Optical Fiber Alignment in Catheter Tips Using Segmented Support
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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, which affects the accuracy of tissue ablation procedures.
Innovation Solution
A method and structure for assembling and aligning optical fibers in catheter tips, involving a support structure with alignment orifices, threading optical fibers through these orifices, applying adhesive, cleaving excess fibers, attaching lenses, and securing a cap with optical ports aligned with the lenses to ensure precise alignment and fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If optical fibers are assembled in catheter tips using conventional methods, then the assembly process is simple, but the alignment precision of optical fibers is poor leading to variable ablation results
Solution Approach 1:
The support structure is divided into multiple components including a distal end with alignment orifices, a body, and a cap with optical ports. This segmentation allows each component to perform its specific function - the distal end provides alignment features, the body provides structural support, and the cap provides optical access - while collectively achieving precise fiber alignment without requiring an overly complex monolithic structure
Solution Approach 2:
Alignment orifices are introduced as intermediary features in the distal end of the support structure. These orifices serve as mediators that guide and position the optical fibers during assembly, ensuring precise alignment between the fibers, lenses, and optical ports without requiring complex adjustment mechanisms
2Reliability
If optical fibers are not properly aligned in catheter tips, then the assembly process is faster, but the reliability of ablation results deteriorates
Solution Approach 1:
Alignment orifices are pre-formed in the distal end of the support structure during manufacturing. These orifices are positioned and sized to automatically guide the optical fibers into the correct alignment positions during assembly, eliminating the need for time-consuming post-assembly alignment adjustments and ensuring consistent fiber positioning
Solution Approach 2:
The support structure is designed to self-align the optical fibers through the alignment orifices and the cap with optical ports. The geometric constraints provided by these features cause the fibers, lenses, and ports to automatically align during assembly without requiring external alignment tools or complex adjustment procedures, thereby ensuring reliable results while minimizing assembly time
Data Source
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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, wherein the distal end includes 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.