Claims:What is claimed is:
1. An undrilled needle swaging system for metal on metal swaging of needles, comprising:

a plurality of needle rods with plugs fed into at least one hopper and a plurality of metal tube bits fed into at least one vibrator, whereby the plurality of metal tube bits move towards the top of the at least one vibrator and through a pathway marked for the plurality of metal tube bits;

at least one vacuum suction gripper configured to suck the plurality of metal tube bits, such that the plurality of metal tube bits are placed on at least one swaging assembly by the at least one vacuum suction gripper;

at least one first plunger configured to push the plurality of needle rods with plugs towards the plurality of metal tube bits placed on the at least one swaging assembly, whereby the at least one swaging assembly comprises at least one mechanical ram configured to use a hydraulic/pneumatic/ mechanical press to swage the plurality of metal tube bits and the plurality of needle rods into a swaged needle; and

at least one crimping assembly configured to crimp the swaged needle by adjusting the number of strokes required to ensure secure metal on metal swaging.

2. The system of claim 1, wherein the at least one mechanical ram is configured to push out the swaged needle towards a channel.

3. The system of claim 1, wherein the at least one swaging assembly comprises at least one second plunger configured to push the swaged needle into the at least one crimping assembly.

4. The system of claim 1, wherein the vibrator loads the plurality of metal tube bits into a horizontal feeder channel.

5. The system of claim 1, wherein the plurality of needle rods with plugs are loaded on to the at least one swaging assembly sequentially or in parallel depending on the number of swaging operations happening concurrently.

6. The system of claim 5, wherein the plurality of needle rods with plugs are placed in a plurality of parallel slots and the plurality of metal tube bits are aligned accordingly in corresponding positions.

7. The system of claim 1, wherein the plurality of metal bits accommodates to snugly fit the plurality of needle rods with plugs which are swaged along the axis of the needle rods.

8. The system of claim 1, wherein the at least one hopper into which the plurality of processed needle rods with plugs and the plurality of metal tube bits are loaded such that the lengths of the metal tube bits match the diameter of the needle rods and the length of the corresponding plugs on said needle rods.

9. The system of claim 1, wherein the plurality of needle rods with plugs are loaded into the at least one swaging assembly so that the piercing-end of said needle rods with plugs is on the axis of said needle rods and facing away from the swaging end.

10. A method for metal on metal swaging of needles, comprising:

feeding a plurality of needle rods with plugs into at least one hopper and a plurality of metal tube bits into at least one vibrator, whereby the plurality of metal tube bits are moved towards the top of the at least one vibrator through a pathway marked for the plurality of metal tube bits;

picking the plurality of metal tube bits by a vacuum suction gripper attached with a vacuum pump and placed at a swaging assembly;

facing the plurality of needle rods with plugs towards the swaging assembly by a first plunger, delivering the plurality of needle rods with plugs into a sliding path one at a time, and moving the needle rods with plugs towards the swaging assembly by the vacuum suction gripper;

using a hydraulic/pneumatic/mechanical press by a mechanical ram to swage the plurality of needle rods with plugs and the plurality of mechanical tube bits;

pushing out a swaged needle towards a crimping assembly by the mechanical ram;

crimping the swaged needle by adjusting the number of strokes required to ensure secure metal on metal swaging (crimping) by the crimping assembly; and

collecting the crimped needle in an output bin and readying it for subsequent processes.

11. The method of claim 11, wherein the needle rod of the required diameter is cut into desired lengths.

12. The method of claim 11, wherein the needle rods’ one end serves as a swaging end which is ground to form the plug of defined length and diameter.

13. The method of claim 11, wherein the metal tube bits are cut into a required length to match the corresponding needle rod’s diameter and the corresponding plug’s length. , Description:TECHNICAL FIELD
[001] The disclosed subject matter relates generally to surgical devices. More particularly, the present disclosure relates to an undrilled needle swaging system and method for metal on metal swaging of needles.

BACKGROUND
[002] The selection of the materials used to manufacture needles (for example, surgical needles) depends upon a variety of factors including manufacturability, machinability, cost, biocompatibility, and mechanical properties. For many years, medical practitioners have employed needle-suture combinations in which a suture is attached to the end of a needle. The needle-suture combinations include suture materials such as nylon, silk, polyester, linen, cotton, etc. The swage or crimp operations for the needle-suture combinations are difficult to achieve desired parameters.

[003] A bore hole is drilled in a needle (for example, a surgical needle) which is then used to swage the suture material, the length of the bore and the diameter of the hole may not be consistent as it is a manual process. It requires high degree of skill to deliver consistent results. The bore hole extends axially into the needle to constitute a suture receptacle and is formed by mechanical or laser drilling. Nowadays, the bore hole in the needle is drilled using laser drilling machines and swaging is completed. The laser drilling machines utilize specific cycles to obtain desired bore hole diameter and depth by controlling laser beam parameters, for example, beam power, energy density, pulse shape, etc. But, those laser drilling machines are expensive and require complex setting up procedures as a precursor to the manufacturing process. Various methods for swaging needles to sutures are known. Swaged needles are eyeless needles permanently attached to the suture strand. In swaging, it is desirable to preserve a smooth and continuous exterior needle surface in the area of the suture receptacle. Sharp edges produced by swaging increase the drag that the needle experiences when passing through the tissue being sutured, injure the tissue and/or unnecessarily enlarge the hole in the tissue made by the needle as it passes through the tissue during use. Improper positioning also leads to the formation of swaging artifacts that cause damages to the tissue.

[004] In the light of aforementioned discussion, there exists a need for an undrilled needle swaging system and method for swaging surgical needles.

BRIEF SUMMARY
[005] The following presents a simplified summary of the disclosure in order to provide a basic understanding to the reader. This summary is not an extensive overview of the disclosure and it does not identify key/critical elements of the invention or delineate the scope of the invention. Its sole purpose is to present some concepts disclosed herein in a simplified form as a prelude to the more detailed description that is presented later.

[006] An objective of the present disclosure is directed towards making secure swaging to get consistent results.

[007] Yet another objective of the present disclosure is directed towards obtaining accuracy of the bore length and diameter, thereby eliminating errors due to manual processes.

[008] Yet another objective of the present disclosure is directed towards overcoming the manufacturing process challenges of laser drilling by undrilled needles without requiring the process of annealing.

[009] Another objective of the present disclosure is directed towards delivering the quality of output without the undrilled needle swaging system is expensive and without compromising the swaging accuracy.

[0010] Another objective of the present disclosure is directed towards using the process of metal on metal swaging to attach a metal tube to a needle rod with a plug.

[0011] Another objective of the present disclosure is directed towards developing suture needles for swaging that do not require drilling of a bore hole at the swaging end of the needle. The swaging end of the needle is the end which is in opposition to the penetrating end of the needle.

[0012] Exemplary embodiments of an undrilled needle swaging system and method for metal on metal swaging of needles.

[0013] According to an exemplary embodiment of the present disclosure, the undrilled needle swaging system for metal on metal swaging of needles comprising a plurality of needle rods with plugs fed into at least one hopper and a plurality of metal tube bits fed into at least one vibrator.

[0014] According to another exemplary embodiment of the present disclosure, the plurality of metal tube bits moved towards the top of the at least one vibrator and through a pathway marked for the plurality of metal tube bits.

[0015] According to another exemplary embodiment of the present disclosure, the undrilled needle swaging system comprising at least one vacuum suction gripper configured to suck the plurality of metal tube bits and then the plurality of metal tube bits placed on at least one swaging assembly by the at least one vacuum suction gripper.

[0016] According to another exemplary embodiment of the present disclosure, the undrilled needle swaging system further comprising at least one first plunger configured to push the plurality of needle rods with rods towards the plurality of metal tube bits placed on the at least one swaging assembly, the at least one swaging assembly comprises at least one mechanical ram configured to use a hydraulic press to swage the plurality of metal tube bits and the plurality of needle rods.

[0017] According to another exemplary embodiment of the present disclosure, the undrilled needle swaging system comprising at least one crimping assembly configured to crimp the swaged needle by adjusting the number of strokes required to ensure secure metal on metal swaging.

BRIEF DESCRIPTION OF DRAWINGS
[0018] Other objects and advantages of the present invention will become apparent to those skilled in the art upon reading the following detailed description of the preferred embodiments, in conjunction with the accompanying drawings, wherein like reference numerals have been used to designate like elements, and wherein:

[0019] FIG. 1 is a diagram depicting an exemplary embodiment of an undrilled needle swaging system, in accordance with one or more exemplary embodiments.

[0020] FIG. 2 is a diagram depicting another exemplary embodiment of an undrilled needle swaging system, in accordance with one or more exemplary embodiments.
[0021] FIG. 3A-3B are diagrams depicting another exemplary embodiment of the undrilled needle swaging system, in accordance with one or more exemplary embodiments.

[0022] FIG. 4A-FIG. 4B are diagrams depicting another exemplary embodiment of the undrilled needle swaging system, in accordance with one or more exemplary embodiments.

[0023] FIG. 5A-FIG. 5B are diagrams depicting another exemplary embodiment of the undrilled needle swaging system, in accordance with one or more exemplary embodiments.

[0024] FIG. 6A-FIG. 6B are diagrams depicting another exemplary embodiment of the undrilled needle swaging system, in accordance with one or more exemplary embodiments.

[0025] FIG. 7A-FIG. 7B are diagrams depicting another exemplary embodiment of the undrilled needle swaging system, in accordance with one or more exemplary embodiments.

[0026] FIG. 8A-8B are diagrams depicting another exemplary embodiment of the undrilled needle swaging system, in accordance with one or more exemplary embodiments.

[0027] FIG. 9 is a flow chart depicting a method for crimping swaged needles, according to an exemplary embodiment of the present disclosure.

[0028] FIG. 10 is a flow chart depicting a method of pre-processing for metal on metal swaging of needles, according to an exemplary embodiment of the present disclosure.

DETAILED DESCRIPTION
[0029] It is to be understood that the present disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The present disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

[0030] The use of “including”, “comprising” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. Further, the use of terms “first”, “second”, and “third”, and the like, herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another.

[0031] Preparation of needle rod includes a metal wire cut to the desired length and the tip of the metal wire ground to create a plug (also known as step) of defined length and diameter. The needle rod of the required diameter is cut into the desired lengths. The preparation of a needle rod is done through a manual/machine grinding process. Preparation of metal tube for attachment includes a metal tube of uniform diameter is sourced and then cut by the manual/ machine process to required lengths of metal tube bits to match the needle rod diameter and the length of the plug. Metal on metal swaging using the undrilled needle swaging system as outlined in the present disclosure.

[0032] Referring to FIG. 1, FIG. 1 is a diagram 100 depicting an exemplary embodiment of an undrilled needle swaging system, in accordance with one or more exemplary embodiments. The undrilled needle swaging system 100 includes a vacuum pump 102, a base 104, a vibrator 106, a hopper 108, a first plunger 110, a second plunger 112, a mechanical ram 114, a swaging assembly 116, a crimping assembly 118, an electric motor 120, and an output bin 122. The undrilled needle swaging system 100 uses the process of metal on metal swaging (by crimping) to attach the metal tube bit to the needle rod with plug. After the swaging, the surgical needle is ready for processes such as hydraulic pressing of the needle, grinding of the needle, buffing, polishing, bending and coating, and so forth. The swaging assembly 116 may have a channel at the base into which the metal tube bit is placed and the needle rod with plug is pushed into. The base 104 may be configured to hold the vibrator 106, the hopper 108, the first plunger 110, the second plunger 112, the mechanical ram 114, the swaging assembly 116, the crimping assembly 118, the electric motor 120, and the output bin 122.

[0033] An undrilled needle may be manufactured/processed by swaging a needle rod with plug to a metal tube bit. A plug may be created to the needle rod to affix the metal tube bit so that it may be further processed to complete the undrilled needle for surgery. The undrilled needle includes the metal rod with plug which is processed for swaging, the metal tube which is cut along the diameter, inner diameter of the metal tube may accommodate to snugly fit the metal rod with plug which has to be swaged along the axis of the needle rod, and any gaps in the swaging may be addressed by further processes. Swaging may be accomplished by attaching any two metal components. The attachment of metal components may include, but not limited to, a particular grade of surgical steel, titanium, and cobalt chromium, surgical stainless steel of various grades, tungsten rhenium, and so forth.

[0034] The needle rods may be fed into the hopper 108 and the metal tube bits may be fed into the vibrator 106. The vibrator 106 which loads the metal tube bits into a horizontal feeder channel 126, from which a vacuum suction gripper 124 configured to suck each metal tube bit by the suction force and thereby place each metal tube bit along the axis of the swaging assembly 116. The vacuum pump 102 may be configured to provide a suction force to the vacuum suction gripper 124. The metal tube bit placed in the vibrator 106 starts moving towards the top and through a pathway marked for the metal tube bits. The needle rod with plug may be placed with the plug ends facing towards the swaging assembly 116. The needle rod in the hopper 108 may be delivered into the sliding path one at a time. The first plunger 110 may be configured to push the needle rod with rod towards the metal tube bit placed on the swaging assembly 116. The swaging assembly 116 includes a mechanical ram 114 configured to use a cam operated mechanical press to swage the metal tube bits and the needle rods. The pre-processed needle rod with plug may be loaded into the swaging assembly 116 so that the piercing end is on the axis of the bit and facing away from the swaging assembly 116. The needle rod with plug may be loaded sequentially or in parallel depending on the number of swaging operations happening in the undrilled needle swaging system 100 at the same time. Where the needle rods may be placed in parallel slots and the metal tube bits may be aligned accordingly in corresponding positions. The undrilled needle swaging system 100 uses the hydraulic/mechanical press to secure the attachment.
[0035] The mechanical ram 114 may be configured to press the placed metal tube and then hold it. The first plunger 110 may be configured to move the needle rod with plug towards the mechanical ram 114 for joining with the metal tube bit. The mechanical ram 114 configured to attach the needle rod with plug and the metal tube bit using a hydraulic/pneumatic press. For example, the hydraulic pressing of the needles to bring them to the required profile- taper cut, reverse cut, and so forth. The mechanical ram 114 may be configured to push out the swaged needle into the channel for crimping. The channel may include, but not limited to, sliding path. The second plunger 112 may be configured to push the swaged needle towards the crimping assembly 118. The crimping assembly 118 may complete the crimping process by adjusting the number of strokes required to ensure secure metal on the metal swaging. The crimping needle may be fallen through the output bin 122. Hydraulic pressing of the needles to bring them to the required profile-taper cut, reverse cut, and so forth. The needles may grind at the opposite end to ensure penetration is delivered. The needles may be buffed, bent and coated to render them ready for sterilization before use during surgery.

[0036] Referring to FIG. 2, FIG. 2 is a diagram 200 depicting another exemplary embodiment of an undrilled needle swaging system, in accordance with one or more exemplary embodiments. The undrilled needle swaging system 200 includes the needle rod with plug placing detailed view 201. The needle rod with plug placing detailed view 201 includes the first plunger 110 configured to move the needle rod with plug 203 towards the mechanical ram 114 for joining with the metal tube bit. Where the needle rod with plug 203 may be collected from the hopper 108. For example, the first plunger 110 moves in a forward direction to move the needle rod with plug 203 towards the mechanical ram 114.

[0037] Referring to FIG. 3A-3B, FIG. 3A-3B are diagrams 300a, 300b depicting another exemplary embodiment of the undrilled needle swaging system, in accordance with one or more exemplary embodiments. The undrilled needle swaging system 300a, 300b includes the metal tube bit picking detailed view 301. The metal tube bit picking detailed view 301 includes the vibrator 106 configured to move the metal tube bit 303 towards the vacuum suction gripper (4) 124. The vacuum suction gripper (4) 124 may be configured to suck the metal tube bit 303 by the vacuum pump 102. The undrilled needle swaging system 300a, 300b includes the more detailed view 305 of metal tube picking. The more detailed view 305 includes a detailed view of the vacuum suction gripper 124.

[0038] Referring to FIG. 4A-4B, FIG. 4A-FIG. 4B are diagrams 400a, 400b depicting another exemplary embodiment of the undrilled needle swaging system, in accordance with one or more exemplary embodiments. The undrilled needle swaging system 400a, 400b includes the metal tube placing detailed view 401. The metal tube placing detailed view 401 includes the vacuum suction gripper 124 configured to direct towards the swaging assembly116 and the metal tube bit 403 is placed on the swaging assembly116 by the vacuum pump 102. The undrilled needle swaging system 400a, 400b further includes more detailed view 405. The more detail view 405 includes a detailed view of the vacuum suction gripper 124.

[0039] Referring to FIG. 5A-FIG. 5B, FIG. 5A-FIG. 5B are diagrams 500a, 500b depicting another exemplary embodiment of the undrilled needle swaging system, in accordance with one or more exemplary embodiments. The undrilled needle swaging system 500a, 500b includes detailed joining view 501, more detailed joining view 505. The first plunger 110 may be configured to push the needle rod with plug (8) 503 for joining towards the metal tube bit. The detailed joining view 501 includes the mechanical ram 114 configured to press the placed metal tube and then hold it. The more detailed joining view 505 includes the detailed needle rod with plug (8) 503.
[0040] Referring to FIG. 6A-FIG. 6B, FIG. 6A-FIG. 6B are diagrams 600a, 600b depicting another exemplary embodiment of the undrilled needle swaging system, in accordance with one or more exemplary embodiments. The undrilled needle swaging system 600a, 600b includes the detailed mechanical ram view 601, and more detailed mechanical ram view.603. The detailed mechanical ram view 601 and more detailed mechanical ram view 603 includes the mechanical ram 114 moves up direction. The mechanical ram 114 may be configured to push out the swaged needle (for example, joined assembly) towards the sliding path, by means of pusher 607.

[0041] Referring to FIG. 7A-FIG7B, FIG. 7A-FIG. 7B are diagrams 700a, 700b depicting another exemplary embodiment of the undrilled needle swaging system, in accordance with one or more exemplary embodiments. The undrilled needle swaging system 700a, 700b includes the detailed swaged needle and crimping assembly view 701, and the more detailed needle and swaging assembly view 705. The detailed swaged needle and crimping assembly view 701 and the more detailed swaged needle and crimping assembly view 705 includes the needle 703 and the swaging assembly 707. The second plunger 112 may be configured to push the needle 703 towards the swaging assembly 707.

[0042] Referring to FIG. 8A-8B, FIG. 8A-8B are diagrams 800a, 800b depicting another exemplary embodiment of the undrilleds needle swaging system, in accordance with one or more exemplary embodiments. The undrilled needle swaging system 800a, 800b includes the detailed crimping assembly view 801, and more detailed crimping assembly view 805. The detailed crimping assembly view 801, and more detailed crimping assembly view 805 includes the crimping assembly 807. The crimping needle may be fallen through the slot 809.

[0043] Referring to FIG. 9, FIG. 9 is a flow chart 900 depicting a method for crimping swaged needles, according to an exemplary embodiment of the present disclosure. As an option, the method 900 is carried out in the context of the details of FIG. 1, FIG. 2 FIG. 3A, FIG. 3B, FIG. 4A, FIG. 4B, FIG. 5A, FIG. 5B, FIG. 6A, FIG. 6B, FIG. 7A, FIG. 7B, FIG. 8A, and FIG. 8B. However, the method 900 is carried out in any desired environment. Further, the aforementioned definitions are equally applied to the description below.

[0044] The method commences at step 902, the needle rods with plug are fed into the hopper and the metal tube bits are fed into the vibrator. Thereafter, at step 904, the metal tube bits are moved towards the top of the vibrator and through the pathway marked for the metal tube bits. Thereafter, at step 906, the metal tube bits are picked up at the top of the vibrator end by the vacuum suction gripper actuated by the vacuum pump and fed into the ‘V’ block side one at a time. Thereafter, at step 908, the needle rods with plugs are faced towards the assembly station by the first plunger, where the needle rods with plugs are delivered into the sliding path one at a time and then the needle rods with plugs may then be moved towards the swaging assembly. Thereafter, at step 910, assemble the needle rod with plug into the cut metal tube bit by pushing one against the other by means of a ram actuated by a pneumatic cylinder. Thereafter, at step 912, the assembled needle is pushed by a feeder into another ‘V’ block, which is aligned to the swaging assembly from where it is pushed into the crimping assembly by another pneumatically actuated ram. Thereafter, at step 914, the swaged needles are crimped by adjusting the number of strokes required to ensure secure metal on metal swaging (crimping) by the crimping assembly. Thereafter, at step 916, the crimped needles (undrilled needles) are collected in the output bin and ready for subsequent processes.

[0045] Referring to FIG. 10, FIG. 10 is a flow chart 1000 depicting a method of pre-processing for metal on metal swaging of needles, according to an exemplary embodiment of the present disclosure. As an option, the method 1000 is carried out in the context of the details of FIG. 1, FIG. 2 FIG. 3A, FIG. 3B, FIG. 4A, FIG. 4B, FIG. 5A, FIG. 5B, FIG. 6A, FIG. 6B, FIG. 7A, FIG. 7B, FIG. 8A, and FIG. 8B, FIG. 9. However, the method 1000 is carried out in any desired environment. Further, the aforementioned definitions are equally applied to the description below.

[0046] At step 1002, the needle rod (metal wire) of the required diameter is cut into equal lengths. Thereafter, at step 1004, one end of the needle rod (metal wire) which serves as a swaging end is ground to form the plug of defined length and diameter. Thereafter, at step 1006, the metal tube is cut into the required length to match the needle rod (metal wire) diameter and the length of the plug. Post finishing the metal on metal swaging, Hydraulic pressing of the needles to bring them to the required profile-taper cut, reverse cut, and so forth. The needles may grind at the opposite end to ensure penetration is delivered. The needles may be buffed, bent and coated to render them ready for sterilization before use during surgery.

[0047] Although the present disclosure has been described in terms of certain preferred embodiments and illustrations thereof, other embodiments and modifications to preferred embodiments may be possible that are within the principles and spirit of the invention. The above descriptions and figures are therefore to be regarded as illustrative and not restrictive.

[0048] Thus the scope of the present disclosure is defined by the appended claims and includes both combinations and sub-combinations of the various features described hereinabove as well as variations and modifications thereof, which would occur to persons skilled in the art upon reading the foregoing description.