Side-fire laser fiber having a molded reflective surface

1. A side-fire laser fiber comprising:

an optical fiber having a distal end and a distal facing surface at the distal end; and

a fiber cap having a proximal end and a proximal facing surface at the proximal end, the fiber cap being coupled to the distal end of the optical fiber via a non-fused connection, and the fiber cap comprising a molded reflective surface and a sealed cavity, wherein the distal facing surface at the distal end of the optical fiber is flush against the proximal facing surface at the proximal end of the fiber cap;

wherein:

the molded reflective surface defines a wall of the cavity; and

laser energy discharged from the distal end along a central axis of the optical fiber is reflected off the molded reflective surface in a direction that is transverse to the central axis.

2. The laser fiber of claim 1 , wherein laser energy reflected off the molded reflective surface is discharged through a wall of the fiber cap.

3. The laser fiber of claim 1 , wherein the cavity is filled with air.

4. The laser fiber according to claim 1 , wherein laser energy discharged from the distal end of the optical fiber has a cross-sectional area, measured in a plane that is perpendicular to the central axis, that expands with distance from the distal end of the optical fiber along the central axis.

5. The laser fiber according to claim 1 , wherein the reflective surface is curved in a plane extending at least one of parallel or perpendicular to the central axis.

6. The laser fiber according to claim 1 , wherein the molded reflective surface comprises stepped surfaces, wherein each stepped surface is at a unique angle to the central axis.

7. The laser fiber according to claim 1 , wherein the fiber cap includes a main body that defines the molded reflective surface and an opening to the cavity, and a cover member attached to the main body that seals the opening.

8. A laser fiber according to claim 1 , wherein a portion of the cavity extends between the distal end of the optical fiber and the molded reflective surface.

9. The laser fiber according to claim 8 , wherein the fiber cap includes a main body having a proximal end attached to the optical fiber and a distal end having an opening to the cavity, and a cover member attached to the main body that seals the cavity and supports the molded reflective surface.

10. The laser fiber according to claim 9 , wherein portions of the main body surrounding the cavity include a highly reflective coating.

11. The laser fiber according to claim 9 , wherein the main body includes a distal surface that is oriented at an oblique angle to the central axis, and the cover member is attached to the distal surface.

12. The laser fiber according to claim 1 , wherein the molded reflective surface is selected from the group consisting of a molded spherical piano concave reflective surface, molded spherical piano convex reflective surface, a molded cylindrical piano concave reflective surface and a molded cylindrical piano convex reflective surface.

13. A side-fire laser fiber comprising:

an optical fiber having a distal end and an exterior surface, the optical fiber including cladding on at least a portion of the exterior surface;

a molded glass cap attached to the distal end of the optical fiber and comprising:

a proximal end;

a distal end;

a total internal reflection surface; and

an internal cavity formed between the proximal end and distal end, wherein the internal cavity:

(i) is defined by the total internal reflection surface adjacent the proximal end of the molded glass cap, wherein the total internal reflection surface is spaced apart from the distal end of the optical fiber;

(ii) is sealed at the distal end of the molded glass cap with a biocompatible material attached to the molded glass cap; and

(iii) is filled with air; and

a metal cap portion attached to the exterior surface of the optical fiber adjacent the distal end of the optical fiber, the metal cap portion comprising:

a proximal end;

a distal end;

at least one irrigation opening to allow an irrigant to flow from an exterior of the metal cap portion to an interior of the metal cap portion and around at least a portion of the molded glass cap; and

a side port to allow transmission of laser energy reflected off the total internal reflection surface of the molded glass cap, wherein:

the proximal end of molded glass cap is attached to the distal end of the optical fiber via a non-fused connection;

the distal end of the metal cap portion is attached to the distal end of the molded glass cap; and

the proximal end of the metal cap portion is attached to the cladding on the distal end of the optical fiber.

14. The laser fiber according to claim 13 , wherein the proximal end of the molded glass cap is flush with the distal end of the optical fiber.

15. The laser fiber according to claim 13 , wherein the total internal reflection surface is selected from the group consisting of a spherical piano concave reflective surface, spherical piano convex reflective surface, a cylindrical piano concave reflective surface and a cylindrical piano convex reflective surface.

16. A side-fire laser fiber comprising:

an optical fiber having a distal end and an exterior surface, the optical fiber including cladding on at least a portion of the exterior surface;

a cap of a biocompatible material attached to the distal end of the optical fiber via a non-fused connection and comprising:

a proximal end;

a distal end;

a total internal reflection surface; and

an internal cavity formed between the proximal end and distal end, wherein the internal cavity:

(i) is sealed at the distal end of the cap with a cover member;

(ii) is sealed at the proximal end by the total internal reflection surface; and

(iii) is filled with air,

wherein the total internal reflection surface is distal of a distalmost end of the optical fiber.

17. The laser fiber according to claim 16 , further comprising a metal cap having a proximal end attached to the distal end of the optical fiber, wherein at least a portion of the fiber cap is received within a distal end of the metal cap.

18. The laser fiber according to claim 17 , wherein the distal end of the metal cap includes a side port in a wall of the metal cap through which the laser energy is discharged.

19. The laser fiber according to claim 18 , wherein:

the laser fiber further comprises a fluid conduit and fluid channels between the metal cap and the fiber cap;

the optical fiber is within the fluid conduit; and

fluid delivered through the fluid conduit travels through the fluid channels and out the side port of the metal cap.

20. The laser fiber according to claim 19 , further comprising a seal between a distal end of the fluid conduit and the metal cap.