Abstract:
A method for manufacturing an optical probe which uses optical fibers arranged in parallel which can be easily bent by application of a heat source to improve the performance of the optical probe. The bend may be created by application of heat by a heat source and then forcing a change in the shape of the optical probe. Alternatively, an optical probe may be bent in room temperature and then by applying heat from a heat source, a bend can be created in the optical probe.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims priority from U.S. Provisional Application No. 60/952,768 filed on Jul. 30, 2007 in the United States Patent Office, the disclosure of which is incorporated herein in its entirety by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates to an optical probe and more particularly, to a method for manufacturing a probe which uses optical fibers arranged in parallel which can be easily bent by application of a heat source to improve the performance and reduce the diameter of the optical probe. 
         [0004]    2. Description of the Related Art 
         [0005]    Industry has been working on varying angles of light incident to various materials to obtain information about optical properties of materials at different depths from surfaces for sensing or diagnostic purposes. For Example, Early Cervical Cancer Detection is based on looking at light interactions at different depths of epithelial layer of tissue. Generally, different incident angles of light illumination and collection are employed to look at different depths in tissue. Numerous automated diagnostic methods have been developed which allow faster, more effective patient management and potentially further reduce mortality. Accordingly, in much of the related technology specific focus is on the epithelial layer of tissue which is 300 to 500 microns thick where it is believed that cancer can be detected at the very onset. U.S. Pat. No. 7,202,947 is an example of this work. Earlier related patents on the same topic include U.S. Pat. Nos. 5,991,653 and 5,697,373. 
         [0006]    Many diagnostic techniques which use varying incident angles of light require the use of a probe, In some cases, the diameter of the probe must be small enough to fit into areas that are obstructed, difficult to access or when employed for medical purposes, it must be small enough to fit into areas where if the size is not adequately small enough, the prove may potentially give the patient discomfort or increase the potential for harm. Typical optical probes found in industry are relatively large in diameter because the fiber must be bent mechanically to achieve the required incident angle. This bend must be of sufficient radius to prevent the optical fiber from breaking. Additionally, the surface atypical probes are often stainless steel or some other metal material and highly reflective. One method used to reduce the reflection of the stainless steel surface is to use blackened or anti-reflective tapes or coatings. However, these tapes or coatings are generally not suitable for use in clinical use or other high purity environments. Additionally, probes used in the related art have had a significant spacing between fibers. This separation distance can make it hard to capture adequate light in fibers with a high angle of incidence to the probe tip because these fibers have an angled facet which presents significant optical losses between the fiber and the adjacent medium. 
       SUMMARY OF THE INVENTION 
       [0007]    Accordingly, the present invention has been made to solve the above-mentioned problems occurring in the related art, and an aspect of the present invention is to provide a method for manufacturing a medical optical probe which uses an optical fibers arranged in parallel Which can be easily bent by application of heat by a heat source to improve the performance of the medical probe 
         [0008]    Additional advantages, aspects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention. 
         [0009]    In an aspect of the present invention, an optical probe comprising arranging a plurality of optical fibers substantially in parallel and at least one of the plurality of fibers contains a bent portion. The bent portion of the fiber is towards the end of the probe. 
         [0010]    In another aspect of the present invention, the plural optical fibers are fixed in resin in the optical probe. 
         [0011]    In another aspect of the present invention, the plural optical fibers are fixed on a substrate in the resin, parallel inside an outer case, wherein said plural optical fibers are fixed in V-groves in the substrate. 
         [0012]    In another aspect of the present invention, wherein the resin is a low-reflective epoxy. 
         [0013]    In another aspect of the present invention, wherein said bent portion is bent by heating up the bent portion by a heat source. The heat source may apply heat ranging from 300 to 1400 degrees centigrade. 
         [0014]    In another aspect of the present invention, the bent portion is bent by first bending an optical probe in room temperature and then applying the heat source to the bent region. 
         [0015]    In another aspect of the present invention, the bent portion is bent by first applying the heat source to the bent region and then applying force to the optical probe. 
         [0016]    In another aspect of the present invention, the bent portion is bent at angle of 0 to 45 degrees. 
         [0017]    In another aspect of the present invention, the bent portion is bent at a predetermined angle by using a bending device. 
         [0018]    In another aspect of the present invention, the outer casing of said optical probe contains angled portions towards the end the optical probe. 
         [0019]    In another aspect of the present invention, the angled portions of said optical fibers have less than 200 μm sparing from one of a plurality of optical fibers and straight portions of said optical fibers have a 200 to 400 μm spacing from one of a plurality of optical fibers. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0020]    The above and other objects, features and advantages of the present invention will be apparent from the following detailed description taken in conjunction with the accompanying drawings, in which: 
           [0021]      FIGS. 1   a  and  1   b  illustrate a method to bend a portion of an optical fiber according to an exemplary embodiment of the present invention; 
           [0022]      FIG. 2  illustrates an optical probe which contains optical fibers according to an exemplary embodiment of the present invention; 
           [0023]      FIG. 3  illustrates an optical probe which contains optical fibers according to another exemplary embodiment of the present invention; 
           [0024]      FIG. 4  illustrates a trimmed probe age present at the end of the optical probe according to an exemplary embodiment of the present invention; 
           [0025]      FIGS. 5   a  and  5   b  illustrate a method to bend a portion of an optical fiber according to another exemplary embodiment of the present invention; 
           [0026]      FIGS. 6 and 7  illustrate a device and the use of the device to precisely bend an optical fiber according to an exemplary embodiment of the present invention; 
           [0027]      FIG. 8  illustrates another device that can be used to precisely bend an optical fiber according to another exemplary embodiment of the present invention. 
       
    
    
     DESCRIPTION OF EXEMPLARY EMBODIMENTS 
       [0028]    Advantages and features of the present invention and methods of accomplishing the same may be understood more readily by reference to the following detailed description of the exemplary embodiments and the accompanying drawings. The present invention may, however, be embodied in many different forms and should not be construed as being limited to the exemplary embodiments set forth herein. Rather, these exemplary embodiments are provided so that this disclosure will be thorough and complete and will fully convey the concept of the invention to those skilled in the art, and the present invention will only be defined by the appended claims. Like reference numerals refer to like elements throughout the specification. 
         [0029]      FIGS. 1   a  and  1   b  are views illustrating an optical fiber according to an exemplary embodiment of the present invention. In  FIG. 1   a,  the optical fiber  1  typically has a diameter d of 125 μm. One of ordinary skill in the art would comprehend that concepts of the present invention can be implemented with varying diameters d. In this exemplary embodiment, a heat source  2  applies heat  3  to region  4  of the optical fiber  1 . Region  4  is preferably towards the end of the optical fiber  1 . The heat source  2  may include a CO 2  LASER, electric heater, infrared furnace and a flame. The temperature of the heat  3  being applied to the fibers in section  4  of the optical fiber  1  is typically at least 300 degrees centigrade. However, it is preferred that a temperature from 300 degrees to 1400 degrees centigrade is applied, The temperature of the heat  3  that is applied varies on the glass composition of the fiber  1 . The specific temperature of the heat is not critical to the invention; rather it must simply be sufficient to create a permanent bend in the fiber  1 . 
         [0030]      FIG. 1   a  illustrates that the heat source  2  applies heat  3  at a temperature of 1400 degrees centigrade to region  4  of the optical fiber  1 . If only heat  3  and no other physical three is applied on the optical fiber  1 , there is no change in the shape of the optical fiber  1 . In such a scenario, the optical fiber  1  at region  4  merely heats up and cools off. Therefore, the optical fiber  1  retains its shape pre-application of heat  3  from heat source  2  and post-application of heat  3  from heat source  2 . 
         [0031]    As stated above, mere application of heat  3  by a heat source  2  does not lead to the change of shape of the optical fiber  1 . Therefore, to cause a bend in the optical fiber  1  in region  4  to which the heat  3  is being applied, a downward force  5  is applied towards the far end of the optical fiber  1 . 
         [0032]      FIG. 1   b,  illustrates the result of the application of the force  5  which causes a bend in the optical fiber  1  at region  4 . After, the optical fiber  1  is bent to an angle α of a desired amount, the application of the heat  3  by the heat source  2  is halted. As the optical fiber  1  cools, it retains its bent shape. Accordingly, an optical fiber  1  can be reshaped without having to use any other form of support or utensils to preserve that shape. Thereafter, the optical fiber  1  has a straight portion  21  and an angled portion  22 . 
         [0033]      FIG. 2 , illustrates an optical probe  100  using multiple optical fibers  1  bent according to an exemplary embodiment of the present invention. Four optical fibers  1  are arranged substantively in parallel to form the optical probe  100 . One of the optical fibers  1  contains an angled portion  22 . Some of these optical fibers  1  are used for light illumination while some of them are used for detecting light. These optical fibers  1  are fixed in a resin  102  inside an outer case  103 . In the exemplary embodiment illustrated in  FIG. 2 , the outer case  103  is a stainless steel pipe, Furthermore, any curable resin may be used for the resin  102 , but low reflection material is preferable. One of ordinary skill in the art would comprehend that materials with similar properties can be used to function as the resin  102 . 
         [0034]    Additionally, the outer surface of the optical probe  100  may use non-reflective epoxies rather than a metal probe face (not illustrated). Therefore, noise generated by multi reflection between the probe surface and tissue may be reduced. 
         [0035]    Further, optical fibers  1  can also be fixed within a substrate in the resin  102 .  FIG. 3  illustrates according to another exemplary embodiment of the present invention, four optical fibers  1  fixed on a substrate  104  with four V-grooves  105 . One of the optical fibers  1  which has been bent applying any of the methods provided in the exemplary embodiments of the present invention, contains a straight portion  21  and an angled portion  22 . The straight portion  21  is aligned in a corresponding V-Groove  105 , while the angled portion  22  juts out. The presence of these V-Grooves  105  allows for precise fiber arrangement. Once of ordinary skill in the art would comprehend that the substrate  104  may contain an unlimited amount of V-Grooves  105  and the substrate  104  is not limited to the shape illustrated in  FIG. 3 . Furthermore, in this exemplary embodiment, in sections of the optical probe  100  which contains angled portions  22  of optical fibers  1 , there is a 200 μm spacing between the optical fibers  1 , while portions of the optical probe  100  with straight portions of fiber  1  have a 200 to 400 μm spacing between the optical fibers  1 . Due to the lessened spacing between the optical fibers  1 , the desired bend is achieved over a wide spectrum of diameters including a relatively smaller relative diameter of 3 mm. This allows for prevention of “beam” type stresses or breaking forces being applied to the fiber. 
         [0036]      FIG. 4  is an illustration of a side view trimmed probe edge  31  present at one end of optical probe  100  according to an exemplary embodiment of the present invention. As discussed above one of the optical fibers  1  has the bent region  4  and therefore the angled portion  22  towards the end of the optical probe  100 . As illustrated in  FIG. 4 , the outer casing  103  contains a trimmed probe edge  31  towards the end of the optical probe  100 . As the optical probe  100  is round, the trimmed probe edge  31  goes all the way around as well. The trimmed probe edge  31  is at a sharp angle which aids in reducing reflective profile of a stainless steel tube edge. 
         [0037]      FIGS. 5   a  and  5   b , illustrate another exemplary embodiment of the present invention. In  FIG. 5   a , the optical fiber  1  is bent in room temperature by application of forces  15  and  15 ′ at the respective ends. Thereafter, a heat source  2  applies heat  3  to a region  4  of the optical fiber  1 . The region  4  is preferable closer to one end of the optical probe  1 . Region  4  of the optical fiber  1  which is exposed to heat  3  from the heart source  2  become soft and the region  4  bends in accordance with angles depending on forces  15  and  15 ′ that are applied to the respective ends.  FIG. 5   b  illustrates the result of the application of the respective threes  15  and  15 ′, as well as heat  3  from the heat source  2 , resulting in a bend with approximately an angle α of 30 degrees being created. 
         [0038]    However, the application of the present inventions as presented in the exemplary embodiments of  FIGS. 1 and 5  does not necessarily lead to an accurate selection of the angle of the bend of the optical fiber  1 . As the optical fiber  1  is used for sensitive diagnosis, any changes in shape must be extremely precise. For this purpose,  FIG. 6  illustrates a plate which can be used to precisely bend the optical probe at a particular angle α according to another exemplary embodiment of the present invention. 
         [0039]      FIG. 6  displays a plate  6  which contains a mechanism to precisely choose an angle of the bend in the optical fiber  1 . The plate  6  contains a guide  7  with a fixed portion  8  and a movable portion  9 . The fixed portion and the movable portion are connected at a pivot point  10 . The plate displays varying angles to which a user can move the outside edge of the movable portion  9 . Accordingly, in an exemplary embodiment if a user wants a 30 degree angle of bend, the user moves the outside edge to 30 degrees and locks the movable portion at that angle through a locking mechanism (not illustrated). Furthermore, the fixed portion  7  contains latches  11  or another locking mechanism to secure the optical fiber  1  to the guide  7 . 
         [0040]      FIG. 7  illustrates the plate  6  of  FIG. 6  being utilized to bend the optical fiber  1  so that the optical fiber  1  has a bend angle α of 30 degrees. An optical fiber  1  is placed on the plate  6  and secured on the fixed portion  8  of the guide  7  using latches  11 , A user previously sets the moving portion  9  to be at an angle α of thirty degrees. Thereafter, a heat source  2  applies heat  3  at a region  4  of the optical fiber  1  which straddles the pivot point  10 . Due to the heat  3 , the optical fiber  1  at region  4  softens and when a force  5  is applied downwards, a bend is created in the optical fiber  1  at region  4 . A force  5  is continually applied till the angled portion  22  of the optical fiber  1  is completely flat against the movable portion  9  of the guide  7 . Thereafter, as soon as the fiber  1  is no longer exposed to the heat source  2 , the optical fiber  1  begins to cool off. As the optical fiber  1  cook off, it retains its shape autonomously, therefore preserving the bent shape of the optical fiber  1  at exactly thirty degrees. 
         [0041]      FIG. 8  illustrates another mechanism to precisely bend an optical fiber  1  according to an exemplary embodiment of the present invention. In this exemplary embodiment, the optical fiber  1  is first bent in room temperature and then a heat source  2  applies heat  3  to a region  4  of the optical fiber  1  to cause a bending of the optical fiber  1  at region  4 . The forces that are applied to bend the optical fiber  1  in room temperature are applied by Force Applying Devices (FADs)  12  and  13 . FAD  12  may either be fixed or movable in the vertical direction. FAD  13  may further be fixed or movable in the horizontal direction. FADs  12  and  13  can not only apply the forces to cause a bend but may also independently hold the optical fiber  1 . Previous calculations allow the user to arrange the positions of the FADs  12  and  13  depending on a desired angle α and on the position of the optical fiber  1  where the user desires the bend (therefore, the region  4 ) to occur. 
         [0042]    One of ordinary skill in the art would comprehend that the structure can be slightly altered to implement the principles of the present invention to produce similar results. 
         [0043]    In another exemplary embodiment of the present invention in which the heat source  2  of FIGS.  1  and  5 - 8  is a flame, the flame is formed by a combination of C x H y O z  and Oxygen. The x, y and z in C x H y O x  each represent respective integer values including zero. 
         [0044]    As described above, according to the exemplary embodiment of the present invention, a medical probe with a narrow width, made of non-reflective material, is bent accurately, thus the performance of the medical probe in clinical studies can be improved. 
         [0045]    Although exemplary embodiments of the present invention have been described for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims. The foregoing embodiments are merely exemplary and are not to be construed as limiting the present invention. Therefore, the scope of the present invention should be defined by the accompanying claims and their legal equivalents.