Methods and systems for manufacturing a thermally robust laser probe assembly

Abstract

Certain embodiments of the present disclosure provide a thermally robust laser probe assembly. The probe assembly comprises 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 also 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.

What is claimed is: 
     
         1 . 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;   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.   
     
     
         2 . The probe assembly of  claim 1 , wherein the sealing location comprises a gap between an inner surface of the distal end of cannula and an outer surface of the protective component. 
     
     
         3 . The probe assembly of  claim 2 , wherein the sealing location is sealed by a sealant with a viscosity in a range of about 500 to about 5000 centipoise. 
     
     
         4 . The probe assembly of  claim 2 , wherein the sealing location is sealed with a dual-cure sealant. 
     
     
         5 . The probe assembly of  claim 1 , wherein the sealing location is dual-cured. 
     
     
         6 . The probe assembly of  claim 1 , wherein the protective component is press-fitted into the distal end of the cannula. 
     
     
         7 . A sealant application system, comprising:
 a sealant applicator comprising a wire;   a stage machine configured to hold the sealant applicator and to position the wire at a sealing location at a distal end of a cannula of a probe assembly; 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.   
     
     
         8 . The sealant application system of  claim 7 , wherein the probe assembly comprises:
 the cannula through which one or more optical fibers extend at least partially through for transmitting laser light from a laser source to a target location;   a lens housed in the cannula; and   a protective component at the distal end of the cannula;   wherein the lens is positioned between the one or more optical fibers and the protective component.   
     
     
         9 . The sealant application system of  claim 8 , wherein the sealing location comprises a gap between an inner surface of the distal end of cannula and an outer surface of a distal end of the protective component. 
     
     
         10 . The sealant application system of  claim 7 , wherein the stage machine is configured to move the wire forward or backward while the actuator rotates the cannula. 
     
     
         11 . The sealant application system of  claim 7 , wherein the sealing location is sealed by a sealant with a viscosity in a range of about 500 to about 5000 centipoise. 
     
     
         12 . The sealant application system of  claim 7 , wherein the sealing location is sealed with a dual-cure sealant. 
     
     
         13 . The sealant application system of  claim 7 , wherein the sealing location is dual-cured. 
     
     
         14 . The sealant application system of  claim 7 , further comprising a cannula holder configured to secure the cannula during application of the sealant. 
     
     
         15 . The sealant application system of  claim 14 , wherein the actuator is configured to rotate the cannula holder along with the cannula. 
     
     
         16 . The sealant application system of  claim 7 , wherein the wire is made of Nitinol. 
     
     
         17 . The sealant application system of  claim 7 , wherein a diameter of the wire is within a range of about 20 to about 40 micrometers. 
     
     
         18 . A method of manufacturing a probe assembly, the method comprising:
 positioning a wire coated with sealant at a sealing location at a distal end of a cannula of the probe assembly;   rotating the cannula to apply the sealant to the sealing location.   
     
     
         19 . The method of  claim 18 , further comprising:
 moving the wire forward and backward during the rotating.   
     
     
         20 . The method of  claim 18 , further comprising:
 dual-curing the sealing location after it is sealed.