Apparatus and method for batch spray coating of surgical needles

A method of spray coating surgical needles with a lubricious silicone coating composition in a bulk manner using an apparatus comprising:

• a needle separation tower for receiving bulk surgical needles and separating the needles, the needle tower comprising:
• a tower frame having a top, a bottom, a first end and a second end;
• a top tower belt, an intermediate tower belt, and a bottom tower belt mounted to the tower frame, each belt having a first end and a second end, and a top and a bottom;
• a bulk needle receiving structure associated with the top, first end of the tower frame for receiving a plurality of bulk surgical needles and directing the needles to the top tower belt;
• an angled baffle member for directing needles from the top tower belt to the intermediate tower belt;
• an overspill barrier member for directing needles from the intermediate tower belt to the bottom tower belt;
• a first belt stepper motor engaging the top tower belt;
• a second belt stepper motor engaging the intermediate tower belt;
• a third belt stepper motor engaging the bottom tower belt;
• and,
• a rotating member mounted to the top of the tower frame at the second end and situated over the top belt for engaging needles on the top belt;
• an upper paper conveyor for receiving needles from the bottom tower belt of the needle separation tower, the upper paper conveyor having a first end and a second end, an upper frame, an upper absorbent belt, an upper drive roll, an upper take-up roll, an upper first end roll and a second magnetic end roll for engaging needles, and a stepper motor engaging the upper drive roll;
• a lower paper conveyor for receiving needles from the upper paper conveyor, the lower paper conveyor having a first end and second end, a lower frame, a lower absorbent belt, a lower drive roll, a lower take-up roll, a lower first end roll and a lower second end roll, and a stepper motor engaging the lower drive roll;
• and
• at least one spray nozzle moveably mounted over the upper and lower paper conveyors for spraying a silicone lubricious coating onto surgical needles on the upper and lower absorbent belts,
• comprising the steps of:
• loading a plurality of surgical needles into the bulk needle receiving structure such that the needles are transferred to the top tower belt;
• moving the needles from the top tower belt, to the intermediate tower belt, and then to the lower tower belt such that the plurality of needles is substantially singulated;
• moving the singulated needles from the bottom tower belt to the upper paper conveyor and applying a spray coating of a silicone coating composition to the first sides of the singulated needles;
• moving the needles to the second end of the upper paper conveyor such that the second magnetic end roller engages the needles;
• moving the needles in a manner such that the needles are flipped onto their first coated sides onto the top of the second paper belt exposing the second uncoated sides;
• and,
• applying a spray coating of a silicone coating composition to the second uncoated sides of the singulated needles such that each needle is coated on both sides.