Molded Reflective Surface Side-Fire Laser Fiber

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Solution Overview

Problem

Medical laser fibers with beveled terminating ends often suffer from surface deformities due to fusion with fiber caps, leading to non-uniform laser energy distribution and potential damage, necessitating improvements in manufacturing and reliability.

Innovation Solution

A side-fire laser fiber with a molded reflective surface and sealed cavity, where the laser energy is reflected transversely, reducing the risk of surface deformities and allowing for customizable beam profiles, and incorporating a metal cap with fluid channels for cooling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the beveled surface is formed by mechanical polishing, then the surface can be manufactured, but the surface becomes deformed due to fusion with fiber cap, resulting in non-uniform laser energy distribution

Engineering Contradiction:

Improvesurface formationVSAvoidsurface uniformity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent replaces mechanical polishing with a molding process to form the beveled surface. The fiber cap is molded with the beveled surface geometry integrated into the mold, eliminating the need for subsequent mechanical polishing operations that cause deformation during fusion.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The beveled surface geometry is predetermined and built into the fiber cap mold before assembly. This preliminary formation of the correct geometry prevents deformation that would occur if the surface were formed mechanically after assembly and fusion.

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If mechanical polishing is used to form the beveled surface, then the surface can be created, but laser energy is scattered at deformed areas, leading to irregular output beam

Engineering Contradiction:

Improvesurface creationVSAvoidlaser energy delivery

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent eliminates mechanical polishing by using a molding process that forms the beveled surface geometry directly in the fiber cap. This integration ensures uniform surface quality throughout the beveled area, preventing laser energy scattering and maintaining reliable, uniform laser delivery.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The beveled surface formation is merged with the fiber cap manufacturing process itself through molding. This integration ensures that the surface geometry and uniformity are achieved simultaneously during fabrication, eliminating the separate mechanical polishing step that causes deformation and scattering.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If mechanical polishing is used, then the surface can be formed, but the process is time-consuming and costly

Engineering Contradiction:

Improvesurface formationVSAvoidmanufacturing efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent replaces time-consuming mechanical polishing with a more efficient molding process. The beveled surface is formed directly during fiber cap manufacturing, significantly reducing manufacturing time and cost while improving productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The beveled surface geometry is prepared in advance within the mold design, allowing direct formation during the primary manufacturing process. This eliminates the need for subsequent time-consuming mechanical polishing operations, thereby increasing productivity.

Inventive Principle:

Principle #10Preliminary action

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 solution provides a reliable and cost-effective means to deliver precise laser energy with improved beam uniformity and reduced risk of fiber damage, enabling more effective medical treatments while reducing manufacturing costs.

Implementation Method 1

Laser energy discharged from the distal end along a central axis of the optical fiber is reflected off the molded reflective surface in a direction that is transverse to the central axis

Methodology Applied

Scientific EffectReflection: Reflection

Implementation Method 2

A beveled terminating end surface 320 is formed at the distal end of the core 308. An air cavity 322 surrounds the surface 320 to promote total internal reflection of laser energy 310 off the surface 320

Methodology Applied

Scientific EffectTotal internal reflection: Total Internal Reflection

Data Source

PatentUS11399892B2Side-fire laser fiber having a molded reflective surface

Publication Date: 2022.08.02 BOSTON SCIENTIFIC SCIMED INC

AI summary

A side-fire laser fiber includes an optical fiber having a distal end and a fiber cap. The fiber cap is coupled to the distal end of the optical fiber and includes a molded reflective surface and a sealed cavity. The molded reflective surface defines a wall of the cavity. Laser energy discharged from the distal end along a central axis of the optical fiber is reflected off the molded reflective surface in a direction that is transverse to the central axis.