Assembling a multi-fiber multi-spot laser probe
View Patent ↗In certain embodiments, assembling a multi-fiber multi-spot laser system includes heating a ferrule until an interior diameter of an interior volume of the ferrule has expanded to greater than a predetermined diameter. End portions of a number of optical fibers are disposed within the interior volume. The ferrule is cooled to allow a cross-section of the fibers to conform to a fiber pattern having the predetermined diameter. At least a portion of the ferrule is disposed within a connector body to yield at least a portion of an optical fiber connector. In certain embodiments, the ferrule is rotated with respect to the connector body to align the fiber pattern with a laser spot pattern.
1. A method comprising:
heating a ferrule until an interior diameter of an interior volume of the ferrule has expanded to greater than a predetermined diameter, the ferrule having a cylindrical shape with a surface that defines the interior volume, the surface defining an aperture at an end of the cylindrical shape;
disposing an end portion of each optical fiber of a plurality of optical fibers within the interior volume, the end portion disposed proximate to the aperture;
cooling the ferrule to allow a cross-section of the fibers to conform to a fiber pattern having the predetermined diameter; and
disposing at least a portion of the ferrule within a connector body to yield at least a portion of an optical fiber connecter.
2. The method of claim 1 , the fiber pattern matching a laser spot pattern of a laser system, the optical fiber connecter configured to be coupled to the laser system.
3. The method of claim 1 , further comprising:
rotating the ferrule with respect to the connector body so the fiber pattern is at a desired alignment that corresponds to a laser spot pattern of a laser system.
4. The method of claim 1 , further comprising:
rotating the ferrule with respect to the connector body so the fiber pattern is at a desired alignment that corresponds to a laser spot pattern of a laser system; and
bonding the ferrule and the connector body.
5. The method of claim 1 , further comprising:
rotating the ferrule with respect to the connector body so the fiber pattern is at a desired alignment with respect to a key of the connector body.
6. The method of claim 1 , the heating further comprising heating the ferrule to a temperature greater than 450° Fahrenheit.
7. The method of claim 1 , the cooling further comprising cooling the ferrule to room temperature.
8. The method of claim 1 , further comprising:
polishing the end portions of the optical fibers through the aperture.
9. The method of claim 1 , further comprising:
bonding the end portions of the optical fibers to the ferrule.
10. A method comprising:
heating a ferrule until an interior diameter of an interior volume of the ferrule has expanded to greater than a predetermined diameter, the ferrule having a cylindrical shape with a surface that defines the interior volume, the surface defining an aperture at an end of the cylindrical shape;
disposing an end portion of each optical fiber of a plurality of optical fibers within the interior volume, the end portion disposed proximate to the aperture;
cooling the ferrule to allow a cross-section of the fibers to conform to a fiber pattern having the predetermined diameter, the fiber pattern matching a laser spot pattern of a laser system;
disposing at least a portion of the ferrule within a connector body to yield at least a portion of an optical fiber connecter configured to be coupled to the laser system; and
rotating the ferrule with respect to the connector body so the fiber pattern is at a desired alignment that corresponds to the laser spot pattern of a laser system.
11. The method of claim 10 , further comprising:
bonding the ferrule and the connector body.
12. The method of claim 10 , the rotating further comprising:
rotating the ferrule with respect to the connector body so the fiber pattern is at a desired alignment with respect to a key of the connector body.
13. The method of claim 10 , the heating further comprising heating the ferrule to a temperature greater than 450° Fahrenheit.
14. The method of claim 10 , the cooling further comprising cooling the ferrule to room temperature.
15. The method of claim 10 , further comprising:
polishing the end portions of the optical fibers through the aperture.
16. The method of claim 10 , further comprising:
bonding the end portions of the optical fibers to the ferrule.
17. A method comprising:
heating a ferrule until an interior diameter of an interior volume of the ferrule has expanded to greater than a predetermined diameter, the ferrule having a cylindrical shape with a surface that defines the interior volume, the surface defining an aperture at an end of the cylindrical shape;
disposing an end portion of each optical fiber of a plurality of optical fibers within the interior volume, the end portion disposed proximate to the aperture;
cooling the ferrule to allow a cross-section of the fibers to conform to a fiber pattern having the predetermined diameter;
disposing at least a portion of the ferrule within a connector body to yield at least a portion of an optical fiber connecter; and
coupling the optical fiber connecter to a cable configured to be coupled to a laser probe.
18. The method of claim 17 , the fiber pattern matching a laser spot pattern of a laser system, the optical fiber connecter configured to be coupled to the laser system.
19. The method of claim 17 , further comprising:
rotating the ferrule with respect to the connector body so the fiber pattern is at a desired alignment that corresponds to a laser spot pattern of a laser system.