Contact lens package and methods of handling and manufacturing

Abstract

The present invention relates to improved contact lens packages and methods of use and manufacture / assembly. The contact lens packages contain a contact lens and a packaging solution, and are configured to lift the contact lens from the packaging solution when a force is applied to a lever of the package and / or when the package is squeezed by a user.

Description

[0001] I. Cross-referencing of related applications

[0002] This patent application claims priority to the following patent applications: U.S. Provisional Application No. 63 / 077779, filed September 14, 2020; U.S. Provisional Application No. 63 / 077,784, filed September 14, 2020; U.S. Provisional Application No. 63 / 124,835, filed September 13, 2020; and U.S. Provisional Application No. 63 / 243,525, filed September 13, 2021. Background Technology

[0003] In standard contact lens packaging, the contact lens is typically housed in a molded plastic base with a cavity (or "bowl") that receives the lens with its concave side facing upwards. Therefore, the user experience of transferring a contact lens from the packaging to the eye often involves the user "fishing" the lens out of the bowl with their fingers and then flipping it so that it is correctly oriented on their fingers for placement on the eye. This process requires multiple touches of the lens, which can transfer contaminants or pathogens from the hands to the lens and ultimately to the eye. This experience is not only unhygienic but also cumbersome, messy, and mechanically stressful on the lens, which can tear, fray, or deform under excessive manipulation. While some packaging is designed to present the lens with its convex side facing upwards to avoid the need to flip it, it is still generally necessary to "fish" the lens out of the packaging solution or to manipulate and / or touch the lens multiple times to transfer it to the eye.

[0004] Given the growing awareness of eye health and the demand for a more convenient experience, there is a need for contact lens packaging that enables a less messy and more hygienic contact lens handling process. Ideally, contact lens wearers would want a "one-touch" package—one that allows them to remove the lens from the storage package with a single touch of one finger and then place it correctly on their eye with just one touch. In this design, there is no need to transfer and manipulate the lens from one finger to another before placing it on the eye. Providing such a one-touch package not only simplifies the lens preparation and insertion process but also reduces the likelihood of the lens falling out or being exposed to additional bacteria on the wearer's other fingers when preparing to orient and insert it into the eye. It also reduces the likelihood of the contact lens being intended to contact the side of the eye.

[0005] The design of single-contact contact lens packaging presents several significant challenges. Ideally, the wearer should be able to consistently position the lens for adhesion to their finger during removal from the packaging, and then consistently release the lens from the finger onto the eye. Contact lenses (both reusable and daily disposable) each have their unique surface, volume, and geometry. Finger size and the force applied to the lens by the wearer during transfer can also vary. These factors can affect the process of removing the lens from the packaging to the finger and then placing it on the eye. Among other considerations: the wearer desires the ability to flush away any packaging solution that might affect the ability to adhere the lens to the finger, as variations in the amount of packaging solution adhering to both the lens and the packaging can affect the process of placing the lens on the finger. A controlled flushing method to prevent spillage is also desirable. It is also beneficial that the packaging solution remains sterile after opening and is available for the wearer to allow for rewetting or cleaning of the lens. Furthermore, the wearer may be concerned about the possibility of transferring bacteria or external products such as cosmetics onto the contact lens; and, of course, the packaging itself should be manufactured in accordance with anticipated industry standards recognized by the medical and commercial provider groups.

[0006] Furthermore, ideally, one-touch packaging should not result in an excessive increase in product cost relative to current contact lens packaging, as this could lead to increased costs for the wearer population. The packaging should not make the lenses difficult to hold when removed from the package. Additionally, if the packaging configuration is maintained, or even reduced, the volume of solution required to package the lenses, the ecological impact of lens packaging will be reduced. Similarly, it would be beneficial if the packaging could be made wholly or partially from recycled materials and / or wholly or partially recyclable.

[0007] Additionally, it is advantageous if the packaging is composed of materials approved by various regulatory agencies, and ideally, it does not require alteration of the solution chemistry or lens composition. Similarly, if such components may adversely affect the performance of the packaging or lens, the packaging should preferably not contain any electronic or other electrical components.

[0008] Several desirable properties make achieving the functionality of one-touch packaging challenging, and these properties are often lacking in known attempts to create one-touch packaging. These properties include, for example, the following: i) ideally, the packaging should protect the lens, i.e., it should ensure the integrity of the lens (e.g., lens shape and optical integrity) while preventing crushing or damage to the lens; ii) the lens packaging should maintain the hydration of the lens during storage to preserve its performance; and iii) the lens in its packaging should preferably be constructed such that it is fully immersed in the packaging solution when needed, but the solution is removed when ready to be transferred from the packaging; iv) the packaging should generally have a retortable seal and include both the lens and the solution; v) the packaging preferably holds the lens in a convex orientation desired by the wearer; vi) the lens should be positioned to facilitate easy removal by the wearer; and vii) ideally, the packaging should allow the packaging solution to be effectively drained from the lens upon opening and before removal, so as to facilitate transfer to the wearer's fingers and then to the eyes.

[0009] Known packaging designs attempting to provide reduced touch or one-touch orientation fail to offer one or more of the aforementioned desirable properties for one-touch packaging. For example, WO2014 / 195588, WO2009 / 069265, and JP6339322 disclose packaging with lenses shaped like convex bowl bottoms. However, the lens support structure essentially matches the shape of the contact lens, providing an undesirable contact area between the lens and the lens support. These references also fail to mention mechanisms for efficient drainage of solution from the lens and lens support.

[0010] Similarly, US20200229560 discloses a lens support having a concave (front or front) surface supporting the contact lens or a package having a grid supporting the peripheral edge of the contact lens, allowing the packaging solution to be discharged through the grid into the bottom chamber when the lens package is opened. The aforementioned deficiencies of the prior art are merely exemplary and not exhaustive.

[0011] Therefore, there remains a need for contact lens packages that provide a consistent one-touch lens removal experience, effective solution management, or address one or a combination of the challenges or deficiencies mentioned above. Summary of the Invention

[0012] It has now been found that some or all of the above and related objectives can be achieved in contact lens packaging having one or more aspects described herein. For example, the contact lens packaging of the present invention can contain a contact lens and a packaging solution, wherein the packaging is configured to lift the contact lens from the packaging solution when the packaging is squeezed by a user. The contact lens packaging may have a lid and a base, the base including a cavity for receiving the contact lens and the packaging solution and a lever configured to hinge along a pivot axis in the base when a force is applied to the lever. The packaging may further include a lens support intersecting the pivot axis, such that a force applied to the lever causes the lens support to lift the contact lens from the packaging solution to a position on the lens support that can be transferred by a single touch by the user. In some cases, the lever is a separate component connected to the base by an attachment device. The pivot axis may be defined by at least one gap in the base and may be applied to the base by one or more of the following: creases, cuts, lines, and etchings, etc. The base of the packaging may be made of plastic, and the lid may be a film. In some cases, the base and lens support and / or lever and lens support are a single integral component.

[0013] The lens support can be attached to the base by: i) laser welding; ii) heating; iii) ultrasonic welding; iv) adhesive, etc. The base may include one or more finger engagement features configured to assist a user in gripping the package or to guide applied force causing the lever to hinge downwards. Possible finger engagement features include protrusions in the base located at the distal end of the package and / or overhangs along at least a portion of the package's periphery. Recesses sized to accommodate a user's fingers or thumb may be positioned at the user-proximity end of the base. The finger engagement features may be paired, such that one is positioned at the user-proximity end of the base, and the other is a distal finger engagement feature positioned at the user-remote end of the base. Alternatively, the finger engagement features may be positioned on any other opposite side or end of the package.

[0014] The cover of the package may include one or more lens-facing surfaces that, when the package is unopened, extend downward into a cavity above the contact lens. The lens-facing surfaces and a lens support may be constructed within the cavity such that, when the package is unopened, the optical region of the contact lens is suspended in a packaging solution between the lens-facing surfaces and the lens support. Whether the package is unopened or open, the cavity of the package can accommodate the contact lens in a convex position. The lens support may have a profile that substantially does not match the profile of the contact lens. When the package is open, the wetting contact area between the lens support and the contact lens may be less than approximately 30 mm². 2 Less than approximately 25mm 2 or less than approximately 20mm 2The package may include a cap insert having at least one alignment feature and / or one or more locking features. Attached Figure Description

[0015] The above and other features and advantages of the invention will become apparent from the following more detailed description of preferred embodiments of the invention as shown in the accompanying drawings.

[0016] Figures 1A to 1D The steps for opening a contact lens package according to an exemplary embodiment of the present invention are shown.

[0017] Figure 2 A perspective view of a contact lens package in an opened state according to an embodiment is shown.

[0018] Figure 3 An exploded perspective view of the contact lens package according to an embodiment is shown.

[0019] Figure 4 A close-up view of the cover insert in the cavity of the embodiment is shown.

[0020] Figure 5A and Figure 5B A cross-sectional view of an unopened contact lens package according to an embodiment is shown.

[0021] Figure 6 An air intake guide for a contact lens package according to an embodiment is shown.

[0022] Figure 7A and Figure 7B The lens support of the embodiment is shown in side view and top view, respectively.

[0023] Figure 8A and Figure 8B The lens support of an alternative embodiment is shown in side and top views, respectively.

[0024] Figure 9 The contact lens package in a nested configuration is shown.

[0025] Figure 10 An exemplary method of manufacturing a contact lens package according to certain embodiments is shown. Detailed Implementation

[0026] Reference will now be made specifically to the representative embodiments shown in the accompanying drawings, wherein the reference numerals indicate certain elements. The following description is not intended to limit the numerous embodiments to a single preferred embodiment. Rather, it is intended to cover alternatives, modifications, and equivalents that may be included within the substance and scope of the embodiments defined by the appended claims.

[0027] References to "an implementation scheme," "implementation scheme," "some implementation schemes," "example implementation scheme," etc., mean that the implementation scheme may include a particular feature, structure, aspect, or characteristic, but each implementation scheme need not include that particular feature, structure, or characteristic. Furthermore, these terms do not necessarily refer to the same implementation scheme. Moreover, when a particular feature, structure, aspect, or characteristic is described in conjunction with an implementation scheme, whether or not it is explicitly described, it should be assumed that implementing such a particular feature, structure, or characteristic in conjunction with other implementation schemes is within the knowledge of a person skilled in the art.

[0028] As used herein, the following terms have the following meanings. Certain embodiments of the invention offer the advantage of facilitating consistent one-touch lens transfer from the package to the wearer's finger, and then from the finger to the wearer's eye, without requiring the lens to be inverted, detached from the finger, or subjected to further manipulation. Consistent lens transfer includes a transfer rate of at least about 70%, at least about 80%, or at least about 90% upon the first touch (or "tap") of the finger. The lens also ideally "sits" on the finger without collapsing or inverting, and is then transferred to the eye while placed there. Packages of certain embodiments can provide the desired one-touch transfer across a range of finger sizes and tapping pressures. Environmental conditions such as temperature and whether the finger is wet or dry can also affect the transfer rate, with higher temperatures generally improving lens transfer.

[0029] Lenses or contact lenses refer to ophthalmic devices that reside on the eye. They have a generally hemispherical shape and can provide optical correction, cosmetic enhancement, UV blocking and visible light or glare reduction, therapeutic effects including wound healing, drug or nutrient delivery, diagnostic assessment or monitoring, or any combination thereof. The term lens includes soft hydrogel contact lenses, which are typically provided to consumers in a hydrated state in packaging and have a relatively low modulus, allowing them to conform to the cornea. Contact lenses suitable for use with the packaging of this invention include all hydrated contact lenses, including conventional and silicone hydrogel contact lenses.

[0030] Hydrogels are hydrated cross-linked polymer systems containing water in equilibrium, and may contain at least about 25% or at least 35% hydrated water. Hydrogels typically possess oxygen permeability and biocompatibility, making them excellent materials for the production of contact lenses.

[0031] Conventional hydrogel contact lenses do not contain silicone-containing components and typically have higher water content, lower oxygen permeability, modulus, and shape memory than silicone hydrogels. Conventional hydrogels are prepared from monomer mixtures primarily containing hydrophilic monomers such as 2-hydroxyethyl methacrylate (“HEMA”), N-vinylpyrrolidone (“NVP”), or polyvinyl alcohol. U.S. Patents 4,495,313, 4,889,664, and 5,039,459 disclose the formation of conventional hydrogels. Conventional hydrogels can be ionic or nonionic and include polymacon, etafilcon, nelfilcon, ocufilcon, lenefilcon, etc. The oxygen permeability of these conventional hydrogel materials is typically below 20-30 barel.

[0032] Silicone hydrogel formulations include balafilcon, samfilcon, lotrafilcon A and B, delfilcon, galyfilcon, senofilcon A, B and C, narafilcon, comfilcon, formofilcon, riofilcon, fanfilcon, stenfilcon, somofilcon, kalifilcon, etc. "Organosilicon hydrogel" refers to a polymer network made of at least one hydrophilic component and at least one component containing organosilicon. Organosilicon hydrogels can have a modulus in the range of 60psi-200psi, 60psi-150psi, or 80psi-130psi, and a water content in the range of 20% to 60%.Examples of silicone hydrogels include acquafilcon, asmofilcon, balafilcon, comfilcon, delefilcon, enfilcon, fanfilcon, formofilcon, galyfilcon, lotrafilcon, narafilcon, riofilcon, samfilcon, senofilcon, somofilcon, and stenfilcon, verofilcon, including all their variants, and such as U.S. Patent Nos. 4,659,782, 4,659,783, 5,244,981, 5,314,960, 5,331,067, 5,371,147, 5,998,498, 6,087,415, 5,760,100, 5,776,999, 5,789,461, 5,849,811, and 5,96 5,631, 6,367,929, 6,822,016, 6,867,245, 6,943,203, 7,247,692, 7,249,848, 7,553,880, 7,666,921, 7,786,185, 7,956,131, 8,022,158, 8,273,802, 8,399,538, 8,470,906, 8,450,387, 8,487,058, 8,5 Silicone hydrogels prepared as described in WO 07,577, 8,637,621, 8,703,891, 8,937,110, 8,937,111, 8,940,812, 9,056,878, 9,057,821, 9,125,808, 9,140,825, 9156,934, 9,170,349, 9,244,196, 9,244,197, 9,260,544, 9,297,928, 9,297,929, and WO 03 / 22321, WO 2008 / 061992 and US 2010 / 0048847. The entire contents of these patents are incorporated herein by reference. Silicone hydrogels can exhibit higher shape memory than conventional contact lenses.

[0033] Hydrogel lenses are viscoelastic materials. Optical distortion can occur in contact lenses if they interact with the packaging or any air bubbles within it. The degree of optical distortion and the time required for distortion to relax will depend on the chemical composition and, to a lesser extent, the lens geometry. Compared to silicone hydrogels, conventional lens materials, such as those based on poly(hydroxyethyl methacrylate) like Etafencon A or Polymacon, have lower loss modulus and loss tangent values, and are likely to exhibit less severe optical distortion due to contact with the packaging. Incorporation of silicone (which typically increases the overall elastic response), wetting agents (such as PVP) (which typically increases the viscous response), or coatings of conventional hydrogel materials (which may reduce the elastic response at the lens interface) can alter the viscoelasticity of the lens. Conventional hydrogel contact lenses with short or hard crosslinking agents and / or hardeners, as well as silicone hydrogel contact lenses, have short shape memory and may be less prone to deformation during storage. As used in this paper, after accelerated aging at 55°C for 5 weeks, hydrogels with high or higher shape memory exhibit optical deformation of at least approximately 0.18 due to contact with air bubbles or packaging. Viscoelasticity, including loss modulus and loss tangent, can be measured using dynamic mechanical analysis.

[0034] Contact lenses can be of any geometry or diopter and have a generally hemispherical shape, with a concave rear side that rests against the eye when in use and a convex front side that is away from the eye and is contacted by the eyelid during blinking.

[0035] The center or apex of a lens is the center of its optical zone. The optical zone provides optical correction and can have a diameter between approximately 7 mm and 10 mm. The lens periphery or edge is the edge where the front and back sides meet.

[0036] Wetting lens refers to any residual packaging solution adhering to the lens after it has been drained. Wetting contact is the total contact area between the wetting lens and the lens support.

[0037] Implementations may include a lens support surrounded by a sealable cavity, which may also be interchangeably referred to as a chamber. The cavity may have any convenient form and may include a packaging base and at least one cap, each of which will be described in detail below. As used herein, the phrases “the cap,” “cap,” “the base,” and “base” cover both the singular and plural. The cap and packaging base seal against each other to form a cavity that keeps the contact lens, support, and packaging solution sterile during transport and storage prior to use. The contact lens packaging is made of a material compatible with the contact lens and solution, and is retort-safe and bio-inert.

[0038] "Film" or "multilayer film" is a film used for sealing packaging and is commonly referred to as a cover material. Multilayer films used in conventional contact lens packaging can be used in the packaging of this invention as a base, a component of a cover, or both. A multilayer film comprises multiple layers, including barrier layers, including foil layers, or coatings, sealing layers, which seal the film to the remainder of the packaging, and may also include additional layers selected from peel-off initiation layers, laminated layers, and layers that improve other packaging properties such as stiffness, temperature resistance, printability, puncture resistance, and barrier properties against water or oxygen. The multilayer film forms a steam-sterilizable (retortable) seal. The multilayer film may contain PET, BON, or OPP film layers to increase stiffness and temperature resistance, or contain EVOH or PVDC coatings to improve barrier properties against oxygen or moisture.

[0039] As used in this article, “unopened” or “unopened” refers to a contact lens package that is sealed and contains the contact lens in a solution.

[0040] As used herein, "opened state" or "opened" refers to a contact lens package after the sterile seal has been broken. In the context of this document, "opened state" extends to the package state when a user has manipulated the package to lift the lens from the packaging solution for user transfer.

[0041] As used herein, “wearer” or “user” refers to a person who opens and handles the contact lens package. A user is generally referred to as the person who opens the package and transfers the contact lens contained therein to their eyes. However, in some cases, a user may be a person who operates the contact lens package on behalf of the wearer, such as an eye care provider (“ECP”) or another individual demonstrating or assisting the wearer.

[0042] Packaging solutions are any physiologically compatible solutions that are compatible with the material and packaging of the selected lens. Packaging solutions include buffered solutions with a physiological pH, such as buffered saline solutions. Packaging solutions may contain known components, including buffers, pH and tension regulators, lubricants, wetting agents, nutrients, pharmaceuticals, packaging coating components, etc.

[0043] The packaging base forms the bottom of the package. It can be made of any material suitable for packaging medical devices, including plastic. The packaging cap is typically located in the upper portion of the package and is sealed with the base to form a cavity including at least a portion of a lens support, a lens, and a packaging solution. The cap can be made of any material suitable for packaging medical devices, including molded foil or plastic sheets, laminated films, or plastics. Packages comprising plastic for one structure and foil or laminated film as another structure, or packages comprising foil or laminated film as an outer layer of a cap and a base, are known in the art and are examples of suitable combinations.

[0044] References to injection molding processes and the use of materials conventionally applied to injection molding throughout this description should be understood as exemplary. Those skilled in the art will understand that other manufacturing methods are possible within the scope of the appended claims, including, but not limited to, alternative molding processes, thermoforming, 3D printing, etc. Similarly, references to heat sealing are examples of embodiments described herein. Other methods of securing packaging components will be apparent to those skilled in the art, including the use of adhesives, glues, thermal bonding, welding such as heating, ultrasonic or laser welding, or mechanical trapping, etc.

[0045] Certain aspects of this invention can be used to reduce or prevent significant optical damage to contact lenses caused by interaction with bubbles or the interior of the lens package during storage or transport due to gravity or other forces, such as mechanical pressure applied from the outside of the package. As used herein, significant optical damage means a root mean square (RMS) value equal to or greater than about 0.08 μm.

[0046] Refer to the attached diagram. Figures 1A to 1D The steps of operating a contact lens package comprising a contact lens in a packaging solution are illustrated according to an exemplary embodiment of the present invention. Figure 1A An unopened contact lens package 100 with a cap 106 and a base 110 is shown. In this embodiment, the cap 106 is a multilayer film, also referred to herein as a foil, and the base 110 is made of a thermoplastic polymer, such as polypropylene plastic. While in this embodiment the cap 106 is in the form of a relatively flexible material (i.e., a multilayer film) and the base 110 is in the form of a relatively rigid material, it should be understood that other embodiments may include substantially rigid components for both the cap and the base. For example, in some embodiments, both the base and the cap may be made of polypropylene plastic or other relatively rigid materials. The base 110 includes a pivot axis 114 along which a portion of the forming lever 118 of the base can be hinged when a force is applied to the lever 118.

[0047] The base 110 further includes several optional finger engagement features 122a-122c to assist the user in manipulating the contact lens package during the opening process. The finger recess 122a is sized to accommodate a user's finger or thumb and is located at the user-proximity end of the base 110; an overhang 122b is located along the peripheral edge of the base 110; and a protrusion 122c is located at the user-remote end of the package 118. In this embodiment, the finger recess 122a is also angled downwards such that a force, for example, applied by the user's thumb, causes the lever 118 to hinge downwards at the pivot 114. In this embodiment, the package 100 is further configured with a profile sloping from proximal to distal to further facilitate a downward torque at the lever, for example, when the lever is pressed or when the user squeezes the package, i.e., when the user applies pressure with their hand at opposite ends of the package, via a finger at one end and a thumb at the other. In this embodiment, the package 100 is configured such that a squeezing force is applied at both the proximal and distal ends. However, alternative implementations are possible, which involve applying opposing forces of compression at alternative opposite ends of the package, such as, but not limited to, the left and right sides of the package.

[0048] exist Figure 1B In the first step shown, the user holds the unopened contact lens package 100 via its base 110. As shown, the user's grip on the package 100 can be improved by one or more finger engagement features 122a-c, which are positioned and configured to provide a stronger grip on the package and / or facilitate the application of force that causes the contact lens included in the package to rise to the user and be transferred to the user's eye in subsequent steps. A finger recess 106 is positioned on the lever 118 of the base 110 and is sized for the user's thumb 126 to grip the package. At the opposite end of the package 100, the user can hold the package as shown by firmly positioning their fingers under the overhang 122b and against the protrusion 122c at the end of the base 110. In the case of the overhang, the overhang area can be curved or can be flattened to provide increased area through which a reaction force can be supplied when the package is squeezed. Next, the user can open the package by opening the cap 106. In this embodiment, this involves the user peeling the foil 106 from the proximal end to the distal end of the base 110 in the direction indicated by arrow 134, thereby breaking the sterile seal between the foil (cap) 106 and the base 110. Although not mandatory, in this preferred embodiment, the package is optimized so that the user holds the base with one hand and peels the cap 106 with the other hand.

[0049] like Figure 1CAs shown in the steps, the packaging cap 106 has been opened either by completely removing the cap as shown or alternatively by partially removing it sufficient to substantially expose the lens cavity 136, which houses the contact lens 138 suspended in a packaging solution (not shown) above the lens support 140. With the packaging 100 opened, the user then applies force 142 to the lever 118. In this embodiment, the packaging is configured to be squeezed by the user, whereby one or both hands of the user apply opposing forces 142 and 146 at the proximal and distal ends of the packaging, respectively, thereby generating a greater force on the lever 118.

[0050] Turn Figure 1D The force applied by the user to the lever causes the lens support 140 to lift the contact lens 138 from the packaging solution (not shown). Ideally, the lens support is configured to lift the contact lens high enough above the packaging cavity that the lens faces the user, is visible from the support, and is transferable, but not so high that the lens slips off the support under gravity. This can be achieved by a lifting angle between about 15° and 60° relative to the horizontal plane of the top of the defining base when the user applies force. The lens support is preferably configured such that when lifted in this way, the packaging solution is sufficiently drained from the contact lens to allow the user to transfer it with a single touch, as shown in an exemplary embodiment, where the user transfers the contact lens 138 from the lens support 140 by tapping (or alternatively referred to as "slapping") the convex surface of the contact lens 138, such that the tap causes the contact lens to be released from the lens support 138 and adhere to the user's finger 154.

[0051] In this embodiment, the contact lens 138 is conveniently presented to the wearer in a convex orientation, meaning that the convex surface of the lens 138 is available to the wearer without requiring reorientation of the lens before placing the concave surface of the lens onto the wearer's eye surface. However, it should be understood that other orientations, such as the concave orientation of conventional blister packs, are also possible within the scope of the invention. The transfer of the contact lens 138 from the lens support 140 can be performed by the wearer's finger 154, either by direct touch of the lens or indirectly by an application film (e.g., as described in US20190046353) or other covering applied to the finger, or by another transfer method, such as a manual or automatic application device or tool. When transferring the contact lens 138 from the pack 100, the lens rests on the finger 154 (or other transfer device), as shown in the illustrated steps, wherein the convex surface of the contact lens 138 abuts against the finger 154, and the concave surface of the contact lens 138 is oriented for direct application to the user's eye surface.

[0052] Turn now Figure 2 and Figure 3 , Figure 2 A perspective view of the contact lens package 100 in an opened state is shown, wherein the lens support 140 has lifted the contact lens 138 from the packaging solution (not shown). Figure 3 A perspective view of a contact lens package 100 is shown. The contact lens package 100 includes a base 110 having a proximal end (A) and a distal end (B). At its distal end (B), the base 110 includes a cavity 136 for receiving a contact lens 138 in a packaging solution and a lever 118 configured to hinge along a pivot axis 114 in the base when a force is applied to the lever 118. In this embodiment, the lever 118 is formed as part of an integral component constituting the base 118. More specifically, the base 110 including the lever 118 is formed as an integrally injection-molded polypropylene plastic part. Those skilled in the art will understand alternative materials and methods for forming the base, including thermoforming and 3D printing (using materials such as ABS, PLA, HIPS, PETG, nylon, etc.). Preferably, the material used for the base is relatively rigid and has a glass transition temperature (T0) of approximately 125°C as measured according to ASTM D1238-10 (a standard test method for determining the melt flow rate of thermoplastic plastics by extrusion plasticizer). g In this embodiment, the pivot axis 114 is defined by a plurality of gaps 158 in the base. The gaps 158 are positioned in a linear configuration along a horizontal axis at the points where their levers 118 hinge. The lack of material creating the gaps 158 along a line in the substrate provides sufficient release to cause the lever 118 to hinge in the desired position when a force is applied to the lever by the user. The distance of the lifting arm, i.e., the distance from the pivot axis to the center of the contact lens when resting on the support, is between 10 mm and 12 mm, and preferably between 12 mm and 17 mm. The use of one or more gaps is merely one of many ways in which the pivot axis can be defined within the scope of the invention. For example, in other embodiments where the lever is formed of the same material as the rest of the base, the pivot axis can be created by molding the plastic thinner along the pivot axis and / or by cutting, etching, or otherwise applying the pivot axis into the substrate, thereby laterally indenting the plastic at the desired location. Furthermore, in embodiments where the lever is in the form of discrete components, the pivot axis may simply represent the horizontal interface between the lever and the rest of the base. In such embodiments, the hinge along the pivot axis can be achieved by a hinged component, a rotatable interlocking attachment, etc. It should be understood that, within the scope of the invention, alternative embodiments are possible, wherein the lever is a separate component attached to the remainder of the base via an attachment device. For example, the lever can be formed as a separate injection-molded component and then attached to a separately molded (or printed, etc.) component forming the remainder of the base via a series of attachment methods (including laser welding, ultrasonic welding, adhesives, mechanical connections, thermal riveting, etc.).

[0053] The underside of the base can be inclined, as in the illustrated embodiment, allowing the package to be "nested," thereby enabling more compact secondary packaging during storage and transport, in addition to reducing the amount of primary packaging material and packaging solution required to maintain contact lens hydration (as shown in the reference). Figure 9 (Further description). In this example, the base 110 is inclined at an angle of approximately 14° from the proximal end (A) to the distal end (B) and has a footprint of approximately 29 mm wide, 44 mm long, and 9.5 mm high. A preferred slope range is between approximately 10° and 20°, but the slope can be made even steeper, for example, between approximately 20° and 30°, as needed. The base includes a well, i.e., cavity 136, formed in a conical region, in which the contact lens 138 and lens support 140 are accommodated when the package 100 is unopened. In this embodiment, the cavity has a volume of approximately 2240 μL, which is filled with approximately 2080 μL of packaging solution, sufficient to completely immerse the contact lens 138 within the cavity 136. The foil cap 106 is secured to the base 110 via a retortable seal formed between beads 152 on the upper surface of the base surrounding the cavity 136. This seal can be formed using well-known heat-sealing techniques and related equipment.

[0054] The finger engagement feature (recess) 122a is sized to accommodate a user's finger or thumb and is located at the user-proximity end of the base 110. In this embodiment, the finger recess 122a is also angled downwards such that a force, such as pressure applied by the user's thumb, causes the lever 118 to hinge downwards at the pivot axis 114. The position of the finger recess and the position of the user's finger relative to the pivot axis affect the amount of compressive force required to cause the lever to hinge along the pivot axis. In this example, the indentation depth below the pivot axis is 4.5 mm when measured from the sealing level to the recess base.

[0055] Lens support 140 is coupled to lever 118 such that a force applied to lever 118 causes lens support 140 to lift contact lens 138 from the packaging solution. In the illustrated embodiment, lens support 140 is a separately molded (or printed) component that is fixedly attached to the lever 118 portion of the base. Attachment is here via a post 162 formed in the lever portion of the substrate. Lens support 140 has an opening 166 corresponding to post 162 such that when lens support 140 is placed on the base, post 162 engages with opening 166. Heat is applied to the post / opening using a hot plate to deform the plastic material using heat and force, thereby firmly securing the post in place like a rivet. The engagement is achieved by partially deforming post 162 around opening 166. Within the scope of the claims, many other attachment methods besides thermal riveting are possible, including, for example, laser welding, ultrasonic welding, bonding, mechanical clamping, etc. Furthermore, it should be noted that in an alternative embodiment, the lens support may be formed as part of an integrally molded or printed component identical to the lever and / or the entire base. The connection / attachment point between the lens support and the lever is preferably approximately 2 mm to 5 mm from the pivot axis to the front of the nail / pile. In many embodiments, such as the illustrated embodiment where the pivot axis is formed by folding in plastic or other substantially rigid material, the pivot axis may have thickness, i.e., it may not be entirely sharp. In these cases, such separation between the attachment point and the pivot axis may be necessary to maximize the lift angle for a given bending force.

[0056] like Figure 2 As can be seen, the lower side of the cover 106 includes a plurality of lens-facing surfaces 168, which in this embodiment are formed as protrusions extending downward toward a convex surface toward the lens. The lens-facing surfaces 168 are generally shaped to mirror the convex lens surface of the contact lens to be received in the cover cavity 136. The lens-facing surfaces 168 serve to align the contact lens on the lens support and protect the contact lens from significant optical damage caused by gravity or air forces. In some embodiments, the lens-facing surfaces also serve as air intake guides, which reduce the likelihood of the contact lens sticking to the package upon opening by guiding air into the package above the contact lens. In this case, the lens-facing surfaces are disposed on a molded plastic cover insert 170, wherein the cover insert 170 is attached to the inner surface of the foil cover 106 by a heat seal. However, in other embodiments, such as where the cover is substantially rigid, the lens-facing surfaces may be integral with the cover rather than a separate component. It should be understood that all features described as applied to the cover insert can be equally applied to embodiments in which the same features are made integral with the cover.

[0057] When loaded under these forces, the lens-facing surface of the present invention serves to support the lens to avoid or reduce significant optical damage. For example, without proper counterbalancing, gravity and interaction with air bubbles in the packaging solution can cause optical damage. In one aspect, as in the lens-facing surface 168 of the illustrated embodiment, the lens-facing surface comprises a relatively large accessible surface area, at least about 3% and preferably at least about 20% or as large as possible, while still accommodating any desired venting channels. The accessible surface area is understood to mean the contact area between the lens and the lens-facing surface when the lens is loaded, i.e., when in contact under applied forces (such as, but not limited to, gravity or air bubble interaction). The accessible surface area determines the pressure applied to the lens region when / if it is loaded. The larger the area, the greater the pressure reduction. In the illustrated embodiment, the lens-facing surface 168 has a diameter of 100 mm. 2 The contactable surface area is approximately 215 mm². 2 The surface area. As discussed in more detail below, preferably, at least 10% of the surface area above the lens is exposed to facilitate air travel into the package, thereby reducing any tendency for the lens to stick to the lens surface / cap insert.

[0058] The lens-facing surface 168 is also spaced to define an venting channel 169, allowing air, particularly air bubbles in the packaging solution, to travel from the contact lens into the peripheral volume of the cavity 136. Advantageously, the venting channel has a positive gradient toward the peripheral volume, with a vertical rise of at least about 2 mm. The venting channel allows smaller air bubbles to escape from the area around the lens surface while preventing larger air bubbles from entering the space above the lens. For this purpose, a preferred embodiment includes at least two venting channels, each with a width between about 1 mm and 1.5 mm, or preferably between 1.5 mm and 2 mm, and specifically 1.5 mm in the illustrated embodiment. In a related aspect, the venting channels 169 are advantageously formed in an "X" configuration. This configuration of the venting channels relative to each other allows at least one channel to always have a central axis from near the center of the cavity, which is angled relative to a plane perpendicular to gravity, when the package is rotated in a lateral orientation. This aspect utilizes buoyancy to allow air bubbles to escape from the lens regardless of the orientation of the lens package, thereby reducing optical damage that might otherwise be caused, for example, due to air bubbles forcing the lens into the lens support.

[0059] In this embodiment, the cap insert 170 is thermally attached to the inner surface of the cap 106 via a heat seal between the multilayer film cap 106 and the flat surfaces 172a-d on the upper side of the cap insert. As discussed in more detail later herein, alignment of the cap insert with the base during the heat sealing process and during storage can be aided by including one or more alignment features in the base and / or the cap insert. For example, in the illustrated embodiment, the alignment feature 174 takes the form of a post on the inner wall of the cavity 136 of the base 110. When pressure is applied to seal the package 100 or during normal use, the alignment feature 174 resists rotation and lateral movement of the cap insert 170. Alternative alignment features are possible, such as, but not limited to, forming the cavity and the cap insert (or an integral portion of the cap including the lens-facing surface) in a non-circular shape, such that the components interlock and inherently resist rotation.

[0060] Now for reference Figure 4 The image shows a close-up view of the cover insert 170 when embedded in the cavity 132 of the base 110. The position of alignment features (e.g., post 174) on the wall of the cavity 136 of the base 110 corresponds to the opening 178 in the cover insert 170. Post 174 and opening 178 cooperate as components to restrict rotational and lateral movement of the cover insert 170. On the other hand, the cover insert may be configured to prevent the lens support from lifting (except for the expected time during opening) and to ensure that the lens is not compressed in the package due to external forces when sealing pressure is applied or during storage, transportation, or when the user opens the package. For example, locking features may be included to prevent the cover features, such as the lens-facing surface (whether integral with the cover or included in the cover insert), from colliding with the lens when pressure is applied overhead, such as when the cover is sealed to the base, or when the cover insert (if present) is sealed to the cover. Other locking features may be included to prevent the lens support from impacting the lens (e.g., due to bending the packaging at the pivot before it is opened) by forming a contact point between the lens support and the cap insert. Additionally, another locking feature in this embodiment is created by a flange 180 along the periphery of the bottom of cavity 136. One function of the flange 180 is to prevent pinching around the lens during assembly. The height of the flange above the bottom of the cavity is sufficient to stop the cap insert and / or the lens-facing feature of the cap above the height at which the lens is received below. In this embodiment, the flange measures approximately 0.8 mm above the lens base. It should be understood that the flange is yet another exemplary locking feature with many possibilities. It is certain that the cap insert can be locked at any level (e.g., flush with the lens base, flush with the top of the packaging).

[0061] Figure 5A and Figure 5B A cross-sectional view of the contact lens package 100 in its unopened state is shown. Specifically, Figure 5B It shows in Figure 5A The cross-section AA indicated in the perspective side view is shown. As shown, the package 100 is configured such that, when unopened, the contact lens 138 is substantially suspended between the lens support 140 and the lens-facing surface 168. The package of the present invention preferably minimizes contact with the contact lens when the package is closed and the lens is suspended in the packaging solution. Ideally, the optical area of ​​the lens is free-floating and contact with the lens support is temporary or non-existent during storage. Depending on the buoyancy and orientation of the lens in the packaging solution, the lens may rest on its peripheral edge located at the bottom of the cavity 136 in the package base or on the lens-facing surface of its convex surface. As shown, the contact lens package 100 is in a cap-on orientation, wherein the peripheral edge of the contact lens rests on the bottom of the cavity 136 in the base 110. However, the optical area of ​​the contact lens 138 is effectively suspended between the lens support 140 and the lens-facing surface 168.

[0062] Cavity 132 is preferably substantially filled with a packaging solution; however, the manufacturing process may not allow for sealing the package under vacuum pressure. In this case, some amount of air is expected to be trapped in the cavity. If these air bubbles are not addressed, they may interact with the lens and cause serious optical damage. Therefore, a peripheral volume can be provided in the cavity, i.e., the volume around the lens position above the lens support within the cavity. Ideally, this volume should be located at the distal and proximal ends of the package, such as 132' and 132' of cavity 132 of package 100, so that air bubbles have a place to reside during transport or storage, regardless of the orientation of the package.

[0063] In one respect, the lens-facing surface can act as an air intake guide through placement and configuration, causing air entering the package upon opening to travel above the contact lens to prevent it from sticking to the cap or its lens-facing surface. For example... Figure 6 As shown, the contact lens package 100 is depicted in an assembled, unopened state, with the foil cover not shown, allowing the components within the package 100 to be seen in this embodiment. The package 100 is configured to open from the proximal end (A) to the distal end (B), allowing air to enter the package in the direction indicated by arrow 190. To ensure air travel over the lens, the cover insert 170 is configured such that the convex surface of the lens 138 is exposed above the lens edge, closest to the point 192 where air enters the cavity upon opening. This is achieved by positioning the lens-facing surface primarily over the lateral and distal surface area of ​​the contact lens and exposing at least about 10% of the surface area of ​​the contact lens closest to the point 192 where air enters the cavity. More specifically, in this embodiment, 15% of the surface area of ​​the contact lens is exposed.

[0064] The lens support of the present invention can take on numerous shapes and forms capable of lifting the lens from the packaging solution when a user applies force to the packaging (such as squeezing the packaging as described in the embodiments herein). However, as mentioned above, it is preferred that the lens support maintains the lens in a desired convex orientation (bowl downward relative to the base) and position (centered on the support) during transport and storage. Ideally, the lens support may provide an open structure below the lens to allow the packaging solution to drain from the lens and support upon opening without water accumulation between the support and the underside of the lens. It is also preferred that the lens support has a sufficient number of contact points with the lens to prevent the lens from collapsing onto the support, rotating away, or translating through the support. This allows the apex of the lens to be supported by the elastic stiffness of the lens itself, or minimizes the sinking of the lens apex while limiting the contact area between the support and the lens. Excessive contact between the support and the lens after the solution has drained and water accumulation between the support and the lens can create surface tension greater than that between the lens and the lens support and the surrounding water, thus interfering with the effective transfer of the lens. The total wetting contact area is the sum of the contact between the lens and the lens support when the packaging is opened, and the solution drained from the lens and the lens support. This area can be less than approximately 30 mm². 2 Less than 25mm 2 or less than 20mm 2 And at least distributed around the periphery of the lens, as described herein. As used herein, “wetting contact area” means the area of ​​direct solid contact between the lens support and the lens, plus any meniscus, reservoir, or solution bridge formed between the lenses after lifting the lens and allowing the packaged solution to drain in less than about 30 s, less than about 5 s, or less than about 2 s, depending on the intended user experience of the package.

[0065] For lenses made of polymers with long shape memory, the lens support can be designed to limit contact between the lens and the support during storage. This contact can be distributed around the peripheral edge of the lens. Contact between the lens optical zone, the lens support, and the inside of the cap (including any air intake guides) may be temporary, or there may be no contact between the optical zone and the support, cap, or air intake guide. Lenses such as conventional hydrogels with shorter shape memory are less prone to deformation due to packaging contact, and contact points can be distributed around the periphery and throughout the lens profile, including the central area of ​​the lens (approximately 9 mm or approximately 5 mm in diameter).

[0066] The lens support of the present invention preferably allows both the fingertip and the lens to deform to match each other's shape upon tapping, without causing the lens to invert or be damaged during removal due to excessive pressure during tapping. Therefore, one aspect of removing the lens from the packaging of the present invention is to control the ratio of the contact area between the finger and the lens to the area between the lens and the lens support, such that the contact area between the finger and the lens exceeds the contact surface area of ​​the lens support below the lens. This ensures that the surface tension between the finger and the lens exceeds the surface tension between the lens and the lens support. Thus, the lens will adhere to the finger, facilitating the transfer and placement of the lens onto the eye.

[0067] The lens support preferably provides at least 2, at least 3, 3 to 14, 4 to 14, 3 to 8, 4 to 8, 4 to 6, or 6 contact points along the peripheral support and the edge of the contact lens. When using two peripheral supports, they can be wider to provide stability without exceeding the contact area required for consistent lens transfer. The peripheral contact points prevent the lens from rotating off the lens and can be distributed in various configurations, where the space between the furthest adjacent contacts is smaller than the diameter of the lens. As the number of peripheral supports increases, the likelihood of residual packaging solution forming a film between adjacent peripheral supports and solution bridging between the support and the lens during drainage may increase. Peripheral supports with less than 50% open space, such as supports in the form of screens or filters, typically provide insufficient drainage and cannot ensure transfer in a single touch. Similarly, excessive contact between the support and the lens after solution drainage and water accumulation between the support and the lens can create surface tension greater than that between the wearer's fingers and the lens on the lens and the surrounding water, thus interfering with effective lens transfer. The width of the component of the lens support varies between the limitations of the selected molding process and the width required to effectively drain the packaging solution upon opening. Suitable widths include about 0.5 mm to about 1.5 mm, about 0.5 mm to about 1 mm, or about 0.5 mm to about 0.7 mm, and it should be understood that a lens support design with fewer contact points may have a thicker arm.

[0068] The lens support enables adequate drainage of the packaging solution from the lens, allowing for one-touch transfer via one or a combination of drainage techniques, referred to herein as channel drainage and back drainage. Channel drainage involves forming a channel member on the lens support, along which the packaging solution is guided away from the lens by gravity when the lens support is lifted. Back drainage, on the other hand, refers to drainage from the underside of the lens, where the lens rests on the lens support. Due to the hydrophilicity of modern contact lens materials, this area below the lens apex tends to accumulate packaging solution. In some embodiments, this can be achieved by designing a channel member with at least approximately 12 mm of packaging solution below the lens apex. 3The lens support with a central opening achieves enhanced back exhaust.

[0069] Then refer to Figure 7A and Figure 7B An exemplary lens support 140 is shown in side and top views, respectively. Lens support 140 represents an example of a lens support that utilizes a combination of back drain and channel drain to adequately remove packaging solution from the lens for single-touch transfer. Lens support 140 includes a central support consisting of three central support members 200a-c in a semi-circular configuration with a diameter of approximately 8 mm. The central support members 200a-c are raised 2.5 mm by pillars 204. Pillars 204 extend upward from channel members 204a and 204b, which transition along their length from proximal (A) to distal (B) to form a channel into a peripheral support 208. These members cooperate such that when the contact lens is lifted from the packaging, or when the lens is lifted from the packaging solution, it rests on the lens support 240 at seven contact points in a preferred convex orientation (relative to the bowl bottom of the packaging base).

[0070] The lens support 140 is designed to create a central opening 212 to allow the packaging solution to flow back from the lens and lens support 140 when the package is opened and the lens support is lifted from the packaging solution. This allows the apex of the lens to be supported by the lens's own elastic stiffness and minimizes the sinking of the lens apex while limiting the contact area between the support 140 and the lens. The design also provides sufficient support for the contact edges at points along the channel members 204a and 204b and along the peripheral support 208. When measured 2 seconds after the lens support 140 has been lifted, this configuration adequately reduces the wetting contact area between the lens support 140 and the contacting lens to at least approximately 25 mm. 2 .

[0071] Figure 8A and Figure 8BOne of numerous alternative embodiments of the lens support within the scope of the invention is shown in side and top views, respectively. Lens support 300 represents an example of a lens support that relies on back discharge to adequately remove packaging solution from the lens for one-touch transfer. Lens support 300 includes a central support 310 consisting of four equidistant radial spokes extending through a diameter of approximately 10.5 mm. The central support member 310 is elevated 2.7 mm by a strut 314. In some embodiments of the invention, the strut 314 extends upward from a support member 318, which includes a tab 324 through which the lens support 300 is coupled to a base of the contact lens package. Peripheral support members 328 and 330 are formed in a continuous butterfly configuration to provide support for the edges of the contact lens when the lens is lifted from the package and placed on the support. The central and peripheral support components of the support 300 cooperate with each other so that when the contact lens is lifted from the package, or when the lens is lifted from the package solution, it rests on the lens support 300 at five contact points in a preferred convex orientation (relative to the bottom of the bowl of the package base).

[0072] The lens support 300 is designed with sufficient open space between the spokes of the central support 310 to allow the packaging solution to flow back from the lens and lens support 140 when the package is opened and the lens support is lifted from the packaging solution. This allows the apex of the lens to be supported by the lens's own elastic stiffness and minimizes the sinking of the lens apex while limiting the contact area between the support 300 and the lens. The design also provides sufficient support for the edges of the contact lens at points along the peripheral support members 328 and 330. When measured 2 seconds after the lens support 300 has been lifted, this configuration adequately reduces the wetting contact area between the lens support 300 and the contact lens to at least approximately 25 mm. 2 It must be emphasized that the lens support embodiments shown and described herein are merely two of numerous embodiments of lens supports within the scope of the invention as set forth in the appended claims. It is certainly true that Appendix A describes some additional illustrative but non-limiting exemplary lens supports.

[0073] As described above, in one aspect, the contact lens package of the present invention can be configured to allow for nesting configurations. Figure 9Two contact lens packages 100 are shown, displayed as nested packages 100' and 100'". Nested configurations, such as those in which packages are securely assembled together within a smaller volume, are useful for reducing the amount of secondary packaging (e.g., cartons or other containers used to provide primary packaging to consumers). In this embodiment, packages 100' and 100' are designed to nest when arranged base to base and inverted relative to each other from proximal to distal. The nesting capability of contact lens packages 100' and 100'" is achieved by a combination of features including: a tapered shape in the bases 110' and 110'" of each package, and finger-engaging features (recesses) 122a' and 122a'" that act as stops to prevent lateral movement of the bases 110' and 110'".

[0074] Turn now Figure 10 An exemplary method for manufacturing / assembling a contact lens package according to an embodiment is shown. A first exemplary method for manufacturing / assembling an exemplary contact lens package 100 is shown as steps 1001A, 1002A, 1003A, 1004A, and 1005. In the first step 1001A, in this embodiment, a contact lens 138 is placed on a lens support 140, wherein the contact lens is placed on the lens support 140 with a concave surface on the lens support. The lens support may be pre-dispensed with a packaging solution sufficient to bond the contact lens to the support. In a slightly alternative method not shown, the lens support may first be embedded in a cavity, and then the contact lens may be placed on the support. In the next step 1002A, the lens support 140 on which the contact lens 130 rests is embedded into a cavity 136 of a base 110. Then, in step 1003, a cover insert 170 including a lens-facing surface 168 is placed on the convex surface of the contact lens 138. Next, at step 1003A, sufficient packaging solution is dispensed into the cavity to completely immerse the contact lens 138 within the cavity, ideally filling it as much as possible without overflowing. Preferably, at least one of the fittings and / or surface features of the cap insert abuts against the base cavity to create a frictional fit, such that the cap insert does not float out of position when the packaging solution is added to the cavity. Finally, at step 1005, the cap 106 is sealed to the base 110, for example by heat-sealing the foil to the base as described in more detail above, such that the seal will enclose the contact lens 138 and the packaging solution within the cavity 136 in a sterile environment.

[0075] Alternative exemplary methods for manufacturing / assembling the exemplary contact lens package 100 are shown as steps 1001B, 1002B, 1003B, 1004B, and 1005. In the first step 1001B, a package base 110 is provided, wherein a cavity 136 of the base 110 has a lens support 140 attached thereto. In this example, the lens support 140 is attached to the base by a thermal riveting process as described in more detail above. However, as noted, other attachment methods are possible within the scope of the claims, including, for example, laser welding, ultrasonic welding, adhesive bonding, mechanical clamping, etc. Next, in step 1002B, a contact lens 138 is placed onto the lens-facing surface of a cover insert 170, in this embodiment, the convex surface of the lens resting against the lens-facing surface 168 of the cover insert 170. The lens 138 can be placed onto the cover insert manually or automatically, such as via a lens transfer nozzle. Then, at step 1003B, the cap insert 170, on which the contact lens 138 rests, is placed onto the lens support 140 in the cavity 136 of the base 110. Next, at step 1004B, sufficient packaging solution is dispensed into the cavity 136 to completely immerse the contact lens 138 within the cavity 136, ideally filling it as completely as possible without overflowing. Finally, at step 1005, the cap 106 is sealed to the base 110, for example by heat-sealing the foil to the base as described in more detail above, such that the seal will enclose the contact lens 138 and the packaging solution within the cavity 136 in a sterile environment.

[0076] In some manufacturing / assembly methods of contact lens packaging within the scope of this invention, the supply of the packaging solution to the cavity may be performed in multiple doses at different steps of the assembly process, rather than all at once as described in the exemplary methods above. For example, in embodiments where the lens is placed on a lens support (e.g., step 1001A above), it may be advantageous to pre-dispense a small amount of packaging solution onto the lens support before placing the lens on it, such that the lens is held to the lens by the surface tension of the solution. Dispensing the packaging solution when filling the cavity may also be advantageous, such as, for example, by dispensing a dose of approximately 2080 μL into two substantially equal doses, for example, at steps (1001B and 1004B) above.

[0077] For purposes of explanation, the foregoing description uses specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to those skilled in the art that practicing the described embodiments does not require many specific details. Therefore, for purposes of illustration and description, the foregoing description of specific embodiments described herein is presented. They are not intended to be exhaustive or to limit the embodiments to the specific forms disclosed. It will be apparent to those skilled in the art that many modifications and variations are possible in light of the above teachings.

[0078] The summary and abstract section may set forth one or more embodiments of the invention as contemplated by the inventors, but not all exemplary embodiments, and is therefore not intended to limit the invention and the appended claims in any way.

[0079] The foregoing description of specific embodiments, without departing from the general concept of the invention, will fully reveal the general nature of the invention, namely that others can readily modify and / or adapt such particular embodiments for various applications without excessive experimentation by applying the knowledge of those skilled in the art. Therefore, based on the teachings and guidance presented herein, such modifications and adaptations are intended to fall within the meaning and scope of equivalents of the disclosed embodiments. It should be understood that the wording or terminology herein is for descriptive purposes and not for limitation, and that the terminology or terminology of this specification should be interpreted by those skilled in the art based on the teachings and guidance.

[0080] The packaging of this invention can be manufactured using known materials and processes. The packaging material can be natural, recyclable, or a combination thereof. The volume within the packaging cavity can vary depending on the selected design.

[0081] Not all features described herein need to be incorporated into every package, and those skilled in the art can combine these features using the teachings herein to provide various improved contact lens packages. In summary, the contact lens packages of the present invention include several novel functions that can be combined in various combinations as described herein to provide desired improvements and / or one-touch packaging. The breadth and scope of the invention should not be limited to any of the exemplary embodiments described above, but should be defined only by the following claims and their equivalents.

Claims

1. A contact lens packaging package, the contact lens packaging package comprising: build; Base, the base comprising: A cavity, the cavity containing a contact lens and a packaging solution; and A lever, configured to pivot along a pivot axis in the base when a force is applied to the lever; and A lens support, which intersects the pivot axis, such that the force applied to the lever causes the lens support to lift the contact lens from the packaging solution to a position on the lens support that can be moved by a single touch by the user; The lens support is fixedly attached to the lever, and the attachment point of the lens support to the lever and the pivot axis are separate from each other.

2. The contact lens package according to claim 1, wherein the lever is a discrete component connected to the base by an attachment device.

3. The contact lens package of claim 1, wherein the pivot axis is defined by at least one gap in the base.

4. The contact lens package of claim 1, wherein the pivot axis is applied to the base by one or more of the following: crease, cut, line, and etching.

5. The contact lens package according to claim 1, wherein the base is made of a relatively rigid material.

6. The contact lens package of claim 5, wherein the cover comprises a film and the base comprises a plastic material.

7. The contact lens packaging according to claim 1, wherein the base is a single integral component.

8. The contact lens package according to claim 1, wherein the lens support is a single integral component.

9. The contact lens package of claim 1, wherein the lens support is connected to the base by at least one of: i) laser welding; ii) heating; iii) ultrasonic welding; and iv) adhesive.

10. The contact lens package of claim 1, wherein the base includes at least one finger engagement feature configured to i) assist a user in holding the contact lens package or i) guide the applied force to pivot the lever downward.

11. The contact lens package of claim 10, wherein the at least one finger engagement feature includes a protrusion in the base located at the distal end of the contact lens package.

12. The contact lens package of claim 10, wherein the at least one finger engagement feature includes an overhang along at least a portion of the periphery of the contact lens package.

13. The contact lens package of claim 10, wherein the at least one finger engagement feature includes a recess sized to accommodate the user's finger or thumb, wherein the recess is positioned at the end of the base near the user.

14. The contact lens package of claim 10, wherein the at least one finger engagement feature comprises a proximal finger engagement feature located on the base near the user and a distal finger engagement feature located on the base away from the user.

15. The contact lens package of claim 1, wherein the cover includes a lens-facing surface that extends downward into the cavity above the contact lens when the contact lens package is in an unopened state.

16. The contact lens package of claim 15, wherein the lens-facing surface and the lens support are configured within the cavity such that, when the contact lens package is in an unopened state, the optical zone of the contact lens is suspended in the packaging solution between the lens-facing surface and the lens support.

17. The contact lens package of claim 1, wherein when the contact lens package is unopened or opened, the cavity accommodates the contact lens in a convex position.

18. The contact lens package of claim 1, wherein the lens support has a profile that does not match the profile of the contact lens.

19. The contact lens packaging according to claim 1, wherein when the contact lens packaging is in an open state, the wetting contact area between the lens support and the contact lens is less than 30 mm². 2 Less than 25mm 2 or less than 20mm 2 .

20. The contact lens package of claim 1, wherein the contact lens package includes at least one lens-facing surface in the cavity above the convex surface of the contact lens, wherein when the contact lens package is in an unopened state, the at least one lens-facing surface is configured to align the contact lens on the lens support; or to protect the contact lens from significant optical damage caused by gravity, mechanical forces or air-induced forces.

21. The contact lens package of claim 20, wherein at least one lens-facing surface is disposed on a cover insert, wherein the cover insert is attached to the inner surface of the cover.

22. The contact lens package of claim 21, wherein the cover insert includes at least one alignment feature.

23. The contact lens package of claim 21, wherein the cover insert includes at least one locking feature.

24. A contact lens package containing a contact lens and a packaging solution, wherein the contact lens package is configured to lift the contact lens from the packaging solution when the contact lens package is squeezed by a user; The contact lens package includes a lever configured to pivot along a pivot axis in the base of the contact lens package when a force is applied to the lever. and a lens support, the lens support being configured such that the force applied to the lever causes the lens support to lift the contact lens from the packaging solution; as well as The lens support is fixedly attached to the lever, and the attachment point of the lens support to the lever and the pivot axis are separate from each other.

25. The contact lens package of claim 24, wherein the contact lens package is configured such that the force applied to the lever causes the lens support to lift the contact lens from the packaging solution to a position on the lens support that can be transferred by a single touch by the user.

26. The contact lens package of claim 24, wherein the lever is a discrete component connected to the base by an attachment device.

27. The contact lens package of claim 24, wherein the pivot axis is defined by at least one gap in the base.

28. The contact lens package of claim 24, wherein the pivot axis is applied to the base by one or more of the following: creases, cuts, lines, and etchings.

29. The contact lens package of claim 24, wherein the base is made of a relatively rigid material.

30. The contact lens package of claim 24, wherein the base is a single integral component.

31. The contact lens package of claim 24, wherein the lens support is a single integral component.

32. The contact lens package of claim 24, wherein the lens support is connected to the base by at least one of: i) laser welding; ii) heating; iii) ultrasonic welding; and iv) adhesive.

33. The contact lens package of claim 24, wherein the base includes at least one finger engagement feature configured to i) assist a user in holding the contact lens package or i) guide the applied force to pivot the lever downward.

34. The contact lens package of claim 33, wherein the at least one finger engagement feature includes a protrusion in the base located at the distal end of the contact lens package.

35. The contact lens package of claim 33, wherein the at least one finger engagement feature includes an overhang along at least a portion of the periphery of the contact lens package.

36. The contact lens package of claim 33, wherein the at least one finger engagement feature includes a recess sized to accommodate the user's finger or thumb, wherein the recess is positioned at the end of the base near the user.

37. The contact lens package of claim 33, wherein the at least one finger engagement feature comprises a proximal finger engagement feature located on the base near the user and a distal finger engagement feature located on the base away from the user.

38. The contact lens package of claim 24, wherein the cover of the contact lens package includes a lens-facing surface, and when the contact lens package is in an unopened state, the lens-facing surface extends downward into a cavity of the base above the contact lens.

39. The contact lens package of claim 38, wherein the lens-facing surface and the lens support are configured within the cavity such that, when the contact lens package is in an unopened state, the optical zone of the contact lens is suspended in the packaging solution between the lens-facing surface and the lens support.

40. The contact lens package of claim 24, wherein when the contact lens package is unopened or opened, the contact lens package accommodates the contact lens in a convex position.

41. The contact lens package of claim 24, wherein the lens support has a profile that does not match the profile of the contact lens.

42. The contact lens packaging according to claim 24, wherein when the contact lens packaging is in an open state, the wetting contact area between the lens support and the contact lens is less than 30 mm². 2 Less than 25mm 2 or less than 20mm 2 .

43. The contact lens package of claim 24, wherein the contact lens package includes at least one lens-facing surface in a cavity of the base above the convex surface of the contact lens, wherein when the contact lens package is in an unopened state, the at least one lens-facing surface is configured to align the contact lens on the lens support; or to protect the contact lens from significant optical damage caused by gravity, mechanical forces or air-induced forces.

44. The contact lens package of claim 24, wherein the contact lens package includes a cap insert, wherein the cap insert is attached to the inner surface of the cap of the contact lens package.

45. The contact lens package of claim 44, wherein the cover insert includes at least one alignment feature.

46. ​​The contact lens package of claim 44, wherein the cover insert includes at least one locking feature.

47. A method of operating a package comprising a contact lens in a packaging solution, the method comprising: Open the lid of the package; Squeezing the package causes the lens support to lift the contact lens from the package solution; as well as Transfer the contact lens from the lens support to the user's eye; The package includes a base with a lever configured to pivot along a pivot axis in the base when a force is applied to the lever; and The lens support is fixedly attached to the lever, and the attachment point of the lens support to the lever and the pivot axis are separate from each other.

48. The method of claim 47, wherein the squeezing comprises the user’s hand applying force at opposite ends of the package.

49. The method of claim 48, wherein the opposite ends of the package are the distal and proximal ends of the package relative to the user.

50. The method of claim 48, wherein the opposite ends of the package are the left and right sides of the package relative to the user.

51. The method of claim 47, wherein the cover comprises foil, and the opening comprises peeling the foil from at least a portion of the package.

52. The method of claim 47, wherein the lens support causes the contact lens to lift at an angle between 15° and 60° relative to the horizontal plane defined by the top of the package.

53. The method of claim 47, wherein the method further comprises transferring the contact lens from the lens support to the user's hand, wherein transferring the contact lens comprises tapping a convex surface of the contact lens such that the tapping causes the contact lens to be released from the lens support and adhere to the user's finger.

54. A method of manufacturing a package comprising a contact lens in a packaging solution, the method comprising: Place the contact lens onto the lens support; The lens support is embedded in a cavity of the base of the package, wherein the base includes a lever configured to pivot along a pivot axis in the base when a force is applied to the lever, and wherein the lens support is fixedly attached to the lever, and the attachment point of the lens support to the lever and the pivot axis are separate from each other; An insert, including a surface facing the lens, is placed onto the contact lens; Dispensing the packaging solution into the cavity; and The cap is sealed to the base, wherein the seal surrounds the contact lens and the packaging solution within the cavity in a sterile environment.

55. The method of claim 54, wherein placing the contact lens on the lens support occurs after the step of embedding the lens support into the cavity of the base.

56. The method of claim 54, wherein placing the contact lens onto the lens support comprises placing the concave surface of the contact lens onto the lens support.

57. The method of claim 54, wherein the method further comprises the step of dispensing a packaging solution to the lens support prior to placing the contact lens onto the lens support.

58. A method of manufacturing a package comprising a contact lens in a packaging solution, the method comprising: A base for the package is provided, the base including a lever and a cavity having a lens support coupled to the base, wherein the lever is configured to pivot along a pivot axis in the base when a force is applied to the lever, and wherein the lens support is fixedly attached to the lever, and the attachment point of the lens support to the lever and the pivot axis are separate from each other; Place the contact lens onto the lens-facing surface of the cover insert; The lens-facing surface on which the contact lens rests is embedded into the lens support in the cavity of the base; Dispensing the packaging solution into the cavity; and The cap is sealed to the base, wherein the seal surrounds the contact lens and the packaging solution within the cavity in a sterile environment.

59. The method of claim 58, wherein placing the contact lens onto the lens-facing surface of the cover insert comprises placing the convex surface of the contact lens onto the lens-facing surface.

60. The method of claim 58, wherein the method further comprises aligning the cover insert within the cavity of the base, wherein the alignment comprises translating the cover insert over an alignment feature in the cavity of the base.

61. The method of claim 58, wherein the method further comprises locking the cover insert within the cavity of the base, wherein the locking comprises applying pressure to the cover insert sufficient to cause a protrusion on one side of the cover insert to be frictionally secured to the sidewall of the cavity.

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