Optical Probe Interlocking Joint for High-Temperature Ophthalmic Use

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Solution Overview

Problem

Ophthalmic surgical probes face challenges in maintaining structural integrity due to heat absorption issues, leading to 'hot spots' and potential detachment during procedures, especially when blood is present, causing high temperature failures.

Innovation Solution

A laser-induced interlocking attachment method is applied to the cannula/ferrule joint of an optical probe, creating engaged deformations that enhance thermal robustness and structural integrity, allowing the probe to withstand higher temperatures and prevent detachment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If adhesive is used to join components of the surgical probe, then assembly is simple and low-cost, but structural integrity fails at high temperatures causing detachment

Engineering Contradiction:

Improveassembly simplicityVSAvoidstructural integrity at high temperature

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The joining process is segmented into two distinct stages: first, adhesive bonding for initial assembly and alignment; second, laser welding for permanent high-temperature structural integrity. This segmentation allows each method to perform its optimal function without compromise.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The adhesive is applied as a preliminary action to join components before the final laser welding step. This preliminary bonding holds components in proper alignment and position during assembly, enabling subsequent welding to create the permanent high-temperature resistant joint.

Inventive Principle:

Principle #10Preliminary action

2Temperature

If thermally conductive materials are used to reduce hot spots, then heat transfer efficiency improves, but high temperature failures still occur when blood absorbs light on the probe tip

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidresistance to high temperature failure

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The laser energy that would normally be absorbed by blood causing harmful heating is instead utilized to create beneficial engaged deformations at the cannula-ferrule joint. The same laser technology that poses a thermal risk is converted into a solution that strengthens the structural connection.

Inventive Principle:

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

Solution Approach 2:

The joint structure combines multiple materials with complementary properties: adhesive material for initial bonding, cannula material with specific thermal and mechanical properties, and ferrule material that receives the engaged deformation. This composite approach allows the joint to withstand temperatures that would fail单一 materials.

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If adhesive bonding is used to attach the beam splitter, then component attachment is simple, but degradation and failure occur when hot spots develop near the adhesive joint

Engineering Contradiction:

Improvecomponent attachment simplicityVSAvoidjoint strength near hot spots

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The attachment process is divided into two sequential operations: adhesive application for initial component attachment, followed by laser-induced engaged deformation to create thermal-resistant reinforcement. This segmentation allows simple initial assembly while ensuring high-temperature joint strength.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The adhesive serves as an intermediary material that facilitates initial component attachment and positioning, while the engaged deformation created by laser energy acts as a secondary intermediary that provides the final high-temperature resistant bonding mechanism.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 interlocking attachment significantly reduces the risk of degradation and detachment of the cannula/ferrule joint, enabling the optical probe to maintain structural integrity during surgical procedures and allowing for efficient heat transfer, thus preventing high temperature failures.

Implementation Method 1

applying laser energy to the cannula causes the cannula to deform and create an interlocking attachment with the ferrule

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

applying laser energy to the cannula causes the cannula to deform

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentEP3134045B1Surgical probe with interlocking attachment

Publication Date: 2024.02.21 ALCON INC

Figure 1~7
Figure 2a
Figure 2b

AI summary

A method of manufacturing an optical probe for use in ophthalmic procedures can comprise: positioning a ferrule within a proximal portion of a cannula, wherein an optical fiber extends at least partially through the ferrule towards an optical element disposed within a distal portion of the cannula; and coupling the cannula to the ferrule by applying laser energy to the cannula. An optical probe can be provided that includes a cannula including a proximal portion and a distal portion; a ferrule disposed within the proximal portion of the cannula, the cannula and the ferrule coupled together by engaged deformations in the cannula and the ferrule; and an optical fiber positioned at least partially within the optical probe, the optical fiber configured to receive a light from a light source and guide the light to an optical element positioned within the distal portion of the cannula.