Optical fiber cable connector

Abstract

A laser energy coupling device having a male launch connector. The male launch connector has a body portion in which an optical fiber line terminates at an optical connection component comprising a male ferrule. The optical connection component is elongate and generally cylindrical with a central circumferential band. The body portion defines a cavity that form fits with the optical connection component and is spaced around the optical connection component. An elastomeric support that engages the optical connection portion provides flexibility when the coupling is completed and centering before the coupling is completed. The elastomeric support is positioned rearward of the optical connection component. The elastomeric support can grip the optical fiber line in the elastomeric support. A forward facing annular surface displaced rearward from a forward most portion of the male ferrule provides a stop surface when the coupling is completed and provides a heat transfer means to dissipate heat from the male ferrule by entering the receiving coupling device.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Provisional Application No. 63 / 013,178, filed April 21, 2020, and U.S. Provisional Application No. 62 / 927,419, filed October 29, 2019. Both applications are incorporated herein by reference.

[0003] This application relates to U.S. Patent Nos. 10,082,632 and 10,663,677, owned by their respective owners. These patents are incorporated herein by reference for all purposes. Background Technology

[0004] Laser-based medical devices use laser radiation for medical treatment. The type, power, and parameters of the laser radiation vary depending on the treatment. The laser energy generator is connected to the medical device using a connection system with both optical and mechanical connections.

[0005] Connectors are critical components of transmission systems. Typically, fiber optic connectors have decreased in size over time due to the need for higher density connectors on telecommunications equipment; that is, more connectors per square inch of equipment space. Typical connectors for medical purposes include slightly modified optical connectors developed for telecommunications equipment, such as the SMA-905 or SMA-906 modified connectors, which have a forward-projecting ferrule with an exposed fiber end face. These connectors are small, as are the mating parts—specifically, the ferrule securing the fiber and the mating female component. The small size of the grippable portion requires delicate handling to connect the fiber to the medical device. The small size of the connector is inconvenient for handling while wearing gloves and does not allow for rapid connection. Furthermore, the input fiber end face is easily contaminated or damaged during mating with the connector on a medical device on a laser energy generator, as this end face is exposed and defines the furthest part of the connector. Any problems related to the integrity of the connection between the laser source and the medical device can affect the performance of the medical device and possible medical procedures.

[0006] Compared to telecommunications, medical laser applications require optical fibers and connectors to efficiently handle higher power levels. Even minor misalignments in the optical connectors can generate excessive heat and cause power loss in the medical device. Excessive heat generation can damage the connector components, especially if thermal management associated with the connector is inadequate.

[0007] Most conventional fiber optic connectors for laser applications have optical connection portions that are substantially fixed within the mechanical connection portions. In telecommunications applications, where alignment of the optical connection portions is not critical, this fixed relationship between the optical connection portions and the mechanical connection portions is satisfactory. This is in part due to the low power handling requirements of such telecommunications connectors. Thermal management is not a significant factor, and slight misalignment is not a significant problem. Fiber optic connectors in laser telecommunications applications typically connect one optical fiber to another optical fiber, and such connections have one fiber end face that faces the end face of the other fiber. Thus, sufficient alignment between the optical connection portions of mating connectors is relatively simple, and fixing the optical connection portions to the mechanical connection portions is not a significant problem.

[0008] This is in contrast to launch connectors in laser medical devices, where the importance associated with alignment, and in some cases thermal management, is high. In a typical laser energy generator for a medical device, the launch connector that connects to the laser energy generator has an internally exposed fiber end face that must be aligned with a focused laser beam that is tapered at the connection of the laser generator. Any misalignment can result in energy loss and overheating of the connector portions.

[0009] Significant progress has been made in launch connectors for medical devices that plug into laser energy generators. Separating and isolating the mechanical connection portions from the optical connection portions, and allowing the optical connection portion of the launch connector (e.g., a cylindrical male ferrule having a fiber end face at the forward end) to resiliently float within the annular mechanical portion of the launch connector when mated with a female ferrule having a cylindrical bore at the laser generator, can provide acceptable alignment. See U.S. Patent No. 10,663,677 to the owner of the present application. The '677 patent is incorporated herein by reference for all purposes. The '677 patent discloses embodiments in which the cylindrical male ferrule is simply supported within a uniform diameter bore of the housing by the fiber cable. Other embodiments disclose that the cylindrical male ferrule is supported within a uniform diameter bore of the launch connector housing with an elastomeric material body positioned rearward of the male ferrule, thereby providing centering of the male ferrule. While these embodiments provide improvements over known launch connectors for medical applications, any further improvements related to easier manufacturing, assembly, robustness, and thermal management would be highly desirable. SUMMARY

[0010] A delivery system extending from a source of laser radiation for connection to a medical device that utilizes laser radiation for medical treatment. The delivery system includes an optical cable having an optical fiber extending from a laser source, the delivery system having a male activation connector with a male ferrule on the optical cable. The activation connector is coupled to a receiving connector having a female ferrule that interfaces with a male ferrule on the medical device. The male activation connector has a body portion with an outer wall defining an interior and a forwardly projecting tubular portion with an outermost or forwardmost edge and with a central axial recess defined therein. The optical fiber terminates at a male ferrule positioned in the central recess rearward of the forwardmost edge of the body portion and presents a forward facing optical fiber end face. In embodiments, the male ferrule is flexibly positioned within the central recess when not connected to the receiving connector. In embodiments, the male ferrule is flexibly positioned by means of an elastomeric material body that directly or indirectly supports the male ferrule relative to the body portion and has a matching clearance extending circumferentially and axially between the male ferrule and the wall surface of the body portion in the central axial recess, thereby providing axial flexibility of the male ferrule and limited freedom of movement in all radial directions when the activation connector is not connected.

[0011] In embodiments, the male ferrule is disposed in a rigid sleeve with the ferrule extending forwardly from the sleeve, the sleeve engaging and / or supported by an elastomeric material body disposed in the body portion, the sleeve spaced from the interior body wall surface, thereby providing elasticity and radial flexibility in all radial directions when the activation connector is not attached to the receiving connector. In embodiments, flexibility and elasticity are provided in forward and rearward axial directions. In embodiments, the elastomeric material body is configured as an annular member extending between the sleeve and the interior wall surface of the body portion. In embodiments, the elastomeric material body is configured as one or more blocks of elastomeric material body with the rearward edge or edge portion of the rigid sleeve engaging or facing the elastomeric material body.

[0012] In embodiments, the male ferrule, any sleeve or fitting on the male ferrule, and the optical fiber and any covering on the optical fiber are supported within the body portion solely by virtue of the flexible material providing centering and flexibility when not connected to a receiving connector. In embodiments, the flexibility is in all directions. In embodiments, movement of the ferrule is constrained by the body portion, or by other structures of the launch connector that surround the male ferrule and any sleeve or fitting on the male ferrule. The body portion or other structures can provide a form-fitting cavity for the male ferrule and any sleeve or fitting on the male ferrule.

[0013] In embodiments, components of the launch connector are assembled together with minimal or no soldering, glue, adhesive, or separate fasteners. In embodiments, all externally facing components, the forward plug portion, the handle portion, and the stress relief member can be assembled without soldering, glue, adhesive, or separate fasteners, and held together by polymer features on these components.

[0014] In embodiments, clamshell halves that define the handle portion and the body portion of the launch connector housing are held together by snap-together features on the polymer clamshell halves, and the optical connection portion and plug are held in the housing by matching features molded into the polymer clamshell halves. In embodiments, the housing of the launch connector includes a polymer handle portion molded as a single unitary component and a polymer forward plug portion molded as a single unitary component. The launch connector is rotationally assembled by virtue of mating threaded connection portions, one unitary handle portion, and one unitary forward plug portion. The threaded connection portions are hidden when assembled. In embodiments, an O-ring is located at the junction between the plug portion and the handle portion, which is compressed when making a connection, providing external pressure on the respective plug and handle portions of the housing, resisting any disconnecting torque and providing a gas-tight seal. In embodiments, the O-ring is compressed at an angle to the axis of the plug portion, the acute angle of the respective axis being greater than 20 degrees and less than 70 degrees. In embodiments, the polymer plug portion and polymer handle portion of the housing can be snap-fit assembled together by pushing them axially together, where mating features on the connection portions of the components are mated.

[0015] In embodiments, the launch connector has a polymeric housing defined by a nose or plug portion and a grip or handle portion, the plug portion defining a mechanical connection portion of the launch connector. The optical connection portion has a rigid, male ferrule component that is flexibly centered, the rigid, male ferrule component being connected to an optical fiber and flexibly centered by a support formed of an elastomeric material body, the support being positioned rearward of the rigid, male ferrule component and engaging and / or capturing a rearmost portion of the rigid, male ferrule component. In embodiments, none of the rigid, male ferrule portions of the optical connection portion extend rearward of the elastomeric support. In embodiments, the flexibly centered, male ferrule component extends forward from and is suspended from the elastomeric support. In embodiments, the elastomeric support is a cup-shaped member having a central opening for the optical fiber. In embodiments, the elastomeric support is block-shaped, having two separable portions that grip or clamp onto the optical fiber extending through the two separable portions. In embodiments, when the launch connector is connected to a laser energy generator at the female coupling portion, the elastomeric support is primarily deflected in the axial direction and thus primarily compressed.

[0016] In embodiments, when the launch connector is not connected to the receiving connector, any covering on the optical fiber and tension on the fiber can provide a compression condition of the sleeve and elastomeric material body.

[0017] In embodiments, the optical fiber and any covering on the fiber are flexibly and elastically connected to the body portion by means of the elastomeric material body, which also engages and supports the male ferrule portions of the optical connection portion.

[0018] In embodiments, the optical cable has a jacket that engages the rearward end of the body portion at spaced-apart, discrete attachment areas.

[0019] In embodiments, the male ferrule has a degree of freedom of movement provided by the flexibility of the optical cable forward of the anchoring location. The ferrule can be constrained in the lateral direction by a structure within the body portion or a portion of the body portion, such as by a tubular portion of the body portion, limiting the degree of freedom of movement in the lateral direction. Such a structure provides a circumferential gap around the ferrule over the entire length of the ferrule when the ferrule is centered in the axial direction within the tubular portion. In embodiments, an elastomeric material body can be attached to a rearward end portion of the male ferrule for controlling the degree of freedom of movement in the radial or lateral direction, which does provide some resistance to lateral movement beyond that provided by the optical fiber or optical cable.

[0020] In embodiments, the male ferrule has freedom of movement provided by the flexibility of the optical cable forward of the anchoring location and the engagement of the rearward portion of the optical connection portion with the elastomeric member. In embodiments, the optical connection portion can be a ferrule or a ferrule seated in a sleeve. The ferrule can also be constrained laterally and axially by structures within the body portion or a portion of the body portion, such as a tubular portion of the body portion, thereby limiting the lateral freedom of movement of the optical connection portion. Such structures provide a circumferential gap around the ferrule over its entire length when the ferrule is centered axially within the tubular portion. In embodiments, an elastomeric material body can be attached to the rearward end portion of the male ferrule, thereby controlling the radial or lateral freedom of movement, which does provide some resistance to lateral movement beyond that provided by the optical fiber or optical cable.

[0021] In embodiments, the ferrule has a registration surface, such as an outer cylindrical surface, that registers with a mating inward facing cylindrical surface on a female ferrule of the receiving connector, while the female ferrule does not have an axial stop for the male ferrule in the optical registration receiver. The male ferrule is slidingly received within the inward facing cylindrical surface of the female ferrule, with the only contact of the mating ferrules being between the respective cylindrical surfaces. The inventors have found that laser energy focused at the forward face of the male ferrule, particularly at the fiber end face, can create a substantial amount of excess heat that is advantageously controlled. The interface of the respective cylindrical surfaces of the male ferrule and the female ferrule can not be sufficient to manage and provide adequate heat transfer away from the male ferrule. The inventors have further found that managing the dissipation of heat from the laser energy focused at the forward face of the male ferrule, preferably by transferring and dissipating the heat through the medical device connector on the laser energy generator, provides a heat dissipation capacity that is substantially greater than that of the launch connector and the attached optical cable. The receiving connector and associated structures are better suited for dissipating the excess heat of the launch connector and the optical fiber cable to the medical device. The inventors have found that axially facing surfaces, particularly surfaces that are pushed together under compression, are more effective at transferring heat from the launch connector to the receiving connector than are the sliding cylindrical surfaces of the male ferrule and the female ferrule.

[0022] Features and advantages of embodiments are a launch connector with a male ferrule that engages a receiving connector on a laser energy generator by virtue of a sliding engagement of an outer cylindrical surface of the male ferrule with an inward facing cylindrical surface of a female ferrule. Laser energy is focused on a front side of the male ferrule, thereby heating the male ferrule. A tubular sleeve surrounds the male ferrule and has a forward facing annular front surface that is perpendicular to a connector axis that engages a mating annular surface on the receiving connector. In embodiments, the mating annular surface is an annular surface of the female ferrule. In embodiments, the forward facing annular surface of the sleeve that supports the male ferrule is compressively engaged with the mating annular surface of the female ferrule by virtue of compression of a resilient portion rearward of a front face of the male ferrule. In embodiments, the resilient portion is a body of elastomeric material positioned between the tubular sleeve and a main body of the launch connector. In embodiments, the body of elastomeric material is configured as an annular member. In embodiments, the body of elastomeric material is one or more blocks that engage a rearward end of the tubular sleeve.

[0023] In embodiments, a launch connector connects to a receiving connector on a laser energy generator, where a heat transfer path extends from the male ferrule through an annular heat transfer member that is internal to a grip portion of the launch connector and that engages an annular engagement member of the receiving connector, the laser energy generator providing a heat sink for heat energy transferred from the male ferrule. In embodiments, a resilient member provides for rearward axial displacement of the annular heat transfer member and provides for forward bias, thereby providing compressive engagement with the annular engagement member of the receiving connector when connected.

[0024] Traditional fiber optic connector technology relies on an axial stop surface that engages a forward facing face of a male ferrule. In the context of a launch connector, this complicates engagement of the male ferrule with a female ferrule. In embodiments, a forward most front end of a male ferrule does not engage any stop surface. A shoulder rearward of the forward most front end can engage an annular surface of a female ferrule when a connection is completed. Engagement of the shoulder with the annular surface provides a heat sink path for heat generated by laser beam energy focused on a forward facing face of an optical fiber in the male ferrule.

[0025] In embodiments of the invention, when a ferrule is engaged with a portion of a connector of a medical device, an optical fiber rearward of the ferrule is secured to an elastomeric support member that provides for axial cushioning and / or resilience. The securing of the optical fiber relative to a launch connector main body can be in an elastomeric disk that defines a septum.

[0026] In embodiments of the application, the ferrule is slidingly received in a bore of an optical registration receiver, which can have a tapered concave registration surface and a cylindrical registration surface, and the male ferrule has a mating outer convexly tapered outer surface and a cylindrical registration surface to closely engage the cylindrical registration surface of the optical registration receiver.

[0027] In embodiments of the application, the outer tubular portion of the launch connector engages a mechanical registration receiver attached to a receiving coupling device of, for example, a laser energy generator. The front edge of the outer tubular portion and / or the outermost edge of the mechanical registration receiver can be tapered to provide for insertion tolerance.

[0028] It is a feature and advantage of embodiments of the application to have a single fiber launch connector with an inner movable ferrule that is positionally fixed by means of only the single optical fiber, any jacket on the optical fiber, and the elastomeric body. The ferrule is positionally constrained but not positionally fixed by being partially positioned in a bore of the inner tubular portion of the launch connector. It is an advantage and feature of embodiments to not use metal springs and coil springs in positioning the male ferrule in the launch connector, and the resilience and flexibility of the positioning of the male ferrule (and any sleeve on the male ferrule) is provided by the elastomeric body and / or the optical fiber cable (and any jacket on the optical fiber cable). In such embodiments, the flexibility of the male ferrule in the launch connector is believed to be more easily controlled, assembly and manufacturing is believed to be easier, and the complexity of components is less due to the use of the elastomeric body rather than the use of metal springs and / or coil springs.

[0029] In embodiments, the start connector is assembled by opening one of the two clamshell halves of the housing, with a portion of the elastomeric material body positioned in the one of the two clamshell halves, positioned behind the receiving area of the male ferrule or the combination of the male ferrule and the sleeve; placing the male ferrule or the combination of the male ferrule and the sleeve into the one of the two clamshell halves, with the optical fiber (and any jacket on the optical fiber) extending from the male ferrule or the combination of the male ferrule and the sleeve placed on the surface of the portion of the elastomeric material body, and with the rearward end positioned at the forward surface of the portion of the elastomeric material body, and placing the male ferrule or the combination of the male ferrule and the sleeve in the defined cavity for receiving the male ferrule or the combination of the male ferrule and the sleeve; and closing the one of the two clamshell halves onto the other of the two clamshell halves, and securing the two clamshell halves together. Other can have a second portion of the elastomeric material body, so that when the two clamshell halves are assembled together, the optical fiber and any jacket on the optical fiber are sandwiched or otherwise secured or constrained between the first portion and the second portion of the elastomeric material body. In embodiments, the two portions of the elastomeric material body can define two webs at the forward facing portion of the elastomeric material body, the two webs supporting the optical fiber and any jacket on the optical fiber.

[0030] Embodiments of the present invention feature and advantage optical fiber start connectors with a single optical fiber, the optical fiber start connector having an inner movable ferrule that is secured to only the single optical fiber and optionally to a jacket on the optical fiber. The ferrule is constrained in position by being partially positioned in a bore of an inner tubular portion of the start connector, but is not fixed in position.

[0031] Embodiments of the present invention feature and advantage optical fiber coupling devices with mating connectors, one connector being a start connector with a ferrule that supports an optical fiber having an optical fiber end face, the other connector receiving the one connector and having an optically registered receiver that receives the ferrule. Each connector has an optical connection portion of the connector that is recessed from an exterior of the connector.

[0032] In embodiments, an optical connection portion including a ferrule is held in a launch connector housing, with the aid of an optical fiber extending rearward from the optical connection portion, the optical fiber being clamped by an elastomeric block rearward of the optical connection portion, a rearward facing end of the optical connection portion facing a forward facing surface of the elastomeric block. In embodiments, the optical fiber is under tension, and the elastomeric block is compressively loaded by the rearward facing end of the optical connection portion. In embodiments, the optical connection portion includes a glass or ceramic ferrule seated in a metal sleeve, the metal sleeve providing a rearward facing engagement end that is circular, the circular rearward facing engagement end engaging and compressing the elastomeric sleeve. In embodiments, the optical connection portion includes a stainless steel ferrule. In embodiments, the clamping of the optical fiber in the elastomeric block allows for axial flexibility of the optical fiber and axial flexibility of the optical connection portion. In embodiments, the optical fiber extends centrally through the elastomeric block, the elastomeric block being formed of two separable block portions. The optical fiber is clamped between the two separable block portions, with an interference fit between the optical fiber and the block portions.

[0033] In embodiments, an optical connection portion of a launch connector has a forward cylindrical portion, an intermediate cylindrical portion that is larger in diameter than the forward cylindrical portion, and a rearward cylindrical portion that is smaller in diameter than the intermediate cylindrical portion. The forward cylindrical portion has a central axial bore that is sized to mate with an optical fiber, and the optical fiber is secured in the central axial bore, and the optical fiber has an end exposed at a forward end of the optical fiber. In embodiments, the forward cylindrical portion is equal in diameter to the rearward cylindrical portion. In embodiments, a housing of the launch connector provides an internal cavity that is shaped to match the three cylindrical portions of the optical connection portion of the launch connector. In embodiments, the three cylindrical portions are provided by a glass or ceramic cylindrical ferrule extending from a stainless steel fitting, the stainless steel fitting providing the intermediate cylindrical portion and the rearward cylindrical portion, and the glass or ceramic cylindrical ferrule providing the forward cylindrical portion. In embodiments, the three cylindrical portions are provided by a one-piece stainless steel ferrule. In embodiments, the ferrule can be of other compositions, such as ceramic materials.

[0034] In embodiments, a pair of mating connectors are used to connect a laser source to a medical device for delivery of laser energy, each connector having an outer mechanical coupling portion and an inner optical coupling portion, each of the outer mechanical coupling portions is configured as an outer tubular portion having a forward edge, each outer tubular portion has a tubular wall and defines a respective axial recess, the optical coupling portion is positioned concentrically within the axial recess and spaced apart from the tubular wall, the optical coupling portion is inserted from the respective forward edge. In embodiments, one connector provides an optical cable having an optical fiber connected to a ferrule and presenting an optical fiber end face. The ferrule has a central location, the ferrule is housed within a female portion of an optical registration receiver. In embodiments, one of the tubular mechanical coupling portions is interleaved between the tubular mechanical coupling portion of the other coupling device and the optical coupling portion of the other coupling device. The tubular mechanical coupling portions slidingly engage one another. In embodiments, the connector that supplies laser energy to the medical device (the launch connector) has its outer tubular portion that extends within the outer tubular portion of the connector associated with the medical device. In embodiments, when the connectors are manually manipulated, the outer mechanical coupling devices first engage and axially align the connectors, as the outer mechanical coupling devices slidingly engage and come together, the connectors become axially aligned before the optical coupling portions engage one another. The optical coupling portions are then pre-aligned and the optical coupling devices enter into a final operational alignment when the optical coupling portions engage tapered surfaces on one or both optical coupling portions. In embodiments, one optical coupling portion is able to move laterally relative to its respective mechanical coupling portion. BRIEF DESCRIPTION OF DRAWINGS

[0035] Figure 1 is a perspective view of a delivery system according to the present application with the launch connector disconnected from the connector on the laser energy generator.

[0036] Figure 2 is a perspective view of the launch connector of Figure 1 connected to the laser energy generator.

[0037] Figure 3 is a cross-sectional view of a coupling device according to embodiments including a launch connector and a receiving connector.

[0038] Figure 4 is a cross-sectional view of the coupling device of Figure 3 in an uncoupled state.

[0039] Figure 5 is an enlarged detail of a cross-section of Figure 3 .

[0040] Figure 6 is an exploded view of the launch connector of Figure 3 .

[0041] Figure 7 This is a perspective view of another embodiment of the start connector.

[0042] Figure 8 yes Figure 7 Exploded view of the starter connector.

[0043] Figure 9 yes Figure 7 Another exploded view of the starter connector.

[0044] Figure 10 yes Figure 7 A cross-sectional view of the starter connector.

[0045] Figure 11 This is a perspective view of another starter connector according to an embodiment.

[0046] Figure 12 yes Figure 11 A cross-sectional view of the start connector together with the concave ferrule that receives the convex ferrule of the start connector.

[0047] Figure 13A yes Figure 11 Exploded view of the starter connector.

[0048] Figure 13B yes Figure 11 Exploded view of the starter connector.

[0049] Figure 14A and Figure 14B yes Figure 11 A perspective view of the front nose portion of the connector.

[0050] Figure 14C yes Figure 14A and Figure 14B A cross-sectional view of the nose-shaped portion.

[0051] Figure 15A and Figure 15B yes Figure 11 A perspective view of the main body or housing of the starter connector.

[0052] Figure 15C yes Figure 15A and Figure 15B A cross-sectional view of the shell.

[0053] Figure 16A and Figure 16B yes Figure 1 A perspective view of the convex ferrule of the starter connector.

[0054] Figure 16C yes Figure 16A and Figure 16B A cross-sectional view of the convex insert.

[0055] Figure 16D is a front end view of the male core. Figures 16A to 16C

[0056] Figure 17A and Figure 17B is a perspective view of a block of elastomeric material configured as a bushing and serving as an elastomeric support.

[0057] Figure 17C is a cross-sectional view of the elastomeric support of Figure 17A and Figure 17B .

[0058] Figure 18A and Figure 18B is a perspective view of a retainer for the elastomeric support of Figure 17C .

[0059] Figure 18C is a cross-sectional view of the retainer of Figure 18A and Figure 18B . DETAILED DESCRIPTION

[0060] With reference to Figure 1 and Figure 2 , the laser energy delivery system 20 includes an optical fiber cable 22 and a launch connector 24. The launch connector 24 and the connector 28 define a fiber optic coupling 32 for providing laser radiation from a laser radiation source 30 to a medical device 34.

[0061] With reference to Figure 3 , Figure 4 , Figure 5 and Figure 6 ​The coupling device 600 includes an activation connector 602 and a medical device connector 604 that receives the activation connector and is part of a laser energy generator 607. The activation connector includes an optical connection portion 610 and a mechanical connection portion 612. The mechanical connection portion of the activation connector includes a body portion 614 with a forward projecting tubular portion 616 having a tubular wall portion 618 with an interior wall surface 620, an exterior wall surface 622, and a forward annular stop surface 623. The optical connection portion includes an optical connection component 624 having a male ferrule 630 and an optical fiber wire 632 extending from the male ferrule 630. The male ferrule has a forward portion 633, a forward face 634, a rearward portion 636, a cylindrical surface 638, and a rear end 640 from which the optical fiber wire 632 extends. An optical fiber end face 642 is exposed at the forward face of the male ferrule. The optical connection component 624 can also include a rigid fitting 650 configured as a sleeve within which the male ferrule 630 is secured. The sleeve can be formed of a high thermal conductivity material such as stainless steel, other materials and metals can also be suitable. The sleeve has a forward edge 656, a forward tubular portion 658, a middle tubular portion 660, and a rearward tubular portion 662. The middle tubular portion has a greater diameter than the forward and rearward tubular portions and includes a forward stop surface 670 and a rearward stop surface 672 that face corresponding forward and rearward stop surfaces 674 and 676 on the tubular wall portion 618. The body portion 614 defines a cavity 677 that mates with the male ferrule 630 and the attached sleeve 650, providing a limited amount of freedom of movement of the sleeve and ferrule. The sleeve can be joined and supported by an elastomeric material body 678 configured as a block 679. The block can have a corresponding block portion 679.1 that can be configured as a half, as shown in Figure 11 FIG. 6A, for attachment around the optical fiber wire. The block portion 679.1 can also have a cavity 679.3 that provides webbing 679.5 at the forward end of the elastomeric material body 678. The optical fiber wire can be further anchored at the tail 679.6 of the body portion, such as by an elongated grommet 679.7 configured as a strain relief member.

[0062] The receiving connector 604 includes an optical connection portion 680 and a mechanical connection portion 682. The optical connection portion has a female ferrule 683 with an inward facing cylindrical surface 684 that mates with the outer cylindrical surface 638 of the male ferrule. The laser energy generator 607 provides a focused energy beam 640 from the lens 642 on the fiber end face 642 of the male ferrule.

[0063] The mechanical connection portion receives the forwardly projecting tubular portion 616 or nose portion of the launch connector in a recess 686 defined by the laser energy generator connector housing 687.

[0064] The heat generated on the male ferrule by the focused energy beam can be dissipated by means of a heat path 690 indicated by the arrows that extends from the male ferrule to the sleeve, to the outward annular face 692 of the female ferrule 683, to the housing 695 or other structure of the laser energy generator 607. The housing 687 or other structure of the laser energy generator connector serves as an important heat sink for dissipating heat from the male ferrule. The heat capacity, i.e. the ability of the sleeve, particularly when the sleeve is formed of a metal such as steel, is significantly greater than a polymer, for example, that can be used for the body portion of the launch connector.

[0065] When the connection is made, and the sleeve pushes the resilient member rearwardly, the resilience of the resilient member can provide a compressive force of the forward annular face of the sleeve on the outward annular face of the female ferrule. This compressive force contributes to an enhanced thermal connection between the respective components. In other embodiments, the heat flow path can be through other structures than the female ferrule.

[0066] Reference Figures 7 to 10 In embodiments, the launch connector 700 has a housing 701 configured as a body portion 702, with a grip portion 704, a tail portion 706, a forward flange 708, and a nose portion 710 that projects forwardly from the grip portion 704 for insertion into a receiving connector of a laser radiation source as previously described. An optical connection portion including a male ferrule 711 is compliantly positioned within the body portion at the nose portion. In other embodiments, a cylindrical male ferrule can be seated in a fitting as previously illustrated.

[0067] As Figures 8 to 10As best illustrated, in embodiments, the body portion can comprise three outer components and an inner component. Specifically, the grip portion and flange can be formed by two clamshell pieces (clip shells) 712, 714 configured as a housing 715 having an outer wall 715.5 defining an open interior 717. The clamshell pieces, when assembled, capture a rear flange 718 at a rear end 719 of a nose piece 720 within an annular recess 716 that is also part of the housing 715. An O-ring 726 in an O-ring groove 728 of the nose piece 720 can provide a seal to the housing, as well as improved tightness and security in the connection 729 between the nose piece and the two clamshell pieces. Thus, the nose piece 720 and the two clamshell pieces 712, 714 are the externally exposed components of the housing. An optical fiber wire 732 extends through the open interior 717 and through an inner component of the body portion configured as a rigid bushing 733. This bushing 733 is captured between the rear end 719 of the nose piece and the two clamshell pieces by means of stop portions 734, 735 configured as wall portions integral with the clamshell pieces. The wall portions 734, 735 and the nose piece 720 define a slot 740 for reception and seating of the bushing. The rigid bushing 733 is radially centered and has a central hole 742 for the optical fiber wire 732 and a forward facing central bushing recess 743 defined by a bushing annular wall 744 for receiving a resilient body member configured as a resilient and compliant bushing or block 745. The bushing can have a rearward extension 733.2 that can be used to position an RFID tag 745.6 within the housing. In embodiments, the housing components and the rigid bushing can be formed of injection molded polymer.

[0068] Reference is made to Figure 10, the optical fiber line extends into the male ferrule 711 and has an exposed end face 750 at a forward end 752 of the ferrule. The male ferrule can be formed of stainless steel or other material. The forward end can have a recess referred to as a power sink 753 so that laser radiation that overfills the forward end face of the optical fiber will be defocused upon impinging the ferrule. The forward end has a lead-in tapered portion 754 having an outer surface 755 and a first forward cylindrical portion 758 having a cylindrical outer surface 759 of a first radius r1. Another second forward cylindrical portion 764 having a cylindrical outer surface 765 and a second radius r2 extends rearwardly from the first forward cylindrical portion and an intermediate or third cylindrical portion 768 having a cylindrical outer surface 767 and a third radius r3 is located rearwardly of the second forward cylindrical portion. A rearward cylindrical portion 770 having a cylindrical outer surface 771 is contiguous with the third cylindrical portion and is rearward or has a fourth radius r4. In embodiments, the second radius r2 is greater than the first radius r1, the third radius r3 is greater than the second radius r2 and also greater than the fourth radius r4. In embodiments, the fourth radius r4 can be equal to the second radius r2. The intermediate or third cylindrical portion 768 defines an intermediate cylindrical band 776 having a forward stop surface 777 and a rearward stop surface 778. The ferrule is constrained axially and radially within a ferrule cavity 780 defined by an inner wall surface 782 of the nosepiece and an inner surface 783 of the bushing 733. The ferrule cavity has a mating portion that matches the shape of the ferrule. An internal shoulder 785 on the nosepiece wall provides an axial stop for constraining the male ferrule. The inward facing cylindrical surface 782 of the nosepiece that defines the ferrule cavity provides a radial or lateral stop surface. The male ferrule is configured substantially similar to the male ferrule and rigid sleeve of the embodiments of Figures 3 to 6 . This embodiment of the launch connector 602 will also interface with the connector and female ferrule of the laser energy generator, such as illustrated in Figure 3 and Figure 4 . Figure 3 and Figure 4 The thermal management of the embodiments of

[0069] With continued reference to Figure 10In embodiments, the first radius can be 0.055 inches to 0.070 inches. The second radius can be 0.090 inches to 0.110 inches, and the third radius can be 0.110 inches to 0.125 inches, and the fourth radius can be 0.090 inches to 0.110 inches. In embodiments, the difference in the radius measurement between the second radius and the third radius is from 0.015 inches to 0.020 inches. In embodiments, the difference in the radius measurement between the fourth radius and the third radius is from 0.015 inches to 0.020 inches. In embodiments, there is a minimum gap of 0.005 inches to 0.020 inches between the outer surfaces of the ferrule or ferrules in the ferrule or ferrules when centered in the form-fitting cavity of the body portion, all measured in the radial direction around the ferrule or ferrules in the ferrule or ferrules.

[0070] The fiber optic wire can be conventionally secured within the rear recess of the male ferrule with epoxy 788 or similar. The elastomeric block 745 can have two portions 745.1, 745.2 configured as halves as shown in Figure 8 and Figure 9 The two portions 745.1, 745.2 grip around the fiber optic wire. An axial groove 790 can be in one or both portions. In embodiments, the groove is undersized relative to the fiber optic wire. Further, the elastomeric portions can be slightly oversized relative to the sleeve recess in size, such that when the two elastomeric block halves are clamped around the fiber optic wire and inserted into the sleeve recess, there is an interference fit with respect to the fiber optic wire and the block halves, and with respect to the block halves and the sleeve, such that the block halves are compressed and grip around the fiber optic wire, thereby clamping the fiber optic wire and holding it in place. Due to the flexible resilience of the elastomeric block material, the joint still allows some forward and backward movement of the fiber optic wire 732 relative to the housing, which movement will be primarily in the axial direction. A central circumferential recess 745.8 around the elastomeric block can enhance the freedom of movement forward and backward of the fiber optic wire when clamped in the block, i.e., increase flexibility. As such, the block acts as an elastomeric clamp on the fiber optic wire. Further, when the block halves are clamped around the fiber optic wire, the optical connection portion including the male ferrule or male ferrule seated in a rigid sleeve fitting can be pulled to the forward facing surface of the elastomeric block in order to contact or slightly press the elastomeric block at the forward face of the block. This provides centering of the optical connection portion, with the rearward portion of the mating ferrule or ferrule spaced and distributed radially around the forward exit point of the fiber optic wire of the elastomeric block. In embodiments, the forward face can be form-fitted to the rearward end of the ferrule or ferrule. In embodiments, the fiber optic wire can be under slight tension between the optical connection portion and the elastomeric block, pulling the optical connection portion into the elastomeric block and deflecting the elastomeric block, thereby providing a more secure centering of the optical connection portion.

[0071] Referring to Figures 11 to 13B , another embodiment of a launch connector 800 is illustrated as having a housing 801 with a gripping portion 804, a forward flange 808, and a plug portion or forward nose portion 810 extending forward from the forward flange for plugging into a laser energy generator, such as Figures 1 to 5 The tail portion is configured as a strain relief member 811 that secures the fiber cable 812.

[0072] Referring to Figures 12 to 13B , the connector 800 generally includes a mechanical connection portion 813 formed by the housing, particularly the plug portion 810 and the forward flange 808, and also includes an optical connection portion 814 formed by the male ferrule 816, an elastomeric support 818 that captures a rearward end 820 of the male ferrule 816, and a retainer 824 for securing the elastomeric support relative to the housing 801. The assembled components of the housing 801 are the nose portion 810 and the gripping portion 804, each of which has a mating rotational attachment portion 826, 828, illustrated as having threads 830, allowing for the joining of the components by partial rotation. An O-ring 833 can be positioned in a joint 834 between the plug portion 810 and the gripping portion. The gripping portion can have an O-ring engagement surface 835 that is angled relative to the axis a1 of the launch connector. An O-ring is seated in an annular groove 836 of a flange portion 838 of the nose portion 810. This angled surface allows for a full locking rotation of the mating threaded components such that distally located annular stop surfaces 841, 842 on the respective components abut one another, providing a tight joint. In addition, the O-ring provides an expansion or separation force between the joined components at the joint that is considered effective to lock the components together such that they will not inadvertently separate. The O-ring also provides an air-tight seal at the joint 834.

[0073] The elastomeric support 818 can be configured as a cup-shaped bushing having a central aperture 844 for the optical fiber 812 and is U-shaped in cross-section, as illustrated in Figure 12As shown, the rearward end of the male ferrule is seated in the recess. The support 818 is seated in an annular recess 846 at the rearward end 847 of the nose portion 810, and the forwardmost and forward-facing annular surface 847.5 of the forwardly extending annular wall 847.7 of the elastomeric support 818 abuts an interior shoulder 848 of the nose portion, which interior shoulder 848 has a rearward-facing annular shoulder surface 849 that is perpendicular to the axis a1. The support can be compressed by a retainer 853 that is shaped as a disc with radial slots 854 that facilitate assembly, allowing the retainer to slide over the optical fiber 812 during assembly. The retainer has a peripheral flange that sits between and is clamped between the respective annular engagement surfaces 857, 858 of the grip portion 804 and the nose portion 810. Advantageously, the forwardmost and forward-facing annular surface 847.5 of the elastomeric support also engages the male ferrule at a rearward shoulder 860 at a rearward-facing annular surface 861. This provides a "soft" elastic and flexible axial positioning of the male ferrule within the interior of the housing, which is shaped to match the male ferrule. In addition, the interior base seating surface 863 of the base 864 of the elastomeric support can also engage a rearward-facing rearmost surface of the male ferrule 816, providing further elastic and flexible axial positioning of the male ferrule.

[0074] With continued reference to Figures 11 to 18C As in the previous embodiments, the male ferrule can have a forward-facing shoulder 867 having a forward-facing annular face or surface 868. The forward-facing shoulder 867 faces a rearward-facing interior shoulder 870 of the nose portion, providing a shape of the wall of the nose portion that matches the shape of the male ferrule, with a circumferential gap 872 and an axial gap 873 at the forward-facing shoulder of the male ferrule. As Figure 12 As best shown, the forward-facing face 868 of the male ferrule cooperates with an annular face 879 of the female ferrule 880, providing a path for heat generated at the forward end of the male ferrule when laser energy is focused on the forward end of the male ferrule.

[0075] With particular reference to Figure 16C The optical connection component 890 is configured as a unitary male ferrule. A first or forward cylindrical portion 891 has a first diameter D1, and a second or intermediate cylindrical portion 892 has a second diameter D2 that is greater than the first diameter. A third cylindrical portion, which is also a second intermediate cylindrical portion 893, has a third diameter D3 that is greater than the first diameter and greater than the second diameter. A rearward or fourth cylindrical portion 894 has a rearward or fourth diameter D4 that is less than the diameter of the second intermediate cylindrical portion and greater than the diameter D1 of the forward cylindrical portion 891. In embodiments, the unitary optical connection component can comprise stainless steel.

[0076] In embodiments, the mechanical connection portion can be configured as a bayonet connection, a threaded connection, a press fit connection, or a detent connection. In embodiments, the elastomeric support can be replaced by other elastically flexible supports, for example, in some embodiments a helical spring configuration can be suitable.

[0077] For all purposes, the following U.S. patents / publications are incorporated by reference: 5,329,541; 5,337,386; 5,907,650; 5,943,460; 6,238,103; 7,503,701; 8,419,293; 8,888,378; 9,329,350; 9,393,081; 9,395,496; 9,429,713; 10,082,632; and US 2019 / 0094472.

[0078] The present invention is not limited to the details of the foregoing one or more embodiments. The present invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any reference incorporated by reference, any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process disclosed. For all purposes, the above references in all parts of this application are incorporated by reference in their entirety.

[0079] While the text has illustrated and described particular examples, it will be understood by those skilled in the art that any arrangement which is calculated to achieve the same purpose can be substituted for the specific examples shown. This application is intended to cover any adaptations or variations of the present subject matter. Therefore, it is intended that the application be defined by the following claims and their legal equivalents, as well as by the following descriptive aspects. The foregoing described aspects of the application are merely descriptive of its principles and are not to be considered limiting. Other modifications of the application will occur to those skilled in the art upon the reading of the disclosure and are intended to be within the scope of the application.

Claims

1. A fiber optic connector coupling device for connecting a source of laser radiation to a device, the coupling device comprising an activation connector including a body portion with an optical fiber extending into the body portion from a rearward end, the activation connector having a mechanical connection portion and an optical connection portion housed within the mechanical connection portion and including a male ferrule connected to the optical fiber, the optical fiber having a forwardly exposed end face at a forward end of the ferrule, a flexible elastomeric body engaging a rearward portion of the optical connection portion and attached to a rearward end portion of the male ferrule, the flexible elastomeric body anchored relative to the body portion whereby the male ferrule is flexibly positioned within the body portion of the activation connector by means of the elastomeric body, the flexible elastomeric body configured as an elastomeric block, wherein the body portion defines a slot for receiving the block portion, the elastomeric block clamping the optical fiber wire and having an interference fit with the optical fiber wire whereby the optical fiber wire is clamped in the elastomeric block, the elastomeric block providing axial flexibility to the optical fiber wire.

2. The fiber optic connector coupling device of claim 1, wherein, the ferrule is a cylinder having a diameter and is formed of one of a glass or ceramic material, and wherein the optical connection portion further includes a metal fitting having a forward tubular portion with a cylindrical outer surface having a diameter greater than the diameter of the ferrule, the ferrule seated in the forward tubular portion, a forwardmost edge of a metal sleeve displaced rearwardly from the forward end of the ferrule and providing a stop surface for the optical connection portion when connected.

3. The fiber optic connector coupling device of claim 1, wherein, the body portion has a forward nose having a tubular portion housing the optical connection portion, the optical connection portion being generally cylindrical with a central circumferential band, the forward nose having a cavity that shape fits the optical connection portion but has a gap between the optical connection portion and the nose whereby the optical connection has constrained movement in the nose.

4. The fiber optic connector coupling device of claim 1, wherein, an elastomeric material is located in the block, the optical fiber wire extending through the block.

5. The fiber optic connector coupling device of claim 4, wherein, the elastomeric block has two halves that clamp the optical fiber wire and have an interference fit with the optical fiber wire around the optical fiber wire.

6. The fiber optic connector coupling device of claim 4, wherein, the elastomeric block contacts a rearward end of the optical connection portion.

7. The fiber optic connector coupling device of claim 1, wherein, the body portion has a forward nose having a tubular portion housing the optical connection portion, the body portion having a gripping portion rearward of the nose, the nose having a flange seated in an annular groove of the gripping portion, the connector coupling device further including an O-ring positioned between the nose and the gripping portion.

8. A fiber optic connector coupling device for connecting a laser radiation source to a device, the fiber optic connector coupling device comprising a launch connector having a forward end, a rearward end and an axis, the launch connector comprising a body portion with an optical fiber extending into the body portion at the rearward end, the launch connector having a mechanical connection portion and an optical connection portion defined by the body portion, the optical connection portion being housed within the mechanical connection portion and comprising a male ferrule connected to the optical fiber, the optical fiber having a forwardly exposed end face at a forward end of the ferrule, a block of flexible elastomeric material positioned centrally within the body portion about the axis of the launch connector and abutting a rearward facing surface of the optical connection portion, and a rearward end portion of the male ferrule, wherein the fiber optic line being clamped within the elastomeric block providing axial flexibility to the fiber optic line, and the optical connection portion having a forwardly facing annular face rearwardly displaced from a forwardmost end of the male ferrule, the annular face providing a stop surface for the optical connection portion when the launch connector is connected.

9. The fiber optic connector coupling device of claim 8, wherein, the body portion having a forward nose with a tubular portion housing the optical connection portion, the optical connection portion being generally cylindrical with a central circumferential band, the forward nose having a cavity mating the shape of the optical connection portion but having a gap between the optical connection portion and the nose whereby the optical connection has constrained movement in the nose.

10. The fiber optic connector coupling device of claim 8, wherein, the body portion having a forward nose with a tubular portion housing the optical connection portion, the body portion having a gripping portion rearward of the nose, the nose having a flange seated in an annular groove of the gripping portion, the connector coupling device further comprising an O-ring positioned between the nose and the gripping portion.

11. A laser energy coupling device comprising a launch connector with a fiber optic line extending to an optical connection portion housed within a mechanical connection portion, the launch connector having an axis, the optical connection portion comprising a male ferrule within a cavity defined by a body portion, the optical connection portion being axially rearwardly movable within the body portion and having a flexible stop provided by an engagement of the optical connection portion with an elastomeric block positioned rearward of the optical connection portion about the axis and attached to a rearward end portion of the male ferrule, wherein the male ferrule and sleeve being resiliently forwardly and rearwardly movable by resiliency when the launch connector is not connected to a receiving connector, the resiliency being provided by the fiber optic line being clamped within the elastomeric pad, the optical connection portion having a forwardly facing annular face positioned rearward of a forward end of the male ferrule, and the annular face providing a stop surface when the launch connector is connected to a receiving connector of the coupling device.

12. The laser energy coupling device of claim 11, wherein, The body portion defines a housing having a cavity that is oversized relative to the optical portion, thereby constraining the optical portion within the housing while allowing radial, forward and rearward movement of the optical connection portion.

13. The laser energy coupling device of claim 11, wherein, Engagement of the optical connection portion is achieved by contact of a rearward facing surface of the optical connection portion with the elastomeric block.

14. The laser energy coupling device of claim 13, wherein, The rearward facing surface of the optical connection portion is held against the elastomeric block by tension in the optical fiber line.

15. The laser energy coupling device of claim 11, wherein, The body portion has a forward nose having a tubular portion that houses the optical connection portion, the optical connection portion being generally cylindrical with a central circumferential band, the forward nose having a cavity that mates with the shape of the optical connection portion but has a gap between the optical connection portion and the nose, whereby the optical connection has constrained movement in the nose.

16. The laser energy coupling device of claim 11, wherein, The body portion has a forward nose having a tubular portion that houses the optical connection portion, the body portion having a gripping portion rearward of the nose, the gripping portion including two clamshell portions, the nose having a flange that is seated in an annular groove of the gripping portion, the laser energy coupling device further including an O-ring that is positioned between the nose and the gripping portion.

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