Abstract:
Embodiments of endo-illuminators and related methods are disclosed. One embodiment of an illuminator can comprise a cannula defining a passage, an optical element disposed at an end of the cannula, and an optical fiber running through the passage with the distal end of the optical fiber in contact with the optical element. The optical fiber includes at least a heat preconditioned distal portion that terminates in the distal end that is in contact with the optical element. One embodiment of a method can comprise inserting an optical fiber through a proximal portion of a cannula and optical element assembly until the distal end of the optical fiber contacts the optical element, heating a distal portion of the optical fiber to between a softening temperature and a melting temperature for a period of time to cause the distal portion to axially shrink and moving the optical element so that the optical element is in contact with the distal end of the optical fiber when the distal portion of the optical fiber has axially shrunk. Moving the optical element so that the optical element is in contact with the distal end of the optical fiber when the distal portion of the optical fiber has axially shrunk can comprise applying a force to the cannula and optical element assembly to maintain the optical element in continuous contact with the distal end of the optical fiber while the optical fiber axially shrinks.

Description:
TECHNICAL FIELD OF THE INVENTION 
       [0001]    Systems and methods disclosed herein relate generally to surgical instrumentation. In particular, the systems and methods relate to surgical instruments for illuminating an area during eye surgery. Even more particularly, the systems and methods relate to illuminators for illumination of a surgical field that are preconditioned to relieve stress. 
       BACKGROUND OF THE INVENTION 
       [0002]    In ophthalmic surgery, and in particular in vitreo-retinal surgery, it is desirable to use a wide-angle surgical microscope system to view as large a portion of the retina as possible. Wide-angle objective lenses for such microscopic systems exist, but they require a wider illumination field than that provided by the cone of illumination of a typical fiber-optic probe. As a result, various technologies have been developed to increase the beam spreading of the relatively incoherent light provided by a fiber-optic illuminator. These known wide-angle illuminators can thus illuminate a larger portion of the retina as required by current wide-angle surgical microscope systems. 
         [0003]    Current wide-angle illuminators can experience run-away heating that degrades the performance of the illuminator. Run-away heating occurs when the cannula of an illuminator absorbs light from the optical fiber running through the illuminator and, consequently, increases in temperature. As the cannula heats, the optical fiber may begin to deform, causing even more light to be incident on the cannula, increasing the temperature of the cannula further and, hence, increasing the deformation in the optical fiber. This cycle can lead to catastrophic failure of the illuminator. 
       SUMMARY 
       [0004]    The various embodiments of the method and system of the present invention provide for an illuminator that is resistant to run-away heat deformation. In general, the optical fiber of the illuminator undergoes heat preconditioning at its distal portion to relieve axial stress at the distal portion prior to or in lieu of the distal portion being fixed in place relative to other components of the illuminator. Such preconditioned illuminators can be used for longer periods of time using more intense light than traditional illuminators. 
         [0005]    According to one embodiment, an illuminator can comprise a cannula defining a passage, an optical element disposed at a distal end of the cannula, and an optical fiber running through the passage with the distal end of the optical fiber in contact with the optical element. The optical fiber includes at least a heat preconditioned distal portion that terminates in the distal end that is in contact with the optical element. 
         [0006]    One embodiment of preconditioning an illuminator can comprise inserting an optical fiber through a proximal portion of a cannula/optical element assembly until the distal end of the optical fiber contacts the optical element, heating a distal portion of the optical fiber to between a softening temperature and a melting temperature for a period of time to cause the distal portion to axially shrink and moving the optical element so that the optical element is in contact with the distal end of the optical fiber when the distal portion of the optical fiber has axially shrunk. Moving the optical element so that the optical element is in contact with the distal end of the optical fiber when the distal portion of the optical fiber has axially shrunk can comprise applying a force to the cannula/optical element assembly to maintain the optical element in continuous contact with the distal end of the optical fiber while the optical fiber axially shrinks. In a vertical arrangement, this can be done through the force of gravity. 
         [0007]    Yet another embodiment of an illuminator method comprises inserting an optical fiber through a proximal portion of a cannula until the distal end of the optical fiber contacts a lens, vertically aligning the cannula with an opening defined by a heating member, lowering the heating member until the cannula is inserted a desired insertion depth in the opening, heating a distal portion of the optical fiber to between a softening temperature and a melting temperature for a period of time to cause the distal portion to axially shrink and allowing the cannula to move so that the lens remains in contact with the distal end of the optical as the distal portion axially shrinks. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0008]    A more complete understanding of the various embodiments and the advantages thereof may be acquired by referring to the following description, taken in conjunction with the accompanying drawings in which like reference numbers indicate like features and wherein: 
           [0009]      FIG. 1  is a simplified diagram of a surgical system; 
           [0010]      FIG. 2  is a diagrammatic representation of a portion of an illuminator; 
           [0011]      FIG. 3  is a graph showing data for run-away thermal deformation; 
           [0012]      FIG. 4A  is a diagrammatic representation of one embodiment of a system for preconditioning an illuminator; 
           [0013]      FIG. 4B  is a diagrammatic representation of one embodiment of an arrangement during preconditioning an illuminator; 
           [0014]      FIG. 5  is a diagrammatic representation of another embodiment of a system for preconditioning an illuminator; 
           [0015]      FIG. 6  is a graph illustrating resistance to run-away thermal deformation due to preconditioning; 
           [0016]      FIG. 7  is a graph illustrating optical performance for a preconditioned versus non-preconditioned illuminator; and 
           [0017]      FIG. 8  is another graph illustrating optical performance for a preconditioned versus non-preconditioned illuminator. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0018]    Preferred embodiments of the present invention are illustrated in the FIGURES, like numerals being used to refer to like and corresponding parts of the various drawings. 
         [0019]      FIG. 1  is a simplified diagram of a surgical system  2  comprising a handpiece  10  for delivering a beam of light, which can be incoherent light, from a light source  12  through cable  14  to the distal end of a stem (cannula)  16 . Handpiece  10  can be any surgical handpiece as known in the art, such as the Revolution-DSP™ handpiece sold by Alcon Laboratories, Inc. of Fort Worth, Tex. Light source  10  can be a xenon light source, a halogen light source, or any other light source capable of delivering relatively incoherent light which can be transmitted through a fiber optic cable. By way of example, but not limitation, light source  10  can be an Accurus High Brightness Illuminator or a Constellation Illuminator, both manufactured and sold by Alcon Laboratories, Inc. Cable  14  can comprise a proximal optical fiber  13  of any gauge fiber optic cable as known in the art, but proximal optical fiber  13  is preferably a 20 or 25 gauge compatible fiber. Cannula  16  can be a small gauge cannula, preferably on the order of 19, 20, 23 or 25 gauge, as known to those having skill in the art. Stem  16  can be stainless steel or a suitable biocompatible polymer (e.g., PEEK, polyimide, etc.) as known to those having skill in the art. Cannulla  16  is configured to house a distal optical fiber  20 , as is more clearly illustrated in  FIG. 2 . Coupling system  32  can comprise an optical fiber connector at the proximal end of optical cable  14  to optically couple light source  12  to proximal optical fiber  13  within optical cable  14 . 
         [0020]    The proximal optical fiber  13 , distal optical fiber  20  and/or stem  16  can be operably coupled to the handpiece  10 , for example, via an adjusting mechanism. The adjusting mechanism can comprise, for example, a simple push/pull mechanism as known to those having skill in the art. Light source  12  can be operably coupled to handpiece  10  (i.e., optically coupled to proximal optical fiber  13  within optical cable  14 ) using, for example, standard SMA (Scale Manufacturers Association) optical fiber connectors at the proximal end of fiber optic cable  14 . This allows for the efficient transmission of light from the light source  12  to a surgical site through proximal optical fiber  13 , passing within handpiece  10 , through tapered section  26  (whether separate or integral to distal optical fiber  20 ) and optical fiber  20  to emanate from the distal end of distal optical fiber  20  and stem  16 . Light source  12  may comprise filters, as known to those having skill in the art, to reduce the damaging thermal effects of absorbed infrared radiation originating at the light source. The light source  12  filter(s) can be used to selectively illuminate a surgical field with different colors of light, such as, for example, to excite a surgical dye. 
         [0021]      FIG. 2  is a diagrammatic representation of a portion of one embodiment of an endo-illuminator of the present invention including a cannula  16 , a distal optical fiber  20  and a proximal optical fiber  13 . Distal optical fiber  20  can be optically coupled to proximal optical fiber  13  at coupling  30 , which can, in turn, be optically coupled to light source  12  (see  FIG. 1 ) to receive light from the light source  12 . Proximal optical fiber  13  can be a larger diameter, small NA (e.g., 0.5 NA) optical fiber, such as a 20 gauge compatible optical fiber. Distal optical fiber  20  can be a high numerical aperture (“NA”), smaller diameter (e.g., 25 gauge compatible) optical fiber or light pipe (e.g., cylindrical light pipe) located downstream of the proximal optical fiber. An optical element  26  is in contact with the distal end of distal optical fiber  20 . One or more of proximal optical fiber  13  or distal optical fiber  20  may include a protective sheath made out of a suitable material, such as PVC or other material. 
         [0022]    Fiber(s)  20  is terminated by optically coupling to optical element  26 . Optical element  26  can be an optical grade sapphire diffuser having a hemispherical or slightly larger than hemispherical shape. Optical element  26  can comprise a polished flat surface  28  at the distal end of stem  16  (i.e., facing out towards a surgical field) and a hemispherical surface  29  facing the distal end of fiber  20 . Optical element  26  is sized for housing within stem  16  (e.g., a 19 to 30 gauge cannula). For example, optical element  26  can have a diameter of about 0.75 mm to about 0.4 mm. The flat surface  28  of optical element  26  can be co-incident with the open aperture at the distal end of stem  16 . 
         [0023]    The embodiment of the high throughput endo-illuminator of this invention illustrated in  FIG. 2  comprises a low-NA, larger diameter proximal optical fiber  13  optically coupled to a tapered, high-NA, smaller diameter distal optical fiber  20 . The proximal optical fiber  13  can be a 0.50 NA plastic fiber (e.g., to match the NA of the light source  12 ), having a polymethyl methacrylate (PMMA) core and a 0.030″ (750 micron) core diameter, or another such comparable fiber as known to those having skill in the art. For example, such a fiber is compatible with the dimensions of the focused light spot from a 20 gauge light source  12 , such as the ACCURUS® illuminator manufactured by Alcon Laboratories, Inc. of Fort Worth, Tex. As one example, suitable fibers for the proximal optical fiber  13  of the embodiments of this invention are produced by Mitsubishi (Super-Eska fiber), which can be purchased through Industrial Fiber Optics, and Toray, which can be purchased through Moritex Corporation. 
         [0024]    Suitable fibers for the distal optical fiber  20  (downstream fiber) are Polymicro&#39;s High OH (FSU), 0.66 NA, silica core/Teflon AF clad optical fiber, having a core diameter that can be custom-made to required specifications and Toray&#39;s PJU-FB500 0.63 NA fiber (486 micron core diameter). Proximal optical fiber  13  and distal optical fiber  20  can be optically coupled together using any suitable mechanism known to those skilled in the art. 
         [0025]    In the embodiment of  FIG. 2 , the endo-illuminator comprises a proximal optical fiber  13  coupled to a distal optical fiber  20  at a coupling  30 . Various methods of coupling optical fibers are described in U.S. patent application Ser. No. 11/354,615 entitled “High Throughput Endo-Illuminator Probe”, filed Feb. 15, 2006, by Alcon Research, Ltd. (Attorney Docket No. 2825), which is hereby fully incorporated by reference herein. 
         [0026]    Cannula/optical element assembly  32  can be formed by selecting a cannula  16  of a desired diameter, such as a 23 gauge or 25 gauge cannula, selecting an optical element material that is slightly larger than the inner diameter cannula  16  and press fitting the optical element material into the cannula. For example, a sapphire ball can be selected and press fit into the distal end of cannula  16 . The optical element material can then be ground to a desired shape. In one embodiment, for example, the sapphire ball (and potentially the end of the cannula) can be ground away until the remaining optical element  26  is slightly larger than hemispherical. 
         [0027]    According to one method of assembly, the distal optical fiber  20  is slid into the proximal end of cannula  16  until the distal end of distal optical fiber  20  contacts the optical element  26 . If the cannula  16  were to be bonded at this point to optical fiber  20  without preconditioning optical fiber  20 , the resulting device is more susceptible to experience runaway heating and catastrophic failure during use. This results because plastic optical fiber is created through a drawing process that stretches the fiber axially before it hardens, causing potential energy to be stored in the fiber. When the fiber is heated and the softening point reached (around 105©)), the potential energy is released by axial shrinking and lateral swelling of the fiber. 
         [0028]    When a high-luminance xenon light is coupled to the fiber, a significant amount of luminous flux passes through the distal end of the probe through optical element  26  to illuminate the retina. However, from distal fiber  20 , some amount may be absorbed by cannula  16 , causing the distal end of cannula  16  and consequently the distal portion of distal fiber  20  to increase in temperature. If the temperature becomes high enough, the distal portion of distal fiber  20  will soften and axially shrink. Because the proximal end of the cannula is bonded to the distal fiber  20 , the distal end of distal fiber  20  will tend to pull away from the optical element  26 . This will cause more light to be absorbed by the cannula, which can cause a runaway cycle of thermal deformation to occur. This phenomenon is illustrated in  FIG. 3 . 
         [0029]      FIG. 3  is a graph illustrating flux over time through a cannula  16  in which cannula  16  is bonded to distal fiber  20  without preconditioning. Over time the luminous flux provided by the source light gradually increases and the output of the probe increases correspondingly. However, at  8  minutes, the flux of the source light becomes large enough to cause softening of the distal fiber  20 , causing distal fiber  20  to begin shrinking axially. As the distal end of distal fiber  20  moves away from optical element  26 , the output of the probe begins to gradually decrease and then, at around point 11 minutes, falls off precipitously, indicating catastrophic failure of the probe. 
         [0030]    To prevent such failure, distal optical fiber  20  can be preconditioned to release potential energy, thereby reducing or eliminating runaway thermal deformation. To precondition the distal optical fiber  20 , cannula  16  is not bonded to fiber  20  after optical fiber  20  is brought in contact with optical element  26 . Instead, distal optical fiber  20  is heated to or above its softening point, but below its melting point for a defined period. This causes at least the distal portion of fiber  20  (a portion of fiber  20  starting at the distal end and ending at any point prior to the proximal end of the cannula) to shrink axially and expand laterally. Because distal fiber  20  is not yet bonded to cannula  16 , optical element  26  and cannula  16  will move with optical fiber  20  as it shrinks axially. Consequently, potential energy can be released while fiber  20  remains in contact with optical element  26 . 
         [0031]      FIG. 4A  is a diagrammatic representation of an embodiment of a fixture for preconditioning a fiber of an endo-illuminator in accordance with the teachings of the present invention. In the embodiment shown in  FIG. 4A , proximal fiber  13  is coupled to distal fiber  20  and the cannula and optical element assembly  32  is already assembled. Distal fiber  20  is inserted into cannula  16  until the distal end of distal fiber  20  contacts the optical element  26  (shown in  FIG. 2 ). A portion of the endo-illuminator can be clamped or otherwise secured to a work surface  45 . A heating member  50  can be used to heat a distal portion of the cannula  16  and optical element assembly  32 . Heating member  50  can be made of any suitable material including, but not limited to, metals and ceramics, that can be heated to a desired temperature. Heating of heating member  50  can occur by, for example, running a current through resistors in heating member  50 , preheating heating member  50  from another heat source or otherwise heating member  50  in a way known to those skilled in the art. Heating member  50  can have any suitable shape and size. According to one embodiment, heating member  50  can be a metal cylinder having an axial opening  51  with an inner diameter that is slightly larger than the outer diameter of cannula  16 . The axial opening  51  can extend partially or completely through the length of heating member  50 . Heating member  50  can be coupled to a computer controlled translation stage  52  that allows heating member  50  to translate along at least one axis for positioning. A computer  54  can control movement of stage  52 . 
         [0032]      FIG. 4B  is a diagrammatic representation of an embodiment of an arrangement for heating of cannula  16 /optical element assembly  32 . The opening in heating member  50  can be axially aligned with cannula  16 . This can be done using, for example, cameras. Heating member  50  is then moved over some or all of cannula  16  to a desired insertion depth. Cannula  16  remains inserted in heating member  50  for a desired dwell time. To save time, heating member  50  is preferably heated to a desired temperature prior to insertion of cannula  16 . However, in other embodiments, heating member  50  may be heated after insertion of cannula  16 . A small force can be applied to cannula  16  as it is heated to move cannula  16  as the distal fiber  20  axially shrinks, in a direction so as to keep optical element  26  in contact with the distal end of distal fiber  20 . However, the force can be limited to prevent or reduce concavity at the distal end of distal fiber  20  as optical element  26  pushes against distal fiber  20 . 
         [0033]    In another embodiment, an endo-illuminator can be preconditioned using a vertical arrangement. The force of gravity on cannula  16  is a sufficient force with which to move cannula  16 .  FIG. 5  is a diagrammatic representation of a heating fixture with a vertical arrangement. According to one embodiment, an alignment tube  55  can be prealligned with heating member  50 . Alignment tube  55  includes an opening through which cannula  16  can at least partially pass such that the distal end of cannula  16  is aligned with the opening  51  of heating member  50 . There can be enough clearance between alignment tube  55  and cannula  16  to allow cannula  16  to move down as the distal end of distal fiber  20  softens. Heating member  50  can be coupled to a computer controlled translation stage  52  that allows heating member  50  to translate along at least one axis for positioning. A computer  54  can control movement of stage  52 . 
         [0034]    In operation, heating member  50  is heated to a desired temperature and translated downward (or cannula  16  translated upwards) such that the distal end of cannula  16  is inserted in heating member  50  to a desired insertion depth. Heating member  50  can heat cannula  16  for a desired time. As the distal portion of distal fiber  20  shrinks axially, gravity will cause optical element  26  to remain in contact with the distal end of distal fiber  20 , but not cause so much force as to result in unacceptable amounts of concavity in the distal end of distal fiber  20 . 
         [0035]    The preconditioning parameters for a given heating element  50  and illuminator include the temperature of the element, insertion depth of the cannula  16 , the dwell time (amount of time cannula  16  is inserted in heating element  50 ) and amount of force applied to maintain contact between the optical element  26  and distal fiber  20 . Whether a particular set of preconditioning parameters are acceptable can be based on whether the endo-illuminator can experience a greater flux without catastrophic failure after preconditioning and whether any decrease in optical performance due to preconditioning is acceptable. By way of example, but not limitation, the following recipes have been found to create acceptable endo-illuminators: 
         [0036]    For a 23 gauge wide angle illuminator probe using a heating element  50  with an opening having an inner diameter of 0.100″ to 0.200″:
       376 degree set point   0.1″ insertion depth   18-40 seconds dwell time   Insertion occurs with heating element at 400 deg F. actual temperature with temperature on the rise.       
 
         [0041]    For a 25 gauge wide angle illuminator probe using a heating element  50  with an opening with an inner diameter of 0.100″ to 0.200″:
       376 degree set point   0.1″ insertion depth   6-12 seconds dwell time   Insertion occurs with heating element is at 400 deg F. actual temperature with temperature on the rise.       
 
         [0046]    In the embodiments discussed above, the distal portion of cannula  16  and optical element assembly  32  is heated using an external heating element  50 . This, in turn, causes the distal portion of distal fiber  20  to heat and soften. According to another embodiment, however, preconditioning can be performed using high intensity light. According to this embodiment, the endo-illuminator without the handpiece and without distal fiber  20  adhered to cannula  16  can be subjected to high intensity light, such as xenon or other light. This can cause heating and softening of the distal portion of distal fiber  20 . If a small force, such as the force of gravity, is applied to the cannula  16  in the direction of axial shrinkage of the fiber, cannula  16  will move with the axially shrinking distal portion. Consequently, the optical element  26  will remain in contact with the distal end of the distal optical fiber  20 . This can allow the residual stress in the distal portion of the distal optical fiber  20  to be released while maintaining zero gap between the optical element  26  and the distal end of distal fiber  20 . 
         [0047]    Preconditioning of distal fiber  20  causes the fiber to adhere to the cannula due to lateral swelling of the fiber to fill the inner diameter of the cannula and the sticking of tacky cladding material to the cannula. This can eliminate the need to adhere the proximal portion of cannula  16  to distal fiber  20 . In other embodiments, the proximal portion of cannula  16  can be adhered to distal fiber  20  using a suitable adhesive such as Loctite 4014 by the Henkel Loctite Corporation of Rocky Hill, Conn. 
         [0048]    Preconditioning of distal fiber  20  relieves the axial stress stored in the fiber and reduces the susceptibility of the fiber to thermal deformation from subsequent exposure to high intensity light. Data shows that the flux can be increased greatly when compared to  FIG. 3  without catastrophic failure if the distal portion of distal fiber  20  has been preconditioned as described above.  FIG. 6 , for example, illustrates data from a 23 gauge wide angle illuminator that was preconditioned using xenon light. Preconditioning using a heating member provides similar results. The decreased susceptibility of the fiber to thermal deformation is accomplished with little decrease in optical performance.  FIG. 7  illustrates relative luminous intensity versus viewing angle in air of a 23 gauge wide angle illuminator without preconditioning (line  60 ) and with preconditioning (line  65 ) using a heating element.  FIG. 8  shows a similarly modest decrease in optical performance when preconditioning is done using xenon light (line  70 ) versus the 23 gauge wide angle illuminator without preconditioning. 
         [0049]    In the above examples, preconditioning occurs after distal optical fiber  20  is coupled to proximal optical fiber  13 . In other embodiments, preconditioning of distal optical fiber  20  can occur first. Additionally, similar preconditioning can be performed on devices that utilize only one optical fiber or one gauge of optical fiber. Furthermore, while distal optical fiber  20  is discussed in terms a single fiber, distal optical fiber  20  can be a collection of smaller optical fibers. 
         [0050]    As used herein, the terms “comprises,” “comprising,” “includes,” “including “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, process, article, or apparatus that comprises a list of elements is not necessarily limited only those elements but may include other elements not expressly listed or inherent to such process, process, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive or and not to an exclusive or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present). 
         [0051]    Additionally, any examples or illustrations given herein are not to be regarded in any way as restrictions on, limits to, or express definitions of, any term or terms with which they are utilized. Instead these examples or illustrations are to be regarded as being described with respect to one particular embodiment and as illustrative only. Those of ordinary skill in the art will appreciate that any term or terms with which these examples or illustrations are utilized will encompass other embodiments which may or may not be given therewith or elsewhere in the specification and all such embodiments are intended to be included within the scope of that term or terms. Language designating such non-limiting examples and illustrations includes, but is not limited to: “for example”, “for instance”, “e.g.”, “in one embodiment”.