Apparatus and method for attaching surgical needle suture components

An apparatus for attaching a first elongated member having an end portion with an elongated aperture defined therein and a second elongated member having a generally elongated end portion to be positioned in the elongated aperture of the first elongated member, which comprises a pair of dies, each die defining a longitudinal axis and having an inner die surface, the inner die surface including at least two raised swaging portions extending generally along the longitudinal axis and a generally recessed portion defined between adjacent swaging portions and extending substantially along the lengths of adjacent swaging portions, the swaging portions each having an engaging surface defining a plane oriented at an acute angle relative to a longitudinal bisecting plane and tapering outwardly from a front surface of the die to a rear surface of the die, the recessed portion defining a relief zone such that when an end portion of the second elongated member is positioned within the aperture of the first elongated member and the dies are positioned about the end portion of the first elongated member with the at least two swaging portions of each die generally facing the outer surface of the first elongated member, applying inward crimping force to the dies causes the engaging surfaces of the dies to produce inward crimping forces on opposed sides of the first elongated member portion to cause a reduction of the dimension of the elongated aperture of the first elongated member to thereby attach the first elongated member to the second elongated member, wherein the recessed portion defined between the adjacent swaging portions are for receiving and collecting deformed material from the first elongated member.

A method for attaching a surgical needle to a suture, the needle having an end portion with an elongated aperture formed therein, the suture having an end portion suitably configured for insertion into the aperture, the method comprising the steps of:

• positioning a pair of dies adjacent the needle end, each die defining a longitudinal axis and having an inner die surface portion, the inner die surface portion including at least two raised swaging portions extending generally along the longitudinal axis and a recessed portion disposed between adjacent swaging portions and extending the lengths thereof, the swaging portions of each die having an engaging surface defining a plane oriented at an acute angle relative to a longitudinal plane which is disposed between the swaging portions of each die, the engaging surfaces of the swaging portions facing the outer surface of the needle end and the recessed portion extending along the direction of the needle end which defines the elongated aperture;
• inserting the suture end portion into the elongated aperture;
• and
• applying inward impact force to the dies to displace the dies toward each other causing the two engaging surfaces of each die to engage the outer surface of the needle end to thereby cause crimping of the needle end and reduction of an average dimension of the aperture defined therein, whereby the recessed portion disposed between the engaging surfaces is configured and dimensioned to permit deformed material of the needle to be received and collected therewithin so as to facilitate attachment of the needle and the suture.

A method for attaching a surgical needle to a suture, the needle having an end portion with an elongated aperture formed therein, the suture having an end portion suitably configured for insertion into the aperture, the method comprising the steps of:

• positioning a pair of dies adjacent the needle end, each die defining a longitudinal axis and having an inner die surface portion, the inner die surface portion including at least first and second raised swaging portions extending generally along the longitudinal axis and a recessed portion disposed between adjacent swaging portions and extending the lengths thereof, the first and second swaging portions of each die having respective first and second engaging surfaces, the first engaging surface defining a plane oriented at a positive acute angle relative to a longitudinal bisecting plane of the die, the second engaging surface defining a plane oriented at a negative acute angle relative to a longitudinal bisecting plane of the die, the angles defined by the planes of the first and second swaging portions range from about 30.degree. to about 60.degree., the engaging surfaces of the swaging portions facing the outer surface of the needle end and the recessed portion extending along the direction of the needle end which defines the elongated aperture;
• inserting the suture end portion into the elongated aperture;
• and
• applying inward impact force to the dies to displace the dies toward each other causing the two engaging surface of each die to engage the outer surface of the needle end to thereby cause crimping of the needle end and reduction of an average dimension of the aperture defined therein, whereby the recessed portion disposed between the engaging surfaces is configured and dimensioned to permit deformed material of the needle to be received and collected therewithin so as to facilitate attachment of the needle and the suture.

A needle-suture combination, which comprises:

• a) a surgical needle including a sharp end and a blunt end, the blunt end defining an elongated aperture therein, the blunt end defining a longitudinal bisecting plane;
• b) a suture having a generally elongated end portion which is positioned within the elongated aperture of the needle;
• and
• c) a portion of the blunt end swaged to cause attachment of the needle to the suture, the swaged portion including at least two generally longitudinal extending planar surface portions and at least one substantially arcuate raised portion disposed between adjacent planar surface portions and extending substantially the lengths thereof, a first of the planar surface portions being disposed on one side of the longitudinal bisecting plane and being oriented at a positive acute angle of orientation with respect to the longitudinal bisecting plane and a second planar surface portion being disposed on the other side of the longitudinal bisecting plane and being oriented at a negative acute angle of orientation with respect to the longitudinal bisecting plane, at least one of the first and second planar surface portions also tapering toward the pointed end of the needle.

A needle-suture combination, which comprises:

• a) a surgical needle including a pointed end and a blunt end, the blunt end having an elongated aperture therein and defining a longitudinal bisecting plane;
• b) a suture having a generally elongated end portion which is positioned within the elongated aperture of the needle;
• and
• c) a portion of the blunt end swaged to cause attachment of the needle to the suture, the swaged portion including first and second pairs of opposed generally longitudinal extending planar portions, each pair of planar portions having a first planar portion on one side of the longitudinal plane and being oriented at a positive acute angle of orientation with respect to the longitudinal plane and a second planar portion on the other side of the longitudinal plane and being oriented at a negative acute angle of orientation with respect to the longitudinal plane, the first planar portions of the first and second pairs of planar portions being in different planes and tapering toward the pointed end of the needle.