Thermally Robust Multi-Spot Laser Probe Brazed Joint

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Multi-spot laser probes used in medical procedures, such as laser photocoagulation therapy, face thermal-induced failure due to significant light absorption at the probe tip, especially during bleeding or occlusion, which can cause meltdown and probe failure.

Innovation Solution

A thermally robust multi-spot laser probe design featuring a cannula with a brazed joint coupling an optically clear optical element, such as sapphire or fused silica, to the cannula, forming a hermetic seal and isolating the lens from foreign substances, preventing thermal runaway and meltdown.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If multi-spot laser probes deliver high power (1-3 W) through a confined space at the probe tip to produce multiple burn spots simultaneously, then productivity is improved, but thermal-induced failure occurs due to significant light absorption at the tip

Engineering Contradiction:

Improvenumber of burn spots produced simultaneouslyVSAvoidprobe resistance to thermal failure

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The probe tip is segmented into distinct functional zones: an optical element (sapphire window) that transmits laser light, a hermetic seal layer that prevents fluid ingress, and a cannula structure that provides mechanical support. This segmentation allows each component to be optimized for its specific function while working together to manage thermal loads.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The hermetic seal acts as an intermediary barrier between the optical elements and the external surgical environment. This seal prevents blood and fluids from contacting the optical components, eliminating the harmful interaction between absorbed light energy and fluid media that causes thermal runaway.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If the probe operates in bleeding or occlusion conditions where significant light absorption occurs at the probe tip, then the ability to treat difficult cases is improved, but thermal runaway and meltdown occur

Engineering Contradiction:

Improveability to treat bleeding and occlusion casesVSAvoidthermal runaway and meltdown

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The hermetic seal converts the harmful effect of light absorption by blood into a beneficial isolation mechanism. By preventing blood from contacting optical elements, the seal ensures that even when significant light absorption occurs in the surgical field, the thermal energy cannot accumulate at the probe tip to cause meltdown.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The hermetic seal creates an inert environment around the optical elements, isolating them from the reactive surgical environment containing blood and tissues. This inert barrier prevents harmful thermal interactions while allowing the probe to maintain high power operation in difficult surgical conditions.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

3Device complexity

If conventional laser probes lack a hermetic seal, then device complexity is reduced, but foreign substances can contact optical elements causing thermal-induced failure

Engineering Contradiction:

Improvestructure simplicityVSAvoidprotection against thermal failure

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The hermetic seal is implemented as a thin film or shell structure that provides comprehensive protection around the optical elements. This thin barrier effectively isolates the optical components from foreign substances without adding significant structural complexity or bulk to the probe design.

Inventive Principle:

Principle #30Flexible shells and thin films

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 design enhances the probe's resistance to thermal failure by creating a hermetic seal and thermal insulation, allowing for high-power laser beam transmission with reduced risk of overheating and meltdown, ensuring reliable performance during surgical procedures.

Implementation Method 1

The brazed joint may form a hermetic or liquid-tight seal between the optical element and the cannula

Methodology Applied

Scientific EffectSealing:

Implementation Method 2

The optical element is configured to receive the laser beam from the distal end of the lens and emit the laser beam from the probe

Methodology Applied

Scientific EffectLight transmission: Light

Implementation Method 3

The lens is adapted to receive a laser beam from the optical fiber at a proximal end of the lens and to transmit the laser beam towards a distal end of the lens

Methodology Applied

Scientific EffectOptical focusing: Lens

Data Source

PatentUS11213426B2Thermally robust multi-spot laser probe

Publication Date: 2022.01.04 ALCON INC

AI summary

A laser probe includes a cannula, at least one optical fiber positioned within the cannula, and a lens positioned within the cannula at a distal end of the fiber. The lens is adapted to receive a laser beam from the optical fiber at a proximal end of the lens and to transmit the laser beam towards a distal end of the lens. The laser probe includes an optical element configured coupled to the cannula by a brazed joint and to receive the laser beam from the distal end of the lens and emit the laser beam from the probe. The brazed joint may form a hermetic or liquid-tight seal between the optical element and the cannula.