Optical Fiber Packaging System with Cylindrical Spool Design
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Solution Overview
Problem
Current packaging solutions for surgical and optical fibers are inadequate in protecting the fragile fibers during handling, shipping, and sterilization, as they fail to securely hold various diameters, prevent damage from pinch points, and maintain sterility, especially due to the conflicting mechanical properties of small and large core fibers.
Innovation Solution
A packaging system comprising a rigid tray with opposing circular troughs that encase the fiber, a press-fit lid and base for secure storage and dispensing, and a tip protector to safeguard the distal end, along with ventilation for sterilization, allowing for controlled dispensing and accommodating different fiber diameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a single plane card with tabs is used to hold optical fibers, then the fiber can be stored and dispensed, but the fiber is damaged at pinch points and difficult to remove
Solution Approach 1:
The patent replaces the flat planar card with a cylindrical form factor. The fiber is wound around a cylindrical spool or drum, eliminating the sharp corners and tabs that create pinch points. The curved surface of the cylinder distributes mechanical stresses evenly along the fiber length, preventing localized damage while allowing smooth winding and unwinding during dispensing and removal operations.
2Adaptability or versatility
If multiple tabs are used to support different fiber sizes, then various fiber diameters can be accommodated, but the structure becomes complex and fibers can spring off
Solution Approach 1:
The cylindrical spool design serves multiple functions with a single structure: it winds and stores fibers of varying diameters, provides mechanical support through the winding tension, enables controlled dispensing through unwinding, and prevents fiber springing off through the continuous curved surface. The cylindrical geometry universally accommodates different fiber sizes without requiring multiple specialized tabs or adjustment mechanisms.
3Volume of stationary object
If the optical fiber is wound tightly to fit in compact packaging, then storage density is improved, but large core fibers become dangerous and small core fibers fracture
Solution Approach 1:
The cylindrical spool provides a controlled curvature radius that balances compactness with fiber safety. By optimizing the spool diameter, the design achieves tight winding for compact packaging while maintaining a minimum bend radius that prevents fracture of small core fibers and reduces springing danger of large core fibers. The circular geometry distributes mechanical stresses uniformly, preventing the localized stress concentrations that occur with sharp corners or irregular shapes.
4Ease of operation
If the cleaved distal end is exposed for surgical use, then the fiber can be connected to the laser system, but the sharp edge is easily damaged and can puncture packaging
Solution Approach 1:
The hazardous cleaved distal end with its sharp edge is extracted or separated from the main fiber body in terms of packaging handling. The fiber is wound on the spool with the distal end positioned in a controlled manner, allowing connection operations without exposing the entire fiber length to damage risks. The cylindrical winding structure isolates the vulnerable sharp end from pinch points and mechanical stresses that affect the coiled portion.
Data Source
AI summary
A packaging system and method for use with a fiber, and in particular, an optical fiber of the type typically used for surgical procedures, in order to protect the fiber during storage and shipping and also allow the fiber to be easily dispensed in a controlled manner by an end user.