Rigid needle cover with needle sealing plug and method of manufacture

Abstract

A needle cover is disclosed which includes an elongate rigid tubular housing having a generally cylindrical central bore. A hollow frusto-conical shaped needle guide, which gradually reduces in diameter toward the distal end of the cover is located within the housing and effectively separates the fore into a proximal chamber and a cylindrical distal chamber. The distal chamber receives and retains a resilient plug which functions as a sealing member to seal the distal lumen opening of a needle cannula. The needle guide includes a distal opening which defines the boundary between the proximal and distal chambers. The guide functions to direct the tip of the needle through the proximal chamber and into the central portion of the resilient plug located in the distal chamber. During manufacture, the resilient plug functions to seal the tip of the needle cannula in a fluid tight seal. The needle cover housing, including the needle guide, is formed as an integral unit. The resilient plug is then inserted into the distal chamber and the end thereof is swagged to permanently secure the plug within the distal chamber in abutting relationship with the distal end surface of the needle guide. The needle guides outer surface, cooperates with a portion of the bore wall and with a portion of the plug insert to form an annular cavity which facilitates manufacture of the cover and decreases the total amount of material required therefor.