Optical catheter with stranded fibers

• US 5,415,653 A
• Filed: 09/20/1993
• Issued: 05/16/1995
• Est. Priority Date: 08/26/1992
• Status: Expired due to Term

• Current Assignee: Spectranetics Corporation (Koninklijke Philips N.V.)
• Original Assignee: Advanced Interventional Systems, Inc. (Koninklijke Philips N.V.)
• Inventors: Wardle, John L., Goldenberg, Tsvi
• Primary Examiner(s): Aschenbrenner, Peter A.
• Assistant Examiner(s): PEFFLEY, MICHAEL F
• Application Number:
  US08/124,383
• Time in Patent Office: 603 Days
• Field of Search: 606/7, 606/13-16, 607/88, 607/89, 385/103, 385/104, 604/282, 604/21, 604/22
• US Class Current: 606/7
• CPC Class Codes: A61B 18/24 with a catheter A61B18/26, A61B18/28 take precedence
• CPC Class Codes: A61B 2018/2216 Braided or helically wound
• CPC Class Codes: A61B 2018/2244 Features of optical fibre cables, e.g. claddings
• CPC Class Codes: A61M 2025/0183 Rapid exchange or monorail catheters
• CPC Class Codes: G02B 23/26 using light guides for illumination G02B23/2469

Abstract

A catheter having an axis extending between a proximal end and an opposing distal end includes a plurality of optical fibers arranged to spiral in a first direction to form a circumferential layer around the axis. Rotation of the catheter in the first direction tends to expand the layer while rotation of the catheter in a second opposite direction tends to contract the circumferential layer. An outer jacket limits the expansion of the circumferential layer while an inner core limits the contraction of the circumferential layer to increase torquability of the catheter. The stranded fibers equalize bending stresses to maintain a circular cross-sectional configuration, increase flexibility and a reduced diameter for the catheter.

Claims

1. A fiberoptic catheter having an axis extending between a proximal end and an opposing distal end, the catheter comprising:

a first plurality of optical fibers disposed in an ordered spiral configuration around the axis and arranged in a circumferential layer having a thickness equal to the diameter of one of the fibers with adjacent fibers in the layer having a contiguous relationship;

the fibers being arranged to spiral in a first direction between the proximal end and the distal end of the catheter so that rotation of the catheter in the first direction tends to expand the circumferential layer while rotation of the catheter in a second direction opposite to the first direction tends to contract the circumferential layer;

first means disposed outwardly of the circumferential layer for limiting the expansion of the circumferential layer when the catheter is rotated in the first direction;

second means disposed inwardly of the circumferential layer for limiting the contraction of the circumferential layer when the catheter is rotated in the second direction;

a second plurality of optical fibers included in the second means and arranged in a spiral configuration around the axis in a second circumferential layer, the second layers arranged to spiral in the second direction between the proximal end and the distal end of the catheter so that axial rotation of the catheter in the first direction tends to contract the second circumferential layer while axial rotation of the catheter in the second direction tends to expand the second circumferential layer;

a third plurality of optical fibers included in the first means and arranged in a spiral configuration around the axis in a third circumferential layer;

the third fibers being arranged to spiral in the second direction between the proximal end and the distal end of the catheter so that axial rotation of the catheter in the second direction contracts the third cylindrical layer while axial rotation of the catheter in the first direction expands the third cylindrical layer;

whereby

an interference fit exists between the first layer and the third layer when the catheter is rotated in the first direction, and between the first layer and the second layer when the catheter is rotated in the second direction.

2. The catheter recited in claim 1 wherein the first, second and third plurality of optical fibers include at least one fiber having a particular diameter and at least one other fiber having a diameter greater than the particular diameter.

3. The catheter recited in claim 2 wherein the one fiber and the one other fiber are disposed in different layers.

4. A fiberoptic catheter having an axis extending between a proximal end and an opposing distal end, the catheter comprising:

a multiplicity of optical fibers arranged to spiral around the axis of the catheter in at least first, second, and third circumferential layers;

the fibers in the first circumferential layer forming a first spiral having a first pitch;

the fibers in the second circumferential layer forming a second spiral having a second pitch;

the fibers in the third circumferential layer forming a third spiral having a third pitch; and

at least one of the first pitch, second pitch and third pitch being different than the other two of the first, second, and third pitch.

5. The catheter recited in claim 4 wherein the first pitch and the third pitch are substantially equivalent.

6. The catheter recited in claim 4 wherein each of the first pitch, second pitch and third pitch is within a range of about 0.125 to 1.0 inches.

7. The catheter recited in claim 4 wherein each of the first pitch, second pitch and third pitch is within a range of about 0.2 to 0.8 inches.

8. The catheter recited in claim 4 wherein each of the optical fibers has a diameter in a range of about 30 microns to 200 microns.

9. The catheter recited in claim 8 wherein each of the optical fibers has a diameter in a range of about 50 microns to 80 microns.

10. A catheter having an axis extending between a proximal end and an opposing distal end, the catheter comprising:

a plurality of optical fibers extending between the proximal end and the distal end of the catheter in an ordered arrangement wherein adjacent fibers in the arrangement have a contiguous relationship, the ordered arrangement including a plurality of first fibers disposed to spiral around the axis in a first direction and to form a first circumferential layer, and further including

a plurality of second fibers disposed to spiral around the axis and the first fiber in a second direction to form a second circumferential layer outwardly of the first circumferential layer;

the catheter being bendable between a first position wherein the axis of the catheter is generally straight and the catheter in radial cross-section has a first shape, and a second position wherein the axis of the catheter forms a curve having an inner radius and an outer radius and the catheter in radial cross-section has a second shape along the curve;

at least one of the fibers extending from a first point in proximity to the outer radius of the curve, where the fiber has a tensile stress, and a second position in proximity to the inner radius of the curve, where the fiber has a compressive stress, so that the bending stresses in the fiber tend to equalize;

whereby

the second shape is maintained in a configuration substantially similar to the first shape.

11. The catheter recited in claim 10 wherein the arrangement includes a plurality of third fibers disposed to spiral around the axis, the first layer, and the second layer in the first direction to form a third circumferential layer outwardly of the second circumferential layer.

12. The catheter recited in claim 11 wherein at least one of the first, second and third fibers is an electrical fiber.

13. The catheter recited in claim 11 wherein at least one of the first, second and third fibers includes a radiopaque fiber.

14. A fiberoptic catheter having an axis extending between a proximal end and an opposing distal end, the catheter comprising:

a first axial section of the catheter;

a second axial section of the catheter disposed distally of the first axial section of the catheter;

a first plurality of optical fibers arranged contiguously in a spiral configuration to form a first circumferential layer extending in the first axial section and the second axial section around the axis of the catheter;

the first plurality of optical fibers in the first axial section having a first pitch;

the first plurality of optical fibers in the second axial section having a second pitch different from the first pitch;

a second plurality of optical fibers arranged contiguously in a spiral configuration to form a second cylindrical layer outwardly of the first cylindrical layer;

a third plurality of optical fibers arranged contiguously in a spiral configuration to form a third cylindrical layer outwardly of the second cylindrical layer;

the first plurality of fibers arranged to spiral in one of a clockwise and a counter-clockwise direction; and

at least one of the second and third plurality of fibers arranged to spiral in the other of the clockwise and counter-clockwise direction.

15. The catheter recited in claim 14 wherein at least two of the fibers have a different diameter.

16. The catheter recited in claim 14 wherein at least two of the fibers spiral at a different pitch.

17. The catheter recited in claim 14 wherein at least two of the fibers spiral in different directions.

18. The catheter recited in claim 14 wherein the circumferential layers include at least one radiopaque fiber.

19. The catheter recited in claim 14 wherein the circumferential layers include at least one electrical fiber.

20. A laser catheter having an axis extending between a proximal end and an opposing distal end, the catheter comprising:

a longitudinal core extending along the catheter;

a multiplicity of optical fibers arranged around the core and having properties for conducting light between the proximal end and the distal end of the catheter;

a first plurality of the fibers spiraling around the core in one of a clockwise and counterclockwise direction and forming a first circumferential layer around the core; and

a second plurality of the fibers spiraling around the core in the other of the clockwise and counterclockwise directions and forming a second circumferential layer outwardly of the first circumferential layer.

21. The laser catheter recited in claim 20 further comprising:

a third plurality of fibers spiraling around the core in the one direction and forming a third circumferential layer outwardly the first circumferential layer, second circumferential layer, and the core.

22. The laser catheter recited in claim 20 wherein the core is an optical fiber disposed along the axis of the catheter.

23. The laser catheter recited in claim 20 wherein the core is a tube forming an open channel along at least a portion of the axis of the catheter.

24. The laser catheter recited in claim 23 wherein:

portions of the tube define an exit port extending from the channel through the tube; and

the exit port is spaced from the distal end of the catheter a distance which is not less than 25 centimeters.

25. The laser catheter recited in claim 24 wherein the exit port is spaced from the distal end of the catheter a distance which is in a range between 25 and 50 centimeters.

26. A method of making a catheter having an axis extending between a proximal end and an opposing distal end, the method comprising the steps of:

providing a first plurality of optical fibers each having properties for conducting light between the proximal end and the distal end of the catheter;

wrapping the fibers around the axis of the catheter to form a first cylindrical layer between the proximal end and the distal end of the catheter, the first layer having properties for expanding radially when the catheter is twisted in a first direction and properties for contracting radially when the catheter is twisted in a second direction opposite to the first direction;

providing a cylindrical outer surface inwardly of the first layer creating an interference fit with the contracting first layer when the catheter is twisted in the second direction;

providing a second optical fiber having a cylindrical outer surface disposed inwardly of the first layer and creating an interference fit with the contracting first layer when the catheter is twisted in the second direction; and

providing a cylindrical inner surface outwardly of the fiber layer to create an interference fit with the expanding fiber layer when the catheter is twisted in the first direction.

27. The method recited in claim 26 wherein the first providing step includes the step of providing a plurality of fibers including at least one radiopaque fiber.

28. A method of making a catheter having an axis extending between a proximal end and an opposing distal end, the method comprising the steps of:

providing a first plurality of optical fibers each having properties for conducting light between the proximal end and the distal end of the catheter;

wrapping the fibers around the axis of the catheter to form a first cylindrical layer between the proximal end and the distal end of the catheter, the first layer having properties for expanding radially when the catheter is twisted in a first direction and properties for contracting radially when the catheter is twisted in a second direction opposite to the first direction;

providing a cylindrical outer surface inwardly of the first layer creating an interference fit with the contracting first layer when the catheter is twisted in the second direction;

providing a second plurality of optical fibers;

wrapping the second plurality of optical fibers around the first plurality of optical fibers to form a second cylindrical layer around the first cylindrical layer, the second circumferential layer providing a cylindrical inner surface outwardly of the first layer to create an interference fit with the expanding first layer when the catheter is twisted in the first direction.

29. The method recited in claim 28 wherein the first wrapping step includes the step of spiraling the first optical fibers around the axis of the catheter to form the single cylindrical layer;

and

the second wrapping step includes the step of spiraling the second optical fibers around the first optical fibers to form the second cylindrical layer.

30. A method of making a catheter having an axis extending between a proximal end and an opposing distal end, the method comprising the steps of:

providing a plurality of optical fibers each having properties for conducting light between the proximal end and the distal end of the catheter, the plurality of optical fibers including

at least a pair of optical fibers having different diameters;

wrapping the fibers around the axis of the catheter to form a single generally cylindrical layer between the proximal end and the distal end of the catheter, the layer having properties for expanding radially when the catheter is twisted in a first direction and properties for contracting radially when the catheter is twisted in a second direction opposite to the first direction;

providing a cylindrical outer surface inwardly of the fiber layer creating an interference fit with the contracting fiber layer when the catheter is twisted in the second direction;

providing a cylindrical inner surface outwardly of the fiber layer to create an interference fit With the expanding fiber layer when the catheter is twisted in the first direction.

31. A method of making a catheter having an axis extending between a proximal and an opposing distal end, the method comprising the steps of:

spiraling at least a first, second and third fibers around the axis to form a respective inner layer, a middle layer disposed outwardly of the inner layer, and an outer layer disposed outwardly of the middle layer;

torquing the catheter in a first axial direction to expand the middle layer radially outwardly and contract the outer layer radially inwardly to form an interference fit between the middle layer and the outer layer; and

torquing the catheter in a second axial direction opposite to the first axial direction to contract the middle layer radially inwardly and expand the inner layer radially outwardly to form an interference fit between the middle .layer and the inner layer of the catheter.

32. The method recited in claim 31 wherein the spiraling step includes the step of spiraling the second fiber in a direction opposite to at least one of the first fiber and the third fiber.

33. The method recited in claim 31 wherein the spiraling step comprises the step of spiraling the second fiber at a pitch different than the pitch of one of first fiber and the third fiber.

34. The method recited in claim 31 wherein at least one of the first, second and third fibers is spiraled at a variable pitch in its respective layer.

35. The method recited in claim 31 further comprising the step of forming a jacket around the fibers.

36. The method recited in claim 35 wherein the forming step includes the step of extruding a jacket around the fibers between the proximal end and the distal end of the catheter.

37. A laser catheter having an axis extending between a proximal end and an opposing distal end, the catheter comprising:

a longitudinal core extending along the catheter;

a multiplicity of optical fibers arranged around the core and having properties for conducting light between the proximal end and the distal end of the catheter;

a circumferential layer of the fibers disposed around the core and having properties for expanding circumferentially when the catheter is torqued in a first direction and properties for contracting circumferentially when the catheter is torqued in a second direction opposite to the first direction;

means for limiting the expansion of the layer of fibers when the catheter is torqued in the first direction and for limiting the contraction of the layer of fibers when the catheter is torqued in the second direction;

first means included in the limiting means for limiting the expansion of the layer, the first means including a second layer of fibers disposed circumferentially outwardly of the first layer and having properties for contracting circumferentially when the catheter is torqued in the first direction; and

second means included in the limiting means and disposed inwardly of the layer of fibers to limit the contraction of the layer when the catheter is torqued in the second direction.

38. A laser catheter having an axis extending between a proximal end and an opposing distal end, the catheter comprising:

a longitudinal core extending along the catheter;

a multiplicity of optical fibers arranged around the core and having properties for conducting light between the proximal end and the distal end of the catheter;

a circumferential layer of the fibers disposed around the core and having properties for expanding circumferentially when the catheter is torqued in a first direction and properties for contracting circumferentially when the catheter is torqued in a second direction opposite to the first direction;

means for limiting the expansion of the layer of fibers when the catheter is torqued in the first direction and for limiting the contraction of the layer of fibers when the catheter is torqued in the second direction;

first means included in the limiting means and disposed outwardly of the layer of fibers for limiting the expansion of the layer when the catheter is torqued in the first direction; and

second means included in the limiting means for limiting the contraction of the layer when the catheter is tourqued in the second direction, the second means including a second layer of the fibers disposed circumferentially inwardly of the first layer and having properties for expanding circumferentially when the catheter is torqued in the second direction.

39. A laser catheter having an axis extending between a proximal end and a distal end of the catheter, comprising:

a first axial section of the catheter;

a second axial section of the catheter disposed proximally of the first axial section of the catheter;

a tube defining a lumen along the axis of at least the first axial section;

first portions of the tube disposed in the first axial section and second portions of the tube disposed in the second axial section;

torque means disposed in the lumen of the second portion of the tube for rotating the catheter along the axis of the catheter;

a multiplicity of optical fibers extending through the first axially section and the second axial section;

the fibers in the first axial section forming a first spiral having a first pitch; and

the fibers in the second axial section forming a second spiral having a second pitch longer than the first pitch.

40. A laser catheter having an axis extending between a proximal end and a distal end of the catheter, comprising:

a first axial section of the catheter;

a second axial section of the catheter disposed proximally of the first axial section of the catheter;

a third axial section of the catheter disposed proximally of the second axial section;

a multiplicity of optical fibers extending through the first axial section, the second axial section, and the third axial section;

the fibers in the first axial .Section forming a first spiral having a first pitch;

the fibers of the second axial section forming a second spiral having a second pitch longer than the first pitch; and

the fibers in the third axial section extending in a generally parallel relationship with the axis of the catheter.

41. A laser catheter having an axis extending between a proximal end and a distal end of the catheter, comprising:

a first axial section of the catheter;

a second axial section of the catheter disposed proximally of the first axial section of the catheter;

a first plurality of optical fibers forming a first spiral and one of a clockwise and counter-clockwise direction around the axis;

a second plurality of optical fibers forming a second spiral in the other of the clockwise and counter-clockwise direction around the axis of the catheter;

at least the first plurality of fibers extending through the first axial section and the second axial section of the catheter;

the first plurality of fibers in the first axial section forming a first spiral having a first pitch; and

the first plurality of optical fibers in the second axial section forming a second spiral having a second pitch longer than the first pitch.

42. A laser catheter system, comprising:

a laser;

a catheter coupled to the lasers and having an axis extending between a proximal end and an opposing distal end;

a core included in the catheter and having a generally cylindrical outer surface;

a multiplicity of optical fibers having properties for conducting light between the proximal end and the distal end of the catheter, the fibers being enclosed in an ordered arrangement along substantially the entire distance between the proximal end and the distal end, with each of the fibers having a non-parallel relationship with the axis of the catheter;

a first layer of the optical fibers surrounding the core;

a second layer of the optical fibers surrounding the first layer of optical fibers;

a first optical fiber included in the first layer and having a first bending path around the core;

a second optical fiber included in the first layer and having a second bending path around the core; and

the first bending path having substantially the same length as the second bending path.