U.S. patent application number 14/352012 was filed with the patent office on 2014-09-25 for contact lens secondary packaging and methods.
This patent application is currently assigned to MENICON SINGAPORE PTE LTD.. The applicant listed for this patent is MENICON SINGAPORE PTE LTD.. Invention is credited to Stephen D. Newman.
Application Number | 20140284229 14/352012 |
Document ID | / |
Family ID | 54256934 |
Filed Date | 2014-09-25 |
United States Patent
Application |
20140284229 |
Kind Code |
A1 |
Newman; Stephen D. |
September 25, 2014 |
CONTACT LENS SECONDARY PACKAGING AND METHODS
Abstract
A contact lens package assembly includes a sealable primary lens
package, at least one contact lens sealed within the primary lens
package, and a sealable secondary lens package. The primary lens
package is sealed within the secondary lens package to increase a
shelf life of the at least one contact lens. The secondary lens
package may be resealable. The secondary lens package may be
configured to retain a plurality of primary lens packages. The
contact lens package assembly may further include at least one
inert gas sealed within the secondary lens package and outside of
the primary lens package.
Inventors: |
Newman; Stephen D.;
(Singapore, SG) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
MENICON SINGAPORE PTE LTD. |
Singapore |
|
SG |
|
|
Assignee: |
MENICON SINGAPORE PTE LTD.
Singapore
SG
|
Family ID: |
54256934 |
Appl. No.: |
14/352012 |
Filed: |
October 18, 2012 |
PCT Filed: |
October 18, 2012 |
PCT NO: |
PCT/SG2012/000389 |
371 Date: |
April 15, 2014 |
Current U.S.
Class: |
206/213.1 ;
206/5.1; 53/467 |
Current CPC
Class: |
B65D 2585/545 20130101;
B65D 77/003 20130101; B65D 75/367 20130101; A45C 11/046
20130101 |
Class at
Publication: |
206/213.1 ;
206/5.1; 53/467 |
International
Class: |
A45C 11/04 20060101
A45C011/04 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 18, 2011 |
SG |
201107631-2 |
Claims
1. A contact lens package assembly, comprising: a sealable primary
lens package; at least one contact lens sealed within the primary
lens package; a sealable secondary lens package; wherein the first
lens package is sealed within the secondary lens package to
increase a shelf life of the at least one contact lens.
2. The contact lens package assembly of claim 1, wherein the
secondary lens package is resealable.
3. The contact lens package assembly of claim 1, wherein the
secondary lens package is configured to retain a plurality of
primary lens packages.
4. The contact lens package assembly of claim 1, further comprising
at least one inert gas sealed within the secondary lens package and
outside the primary lens package.
5. The contact lens package assembly of claim 1, further comprising
a support structure interposed between the primary lens package and
the secondary lens package.
6. The contact lens package assembly of claim 1, wherein the
secondary lens package includes opposing first and second package
portions that are sealed around a perimeter of the secondary lens
package to form an interior within which the primary lens package
is positioned.
7. The contact lens package assembly of claim 6, wherein each of
the first and second package portions of the secondary lens package
include at least one foil layer.
8. The contact lens package assembly of claim 6, wherein each of
the first and second package portions of the secondary lens package
include a laminate material having at least one polymer layer and
at least one layer comprising a metal material.
9. The contact lens package assembly of claim 1, wherein the
secondary lens package is constructed as a pouch comprising
flexible material.
10. The contact lens package assembly of claim 1, wherein the
secondary lens package is waterproof.
11. A package system, comprising: a first package configured to
hold a product with a finite shelf life; a second package
configured to hold the first package, the second package providing
an inert environment for the first package that extends the shelf
life of the product.
12. The package system of claim 11, wherein the product is a
contact lens.
13. The package system of claim 11, wherein the product is a
medicament.
14. The package system of claim 11, wherein the product has
nutritional value.
15. The package system of claim 11, wherein the second package is
resealable.
16. The package system of claim 11, wherein the second package has
a flexible construction.
17. The package system of claim 11, wherein the second package
retains a volume of inert gas.
18. A method for manufacturing a contact lens package, comprising:
sealing a contact lens within a primary lens package; sealing the
primary lens package within a secondary lens package, the secondary
lens package providing an inert storage condition for the primary
lens package.
19. The method of claim 18, further comprising storing a volume of
inert gas within the secondary lens package.
20. The method of claim 18, further comprising providing the
secondary lens package with a resealable opening.
21. The method of claim 18, further comprising providing the
secondary lens package with first and second laminate layers that
are sealed together arranged a periphery of the secondary lens
package to form an interior sized to receive the primary lens
package.
22. The method of claim 21, wherein the secondary lens package
includes two foil layers that are secured together to define an
interior sized to receive the primary lens package.
23. A method of forming a secondary contact lens package,
comprising: providing first and second foil layers; connecting the
first and second foil layers together to define a package interior,
the package interior configured to receive a primary contact lens
package that holds at least one contact lens; creating an inert
environment within the package interior.
24. The method of claim 23, further comprising forming a resealable
opening in the secondary contact lens package.
25. The method of claim 23, wherein connecting the first and second
foil layers includes creating a heat seal.
26. The method of claim 23, wherein creating an inert-environment
includes filling the package interior with an inert gas.
27. The method of claim 23, further comprising sealing closed the
package interior to maintain the inert environment.
28. The method of claim 23, wherein creating the inert environment
includes providing the first and second foil layers with inert
materials.
29. The method of claim 23, further comprising providing a
waterproof environment within the package interior.
30. The contact lens package assembly of claim 10, wherein the
secondary lens package is made of one of a laminate foil substrate,
an injection cast molded plastic packaging, a wax or polymer coated
paper, or a vacuum formed plastic.
Description
TECHNICAL FIELD
[0001] The present systems and methods relate to contact lens
packaging and more particularly, to secondary contact lens
packaging and related methods.
BACKGROUND
[0002] Soft disposable contact lenses are commonly contained in
disposable packages. As packaging adds to the overall cost of the
lens, it should be made as economically as possible but without
compromise to the requisite packaging criteria. The traditional
blister pack packaging used for disposable lenses (both bi-weekly
and daily) consists of a polypropylene receptacle for the lens
(herein after referred to as a "boat"), topped by a multi-layer
film that may include polyethylene, aluminum, a bonding agent and
polypropylene. The boat is typically an injection molded plastic
which has high stiffness and includes a preformed recess. The boat
is filled with a suitable storage solution, such as saline, and
receives a single lens in situ. The blister pack is then
sterilized, typically by being autoclaved using steam and pressure,
to terminal sterility. These blister packs are presented to the
patient in boxes of individual packs or as multiple blister
strips.
[0003] The lens is stored in the package for an extended period of
time, which may include months or years. The lens must be kept
hydrated while in the package. Consequently, the package must be
well sealed and should minimize water vapor transmission through
the boat and laminated layer to maximize the shelf life and prevent
dehydration of the lens contained therein. During use, the user
removes the laminated material from a flange formed on the boat by
peeling back the cover to expose the lens immersed in a hydrating
solution.
[0004] The package may be exposed to various potentially
detrimental environmental conditions and damaging forces during
shipping, handling and storing of the package. As the package
becomes smaller, thinner and lighter as a result of efforts to
reduce material and manufacturing costs, the more susceptible the
package may become to such environmental conditions and damaging
forces. Further, the use of certain materials and constructions for
the package may affect the shelf-life of the product held in the
package.
[0005] In order to protect the package during shipping, handling,
and storage, primary contact lens packages are typically grouped
into a usable quantity and inserted into a secondary package for
storage and transport. Traditionally, secondary packages for
contact lenses constitute a cardboard box including supplier
information and directions printed thereon.
[0006] Many contact lens users store their contact lenses in the
bathroom where they have access to a mirror and a sink to aid in
the insertion or retraction of their contact lenses. Bathrooms are
usually wet environments. However, traditional secondary packages
for contact lenses are typically made from a paper-based material
that is inadequate for use in a wet environment.
SUMMARY
[0007] One aspect of the present disclosure relates to a contact
lens package assembly. The contact lens package assembly includes a
sealable first lens package, at least one contact lens sealed
within the first lens package, and a sealable second or secondary
lens package. In one embodiment, the secondary package is
waterproof. The first or primary lens package is sealed within the
second or secondary lens package to increase a shelf life of the at
least one contact lens. The secondary lens package may be
resealable. The secondary lens package may be configured to retain
a plurality of first lens packages. The contact lens package
assembly may further include at least one inert gas sealed within
the secondary lens package and outside of the first lens
package.
[0008] Another aspect of the present disclosure relates to a
package system that includes primary and secondary packages. The
primary package is configured to hold a product with a finite shelf
life. The secondary package portion may be configured to hold the
primary package and provides an inert environment for the primary
package that maintains or extends the shelf life of the product.
The product may be, for example, a contact lens or a medicament,
and may have a nutritional value.
[0009] Another aspect of the present disclosure relates to a method
for manufacturing a contact lens package. The method includes
sealing a contact lens within a first or primary package, and
sealing the first or primary lens package within a secondary lens
package, wherein the secondary lens package provides an inert
storage conditioned for the first or primary lens package. The
method may further include storing a volume of inert gas within the
secondary lens package. The secondary lens package may include two
foil layers that are secured together to define an interior sized
to receive the first or primary lens package.
[0010] Another aspect of the present disclosure relates to a method
of forming a secondary contact lens package. The method includes
providing first and second foil layers, connecting the first and
second foil layers together to define a secondary package interior,
wherein the secondary package interior is configured to receive a
primary contact lens package that holds at least one contact lens.
The method also includes creating an inert environment within the
secondary package interior. The method may include providing a
waterproof environment within the secondary package interior.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The accompanying drawings illustrate various embodiments of
the principles described herein and are a part of the
specification. The illustrated embodiments are merely examples and
do not limit the scope of the claims.
[0012] FIG. 1 is a top perspective view of an example contact lens
package assembly in accordance with the present disclosure.
[0013] FIG. 2 is a partially exploded top perspective view of the
contact lens package assembly of FIG. 1.
[0014] FIG. 3 is a partially, exploded bottom perspective view of
the contact lens package assembly of FIG. 1.
[0015] FIG. 4 is an exploded top perspective view of the contact
lens package assembly of FIG. 1.
[0016] FIG. 5 is a cross-sectional side view of the contact lens
package assembly of FIG. 1 taken along cross-section indicators
5-5.
[0017] FIG. 5A is a cross-sectional view of the contact lens
package assembly of FIG. 5 taken along cross-section indicator
5A.
[0018] FIG. 6 is a cross-sectional view of the contact lens package
assembly of FIG. 1 taken along cross-section indicators 6-6.
[0019] FIG. 7 is a top perspective view of another example contact
lens package assembly in accordance with the present
disclosure.
[0020] FIG. 8 is an exploded top perspective view of the contact
lens package assembly of FIG. 7.
[0021] Throughout the drawings, identical reference numbers
designate similar, but not necessarily identical, elements.
DETAILED DESCRIPTION
[0022] The present disclosure relates to a secondary packaging for
use with primary contact lens packages. In one example, at least
one contact lens is held in a first or primary contact lens
package, and the first contact lens package is inserted into and
sealed within a second or secondary contact lens package. The
secondary contact lens package may provide an inert environment
that helps maintain a useful life or shelf life of the contact lens
held in the primary contact lens package. The secondary contact
lens package may also provide a waterproof environment within which
the primary contact lens package is stored. The secondary contact
lens package may also provide a level of protection for the primary
contact lens package during shipping and handling.
[0023] The secondary contact lens package may, according to one
exemplary embodiment, be a resealable package that permits
inserting and removing at least one primary contact lens package.
The secondary contact lens package may, according to one exemplary
embodiment, include inert materials. The secondary contact lens
package may also, according to one exemplary embodiment, include
layers of metal-based materials such as foil. The secondary contact
lens package may further include at least first and second laminate
sheets or members that are sealed together around a periphery to
define an interior sized to receive the primary contact lens
package that holds at least one contact lens. Each of the laminate
sheets may include a polymer layer and a metal (e.g., foil)
layer.
[0024] The secondary contact lens package may have other uses
outside of retaining at least one primary contact lens package that
holds at least one contact lens. Other example uses include, for
example, retaining one or more pre-packaged medicaments, vitamins,
supplements, and other volatile products that would benefit from
storage within an inert secondary storage environment.
[0025] The secondary package may be used in combination with a
support structure such as a drawer or tray type structure that
retains at least one primary contact lens package and is insertable
with the primary contact lens package into the secondary package.
The support structure may provide additional rigidity and
resistance to deformation and impact forces that might otherwise
damage the primary contact lens package and the at least one
contact lens retained therein. In at least some examples, the
secondary contact lens package has a flexible or deformable
construction and the support structure provides at least some
rigidity for a contact lens package assembly that comprises the
primary and secondary contact lens packages and the support
structure. Further details concerning example support structures
are provided in Singapore Patent Application filed on 18 Oct. 2011
and entitled "Support Structure for Shipping and Storage of
Replacement Contact Lenses", which is incorporated herein in its
entirety by this reference.
[0026] As disclosed in the above-mentioned Singapore Patent
Application entitled "Support Structure for Shipping and Storage of
Replacement Contact Lenses", the support structure may be used to
support at least one primary contact lens package during shipping
of the contact lens package. Similarly, the support structure may
be used to carry or support at least one primary contact lens
package during storage of the contact lens package. The same
support structure may be used for both shipping and storage of at
least one primary contact lens package. The support structure may
have a greater rigidity property than the primary contact lens
package. The support structure may further provide at least one of
additional strength, support and protection for the primary contact
lens package during at least one of shipping and storage of the
primary contact lens package.
[0027] The support structure may be insertable into the secondary
contact lens package. The secondary contact lens package may define
an interior sized to receive at least one support member carrying
at least one primary contact lens package. The support member may
be configured to be removably positioned within a separate storage
case for storage of at least one primary contact lens package
retained in the support member. According to one exemplary
embodiment, the support member may have a drawer-shaped
construction having a cavity or interior sized to receive at least
one contact lens package. The drawer-shaped support member may
slide into and out of a storage case having at a least one slot or
opening sized to receive the support member. The support member may
be substantially enclosed within the storage case. A portion of the
support member may be visible from outside of the storage case when
the support member is positioned within the storage case.
[0028] The support member may include at least one graphic that is
visible when the support member is stowed within the storage case.
The graphic may include information related to the at least one
primary contact lens package retained by the support member. The
graphic of the storage case may also provide information related to
the at least one primary contact lens package retained by the
support member. The support member may comprise materials that are
recycled from other contact lens-related manufacturing processes.
For example, the support member may include materials recycled from
the plastic molds used to form the contact lenses that are held in
the primary contact lens packages. Using such recycled materials
may reduce overall material waste in the process of manufacturing,
shipping and storage of contact lens-related products.
[0029] The example secondary packages disclosed herein may have
several advantages as compared to traditional paper-based secondary
packages commonly used for storing primary packages. Traditional
secondary packaging comprises paper-based materials that generally
lack sterility and resistance to water/humidity damage. Further,
traditional secondary packages are bulky and occupy a significant
amount of space. The example secondary packages disclosed herein
may be relatively slim, lightweight and take up a smaller volume of
space as compared to paper-based secondary packaging. Further, the
example secondary packaging may be waterproof as discussed above
and provide an improved sterile environment. The inclusion of foil
layers in the secondary packaging may help minimize light and
oxygen transmission into the secondary packaging. Further, the
secondary packaging may be filled with an inert gas that
contributes to greater product stability and improved shelf life of
the product held within the secondary package.
[0030] As used in the present specification and in the appended
claims, the term "inert" refers generally to something that is not
chemically reactive, or, in other words, something that is
chemically stable. Typically, the noble gases have been considered
inert gases because of their perceived lack of participation in any
chemical reactions. The term inert may be applied in a relative
sense to describe the lack of chemical reactions for an object
under normal or typical environmental conditions.
[0031] The terms "sterile" and "sterilize" refer generally to any
material or combination of materials which may come into physical
and fluid contact with a contact lens or other object contained
within a finally formed package. Although polypropylene is commonly
used as a sterilizable material in packages, any other material
that is capable of creating a sterile environment for contact
lenses, medical devices, or dental devices can be used in the
present article and method as well. According to one exemplary
embodiment, a sterile material may include any material accepted by
the U.S. Food and Drug Administration (FDA) as suitable for the
packaging of sterile medical devices.
[0032] The phrases "shelf life" and "useful life" refer generally
to a length of time that food, drink, medicine, chemicals, and many
other perishable items are given before they are considered
unsuitable for sale, use, or consumption. Shelf life or useful life
is the recommendation of time that products can be stored, during
which the defined quality of a specified proportion of the goods
remains acceptable under expected (or specified) conditions of
distribution, storage and display. Most shelf life labels or listed
expiration dates are used as guidelines based on normal handling of
products. Contact lenses are a product that is typically subject to
a predetermined shelf life. The shelf life of a contact lens may be
dependent on a number of conditions such as, for example, the
material of the contact lens, packaging conditions, and storage
conditions.
[0033] In the following description, for purposes of explanation,
numerous specific details are set forth in order to provide a
thorough understanding of the present systems and methods. It will
be apparent, however, to one skilled in the art that the present
apparatus, systems and methods may be practiced without these
specific details. Reference in the specification to "an
embodiment," "an example" or similar language means that a
particular feature, structure, or characteristic described in
connection with the embodiment or example is included in at least
that one embodiment, but not necessarily in other embodiments. The
various instances of the phrase "in one embodiment" or similar
phrases in various places in the specification are not necessarily
all referring to the same embodiment.
[0034] Referring now to FIGS. 1-6, an example contact lens package
assembly 10 is shown and described. The contact lens package
assembly 10 includes a plurality of first or primary lens packages
14, and a second or secondary lens package 12. At least one primary
lens package 14 may be inserted into and stored within the
secondary contact lens package 12. In some embodiments, the
secondary contact lens package 12 is at least partially formed
around at least one primary lens package 14 rather than the primary
lens package 14 being inserted into the secondary contact lens
package 12. The secondary contact lens package 12 may provide an
inert environment within which the primary lens package 14 is
stored. The secondary contact lens package 12 may, according to one
exemplary embodiment, include a pair of foil layers that are sealed
around a periphery of the secondary contact lens package 12 to
define an interior or cavity within which the primary lens package
14 is stored. According to one exemplary embodiment, the secondary
contact lens package 12 may define a flexible, pliable
construction. The secondary contact lens package 12 may also be
resealable.
[0035] The first or primary lens packages 14 may, according to the
exemplary embodiment, each include a plurality of first lens
package portions 20A-C that each include a substrate 26, a cover
sheet 28 and a contact lens receiving portion 30 (see FIGS. 4-6).
The first exemplary lens package portions 20A-C may be separable
along perforation lines 22 (see FIG. 4). The first lens packages 14
may retain a plurality of contact lenses 24 that are held within
the contact lens receiving portions 30 between the substrate 26 and
cover sheet 28 (see FIG. 4). The present exemplary system and
method will be described, for ease of explanation only, as
incorporating primary contact lens packages that include a
polypropylene boat for receiving and holding the lens, topped by a
multi-layer film. However, any primary contact lens packaging
configuration may be secured within the present secondary contact
lens package 12, including, but in no way limited to, primary
contact lens packaging disclosed in U.S. Pat. No. 7,828,137, which
patent is incorporated herein by reference in its entirety.
[0036] Each of the primary lens packages 14 illustrated in FIG. 4
includes three primary lens package portions. Other constructions
and configurations are possible for the primary lens packages 14
including, for example, a construction having a single first lens
package portion that retains a single contact lens 24. Other
embodiments include two or more primary lens package portions that
each includes a single contact lens 24 for each of the primary lens
packages 14.
[0037] The primary lens packages 14 may be relatively thin and have
a relatively low profile. In one example, the first lens packages
14 may have a maximum thickness between about 0.25 to 2 times a
sagittal height of the contact lens 24 when the contact lens 24 is
uncompressed and in a state of rest. In another example, the first
lens packages 14 have a maximum thickness that is less than a
sagittal height of the contact lens 24 when the contact lens 24 is
uncompressed and in a state of rest.
[0038] At least one of the substrate 26 and cover sheet 28 may
comprise a metal material such as a foil. The metal material of the
substrate 26 and cover sheet 28 may be provided as a layer or sheet
of material. At least one of the substrate 26 and cover sheet 28
may also include a polymer material that is provided in the form of
a layer or sheet. The polymer material may include, for example,
polypropylene. The substrate 26 and cover sheet 28 may be sealed
together using, for example, a heat seal or adhesive. Additionally,
according to one exemplary embodiment, the primary lens package may
assume any configuration, including, but in no way limited to, a
package formed from a plurality of sheets.
[0039] Storing the first lens packages 14 in an inert environment
may increase the shelf-life or useful life of the contact lenses 24
retained within the first lens packages 14. Further, the first lens
packages 14 may have a generally flexible, pliable construction
that may benefit from being stored and shipped within a structure
having additional rigidity and strength to help protect the contact
lenses 24. A secondary contact lens package 12 may provide such
additional protection and support as well as an inert environment
for the first lens packages 14 containing the contact lenses
24.
[0040] The secondary contact lens package 12 may include first and
second sheets or layers 40, 42, first and second ends 44, 46, first
and second side edges 48, 50, a top surface 52, and a bottom
surface 54. The secondary contact lens package 12 may define an
interior 56 having an interior opening 58 at the first end 44 (see
FIG. 2). The secondary contact lens package 12 may also include a
closure assembly 60 positioned at the first end 40 and associated
with the interior opening 58. The closure assembly 60 may include
first and second closure members 59, 61 that meet together to
releasably close the interior opening 58.
[0041] According to one exemplary embodiment, the first and second
sheets 40, 42 may be connected to each other around a periphery. A
sealed portion 63 may extend around a portion of the periphery of
the first and second sheets 40, 42, such as, for example, around
all edges except for at the interior opening 58. Separate sealing
steps or features (e.g., the closure assembly 60) may be used to
seal closed the interior opening 58. The sealed portion 63 may be
defined using a heat sealing method. Other methods and forms of
connecting the first and second sheets 40, 42 are possible
including, for example, adhesives, and infrared, ultrasound, and
sonic bonding (see FIG. 4).
[0042] The secondary contact lens package 12 may include a
plurality of graphics positioned on the top and bottom surfaces 52,
54. FIGS. 1 and 3 illustrate a first graphic 62 positioned on the
top surface 52, and second a third graphics 64, 66 positioned on
the bottom surface 54. An additional graphic or reflective member
70 may be positioned on one of the surfaces, such as the bottom
surface 54 as shown in FIG. 3. A reflective member support 72 (see
FIG. 4) may be included with the sheet upon which the reflective
member 72 is mounted (e.g., on an internal surface of the second
sheet 42 opposite a position of the reflective members). Any one or
all of the first, second and third graphics 62, 64, 66 and the
reflective member 72 may convey information to a user or provide
other functions. For example, the contents of the package,
directions, logos, and other information may be conveyed through
the first, second and third graphics 62, 64, 66. One of the first,
second and third graphics 62, 64, 66 and the reflective member 72
may include, for example, a bar code, security features, and
tracking data.
[0043] According to one exemplary embodiment, the secondary contact
lens package 12 may be filled with an inert gas that assists in
providing an inert environment within the interior 56. In an
example assembly method, the at least one primary lens package 14
is inserted through the interior opening 58 into the interior 56 of
the secondary contact lens package 12. An inert gas is then
injected into the interior 56 to expose exterior surfaces of the
primary lens package 14 to the inert gas. The closure assembly 60
is sealed or otherwise closed to retain the inert gas within the
interior 56. An additional method step may include removing air or
oxygen from within the interior 56 prior to, during, or after
injecting the inert gas into the interior 56. In some arrangements,
an additional seal may be formed along the interior opening 58 in
addition to or in place of the closure assembly 60, wherein that
additional seal may be broken to obtain access to the first lens
packages 14. The closure assembly 60 may be used after breaking the
additional seal to provide waterproof releasable closing of the
interior opening 58.
[0044] Each of the first and second sheets 40, 42 of the secondary
contact lens package 12 may, according to one exemplary embodiment,
include a plurality of layers. The first and second sheets 40, 42
may be constructed as laminates. Referring to FIG. 5A, the first
sheet 40 may include a first foil layer 90 and a first polymer
layer 92. The second sheet 42 may include a second foil layer 94
and a second polymer layer 96. The first and second polymer layers
92, 96 may be arranged facing each other so that application of
heat to the first and second sheets 40, 42 bonds the first and
second polymer layers 92, 96 to form the seal portion 63.
[0045] Each of the first and second sheets 40, 42 may include
additional materials and layers including, for example, at least
one layer that includes one or more of the graphic portions 62, 64,
66. The use of foil layers in a secondary contact lens package 12
may provide light reflectivity that inhibits the egress of light
into the interior 56, wherein that light may otherwise provide at
least some degradation of the first lens packages 14 or influence
the inert environment within the interior 56. The polymer layers
92, 96 of the first and second sheets 40, 42 may include an inert
material such as polypropylene. Other inert materials may similarly
be used to create an inert environment within the secondary contact
lens package 12.
[0046] The foil layers 90, 94 of the secondary contact lens package
12 may also provide additional strength and durability for the
secondary contact lens package 12. The foil layers 90, 94 may also
comprise a corrosive resistant material. The foil layers 90, 94 may
be encapsulated within other layers of non-corrosive material such
as, for example, polymer-based layers.
[0047] The material composition of the first and second sheets 40,
42 and other features of the secondary contact lens package 12 may
provide a waterproof environment within the interior 56. Providing
a waterproof environment may have advantages when using the contact
lens package assembly 10 in a high moisture environment such as,
for example, within a storage cabinet, on a sink top, or in a
cupboard in a bathroom where contact lenses are typically stored.
The waterproof aspects of the secondary contact lens package 12 may
also provide benefits when transporting the contact lens package
assembly 10 in, for example, a person's pocket, purse, wallet, bag,
suitcase or other carrying member where the contact lens package
assembly 10 may be exposed to, for example, perspiration, food or
drink, or high humidity conditions.
[0048] The combination of a foil layer with a polymer layer such as
polypropylene in the first and second sheets 40, 42 of the
secondary contact lens package 12 may provide improved resistance
to the passage of moisture or gas through a secondary contact lens
package 12 either into or out of the interior 56. Details
concerning the construction, advantages and manufacturing of a
package layer comprising foil, such as foil-on-foil packaging, and
related systems and methods are disclosed in U.S. Pat. No.
7,828,137, which is hereby incorporated in its entirety by this
reference. Other features and functionality related to lens package
constructions and materials are described in Singapore Patent
Application filed on 18 Oct. 2011 and entitled "Packaging for
Disposable Soft Contact Lenses Having Pre-Formed Multi-Layer
Structural Laminate", which patent application is incorporated
herein in its entirety by this reference.
[0049] As disclosed in the above-mentioned Singapore Patent
Application entitled "Packaging for Disposable Soft Contact Lenses
Having Pre-Formed Multi-Layer Structural Laminate", a primary lens
package may include a preformed laminate substrate. One layer of
the laminate substrate is configured to provide sufficient
structural rigidity to maintain a shape (e.g., a lens receiving
portion) that is preformed in the substrate. In one example, the
first layer includes a polymer material such as polypropylene.
Another layer of the laminate substrate may include a second
material that provides different properties from the first layer
such as, for example, light-reflectivity, strength, and resistance
to water/vapor permeability. The package also includes a cover
sheet that is connected to the substrate and seals a contact lens
within a lens receiving portion formed in the substrate. The cover
sheet may also be a laminate having at least two layers. The first
layer may comprise, for example, a polymer that assists in
connecting the cover sheet to the substrate. Another layer of the
cover sheet may include a material having different properties such
as, for example, greater light-reflectivity, strength, or
resistance to water/vapor permeability.
[0050] A further aspect related to the primary lens package is
directed to a single contact lens package that houses multiple
contact lenses. The contact lens package may include a plurality of
lens receiving portions (e.g., recesses, depressions or "boats")
formed in the substrate. The lens receiving portions may be
arranged in multiple directions such as multiple rows, wherein each
row includes at least one contact lens receiving portion. The rows
may be arranged opposite each other or side-by-side. Some contact
lens packages may provide for separation of at least one lens
receiving portion from the other lens receiving portions. Other
arrangements may include a plurality of lens receiving portions
that are inseparable from each other once the contact lens package
is assembled.
[0051] Some primary lens packages may include layers of material
for the cover sheet and substrate that are added during assembly of
the contact lens package rather than being provided with the
substrate and/or cover sheet as a laminate. In one example, at
least one layer of light-reflective material or liquid/vapor
impermeable material is added to the substrate or the cover sheet
after sealing a contact lens within a lens receiving portion of the
substrate.
[0052] The primary lens packages may be created in a single
manufacturing line. The substrate and sheet may include materials
capable of maintaining a sterile environment within the package
where the lens is disposed. The sterile environment may be created
by heating the first material of the substrate. Light-sensitive
materials disposed within the package may also be protected from
light to limit degradation of the light-sensitive materials. The
substrate and cover sheet may comprise materials that permit
printing of graphics that minimize negative effects on the
light-reflecting attributes or the sterile environment of the
contact lens package. In some arrangements, the contact lens
package may be configured for use as an insertion aid. The
materials of the contact lens package may promote improved sealing
between the substrate and cover sheet layers. For example, the
laminate materials used for at least one of the substrate and cover
sheet may include layers of material in the area where a seal is
formed between the substrate and cover sheet that provide improved
seals (e.g., releasable seals, permanent seals, hermetic seals,
heat seals, etc.).
[0053] The secondary contact lens package 12 disclosed herein may
have other constructions such as a construction wherein one of the
first and second sheets 40, 42 is configured as a substrate that is
relatively rigid and the other of the first and second sheets 40,
42 is configured as a cover sheet sealed to the substrate to define
an interior sized to receive at least one of the first lens
packages 14. This alternative embodiment may provide an inert
environment for storage of the first lens packages 14. The
alternative embodiment may provide a waterproof environment for
storage of the first lens packages 14. The alternative embodiment
may include one or more foil layers.
[0054] One objective in providing an inert environment within the
interior 56 of the secondary contact lens package 12 (e.g., using
an inert gas) is to improve a sterility assurance level for the
primary lens package 14. Providing an inert environment within the
interior 56 may limit the growth of bacteria. Providing an inert
environment may also permit storage within the secondary contact
lens package 12 of a primary package (e.g., the primary lens
package 14) having lower standards of water-resistance, light
reflectivity, gas permeability, etc. Furthermore, the additional
protection against environmental conditions provided by the
secondary contact lens package 12 may permit reduced standards for
the primary lens package 14 related to strength, durability, and
protection against environmental conditions.
[0055] Another application for the secondary contact lens package
12 is for the storage of non-contact lens products that may be
volatile for any number of reasons such as, for example, freshness
and shelf-life. In one example, the secondary contact lens package
12 is referred to generally as a secondary package used to store
pre-packaged products such as, for example, medications, vitamins,
supplements, and other food and drug-related products. In at least
some instances, both physical and chemical aspects of the product
being stored may be protected and/or given an extended shelf life
as a result of storage within the inert environment provided by the
secondary packaging.
[0056] The use of a secondary package for storing of such
relatively volatile products may be enhanced with the use of a cold
sterilization process when sterilizing the secondary package after
product has been sealed therein. Even after the secondary package
has been opened to obtain access to the product, providing the
secondary package with a resealable opening may further extend at
least some benefits of using the secondary package such as, for
example, the waterproof environment, protection against physical
harm, reduced exposure to light, and protection against egress of
bacteria, additional oxygen or other debilitating conditions for
the stored product.
[0057] In addition to a foil based package, the secondary contact
lens package 12 disclosed herein may be manufactured in according
to any number of manufacturing methods and using a number of
materials. Specifically, according to one exemplary embodiment, the
secondary contact lens package 12 may be an injection case molded
plastic packaging, a card or paper material that is wax or polymer
coated so as to be waterproof, a foil or foil composite package, a
package made from materials that are recycled from other contact
lens-related manufacturing processes such as plastic molds used to
form the contact lenses that are held in the primary contact lens
packages, and combinations thereof.
[0058] Referring now to FIGS. 7-8, another example contact lens
package assembly 100 is shown. The contact lens package assembly
100 includes a first or primary lens package 112 stored within a
second or secondary lens package 114. The first lens package 112
may be held within a support member 182 prior to being inserted
into and stored within a secondary package 114. The primary lens
package 112 may have the same or similar construction to the
primary lens packages 14 described above with reference to FIGS.
1-6.
[0059] The secondary lens package 114 may include first and second
ends 144, 146, first and second side edges 148, 150, top and bottom
surfaces 152, 154, an interior 156, an interior opening 158, and
sealed portions 162 at opposing ends (see FIG. 7). The secondary
lens package 114 may also include an expansion portion 180 along
the first and second side edges 148, 150. The expansion portion 180
may include a fold or expandable portion that helps increase a size
of the interior 156 to accommodate, for example, the support member
182.
[0060] The support member 182 may include a periphery wall 184 and
a recess or cavity 186. The cavity 186 may be sized to receive at
least one of the primary lens packages 112. A plurality of primary
lens packages 112 may be positioned within the cavity 186. The
support member 182 retaining the primary lens package 112 may be
inserted through the interior opening 158 into the interior 156. An
inert gas may be injected into the interior 156 prior to sealing
closed the secondary lens package 114. At least one of the sealed
portions 162 may include a closure assembly that provides a
resealable opening into the secondary lens package 114.
[0061] Details concerning the support member 182 and its possible
functions related to, for example, carrying and supporting the
first lens package 112 during shipping, storage and use is
described in Singapore Patent Application filed on 18 Oct. 2011 and
entitled "Support Structure for Shipping and Storage of Replacement
Contact Lenses", mentioned above.
[0062] The secondary lens package 114 may, according to one
exemplary embodiment, be formed using a single sheet (e.g., a
laminate sheet including a foil layer) that is folded over and
sealed along opposing free edges to create a tubular-shaped
structure. The tubular-type structure may be sealed at opposing
ends to create the secondary lens package 114 shown in FIGS. 7 and
8. The expansion portions 180 may be folded or otherwise formed
into the secondary lens package 114 prior to creating the sealed
portions 162. The primary lens package 112 may be inserted into the
secondary lens package 114 before sealing either of the sealed
portions.
[0063] In other examples, first and second sheets of material
(e.g., laminate sheets each including a foil layer) may be sealed
together around a periphery such as described above with reference
to secondary contact lens package 12. The sealed portions 162 may
be formed in the first and second ends 144, 146 in separate sealing
steps. In a still further embodiment, the secondary lens package is
formed using a continuous, unbroken tubular member that is sealed
closed at the first and second ends 144, 146 to create the sealed
portions 162. The expansion portions 180 may be formed in the
tubular structure prior to or as part of forming the sealed
portions 162.
[0064] The materials used for the secondary lens package 114 may
have the same or similar properties, features, layers,
manufacturing methods and constructions as described above with
reference to secondary contact lens package 12.
[0065] One aspect of the present disclosure relates to packaging
with the inclusion of some form of inert medium to preserve a
desired condition within the packaging until the time of opening
the packaging. Another aspect relates to packaging and other
features that may be used to tune or match the internal conditions
of the packaging to the properties of the product being stored in
the packaging to optimize a shelf-life or product-life of that
product. Another aspect relates to an ability to use
thermally-sensitive ingredients, dyes, and material as part of the
primary packaging held within the secondary packaging because of
the inert environment provided within the secondary packaging.
Another aspect relates to secondary packaging that provides an
improved storage and/or shipping condition for thermally-sensitive
medications, vitamins, supplements, and other products. A still
further aspect relates to secondary packaging and permits the use
of primary packaging designs and materials that have lower
standards of, for example, strength, sterility, shelf-life, and gas
permeability. At least some of these aspects of the present
disclosure are possible or enhanced with the use of cold
sterilization techniques related to sterilizing the secondary
packaging.
[0066] Some example inert gasses or other gasses that may be used
within the secondary packaging include, for example, nitrogen,
argon, and other gasses (e.g., noble gases) that may, for example,
match the properties, attributes, or other aspects of the product
held in the secondary packaging.
[0067] Example methods in accordance with the present disclosure
relate to assembly of a contact lens package having at least one
first lens package stored within a secondary lens package. Other
aspects relate to methods of manufacturing or forming a secondary
lens package. Further aspects relate to creating an inert
environment for storage of at least one primary lens package. Other
aspects relate to methods of accessing and storing a plurality of
first lens packages within a secondary, resealable lens package.
Another method relates to storage of a plurality of first lens
packages within a waterproof secondary lens package. The secondary
lens package may be resealable. Many other methods and aspects of
the present disclosure are possible.
[0068] The preceding description has been presented only to
illustrate and describe exemplary embodiments of the system and
process. It is not intended to be exhaustive or to limit the system
and process to any precise form disclosed. Many modifications and
variations are possible in light of the above teaching. It is
intended that the scope of the system and process be defined by the
following claims.
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