Durable fiber optic diffuser tip and method of making same

The present invention relates, in general, to an improved, more durable diffuser tip to diffuse light from a light-emitting end of an optical fiber. More particularly, the invention relates to a diffuser which includes a decladded optical fiber core which is covered by a protective coating and an optical coupling layer wherein the protective coating has an index of refraction between the indices of refraction of the core and the optical coupling layer while at the same time the protective coating increases the bending moment required to break the core. The protective coating is made of polymethyl methacrylate or methylpentene. An medical instrument for diffusing light from an optical fiber is provided. The medical instrument includes an optical fiber having a proximal portion including a cladding layer surrounding the core and a distal portion having a diffuser tip comprising a protective coating made of acrylic or methylpentene surrounding the core, an optical coupling layer, and a sleeve. The protective coating strengthens the distal end of the optical fiber so that it can withstand a higher bending moment at failure than the uncladded core. At the same time, the protective layer has an index of refraction that is between the indices of refraction of the core and the optical coupling layer to direct light out of the core through to the optical coupling layer.