The present disclosure relates generally to methods and systems for manufacturing a thermally robust laser probe assembly.
A laser probe assembly may be used during a number of different procedures and surgeries. As an example, a laser probe assembly may be used during retinal laser surgeries in order to seal retinal tears, among other things. Laser light is typically transmitted from a laser source through an optical fiber cable. The optical fiber cable proximally terminates in a laser connector, which connects to the laser source, and distally terminates in a probe assembly that is manipulated by the surgeon. Note that, herein, a distal end of a component refers to the end that is closer to a patient's body, or where the laser light is emitted out of the laser probe. On the other hand, the proximal end of the component refers to the end that is facing away from the patient's body or in proximity to, for example, the laser source.
The probe assembly comprises a hand-piece coupled to a cannula that is partly inserted in a patient's eye. The optical fiber cable extends through the hand-piece and the cannula to transmit laser light onto the patient's retina. A lens may also be used to collimate and project the laser beams propagated by the optical fiber on the patient's retina for increased performance. Typically, the lens is placed in front of the optical fiber and is attached to the cannula.
In certain cases, the optical fiber cable houses more than one optical fiber, enabling the laser probe assembly to deliver more than one photocoagulation beam at the same time. For example, in certain cases, the optical fiber cable may house four optical fibers or a multi-core optical fiber, In such cases, due to the high power throughput a confined space (e.g., within the cannula), the cannula and the lens may experience excessive heat when blood or other dark materials exist in front of or at least partially block or touch the tip of the cannula or the lens. In some cases, the excessive heat is created because the laser beams propagated by the optical fibers are reflected back by the blood or the dark material onto the lens, the cannula, and the adhesive bonding between the lens and the cannula. This overheating and thermal run-away results in the cannula and the lens melting and also causing the lens to detach from the cannula.
The present disclosure relates generally to methods and systems for manufacturing a thermally robust laser probe assembly.
Particular embodiments of the present invention provide a probe assembly comprising a cannula through which one or more optical fibers extend at least partially for transmitting laser light from a laser source to a target location. The probe assembly further comprises a lens housed in the cannula and a protective component at a distal end of the cannula, wherein the lens is positioned between the one or more optical fibers and the protective component, and wherein the distal end of the cannula is sealed at a sealing location of the probe assembly.
Particular embodiments of the present invention provide a sealant application system comprising a stage machine comprising a mount configured to hold a sealant applicator comprising a wire, wherein the stage machine is configured to position the wire at a sealing location at a distal end of a cannula of a probe assembly. The sealant application system also comprises a cannula holder comprising a groove for holding the cannula and an actuator configured to rotate the cannula once the stage machine has positioned the wire at the sealing location such that sealant on the wire is able to be applied to the sealing location.
Particular embodiments of the present invention provide a method of manufacturing a probe assembly. The method comprises positioning a wire coated with sealant at a sealing location at a distal end of a cannula of the probe assembly. The method further comprises rotating the cannula to apply the sealant to the sealing location.
The following description and the related drawings set forth in detail certain illustrative features of one or more embodiments.
The appended figures depict certain aspects of the one or more embodiments of the present invention and are therefore not to be considered limiting of the scope of this disclosure.
To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the drawings. It is contemplated that elements and features of one embodiment may be beneficially incorporated in other embodiments without further recitation.
Aspects of the present disclosure provide methods and systems for manufacturing a thermally robust laser probe assembly.
As described above, a probe assembly with a high power throughput may experience overheating (e.g., when blood contaminates the lens or blocks the laser beam) such that the lens within the cannula may melt. A melting lens may also detach from the cannula resulting in the probe assembly malfunctioning.
In certain embodiments of the present invention, in order to protect lens 110, a protective component is attached to and/or inserted into, the distal end of a probe assembly's cannula. The protective component (e.g., protective window) is placed in front of the distal end of the lens that is itself placed in front of one or more optical fibers. The protective component protects the lens by restricting movements of the lens along the cannula and/or also by preventing the lens from detaching from the cannula.
Protective component 212 comprises proximal end 215 and distal end 213. In certain embodiments, protective component 212 comprises an optically clear or transparent material. Examples of suitable transparent materials include sapphire, fused silica, or other glass or ceramic materials with high transition temperatures.
In certain embodiments, protective component 212 is attached to cannula 104 by way of press-fitting component 212 into cannula 104. Press-fitting, also known as interference fitting or friction fitting, is a technique for securing protective component 212 to cannula 104, the securing being achieved by friction between protective component 212 and cannula 104 after protective component 212 is pushed into cannula 104. In certain embodiments, protective component 212 may be attached to cannula 104 using brazing techniques.
In certain cases, protective component 212 and cannula 104 do not have matching dimensional tolerances. Dimensional tolerances are assigned to parts, such as protective component 212 and cannula 104, as boundaries for acceptable build for manufacturing purposes. In situations where protective component 212 and cannula 104 do not have matching tolerances, the inner diameter of cannula 104 may be larger than the outer diameter of protective component 212 in certain areas, resulting in a gap. Also, in some situations, protective component 212 and cannula 104 may have surfaces with different degrees of roughness. Such incompatibilities and differences in dimensional tolerance and surface roughness may make the probe vulnerable to leaking. For example, fluids such as balanced salt solution (BSS), perfluorooctane (PFO), blood, etc., may leak into the cannula and reach in-between the lens and the fibers (e.g., lens 210 and fiber 108 of
Accordingly, certain embodiments described herein relate to sealant application techniques for sealing openings or gaps in-between the inner diameter of the distal end of a cannula and the outer diameter of a protective component attached to the distal end of the cannula.
As the protective component and the cannula tip are of miniature size, applying a very small amount of sealant (e.g., adhesive material) accurately to the cannula and the protective component, at a sealing location described below, can be a challenge. Without a well-controlled sealant application technique, the protective component may be contaminated by sealant, resulting in blocking of the laser beam and a potential failure of the probe assembly. Also, excess sealant may be applied to the outer surface of the distal end of the cannula, resulting in an enlargement of the outer diameter of the distal end of the cannula, thereby, making it difficult for the surgeon to insert and remove the probe assembly's cannula into and from a trocar cannula that is inserted into the patient's body part.
Referring back to
Using the XYZ stage machine, wire 532 may be precisely placed at the sealing location, such that the sealant makes contact with both protective component 212 and cannula 104 at the sealing location. Once wire 532 is placed at the sealing location, cannula 104 may be rotated so that the sealant can be evenly distributed around and applied to the entire circumference of protective component 212 at the sealing location.
At the same time, as shown in
In certain embodiments, the duration for which cannula 104 is rotated and the speed at which cannula 104 is rotated are parameters that can be controlled and adjusted by a user. In certain other embodiments, the actuator is controlled and operated by a control module. In such embodiments, the control module operates the actuator for a certain number of rotations (e.g., or a certain amount of time) at a certain speed. The control module may also be configured to terminate the operation of the actuator after a user-defined number of rotations is performed.
In certain embodiments, a clamp may be used to further secure cannula 104 and prevent any undesired movements during the sealant application process. Using a clamp is especially advantageous when cannula 104 is not straight. For example, in some cases, a cannula's distal tip is curved as shown in
As shown in
At step 1002, a cannula (e.g., cannula 104) of a probe assembly is positioned in a u-shaped groove of a cannula holder, such as by a user. As described in relation to
At step 1004, a sealant applicator's wire is dipped into a sealant.
At step 1006, the sealant applicator is placed in an XYZ stage mount of an XYZ stage machine.
At step 1008, the position of the sealant applicator is adjusted such that a wire of the sealant applicator is placed at a sealing location of a laser probe. Placing the wire at the sealing location causes the sealant on the wire to be applied to at least an area of the sealing location (e.g., sealing location 430 of
At step 1010, the operation of the actuator to rotate the cannula is initiated. Rotating the cannula allows for the sealant on the wire to be applied to all areas of the sealing location.
At step 1012, optionally the XYZ stage machine moves the wire forward in order to apply sealant in other areas (e.g., lower areas) of the wire to the sealing location. The actuator continues to rotate the cannula until the sealing location is completely sealed.
Performing steps 1002 through 1010 (and optionally 1012) of flowchart 1000 results in a thermally robust laser probe assembly with a sealed distal end that prevents or, at least, reduces the amount of fluids that may leak into the probe. In certain embodiments, after the sealing location is sealed, the probe may be dual-cured (ultraviolet (UV)+thermal curing of the adhesive).
The foregoing description is provided to enable any person skilled in the art to practice the various embodiments described herein. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments. Thus, the claims are not intended to be limited to the embodiments shown herein, but are to be accorded the full scope consistent with the language of the claims.
This application: (a) is a continuation application of U.S. Non-Provisional patent application Ser. No. 16/218,243, filed Dec. 12, 2018, titled “METHODS AND SYSTEMS FOR MANUFACTURING A THERMALLY ROBUST LASER PROBE ASSEMBLY,” whose inventors are Chenguang Diao, Christopher Cook, and Alireza Mirsepassi, which is hereby incorporated by reference in its entirety as though fully and completely set forth herein; (b) claims the benefit of priority of U.S. Provisional Patent Application Ser. No. 62/597,550 titled “SURGICAL PROBE WITH SHAPE-MEMORY MATERIAL,” filed on Dec. 12, 2017, whose inventors are Alireza Mirsepassi, Kambiz Parto and Christopher Cook (U.S. Non-Provisional patent application Ser. No. 16/218,243 claimed the benefit of priority of U.S. Provisional Patent Application Ser. No. 62/597,550), which is hereby incorporated by reference in its entirety as though fully and completely set forth herein; (c) claims the benefit of priority of U.S. Provisional Patent Application Ser. No. 62/598,653 titled “MULTIPLE-INPUT-COUPLED ILLUMINATED MULTI-SPOT LASER PROBE,” filed on Dec. 14, 2017, whose inventors are Ronald T. Smith, Alireza Mirsepassi and Jochen Horn (U.S. Non-Provisional patent application Ser. No. 16/218,243 claimed the benefit of priority of U.S. Provisional Patent Application Ser. No. 62/598,653), which is hereby incorporated by reference in its entirety as though fully and completely set forth herein; (d) claims the benefit of priority of U.S. Provisional Patent Application Ser. No. 62/622,299 titled “THERMALLY ROBUST MULTI-SPOT LASER PROBE,” filed on Jan. 26, 2018, whose inventors are Alireza Mirsepassi and Christopher Cook (U.S. Non-Provisional patent application Ser. No. 16/218,243 claimed the benefit of priority of U.S. Provisional Patent Application Ser. No. 62/622,299), which is hereby incorporated by reference in its entirety as though fully and completely set forth herein; and (e) claims the benefit of priority of U.S. Provisional Patent Application Ser. No. 62/630,865 titled “MULTIPLE-INPUT-COUPLED ILLUMINATED MULTI-SPOT LASER PROBE,” filed on Feb. 15, 2018, whose inventors are Ronald T. Smith, Alireza Mirsepassi, Mark Harrison Farley and Gerald David Bacher (U.S. Non-Provisional patent application Ser. No. 16/218,243 claimed the benefit of priority of U.S. Provisional Patent Application Ser. No. 62/630,865), which is hereby incorporated by reference in its entirety as though fully and completely set forth herein.
Number | Date | Country | |
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62597550 | Dec 2017 | US | |
62598653 | Dec 2017 | US | |
62622299 | Jan 2018 | US | |
62630865 | Feb 2018 | US |
Number | Date | Country | |
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Parent | 16218243 | Dec 2018 | US |
Child | 17193364 | US |