Patent ID: 7757370

Claim:
A method of forming a needle and hub assembly for automatic injectors, the method comprising: forming a first hub portion having a forward section and a flange section, the forward section defining a needle-receiving channel; inserting a needle in the needle-receiving channel; forming a cap having an engaging portion and a needle supporting portion, the engaging portion configured to engage a medicament cartridge of an automatic injector, the needle-supporting portion having a wall that includes an opening therein, the wall defining interior and exterior surfaces opposite each other; arranging the cap over the needle and the first hub portion such that: the needle and the forward section of the first hub portion extend through the opening in the wall of the cap, and the flange section of the first hub portion extends along and abuts the interior surface of the wall of the cap; and forming a second hub portion over the needle and first hub portion, the second hub portion having a forward tapering section and a plurality of radially-extending structures, the forward tapering section defining a needle-receiving channel in alignment with the needle-receiving channel of the first hub portion, the forward tapering section of the second hub portion engaging the forward section of the first hub portion, and the radially-extending structures abutting the exterior surface of the wall of the cap and extending outwardly across the wall to form a contiguous structure of the second hub portion that extends along the interior and exterior surfaces of the wall, the wall, and the first hub portion.