Optical Fiber Alignment in Catheter Tips Using Support Structures
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Solution Overview
Problem
Ablation catheters using optical fibers often produce variable or inconsistent results due to improper alignment of optical fibers in catheter tips, affecting the accuracy of tissue ablation procedures.
Innovation Solution
The development of methods and structures for accurately assembling and aligning optical fibers within catheter tips, including the use of support structures with alignment orifices and adhesive materials to secure the fibers and lenses, ensuring precise alignment and secure positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If optical fibers are assembled in catheter tips without proper alignment structures, then the assembly process is simpler, but the alignment precision and ablation accuracy deteriorate
Solution Approach 1:
Alignment orifices are pre-formed in the catheter tip structure before optical fiber insertion. These orifices are precisely positioned during catheter manufacturing to define the exact location where optical fibers should be inserted, ensuring accurate alignment without requiring complex alignment procedures during assembly
Solution Approach 2:
Adhesive material is introduced as an intermediary substance between the optical fiber and the catheter tip structure. The adhesive fills the alignment orifices and secures the optical fibers in the correct positions, maintaining alignment precision while simplifying the assembly process
2Reliability
If optical fibers are secured in catheter tips without adhesive material, then the assembly process is faster, but the positioning stability and consistency deteriorate
Solution Approach 1:
The adhesive material performs multiple functions simultaneously: it secures the optical fibers in position, fills gaps between components, and provides structural support. This self-service approach ensures reliable positioning without requiring additional separate steps for fiber securing, maintaining assembly efficiency
3Manufacturing precision
If alignment orifices are added to the catheter tip, then the optical fiber alignment improves, but the manufacturing complexity increases
Solution Approach 1:
The catheter tip is designed with discrete alignment orifices that are separately formed and then integrated into the overall catheter structure. This segmentation allows for precise positioning of each orifice using standard manufacturing techniques, reducing overall manufacturing complexity while achieving high alignment accuracy
Solution Approach 2:
Alignment orifices are pre-formed in the catheter tip structure before final assembly. This preliminary creation of alignment features allows for precise positioning to be achieved during tooling and molding stages, rather than requiring complex post-processing or manual alignment procedures
Data Source
AI summary
Described herein are methods, devices, and support structures for assembling optical fibers in catheter tips and facilitating alignment and structural support. A method for assembling a plurality of optical fibers and lenses in a support structure for an ablation catheter includes providing a support structure with a proximal end, a body, and a distal end, the distal end including a plurality of alignment orifices or slits. A plurality of optical fibers are threaded through the alignment orifices or slits, such that each optical fiber is threaded through a corresponding alignment orifice or slit. An adhesive material is applied at each alignment orifice or slit to secure the optical fibers, and the plurality of optical fibers are then cleaved at the distal end to remove portions of the fibers extending out of the distal end. Finally, a lens is attached to each of the ends of the plurality of optical fibers.