Optical sensor for fluid parameters

• US 5,335,305 A
• Filed: 10/23/1992
• Issued: 08/02/1994
• Est. Priority Date: 12/19/1991
• Status: Expired due to Term

• Current Assignee: Bruce A. Mckinley, Camino Neurocare, Inc.
• Original Assignee: Optex Biomedical, Inc.
• Inventors: Schlain, Leslie A., Twiggs, Gene J., Costello, David J., Singh, Raghuvir, Salter, James R., Kosa, Nadhir B.
• Primary Examiner(s): Ullah, Akm E.
• Application Number:
  US07/965,232
• Time in Patent Office: 648 Days
• Field of Search: 385/59, 385/12, 385/147, 385/60, 128/634, 422/58, 422/82.07, 422/82.06, 436/172
• US Class Current: 385/147
• CPC Class Codes: G01N 2021/6432 Quenching
• CPC Class Codes: G01N 2021/7793 Sensor comprising plural indicators
• CPC Class Codes: G01N 21/7703 using reagent-clad optical fibres or optical waveguides using measurement of total internal reflection or attenuated total reflection G01N21/552; optical fibres or waveguides per se G02B
• CPC Class Codes: G01N 21/80 Indicating pH value
• CPC Class Codes: G02B 6/2552 reshaping or reforming of light guides for coupling using thermal heating, e.g. tapering, forming of a lens on light guide ends
• CPC Class Codes: G02B 6/362 Vacuum holders for optical elements
• CPC Class Codes: G02B 6/3624 Fibre head, e.g. fibre probe termination optical details of light guide terminations G02B6/241; reshaping of light guides G02B6/2552; optical details of coupling light into or out of fibre end G02B6/262

Abstract

Methods for making optical fiber sensor probes for measuring or monitoring parameters of fluids, including but not limited to measuring blood gas concentrations and pH either in a vessel in vitro or in a human artery. Such probes, in one aspect, have one or more optical fibers with one or more chambers with a chemical indicating materialtherein which changes in response to light transmitted therethrough. In one aspect such probes have a probe body including a plurality of fibers having a substantial portion of their surfaces covered with an opaque material to enhance light signal transmission therethrough. Such probes may also have a coating thereon of an anti-thrombogenic mnaterial.

Claims

1. A method for making an optical fiber sensor probe having a plurality of optical fibers, the method comprising

aggregating together a plurality of optical fibers, certain of the optical fibers having a bend therein, the fiber bends disposed in a first section of the optical fiber probe near or at a first end of the optical fiber probe, the optical fiber probe having a second section adjacent the first section and a third section adjacent the second section,

encapsulating the second section of the optical fiber probe in plotting material and curing the potting material, loose ends of the optical fibers extending from the second section and into the third section,

emplacing a first tube over a portion of the third section of the optical fiber probe, and

emplacing a second tube over the first section of the optical fiber probe.

2. The method of claim 1 wherein the first tube is opaque and flexible.

3. The method of claim 1 including also

filling the first tube with adhesive to strengthen the optical fiber probe'"'"'s third section.

4. The method of claim 1 comprising also

prior to emplacing the first tube, disposing a thermocouple in the third section of the optical fiber probe, the thermocouple having thermocouple leads extending from the third section.

5. The method of claim 1 wherein

the optical fiber probe'"'"'s second section is larger in cross-section than the third section, the probe has a fourth section between the second and third section, and the fourth section tapers from the larger second section to the third section.

6. The method of claim 2 wherein the first tube is a polyimide tube.

7. The method of claim 1 wherein the second tube is a polyimide tube.

8. The method of claim 1 comprising also, prior to emplacing the second tube,

encapsulating optical fiber portions in the first section, including the fiber bends, with potting material and curing the potting material.

9. The method of claim 8 comprising also, prior to emplacing the second tube,

applying an opaque coating to the optical fiber portions in the first section, including to the fiber bends.

10. The method of claim 1 comprising also

forming a smooth round tip of potting material at an end of the first section distal from the second section, and curing the potting material.

11. The method of claim 1 comprising also

bonding the second tube to the first section of the optical fiber probe.

12. The method of claim 1 comprising also

harnessing loose optical fiber ends extending from the third section of the optical fiber probe and a portion of the first tube in a third flexible tube for connection to an optical fiber connector,

forming a gap in each optical fiber in the second section of the optical fiber probe, the gaps spaced apart from each other, and

installing a chemical analyte sensor in each gap.

13. The method of claim 12 comprising also

the plurality of optical fibers comprising three optical fibers, one gap formed in each of the optical fibers, each gap comprising a chamber,

installing a pCO2 indicator complex in a first chamber of a first optical fiber of the three optical fibers,

installing a pO2 indicator complex in a second chamber of a second optical fiber of the three optical fibers,

applying a curable first permeable membrane over the pO2 indicator complex,

applying a curable second permeable membrane over the pCO2 and allowing the first and second permeable membranes to cure,

applying a third curable permeable membrane covering both the pO2 and the pCO2 indicator complexes and allowing it to cure, then,

installing a pH indicator in a third chamber of a third optical fiber of the three optical fibers, and

applying a permeable membrane over the pH indicator complex.

14. The method of claim 13 comprising also

applying an opaque coating to the first, second and third sections of the optical fiber probe.

15. The method of claim 14 comprising also

applying an anti thrombogenic coating to the first, second, and third sections of the optical fiber probe.

16. The method of claim 1 comprising also

prior to encapsulating the second section, disposing a thermocouple in the first section, the thermocouple having thermocouple leads extending from the optical fiber probe.

17. The method of claim 1 wherein

a plurality of pairs of optical fibers are associated together,

each pair comprising a first and a second optical fiber, the first optical fiber having a bent portion disposed in the first section of the optical fiber probe and a portion extending into the second section of the optical fiber probe, and

the second optical fiber extending from the second section of the optical fiber probe into a third section thereof,

an end of the first optical fiber spaced part from an end of the second optical fiber in the second section of the optical fiber probe, space between the two ends suitable for receiving a chemical indicator.

18. The method of claim 12 wherein the permeable membranes are cured in a humid environment.

19. A method for making an optical fiber sensor probe having a plurality of optical fibers, the method comprising

combining three optical fibers, each having a bend therein, the bends disposed in a first section of the probe near a first end thereof,

the probe having a second section adjacent the first section, a third section adjacent the second section, the second section disposed between the first and third sections,

disposing a thermocouple with the three optical fibers, the thermocouple having thermocouple leads extending from the probe,

encapsulating the second section in potting material and curing it with loose ends of the optical fibers extending from the second section and into the third section,

emplacing an opaque flexible polyimide first tube over a portion of the third section and filling the first tube with adhesive to bond it to the third section and to strengthen the third section,

encapsulating optical fiber portions in the first section and the fiber bends with potting material and curing it,

applying a first opaque coating to the optical fiber portions in the first section, including to the fiber bends,

emplacing a second opaque flexible polyimide tube over the first section and bonding it to the first section,

forming a gap in each optical fiber in the second section, the gaps spaced apart from each other,

installing an analyte indicator complex in each gap, including installing a pO2 indicator complex in one gap, a pCO2 indicator complex in another gap, and a pH indicator complex in another gap.

20. The method of claim 19 comprising also

applying 2 permeable covering membranes over each indicator complex

applying a second opaque coating to the first, second, third, and fourth sections,

applying an anti-thrombogenic coating to the first, second, third and fourth sections, and

the second section larger in cross-section than the third section.

21. An optical fiber probe for sensing blood parameters, the probe comprising

a plurality of three optical fibers,

each optical fiber having a fiber bend therein and a gap therein, each gap containing an analyte indicator complex, one gap containing a pO2 indicator complex, another gap containing a pCO2 indicator complex, and another gap containing a pH indicator complex,

the fiber bends and the indicator complexes encapsulated in cured potting material forming a probe body,

the probe body covered with a permeable opaque first coating, each of the fiber bends covered with a permeable opaque second coating,

a first opaque tube flexible polyimide bonded to the probe body and covering the fiber bends,

a second opaque flexible polyimide tube covering loose ends of the optical fibers extending from the probe body,

a thermocouple disposed in the probe body with thermocouple leads attached to the thermocouple and extending from the probe body, and

an anti-thrombogenic coating over the probe body.

22. An optical fiber probe for sensing blood parameters, the probe comprising

a plurality of three optical fibers,

each optical fiber having a fiber bend therein and a gap herein, each gap containing an analyte indicator complex, one gap containing a pO2 indicator complex, another gap containing a pCO2 indicator complex, and another gap containing a pH indicator complex,

the fiber bends and the indicator complexes encapsulated in cured potting material forming a probe body,

the probe body covered with a permeable opaque first coating, each of the fiber bends covered with a permeable opaque second coating,

a first opaque flexible polyimide tube bonded to the probe body and covering the fiber bends,

a second opaque flexible polyimide tube covering loose ends of the optical fibers extending from the probe body,

a thermocouple disposed in the probe body with thermocouple leads attached to the thermocouple and extending from the probe body, and

an anti-thrombogenic coating over the probe body.