Light delivery system

Abstract

A light delivery system to provide light treatment to a patient includes a catheter assembly having a plurality of light sources that transmit light towards a target site within a patient. In one embodiment, the light delivery system has a plurality of light sources mounted to a flexible transparent base that extends at least partially through a distal tip of the catheter assembly. The light sources can be wire bonded or mounted in a flip chip arrangement onto the base. In one embodiment to produce the distal tip, an array of light energy sources can be held by an array of holders of a fixture device. A vacuum is applied to secure each light energy source in a corresponding holder. While the vacuum is applied, the energy sources are electrically connected by wire bonding. The vacuum can be reduced or stopped thereby permitting removal of the light energy sources from the fixture device.

What is claimed is: 
     
       1. A catheter assembly for performing light therapy on a subject, the assembly comprising:
 a control system adapted to be operated by a user; 
 a catheter body extending from the control system, the catheter body dimensioned for placement within the subject; and 
 a distal tip at an end of the catheter body, the distal tip including
 a transparent substrate having a plurality of locking features, wherein the transparent substrate is a substantially flat strip, wherein the entire flat strip comprises a transparent material, 
 an array of spaced apart light sources for emitting light mounted on the flat strip and controlled by the control system, and 
 a flexible outer member encapsulating both the substrate and the light sources, wherein portions of the flexible outer member pass through the locking features to lock the flexible outer member to the substrate, wherein the substantially flat strip carries a conductive connector adapted to provide power to the array of light sources and transmits most of the light emitted from the array of light sources towards the substrate such that a sufficient amount of light is transmitted through the substrate and the outer member to activate a therapeutically effective amount of treatment agent in the subject. 
 
 
     
     
       2. The catheter assembly of  claim 1  wherein the outer member has a cross-sectional width that is less than about 1.25 mm. 
     
     
       3. The catheter assembly of  claim 1  wherein the substrate has a substantially rectangular cross-sectional shape. 
     
     
       4. A device kit for performing a medical treatment, the device kit comprising:
 a photoreactive agent comprising talaporfin sodium;  
 a plurality of light sources capable of emitting light for treating a patient to activate the photoreactive agent; 
 a distal tip having a substantially flat strip and being dimensioned for placement within a patient, wherein the light sources are coupled to a section of the substantially flat strip, wherein substantially all of the section comprises a transmissive material such that a substantial portion of the light emitted from the plurality of light sources directed towards the strip is transmitted through the strip when the light sources are energized; and 
 an outer member surrounding and encapsulating the strip and the plurality of light sources. 
 
     
     
       5. The device kit of  claim 4  wherein the plurality of light sources is coupled to a flat surface of the strip. 
     
     
       6. The device kit of  claim 4  wherein the outer member is dimensioned for percutaneous delivery to a target region within the patient. 
     
     
       7. The device kit of  claim 4  wherein the outer member is made of plastic and encapsulates the strip and the plurality of light sources. 
     
     
       8. The device kit of  claim 4  wherein the outer member has a cross-sectional width that is less than about 1.25 mm. 
     
     
       9. The device kit of  claim 4  wherein the outer member has a cross-sectional width that is less than about 1 mm. 
     
     
       10. The device kit of  claim 4  wherein the outer member has a cross-sectional width that is less than about 0.75 mm. 
     
     
       11. The device kit of  claim 4  wherein one pair of leads electrically connects each adjacent pair of light sources. 
     
     
       12. The device kit of  claim 4  wherein the plurality of light sources are LEDs mounted to the strip in a flip chip arrangement. 
     
     
       13. The device kit of  claim 4  wherein the strip comprises a plurality of locking structures, at least one of the locking structures positioned between each adjacent pair of light sources. 
     
     
       14. The device kit of  claim 13 , wherein the outer member is an encapsulant surrounding the strip and light sources, wherein each locking structure is a through hole that receives a portion of the encapsulant. 
     
     
       15. The device kit of  claim 4 , further comprising:
 means for electrically connecting the plurality of light sources. 
 
     
     
       16. The device kit of  claim 15  wherein the means for electrically connecting the plurality of light sources comprises traces in communication with the light sources, the traces arranged to provide activation of a selected number of the light sources. 
     
     
       17. The device kit of  claim 4  wherein the outer member physically contacts the plurality of light sources and the substrate. 
     
     
       18. The device kit of  claim 4 , further comprising a conductive connector that provides power to the plurality of light sources, the conductive connector being carried by the strip. 
     
     
       19. The device kit of  claim 18  wherein the conductive connector and the light sources are directly connected to the strip. 
     
     
       20. The device kit of  claim 4  wherein the light sources output light through portions of the distal tip on opposite sides of the strip. 
     
     
       21. The device kit of  claim 4  wherein the light sources emit light in different direction such that light is emitted away from an upper face of the strip and an opposing lower face of the strip. 
     
     
       22. The device kit of  claim 4 , further comprising an optically transparent adhesive that couples the light sources to the section of the substantially flat, transparent support. 
     
     
       23. The device kit of  claim 4 , further comprising connectors that electrically connect the light sources together, wherein the connectors are spaced apart from the strip. 
     
     
       24. A method of producing a catheter for treating a patient, the method comprising:
 coupling a plurality of light sources onto a substantially flat strip, the light sources being spaced from one another with respect to a longitudinal length of the substantially flat strip and mounted on a longitudinal section of the flat strip, wherein substantially all of the longitudinal section of the flat strip comprises a transparent material such that light from the light sources passes through the flat strip; 
 connecting the plurality of light sources to a power source for energizing the plurality of light sources; and 
 placing an outer body around the flat strip and plurality of light sources coupled thereto, the outer body configured for positioning with a patient at a selected treatment location. 
 
     
     
       25. The method of  claim 24  wherein the coupling of the plurality of light sources comprises mounting a series of LEDs upon the flat strip with a bonding material. 
     
     
       26. The method of  claim 24  wherein the connecting of the plurality of light sources comprises connecting adjacent light sources with a pair of leads. 
     
     
       27. The method of  claim 26  wherein each light source has a first side and an opposing second side, the first side is mounted to the flat strip and the leads are connected to the second side. 
     
     
       28. The method of  claim 24  wherein the coupling of the plurality of light sources to the flat strip comprises:
 coupling a pair of electrodes of each light source to a corresponding pair of mounting pads on the flat strip. 
 
     
     
       29. The method of  claim 24 , further comprising:
 placing the light sources in an array of holders of a fixture device; 
 electrically coupling the light sources together while the light sources are retained in the holders; 
 after coupling the light sources together, removing the light sources from the fixture device. 
 
     
     
       30. The method of  claim 29 , further comprising applying a vacuum such that the light sources are pulled into corresponding holders. 
     
     
       31. A method of manufacturing a catheter for treating a patient, the method comprising:
 placing a light transmission assembly in a lumen of an outer member, the light transmission assembly comprising a plurality of light sources coupled to a transparent flat section of a substantially flat strip positioned in the outer member, wherein the light sources are positioned to output light that travels through the transparent flat section of the flat strip; and 
 after the light transmission assembly is in the outer member, thermally encapsulating the light transmission assembly in the outer member. 
 
     
     
       32. The method of  claim 31  wherein the thermal encapsulation of the light transmission assembly includes melting the outer member onto the light transmission assembly. 
     
     
       33. The method of  claim 31  wherein the thermal encapsulation of the light transmission assembly includes placing flowable material into the lumen of the outer member between the light transmission assembly and the outer member, and reflowing at least one of the flowable material and the outer member after placing the flowable material into the lumen of the outer member. 
     
     
       34. The method of  claim 31  wherein the entire strip comprises an optically transparent material. 
     
     
       35. The method of  claim 31  wherein the strip comprises windows positioned beneath the light sources. 
     
     
       36. A method of treating visceral adipose tissue, the method comprising:
 providing a photoreactive agent comprising talaporfin sodium to a patient; 
 providing a catheter having a distal end with a plurality of light sources, a substantially flat and transparent strip, and an outer member, wherein the distal end is sufficiently flexible for placement within a the patient, the light sources are carried by transparent material of the transparent strip, the transparent strip and the light sources are positioned within the outer member; 
 advancing the distal end of the catheter through the patient until the distal end is proximate to the visceral adipose tissue; and 
 illuminating the visceral adipose tissue using the plurality of light sources such that light from the light sources travels through portions of the transparent strip carrying the light sources. 
 
     
     
       37. The method of  claim 36  wherein illuminating the visceral adipose tissue with the plurality of light sources comprises activating a treatment the photoreactive agent in the visceral adipose tissue so as to destroy at least a portion of the adipose tissue. 
     
     
       38. A catheter for treating visceral adipose tissue, the catheter comprising:
 a distal tip dimensioned for delivery through a patient, the distal tip being adapted to emit a sufficient amount of light to activate treatment agent in the visceral adipose tissue when the distal tip is in a treatment position, which is proximate to the adipose tissue, the distal tip including a cover, a substantially flat transparent strip carrying a conductive connector, a plurality of light sources coupled to a substantially flat and transparent section of the transparent strip such that the conductive connector delivers power to the plurality of light sources, the cover surrounding the light sources and the transparent section of the transparent strip, wherein substantially all of the transparent section of the transparent strip comprises a transparent material; and 
 a main body extending from the distal tip, the main body dimensioned for percutaneous delivery of the distal tip to the treatment position. 
 
     
     
       39. The catheter of  claim 38  wherein the energized distal tip emits sufficient amount of light to activate treatment agent in the visceral adipose tissue to destroy the visceral adipose tissue illuminated by the distal tip. 
     
     
       40. A method of manufacturing a catheter for treating a patient, the method comprising:
 coupling a plurality of light sources to a portion of a substantially flat transmissive strip, the entire portion of the strip carrying the light sources comprises a transmissive material; 
 electrically coupling together the plurality of light sources using a conductive connector coupled to the portion of the strip such that a power source can energize the plurality of light sources; and 
 forming an outer body about the strip and plurality of light sources coupled thereto, the strip of transmissive material extending longitudinally along the outer body and between the plurality of light sources, the outer body dimensioned for placement within a patient. 
 
     
     
       41. The method of  claim 40  wherein electrically coupling together the plurality of light sources comprises connecting adjacent light sources with a pair of leads of the conductive connector. 
     
     
       42. The method of  claim 40 , further comprising:
 coupling a power source to the plurality of light sources, the power source capable of simultaneously energizing a substantial number of the light sources. 
 
     
     
       43. A device kit for performing a medical treatment, the device comprising:
 a photoreactive agent comprising talaporfin sodium; 
 a plurality of light sources capable of emitting light for treating a patient to activate the photoreactive agent; 
 a substantially flat and transparent support made of a transmissive material, the support carrying the plurality of light sources such that light emitted from the plurality of light sources directed towards the support is transmitted through portions of the support carrying the light sources when the light sources are energized; and 
 an outer member dimensioned for placement in the a patient and encapsulating the plurality of light sources and the support, the plurality of light sources physically contacting and being embedded in the outer member. 
 
     
     
       44. The device kit of  claim 43  wherein at least one of the light sources extends across most of a width of the transparent support. 
     
     
       45. The device kit of  claim 43 , further comprising an optically transparent adhesive that couples the light sources to the support.