WO1994010554A1 - Method of making an optical fibre sensor probe - Google Patents

Method of making an optical fibre sensor probe Download PDF

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Publication number
WO1994010554A1
WO1994010554A1 PCT/EP1993/002774 EP9302774W WO9410554A1 WO 1994010554 A1 WO1994010554 A1 WO 1994010554A1 EP 9302774 W EP9302774 W EP 9302774W WO 9410554 A1 WO9410554 A1 WO 9410554A1
Authority
WO
WIPO (PCT)
Prior art keywords
section
optical fibre
tube
sensor probe
emplacing
Prior art date
Application number
PCT/EP1993/002774
Other languages
French (fr)
Inventor
Nadhir B. Kosa
Gene J. Twiggs
James R. Salter
Raghuvir Singh
David J. Costello
Leslie A. Schlain
Original Assignee
Optex Biomedical, Inc.
Lucas, Brian, Ronald
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Optex Biomedical, Inc., Lucas, Brian, Ronald filed Critical Optex Biomedical, Inc.
Publication of WO1994010554A1 publication Critical patent/WO1994010554A1/en

Links

Classifications

    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/24—Coupling light guides
    • G02B6/255—Splicing of light guides, e.g. by fusion or bonding
    • G02B6/2552—Splicing of light guides, e.g. by fusion or bonding reshaping or reforming of light guides for coupling using thermal heating, e.g. tapering, forming of a lens on light guide ends
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/75—Systems in which material is subjected to a chemical reaction, the progress or the result of the reaction being investigated
    • G01N21/77—Systems in which material is subjected to a chemical reaction, the progress or the result of the reaction being investigated by observing the effect on a chemical indicator
    • G01N21/7703—Systems in which material is subjected to a chemical reaction, the progress or the result of the reaction being investigated by observing the effect on a chemical indicator using reagent-clad optical fibres or optical waveguides
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/75—Systems in which material is subjected to a chemical reaction, the progress or the result of the reaction being investigated
    • G01N21/77—Systems in which material is subjected to a chemical reaction, the progress or the result of the reaction being investigated by observing the effect on a chemical indicator
    • G01N21/78—Systems in which material is subjected to a chemical reaction, the progress or the result of the reaction being investigated by observing the effect on a chemical indicator producing a change of colour
    • G01N21/80—Indicating pH value
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/62—Systems in which the material investigated is excited whereby it emits light or causes a change in wavelength of the incident light
    • G01N21/63—Systems in which the material investigated is excited whereby it emits light or causes a change in wavelength of the incident light optically excited
    • G01N21/64—Fluorescence; Phosphorescence
    • G01N21/6428—Measuring fluorescence of fluorescent products of reactions or of fluorochrome labelled reactive substances, e.g. measuring quenching effects, using measuring "optrodes"
    • G01N2021/6432—Quenching
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/75—Systems in which material is subjected to a chemical reaction, the progress or the result of the reaction being investigated
    • G01N21/77—Systems in which material is subjected to a chemical reaction, the progress or the result of the reaction being investigated by observing the effect on a chemical indicator
    • G01N2021/7793—Sensor comprising plural indicators
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/24—Coupling light guides
    • G02B6/36—Mechanical coupling means
    • G02B6/3616—Holders, macro size fixtures for mechanically holding or positioning fibres, e.g. on an optical bench
    • G02B6/362—Vacuum holders for optical elements
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/24—Coupling light guides
    • G02B6/36—Mechanical coupling means
    • G02B6/3616—Holders, macro size fixtures for mechanically holding or positioning fibres, e.g. on an optical bench
    • G02B6/3624—Fibre head, e.g. fibre probe termination

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  • Physics & Mathematics (AREA)
  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • General Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Biochemistry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Analytical Chemistry (AREA)
  • Health & Medical Sciences (AREA)
  • General Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Immunology (AREA)
  • Pathology (AREA)
  • Optics & Photonics (AREA)
  • Investigating Or Analysing Materials By The Use Of Chemical Reactions (AREA)
  • Investigating Or Analysing Materials By Optical Means (AREA)

Abstract

A method for making an optical fibre sensor probe, comprising the steps of: (a) taking one or more optical fibres (1, 2, 3) each having a bend therein, the fibre bend(s) disposed in a first section (6) at or adjacent a first end of the optical fibre sensor probe, the optical fibre probe having a second section (7) adjacent the first section (6), and a third section (8) adjacent the second section, (b) encapsulating the second section (7) of the optical fibre sensor probe in potting compound and curing the potting compound, ends of the optical fibre(s) (1, 2, 3) extending from the second section (7) and through the third section (8), (c) emplacing a first tube (13) over the third section (8) of the optical fibre sensor probe, and/or (d) emplacing a second tube (17) over the first section of the optical fibre sensor probe.

Description

METHOD OF MAKING AN OPTICAL FIBRE SENSOR PROBE
This invention relates to a method of making an optical fibre sensor probe and to an optical fibre sensor probe made by said method. EP-A-0 232 369 discloses an optical fibre sensor probe which can be inserted into the arteries of a human being. In the embodiment disclosed a single parameter for example the partial pressure of oxygen or carbon dioxide in the blood can be monitored by passing light through an optical fibre to a chemical indicator in a sample chamber and examining the light transmitted by the chemical and returned via a second optical fibre.
EP-A-0 530 262 discloses a method for making an optical fibre sensor probe which contains a multiplicity of optical fibres, each associated with a separate sample chamber containing a chemical responsive to a separate parameter of the blood, for example the pH, or the partial pressure of carbon dioxide or oxygen.
According to one aspect of the present invention there is provided a method for making an optical fibre sensor probe, which method comprises the steps of:-
(a) taking one or more optical fibres each having a bend therein, the fibre bend(s) disposed in a first section at or adjacent a first end of the optical fibre sensor probe, the optical fibre probe having a second section adjacent the first section, and a third section adjacent the second section, and
(b) encapsulating the second section of the optical fibre sensor probe in potting compound and curing the potting compound, ends of the optical fibre(s) extending from the second section and through the third section, characterized in that said method further comprises the steps of:-
(c) emplacing a first tube over the third section of the optical fibre sensor probe, and/or (d) emplacing a second tube over the first section of the optical fibre sensor probe.
The present invention also provides a method for automatically potting one or more optical fibres, the method comprising disposing at least one optical fibre for applica¬ tion thereto of potting material, applying potting material to the at least one optical fibre by moving a potting material pump along the fibre, the pump applying potting material to at least one optical fibre as it moves therealong.
Further features of the invention are set out in Claims 2-18, 20 and 21.
For a better understanding of the present invention and to show how the same may be carried into effect, reference will now be made, by way of example, to the accompanying drawings, in which:- Figure 1 shows the first step in the manufacture of one embodiment of an optical fibre sensor probe in accordance with the invention;
Figure 2 is a view taken on line II-II of Figure 1;
Figures 3 to 8 are side views showing six further steps in the manufacture of the optical fibre sensor probe;
Figure 9 is a top plan view showing the next step in the manufacture of the optical fibre sensor probe;
Figure 10 is a section on line X-X of Figure 9; Figures 11, 12 and 13 show, to an enlarged scale, details of the sample chambers provided in the optical fibre sensor probe;
Figure 14 shows, to an enlarged scale, a detail of an alternative sample chamber; Figure 15 shows a side view of a second embodiment of optical fibre sensor probe in accordance with the invention; and
Figure 16 shows a top plan view of the optical fibre sensor probe shown in Figure 15. Referring to Figures 1 and 2 of the drawings, three optical fibres 1, 2 and 3 are suspended over vertically spaced mandrels 4 and 5 as shown.
Tension is then applied to the ends of the optical fibres 1, 2, 3, to maintain them in a substantially parallel array. Hot air is then blown onto the bends to aid in the formation of uniform and precise bends which conforms to the curvature of the mandrels 4, 5 and is made permanent by a thermoplastic set.
With the optical fibres 1, 2, 3 in position and held taut, a potting compound comprising a UV (ultravio- let) curable adhesive is uniformly applied to a second section 7 of the optical fibres between a first section 6 and a third section 8 (Fig. 3). The potting compound is applied by a pump in a uniform vertical unidirection pass and is cured by intense pulses of UV light gener¬ ated by two sources of UV light which are disposed on either side of the optical fibres and which are moved vertically along the optical fibres.
An identification mark 9 is placed on the potting compound above the central optical fibre 2. The tension on the optical fibres 1, 2, 3 is then released and the formed body 10 (Fig. 3) is removed from the mandrels 4, 5.
The optical fibres 1, 2, 3 are preferably made from polymeric material whilst the preferred potting compound is ELC 4481 made by Electrolyte Corporation. It is preferred that the maximum diameter of the formed body 10 is kept at or below 600μm when optical fibres having a diameter of 125μm are used. As shown in Figure 4 a thermocouple 11 having wires 12 is next positioned in the third section 8 of the formed body 10. The thermocouple 11 is a type T thermo¬ couple with a lead diameter of 5 x 10~2mm and a bead size of 0.2mm respectively. The loose strands of the optical fibres 1, 2 and 3, together with the leads 12, are passed through a first tube 13 (Figure 5) which is opaque, thin walled, smooth and flexible. A second adhesive (Epotak 301 from Epoxy Technology Co. ) is then introduced into the first tube 13 to give the third section 8 increased structural strength. The extra strength is beneficial in a clinical situation when an optical probe sensor has to be inser¬ ted through a catheter, particularly one which is bent.
Prior to curing the second adhesive the distal end 14 of the tube 13 is pushed against the second section 7 and allowed to relax so that a tapered section 15 of adhesive is formed between the second section 7 and the third section 8.
The tube 13 is preferably black and is preferably made from polyamide material. For this particular device the outside diameter of the tube 13 is preferably about 500μm. The length of the tube 13 is preferably from 75 to 150mm. The relative decrease in diameter from the second section 7 to the third section 8 has significant advantages in clinical applications, since it allows relatively free flow of fluids through the catheter.
The surface of the tapered section 15 is made good using the potting compound. This step is performed by the outward extrusion of the formed body through a precision metal orifice filled with the potting com¬ pound. This step also adds potting material to the optical fibre in the first section 6 and may slightly increase the overall diameter of formed body. However, the surface finish is significantly improved. The bent ends of the optical fibres 1, 2, 3 are thinly coated with potting compound which protects these from harsh solvents contained in subsequent coatings. After this step (Fig. 6) the maximum diameter of the formed body is about 650μm. The first section 6 is then dipped vertically into a solvent based solution to uniformly coat the bent optical fibre portions with an opaque coating 16. The opaque coating 16 enhances optical insulation of the optical fibres both from external light and from ad a- cent optical fibres.
To further optically isolate and strengthen the first portion 6, a second tube 17 is bonded to the optical fibres 1, 2, 3 in the first section 6 using the potting compound. The second tube 17 is short (typically about 2.5mm in length), opaque (preferably black) and thin walled. It is preferably made from polyamide mater¬ ial. A smooth round tip 18 is formed at the end of the first section 6 remote from the second section 7.
Preferably, the outer diameter of the second tube 17 matches that of the second section 7.
At the proximal end 19 of the optical probe sensor, loose optical fibres 1, 2, 3 and the leads 12 from the thermocouple pass through a third tube which, in use, is used to manoeuvre the formed body 10 into position. As shown in Figure 9, the next step is to cut sample chambers 20, .21 and 22 in the second section 7. The sample chambers 20, 21, 22 are cut using an excimer laser and extend through the optical fibres 2, 1 and 3 respectively as can be seen in Figure 10. Typically, the sample chambers 20, 21, 22 are 150μm x 150μm x lOOμm deep. The sample chambers 20, 21, 22 subtend an angle of approximately 140° with respect to the longitudinal axis of the formed body 10.
Each sample chamber 20, 21, 22 is then prepared. Firstly, (Fig. 11) the sample chamber 21 is loaded with a pC02 indicator complex 23. Secondly, (Fig. 12) the sample chamber 20 is loaded with a p02 indicator complex 24.
A patch 25 comprising an 02 permeable membrane is then applied over the sample chamber 20.
A small amount of pC02 support media is then intro¬ duced into the sample chamber 21 to rehydrate the pC02 indicator complex 23.
A patch 26 comprising a C02 permeable membrane is then applied over the sample chamber 21.
The patches 25 and 26 are then permitted to cure in a humid environment to gain structural strength and to effect proper bonding to the surface of the probe.
The first section 6 and the second section 7 are then dipped to form a second coating 27 which is perme- able to both C02 and 02. The second coating 27 is only applied up to a level just below the sensor chamber 22. The second coating 27 is then allowed to cure in a humid environment. Sample chamber 22 (Fig. 13) is then loaded with a pH indicator complex 28. The filled sample chamber 22 is then covered with a patch 29 which, in this case, com¬ prises a water permeable membrane.
The formed body 10 is then dipped to provide an opaque, water permeable membrane 30 which further optic¬ ally isolates the optical fibres 1, 2, 3.
Finally, a thin uniform anti-thrombogenic coating 31 is applied to the whole.
Various modifications to the embodiment thus far described are envisaged. For example, as shown in Fig¬ ure 14 the patch 29 may be replaced by a water permeable dip membrane 29'. Whereas the thermocouple 11 is shown in the third section 8 it could alternatively be provi¬ ded in the first section 6. Such an embodiment is shown in Figures 15 and 16 where similar parts to those in the preceding Figures have been identified by the same reference numerals with the addition of an apostrophe.
The preferred compositions of the pC0 indicator complex 23, the p02 indicator complex 24 and the pH indicator complex 28 together with the compositions of the various coatings is described in more detail in our
PCT application PCT/EP93/ of even date.
Preferably, the pH indicator complex 28 comprises phenal red covalently bonded to the surface of porous glass and made into a slurry or gel with a hydrophobic polymer such as hydroxy ethyl cellulose.
Preferably, the pC02 indicator complex 23 comprises phenal red made into a gel with a hydrophilic polymer and having a desired concentration of bicarbonate to create carbonic acid inside the sample chamber 21 after exposure to C02 .
Preferably, the p0 indicator complex 24 comprises an oxygen quenchable or sensitive fluorescent indicator dye such as a Ruthenium II compound. The anti-thrombogenic coating 31 preferably com¬ prises a heparine complex of benzalkonium chloride.
The gas permeable membrane preferably comprises a polydimethyl siloxane copolymer.

Claims

Claims :
1. A method for making an optical fibre sensor probe, which method comprises the steps of:-
(a) taking one or more optical fibres (1,2,3) each having a bend therein, the fibre bend(s) disposed in a first section (6) at or adjacent a first end of the optical fibre sensor probe, the optical fibre probe having a second section (7) adjacent the first section (6), and a third section (8) adjacent the second sec- tion, and
(b) encapsulating the second section (7) of the optical fibre sensor probe in potting compound and curing the potting compound, ends of the optical fibre(s) (1,2, 3) extending from the second section (7) and through the third section (8), characterized in that said method further comprises the steps of:-
(c) emplacing a first tube (13) over the third section (8) of the optical fibre sensor probe, and/or (d) emplacing a second tube (17) over the first section of the optical fibre sensor probe.
2. A method according to Claim 1, wherein said method comprises the step of emplacing a first tube (13) over the third section (8) of the optical fibre sensor probe, characterized in that the first tube (13) is opaque and flexible.
3. A method according to Claim 1 or 2, wherein said method comprises the step of emplacing a first tube (13) over the third section (8) of the optical fibre sensor probe, characterised in that said method further com¬ prises the step of filling the first tube (13) with adhesive to strengthen the third section (8) .
4. A method according to Claim 1, 2 or 3, wherein said method comprises the step of emplacing a first tube (13) over the third section (8) of the optical fibre sensor probe, characterized in that said method further com¬ prises the step of, prior to emplacing the first tube (13), disposing a thermocouple (11) in the third section (8), the thermocouple (11) having thermocouple leads (12) extending from the third section (8).
5. A method according to any preceding Claim, wherein said method comprises the step of emplacing a first tube (13) over the third section (8) of the optical fibre sensor probe, characterized in that the first tube (13) comprises a polyamide.
6. A method according to any preceding Claim, charac¬ terised in that the second section ( 7 ) of the optical fibre sensor probe is larger in cross-section than the third section (8), the optical fibre sensor probe has a fourth section between the second section (7) and third section ( 8 ) , and the fourth section tapers from the second section (7) to the third section (8) .
7. A method according to any preceding Claim, wherein said method comprises the step of emplacing a second tube (17) over the first section (6) of the optical fibre sensor probe, characterized in that the second tube (17) comprises a polyamide.
8. A method according to any preceding Claim, wherein said method comprises the step of emplacing a second tube (17) over the first section (6) of the optical fibre sensor probe, characterised in that said method further comprises the step of bonding the second tube (17) to the first section (6) of the optical fibre probe.
9. A method according to any preceding Claim, wherein said method comprises the step of emplacing a second tube (17) over the first section (6) of the optical fibre sensor probe, characterised in that said method further comprises the step of, prior to emplacing the second tube (17), encapsulating the portions of optical fibre(s) in the first section (6) in potting compound and curing the potting compound.
10. A method according to Claim 9, characterised in that it comprises the step of, prior to emplacing the potting compound, applying an opaque coating (16) to the optical fibres (1,2,3) in the first section (6).
11. A method according to any preceding Claim, charac¬ terised in that it comprises the steps of forming a smooth round tip (18) of potting compound at the end of the first section (6) remote from the second section (7), and curing the potting material.
12. A method according to any preceding Claim, charac¬ terised in that it further comprises the step of har¬ nessing optical fibre ends extending from the third section (8) of the optical fibre probe and a portion of the first tube (13) in a third tube for connection to an optical fibre connector.
13. A method according to any preceding Claim, wherein said plurality of optical fibres comprises three optical fibres (1,2,3), each having a sample chamber (20,21,22) formed therein, characterised in that said method fur¬ ther comprises the steps of:- installing a pC0 indicator complex (23) in a first sample chamber (22); installing a p02 indicator complex (24) in a second sample chamber (21); applying a curable 02 permeable membrane over the p0 indicator complex; applying a curable C0 permeable membrane over the pC0 ; allowing the 02 and C02 gas permeable membranes to cure, applying a curable 02 and C02 permeable membrane over both the p02 and the pC02 indicator complexes and allowing it to cure; installing a pH indicator in the third sample chamber (23), and applying a liquid permeable membrane over the pH indicator complex.
14. A method according to Claim 13, characterised in that it includes the step of curing the permeable mem¬ branes in a humid environment.
15. A method according to any preceding Claim, charac¬ terised in that it further comprises the step of apply- ing an opaque coating (30) to the first, second and third sections (6,7,8).
16. A method according to Claim 15, characterised in that it further comprises the step of applying a second opaque coating to the first, second and third sections (6,7,8).
17. A method according to any preceding Claim, charac¬ terised in that it further comprises the step of apply¬ ing an anti-thrombogenic coating (31) to the first, second and third sections (6,7,8).
18. A method according to any preceding Claim, charac¬ terised in that it further comprises the step of prior to encapsulating the second section (7), disposing a thermocouple (11' ) in the first section (6' ), the ther¬ mocouple (11') having thermocouple leads (12') extending from the optical fibre probe.
* * *
19. A method for automatically potting one or more optical fibres, the method comprising disposing at least one optical fibre for applica¬ tion thereto of potting material, applying potting material to the at least one optical fibre by moving a potting material pump along the fibre, the pump applying potting material to the at least one optical fibre as it moves therealong.
20. A method according to Claim 19, characterized in that it further comprises the step of curing the potting material by moving a light along the fibres.
21. A method according to Claim 20, characterized in that the potting material comprises ultraviolet-light- curable potting material, and the light is an ultravio¬ let light.
* * *
PCT/EP1993/002774 1992-10-23 1993-10-07 Method of making an optical fibre sensor probe WO1994010554A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US07/965,232 US5335305A (en) 1991-12-19 1992-10-23 Optical sensor for fluid parameters
US07/965,232 1992-10-23

Publications (1)

Publication Number Publication Date
WO1994010554A1 true WO1994010554A1 (en) 1994-05-11

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ID=25509671

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Application Number Title Priority Date Filing Date
PCT/EP1993/002774 WO1994010554A1 (en) 1992-10-23 1993-10-07 Method of making an optical fibre sensor probe

Country Status (2)

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US (1) US5335305A (en)
WO (1) WO1994010554A1 (en)

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