Contact lens package and usage and manufacturing method

Abstract

To provide a contact lens package.SOLUTION: The invention is about an improved contact lens package and its usage manufacturing and assembling methods. The contact lens package is configured as such that it contains contact lens and packaging solution, when a force is applied to the lever of the package and / or when the package is squeezed by the user, the contact lens is lifted out of the packaging solution.SELECTED DRAWING: Figure 1A

Description

[Technical Field]

[0001] (Cross-reference of related applications) This patent application claims the benefits of U.S. Provisional Patent Application No. 63 / 077,779, filed September 14, 2020; U.S. Provisional Patent Application No. 63 / 077,784, filed September 14, 2020; U.S. Provisional Patent Application No. 63 / 124,835, filed December 13, 2020; and U.S. Provisional Patent Application No. 63 / 243,525, filed September 13, 2021. [Background technology]

[0002] In conventional contact lens packaging, the contact lens typically rests on a molded plastic base with a cavity (or "bowl") that houses the contact lens with its concave side facing upwards. As a result, the user experience of transferring the contact lens from the package to the eye generally involves the user "lifting" the contact lens from the bowl with their fingers, then inverting the lens so that it is properly 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 hand to the lens and ultimately to the eye. This handling experience is not only unsanitary but also excessively cumbersome and cumbersome, and places mechanical stress on the lens, which can tear, break, or deform if handled excessively. Some packages are designed to present the lens with its convex side facing upwards to eliminate the need to invert the lens, but often still require "lifting" the lens from the packaging solution or other methods of handling the lens and / or multiple touches to achieve transfer to the eye.

[0003] Given the growing awareness of eye health and customer demand for a more convenient experience, there is a need for contact lens packaging that enables a less cumbersome and more hygienic contact lens handling process. In one respect, it would be ideal to provide contact lens wearers with "one-touch" packaging, that is, packaging that allows contact lens wearers to remove the lens from the lens storage package with a single touch of one of their fingers, and then position the lens correctly in the eye with that same single touch. In such a design, there is no need to transfer and manipulate the lens from one finger to another before placing it on the eye. Providing such one-touch packaging not only streamlines the lens preparation and insertion process, but also reduces the possibility of dropping the lens or exposing it to additional bacteria on the wearer's other fingers when the lens is being prepared for orientation and insertion onto the eye, and also reduces the possibility of touching the sides of the lens that are intended to come into contact with the eye.

[0004] The design of one-touch lens packaging faces several different challenges. Ideally, the wearer should be able to consistently position and adhere the lens to their finger while removing it from the package, and then consistently release the lens from their finger onto their eye. Each contact lens (both reusable and daily disposable types) has its own unique surface, bulk, and geometric properties. Finger size and the force that contact lens wearers apply to the lens during transport can also vary. These factors can affect the process of taking the lens from the package onto the finger and then placing it on the surface of the eye. Among other considerations, it would be desirable for the wearer to be able to expel any package solution that may affect the ability to adhere the lens to their finger, as variations in the amount of package solution adhering to the lens and package can affect the process of positioning the lens on the finger. It would also be desirable to expel the package solution in a controlled manner to avoid leakage. It would also be beneficial for the package solution to remain sterile after opening and be accessible to the wearer in order to allow for re-wetting or cleaning of the lens. Furthermore, wearers may have concerns about the possibility of transferring bacteria or external products such as cosmetics to their contact lenses, and naturally, the manufacturing of the packaging itself should conform to the expected industry standards recognized by organizations of medical and commercial providers.

[0005] Furthermore, one-touch packaging should ideally not result in an exorbitant increase in the cost of goods compared to current contact lens packaging, as this could lead to increased costs for the wearer population. The packaging should not make it difficult to hold the lens when it is removed from the package. In addition, if the packaging design is such that it maintains or even reduces the volume of solution required to wrap the lens, this would reduce the ecological impact of the lens packaging. Similarly, it would be beneficial if all or part of the packaging could be made from recycled materials and / or be made entirely or partially recyclable.

[0006] In addition, it would be advantageous if the package were made of materials that have already been approved by various regulatory bodies and, ideally, do not require any changes to the chemical properties of the solution or the lens composition. Optimally, and moreover, the function of the package is preferably to avoid incorporating any electronic or other electrical components, where such components could adversely affect the performance of either the package or the lens.

[0007] There are several desirable attributes that make achieving the functionality of a one-touch package difficult, and which are often lacking in known attempts to create one-touch packages. These attributes include, for example, the following: i) the package should ideally protect the lens, that is, ensure the integrity of the lens (e.g., lens shape and optical integrity) while preventing the lens from shattering or being damaged; ii) the lens package should maintain the hydration of the lens when stored in order to preserve the properties of the lens; and iii) the lens in the package should preferably be completely immersed in the package solution if desired, and configured to remove such solution when ready to be transferred from the package; iv) the package should generally have a retortable seal to contain both the lens and the solution; v) the package should preferably maintain the lens in the desired convex orientation relative to the wearer; vi) the lens should be positioned so that it can be easily removed by the wearer; and vii) the package should ideally allow the package solution to be effectively drained from the lens when the package is opened and before the lens is removed, making it easier to transfer to the wearer's fingers and then onto the eye.

[0008] Known packages that have attempted to provide reduced touch or one-touch orientation fail to provide one or more of the desired attributes of a one-touch package. For example, International Publication No. 2014 / 195588, International Publication No. 2009 / 069265, and Japanese Patent No. 6339322 disclose packages that present a lens in a configuration with a convex bowl facing downwards. However, the lens support structure substantially matches the shape of the contact lens, thereby providing an undesirable contact area between the lens and the lens support. These references also do not mention a mechanism for effective solution drainage from the lens and lens support.

[0009] Similarly, U.S. Patent Application Publication No. 20200229560 discloses a lens support for supporting the concave (front or anterior) surface of a contact lens, or a package having a grid for supporting the peripheral portion of a contact lens and allowing the package solution to be discharged through the grid into a bottom chamber when the lens package is opened. The aforementioned defects of the prior art are merely illustrative and not exhaustive. [Overview of the project] [Problems that the invention aims to solve]

[0010] Therefore, there is still a need for contact lens packaging that provides a consistent one-touch lens removal experience, effective solution management, or addresses one or a combination of the aforementioned challenges or deficiencies. [Means for solving the problem]

[0011] It has now been found that some or all of the aforementioned and related objectives can be achieved in contact lens packages having one or more embodiments described herein. For example, a contact lens package of the present invention can contain a contact lens and a package solution, and the package is configured to lift the contact lens from the package solution when the package is squeezed by a user. The contact lens package may have a lid and a base including a base, which is a cavity for containing the contact lens and the package solution, and a lever configured to hinge along a pivot line of the base when force is applied to the lever. The package may further include a lens support that intersects the pivot line such that the force applied to the lever causes the lens support to lift the contact lens from the package solution to a position on the lens support that allows for one-touch transfer by the user. In some cases, the lever is a separate component coupled to the base by mounting means. The pivot line may be defined by at least one void in the base and may be given to the base by one or more of the following: folds, cuts, fine lines, and etchings. The base of the package may be made of plastic, and the lid may be made of film. In some cases, the base and lens support, and / or the lever and lens support, are a single, integrated component.

[0012] The lens support can be bonded 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 the user in grasping the package or to direct the application of force so that the lever hinges downward. Possible engagement features include a projection of the base at the distal end of the package and / or an overhang along at least a portion of the perimeter of the package. A dimple sized to accommodate the user's finger or thumb may be located at the proximal end of the base relative to the user. Finger engagement features may be paired such that one is located at the proximal end of the base relative to the user and the other is a distal finger engagement feature located at the distal end of the base relative to the user. Alternatively, finger engagement features may be located on any other opposite side or end of the package.

[0013] The package lid may include one or more lens-facing surfaces that extend downward into the cavity above the contact lens when the package is unopened. The lens-facing surfaces and lens support may be configured within the cavity such that, when the package is unopened, the optical zone of the contact lens floats in the package solution between the lens-facing surfaces and the lens support. The package cavity can accommodate the contact lens in a convex position when the package is unopened or opened. The lens support may also have a profile that does not substantially match the profile of the contact lens. When the package is open, the wet contact area between the lens support and the contact lens is approximately 30 mm². 2 Less than approximately 25mm 2 Less than or approximately 20 mm 2 It may be less than [amount missing]. The package may include a lid insert having at least one alignment feature and / or one or more lockout features. [Brief explanation of the drawing]

[0014] The foregoing and other features and advantages of the present invention will become apparent from the following more specific description of the preferred embodiments of the present invention, as illustrated in the accompanying drawings. [Figure 1A] Shows the step of opening a contact lens package according to an exemplary embodiment of the present invention. [Figure 1B] Shows the step of opening a contact lens package according to an exemplary embodiment of the present invention. [Figure 1C] Shows the step of opening a contact lens package according to an exemplary embodiment of the present invention. [Figure 1D] Shows the step of opening a contact lens package according to an exemplary embodiment of the present invention. [Figure 2] Shows a perspective view of an opened contact lens package according to an embodiment. [Figure 3] Shows an exploded perspective view of a contact lens package according to an embodiment. [Figure 4] Shows an enlarged view of a lid insert within a cavity of an embodiment. [Figure 5A] Shows a cross-sectional view of an unopened contact lens package according to an embodiment. [Figure 5B] Shows a cross-sectional view of an unopened contact lens package according to an embodiment. [Figure 6] Shows an air inlet guide of a contact lens package according to an embodiment. [Figure 7A] Shows a lens support of an embodiment in a side view and a top view respectively. [Figure 7B] Shows a lens support of an embodiment in a side view and a top view respectively. [Figure 8A] Shows a lens support of an alternative embodiment in a side view and a top view respectively. [Figure 8B] Shows a lens support of an alternative embodiment in a side view and a top view respectively. [Figure 9]This shows a contact lens package of one embodiment, which is arranged in a nested configuration. [Figure 10] An exemplary method for manufacturing a contact lens package according to a specific embodiment is shown. [Figure 11] An exemplary lens support is shown. [Figure 12] An exemplary lens support is shown. [Figure 13] An exemplary lens support is shown. [Figure 14] An exemplary lens support is shown. [Figure 15] An exemplary lens support is shown. [Figure 16] An exemplary lens support is shown. [Figure 17] An exemplary lens support is shown. [Figure 18] An exemplary lens support is shown. [Figure 19] An exemplary lens support is shown. [Figure 20] An exemplary lens support is shown. [Figure 21] An exemplary lens support is shown. [Figure 22] An exemplary lens support is shown. [Figure 23] An exemplary lens support is shown. [Figure 24] An exemplary lens support is shown. [Figure 25] An exemplary lens support is shown. [Modes for carrying out the invention]

[0015] Herein, we refer in detail to representative embodiments shown in the accompanying drawings, where reference numerals indicate specific elements. The following description is not intended to limit the numerous embodiments to one preferred embodiment. Rather, it is intended to cover alternatives, modifications, and equivalents that may fall within the spirit and scope of the embodiments described, as defined by the accompanying claims.

[0016] References such as "one embodiment," "an embodiment," "some embodiments," and "an example embodiment" indicate that the described embodiments may include certain features, structures, manners, or characteristics, but not all embodiments may necessarily include those features, structures, or characteristics. Furthermore, such phrases do not necessarily refer to the same embodiment. Moreover, if certain features, structures, manners, or characteristics are described in relation to one embodiment, it is assumed that implementing such features, structures, or characteristics in relation to other embodiments is within the scope of knowledge of those skilled in the art, whether explicitly described or not.

[0017] As used herein, the following terms have the following meanings. The advantage of certain embodiments of the present invention is that they facilitate consistent one-touch lens transfer from the package to the wearer's finger, and then from the finger to the wearer's eye, without inverting the lens, dropping it from the finger, or any further handling. Consistent lens transfer includes a transfer rate of at least about 70%, at least about 80%, or at least about 90% of the initial touch of the finger (or "dab"). The lens also preferably "rises" on the finger without folding or inverting, and then transfers to the eye when placed in the eye. The package of a particular embodiment can provide the desired one-touch transfer over a range of finger sizes and dob pressures. Environmental conditions such as temperature and whether the finger is wet or dry may also affect the transfer rate, with higher temperatures generally improving lens transfer.

[0018] Lenses (one or more) or contact lenses (one or more) refer to ophthalmic devices that are placed on the eye. They generally have a hemispherical shape and can provide optical correction, cosmetic enhancement, UV shielding and reduction of visible light or glare, wound healing, therapeutic effects including delivery of drugs or nutritional supplements, diagnostic evaluation or monitoring, or any combination thereof. The term lenses generally include soft hydrogel contact lenses, which are provided to consumers in a hydrated state package and have a relatively low modulus of elasticity that allows them to conform to the cornea. Contact lenses suitable for use with the package of the present invention include all hydrated contact lenses, including conventional hydrogel contact lenses and silicone hydrogel contact lenses.

[0019] Hydrogels are hydrated crosslinked polymer systems that contain water in equilibrium and can contain at least about 25%, or at least 35%, of water in their hydrated state. Hydrogels are typically oxygen-permeable and biocompatible, making them excellent materials for the manufacture of contact lenses.

[0020] Conventional hydrogel contact lenses do not contain silicone components and generally have higher water content, lower oxygen permeability, elastic modulus, and shape memory than silicone hydrogels. Conventional hydrogels are prepared from monomer mixtures mainly 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 conventional hydrogel formations. Conventional hydrogels can be ionic or nonionic and include polymacon, etafilcon, nelfilcon, ocufilcon, and lenefilcon. The oxygen permeability of these conventional hydrogel materials is typically less than 20-30 bars.

[0021] Examples of silicone hydrogel formulations include balafilcon, samfilcon, lotrafilcon A and B, delfilcon, galyfilcon, senofilcon A, B and C, narafilcon, comfilcon, formofilcon, riofilcon, fanfilcon, stenfilcon, somofilcon, and kalifilcon. "Silicone hydrogel" refers to a polymer network made from at least one hydrophilic component and at least one silicone-containing component. Silicone hydrogels can have an elastic modulus in the range of 60-200, 60-150, or 80-130 psi, and a water content in the range of 20-60%. Examples of silicone hydrogels include acquafilcon, asmofilcon, balafilcon, comfilcon, delefilcon, enfilcon, fanfilcon, formofilcon, galyfilcon, lotrafilcon, narafilcon, riofilcon, and safilcon. In addition to mfilcon, senofilcon, somofilcon, and stenfilcon, verofilcon (including all variations thereof), 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,No. 965,631, No. 6,367,929, No. 6,822,016, No. 6,867,245, No. 6,943,203, No. 7, No. 247,692, No. 7,249,848, No. 7,553,880, No. 7,666,921, No. 7,786,185, No. 7, No. 956,131, No. 8,022,158, No. 8,273,802, No. 8,399,538, No. 8,470,906, No. 8, No. 450,387, No. 8,487,058, No. 8,507,577, No. 8,637,621, No. 8,703,891, No. 8, Examples include silicone hydrogels prepared in Patent Nos. 937,110, 8,937,111, 8,940,812, 9,056,878, 9,057,821, 9,125,808, 9,140,825, 9,156,934, 9,170,349, 9,244,196, 9,244,197, 9,260,544, 9,297,928, 9,297,929, as well as International Publication Nos. 03 / 22321, 2008 / 061992, and U.S. Patent Application Publication No. 2010 / 0048847. These patents are incorporated herein by reference in their entirety. Silicone hydrogels can have higher shape memory than conventional contact lenses.

[0022] Hydrogel lenses are viscoelastic materials. Contact lenses can form optical distortion when the lens interacts with the packaging or any air bubbles within the packaging. The degree of optical distortion and the length of time required for the distortion to relax varies depending on the chemical properties and, to a lesser extent, depending on the geometric shape of the lens. Conventional lens materials, such as polyhydroxyethyl methacrylate lenses like Etafilcon A or Polymacon, have lower loss modulus and tandelta compared to silicone hydrogels, and can form less and less significant optical distortion as a result of contact with the packaging. The incorporation of silicone (generally increasing bulk elastic response), wetting agents such as PVP (generally increasing viscous response), or coatings of conventional hydrogel materials (which may decrease the elastic response at the lens interface) can alter the viscoelastic properties of the lens. Conventional hydrogel contact lenses and silicone hydrogel contact lenses with short or rigid crosslinking agents and / or curing agents may have short shape memory and be less susceptible to deformation during storage. When used herein, hydrogels with high or higher shape memory exhibit an optical strain of at least about 0.18 after accelerated aging at 55°C for 5 weeks from contact with air bubbles or packaging. Viscoelastic properties, including loss modulus and tan delta, can be measured using dynamic mechanical analysis.

[0023] The contact lens may have any geometric shape or power, but is generally hemispherical in shape and has a concave posterior surface that remains stationary against the eye during use, and a convex anterior surface that faces away from the eye and comes into contact with the eyelid during blinking.

[0024] The center or apex of the lens is the center of the lens's optical zone. The optical zone provides optical correction and can have a diameter of approximately 7 mm to 10 mm. The periphery or edge of the lens is the edge where the front and rear surfaces meet.

[0025] The wet lens is the contact lens and any residual package solution adhering to it after the package solution has been discharged. The wet contact is the total contact area between the wet lens and the lens support.

[0026] Embodiments may include a lens support surrounded by a sealable cavity, also interchangeably called a chamber. The cavity may have any convenient form and may include a package base and at least a lid, each of which is described in detail below. As used herein, the terms “the lid,” “a lid,” “the base,” and “a base” encompass both singular and plural forms. The lid and package base seal each other to form a cavity that keeps the contact lens, support, and package solution sterile during transport and storage before use. The contact lens package is made from a material that is compatible with the contact lens and solution, and is also retortable and biologically inert.

[0027] A “film” or “multilayer film” is a film used to seal a package and is often called lid stock. Multilayer films used in conventional contact lens packaging can be used in the package of the present invention as a base, a lid component, or both. A multilayer film comprises multiple layers, including a barrier layer or coating containing a foil layer, a sealing layer that seals the film to the rest of the package, and may also include additional layers selected from peel-initiating layers, lamination layers, and layers that improve other package properties such as rigidity, heat resistance, printability, puncture resistance, and barrier resistance to water or oxygen. The multilayer film forms a steam-sterilizable (retortable) seal. The multilayer film may include PET, BON, or OPP film layers to increase rigidity and heat resistance, or EVOH or PVDC coatings to improve barrier resistance to oxygen or water vapor.

[0028] As used herein, “unopened” or “unopened” refers to a contact lens package that is sealed and contains the contact lenses in a solution.

[0029] As used herein, “opened state” or “opened” refers to a contact lens package after the sterile seal has been broken. Depending on the context described herein, “opened state” is extended to the state of the package when a user manipulates the package to allow the lens to be lifted from the package solution for transfer by the user.

[0030] As used herein, “wearer” or “user” refers to the person who opens the contact lens package. Generally, a user is considered to be the person who opens the package and transfers the contact lenses contained within to their eye. However, in some contexts, a user may be an eye care provider (“ECP”) or another individual demonstrating or assisting the wearer, who handles the lens package on behalf of the wearer.

[0031] The packaging solution is any physiologically compatible solution that is compatible with the selected lens material and packaging. The packaging solution includes a buffer solution having a physiological pH, such as buffered saline solution. The packaging solution may contain known components, including buffers, pH and elasticity modifiers, lubricants, wetting agents, nutritional supplements, pharmaceuticals, and packaging coating components.

[0032] The package base can form the bottom of the package. It can be made from any material suitable for packaging medical devices, including plastic. The package lid is generally located on the top of the package and seals the base, forming a cavity that contains the lens support, lens, and at least a portion of the package solution. The lid can be made from any material suitable for packaging medical devices, including foil or molded sheets of plastic, laminated films, or plastic. Packages comprising plastic for one structure and foil or laminated film as the other, or packages comprising foil or laminated film as the outer layer of the lid and base, are known in the art and are examples of suitable combinations.

[0033] Throughout this description, references to injection molding processes and the use of materials conventionally applied to injection molding should be understood as illustrative. Those skilled in the art will understand that other manufacturing means, including but not limited to alternative molding processes, thermoforming, and 3D printing, are possible within the scope of the appended claims. Similarly, references to heat sealing and heat sealing are illustrative to the embodiments described herein. Other means of securing package components, including the use of adhesives, glues, thermal bonding, welding such as heat, ultrasonic, or laser welding, or mechanical traps, will be apparent to those skilled in the art.

[0034] Certain aspects of the present invention can help reduce or prevent significant optical damage to contact lenses caused by air bubbles or interactions with the inside of the lens package, which may occur during storage or transport due to gravity or other forces, such as mechanical pressure applied from outside the package. As used herein, significant optical damage means a root-mean-squared (RMS) value of about 0.08 μm or larger.

[0035] Referring to the figures, Figures 1A to 1D illustrate the steps of handling a contact lens package containing contact lenses in a package solution according to an exemplary embodiment of the present invention. An unopened contact lens package 100 having a lid 106 and a base 110 is shown in Figure 1A. In this embodiment, the lid 106 is a multilayer film, also referred to herein as foil, and the base 110 is made of a thermoplastic polymer such as polypropylene plastic. In this embodiment, the lid 106 takes the form of a relatively flexible material (i.e., a multilayer film) and the base 110 takes the form of a relatively rigid material, but it should be understood that other embodiments may include substantially rigid components for both the lid and the base. For example, in some embodiments, both the base and the lid may be made of polypropylene plastic or other relatively rigid material. The base 110 includes a pivot line 114, which allows a portion of the base forming the lever 118 to hinge when a force is applied to the lever 118.

[0036] The base 110 further includes several optional finger engagement features 122a-122c to assist the user in handling the contact lens package during the opening process. The finger dimples 122a may be sized to accommodate the user's finger or thumb and are located at the proximal end of the base 110 relative to the user. An overhang 122b along the periphery of the base 110 and a projection 122c are located at the distal end of the package 118 relative to the user. In this embodiment, the finger dimples 122a are also angled downward so that a force, for example, pressure applied by the user's thumb, causes the lever 118 to hinge downward on the pivot line 114. In this embodiment, the package 100 is further configured with a profile that slopes from proximal to distal to further enhance the downward moment at the lever, for example, when the lever is pressed down by the user or the package is being compressed, that is, when the user applies pressure by hand at each opposite end of the package, that is, with a finger at one end and a thumb at the other. In this embodiment, the package 100 is configured so that the compressive force is applied to the distal and proximal ends. However, alternative embodiments are possible in which the opposing force associated with the compression is applied to each opposite end of the package, such as, but not limited to, the sides, left, and right of the package.

[0037] In the first step shown in Figure 1B, the user holds an unopened contact lens package 100 by its base 110. As illustrated, the user's grip on the package 100 can be improved by one or more finger engagement features 122a-c positioned and configured to provide a more stable grip on the package and / or to assist in the application of force to lift the package in a later step to present the contact lenses contained in the package to the user and transfer them to the user's eye. The finger dimples 106 are positioned on a lever 118 on the base 110 and are sized for the user's thumb 126 to grip the package. At each opposite end of the package 100, the user can grip the package as illustrated by positioning their fingers firmly under the overhang 122b and against a projection 122c at the end of the base 110. In the case of an overhang, the overhang area may be curved or flat to provide an increased area on which opposing forces can be supplied when the package is being compressed. Next, the user can open the package by peeling off the lid 106, which in this embodiment involves the user peeling off the foil 106 from the proximal end to the distal end of the base 110 in the direction indicated by the arrow 134, thus breaking the sterile seal between the foil (lid) 106 and the base 110. Although not essential, in this preferred embodiment the package is optimized so that the user grasps the base with one hand and peels off the lid 106 with the other hand to open it.

[0038] As shown in the steps in Figure 1C, the package lid 106 is opened either by completely removing the lid as shown in the figure, or alternatively by partial removal sufficient to substantially expose the lens cavity 136 containing the contact lens 138 suspended in the package solution (not shown) on the lens support 140. With the package 100 opened, the user then applies a force 142 to the lever 118. In this embodiment, the package is compressed by the user, thereby supplying forces 142 and 146 from the user's hand or both hands to the proximal and distal ends of the package, respectively, thereby generating a greater force on the lever 118.

[0039] Referring to Figure 1D, the force applied by the user to the lever causes the lens support 140 to lift the contact lens 138 from the package solution (not shown). Ideally, the lens support is configured to lift the contact lens high enough over the package cavity facing the user, so that it is visible and transferable from the support, but not so high that the lens slides off the support under gravity. This can be achieved by a lifting angle of about 15° to 60° with respect to a horizontal plane defining the top of the base when force is applied by the user. The lens support is preferably configured, as in the illustrated exemplary embodiment, to allow sufficient drainage of the package solution from the contact lens when thus lifted, enabling one-touch transfer by the user, and the user transfers the contact lens 138 from the lens support 140 by tapping (also interchangeably referred to as "dubbing") the convex surface of the contact lens 138, thereby releasing the contact lens from the lens support 138 and allowing it to adhere to the user's finger 154.

[0040] In this embodiment, the contact lens 138 is conveniently presented to the wearer in a convex orientation, meaning that the convex side of the lens is accessible to the wearer without the need to change the orientation of the lens before placing the concave side of the lens 138 on the surface of the wearer's eye. However, it will be understood that other orientations, such as the concave orientation of conventional blister packaging, are possible within the scope of the present invention. Transfer of the contact lens 138 from the lens support 140 can be performed either by the wearer's finger 154 directly touching the lens or indirectly touching it through an applicator film or other cover applied to the finger (such as as described in U.S. Patent Application Publication No. 20190046353), or by another transfer means such as a manual or automated applicator device or tool. When transferring the contact lens 138 from the package 100, the lens is placed on the finger 154 (or other transfer means) with the convex side of the contact lens 138 in contact with the finger 154 and the concave side of the lens 138 oriented for direct application to the surface of the user's eye, as shown in the illustrated steps.

[0041] Referring now to Figures 2 and 3, Figure 2 shows a perspective view of the open contact lens package 100 with the lens support 140 lifting the contact lens 138 from the package solution (not shown). Figure 3 shows an exploded perspective view of the contact lens package 100. 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 housing the contact lens 138 in the package solution and a lever 118 configured to hinge along a pivot line 114 of the base when force is applied to the lever 118. In this embodiment, the lever 118 is formed as part of an integral component that makes up the base 118. More specifically, the base 110 including the lever 118 is formed as an integral injection-molded polypropylene plastic part. Alternative materials and processes for forming the base, including thermoforming and 3D printing (using materials such as ABS, PLA, HIPS, PETG, nylon, or others), will be understood by those skilled in the art. Preferably, the material used for the base is relatively rigid and has a glass transition temperature (T) of about 125°C when measured according to ASTM D1238-10 (Standard Test Method for Melt Flow Rate of Thermoplastics by Extrusion Plastometer). g) has. In this embodiment, the pivot line 114 is defined by a plurality of gaps 158 in the base. The gaps 158 are positioned in a linear configuration along the horizontal axis at the point where the lever 118 hinges. The absence of material that creates the gaps 158 provides sufficient relief along the line in the base material to allow the lever 118 to hinge at the desired position when force is applied to the lever by the user. The distance of the lifting arm, i.e., the distance from the pivot line to the center of the contact lens when placed on the support, is about 10 to 12 mm, preferably 12 to 17 mm. The use of one or more gaps is just one of countless ways in which a pivot line can be defined within the scope of the present invention. For example, in other embodiments in which the lever is formed of the same material as the rest of the base, the pivot line can be created by molding the material to be thinner along the pivot line by folding the plastic laterally at the desired position, and / or by imparting the pivot line to the base material by cutting, etching, or other means. Furthermore, in embodiments where the lever takes the form of a separate component, the pivot line can simply represent the horizontal interface between the lever and the rest of the base. In such embodiments, hinge action along the pivot line can be provided by a hinge component, a rotatable interlock attachment, and the like. It should be understood that alternative embodiments in which the lever is a separate component coupled to the rest of the base by mounting means are possible within the scope of the invention. For example, the lever can be formed as a separate injection-molded part and then attached to a separately molded (or printed, etc.) part forming the rest of the base via a number of mounting means, including laser welding, ultrasonic welding, adhesive, mechanical attachment, heat riveting, and the like.

[0042] The lower side of the base is tilted, as shown in the illustrated embodiment, to allow the package to be "nested," thereby reducing the amount of primary packaging material and packaging solution required to hydrate and hold the contact lens, as well as enabling a more compact secondary package during storage and transport (as further explained with reference to Figure 9). In this embodiment, the base 110 is tilted at an angle of about 14° from the proximal end (A) to the distal end (B) and has a footprint of about 29 mm in width, 44 mm in length, and 9.5 mm in height. A preferred tilt range is about 10–20°, but the tilt can be steeper, for example, about 20–30°, if necessary. The base includes a well, or cavity 136, formed in a tapered region in which the contact lens 138 and lens support 140 are housed when the package 100 is unopened. In this embodiment, the cavity has a volume of approximately 2240 μL, into which approximately 2080 μL of packaging solution is poured, sufficient to completely immerse the contact lens 138 in the cavity 136. The foil lid 106 is secured to the base 110 via a retortable seal formed between beads 152 on the upper surface of the base around the cavity 136. This seal can be formed by well-known heat sealing techniques and associated equipment.

[0043] The finger engagement feature (dimple) 122a is sized to accommodate the user's finger or thumb and is positioned at the end of the base 110 proximal to the user. In this embodiment, the finger dimple 122a is also angled downward so that a force, for example, pressure applied by the user's thumb, causes the lever 118 to hinge downward along the pivot line 114. The position of the finger dimple and the position of the user's finger relative to the pivot line affect the amount of compressive force required to hinge the lever along the pivot line. In this embodiment, the dimple depth below the pivot line is 4.5 mm when measured from the seal level to the base of the dimple.

[0044] The lens support 140 is coupled to the lever 118, so that the force applied to the lever 118 causes the lens support 140 to lift the contact lens 138 from the packaging solution. In the illustrated embodiment, the lens support 140 is a separately molded (or printed) component fixedly attached to a portion of the lever 118 on the base. Here, the attachment is made via a stake 162 formed in the lever portion of the base material. The lens support 140 has an opening 166 corresponding to the stake 162, so that when the lens support 140 is placed on the base, the stake 162 engages with the opening 166. Heat is applied to the stake / opening using a hot plate, and the heat and force are used to deform the plastic material, holding the stake firmly in place like a rivet. The attachment is made by partially deforming the stake 162 around the opening 166. A number of other attachment means other than heat riveting are possible within the scope of the claims, including, for example, laser welding, ultrasonic welding, adhesive, mechanical clipping, etc. Furthermore, it should be noted that in alternative embodiments, the lens support may be formed as part of the same integrally molded or printed component as the entire lever and / or base. The connection / mounting point of the lens support to the lever is preferably about 2–5 mm from the pivot line to the front of the peg / stake. In many embodiments, such as those shown, where the pivot line is formed by a fold in plastic or other substantially rigid material, the pivot line may have thickness, i.e., it may not be perfectly sharp. In these cases, such separation between the mounting point and the pivot line may be necessary to maximize the lift angle for a given bending force.

[0045] As shown in Figure 2, the underside of the lid 106 includes a surface 168 facing multiple lenses, which in this embodiment is formed as a projection extending downward toward the convex surface of the lens. The lens-facing surface 168 is generally molded to mirror the convex lens surface of the contact lens so that it is housed within the lid cavity 136. The lens-facing surface 168 functions to align the contact lens on the lens support and to protect the contact lens from significant optical damage due to gravity or air-induced forces. In some embodiments, the lens-facing surface also functions as an air inlet guide by guiding air into the package above the contact lens to reduce the occurrence of the contact lens sticking to the package upon opening. In this case, the lens-facing surface is provided on a molded plastic lid insert 170, which is attached to the inner surface of the foil lid 106 by heat sealing. However, in other embodiments, for example, if the lid is substantially rigid, the lens-facing surface may be an integral part of the lid rather than a separate component. It will be understood that all features described as being attached to a lid insert can be equally applied to embodiments in which the same features are integrated with the lid.

[0046] The lens-facing surface of the present invention functions to support the lens when loaded by these forces in order to avoid or reduce significant optical damage. For example, gravity and interaction with bubbles in the packaging solution can result in optical damage if not adequately suppressed. In one embodiment, the lens-facing surface, such as the lens-facing surface 168 of the illustrated embodiment, includes a relatively large contactable surface area of ​​at least about 3 percent, preferably at least about 20 percent, or as large as possible, while still accommodating any desired air vent channel. The contactable 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 it is in contact and positioned under an applied force such as, but not limited to, gravity or bubble interaction. The contactable surface area determines the pressure applied to the area of ​​the lens when the lens is loaded. The larger the area, the lower the pressure. In the illustrated embodiment, the lens-facing surface 168 is 100 mm 2 It has a contactable surface area of ​​approximately 215 mm², while conventional contact lenses have a contactable surface area of ​​approximately 215 mm². 2 It has a surface area of ​​. As will be discussed in more detail below, it is preferable that at least 10% of the surface area on the lens is left exposed in order to facilitate the movement of air entering the package and reduce any tendency for the lens to stick to the surface / lid insert facing the lens.

[0047] The surface 168 facing the lens is also spaced apart to define air vent channels 169, allowing air, particularly bubbles in the package solution, to move away from the contact lens into the peripheral volume of the cavity 136. It is advantageous that the air vent channels have a positive slope toward the peripheral volume with a vertical rise of at least about 2 mm. The air vent channels allow smaller bubbles to escape from the area around the lens surface, while simultaneously preventing larger bubbles from entering the space above the lens. To this end, preferred embodiments include at least two air vent channels, each having a width of about 1 mm to 1.5 mm, or preferably 1.5 mm to 2 mm, specifically 1.5 mm in the illustrated embodiment. In relevant embodiments, the air vent channels 169 advantageously form an "X" configuration. This configuration of the air vent channel positions relative to each other allows at least one of the channels to always have a central axis near the center of the cavity angled with respect to a plane perpendicular to gravity when the package is rotated laterally. This embodiment utilizes buoyancy to allow air bubbles to escape from the lens regardless of the orientation of the lens package, and thus reduces optical damage that could otherwise occur from, for example, air bubbles pressing the lens into the lens support.

[0048] In this embodiment, the lid insert 170 is attached to the inner surface of the lid 106 by a heat seal between the multilayer film lid 106 and the upper planes 172a-d of the lid insert. As will be discussed in more detail later herein, alignment of the lid insert with the base during the heat sealing process and during storage can be assisted by including one or more alignment features on the base and / or lid insert. For example, the alignment feature 174 in the illustrated embodiment takes the form of a column on the inner wall of the cavity 136 of the base 110. The alignment feature 174 resists rotation and lateral movement of the lid insert 170 when pressure is applied to seal the package 100 or during normal use. Alternative alignment features are possible, such as, but not limited to, forming the cavity and lid insert (or integral portion of the lid including the surface facing the lens) in a non-circular shape so that the components are essentially interlocked to resist rotation.

[0049] Referring here to Figure 4, an enlarged view of the lid insert 170 when inserted into the cavity 132 of the base 110 is shown. The position of the alignment feature (e.g., column 174) on the wall of the cavity 136 of the base 110 corresponds to the opening 178 of the lid insert 170. The column 174 and the opening 178 cooperate as an assembly to restrict the rotation and lateral movement of the lid insert 170. In another embodiment, the lid insert may be configured to prevent the lens support from being lifted (except for the expected time during opening) and to ensure that the lens is not compressed within the package by external forces when sealing pressure is applied or during storage, transport, or when the user opens the package. For example, a lockout feature may be included to prevent lid features, such as surfaces facing the lens (whether integrated with the lid or included on the lid insert), from colliding with the lens when overhead pressure is applied, such as when the lid is sealed to the base or when the lid insert (if present) is sealed to the lid. Other lockout features may be included to prevent the lens support from colliding with the lens (for example, by bending the pack on the pivot axis before opening) by creating a contact point between the lens support and the lid insert. Furthermore, another lockout feature in this embodiment is created by a ledge 180 along the perimeter of the cavity floor 136. One function of the ledge 180 is to avoid pinch points around the lens during assembly. The height of the ledge above the cavity floor is fabricated sufficiently so that the lid insert and / or lens-facing features of the lid stop at a height above where the lens will be housed below. In this embodiment, the ledge is approximately 0.8 mm above the base of the lens. It should be understood that the ledge is yet another exemplary lockout feature of many possibilities. To ensure this, the lid insert can be locked out at any level (e.g., level with the base of the lens, level with the top of the pack).

[0050] Figures 5A and 5B show cross-sectional views of an unopened contact lens package 100. Specifically, Figure 5B shows a cross-section made across the cross-sectional plane AA shown in the perspective side view of Figure 5A. As illustrated, the package 100 is configured such that, when unopened, the contact lens 138 substantially floats between the lens support 140 and the surface 168 facing the lens. The package of the present invention preferably minimizes contact with the contact lens when the package is closed, and the lens floats in the package solution. Ideally, the optical zone of the lens is freely floating, and contact with the lens support during storage is temporary or nonexistent. Depending on the buoyancy and orientation of the lens in the package solution, the lens may be on its periphery on the floor of the cavity in the base of the package or on its convex surface on the surface facing the lens. As illustrated, the contact lens package 100 is oriented with the lid up, with the periphery of the contact lens on the floor of the cavity 136 in the base 110. However, the optical zone of the contact lens 138 effectively floats between the lens support 140 and the surface 168 facing the lens.

[0051] The cavity 132 is preferably substantially filled with the package solution, however, there are conditions that the manufacturing process may not allow the package to be sealed under vacuum pressure. In such cases, it is expected that some amount of air will be trapped in the cavity. If these bubbles are not controlled, they may interact with the lens and cause significant optical damage to the lens. Therefore, peripheral volume can be provided within the cavity, i.e., volume within the cavity around the position of the lens on the lens support. Ideally, such volume should be provided at the distal and proximal ends of the package, such as 132' and 132'' of the cavity 132 of the package 100, so that bubbles have a place to exist regardless of the orientation of the package during transport or storage.

[0052] In one embodiment, the surface facing the lens can function as an air inlet guide by arrangement and configuration that allows air entering the package upon opening to move over the contact lens, preventing the contact lens from sticking to the lid or the surface facing the lens. As shown in Figure 6, the contact lens package 100 is shown in an assembled, unopened state with the foil lid not shown, so that the components located inside the package 100 can be seen, and the package 100 is configured to open from the proximal end (A) to the distal end (B) so that air enters the package in the direction indicated by arrow 190. To ensure that air moves over the lens, the lid insert 170 is configured so that the convex surface of the lens 138 is exposed over the lens edge closest to the point 192 where air enters the cavity upon opening. This can be achieved by positioning the surface facing the lens mainly over the lateral and distal surface regions of the contact lens, leaving at least about 10% of the surface area of ​​the contact lens closest to the point 192 where air enters the cavity exposed. More specifically, in this embodiment, 15% of the surface area of ​​the contact lens remains exposed.

[0053] As described with respect to the embodiments herein, the lens support of the present invention can take on numerous shapes and forms that can lift the lens out of the package solution when a user applies force(s) to the package, such as squeezing the package. However, as previously described, it is preferable for the lens support to hold the lens in the desired convex orientation (bowl down relative to the base) and position (centered on the support) during transportation and storage. Ideally, the lens support provides an open structure under the lens to allow the package solution to be drained from the lens and the support without trapping water between the support and the underside of the lens upon opening. It is also preferable for the lens support to have a sufficient number of contact points with the lens to prevent the lens from folding over on the support, rotating off the support, or translating across the support. This allows the apex of the lens to be supported by the elastic stiffness of the lens itself or minimizes the sag of the lens apex while limiting the contact area between the support and the lens. Excessive contact between the support and the lens after solution drainage and excessive water trapped between the support and the lens can create a surface tension between the lens and the water on and around the lens support that is greater than the surface tension between the wearer's finger and the lens, potentially interfering with efficient lens transfer. The total contact between the lens and the lens support when the package is opened and the solution is drained from the lens and the lens support is the total wet contact area, which is less than about 30 mm 2 less than, 25 mm 2 less than, or 20 mm 2 and may be less, and is distributed at least around the periphery of the lens, as described herein. As used herein, "wet contact area" refers to the direct solid contact area between the lens support and the lens plus the area of any meniscus reservoir or solution bridge formed between the lenses after the lens has been lifted and the package solution has been drained, for less than about 30 seconds, less than about 5 seconds, or less than about 2 seconds, depending on the intended user experience of the package.

[0054] For lenses made from polymers with longer shape memory, the lens support can be designed to limit contact between the lens and the support during storage. Such contact can be distributed around the lens periphery. Contact between the lens optical zone, the lens support, and the inside of the lid (including any air inlet guides) may be temporary, or there may be no contact between the optical zone and the support, lid, or air inlet guide. Lenses such as conventional hydrogels with shorter shape memory are less prone to distortion from package contact and may have contact points distributed around the periphery and across the entire lens profile, including the lens central zone (approximately 9 mm or approximately 5 mm in diameter).

[0055] The lens support of the present invention preferably allows both the fingertip and the lens to deform to conform to each other's shape during dubbing, without causing lens inversion or damage to the lens during removal from excessively high pressure during dubbing. Therefore, the manner of removing the lens from this package may involve controlling the ratio of the contact area between the finger and the lens to the area between the lens and the lens support, so that the contact area between the finger and the lens exceeds the contact surface area of ​​the lens support on the underside of 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 adheres to the finger for lens transfer and placement on the eye.

[0056] The lens support preferably provides at least 2, at least 3, 3-14, 4-14, 3-8, 4-8, 4-6, or 6 contact points with the contact lens edge along the peripheral support. If two peripheral supports are used, they may be wider to provide stability without exceeding the desired contact area for consistent lens transfer. Peripheral contact points can be distributed in a number of configurations that prevent the lens from coming off and rotating, and the space between the furthest adjacent contacts is smaller than the diameter of the lens. As the number of peripheral supports increases, the possibility of residual package solution forming film and solution bridges between adjacent peripheral supports and between the support and the lens may increase during draining. Peripheral supports with less than 50% open space, such as those in the form of screens or strainers, generally provide insufficient draining to ensure one-touch transfer. Similarly, excessive contact between the support and the lens after solution draining and trapped water between the support and the lens can create surface tension on and around the lens support between the lens and water that is greater than the surface tension between the wearer's fingers and the lens, thus hindering efficient lens transfer. The width of the supporting members of the lens support varies between the limits of the selected molding process and the width required for efficient drainage of the package solution upon opening. Preferred widths include approximately 0.5 to 1.5 mm, approximately 0.5 to 1 mm, or approximately 0.5 to 0.7 mm, and it will be understood that lens support designs with fewer contact points can have thicker arms.

[0057] The lens support can achieve sufficient drainage of the package solution from the lens to enable one-touch transfer by one or a combination of drainage techniques referred to herein as channel drainage and back drainage. Channel drainage involves the formation of channel members on the lens support, which allow the package solution to flow out of the lens through the channels under gravity when the lens support is lifted. Back drainage, on the other hand, refers to enhanced drainage from the underside of the lens where the lens rests on the lens support. This region below the apex of the lens tends to trap the package solution due to the hydrophilicity of modern contact lens materials. In some embodiments, enhanced back drainage extends at least about 12 mm below the apex of the lens. 3 This can be achieved by designing a lens support having a central aperture.

[0058] Referring next to Figures 7A and 7B, exemplary lens support 140 are shown in side and top views, respectively. Lens support 140 represents an example of a lens support that utilizes a hybrid of back discharge and channel discharge to sufficiently remove the package solution from the lens to enable one-touch transfer. Lens support 140 includes a central support consisting of three semicircular central support members 200a-c having a diameter of approximately 8 mm. The central support members 200a-c are raised by 2.5 mm by pillars 204. Pillars 204 extend upward from channel members 204a and 204b, which transition along their length from proximal end (A) to distal end (B) to form a channel in the peripheral support 208. These members cooperate so that when the contact lens is lifted from the package, the contact lens is placed on the lens support 240 in a preferred convex orientation (bowl down relative to the base of the package) at seven contact points when the lens is lifted from the package solution.

[0059] The design of the lens support 140 creates a central opening 212, allowing the package solution to be discharged from the lens and lens support 140 to the back when the package is opened and the lens support is lifted from the package solution. This limits the contact area between the support 140 and the lens, while supporting the lens apex with the lens's own elastic stiffness and minimizing apex sinking. This design also provides sufficient support at the edges of contact with fewer points along the channel members 204a and 204b and along the peripheral support 208. This configuration ensures that the wet contact area between the lens support 140 and the contact lens is at least about 25 mm² when measured 2 seconds after the lens support 140 is lifted. 2 It is reduced to a sufficient level.

[0060] One of the countless alternative embodiments of a lens support within the scope of the present invention is shown in Figures 8A and 8B, in side and top views, respectively. Lens support 300 represents an example of a lens support that relies on back discharge to adequately remove the package solution from the lens to enable one-touch transfer. Lens support 300 includes a central support 310 consisting of four equally spaced radial spokes extending across a diameter of approximately 10.5 mm. The central support member 310 is raised by 2.7 mm by pillars 314. Pillars 314 extend upward from support member 318, which includes tabs 324 that, in a particular embodiment of the present invention, can connect the lens support 300 to the base of a contact lens package. Peripheral support members 328 and 330 are formed in a continuous bowtie configuration and provide support to the edge of the contact lens when the lens is lifted from the package and placed on the support. The central and peripheral support members of the support 300 cooperate at five contact points to ensure that the contact lens is placed on the lens support 300 in a preferred convex orientation (bowl facing down relative to the base of the package) when the contact lens is lifted from the package and when the lens is lifted from the package solution.

[0061] The design of the lens support 300 includes sufficient open space between the spokes of the central support 310, allowing the package solution to be discharged from the lens and lens support 140 to the back when the package is opened and the lens support is lifted from the package solution. This limits the contact area between the support 300 and the lens, while the apex of the lens is supported by the elastic stiffness of the lens itself, and the sinking of the lens apex can be minimized. This design also provides sufficient support to the edge of the contact lens along the peripheral support members 328 and 330. This configuration ensures that the wet contact area between the lens support 300 and the contact lens is at least about 25 mm² when measured 2 seconds after the lens support 300 has been lifted. 2 This is sufficiently reduced. It should be emphasized that the embodiments of lens supports illustrated and described herein are only two of the countless embodiments of lens supports within the scope of the present invention as described in the appended claims. To ensure this, a number of additional exemplary but non-limiting exemplary lens supports are shown in Figures 11 to 25 (Appendix A).

[0062] As described above, in one embodiment, the contact lens package of the present invention can be configured to allow for a nesting configuration. Figure 9 shows two contact lens packages 100, shown as nesting packages 100' and 100''. Nesting configurations, such as those shown, in which packages fit together securely within a smaller volume, are useful for reducing the amount of secondary packaging (e.g., the carton or other container in which the primary package is provided to the consumer). In this embodiment, packages 100' and 100' are designed to nest when the bases are positioned relative to each other and inverted relative to each other from proximal to distal ends. The ability of contact lens packages 100' and 100'' to nest is made possible by a combination of features including tapering of the bases 110' and 110'' of each package, and finger engagement features (dimples) 122a' and 122a'' function as restraints against lateral movement of the bases 110' and 110''.

[0063] Referring here to Figure 10, an exemplary method of manufacturing / assembling a contact lens package according to one embodiment is shown. A first exemplary method of manufacturing / assembling an exemplary contact lens package 100 is shown as steps 1001A, 1002A, 1003A, 1004A, and 1005. In the first step 1001A, the contact lens 138 is placed on the lens support 140, in this embodiment the contact lens is placed on the lens support 140 with its concave side on the lens support. The lens support may be pre-filled with enough packaging solution to bond the contact lens to the support. In a slightly alternative approach not shown, the lens support may first be inserted into the cavity and the contact lens may then be placed on the support. In the next step 1002A, the lens support 140 with the contact lens 130 placed on it is inserted into the cavity 136 of the base 110. Next, in step 1003, a lid insert 170, including a surface 168 facing the lens, is placed on the convex side of the contact lens 138. Then, in step 1003A, the cavity is filled with enough package solution to completely immerse the contact lens 138 in the cavity, ideally as completely as possible without overflowing the cavity. Preferably, at least one of the mounting fixtures and / or surface features of the lid insert to the base cavity creates a friction fit so that the lid insert does not dislodge and float when the package solution is added to the cavity. Finally, in step 1005, the lid 106 is sealed onto the base 110 by heat sealing the foil to the base, for example, as described in more detail above, thereby sealing the contact lens 138 and the package solution inside the cavity 136 in a sterile environment.

[0064] 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, with a lens support 140 bonded to a cavity 136 of the base 110. In this embodiment, the lens support 140 is bonded to the base by a heat scribing process, as described in more detail above. However, as previously stated, other mounting means, including, for example, laser welding, ultrasonic welding, bonding, mechanical clipping, etc., are possible within the scope of the claims. Next, in step 1002B, the contact lens 138 is placed on the lens-facing surface of the lid insert 170, with the convex surface of the lens facing the lens-facing surface 168 of the lid insert 170, in this embodiment. The lens 138 can be placed on the lid insert by manual or automatic means, such as via a lens transfer nozzle. Next, in step 1003B, the lid insert 170 on which the contact lens 138 is placed is positioned on the lens support 140 in the cavity 136 of the base 110. Then, in step 1004B, the cavity 136 is filled with enough package solution to completely immerse the contact lens 138 in the cavity 136, ideally as completely as possible without overflowing the cavity. Finally, in step 1005, the lid 106 is sealed onto the base 110 by heat-sealing the foil to the base, for example as described in more detail above, thereby sealing the contact lens 138 and the package solution inside the cavity 136 in a sterile environment.

[0065] In some methods of manufacturing / assembling contact lens packages within the scope of the present invention, the provision of the packaging solution to the cavity can be done in multiple infusions at different steps of the assembly process, as opposed to all at once, as described in the exemplary methods above. For example, in embodiments in which the lens is placed on a lens support (e.g., step 1001A above), it may be advantageous to pre-infuse a small amount of the packaging solution onto the lens support before placing the lens on the lens support so that the lens is secured to the lens under the surface tension of the solution. Dividing the infusion of the packaging solution may also be advantageous when filling the cavity, for example in steps (1001B and 1004B) above, for example, by dividing an infusion of about 2080 μL into two infusions of approximately equal size.

[0066] The foregoing description uses a specific terminology to provide a complete understanding of the described embodiments for illustrative purposes. However, it will be apparent to those skilled in the art that many of the specific details are not required to carry out the described embodiments. Therefore, the foregoing description of the specific embodiments described herein is presented for illustrative and explanatory purposes only. They are not intended to be exhaustive or to limit this disclosure to the exact form disclosed. It will be apparent to those skilled in the art that many modifications and changes are possible in light of the above teachings.

[0067] The "Summary of the Invention" and "Abstract" sections may illustrate one or more, but not all, exemplary embodiments of the Invention as conceived by the inventors, but are not intended to limit the Invention or the attached "Claims" in any way.

[0068] The above description of specific embodiments fully reveals the general nature of the invention, and others, by applying the knowledge of those skilled in the art, can readily modify and / or adapt such specific embodiments to various uses without excessive trial and error and without departing from the general concept of the invention. Therefore, such adaptations and modifications are intended to be within the meaning and scope of the equivalents of the disclosed embodiments, based on the teachings and guidance presented herein. It should be understood that the expressions and terminology herein are for illustrative purposes only and not limiting, and therefore, the terms and expression herein should be interpreted by those skilled in the art in terms of teachings and guidance.

[0069] The packaging of the present invention can be manufactured using known materials and processes. The packaging material may be virgin, recycled, or a combination thereof. The volume within the packaging cavity can vary depending on the selected design.

[0070] Not all features described herein must be incorporated into every package; those skilled in the art can use the teachings herein to combine these features to provide a wide variety of improved contact lens packages. In summary, the contact lens packages of the present invention incorporate several novel features that, when combined in a wide variety of combinations as described herein, can provide a desired improved and / or one-touch package. The breadth and scope of the present invention should not be limited by any of the exemplary embodiments described above, but should be defined only in accordance with the following "Claims" and their equivalents.

[0071] [Implementation Method] (1) A contact lens package, The lid and It's the base, A cavity for containing contact lenses and package solution, A lever configured to hinge along the pivot line of the base when a force is applied to the lever, It has a base and A lens support comprising a pivot line intersecting the lens support such that the force applied to the lever causes the lens support to lift the contact lens from the package solution to a position on the lens support that allows for one-touch transfer by the user, A contact lens package that includes the following features. (2) The contact lens package according to Embodiment 1, wherein the lever is a separate component connected to the base by mounting means. (3) The contact lens package according to Embodiment 1, wherein the pivot line is defined by at least one void in the base. (4) The contact lens package according to Embodiment 1, wherein the pivot line is provided to the base by one or more of the following: folds, cuts, fine lines, and etchings. (5) The contact lens package according to Embodiment 1, wherein the base is made of a relatively rigid material.

[0072] (6) The contact lens package according to Embodiment 5, wherein the lid includes a film and the base includes a plastic material. (7) The contact lens package according to Embodiment 1, wherein the base and the lens support are a single integrated component. (8) The contact lens package according to Embodiment 1, wherein the lever and the lens support are a single integrated component. (9) The contact lens package according to Embodiment 1, wherein the lens support is bonded to the base by at least one of i) laser welding, ii) heating, iii) ultrasonic welding, and iv) adhesive. (10) The contact lens package according to Embodiment 1, wherein the base comprises at least one finger engagement feature configured to i) assist a user in grasping the package, or i) direct the application of force so that the lever hinges downward.

[0073] (11) The contact lens package according to Embodiment 10, wherein the at least one finger engagement feature includes a projection of the base at the distal end of the package. (12) The contact lens package according to Embodiment 10, wherein the at least one finger engagement feature includes an overhang along at least a portion of the periphery of the package. (13) The contact lens package according to Embodiment 10, wherein the at least one finger engagement feature includes a dimple sized to correspond to the user's finger or thumb, and the dimple is located at the proximal end of the base relative to the user. (14) The contact lens package according to Embodiment 10, wherein the at least one finger engagement feature includes a proximal finger engagement feature located at the end of the base proximal to the user and a distal finger engagement feature located at the end of the base distal to the user. (15) The contact lens package according to Embodiment 1, wherein the lid has a lens-facing surface that extends downward into the cavity above the contact lens when the package is unopened.

[0074] (16) The contact lens package according to Embodiment 15, wherein the surface facing the lens and the lens support are configured within the cavity such that, when the package is unopened, the optical zone of the contact lens floats in the package solution between the surface facing the lens and the lens support. (17) The contact lens package according to Embodiment 1, wherein the cavity accommodates the contact lens in a convex position when the package is unopened or opened. (18) The contact lens package according to Embodiment 1, wherein the lens support has a profile that does not substantially match the profile of the contact lens. (19) When the package is open, the wet contact area between the lens support and the contact lens is approximately 30 mm². 2 Less than approximately 25mm 2 Less than or approximately 20 mm 2 A contact lens package according to Embodiment 1, which is less than [amount missing]. (20) The contact lens package according to Embodiment 1, comprising at least one lens-facing surface within the cavity on the convex side of the contact lens, wherein, when the package is unopened, 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 due to gravity, mechanical force or air-induced force.

[0075] (21) The contact lens package according to Embodiment 20, wherein the surface facing at least one lens is provided on a lid insert, and the lid insert is attached to the inner surface of the lid. (22) The contact lens package according to Embodiment 21, wherein the lid insert includes at least one alignment feature. (23) The contact lens package according to Embodiment 21, wherein the lid insert includes at least one lockout feature. (24) A contact lens package for containing a contact lens and a package solution, wherein the package is configured to lift the contact lens from the package solution when the package is being squeezed by a user. (25) The contact lens package according to Embodiment 24, wherein the package comprises a lever configured to hinge along a pivot line of the base of the package when a force is applied to the lever, and a lens support configured to cause the force applied to the lever to lift the contact lens from the package solution.

[0076] (26) The contact lens package according to Embodiment 25, wherein the package is configured such that the force applied to the lever causes the lens support to lift the contact lens from the package solution to a position on the lens support that allows the user to transfer it with a single touch. (27) The contact lens package according to embodiment 25, wherein the lever is a separate component coupled to the base by mounting means. (28) The contact lens package according to Embodiment 25, wherein the pivot line is defined by at least one void in the base. (29) The contact lens package according to Embodiment 25, wherein the pivot line is provided to the base by one or more of the following: folds, cuts, fine lines, and etchings. (30) The contact lens package according to embodiment 25, wherein the base is made of a relatively rigid material.

[0077] (31) The contact lens package according to embodiment 25, wherein the base and the lens support are a single integrated component. (32) The contact lens package according to embodiment 25, wherein the lever and the lens support are a single integrated component. (33) The contact lens package according to Embodiment 25, wherein the lens support is bonded to the base by at least one of i) laser welding, ii) heating, iii) ultrasonic welding, and iv) adhesive. (34) The contact lens package according to Embodiment 25, wherein the base comprises at least one finger engagement feature configured to i) assist a user in grasping the package, or i) direct the application of force so that the lever hinges downward. (35) The contact lens package according to Embodiment 25, wherein the at least one finger engagement feature includes a projection of the base at the distal end of the package.

[0078] (36) The contact lens package according to embodiment 35, wherein the at least one finger engagement feature includes an overhang along at least a portion of the periphery of the package. (37) The contact lens package according to Embodiment 35, wherein the at least one finger engagement feature includes a dimple sized to correspond to the user's finger or thumb, and the dimple is located at the proximal end of the base relative to the user. (38) The contact lens package according to Embodiment 35, wherein the at least one finger engagement feature includes a proximal finger engagement feature located at the end of the base proximal to the user and a distal finger engagement feature located at the end of the base distal to the user. (39) The contact lens package according to Embodiment 25, wherein the lid of the package has a lens-facing surface that extends downward into the cavity above the contact lens when the package is unopened. (40) The contact lens package according to Embodiment 39, wherein the surface facing the lens and the lens support are configured within the cavity such that, when the package is unopened, the optical zone of the contact lens floats in the package solution between the surface facing the lens and the lens support.

[0079] (41) The contact lens package according to Embodiment 24, wherein the package accommodates the contact lens in a convex position when the package is unopened or opened. (42) The contact lens package according to Embodiment 25, wherein the lens support has a profile that does not substantially match the profile of the contact lens. (43) When the package is open, the wet contact area between the lens support and the contact lens is approximately 30 mm². 2 Less than approximately 25mm 2 Less than or approximately 20 mm 2 A contact lens package according to embodiment 25, which is less than [amount missing]. (44) The contact lens package according to Embodiment 25, comprising at least one lens-facing surface within the cavity on the convex side of the contact lens, wherein, when the package is unopened, 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 due to gravity, mechanical force or air-induced force. (45) The contact lens package according to embodiment 25, comprising a lid insert, wherein the lid insert is attached to the inner surface of the lid.

[0080] (46) The contact lens package according to embodiment 45, wherein the lid insert includes at least one alignment feature. (47) The contact lens package according to embodiment 45, wherein the lid insert includes at least one lockout feature. (48) A method for handling a package containing a contact lens in a package solution, Opening the lid of the aforementioned package, The process involves compressing the package, wherein compressing the package causes the lens support to lift the contact lens from the package solution. Transferring the contact lens from the lens support to the user's eye, Methods that include... (49) The method according to embodiment 48, wherein the squeezing includes the user's hands applying force to each opposite end of the package. (50) The method according to embodiment 49, wherein the opposite ends of the package are the distal end and proximal end of the package with respect to the user.

[0081] (51) The method according to embodiment 49, wherein the opposite ends of the package are the left and right sides of the package with respect to the user. (52) The method of Embodiment 48, wherein the lid includes foil, and opening the package includes peeling the foil from at least a portion of the package. (53) The method according to Embodiment 48, wherein the lens support lifts the contact lens, generating a lifting angle of approximately 15° to 60° with respect to the horizontal plane defined by the top of the package. (54) The method according to Embodiment 48, further comprising transferring the contact lens from the lens support to the user's hand, wherein the transfer of the lens includes tapping the convex surface of the contact lens to release the contact lens from the lens support and allow it to adhere to the user's finger. (55) A method for manufacturing a package for containing a contact lens in a package solution, Placing the contact lens on a lens support, Inserting the lens support into the cavity of the package base, An insert having a surface facing the lens is placed on the contact lens, The package solution is poured into the aforementioned cavity, The lid is sealed onto the base, and the sealing is to seal the contact lens and the package solution inside the cavity in a sterile environment. Methods that include...

[0082] (56) The method according to embodiment 55, wherein the contact lens is placed on the lens support after the step of inserting the lens support into the cavity of the base. (57) The method according to embodiment 55, wherein placing the contact lens on the lens support includes placing the concave side of the contact lens on the lens support. (58) The method according to embodiment 55, further comprising the step of pouring a package solution into the lens support before placing the contact lens on the lens support. (59) A method for manufacturing a package for containing a contact lens in a package solution, To provide a package base, wherein the package base comprises a cavity to which a lens support is bonded. The contact lens is placed on the surface of the lid insert that faces the lens, The contact lens is placed on the surface facing the lens, and the surface facing the lens is inserted onto the lens support in the cavity of the base. The package solution is poured into the aforementioned cavity, The lid is sealed onto the base, and the sealing is to seal the contact lens and the package solution inside the cavity in a sterile environment. Methods that include... (60) The method according to Embodiment 59, wherein placing the contact lens on the surface of the lid insert facing the lens includes placing the convex side of the contact lens on the surface facing the lens.

[0083] (61) The method of Embodiment 55, further comprising aligning the lid insert within the cavity of the base, wherein the aligning includes translating the lid insert onto an alignment feature within the cavity of the base. (62) The method of Embodiment 55, further comprising aligning the lid insert within the cavity of the base, wherein the aligning includes translating the lid insert onto the alignment feature within the cavity of the base. (63) The method of Embodiment 55, further comprising locking the lid insert within the cavity of the base, wherein the locking includes applying sufficient pressure to the lid insert to cause a projection on the side of the lid insert to be fixed to the side wall of the cavity by friction.

Claims

1. A contact lens package (100), comprising: A lid (106); A base (110), a cavity (136) configured to receive a contact lens (138) and packaging solution, the contact lens having a concave posterior side configured to rest against the eye in use and a convex anterior side configured to face away from the eye in use, the cavity configured to receive the contact lens in a convex position with the convex anterior side facing toward the lid; a lever (118) configured to hinge along a pivot line (114) of the base when the contact lens package is squeezed by a user; a base comprising: a lens support (140) that intersects the pivot line such that a force applied to the lever when the contact lens package is squeezed by the user causes the lens support to lift the contact lens from the package solution to a position on the lens support for one-touch transfer by the user; A contact lens package comprising:

2. the lever is a separate component connected to the base by an attachment means; and / or the pivot line is defined by at least one gap (158) in the base; and / or The contact lens package of claim 1 , wherein the pivot line is imparted to the base by one or more of a crease, a cut, a thin line, and an etching.

3. the base is constructed from a relatively rigid material; and / or 3. The contact lens package of claim 1, wherein the lid comprises a film and the base comprises a plastic material.

4. the base and the lens support are a single, integral component; and / or the lever and the lens support are a single integral component; and / or 4. The contact lens package of claim 1, 2, or 3, wherein the lens support is bonded to the base by at least one of: i) laser welding; ii) heat; iii) ultrasonic welding; and iv) an adhesive.

5. the base comprises at least one finger engagement feature (122a-122c) configured to: i) assist the user in gripping the contact lens package; or ii) direct the application of force such that the lever hinges downward; and optionally: the at least one finger engagement feature comprises a protrusion (122c) on the base at the distal end of the contact lens package; and / or the at least one finger engagement feature includes an overhang (122b) along at least a portion of the periphery of the contact lens package; and / or the at least one finger engagement feature includes a dimple (122a) sized to correspond to a finger or thumb of the user, the dimple being positioned at an end of the base proximal to the user; and / or 5. The contact lens package of claim 1, wherein the at least one finger engagement feature includes a proximal finger engagement feature positioned at an end of the base proximal to the user and a distal finger engagement feature positioned at an end of the base distal to the user.

6. the lid comprises a lens-facing surface (168) that extends downward into the cavity over the contact lens when the contact lens package is in an unopened state, and optionally 6. The contact lens package of claim 1, 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 optic zone of the contact lens is suspended in the packaging solution between the lens-facing surface and the lens support.

7. the lens support has a profile that does not substantially match the profile of the contact lens; and / or 7. The contact lens package of claim 1, wherein when the contact lens package is in an open state, the wet contact area between the lens support and the contact lens is less than about 30 mm 2 , less than about 25 mm 2 , or less than about 20 mm 2 .

8. and at least one lens-facing surface within the cavity on a convex side of the contact lens, the at least one lens-facing surface configured to align the contact lens on the lens support or protect the contact lens from significant optical damage due to gravity, mechanical forces, or air-induced forces when the contact lens package is in an unopened state; and optionally the at least one lens-facing surface is provided on a lid insert (170), the lid insert being attached to an inner surface of the lid, and further optionally: the lid insert includes at least one alignment feature; and / or The contact lens package of claim 1 , wherein the lid insert includes at least one lockout feature.

9. 1. A method for manufacturing a package (100) containing a contact lens (138) in a packaging solution, comprising: placing the concave side of the contact lens on a lens support (140); Inserting the lens support (140) into a cavity (136) in the package base (110); placing a lid insert (170) having a lens-facing surface (168) over the contact lens; introducing the packaging solution into the cavity; sealing the lid (106) onto the base, said sealing enclosing the contact lens and packaging solution within the cavity in a sterile environment; A method comprising:

10. and / or - placing the contact lens on the lens support is performed after the step of inserting the lens support into the cavity of the base.

10. The method of claim 9, further comprising the step of applying the packaging solution to the lens support prior to placing the contact lens on the lens support.

11. 1. A method for manufacturing a package (100) containing a contact lens (138) in a packaging solution, comprising: providing a package base (110), the package base having a cavity (136) to which a lens support (140) is coupled; placing the convex side of said contact lens on the lens-facing surface (168) of a lid insert (170); inserting the lens-facing surface onto the lens support within the cavity of the package base with the contact lens positioned on the lens-facing surface; introducing the packaging solution into the cavity; sealing the lid (106) onto the package base, said sealing enclosing the contact lens and packaging solution within the cavity in a sterile environment; A method comprising:

12. further comprising aligning the lid insert within the cavity of the base, wherein the aligning comprises translating the lid insert over an alignment feature within the cavity of the base; and / or 12. The method of any one of claims 9 to 11, further comprising locking the lid insert within the cavity of the base, said locking comprising applying sufficient pressure to the lid insert to cause protrusions on the sides of the lid insert to be secured to the side walls of the cavity by friction.

Images