TIP HOUSING FOR AN ENDOSCOPE WITH A COATED WALL SURFACE

Abstract

A method for manufacturing an endoscope having a tip housing may comprise the steps of moulding at least one tip housing for an endoscope by injection moulding or by multi shot injection moulding. Each tip housing may comprise an integrally formed wall defining an interior cavity and a proximal opening providing access to the interior cavity. The wall may comprise a longitudinally extending side wall portion, a distal end wall portion, and a window portion. The window portion may consist essentially of a transparent first material and form part of the side wall portion and/or the distal end wall portion. The wall may further comprise a wall surface facing the exterior of the tip housing and having a window surface of the window portion and a distally facing end surface of the distal end wall portion. The method may further comprise positioning the at least one tip housing in a treatment chamber; and applying, in the treatment chamber, a treatment formulation to provide a coating on at least the wall surface.

Claims

1. A method for manufacturing an endoscope, the method comprising: injection moulding a tip housing defining an interior cavity and a proximal opening providing access to the interior cavity, the tip housing comprising: a longitudinally extending side wall portion, a distal end wall portion having a distally facing end surface, and a window portion consisting essentially of a transparent first material and forming part of the side wall portion and/or the distal end wall portion, the window portion having a window surface; and a wall surface facing an exterior of the tip housing and having a window surface of the window portion and a distally facing end surface of the distal end wall portion; providing a jig having a treatment side and a hole with an opening on the treatment side, the hole being a through-hole or a dead-end hole; positioning the tip housing in the hole of the jig so that the window surface of the tip housing is oriented towards the treatment side and/or protrudes from the hole on the treatment side of the jig so that the window surface is exposed for coating when the jig is positioned in a treatment chamber; positioning the jig including the tip housing in the treatment chamber; and applying a treatment formulation to provide a coating on at least the wall surface in the treatment chamber.

2. A method according to claim 1, wherein said injection moulding comprises a two-component injection moulding process, and wherein the wall comprises or consists essentially of the first transparent material and a second material, which is different from the first material.

3. A method according to claim 1, wherein the treatment chamber forms part of a vapor deposition device, and wherein applying the treatment formulation comprises applying, by vapor deposition in the treatment chamber, the treatment formulation.

4. A method according to claim 1, wherein the tip housing comprises a tip working channel portion, and wherein positioning the tip housing in the hole of the jig further comprises arranging a first mandrel in the tip working channel portion of the tip housing.

5. A method according to claim 4, wherein a mandrel sealing element is arranged together with first mandrel to seal the first mandrel against the tip housing.

6. A method according to claim 1, wherein the injection moulding of the tip housing is performed in a mould, and the method further comprises: automatically removing the tip housing from the mould by a first automation device, and automatically placing the tip housing, after said removing and by a second automation device, in the hole of the jig by a second automation device, e.g. a second robotic arm.

7. A method according to claim 6, wherein the first automation device is the same as the second automation device.

8. A method according to claim 1, wherein the window surface comprises a camera window surface configured to be positioned in front of a camera of the endoscope and allowing the camera to look through the camera window surface, and one or more illumination window surfaces configured to be positioned in front of one or more light sources of the endoscope, respectively, and allowing the one or more light sources to provide illumination for the camera through the one or more illumination window surface, wherein applying, in the treatment chamber, the treatment formulation to provide a coating on at least the wall surface, comprises: positioning a first screening device to cover at least the one or more illumination window surfaces of the window surface prior to applying the treatment formulation to prevent the one or more illumination window surfaces from being coated; applying, in the treatment chamber, the treatment formulation, wherein the treatment formulation is a first treatment formulation, to provide a coating on the camera window surface; positioning a second screening device to cover at least the camera window surface of the window surface; and applying, in the treatment chamber, the first treatment formulation or a second treatment formulation to provide a coating on the one or more illumination window surfaces, wherein the coating on the one or more illumination window surfaces is the same or different from the coating on the camera window surface.

9. A method according to claim 8, further comprising: positioning a third screening device to cover at least the window surface prior to coating to prevent the window surface from being coated; applying, in the treatment chamber, the treatment formulation, wherein the treatment formulation is a third treatment formulation, to provide a coating on the wall surface.

10. A method according to claim 9, wherein the tip housing comprises a tip working channel portion having a distal entrance at the distal end wall portion of the tip housing, the method further comprising: positioning a fourth screening device to cover at least the distal entrance of the tip working channel portion to prevent coating of the tip working channel portion.

11. A method according to claim 1, comprising: positioning a camera in the interior cavity of the coated tip housing to look through the window portion and out of the coated window surface; and sealing the proximal opening of the coated tip housing with an adhesive to fluid-seal the interior cavity.

12. A method according to claim 11, further comprising: assembling the coated tip housing in the endoscope; and packing the endoscope in a sterilised packaging.

13. A tip housing for an endoscope, the tip housing comprising a wall defining an interior cavity and a proximal opening providing access to the interior cavity, the wall comprising: a longitudinally extending side wall portion, a distal end wall portion, and a window portion consisting essentially of a transparent first material and forming part of the side wall portion and/or the distal end wall portion; and a wall surface facing the exterior of the tip housing and having a window surface of the window portion and a distally facing end surface of the distal end wall portion; wherein the tip housing comprises a coating provided at least on the wall surface, the coating being one or more selected from the group consisting of: a transparent coating; a hydrophobic coating; an oleophobic coating; a hydrophilic coating; an oleophilic coating; and an optical coating, selected from a group comprising a notch filter coating, an infrared filter coating, an antireflection coating, and/or a low/high/band pass filter coating.

14. A tip housing according to claim 13, wherein the window portion comprises a camera window surface configured to be positioned in front of a camera allowing the camera to look through a camera window surface, and one or more illumination window surfaces configured to be positioned in front of one or more light sources, respectively, allowing the one or more light sources to provide illumination for the camera through the one or more illumination window surfaces, wherein the coating is provided on at least the camera window surface.

15. A tip housing according to claim 14, wherein the coating is also provided on the one or more illumination surfaces.

16. An endoscope comprising: a distal tip with a tip housing according to claim 14; a handle with a handle housing for gripping and a control member; an insertion tube for insertion into a patient, the insertion tube extending between the handle housing and the distal tip, and having a bending section positioned adjacent to the distal tip; one or more steering wires connecting the control member with the bending section, the control member being rotatable around a pivot axis to effect a bending movement of the bending section in one or more planes by tensioning the one or more steering wires; and a camera being positioned in the interior cavity of the tip housing and looking through the window portion.

17. A method according to claim 1, wherein injection moulding comprises multi-shot injection moulding.

18. A method according to claim 1, wherein the window surface comprises a camera window surface configured to be positioned in front of a camera of the endoscope and allowing the camera to look through the camera window surface, and one or more illumination window surfaces configured to be positioned in front of one or more light sources of the endoscope, respectively, and allowing the one or more light sources to provide illumination for the camera through the one or more illumination window surface, wherein applying, in the treatment chamber, a treatment formulation to provide a coating on at least the wall surface, comprises positioning a first screening device to cover at least the one or more illumination window surfaces of the window surface prior to coating to prevent the one or more illumination window surfaces from being coated.

19. A method according to claim 18, further comprising positioning a second screening device to cover at least the camera window surface of the window surface; and applying, in the treatment chamber, a second treatment formulation to provide a coating on the one or more illumination window surfaces.

20. A method according to claim 19, wherein the second treatment formulation is the same as the treatment formulation.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0116] Embodiments of this disclosure will be described in more detail in the following with regard to the accompanying figures. The figures show one way of implementing the present invention and are not to be construed as being limiting to other possible embodiments falling within the scope of the attached claim set.

[0117] FIG. 1a is a schematic perspective view of an endoscope according to this disclosure,

[0118] FIG. 1b is a schematic perspective view of a monitor connectable to the endoscope of FIG. 1a,

[0119] FIG. 2 is a schematic perspective view of a tip housing according to this disclosure,

[0120] FIG. 3 is a schematic cross-sectional view of the tip housing along the lines A-A of FIG. 2,

[0121] FIG. 4a is a schematic perspective view of a treatment arrangement including a first jig for the coating method according to this disclosure,

[0122] FIG. 4b is a schematic illustration of a first screening device,

[0123] FIG. 4c is a schematic illustration of a second screening device,

[0124] FIG. 5 is a schematic detail illustration of a cross-section along lines B-B of FIG. 4a of a first jig of the treatment arrangement of FIG. 4a,

[0125] FIG. 6a is schematic perspective illustration of a second jig with a second lid in an open arrangement,

[0126] FIG. 6b is a schematic illustration of a cross-section along lines C-C in FIG. 6a of the second jig with the second lid in a closed arrangement,

[0127] FIG. 6c is a schematic illustration of a cross-section along lines C-C in FIG. 6a of a third jig with a third lid in a closed arrangement,

[0128] FIG. 7a is a schematic perspective illustration of a fourth jig with a fourth lid in an open arrangement,

[0129] FIG. 7b is a schematic illustration of a cross-section along lines D-D in FIG. 7a of the third jig with the third lid in a closed arrangement.

DETAILED DESCRIPTION OF THE INVENTION

[0130] FIG. 1a illustrates an endoscope 1 which is disposable, and not intended to be cleaned and reused. The endoscope 1 comprises a distal tip 5 with a tip housing 51; a handle 2 with a handle housing 21 for gripping and a control lever 22; an insertion tube 3 for insertion into a patient extending between the handle housing 21 and the distal tip 5 with a bending section 4 positioned proximal to the distal tip 5; two steering wires (not shown) connecting the control member with the bending section 4; and a camera (not shown) positioned in the tip housing 51 and looking through a window portion 70 of the tip housing 51 and out of a window surface 71 of the tip housing 51. The control member is rotatable around a pivot axis to effect a bending movement of the bending section in a single plane by tensioning either of the steering wires. The camera is electrically connected to a circuit (not shown) of the handle 2 via data and power cables.

[0131] In FIG. 1b, a monitor 11 is shown. The monitor 11 allows an operator to view an image captured by the camera assembly 8 of the endoscope 1. The monitor 11 comprises a cable socket 12 to which a monitor cable 13 of the endoscope 1 shown in FIG. 1a can be connected to establish a signal communication between the camera assembly 8 of the endoscope 1 and the monitor 11.

[0132] FIGS. 2 and 3 illustrate the tip housing 51 of the endoscope 1 shown in FIG. 1a. The tip housing 51 comprises an integrally formed wall 60 defining an interior cavity 63 and a proximal opening 62 providing access to the interior cavity 63. The wall 60 is cylindrically cup-shaped or pot-shaped and comprises a longitudinally extending side wall portion 90, a window portion 70 consisting essentially of a transparent polymer material, and a distal end wall portion 80. The remaining portions of the wall other than the window portion 70 consists essentially of an opaque polymer material distinct from the transparent polymer material so that the wall consists essentially of the transparent polymer material and the opaque polymer material. The longitudinal extent of the side wall portion 90 is greater than the diameter of the distal end wall portion 80. The wall 60 further includes a wall surface 61 facing the exterior of the tip housing 51. The wall surface 61 comprises a side wall surface 91 of the side wall portion 90, a distally facing end surface 81 of the distal end wall portion 80, and a window surface 71 of the window portion 70. The window surface 71 comprises a side-facing portion forming part of the side wall surface 91 and a distally facing portion forming part of the distally facing end surface 81. The distally facing portion of the window surface 71 is divided into a camera window surface 72 configured to be positioned in front of the camera (not shown) allowing the camera to look through the camera window surface 72, a first illumination window surface 73 configured to be positioned in front of a first LED (not shown) of the distal tip allowing the first LED to provide illumination for the camera through the first illumination window 73, and a second illumination window surface configured to be positioned in front of a second LED of the distal tip allowing the second LED (not shown) to provide illumination for the camera through the second illumination window 74. The tip housing 51 comprises a tip working channel portion 64 extending between a proximal entrance 65 at a proximal end of the tip housing 51 and a distal entrance 66 at a distal end of the tip housing 51. A partition wall 67 of the tip housing 51 separates the tip working channel portion 64 from the interior cavity 63. The tip working channel portion 64 forms part of a working channel of the endoscope 1 which extends between the distal entrance 66 of the tip working channel portion 64 and a proximal port (not shown) of the handle 2.

[0133] The tip housing 51 comprises a coating covering the entire distal end surface 81, a distal portion of the side wall surface 91, and a distal portion of the tip working channel portion 64. A proximal portion 92 of the tip housing 51 is thus uncoated, the border of the coated portion and the uncoated portion is shown on FIG. 2 as the circumferential line adjacent to the 92 reference numeral. In practice the border may not be exactly sharp but may be a transition over a length of the tip housing 52. The coating is a transparent, hydrophobic, oleophobic coating.

[0134] As illustrated in FIG. 4a, such a tip housing 51 can be manufactured and assembled with the remaining parts of the endoscope 1 in a first embodiment by a method comprising the following steps: [0135] First, moulding a plurality of the tip housing 51 by a two-component injection moulding process, so that each tip housing 51 comprises an integrally formed wall 60 defining an interior cavity 63 and a proximal opening 52 providing access to the interior cavity, the wall 60 comprising: [0136] the longitudinally extending side wall portion 90, and the distal end wall portion 90 including the window portion 70, which consists essentially of a transparent polymer material; and [0137] the wall surface 61 facing the exterior of the tip housing 51 and having the distally facing end surface 81 of the distal end wall portion 80, which includes the window surface 71 of the window portion 70. [0138] Second, providing a first jig 100A having a treatment side 101 and a plurality of holes 102, each with an opening on the treatment side 101. [0139] Third, positioning each tip housing 51 in a separate hole 102 of the first jig 100A so that the window surface 71 of each tip housing 51 is oriented towards the treatment side 101 or protrudes from the hole opening on the treatment side 101 of the first jig 100A. This step is performed by an automation device 130, e.g. a pick and place robotic arm, with an end effector 131 picking each tip housing 51 and placing it in its respective hole 102 of the first jig 100A. The automation device 130 may pick each tip housing 51 directly from the mould after injection moulding thereof or may pick each tip housing 51 from a different container. [0140] Fourth, arranging a first cylindrical mandrel 103 in the tip working channel portion 64 of each tip housing 51 as best seen in FIG. 5. The first mandrel 103 has an outer diameter matching the inner diameter of the tip working channel portion 64. The first mandrel 103 is made of a metal, which is advantageous for a high temperature plasma vapor deposition process. Alternatively, the first mandrel 103 is made of an elastomer sealing against the tip working channel portion 64, which is advantageous for a chemical vapor deposition process. As best seen in FIG. 5, the first mandrel 103 is integrally formed with the first jig 100A and thus protrudes upright from the bottom of each hole 102. Placing the tip housing 51 on the first mandrel 103 ensures that the tip housing 51 is correctly oriented for subsequent coating. Correspondingly, a second mandrel 104 is arranged in the interior cavity 63. The second mandrel 104 has an outer crescent-shaped circumference matching an inner crescent-shaped circumference of the interior cavity 63. [0141] Fifth, preparing and cleaning the window surface 71 of each tip housing 51 for coating by plasma cleaning. [0142] Sixth, positioning the first jig 100A including the plurality of tip housings 51 in a treatment chamber 112 defined by an enclosure 111 of a vapor deposition machine 110. [0143] Seventh, sealing the enclosure 111 gas-tight and evacuating air from the treatment chamber 112 via a pump to provide a negative pressure relative to a surrounding pressure of in the treatment chamber 112. [0144] Eighth, applying to each tip housing 51 in the treatment chamber 112 a treatment formulation comprising hexamethyldisiloxane (HMDSO) by low-pressure plasma-enhanced chemical vapor deposition to provide a transparent, hydrophobic, and oleophobic coating of fluorocarbon on the entire distal end surface 81 including the entire window surface 71 and the distal portion of the side wall surface 91, alternatively, this step may comprise applying to each tip housing 51 in the treatment chamber 112 a treatment formulation comprising by chemical vapor deposition to provide a transparent, hydrophobic, and oleophobic coating of perfluorosilane on the entire distal end surface 81 including the entire window surface 71 and the distal portion of the side wall surface 91. [0145] Ninth, removing the first jig 100A including the plurality of the tip housings 51 from the treatment chamber 112. [0146] Tenth, positioning a camera in the interior cavity 63 of each tip housing 51 so that the camera looks through the window portion 70 and out of the coated window surface 71. [0147] Eleventh, sealing the proximal opening 62 of each tip housing 51 with an adhesive to fluid-seal the interior cavity 63. [0148] Twelfth, assembling each tip housing 51 in an endoscope 1 by connecting the proximal end of the tip housing 51 with the bending section 4 of the endoscope 1. [0149] Thirteenth, sterilising each endoscope 1 and coated tip housing 51. [0150] Fourteenth, packing each endoscope 1 in a sterilised packaging (not shown).

[0151] In a second and third embodiment, the window surface 71 comprises a camera window surface 72 configured to be positioned in front of a camera of the endoscope and allowing the camera to look through the camera window surface 72, and a first 73 and a second illumination window surface 74 configured to be positioned in front of a first and a second LED light source of the endoscope 1, respectively and allowing the two LED light sources to provide illumination for the camera through the first and second illumination window surfaces 73, 74, wherein step eight above is, in the second embodiment, replaced by the following steps: [0152] positioning a first screening device 121, as best seen in FIG. 4b, o cover the entire first and second illumination window surfaces 73, 74 of the window surface 71 to prevent the first and second illumination window surfaces 73, 74 from being coated; [0153] applying, in the treatment chamber 112, a first treatment formulation comprising hexamethyldisiloxane (HMDSO) to provide a first coating comprising fluorocarbon by low-pressure plasma vapor deposition to provide a transparent, optical filter, hydrophobic, and oleophobic coating on the entire camera window surface 72 but not on the illumination window surfaces 73, 74; [0154] positioning a second screening device 122, as best seen in FIG. 4c, to cover the entire camera window surface 72 of the window surface 71; and [0155] applying, in the treatment chamber 112, a second treatment formulation comprising hexamethyldisiloxane (HMDSO) to provide a second coating comprising fluorocarbon by flow-pressure plasma vapor deposition to provide a transparent, hydrophobic, and oleophobic coating on the entire first and second illumination window surfaces 73, 74 but not on the camera window surface 72.

[0156] In the third embodiment, the steps of the second embodiment are replaced by the following steps: [0157] positioning a first screening device 121, as best seen in FIG. 4b, to cover the entire first and second illumination window surfaces 73, 74 of the window surface 71 to prevent the first and second illumination window surfaces 73, 74 from being coated; [0158] applying, in the treatment chamber 112, a first treatment formulation to provide a first coating comprising perfluorosilane by chemical vapor deposition to provide a transparent, optical filter, hydrophobic, and oleophobic coating on the entire camera window surface 72 but not on the illumination window surfaces 73, 74; [0159] positioning a second screening device 122, as best seen in FIG. 4c, to cover the entire camera window surface 72 of the window surface 71; and [0160] applying, in the treatment chamber 112, a second treatment formulation to provide a second coating comprising perfluorosilane by chemical vapor deposition to provide a transparent, hydrophobic, and oleophobic coating on the entire first and second illumination window surfaces 73, 74 but not on the camera window surface 72.

[0161] A fourth embodiment is illustrated in FIGS. 6a and 6b involving a second jig 100B and a second lid 120B. The second jig 100B comprises a plurality of holes 102 (of which only one is shown), each comprising a first mandrel 103 provided in the same way as shown in FIG. 5 but omitting the second mandrel 104.

[0162] The second lid 120B comprises a plurality of openings 124 (of which only one is shown) matching the number of the plurality of holes 102 of the second jig 100B. In this fourth embodiment, a fourth screening device 123 forms part of the second lid 120B and is adjacent to each opening 124. Prior to placing the second jig 100B in the treatment chamber, the second lid 120B is placed on top of the second jig 100B to partially cover the distal entrance 66 of the tip working channel portion 64 of each tip housing 51 in the plurality of holes 102 of the second jig 100B. The tip housings are then coated in the same way as previously described.

[0163] A fifth embodiment is illustrated in FIG. 6c involving a third jig 100C and a third lid 120C corresponding essentially to the second jig 100B and the second lid 120B only differing in that the first mandrel 103 is omitted, the third jig 100C is provided with first jig mating elements 108 in the form of female mating depressions in the treatment side 101, and the third lid 100C is provided with first lid mating elements 128 in the form of male mating protrusions for mating with the first jig mating elements 108. The tip housings are coated in the same way as previously described.

[0164] A sixth embodiment is illustrated in FIGS. 7a and 7b involving a fourth jig 100D and a fourth lid 120D comprising the features of the third jig 100C and the third lid 120C. The fourth jig 100D further comprises a sealing element 105 extending along an outer perimeter enclosing the plurality of holes 102 of the fourth jig 100D. In addition to the first jig mating elements 108 and lid mating elements 128 (which are provided as in the fifth embodiment), second jig female mating elements 109 and corresponding second lid male mating elements 129 are provided at the perimeter of the fourth jig 100D and the fourth lid 120D. The tip housings are coated in the same way as previously described.

[0165] Any of the screening devices (i.e. the first screening device 121, the second screening device 122, the third screening device, or the fourth screening device 123) may be employed in all disclosed embodiments depending on the desired coated and uncoated surfaces. For instance, the first screening device may be employed when no coating is desired on the illumination surfaces, the second screening device when no coating is desired on the camera window surface, and the fourth screening device 123 when no coating is desired on or in the tip working channel portion. Advantageously, the same tip housings can have different surfaces coated by subjecting them to a sequence of coating processes as described above, wherein a different type of screening device is used in each coating process.

LIST OF REFERENCES

[0166] The following is a list of reference numerals used throughout this disclosure. In case of any doubt, the reference numerals of the following list apply.

TABLE-US-00001 1 endoscope 11 monitor 12 cable socket 13 monitor cable 2 handle 21 handle housing 22 control lever 3 insertion tube 4 bending section 5 distal tip 51 tip housing 60 wall 61 wall surface 62 proximal opening 63 interior cavity 64 tip working channel portion 65 proximal entrance 66 distal entrance 67 partition wall 70 window portion 71 window surface 72 camera surface 73 first illumination surface 74 second illumination surface 80 distal end wall portion 81 distal end surface 90 side wall portion 91 side wall surface 92 proximal portion 100 jig 101 treatment side 102 hole 103 first mandrel 104 second mandrel 105 sealing element 108 first jig mating element 109 second jig mating element 110 vapor deposition machine 111 enclosure 112 treatment chamber 120 lid 121 first screening device 122 second screening device 123 fourth screening device 124 opening 128 first lid mating element 129 second lid mating element 130 automation device 131 end effector