Fiber Optic Cable Connectors

Abstract

A laser light energy coupling with a male launch connector. The male launch connector has a body portion with an optical fiber line terminating in an optical connecting element including a male ferrule. The optical connecting element is elongated and generally cylindrical with a central circumferential band. The body portion conforms around the optical connecting element and defines spaced apart cavities. An elastomeric support engaging the optical connecting element provides compatibility when coupling occurs and provides centering before coupling occurs. The elastomeric support is located rearward of the optical connecting element. The elastomeric support can clamp the optical fiber line therein. A rearwardly displaced, forward-facing annular surface of the forward-most portion of the male ferrule provides a stop surface when coupling occurs and provides a heat transfer means to dissipate heat from the male ferrule into the receiving coupling.

Description

[Technical field]

[0001] Related Applications 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 of which are incorporated herein by reference.

[0002] This application is related to commonly owned US Patent Nos. 5,399,623 and 5,443,363, which are incorporated herein by reference for all purposes. [Background technology]

[0003] 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 having optical and mechanical connections.

[0004] Connectors are a critical component of the delivery system. The size of fiber optic connectors has generally decreased over time due to the desire to increase the density of connectors on communication devices, i.e., more connectors per square inch of device space. Common connectors for medical purposes include micro-modified optical connectors developed for communication devices, such as SMA-905 or SMA-906 modified connectors with forward-projecting ferrules with exposed fiber facets. Such connectors are small in size and have small mating parts, specifically, a ferrule that secures the optical fiber and the cooperating female part. The small size of the graspable part requires delicate manipulation to connect the optical fiber to the medical device. The small size of the connector does not lend itself to handling with gloves or to quick connection. Also, because the input fiber facet is exposed and defines the farthest part of the connector, the facet is easily contaminated or damaged during mating with the medical device connector on the laser energy generator. Any issues related to the integrity of the connection between the laser source and the medical device can affect the performance of the medical device and potentially the medical procedure.

[0005] In medical laser applications compared to telecommunications, the fibers and connections must efficiently pass much higher power levels. If there is even a slight misalignment of the optical connection, there can be excessive heating at the connection and loss of power to the medical device. Excessive heating can damage the connector, especially if there are insufficient thermal management measures associated with the connector.

[0006] In most conventional fiber optic connectors for laser applications, the optical connection portion is essentially fixed within the mechanical connection portion. In communications applications where alignment of the optical connection portion is not critical, this fixed relationship between the optical connection portion and the mechanical connection portion is sufficient. This is due in part to the low power handling requirements of such communications connectors. Thermal management is not a critical factor, and slight misalignment is not a significant issue. Fiber optic connectors in laser communications applications typically connect one optical fiber to another, with one optical fiber face facing the other in such connections. Thus, proper alignment between the optical connection portions of the cooperating connectors is relatively simple, and fixing the optical connection portion to the mechanical connection portion is not a significant issue.

[0007] Contrast this with launch connectors in laser medical devices, where there are high criticalities associated with alignment and in some cases thermal management. In a typical laser energy generator for a medical device, the launch connector that interfaces with the laser energy generator has an internal exposed optical fiber face that must be aligned with the cone-shaped focused laser beam at the laser generator connection. Any misalignment can result in energy loss and excessive heating at the connector. [Prior art documents] [Patent documents]

[0008] [Patent Document 1] U.S. Patent No. 10,082,632 [Patent Document 2] U.S. Pat. No. 1,066,3677 [Patent Document 3] U.S. Patent No. 5,329,541 [Patent Document 4] U.S. Pat. No. 5,337,386 [Patent Document 5] U.S. Patent No. 5,907,650 [Patent Document 6] U.S. Pat. No. 5,943,460 [Patent Document 7] U.S. Patent No. 6,238,103 [Patent Document 8] U.S. Patent No. 7,503,701 [Patent Document 9] U.S. Patent No. 8,419,293 [Patent Document 10] U.S. Patent No. 8,888,378 [Patent Document 11] U.S. Patent No. 9,329,350 [Patent Document 12] U.S. Patent No. 9,393,081 [Patent Document 13] U.S. Pat. No. 9,395,496 [Patent Document 14] U.S. Patent No. 9,429,713 [Patent Document 15] US Patent Application Publication No. 2019 / 0094472 Summary of the Invention [Problem to be solved by the invention]

[0009] There have been significant advances in launch connectors for medical devices that connect to laser energy generators. By separating and isolating the mechanical connection from the optical connection, and by resiliently floating the optical connection of the launch connector, e.g., a cylindrical male ferrule with a fiber optic face at the forward end, within the annular mechanical portion of the launch connector, it is possible to provide acceptable alignment when mated with a female ferrule with a cylindrical bore at the laser generator. See the present owner's U.S. Pat. No. 5,399,343, which is incorporated herein by reference for all purposes. The U.S. Pat. No. 5,399,343 patent discloses an embodiment in which the cylindrical male ferrule is supported within a uniform diameter bore of the housing only by the fiber optic cable. Another embodiment discloses that the cylindrical male ferrule is supported within a uniform diameter bore of the launch connector housing, with an elastomeric material disposed rearward of the male ferrule providing centering of the male ferrule. While these embodiments provide improvements over known launch connectors for medical applications, further improvements relating to easier manufacture, assembly, robustness, and thermal management would be welcome. [Means for solving the problem]

[0010] The delivery system extends from a laser radiation source for connection to a medical device that utilizes laser radiation for a medical treatment. The delivery system includes an optical cable with an optical fiber extending from the laser source, the male launch connector having a male ferrule on the optical cable. The launch connector mates with a receiving connector having a female ferrule that mates with the male ferrule on the medical device. The male launch connector has a body portion with an outer wall defining an interior and a tubular portion that projects forward at an outermost or forwardmost edge and has a central axial recess defined therein. The optical fiber terminates in a male ferrule disposed in the central recess aft of the forwardmost edge of the body portion, presenting a forward facing fiber facet. In an embodiment, when not connected to the receiving connector, the male ferrule is conformably disposed within the central recess. In an embodiment, when the launch connector is not connected, the male ferrule is conformably disposed by an elastomeric material that directly or indirectly supports the male ferrule relative to the body portion, and a circumferentially and axially extending conforming gap between the male ferrule in the central axial recess and a wall surface of the body portion provides a defined degree of freedom of movement in all radial directions and axial conformance of the male ferrule.

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

[0012] In an embodiment, the male ferrule, any sleeve or fitting thereon, and the optical fiber and any covering thereon are supported within the body portion only by a compliant material that provides centering and compatibility when not connected to a receiving connector. In an embodiment, the compatibility is in all directions. In an embodiment, movement of the ferrule is restricted by the body portion or other structure of the launch connector that contains the male ferrule and any sleeve or fitting thereon. The body portion or other structure may provide a form-fitting cavity for the male ferrule and any sleeve or fitting thereon.

[0013] In embodiments, the launch connector components are assembled together with minimal or no welding, glue, adhesives, or separate fasteners. In embodiments, all outwardly facing components, the forward plug portion, the handle portion, and the strain relief member are assembled without welding, glue, adhesives, or separate fasteners and are held together by polymeric features on the components.

[0014] In an embodiment, the clamshell halves of the body portion defining the handle portion and a portion of the launch connector housing are held by mating features on the polymer clamshell halves, and the optical connection portion and plug are held in the housing by mating features molded into the polymer clamshell halves. In an embodiment, the launch connector housing includes a polymer handle portion molded as a single integral piece, and a polymer forward plug portion molded as a single integral piece. The launch connector is rotationally assembled by cooperating threaded connection portions, one integral with the handle portion and one integral with the forward plug portion. When assembled, the threaded connection is concealed. In an embodiment, an O-ring is at the interface between the plug portion and the handle portion, and when the connection is made, the O-ring is compressed to provide an external pressure on the respective plug and handle portions of the housing to resist any disconnect torque and provide an airtight seal. In an embodiment, the O-ring is compressed at an angle relative to the axis of the plug portion, the acute angle of each axis measuring greater than 20 degrees and less than 70 degrees. In embodiments, the polymeric plug portion and polymeric handle portion of the housing can be snap-fit ​​assembled by pressing them axially together when cooperating features on the connecting portions of the components mate.

[0015] In an embodiment, the launch connector has a polymer housing defined by a nose or plug portion and a gripping or handle portion, the plug portion defining the mechanical connection portion of the launch connector. The optical connection portion has a compatible centering rigid male ferrule part that is connected to an optical fiber and is compatible centered by a support formed of an elastomeric material disposed rearwardly of the rigid male ferrule part and engaging and / or capturing the rearmost portion thereof. In an embodiment, none of the rigid male ferrule parts of the optical connection portion extend rearwardly of the elastomeric support. In an embodiment, the compatible centering male ferrule part extends forwardly from and is cantilevered therefrom. In an embodiment, the elastomeric support is a cup-shaped member with a central opening for the optical fiber. In an embodiment, the elastomeric support is block-shaped with two separable portions that grip or clamp the optical fiber extending therethrough. In an embodiment, when the launch connector is connected to a laser energy generator at the female coupling portion, the elastomeric support is primarily axially deflected and thereby primarily compressed.

[0016] In an embodiment, when the launch connector is not connected to the receiving connector, tension on the optical fiber and any covering thereon can provide compression of the sleeve with the elastomeric material.

[0017] In an embodiment, the optical fiber and any covering thereon are conformably and resiliently connected to the body portion by an elastomeric material that also engages and supports the male ferrule portion of the optical connection portion.

[0018] In an embodiment, the optical cable has a covering engaged with the rearward end of the body portion at spaced apart attachment areas.

[0019] In an embodiment, the male ferrule has freedom of movement provided by the flexibility of the optical cable forward of the anchor location. The ferrule may be laterally constrained by structure within or part of the body portion, such as the tubular portion of the body portion, thereby limiting its freedom of lateral movement. Such structure provides a circumferential gap around the ferrule throughout its entire length when the ferrule is axially centered within the tubular portion. In an embodiment, a resilient material may be attached to the rear end of the male ferrule to control the radial or lateral freedom of movement that actually provides some resistance to lateral movement beyond that provided by the optical fiber or cable.

[0020] In an embodiment, the male ferrule has freedom of movement provided by the flexibility of the optical cable forward of the anchor location and the engagement of the rear portion of the optical connection portion with the elastomeric member. In an embodiment, the optical connection portion can be a ferrule or a ferrule seated in a sleeve. The ferrule can be laterally and axially constrained by structure within or part of the body portion, such as the tubular portion of the body portion, thereby limiting the lateral freedom of movement of the optical connection portion. When the ferrule is axially centered within the tubular portion, such structure provides a circumferential gap around the ferrule throughout its entire length. In an embodiment, a resilient material can be attached to the rear end of the male ferrule to control the radial or lateral freedom of movement that actually provides some resistance to lateral movement beyond that provided by the optical fiber or cable.

[0021] In an embodiment, the ferrules have a registration surface, such as an outer cylindrical surface, that mates with a cooperating inwardly facing cylindrical surface on the female ferrule of the receiving connector, without the female ferrule having an axial stop for the male ferrule in the optical registration receptacle. The male ferrule is slidingly received within the inwardly facing cylindrical surface of the female ferrule, with the only contact of the cooperating ferrules being between their respective cylindrical surfaces. The inventors have discovered that focused laser energy at the forward face of the male ferrule, particularly at the fiber facet, can generate substantial excess heat that is advantageously managed. The interface of the respective cylindrical surfaces of the male and female ferrules may not be adequate to manage and provide adequate heat transfer away from the male ferrule. The inventors have further discovered that the heat dissipation of the focused laser energy on the forward face of the male ferrule is preferably managed by transferring and dissipating heat through the medical device connector on the laser energy generator, thus providing a method of greater heat sinking capability than that of the launch connector and attached fiber optic cable. The receiving connector and associated structure are adapted to dissipate excess heat from the launch connector and fiber cable to the medical device. The inventors have discovered that axially opposed surfaces, particularly those surfaces that are forced together under compression, transfer heat from the launch connector to the receiving connector more efficiently than the sliding cylindrical surfaces of the male and female ferrules.

[0022] Features and advantages of an embodiment are a launch connector with a male ferrule that engages a receiving connector of a laser energy generator by sliding engagement between an exterior cylindrical surface of the male ferrule and an inwardly facing cylindrical surface of the female ferrule. Laser energy is focused on the front side of the male ferrule, thereby heating the male ferrule. A tubular sleeve surrounds the male ferrule and has a forward facing annular tip surface perpendicular to the connector axis that engages a cooperating annular surface on the receiving connector. In an embodiment, the cooperating annular surface is an annular surface of the female ferrule. In an embodiment, the forward facing annular surface of the sleeve supporting the male ferrule compressively engages the cooperating annular surface of the female ferrule by compression of a resilient portion rearward of the front face of the male ferrule. In an embodiment, the resilient portion is an elastomeric material disposed between the tubular sleeve and the body of the launch connector. In an embodiment, the elastomeric material comprises an annular member. In an embodiment, the elastomeric material is a block that engages the rearward end of the tubular sleeve.

[0023] In an embodiment, the launch connector connects to the receiving connector on a laser energy generator with a heat transfer path extending from the male ferrule through an annular heat transfer member inside the gripping portion of the launch connector and engaging the annular engaging member of the receiving connector, the laser energy generator providing a heat sink for the thermal energy transferred from the male ferrule. In an embodiment, a resilient member provides a rearward axial displacement of the annular heat transfer member and a forward bias that provides a compressive engagement with the annular engaging member of the receiving connector when connected.

[0024] Conventional fiber optic connector technology relies on an axial stop surface that engages the forward face of the male ferrule. In the context of a launch connector, this complicates the engagement of the male and female ferrules. In an embodiment, the forward most front end of the male ferrule does not engage any stop surface. When the connection is made, a shoulder aft of the forward most front end can engage the annular surface of the female ferrule. The engagement of the shoulder with the annular surface provides a path for dissipation of heat generated by laser beam energy focused on the forward facet of the optical fiber within the male ferrule.

[0025] In an embodiment of the invention, the optical fiber rearward of the ferrule is secured to an elastomeric support member that provides axial cushioning and / or resilience when the ferrule engages a portion of the connector of the medical device. The securing of the optical fiber to the launch connector body can be accomplished by a resilient elastomeric disk that defines a diaphragm.

[0026] In an embodiment of the invention, the ferrule is slidingly received in a bore of an optical registration receptor, which may have a tapered concave lead-in registration surface and a cylindrical registration surface, and the male ferrule has a cooperating convex outer tapered surface and a cylindrical registration surface to closely engage the cylindrical registration surface of the optical registration receptor.

[0027] In an embodiment of the invention, the outer tubular portion of the launch connector engages with a mechanical registration receptacle of a receiving coupling attached to, for example, a laser energy generator. The leading edge of the tubular outer portion and / or the outermost edge of the mechanical registration receptacle may be tapered to provide insertion tolerance.

[0028] A feature and advantage of an embodiment of the present invention is a fiber optic launch connector with a single optical fiber, any sheath on the fiber, and a single fiber with an internal moveable ferrule that is positionally fixed only by an elastomeric material. The ferrule is positionally constrained but not positionally fixed by being partially disposed in a bore of the inner tubular portion of the launch connector. A feature and advantage of an embodiment is that metal and coil springs are not utilized in positioning the male ferrule in the launch connector, and the resiliency and compliance for positioning of the male ferrule (and any sleeve thereon) is provided by the elastomeric material and / or the fiber optic cable (and any coating thereon). In such an embodiment, the compliance 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 components are less complex, all due to the utilization of elastomeric material rather than metal and / or coil springs.

[0029] In an embodiment, the launch connector is assembled by opening one of the two clamshell halves of the housing, disposing a portion of an elastomeric material disposed on one of the two clamshell halves rearward of a receiving area for a male ferrule or male ferrule and sleeve combination, placing the male ferrule or male ferrule and sleeve combination into one of the two clamshell halves, disposing an optical fiber (and any coating thereon) extending from the male ferrule or male ferrule and sleeve combination on a surface of the portion of elastomeric material with a rearward end disposed on a forward surface of the portion of elastomeric material, disposing the male ferrule or male ferrule and sleeve combination in a defined cavity for receiving the male ferrule or male ferrule and sleeve combination, and closing one of the two clamshell halves against the other of the two clamshell halves and securing the two clamshell halves together, the other having a second portion of elastomeric material such that the optical fiber and any coating thereon can be sandwiched or otherwise secured or confined between the first and second portions of elastomeric material when the two clamshell halves are assembled together. In an embodiment, the two portions of elastomeric material may define two webbings at the forward facing portions of the elastomeric material, the two webbings supporting the optical fiber and any coating thereon.

[0030] Features and advantages of embodiments of the present invention are a single fiber optic launch connector having an internal moveable ferrule secured only to the single optical fiber and optionally to a sheath on the fiber, the ferrule being positionally constrained but not positionally fixed by being partially disposed in a bore of an inner tubular portion of the launch connector.

[0031] Features and advantages of an embodiment of the present invention are optical fiber couplings with cooperating connectors, one connector being a launch connector with a ferrule supporting an optical fiber with a fiber facet, and the other connector having an optical registration receptacle that receives the first connector and receives the ferrule, each connector having an optical interface recessed from the exterior of the connector.

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

[0033] In an embodiment, the optical connection portion of the launch connector has a forward cylindrical portion, a central cylindrical portion diametrically larger than the forward cylindrical portion, and a rearward cylindrical portion diametrically smaller than the central cylindrical portion. The forward cylindrical portion has a central axial bore sized for an optical fiber and an optical fiber secured therein, and has an exposed end at the forward end of the forward optical fiber. In an embodiment, the forward cylindrical portion is diametrically equal to the rearward cylindrical portion. In an embodiment, the housing of the launch connector provides an internal cavity shaped to fit the three cylindrical portions of the optical connection portion of the launch connector. In an embodiment, 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 cylindrical central portion and the cylindrical rear portion, and the glass or ceramic cylindrical ferrule providing the forward cylindrical portion. In an embodiment, the three cylindrical portions are provided by a unitary stainless steel ferrule. In an embodiment, the ferrule can be of other compositions, such as ceramic materials.

[0034] In an embodiment, there is a pair of cooperating connectors for connecting 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 configured as an outer tubular portion with a forward edge, each of the outer tubular portions having a tubular wall defining a respective axial recess, the optical coupling portions concentrically disposed within the axial recess and spaced from the tubular wall, and the optical coupling portions inset from their respective forward edges. In an embodiment, one connector provides an optical cable with an optical fiber that connects to a ferrule and presents a fiber facet. The ferrule has a central location, and the ferrule is received within a female portion of an optical registration receiver. In an embodiment, one of the tubular mechanical coupling portions is interwoven between the tubular mechanical coupling portion of the other coupling and the optical coupling portion of the other coupling. The tubular mechanical coupling portions are slidingly engaged with one another. In an embodiment, a connector for delivering laser energy to a medical device, a launch connector, has its outer tubular portion extending within an outer tubular portion of a connector associated with the medical device. In an embodiment, when the connector is manually manipulated, the outer mechanical coupling engages first, axially aligning the connector as the outer mechanical couplings are slidingly engaged together, and the connectors axially align before the optical coupling portions engage one another. The optical coupling portions are then pre-aligned, and the optical coupling is aligned into a final operative position when the optical coupling portions engage the tapered surfaces on one or both optical coupling portions. In an embodiment, one optical coupling portion is laterally movable relative to its respective mechanical coupling portion. [Brief description of the drawings]

[0035] [Figure 1] FIG. 1 is a perspective view of a delivery system in accordance with the invention herein, where the launch connector is disconnected from the laser energy generator connector. [Diagram 2]FIG. 2 is a perspective view of the launch connector of FIG. 1 connected to a laser energy generator. [Diagram 3] 1 is a cross-sectional view of a coupling including a launch connector and a receiving connector, according to an embodiment. [Figure 4] FIG. 4 is a cross-sectional view of the coupling of FIG. 3 in an uncoupled state. [Diagram 5] FIG. 4 is an enlarged detail of the cross section of FIG. [Figure 6] FIG. 4 is an exploded view of the launch connector of FIG. [Figure 7] FIG. 13 is a perspective view of another embodiment of a launch connector. [Figure 8] FIG. 8 is an exploded view of the launch connector of FIG. [Figure 9] FIG. 8 is another exploded view of the launch connector of FIG. [Figure 10] FIG. 8 is a cross-sectional view of the launch connector of FIG. [Figure 11] FIG. 13 is a perspective view of another launch connector according to an embodiment. [Figure 12] 12 is a cross-sectional view of the launch connector of FIG. 11 and a female ferrule that receives the male ferrule of the launch connector. [Figure 13A] FIG. 12 is an exploded view of the launch connector of FIG. [Figure 13B] FIG. 12 is an exploded view of the launch connector of FIG. [Figure 14A] FIG. 12 is a perspective view of the front nose portion of the connector of FIG. 11. [Figure 14B] FIG. 12 is a perspective view of the front nose portion of the connector of FIG. 11. [Figure 14C] FIG. 14C is a cross-sectional view of the nose portion of FIGS. 14A and 14B. [Figure 15A] FIG. 12 is a perspective view of a body portion or housing of the launch connector of FIG. [Figure 15B] FIG. 12 is a perspective view of a body portion or housing of the launch connector of FIG. [Figure 15C] FIG. 15C is a cross-sectional view of the housing of FIGS. 15A and 15B. [Figure 16A]FIG. 2 is a perspective view of a male ferrule of the launch connector of FIG. 1. [Figure 16B] FIG. 2 is a perspective view of a male ferrule of the launch connector of FIG. 1. [Figure 16C] FIG. 16C is a cross-sectional view of the male ferrule of FIGS. 16A and 16B. [Figure 16D] FIG. 16C is a front end view of the male ferrule of FIGS. 16A-16C. [Figure 17A] FIG. 1 is a perspective view of a block of elastomeric material configured as a bushing and functioning as an elastomeric support. [Figure 17B] FIG. 1 is a perspective view of a block of elastomeric material configured as a bushing and functioning as an elastomeric support. [Figure 17C] FIG. 17C is a cross-sectional view of the elastomeric support of FIGS. 17A and 17B. [Figure 18A] FIG. 17D is a perspective view of a retainer for the elastomeric support of FIG. 17C. [Figure 18B] FIG. 17D is a perspective view of a retainer for the elastomeric support of FIG. 17C. [Figure 18C] FIG. 18C is a cross-sectional view of the retainer of FIGS. 18A and 18B. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0036] 1 and 2, a laser energy delivery system 20 includes a fiber optic cable 22 and a launch connector 24. The launch connector 24 and a connector 28 define a fiber optic coupling 32 for providing laser radiation from a laser radiation source 30 to a medical instrument 34.

[0037] 3, 4, 5 and 6, a coupling 600 includes a launch connector 602 and a medical device connector 604 that receives the launch connector and is part of a laser energy generator 607. The launch connector includes an optical interface portion 610 and a mechanical interface portion 612. The mechanical interface portion of the launch connector includes a body portion 614 with a forwardly projecting tubular portion 616 having an inner wall surface 620, an outer wall surface 622, and a tubular wall portion 618 with a forward annular stop surface 623. The optical interface portion includes an optical interface piece 624 with a male ferrule 630 and a fiber optic line 632 extending therefrom. The male ferrule has a forward portion 633, a forward face 634, a rear portion 636, a cylindrical surface 638, and a rear end 640 from which the fiber optic line 632 extends. A fiber facet 642 is exposed at the front face of the male ferrule. The optical connection component 624 may further include a rigid fitting 650 configured as a sleeve in which the male ferrule 630 is secured. The sleeve may be formed of a highly thermally conductive material such as stainless steel, although other materials and metals may be suitable. The sleeve has a forward edge 656, a forward tubular portion 658, a central tubular portion 660, and a rearward tubular portion 662. The central tubular portion has a larger diameter than the forward and rearward tubular portions and includes forward and rearward stop surfaces 670, 672 that oppose respective forward and rearward stop surfaces 674, 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, limiting the amount of freedom of movement of the ferrule and sleeve. The sleeve may be engaged and supported by an elastomeric material 678 configured as a block 679. The block may have respective block portions 679.1 that may be configured as halves as shown in FIG. 6 for mounting around a fiber optic line. The block portion 679.1 may further include a cavity 679.3 that accommodates a webbing 679.5 at a forward end of the elastomeric material 678.The fiber optic line may be further secured at the tail 679.6 of the body portion by, for example, an elongated grommet 679.7 configured as a strain relief member.

[0038] The receiving connector 604 includes an optical interface portion 680 and a mechanical interface portion 682. The optical interface portion has a female ferrule 683 with an inwardly facing cylindrical surface 684 that cooperates with the male ferrule's outer cylindrical surface 638. A laser energy generator 607 provides a focused energy beam 640 through a lens 642 to a fiber facet 642 of the male ferrule.

[0039] The mechanical interface 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 .

[0040] Heat generated in the male ferrule from the focused energy beam can be dissipated by thermal paths 690, indicated by arrows, that extend from the male ferrule to the sleeve to the outer annular surface 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 acts as a significant heat sink to dissipate heat from the male ferrule. The thermal capacity, i.e., ability of the sleeve, especially when formed of a metal such as steel, is substantially greater than polymers such as may be used for the body portion of the launch connector.

[0041] When the connection is made and the sleeve is pressed rearward against the elastomeric member, the resilience of the elastomeric member can provide a compressive force on the forward annular surface of the sleeve against the outer annular surface of the female ferrule. The compressive force helps to strengthen the thermal connection between the respective components. In other embodiments, the thermal flow path can be through other structures other than the female ferrule.

[0042] 7-10, in an embodiment, a launch connector 700 has a housing 701 configured as a body portion 702 with a gripping portion 704, a tail portion 706, a forward flange 708, and a nose portion 710 that projects forwardly from the gripping portion 704 for insertion into a receiving connector of a laser radiation source as previously described. An optical interface portion including a male ferrule 711 is matingly disposed within the body portion at the nose portion. In other embodiments, a cylindrical male ferrule can be seated in a fitting as previously shown.

[0043] As best shown in Figures 8-10, the body portion, in an embodiment, can include three exterior components and one interior component. Specifically, the gripping portion and flange can be formed of two clamshell pieces 712, 714 configured as a housing 715 with an exterior wall 715.5 that defines an open interior 717. When assembled, the clamshell pieces capture, within an annular recess 716, an aft flange 718 at the aft end 719 of a nosepiece 720 that is also part of the housing 715. An O-ring 726 in an O-ring groove 728 in the nosepiece 720 can be provided to seal the housing and improve tightness and rigidity at the connection 729 between the nosepiece and the two clamshell pieces. Thus, the nosepiece 720 and the two clamshell pieces 712, 714 are the exterior exposed components of the housing. A fiber optic line 732 extends through the open interior 717 and through the interior component of the body portion configured as a rigid bushing 733. The bushing 733 is captured between the rear end 719 of the nosepiece and the two clamshell pieces by stop portions 734, 735 configured as wall portions integral with the clamshell pieces. The wall portions 734, 735 and the nosepiece 720 define a slot 740 for receiving and seating the bushing. The rigid bushing 733 is radially centered and has a central opening 742 for the fiber optic line 732 and a forward facing central bushing recess 743 defined by a bushing annular wall 744 for receiving an elastomeric 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 an embodiment, the housing components and the rigid bushing can be formed from injection molded polymer.

[0044] Referring to FIG. 10, the fiber optic wire extends into a male ferrule 711 and has a facet 750 exposed at a forward end 752 of the ferrule. The male ferrule may be made of stainless steel or other material. The forward end may have a recess known as a power well 753 so that laser radiation that overfills the forward facet of the fiber will be out of focus when it strikes the ferrule. The forward end has a lead-in tapered portion 754 with an outer surface 755, and a first forward cylindrical portion 758 with a cylindrical outer surface 759 of a first radius r1. Another second forward cylindrical portion 764 with a cylindrical outer surface 765 and a second radius r2 extends rearward from the first forward cylindrical portion, and a central or third cylindrical portion 768 with a cylindrical outer surface 767 and a third radius r3 is rearward of the second forward cylindrical portion. A rear cylindrical portion 770 with a cylindrical exterior surface 771 is adjacent to the third cylindrical portion and is of a rear or fourth radius r4. In an embodiment, the second radius r2 is greater than the first radius r1 and the third radius r3 is greater than the second radius r2 and greater than the fourth radius r4. In an embodiment, the fourth radius r4 may be equal to the second radius r2. The central or third cylindrical portion 768 defines an intermediate cylindrical band 776 with a forward stop surface 777 and a rearward stop surface 778. The ferrule is axially and radially restrained within a ferrule cavity 780 defined by an interior wall surface 782 of the nosepiece and an interior surface 783 of the bushing 733. The ferrule cavity conforms to the shape of the ferrule. An internal shoulder 785 on the nosepiece wall provides an axial stop for restraining the male ferrule. The inwardly facing cylindrical surface 782 of the nosepiece that defines the ferrule cavity provides a radial or lateral stop surface. The male ferrule is constructed substantially similar to the male ferrule and rigid sleeve of the embodiment of Figures 3-6, except that the male ferrule is one piece and formed entirely of stainless steel or other material. This embodiment of the launch connector 602 will also mate with a laser energy generator connector and female ferrule as shown in Figures 3 and 4.Thermal management of the embodiment of Figures 3 and 4 may be enhanced in that the entire ferrule may be stainless steel, which may promote better heat conduction and transfer. The mating female ferrule may also be stainless steel, providing a large area of ​​metal-to-metal contact between the respective optical interfaces of the launch connector and the laser energy generator connector.

[0045] Continuing to refer to FIG. 10, in an embodiment, the first radius can be 0.055 inches to 0.070 inches. The second radius can be 0.090 inches to 0.110 inches, the third radius can be 0.110 inches to 0.125 inches, and the fourth radius can be 0.0090 inches to 0.110 inches. In an embodiment, the difference in the radial measurement between the second and third radii is 0.015 inches to 0.020 inches. In an embodiment, the difference in the radial measurement between the fourth and third radii is 0.015 inches to 0.020 inches. In an embodiment, when the ferrule or ferrule in the fitting is centered within the form-fitting cavity of the body portion, there is a minimum gap between the outer surface of the ferrule or ferrule in the fitting of 0.005 inches to 0.020 inches around the entire circumference of the ferrule or ferrule in the fitting measured radially.

[0046] The fiber optic line may be conventionally secured in the rear recess of the male ferrule with epoxy 788 or the like. The elastomeric block 745 may have two portions 745.1, 745.2 configured as halves as shown in Figures 8 and 9 that clamp around the fiber optic line. There may be an axial groove 790 in one or both portions. In an embodiment, the groove is undersized relative to the fiber optic line. Additionally, the elastomeric portion may be slightly oversized relative to the bushing recess, so that when the two elastomeric block halves are sandwiched around the fiber optic line and inserted into the bushing recess, there is an interference fit against the fiber optic line and block halves, and against the block halves and bushing, so that the block halves compress and clamp around the fiber optic line, thereby clamping and holding the fiber optic line in place. Due to the soft resilience of the elastomeric block material, this engagement still allows some forward and rearward movement of the fiber optic line 732 relative to the housing, and such movement will be primarily axial. A central circumferential recess 745.8 around the elastomeric block may enhance the freedom of movement of the fiber optic line forward and backward when it is clamped in the block, i.e., enhance conformability. In this way, the block acts as an elastomeric clamp for the fiber optic line. Additionally, because the block halves are sandwiched around the fiber optic line, an optical connection portion including a male ferrule or a male ferrule seated in a rigid sleeve fitting may be pulled to the forward facing surface of the elastomeric block so that the forward face of the block contacts or slightly depresses the elastomeric block. This provides centering for the optical connection portion, with fitting engagement with the rear portion or face of the ferrule distributed radially spaced apart around the forward exit point of the fiber optic line in the elastomeric block. In an embodiment, the forward face may be shaped to conform to the rear end of the ferrule or fitting. In an embodiment, the fiber optic line may be in slight tension between the optical connection portion and the elastomeric block, which may pull and deflect the optical connection portion into the elastomeric block, providing tighter centering of the optical connection portion.

[0047] 11-13B, an additional embodiment of a launch connector 800 is shown that includes a housing 801 with a gripping portion 804, a forward flange 808, and a plug or forward nose portion 810 that extends forwardly from the forward flange for plugging into a laser energy generator such as shown in Figures 1-5. A tail portion configured as a strain relief member 811 secures a fiber optic cable 812.

[0048] 12-16D, the connector 800 generally includes a housing, specifically a mechanical interface portion 813 formed by a plug portion 810 and a forward flange 808, and also includes an optical interface portion 814 formed by a male ferrule 816, an elastomeric support 818 capturing a rear end 820 of the male ferrule 816, and a retainer 824 for securing the elastomeric support relative to the housing 801. The components of the housing 801 to be assembled are a nose portion 810 and a gripping portion 804, each of which has cooperating rotational attachment portions 826, 828 shown as having threads 830 that allow mating of both components with partial rotation. An O-ring 833 can be positioned at the interface 834 between the plug portion 810 and the gripping portion. The gripping portion can have an O-ring engagement surface 835 that is oblique to the axis α1 of the launch connector. The O-ring seats in an annular groove 836 in a flange portion 838 of the nose portion 810. Such angled surfaces allow for fully locked rotation of cooperating threaded components such that distally located annular stop surfaces 841, 842 on each component abut one another to provide a rigid joint. In addition, the O-ring provides an expansion or separation force between the engaged components at the joint, which is believed to effectively lock the components together so that they do not inadvertently come apart. The O-ring also provides an airtight seal at joint 834.

[0049] The elastomeric support 818 may be configured as a cup-shaped bushing with a U-shaped cross section with a central opening 844 for the optical fiber 812 as shown in FIG. 12, with the rear end of the male ferrule seated in the recess. The support 818 seats in an annular recess 846 in the rear end 847 of the nose portion 810, with the forward-most and forward-facing annular surface 847.5 of a forwardly extending annular wall 847.7 of the elastomeric support 818 abutting the nose portion internal shoulder 848 with a rearward-facing annular shoulder surface 849 perpendicular to the axis α1. The support may be compressed by a retainer 853 shaped as a disk with radial slots 854 to facilitate assembly, allowing the retainer to slide over the optical fiber 812 during assembly. The retainer has a peripheral flange that seats and is sandwiched between the respective annular engagement surfaces 857, 858 of the nose portion 810 and the gripping portion 804. Advantageously, the forward-most and forward-facing annular surface 847.5 of the elastomeric support also engages the male ferrule at a rearward shoulder 860 at the rearward-facing annular surface 861. This provides a "soft", resilient and compliant axial positioning of the male ferrule within the housing molded to fit the male ferrule. Additionally, an inner bottom seating surface 863 of the base 864 of the elastomeric support can further engage the rearward-most rearward-facing surface of the male ferrule 816 to provide further resilient and compliant axial positioning of the male ferrule.

[0050] 11-18C, as in the previous embodiment, the male ferrule can have a forward-facing shoulder 867 with a forward-facing annular face or surface 868. The forward-facing shoulder 867 opposes a rearward-facing internal shoulder 870 of the nose section that provides a shape that conforms to the shape of the male ferrule in the wall of the nose section with a circumferential gap 872 and an axial gap 873 at the forward-facing shoulder of the male ferrule. As best shown in FIG. 12, the forward-facing surface 868 of the male ferrule cooperates with annular surface 879 of the female ferrule 880 to provide a path for thermal dissipation of heat that is generated at the front end of the male ferrule when laser energy is focused thereon.

[0051] 16C, the optical connection piece 890 is configured as a one-piece male ferrule. The first or front cylindrical portion 891 has a first diameter D1, and the second or middle cylindrical portion 892 has a second diameter D2 that is larger than the first diameter. The third cylindrical portion 893, which is also the second middle cylindrical portion, has a third diameter D3 that is larger than the first diameter and larger than the second diameter. The rear or fourth cylindrical portion 894 has a rear or fourth diameter D4 that is smaller than the diameter of the second middle cylindrical portion and larger than the diameter D1 of the front cylindrical portion 891. In an embodiment, the one-piece optical connection piece may comprise stainless steel.

[0052] In embodiments, the mechanical connection may be configured as a bayonet connection, a threaded connection, a press fit connection, or a detent connection. In embodiments, the elastomeric support may be replaced by other resiliently compliant supports, for example, a coil spring configuration may be appropriate in some embodiments.

[0053] Patent documents 1 and 3-15 are incorporated by reference for all purposes.

[0054] The invention is not limited to the details of the foregoing embodiments. The invention extends to any novel one or any novel combination of features disclosed in this specification (including any documents incorporated by reference, any attached claims, abstracts and drawings), or to any novel one or any novel combination of steps of any method or process so disclosed. The above documents in all sections of this application are incorporated herein by reference in their entirety for all purposes.

[0055] Although specific examples have been illustrated and described herein, it will be understood by those skilled in the art that any configuration calculated to achieve the same purpose may be substituted for the specific examples shown. This application is intended to cover adaptations or variations of the present subject matter. Accordingly, the present invention is intended to be defined by the appended claims and their legal equivalents, as well as the following exemplary aspects. The embodiments of the above-described aspects of the invention are merely illustrative of its principles and should not be considered limiting. Further modifications of the invention disclosed herein will occur to those skilled in the respective arts, and all such modifications are considered to be within the scope of the invention. [Explanation of symbols]

[0056] 20 Laser Energy Delivery System 22 Optical fiber cable 24 Launch Connector 28 Connectors 30 Laser radiation source 32 Optical fiber coupling 34 Medical Devices 600 Coupling 602 Launch Connector 604 Medical Device Connectors 607 Laser Energy Generator 610 Optical connection part 612 Mechanical Connection Parts 614 Main body part 616 Anteriorly projecting tubular section 618 Tubular wall section 620 Internal wall surface 622 External wall surface 623 Front Circular Stop Surface 624 Optical connection parts 630 Male ferrule 632 Fiber Optic Cable 633 Front part 634 Front side 636 rear part 638 Outer cylindrical surface 640 rear end 640 Focused Energy Beam 642 Fiber Facet 642 Lens 650 Rigid fitting, sleeve 656 Front edge 658 Anterior tubular section 660 Central tubular section 662 Posterior tubular section 670 Forward stop surface 672 Rear stop surface 674 Forward stop surface 676 Rear stop surface 677 Cavity 678 Elastomer Materials 679 Block 679.1 Block Parts 679.3 Cavity 679.5 Webbing 679.7 Grommet 680 Optical connection part 682 Mechanical Connections 683 Female Ferrule 684 Inward-facing cylindrical surface 686 Recess 687 Laser Energy Generator Connector Housing 690 Heat Path 695 Housing 700 Launch Connector 701 Housing 702 Main body part 704 Gripping part 706 Tail section 708 Front flange 710 Nose part 711 Male ferrule 712 Clamshell Piece 714 Clamshell Piece 715 Housing 715.5 External walls 716 Circular recess 717 Open interior 718 Rear flange 719 Rear end 720 Nosepiece 726 O-ring 728 O-ring groove 729 Connection 732 Fiber Optic Line 733 Bushing 733.2 Rear extension 734 Stop part 735 Stop part 740 Slots 742 Central opening 743 Forward-facing central bushing recess 744 Bushing annular wall 745 Elastomer Block 745.1 Part 745.2 Part 745.6 RFID Tags 745.8 Central circumferential recess 750 Facets 752 Front end 753 Powerwell 754 Tapered section 755 External Surface 758 First forward cylindrical section 759 Cylindrical outer surface 764 Second forward cylindrical section 765 Cylindrical outer surface 767 Cylindrical outer surface 768 Third cylindrical section 770 Rear cylindrical section 771 Cylindrical outer surface 776 Intermediate Cylindrical Band 780 Ferrule Cavity 782 Internal wall surface 785 Internal Shoulder 788 Epoxy 800 Launch Connector 801 Housing 804 Gripping part 808 Front flange 810 Front nose section 811 Strain relief member 812 Fiber Optic Cable 813 Mechanical Connection Parts 814 Optical connection part 816 Male ferrule 818 Elastomer support 820 Rear end 824 Retainer 826 Rotating mounting part 828 Rotating mounting part 833 O-ring 834 Joint 835 O-ring engagement surface 836 Circular groove 841 Circular Stop Surface 842 Circular Stop Surface 844 Central opening 847.5 Forward-facing annular surface 849 Rear facing annular shoulder surface 853 Retainer 854 radial slot 857 Annular Engagement Surface 858 Annular Engagement Surface 860 Rear shoulder 861 Rear-facing annular surface 863 Inner Bottom Seating Surface 864 Base 867 Forward shoulder 868 Forward-Facing Annular Surface 870 Rear facing internal shoulder 872 Circumferential Gap 873 Axial Gap 879 Annular Surface 880 Female ferrule 890 Optical connection parts 891 Front cylindrical section 892 Middle cylindrical section 893 Third cylindrical section 894 Fourth cylindrical section

Claims

1. 1. A fiber optic connector coupling for connecting a laser radiation source to an instrument, said fiber optic connector coupling comprising: A launch connector having a forward end, an aft end and a shaft Including, the launch connector includes a body portion, an optical fiber extending into the body portion at the rear end; the launch connector having a mechanical interface and an optical interface defined by the body portion; the optical connection portion includes a male ferrule received within the mechanical connection portion and connected to the optical fiber; the optical fiber has a forwardly exposed facet at a forward end of the male ferrule; a block of conformable elastomeric material centrally disposed within said body portion about said axis of said launch connector, said block of conformable elastomeric material configured as a cup with a central opening, said cup including a base portion and an annular wall portion extending forwardly from said base portion, said annular wall portion abutting a rearward facing surface of said optical interface portion, and a rearward end of said male ferrule seated in said base portion.

2. 2. The fiber optic connector coupling of claim 1, wherein the body portion defines a slot for receiving the block of conformable elastomeric material, the block of conformable elastomeric material providing axial conformance to the optical fiber.

3. 2. The fiber optic connector coupling of claim 1, wherein the body portion has a forward nosepiece with a tubular portion that houses the optical interface portion, the optical interface portion being generally cylindrical with a central circumferential band, the forward nosepiece having a cavity that conforms to the optical interface portion but with a gap between the optical interface portion and the forward nosepiece, whereby the optical interface portion is restricted from moving within the cavity.

4. 2. The fiber optic connector coupling of claim 1, wherein the optical interface portion has a forward-facing annular surface displaced rearwardly from a forward-most end of the male ferrule, the forward-facing annular surface providing a stop surface for the optical interface portion when mating the launch connector.

5. 2. The fiber optic connector coupling of claim 1, wherein the body portion has a forward nosepiece with a tubular portion that houses the optical connection portion, the body portion having a gripping portion rearward of the forward nosepiece, the forward nosepiece having a flange seated in an annular groove in the gripping portion, and the fiber optic connector coupling further includes an O-ring disposed between the forward nosepiece and the gripping portion.

6. 2. The fiber optic connector coupling of claim 1, wherein the body portion defines a housing with a large cavity for the optical interface portion, thereby permitting radial, forward and rearward movement of the optical interface portion while constraining the optical interface portion within the housing.

7. 2. The fiber optic connector coupling of claim 1, wherein said rearward facing surface of said optical interface portion is held against said block of conformable elastomeric material by tension in said optical fiber.

8. 2. The fiber optic connector coupling of claim 1, wherein said forward end of said male ferrule includes a power well.

9. 10. The fiber optic connector coupling of claim 1, wherein said male ferrule is formed from stainless steel.

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