Medical apparatus employing flexible light structures and methods for manufacturing same

Abstract

A method of manufacture and medical apparatus that provides an apparatus useful in illuminating at least a portion of a lumen of a body. The apparatus includes an elongated flexible member and a polymer encasement portion encasing a plurality of light emitters. The light emitters may be electrically coupled to one another without the use of wire bonds, and in some embodiments may be coupled without intervening electrical paths or traces. A maximum cross-sectional dimension of the polymer encasement portion may be less than twice a dimension of one of the light emitters. In some embodiments the maximum cross-sectional dimension is less than or equal to the sum of the dimension of one of the light emitters and a marginal dimension by which an outer portion of the polymer encasement portion extends beyond the light emitter. Light emitters may be arranged linearly, helically or in partially overlapping back-to-back relation.

1 . A medical apparatus useful in illuminating at least a portion of a lumen of a body, the apparatus comprising: 
 an elongated flexible member having a distal end and a proximal end, at least a portion of the elongated flexible member being sized and dimensioned to be received and moved within the lumen of the body;    a plurality of light emitters, the light emitters electrically coupled to one another without the use of wire bonds, and operable to emit electromagnetic radiation in at least one characteristic emission waveband; and    a polymer encasement portion encasing the plurality of light emitters, at least a portion of the polymer encasement portion being at least partially transmissive to electromagnetic radiation in the at least one characteristic emission waveband, and the polymer encasement portion being sized and dimensioned to be received and moved within the lumen of the body and positioned proximate the proximal end of the elongated flexible member to be moved in the lumen of the body by movement of the elongated flexible member.    
   
   
       2 . The medical apparatus of  claim 1  wherein each of the plurality of light emitters has a principal axis of emission.  
   
   
       3 . The medical apparatus of  claim 2  wherein the principal axis of emission of a first one of the plurality of light emitters is in a different direction than the principal axis of emission of another one of the plurality of light emitters.  
   
   
       4 . The medical apparatus of  claim 2  wherein a maximum cross-sectional dimension of the polymer encasement portion is less than twice a dimension of one of the light emitters measured along the principal axis of emission.  
   
   
       5 . The medical apparatus of  claim 4  wherein the principal axis of emission of a first one of the plurality of light emitters is not in the same direction as the principal axis of emission of another one of the light emitters.  
   
   
       6 . The medical apparatus of  claim 2  wherein the light emitters are distributed generally along at least a portion of a length of the polymer encasement portion.  
   
   
       7 . The medical apparatus of  claim 6  wherein the principal axis of emission of at least some of the light emitters is diametrically opposed to the principal axis of emission of successively adjacent ones of the light emitters.  
   
   
       8 . The medical apparatus of  claim 6  wherein the principal axes of emission of a first set of at least two successively adjacent ones of the light emitters are parallel and in a same first direction, and the principal axes of emission of a second set of at least two successively adjacent ones of the light emitters are parallel and in a same second direction, the second direction diametrically opposed to the first direction.  
   
   
       9 . The medical apparatus of  claim 1  wherein each of the plurality of light emitters has at least two terminals, a first one of the terminals of the light emitters directly adhered to a terminal of a successively preceding one of the light emitters with an electrically conductive adhesive and without any intervening electrical trace, a second one of the terminals of the light emitters directly adhered to a terminal of a successively succeeding one of the light emitters with an electrically conductive adhesive and without any intervening electrical trace.  
   
   
       10 . The medical apparatus of  claim 1  wherein the light emitters are distributed generally along at least a portion of a length of the polymer encasement portion, successively adjacent ones of the light emitters arranged back-to-back in partially overlapping relationship, and wherein each of the plurality of light emitters has at least two terminals, the terminals respectively adhered to a respective terminal of a preceding one of the light emitters and a respective terminal of a succeeding one of the light emitters without any intervening electrical trace.  
   
   
       11 . The medical apparatus of  claim 1  wherein the light emitters are distributed generally along at least a portion of a length of the polymer encasement portion, successively adjacent ones of the light emitters oriented in opposed relation.  
   
   
       12 . The medical apparatus of  claim 11  wherein each of the plurality of light emitters has at least two terminals, and each of a positive one of the terminals of the light emitters coupled to a negative one of the terminals of the next successively adjacent light emitter, the plurality of light emitters electrically coupled in series.  
   
   
       13 . The medical apparatus of  claim 11  wherein each of the plurality of light emitters has at least two terminals surface mounted to respective ones of at least two electrically conductive paths.  
   
   
       14 . The medical apparatus of  claim 1  wherein the polymer encasement portion is cylindrical with a longitudinal axis.  
   
   
       15 . The medical apparatus of  claim 14  wherein the light emitters are helically distributed about the longitudinal axis of the cylindrical polymer encasement portion.  
   
   
       16 . The medical apparatus of  claim 14  wherein the light emitters are helically distributed about the longitudinal axis of the cylindrical polymer encasement portion such that the principal axes of emission of the light emitters point in at least three different directions.  
   
   
       17 . The medical apparatus of  claim 1  wherein the elongated flexible member is a catheter body.  
   
   
       18 . The medical apparatus of  claim 17  wherein the catheter body has an interior portion that at least partially receives the polymer encasement portion.  
   
   
       19 . The medical apparatus of  claim 18  wherein at least a portion of the catheter body is at least partially transmissive of electromagnetic radiation in the at least one characteristic emission waveband of the plurality of light emitters.  
   
   
       20 . The medical apparatus of  claim 1  wherein the elongated flexible member is a guide wire and the polymer is physically coupled to the guide wire.  
   
   
       21 . The medical apparatus of  claim 1  wherein the elongated flexible member is a catheter body, and the polymer encasement portion has a smooth exterior surface, and further comprising: 
 an expandable member physically coupled to move in the lumen of the body with the polymer encasement portion, and operable to expand between an expanded configuration and an unexpanded configuration.    
   
   
       22 . The medical apparatus of  claim 1  wherein the elongated flexible member comprises a polymer and the polymer encasement portion and the elongated flexible member are both portions of a unitary structure.  
   
   
       23 . The medical apparatus of  claim 1  wherein the polymer encasement portion is a substantially solid cylinder.  
   
   
       24 . A medical apparatus useful in illuminating at least a portion of a lumen of a body, the medical apparatus comprising: 
 an elongated flexible member having a distal end and a proximal end, at least a portion of the elongated flexible member being sized and dimensioned to be received and moved within the lumen of the body;    a plurality of light emitters each having a principal axis of emission, the light emitters operable to emit electromagnetic radiation in at least one characteristic emission waveband; and    a polymer encasement portion encasing the plurality of light emitters, at least a portion of the polymer encasement portion being at least partially transmissive to electromagnetic radiation in the at least one characteristic emission waveband, the polymer encasement portion having a maximum cross-sectional dimension that is less than two times the sum of a dimension of one of the light emitters measured along the principal axis of emission and a marginal dimension by which an outer portion of the polymer encasement portion extends beyond the light emitter along the principal axis of emission in a direction of principal emission, the polymer encasement portion positioned proximate the proximal end of the elongated flexible member to be moved in the lumen of the body by movement of the elongated flexible member.    
   
   
       25 . The medical apparatus of  claim 24  wherein the polymer encasement portion has a maximum cross-sectional dimension that is less than or equal to the sum of the dimension of one of the light emitters measured along the principal axis of emission and the marginal dimension by which the outer portion of the polymer encasement portion extends beyond the light emitter along the principal axis of emission in the direction of principal emission.  
   
   
       26 . The medical apparatus of  claim 24  wherein each of a number of the plurality of the light emitters is electrically directly coupled to at least one successively adjacent light emitter without a wire bond.  
   
   
       27 . The medical apparatus of  claim 24  wherein each of the light emitters has at least two terminals and wherein at least one of the terminals of each of the light emitters is directly adhered to the terminal of at least one successively adjacent light emitter.  
   
   
       28 . The medical apparatus of  claim 24  wherein each of the light emitters has at least two terminals, at least one of the terminals of each of the light emitters surface mounted to an electrically conductive path.  
   
   
       29 . The medical apparatus of  claim 24  wherein each of the light emitters has at least two terminals, each of the terminals of each of the light emitters surface mounted to a respective one of at least two electrically conductive paths.  
   
   
       30 . The medical apparatus of  claim 24  wherein the principal axis of emission of a first one of the plurality of light emitters is not in the same direction as the principal axis of emission of another one of the plurality of light emitters.  
   
   
       31 . The medical apparatus of  claim 24  wherein the light emitters are distributed generally along at least a portion of a length of the polymer encasement portion, successively adjacent ones of the emitters arranged oriented in opposed relation.  
   
   
       32 . The medical apparatus of  claim 24  wherein the light emitters are distributed generally along at least a portion of a length of the polymer encasement portion and wherein the principal axes of emission of a first set of at least two successively adjacent ones of the light emitters are parallel and in a same first direction, and the principal axes of emission of a second set of at least two successively adjacent ones of the light emitters are parallel and in a same second direction, the second direction diametrically opposed to the first direction.  
   
   
       33 . The medical apparatus of  claim 24  wherein the polymer encasement portion is cylindrical with a longitudinal axis.  
   
   
       34 . The medical apparatus of  claim 24  wherein the polymer encasement portion is cylindrical with a longitudinal axis and wherein the light emitters are helically distributed about the longitudinal axis of the cylindrical polymer encasement portion.  
   
   
       35 . The medical apparatus of  claim 24  wherein the elongated flexible member is one of a catheter body or a guide wire.  
   
   
       36 . The medical apparatus of  claim 24  wherein the elongated flexible member is a catheter body, and the polymer encasement portion has a smooth exterior surface, and further comprising: 
 an expandable member physically coupled to move in the lumen of the body with the polymer encasement portion, at least partially transmissive to electromagnetic radiation in the at least one characteristic emission waveband, and operable to expand between an expanded configuration and an unexpanded configuration.    
   
   
       37 . The medical apparatus of  claim 24  wherein the elongated flexible member comprises a polymer and the polymer encasement portion and the elongated flexible member form portions of a unitary structure.  
   
   
       38 . The medical apparatus of  claim 24  wherein the polymer encasement portion is a substantially solid cylinder.  
   
   
       39 . A method of forming a medical apparatus useful in illuminating at least a portion of a lumen of a body, the method comprising: 
 electrically coupling a plurality of light emitters without the use of wire bonds, the light emitters operable to emit electromagnetic radiation in at least one characteristic emission waveband;    encasing the plurality of light emitters in a polymer encasement portion sized and dimensioned to be received in a lumen of a body, at least a portion of the polymer encasement portion being at least partially transmissive to electromagnetic radiation in the at least one characteristic emission waveband; and    physically coupling the polymer encasement portion to an elongated flexible member sized to be at least partially received in a lumen of a body.    
   
   
       40 . The method of  claim 39  wherein each of the plurality of light emitters has at least two terminals, and wherein electrically coupling a plurality of light emitters without the use of wire bonds comprises directly adhering the terminals of the light emitters to respective terminals of at least one successively adjacent light emitter without any intervening electrical trace.  
   
   
       41 . The method of  claim 39  wherein each of the plurality of light emitters has at least two terminals, and wherein electrically coupling a plurality of light emitters without the use of wire bonds comprises directly adhering the terminals of the light emitters to a respective terminal of at least one successively adjacent light emitter with an electrically conductive adhesive and without any intervening electrical trace with the light emitters arranged back-to-back in partially overlapping relationship.  
   
   
       42 . The method of  claim 39  wherein each of the plurality of light emitters has at least two terminals, and wherein electrically coupling a plurality of light emitters Without the use of wire bonds comprises electrically coupling each of a positive one of the terminals of the light emitters to a negative one of the terminals of the next successively adjacent light emitter, the plurality of light emitters electrically coupled in series.  
   
   
       43 . The method of  claim 39  wherein each of the plurality of light emitters has at least two terminals, and wherein electrically coupling a plurality of light emitters without the use of wire bonds comprises electrically coupling each of the terminals of the light emitters to respective ones of at least two electrically conductive paths.  
   
   
       44 . The method of  claim 39  wherein encasing the plurality of light emitters in a polymer encasement portion comprises encasing the plurality of light emitters in a cylindrical polymer encasement portion having a longitudinal axis and a smooth exterior surface.  
   
   
       45 . The method  claim 44 , further comprising: 
 helically distributing the light emitters about the longitudinal axis of the cylindrical polymer encasement portion before encasing the plurality of light emitters in a polymer encasement portion.    
   
   
       46 . The method of  claim 44 , further comprising: 
 helically distributing the light emitters about the longitudinal axis of the cylindrical polymer encasement portion such that the respective principal axes of emission of the light emitters points in at least three different directions before encasing the plurality of light emitters in a polymer encasement portion.    
   
   
       47 . The method of  claim 39 , further comprising: 
 arranging the light emitters such that the polymer encasement portion has a maximum cross-sectional dimension that is less than two times the sum of a dimension of one of the light emitters measured along a principal axis of emission and a marginal dimension by which an outer portion of the polymer encasement portion extends beyond the light emitter along the principal axis of emission in a direction of principal emission, before encasing the plurality of light emitters in a polymer encasement portion.    
   
   
       48 . The method of  claim 39 , further comprising: 
 arranging the light emitters such that the polymer encasement portion has a maximum cross-sectional dimension that is less than or equal to a sum of a dimension of one of the light emitters measured along a principal axis of emission and a marginal dimension by which an outer portion of the polymer encasement portion extends beyond the light emitter along the principal axis of emission in a direction of principal emission.    
   
   
       49 . The method of  claim 39  wherein physically coupling the polymer encasement portion to an elongated flexible member comprises physically coupling the polymer encasement portion to a catheter.  
   
   
       50 . The method of  claim 39  wherein physically coupling the polymer encasement portion to an elongated flexible member comprises physically coupling the polymer encasement portion to a guide wire for a catheter.  
   
   
       51 . A medical apparatus useful in illuminating at least a portion of a lumen of a body, the apparatus comprising: 
 an elongated flexible member having a distal end and a proximal end, at least a portion of the elongated flexible member being sized and dimensioned to be received and moved within the lumen of the body;    a plurality of light emitters operable to emit electromagnetic radiation in at least one characteristic emission waveband, wherein the light emitters of the plurality of light emitters are arranged helically with respect to each other about an imaginary longitudinal axis; and    a polymer encasement portion encasing the plurality of light emitters, at least a portion of the polymer encasement portion being at least partially transmissive to electromagnetic radiation in the at least one characteristic emission waveband, the polymer encasement portion positioned proximate the proximal end of the elongated flexible member to be moved in the lumen of the body by movement of the elongated flexible member.    
   
   
       52 . The medical apparatus of  claim 51  wherein each of the light emitters has a respective principal axis of emission and the principal axes of emission of at least three of the light emitters point in at least three respective different directions.  
   
   
       53 . The medical apparatus of  claim 51  wherein each of the plurality of light emitters has at least two terminals surface mounted to respective ones of at least two electrically conductive paths.  
   
   
       54 . The medical apparatus of  claim 51  wherein the polymer encasement portion is cylindrical with a longitudinal axis that is colinear with the longitudinal axis about which the light emitters are helically distributed.  
   
   
       55 . The medical apparatus of  claim 51  wherein the polymer encasement portion has a smooth exterior surface, and further comprising: 
 an expandable member physically coupled to move in the lumen of the body with the polymer encasement portion, at least partially transmissive to electromagnetic radiation in the at least one characteristic emission waveband, and operable to expand between an expanded configuration and an unexpanded configuration.    
   
   
       56 . The medical apparatus of  claim 51  wherein the elongated flexible member is one of a catheter body or a guide wire.  
   
   
       57 . The medical apparatus of  claim 51  wherein the elongated flexible member comprises a polymer and the polymer encasement portion and the elongated flexible member form a unitary structure.  
   
   
       58 . The medical apparatus of  claim 51  wherein the polymer encasement portion is a substantially solid cylinder.  
   
   
       59 . A method of operating a catheter physically associated with an expandable member and a plurality of light emitters to illuminate a lumen of a body, the method comprising: 
 inflating the expandable member with a fluid medium when the expandable member is positioned in the lumen of the body;    providing power to at least some of the plurality of light emitters to provide illumination therefrom when at least some of the plurality of light emitters are positioned in the lumen of the body; and    circulating the fluid medium into and out of the expandable member while the expandable member is inflated and during at least a portion of a time when the power is provided to at least some of the plurality of light emitters.    
   
   
       60 . The method of  claim 59  wherein circulating the fluid medium into and out of the expandable member while the expandable member is inflated and during at least a portion of a time when the power is provided to at least some of the plurality of light emitters comprises replacing the fluid medium in the expandable member at a first temperature with fluid medium at a second temperature.  
   
   
       61 . The method of  claim 59  wherein circulating the fluid medium into and out of the expandable member while the expandable member is inflated and during at least a portion of a time when the power is provided to at least some of the plurality of light emitters comprises replacing the fluid medium in the expandable member at a first temperature with fluid medium at a second temperature, the second temperature lower than the first temperature.  
   
   
       62 . The method of  claim 59  wherein inflating the expandable member with a fluid medium comprises inflating the expandable member with a heat conducting fluid medium.  
   
   
       63 . The method of  claim 59  wherein inflating the expandable member with a fluid medium comprises inflating the expandable member with a physiologically inert heat conducting fluid medium.  
   
   
       64 . The method of  claim 59  wherein the plurality of light sources are proximate the expandable member and heat produced from the plurality of light sources is transferred away from the lumen by the circulating of the fluid medium into and out of the expandable member.  
   
   
       65 . The method of  claim 59 , further comprising: 
 inserting at least a portion of the catheter having the expandable member into the lumen of the body.    
   
   
       66 . The method of  claim 59 , further comprising: 
 at least partially deflating the expandable member; and    removing the catheter after at least partially deflating the expandable member.