body 37 by laser irradiation or the like and then performing metal plating to the resin surface after the activation.
As shown in
For example, the filling with filler is realized by dropping a filler fluid having a predetermined viscosity to the image pickup unit containing room 40 and the communication groove 46 and curing the filler fluid. In this case, widths of the image pickup unit containing room 40 and communication groove 46 are as small as about 0.5 mm to 1 mm, and therefore, the dropped filler fluid can be kept in interiors of the image pickup unit containing room 40 and the communication groove 46, by surface tension of the filler fluid. By curing the filler fluid kept in the interiors of the image pickup unit containing room 40 and the communication groove 46 in this way, a roughly flat surface of the filler 51 is formed on the side portion of the distal end frame body 37, without performing any special process. Parts of the surface formed on the side portion of the distal end frame body 37 by the filler 51 in this way are exposed on both surfaces of the distal end portion 6, and directly form the external shape of the distal end portion 6. Therefore, for the filler 51, a material having not only light blocking property but also biological compatibility is selected.
For example, the light source containing room 41 includes a through-hole that extends in the direction of the insertion axis O of the insertion portion 2. The light source containing room 41 is a circular hole in which a section shape in a direction orthogonal to the insertion axis O is a roughly circular shape.
The light guide 26 is inserted into the light source containing room 41. Furthermore, an optical member 41a such as an illumination lens or a cover glass is attached to the light source containing room 41, on the distal end side with respect to the light guide 26, and the optical member 41a closes a distal end side of the light source containing room 41, so that the illumination window 6b is formed on the distal end surface of the distal end frame 36.
The channel holding room 42 includes a through-hole that extends in the direction of the insertion axis O of the insertion portion 2. The channel holding room 42 is a circular hole in which a section shape in a direction perpendicular to the insertion axis O is a roughly circular shape.
The treatment instrument channel 27 is fixed to the channel holding room 42 by an unillustrated pipe sleeve. Further, a channel opening portion 6c is formed on the distal end side of the channel holding room 42.
On a proximal end side of the distal end unit 35 configured in this way, a cover member 55 having a tubular shape and configuring the bending portion 7 is connected to the fitting portion 43 by fitting. The cover member 55 is disposed such that a proximal end side covers a part of the filler 51 extending to the fitting portion 43, and is fixed to the fitting portion 43 and filler 51 by an adhesive or the like. Since the cover member 55 is fixed in this way, the proximal end side of the distal end unit 35 is sealed in a liquid-tight manner.
According to such an embodiment, it is possible to realize the reduction in the diameter of the distal end portion 6 while securing the optical performance of the image pickup unit 25, by configuring the distal end unit 35 including the image pickup unit 25 that is made using the water level optics technique and that has the lens unit 30, as an optical unit, constituted by the lens stack body and the image pickup device 33 integrally formed, the distal end frame 36 (the distal end frame body 37) that is constituted by a resin molded article and that has a columnar shape, the image pickup unit containing room 40 in which the first opening portion 40a positioned on the distal end surface of the distal end frame 36 and the second opening portion 40b positioned on the side surface of the distal end frame 36 are continuously formed and that contains the image pickup unit 25 in the interior of the distal end frame 36, and the filler 51 having light blocking property with which the image pickup unit containing room 40 is filled so that the filler 51 covers the outer circumference of the image pickup unit 25.
In other words, in the distal end portion 6 in the embodiment, the distal end frame 36 (the distal end frame body 37) constituted by the resin molded article is directly exposed to the exterior without being covered by a distal end cover or the like, and therefore, it is possible to realize the reduction in the diameter of the distal end portion 6 by a simple configuration.
In this case, for example, as shown in
Further, since the image pickup unit 25 is made using the wafer level optics technique, it is possible to produce a small-size image pickup unit 25 at low cast, and this configuration can also contribute to the reduction in the diameter of the distal end portion 6.
In this case, the outer circumference of the lens unit 30 is not protected from light, because the lens unit 30 is cut out by dicing or the like. However, the image pickup unit containing room 40 is filled with the filler 51 having light blocking property, and the outer circumference of the image pickup unit 25 is covered by the filler 51. Accordingly, it is possible to secure the optical performance of the image pickup unit 25, without covering the image pickup unit 25 using a separate shield member or the like.
In addition, since the image pickup unit containing room 40 is filled with the filler 51, it is possible to strongly hold the image pickup unit 25 in the image pickup unit containing room 40.
Further, by configuring the distal end frame body 37 by the resin molded article having compatibility with the molded interconnect device and forming the first and second lands 50a, 50c and the wiring patterns 50b on the surface of the distal end frame body 37 by the MID technique, it is possible to easily realize the electric connection of the image pickup unit 25 to the signal cables 28 and the like, on the proximal end side of the distal end frame 36.
In this case, by providing the communication groove 46 communicating with the image pickup unit containing room 40 on the side surface of the distal end frame body 37 in the region of the distal end frame 36 that is on the proximal end side and where the cable connection surface 45 is provided and arranging the wiring patterns 50b in the region including the communication groove 46, it is possible to easily realize the wiring from the image pickup unit containing room 40 to the cable connection surface 45.
Furthermore, by also filling the filler 51 into the communication groove 46 integrally with the image pickup unit containing room 40, it is possible to adequately realize insulation of the wiring patterns 50b on the outer circumference of the distal end frame 36.
For example, as shown in
By this configuration, it is possible to more adequately fill the image pickup unit containing room 40 with the filler 51.
In addition, by providing a groove 60 at each of a corner portion that is a connection region between the first side surface 40c and the third side surface 40e and a corner portion that is a connection region between the second side surface 40d and the third side surface 40e, it is possible to prevent interference between the image pickup unit containing room 40 and the image pickup unit 25 (see
Further, for example, by forming a chamfered portion 61 at a corer portion between the first opening portion 40a and the second opening portion 40b as shown in
Further, for example, by forming the cable connection surface 45 such that the cable connection surface 45 is parallel to a bottom surface of the communication groove 46 as shown in
For example, as shown in
Alternatively, for example, as shown in
The present invention is not limited to the respective embodiments described above, various modifications and alterations can be made, and the modifications and alterations are included in the technical scope of the present invention. Needless to say, for example, components of the above-described embodiment and the respective modifications may be appropriately combined.
This application is a continuation application of PCT/JP2019/011115 filed on Mar. 18, 2019, the entire contents of which are incorporated herein by this reference.
Number | Date | Country | |
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Parent | PCT/JP2019/011115 | Mar 2019 | US |
Child | 17401821 | US |