Flexible Polymer Fiber Optic Cables for Medical Devices
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Solution Overview
Problem
Current fiber optic cables are brittle and have limited material and dimension options, making them unsuitable for flexible and re-routable applications, particularly in medical devices like cochlear implants, which face issues with stiffness, power handling, and thermal losses.
Innovation Solution
The development of high-resolution, flexible fiber optic cables using novel microfabrication methods that allow for a wide range of core and cladding materials, including ORMOCOMP photopolymer and CYTOP fluoropolymer, through processes like molding, thermal reflow, and dip coating, enabling the creation of customized, integrated optoelectronic systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional glass fiber optic cables are used, then high-resolution signal transmission is achieved, but flexibility and adaptability are severely limited due to brittleness
Solution Approach 1:
The patent changes the material parameters from traditional glass to polymer materials (ORMOCOMP photopolymer for core, CYTOP fluoropolymer for cladding), enabling the fiber to achieve both high-resolution signal transmission and exceptional flexibility. This material parameter transformation allows the fiber to be bent to a fraction of its diameter while maintaining optical performance
Solution Approach 2:
The patent employs composite material structures with specialized polymer materials - ORMOCOMP photopolymer for the core and CYTOP fluoropolymer for the cladding. These composite polymer materials provide both the optical clarity needed for high-resolution transmission and the mechanical flexibility required for adaptable routing in medical applications
2Strength
If thick cladding is used to protect the core, then structural strength is improved, but fiber diameter increases reducing flexibility
Solution Approach 1:
The patent utilizes thin film technology to create an extremely thin cladding layer (approximately 1.5 micrometers) made from CYTOP fluoropolymer. This thin film cladding provides necessary structural protection and optical isolation while being thin enough to allow the fiber to achieve a diameter of only 3-4 micrometers, enabling extreme flexibility and bendability to a fraction of its diameter
3Adaptability or versatility
If LED-based optical systems are used, then flexibility is improved, but power handling capability and wall-plug efficiency deteriorate
Solution Approach 1:
The patent substitutes LED-based mechanical optical systems with laser-based optical systems integrated into the polymer fiber. Laser diodes provide superior power handling capability and wall-plug efficiency compared to LEDs, while the flexible polymer fiber maintains the flexibility advantage. This substitution resolves the trade-off by combining laser power with flexible fiber delivery
4Power
If large diameter optical fibers are used in cochlear implants, then power handling is improved, but insertion depth is limited due to stiffness
Solution Approach 1:
The patent dramatically changes the diameter parameter from traditional large-diameter optical fibers to an ultra-thin 3-4 micrometer diameter. This parameter change enables the fiber to be flexible enough for deep cochlear implantation while the laser-based optical system integrated with the fiber maintains adequate power handling capability for effective auditory stimulation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting fiber optic components are highly flexible, durable, and customizable, capable of handling high-resolution signals with reduced thermal load, suitable for medical applications such as cochlear implants and other medical devices where traditional cables are inadequate.
Implementation Method 1
The method may include at least partially filling the first sacrificial tubing with the curable polymer and then curing the curable polymer
Implementation Method 2
applying heat to the thermoplastic tubing to thermally reflow material of the thermoplastic tubing around the fiber optic to form a cladding around the fiber optic core
Implementation Method 3
removing the first sacrificial tubing to produce a fiber optic core
Data Source
AI summary
The present disclosure relates to methods of forming a fiber optic core, and a fiber optic component with a highly uniform cladding covering the fiber optic core. In one microfabrication process a first sacrificial tubing is provided which has a predetermined inner diameter. A quantity of a curable polymer is also provided. The first sacrificial tubing is at least partially filled with the curable polymer. The curable polymer is then cured. The first sacrificial tubing is then removed to produce a finished fiber optic core. Additional operations may be performed by which the fiber optic core is placed inside a thermoplastic tubing, which is itself placed inside a sacrificial heat shrink. Heat is applied to reflow the thermoplastic tubing around the fiber optic core, thus forming a highly uniform thickness cladding. When the sacrificial heat shrink tubing is removed a finished fiber optic component is present. Additional microfabrication methods are disclosed which involve dip coating a pre-formed fiber optic core in a polymer, and then curing the polymer to form a finished fiber optic component with a uniform thickness cladding.