Method of forming IV catheter and needle assembly

• US 7,694,403 B2
• Filed: 03/24/2004
• Issued: 04/13/2010
• Est. Priority Date: 03/25/2003
• Status: Active Grant

• Current Assignee: Becton, Dickinson & Co
• Original Assignee: Becton, Dickinson & Co
• Inventors: Moulton, William G.
• Primary Examiner(s): Hong; John C
• Application Number:
  US10/550,642
• Publication Number:
  US 20060264833A1
• Time in Patent Office: 2,211 Days
• Field of Search: 294/695, 294/58, 295/05, 604/164.01, 604/523, 604/272, 604/533, 604/162
• US Class Current: 29/458
• CPC Class Codes: A61M 25/0606 "Over-the-needle" catheter assemblies, e.g. I.V. catheters
• CPC Class Codes: A61M 25/0631 having means for fully covering the needle after its withdrawal, e.g. needle being withdrawn inside the handle or a cover being advanced over the needle
• CPC Class Codes: A61M 25/0637 Butterfly or winged devices, e.g. for facilitating handling or for attachment to the skin
• CPC Class Codes: A61M 5/3273 freely sliding on needle shaft without connection to syringe or needle
• CPC Class Codes: A61M 5/3275 being connected to the needle hub or syringe by radially deflectable members, e.g. longitudinal slats, cords or bands
• CPC Class Codes: A61M 5/343 Connection of needle cannula to needle hub, or directly to syringe nozzle without a needle hub A61M5/322 takes precedence
• CPC Class Codes: Y10T 29/49885 with coating before or during assembling
• CPC Class Codes: Y10T 29/49908 Joining by deforming

Abstract

An IV catheter includes a catheter having a wall defining a lumen, a proximal end, and a distal end. An adapter has a proximal end, a distal end and an internal cavity. The adapter is in fluid communication with the catheter lumen. A septum is positioned within the adapter cavity at the adapter proximal end. An extension tube extends laterally from the adapter and is in fluid communication with adapter cavity. A tip shield has a distal end, a proximal end and an internal cavity. The tip shield is positioned adjacent adapter proximal end and coaxially aligned with adapter. A hub has a proximal portion, a distal portion and an internal cavity. The hub is positioned adjacent the tip shield proximal end and is aligned coaxially with the tip shield. A cannula has a wall defining a lumen, a beveled distal end, an aperture in the wall of said cannula near the cannula distal end and a proximal end in the shape of a hook. The cannula passes through and is coaxially aligned with the catheter, adapter, tip shield and hub.

Claims

1. A method of forming a needle assembly comprising:

providing a cannula having a sharp distal end and a proximal end;

crimping the proximal end to seal the proximal end;

inserting the cannula into a needle hub such that the proximal end of the cannula is disposed in a glue well of the needle hub;

inserting glue into the glue well; and

curing the glue.

2. The method of claim 1 wherein the needle hub includes a neck having a profile substantially matching the profile of the cannula, and wherein the step of inserting the cannula into the needle hub includes positioning the cannula in the neck in a snug fit.

3. The method of claim 1 further comprising forming the proximal end of the cannula into a hook shape, wherein the step of crimping and the step of forming the hook are performed virtually simultaneously, wherein the crimp is formed by pressing a crimp pin onto the proximal end of the cannula, wherein the crimp is formed by pressing the proximal end of the cannula into a die, wherein the crimp pin is pressed into the proximal end of the cannula as the proximal end of the cannula is pressed into the die.

4. A method of forming a needle assembly comprising:

providing a needle cannula having a distal end and a proximal end;

inserting the needle cannula into a needle hub;

extending the proximal end of the needle cannula beyond the needle hub;

crimping the proximal end of the needle cannula such that it is sealed and formed into a mechanical interlock at the proximal end;

displacing the cannula distally such that the mechanical interlock is disposed within a glue well in the needle hub;

inserting glue into the glue well; and

curing the glue with UV light.

5. The method of claim 4 further comprising lubricating the needle before inserting the needle cannula into the needle hub.

6. The method of claim 4 wherein the mechanical interlock is a hook and crimping the needle comprises:

disposing the proximal end of the needle cannula along a crimping pad; and

moving a crimping tool towards the needle cannula such that the tool forces the cannula onto the pad.

7. The method of claim 6 wherein the crimping tool is a crimping pin, and wherein the crimping pin is moved in a straight line towards the needle cannula.

8. The method of claim 7 in which the crimping pin is moved exclusively in a direction perpendicular to the axis of the needle cannula.

9. The method of claim 7 in which the crimping pin is moved in a direction at a selected angle with respect to the axis of the needle cannula.

10. The method of claim 7 in which the crimping pin is displaced in an arcuate path toward the crimping pad.

11. The method of claim 7 in which a groove is disposed in the crimping pad.

12. The method of claim 11 in which the crimping pin deforms the needle cannula into the groove.

13. The method of claim 12 in which the crimping pin moves with respect to the crimping pad in a path that is either in a direction perpendicular to the axis of the needle cannula, in a direction at a selected angle with respect to the axis of the needle cannula, arcuate toward the crimping pad or a combination of these paths.

14. The method of claim 12 in which the axis of the crimping pin is off set from the axis of the groove.

15. The method of claim 14 in which the axis of the crimping pin is off set proximally with respect to the axis of the groove.