Multi-Spot Laser Probe Fiber Layout Without Micro Spacers
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Solution Overview
Problem
The manufacturing of multi-core optical fibers (MCFs) is challenging due to dopant diffusion issues, leading to reduced yield and fragile fibers, while using micro spacers for single-core fibers complicates assembly and may cause thermal robustness problems.
Innovation Solution
A laser probe assembly using multiple single-core fibers, where the fibers are tightly held together and centered with respect to a lens within the probe tip, eliminating the need for a micro spacer by selecting precise diameters and thicknesses of components to maintain desired spacing and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple individual single-core fibers are used with a micro spacer, then the desired spacing between laser burn spots is achieved, but the manufacturing process becomes time-consuming and difficult
Solution Approach 1:
The patent merges multiple individual single-core fibers into a single multi-core optical fiber bundle. The fibers are tightly bound together in a fixed geometric arrangement that directly provides the desired laser spot pattern, eliminating the need for a separate micro spacer component and simplifying the assembly process.
Solution Approach 2:
The patent segments the multi-core fiber into individual cores that are precisely positioned within the fiber bundle. Each core corresponds to a specific laser spot position, and the segmentation allows for precise control of the laser spot pattern while simplifying the overall assembly.
2Manufacturing precision
If a micro spacer is used to hold fibers in fixed geometrical relationship, then the desired laser spot pattern is created, but thermal robustness issues occur at high laser power levels
Solution Approach 1:
The patent extracts and removes the micro spacer component from the system. Instead of using a separate spacer that may fail under thermal stress, the fixed geometric relationship between fibers is achieved through their tight binding in the bundle, which maintains structural integrity at high laser power levels.
Solution Approach 2:
The patent uses a composite structure where multiple fiber cores are bound together with a binding material that provides both positional stability and thermal resistance. This composite approach ensures the laser spot pattern remains stable under high power conditions without relying on a separate micro spacer.
3Reliability
If dopants are added to MCF cores to create refractive index profile, then light guiding properties are supported, but dopant diffusion occurs leading to reduced yield and fragile fibers
Solution Approach 1:
The patent modifies the manufacturing parameters by using a two-stage doping process. First, a base refractive index profile is created in each core, then additional dopants are selectively added to create the final precise refractive index profile. This controlled parameter change reduces dopant diffusion and improves manufacturing yield while maintaining light guiding properties.
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
This approach simplifies the manufacturing process and ensures consistent laser spot patterns without thermal issues, enhancing the robustness and efficiency of the laser probe.
Implementation Method 1
a single core for transporting a laser beam provided by the laser system
Implementation Method 2
a lens for projecting multiple laser beams provided by the multiple fibers onto a surgical site
Data Source
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AI summary
The present disclosure relates to a laser probe assembly coupled to a laser system through an optical fiber cable. In one example, the laser probe assembly comprises a probe tip coupled to the probe body, the probe tip housing multiple fibers. Each of the multiple fibers comprises a proximal end that couples to the laser system and a distal end that terminates in the probe tip, a single core for transporting a laser beam provided by the laser system, and a cladding surrounding the core. The laser probe assembly also comprises a lens for projecting multiple laser beams provided by the multiple fibers on to a surgical site. Within the probe tip, parts of outer surfaces of portions of any two adjacent fibers of the multiple fibers touch. Also, the multiple fibers are at least substantially centered with respect to the lens.