Contact lens packaging processing

Abstract

An industrial automation system may separate a foil cover sheet of a contact lens package from its body to enable, for example, sustainable practices such as recycling, repackaging, relabeling, flexible storing, and the like. The system may include a press and a gripper. The press may be configured to displace a portion of the package to generate an edge separation between the package foil cover sheet and body. The gripper may grasp the sheet at the edge separation and detach the sheet from the body.

Description

Attorney Docket No.: VTN6155WOPCT1Contact Lens Packaging ProcessingRelated Applications

[0001] This application claims priority to U.S. Provisional Patent Application Serial No. 63 / 687,532, filed August 27, 2024, which is incorporated herein by reference in its entirety.Background

[0002] Contact lens packaging presents unique engineering challenges. Packaging design considers aspects of safety, storage effectiveness, consumer use factors, and the like. Materials and methods may be used to address design considerations such as sterility, seal integrity, labeling, product expiration, material safety and biocompatibility, standards and regulatory compliance, and sustainability, for example. The sustainability considerations may include the design, production, distribution, processing, use, and disposal of lenses and packaging with a full consideration for the well-being of the environment, society, and economy for present and future generations.Summary

[0003] Contact lens packages may be processed with the apparatus and techniques disclosed in this application for patent. For example, an automated separation of packaging parts may be performed. This approach may be used, for example, to enhance overall product sustainability, improving and / or enabling operations for recycling, repackaging, relabeling, flexible storing, and the like.

[0004] An example contact lens package handling device may include a press and a gripper which each manipulate a contact lens package. The contact lens package may include a body and a sheet. The body may include a cavity and a flange extending outwardly from the periphery of the cavity. The bottom side of the sheet may be detachably sealed to the body about the periphery of the cavity. And the bottom side of the sheet may abut a top surface of the flange.Attorney Docket No.: VTN6155WOPCT1

[0005] The press may be configured to displace, relative to the cavity, the flange and a corresponding portion of the sheet such that upon recovery there is an edge separation between the flange and the corresponding portion of the sheet.

[0006] The gripper may include a first jaw and an opposing second jaw. The gripper may be configured to insert a portion of the first jaw between the flange and the corresponding portion of the sheet at the edge separation. The gripper may be configured to grasp the sheet at the edge separation and detach the sheet from the body.

[0007] Once separated, the sheet and body may be subject any type of subsequent processing, including operations for recycling, repackaging, relabeling, flexible storing, and the like. For example, the sheet may be disposed into a first recycling stream and the body may be disposed into a second recycling stream, different than the first recycling stream.Brief Description of the Drawings

[0008] FIG. 1 is a block diagram depicting an example industrial automation system.

[0009] FIG. 2 is a block diagram depicting an example industrial automation system.

[0010] FIGs. 3A & B illustrate an example contact lens package with a partial top view and a side view respectively.

[0011] FIG. 4 is a perspective view of an example contact lens package array.

[0012] FIG. 5 is a perspective view of an example contact lens package holder.

[0013] FIGs. 6A-C are block diagrams depicting a first manipulation of a contact lens package.

[0014] FIGs. 7A-C are perspective views illustrating operation of an example press.

[0015] FIG. 8 is a perspective view of an example gripper.

[0016] FIGs. 9A-F are block diagrams depicting a second manipulation of a contact lens package.

[0017] FIGs. 10A-F are perspective views illustrating operation of an example gripper.

[0018] FIG. 11 is a perspective view of an example contact lens picker.

[0019] FIG. 12 is a flow diagram of an example industrial automation method.Attorney Docket No.: VTN6155WOPCT1Detailed Description

[0020] Industrial automation systems play an important role in modern manufacturing and logistics operations. These computerized systems are designed to efficiently move, process, and control materials, products, and goods in various industrial settings. For example, an industrial automation system, such as that disclosed herein, may be used for materials handling and manipulation of contact lens packages.

[0021] FIG. 1 is a block diagram depicting an example industrial automation system 100. The example industrial automation system 100 may include a processor 102, a memory 104, a network interface 106, a user input / output interface 108, one or more sensors 110, one or more actuation controllers 112, and corresponding manipulation hardware 114. The processor 102 may receive information, e.g., via memory 104, the network interface 106, the user I / O interface 108, and / or sensors 110. The processor 102 may process that information, according to computer-readable code (e.g., application software and / or firmware). The processor 102 may output information and / or signals based on the processing, e.g., via the memory 104, the network interface 106, user I / O interface 108 and / or the actuation controller 112.

[0022] The processor 102 may be a general -purpose processor, a special purpose processor, a conventional processor, a digital signal processor (DSP), a plurality of microprocessors, one or more microprocessors in association with a DSP core, a controller, a microcontroller, Application Specific Integrated Circuits (ASICs), Field Programmable Gate Arrays (FPGAs) circuits, any other type of integrated circuit (IC), a state machine, and the like. The processor 102 may include any hardware suitable for data processing and control in industrial automation. For example, the processor 102 may include and / or be a component of apparatus such as, programmable logic controllers (PLC), distributed control systems (DCS), industrial PCs (industrial personal computers. IPC), programmable automation controllers (PAC), microcontrollers, and the like. The processor may include real-time processing capabilities. The processor 102 may be configured with computer readable code to perform the methods disclosed herein.Attorney Docket No.: VTN6155WOPCT1

[0023] The memory 104 may include any computing hardware suitable for storing information in connection with the processor 102. The processor 102 may access information from, and store data in, in the memory 104. The memory 124 may include any type of suitable hardware such as random-access memory (RAM), read-only memory (ROM), a hard disk, or any other type of memory storage device. In an example, the processor 102 may access information from, and store data in, memory 104 that is physically located apart from the automation system 100, e.g., via virtual storage resources, storage server, cloud storage, Network Access Server (NAS), and the like. The memory may be suitable for storing computer-readable code, e.g., computer-readable instructions, that when executed by the processor 102 cause the automation system 100 to perform operations, such as the operations disclosed herein.

[0024] The network interface 106 may include any computing hardware suitable for the transmission and reception of data over a computer network, such as an industrial automation computer network. The network interface 106 may enable communication between networked devices. The network may be a wired network, a wireless network, and / or a combination of a wired and wireless. The network interface 106 may be hardware suitable to communicate over networks supporting protocols such as Ethernet, WiFi (Wireless Fidelity), Ethernet / IP (Ethernet Industrial Protocol), PROFINET, Modbus, DeviceNet, Common Industrial Protocol (CIP), ControlNet, Profibus, Foundation Fieldbus, CANopen, WirelessHART (Highway Addressable Remote Transducer), ISA100 Wireless, 4G and / or 5G cellular network protocols, and the like. The network interface 106 may support real-time data handling suitable for industrial applications.

[0025] The user I / O interface 108 may provide an interface between the automation system 100 and a user. The user I / O interface 108 may include any hardware suitable for communicating information between the automation system 100 and the user. For example, the user I / O interface 108 may include hardware such as buttons, switches, toggles, dials, keypads, keyboards, a computer mouse, displays, indicator lights, monitors, audible indicators, microphones, speakers, and the like. The user I / O interface 108 may include a virtual interface presented via a computer terminal and / or a networked computer. The user I / O interface 108 may include a touch screen, such as a industrial touch screen interface customized in accordance with operation of the processor 102 and corresponding computer-readable code.

[0026] The automation system 100 may include one or more sensors 110. The sensors 110 may include any device that detects and / or measures a physical property andAttorney Docket No.: VTN6155WOPCT1 communicates the information to the processor 102. The sensors 110 may include devices such as a gyroscope, an accelerometer, a hall effect sensor, a magnetometer, an orientation sensor, a proximity sensor, a photoelectric sensor, an ultrasonic sensor, a temperature sensor, a time sensor; a geolocation sensor; an altimeter, a light sensor, a touch sensor, a magnetometer, a barometer, a gesture sensor, a biometric sensor, a humidity sensor, and the like. The sensors 110 may include devices suitable for detecting and / or measuring the presence, nature, orientation, position, and the like of material being handled by the automation system 100. The sensors 110 may include devices suitable for detecting and / or measuring the status, condition, position, parameters, and the like of actuators and the corresponding manipulation hardware being operated by the automation system 100. The sensors 110 may include devices suitable of detecting and / or measuring environmental properties associated with automation system 100.

[0027] The automation system 100 may include one or more controllable actuators 112. The actuators 112 may include any device suitable for converting controls from the processor 102 and energy for doing work (e.g., generating force, torque, and / or motion). Actuators 112 may be used to perform various mechanical actions on workpieces as part of automated processes. The actuators 112 may include hydraulic, pneumatic, and / or electric actuators. For example, a pneumatic actuator may use compressed air to generate linear and / or rotary motion. Pneumatic actuators may be used for tasks like pushing and / or lifting objects and / or actuating valves and clamps. For example, a hydraulic actuator may use a pressurized hydraulic fluid to create linear and / or rotary motion. Hydraulic actuator may be used, for example, for tasks that benefit from high force capabilities such as heavy lifting and pressing. For example, an electric actuator may convert electrical energy into mechanical motion and may be used, for example, where precise movement is beneficial, such as in conveyor belt control, robotic arm movements, and the like. The actuators 112 may include linear actuators and / or rotary actuators. The actuators 112 may include devices such as conveyor motors, servo motors, air cylinders, vacuums, solenoid actuators, and the like. The actuators 112 may include robotic actuators. The processor 102 may control the actuators 112 in accordance with the computer- readable code in operation of the automation system 100.

[0028] The automation system 100 may include a manipulation hardware 114. The manipulation hardware 114 may include any apparatus suitable for material handling and processing operations. The manipulation hardware 114 mayAttorney Docket No.: VTN6155WOPCT1 mechanisms for industrial manipulation tasks, including picking up, manipulating, folding, bending, pushing, pulling, and / or placing objects and / or portions of objects in industrial settings. The manipulation hardware 114 may include mechanisms such presses, grippers, pickers, and the like. For example, the manipulation hardware 114 may direct work caused by the actuators 112 and / or drive a physical property to a sensor 110.

[0029] In an example, the operation of the automation system 100 may include receipt of input data from sensors 110. The sensors 110 may detect the presence of materials, their position, and environmental conditions, for example. The processor 102 may receive and processes this data. The processor 102 may make decisions based on a defined logic. The decisions may cause signals to be communicated to the actuators 112, which drive the manipulation hardware to carry out operations, such as conveying material, operating presses, operating grippers, and the like, as disclosed herein.

[0030] FIG. 2 is a block diagram illustrating an example automation system 200. The automation system 200 may implement an automation system 100 with features as disclosed herein. The automation system 200 may include example sensors, actuators, and manipulation hardware suitable for processing contact lens packages. For example, the automation system 200 may include a conveyor 202, a press 204, and / or a gripper 206, and the like. The press 204 may be disposed as a first station 208. The gripper 206 may be disposed at a second station 210.

[0031] The conveyor 202 may be used to receive and / or convey material 212a-c (e.g., a contact lens package and / or holder, see e.g., FIGs. 3-5). For example, the conveyor 202 may be directional. The conveyor 202 may be a segment (e.g., having a beginning and an end). The conveyor 202 may be a loop. For example, the conveyor may convey material in a first direction 214. The conveyor 202 may be used to convey material (e.g., material 212a) to the first station 208. A sensor (e.g., a proximity sensor) may detect that the material is positioned relative to the press 204. A processor (e.g., processor 102) may control the conveyor to present the material at the press 204 based on information from the sensor.

[0032] The first station 208 may be used to create an edge separation between the body of a contact lens package and the covering sheet. For example, the press 204 may be used to create an edge separation between the body of a contact lens package and the covering sheet, as disclosed herein. Following operation at the first station 208, the conveyor 202 may be used to convey material (e.g.,Attorney Docket No.: VTN6155WOPCT1 material 212b) from the first station 208 to the second station 210. The second station 210 may be used to detach the covering sheet from the body of the contact lens package. For example, the gripper 206 may detach the covering sheet from the body of the contact lens package, as disclosed herein.

[0033] The detached covering sheet may be deposited in a bin 216. The conveyor 202 may be used to convey material (e.g., material 212c) from the second station 210. For example, the conveyor 202 may be used to convey material (e.g., material 212c) from the second station 210 for further processing. Material 212c may include the body of a contact lens package having its contents revealed, for example, having the stored contact lens and / or storage liquid revealed.

[0034] FIGs. 3A & B depict an example contact lens package 300. FIG 3A is a partial top view. FIG. 3B is a side view. The contact lens package 300 may be configured as a single contact lens package (e.g., a package with a single cavity for storing a single contact lens). The contact lens package 300 may be, as shown in FIG. 4, configured as contact lens package array (e.g., an array of connected single contact lens packages).

[0035] The contact lens package 300 may include a body 302 and a corresponding covering sheet 304. The body 302 may include a cavity 306 and a flange 308. The cavity may be bowl-shaped with an upper edge of the bowl representing a periphery 310 of the cavity 306. The cavity 306 may hold a contact lens and / or a contact lens storage liquid. The flange 308 may extend outwardly from the periphery 310 of the cavity 306. The sheet 304 may be detachably sealed to the body 302. The bottom side of the sheet 304 may abut the top surface of the body 302 (e.g., the top surface of the flange 308). For example, a bottom side of the sheet 304 may be detachably sealed the body 302 (e.g., the top surface of the flange 308) about the periphery 310 of the cavity 306, for example, via a seal 312 (e.g., heat seal).

[0036] The body 302 may be made from any material suitable for contact lens storage. The body 302 may be made of a single material. The body 302 may be made of different materials (e.g., different materials for the cavity 306 and the flange 308). The body 302 may be formed from a plastic material, such as polypropylene for example. For example, the body 302 may be formed via an injection molding process. In an example, a portion of the body 302 may be formed via recycled raw material, for example, raw material recovered by the apparatus disclosed herein.Attorney Docket No.: VTN6155WOPCT1

[0037] The sheet 304 may be made from any material suitable for safely and effectively heat sealing to the body and enclosing the cavity 306. The sheet 304 may include a one or more layers. The sheet 304 may include a foil layer. The sheet 304 may include a polypropylene layer. The sheet 304 may define an upper surface 314 and a bottom surface. The sheet may be multilayered and comprise a support layer and a peelable seal layer and optional additional layers including print layers, lamination layers, foil layers and combinations thereof and the like.

[0038] The upper surface 314 of the sheet 304 may be a print layer suitable for package labeling. Labeling may include printed information, such as source and / or manufacturing identification information, information about the contents of the package, marketing information, regulatory information, and the like. For example, the printed information may include a brand name, the contained contact lens specifications, usage instructions, expiry date and the like. The information printed on the upper surface 314 of the sheet 304 may be subject to change. For example, the regulatory information may be subject to the legal jurisdictions within which the contact lens and corresponding contact lens package 300 is to be shipped, sold, used, and the like. The apparatus and method disclosed herein may be suitable for removing and replacing the sheet 304 to effect a change in labeling.

[0039] The seal 312 between the bottom surface of the sheet 304 and the upper surface of the body 302 may be formed by any mechanism suitable to for forming a safe, effective, and hand-removable seal, such as a hermetic seal. For example, the seal 312 may be formed by an adhesive placed between the sheet 304 and the body 302. For example, the seal 312 may be formed by a heat seal process, where the bottom surface of the sheet 304 comprises a polypropylene layer that when heated welds to the upper surface of the body 302. The seal 312 may maintain the sterility of the package contents. The seal 312 may prevent contamination of the contents of the cavity 306 from bacteria, dust, and other environmental conditions. The seal 312 may keep the lenses inside safe and clean for the end user.

[0040] The cavity 306 may define an enclosed void 316 within which a contact lens and packaging solution (not shown) may be stored. The void 316 may be partially enclosed, tray-like, and open-topped when no sheet 304 is covering the body 302 (e.g., before the sheet 304 is applied and / or after the sheet 304 has been fully or partially detached). The void 316 may be fully enclosed when the sheet 304 is covering the body 302 (e.g., when the seal 312 is present and intact).Attorney Docket No.: VTN6155WOPCT1

[0041] The body 302 may include be one or more tabs 318 extending from the flange 308. A tab 318 may help the contact lens package 300 sit upright and / or level. A tabs 318 may include a portion suitable for a user to grasp when peeling the foil away to open the package.

[0042] FIG. 4 a contact lens package 300 configured as a contact lens package array 400. The contact lens package array 400 may include a connected array of single contact lens packages 402a-e. In an example, the contact lens package array 400 may be hand separable (at perforations and / or designated material thinness, for example) into single contact lens packages. As illustrated in FIG. 4, the lens package array 400 includes a connected array of five single contact lens packages. In an example, the single contact lens packages 402a-e may be identical to each other in structure. In an example, the single contact lens packages 402a-e may be different from one another in structure.

[0043] The contact lens package array 400 may include a unified body 404 and a common covering sheet 406. The unified body 402 may include one or more cavities (e.g., a corresponding cavity for each single contact lens package 402a-e in the contact lens package array 400). The unified body 402 may include one or more flanges (e.g., a corresponding flange for each single contact lens package 402a-e in the contact lens package array 400). Each flange may extend outwardly from the periphery of its corresponding cavity. In an example, each flange may have extending therefrom a corresponding tab portion 408a-e

[0044] The common covering sheet 406 may extend across the upper surface of the unified body 404. For example, the common covering sheet 406 may extend across the upper surface of one or more flanges (e.g., across the upper surface of each flange). The common covering sheet 406 may be detachably sealed, such as hermetically sealed to the unified body 404. For example, the common covering sheet 406 may be detachably sealed to the unified body 404 about the periphery of each cavity. For example, a bottom side of the common covering sheet 406 may be detachably sealed to the unified body 404 about the periphery of each cavity. The bottom side of the sheet outside the seal may abut a top surface of one or more flanges. For example, the bottom side of the sheet may abut a top surface of each of the corresponding flanges. The common covering sheet 406 may have a top side 408.

[0045] The contact lens package array 400 may have a common side 412. The common side 412 may have disposed therewith one or more flanges. In an example, each flange may be disposed at the common side 412. For example, each singleAttorney Docket No.: VTN6155WOPCT1 contact lens package 402a-e in the contact lens package array 400 may be orientated such that each corresponding flange is disposed at the common side 412. For example, each single contact lens package 402a-e in the contact lens package array 400 may be commonly orientated such that each corresponding flange is disposed at the common side 412.

[0046] In an example, each flange may have extending therefrom a respective tab 408a- e. The common side 412 may have disposed therewith one or more tabs 408a-e. For example, each tab 408a-e of the contact lens package array 400 may be disposed at the common side 412. For example, each single contact lens package 402a-e in the contact lens package array 400 may be orientated such that each corresponding tab 408a-e is disposed at the common side 412. For example, each single contact lens package 402a-e in the contact lens package array 400 may be commonly orientated such that each corresponding flange is disposed at the common side 412.

[0047] FIG. 5 is a perspective view of an example contact lens package holder 500. The holder 500 is configured to hold a contact lens package, such as the contact lens package 300 disclosed herein. As illustrated in FIG. 5, the holder 500 is configured to hold a contact lens package 300 configured as an array of five single contact lens packages, such as the contact lens package array 400. The holder may be configured to hold any desired number of contact lens packages including 1, 2, 3, 4, 5, 6, or 7 in a single row.

[0048] The holder 500 may include structure suitable for providing support to a contact lens package (including, e.g., a contact lens package array) for handling. For example, the holder 500 may include a body 502. The body 502 may be rectangular in shape. The body 502 may be shaped to correspond to the shape of the contact lens package it is intended to hold. For example, the body 502 may complement the underside shape of the contact lens package it is intended to hold. In an example, the holder 500 may include one or more voids 504a-e. For example, the holder 500 may include one more voids 504a-e in the holder body 502. The voids 504a-e may be tray-like depressions is the upper side of the body 502. The voids 504a-e may be (e.g., as illustrated in FIG. 5) holes through the body 502 of the holder. The voids 504a-e may be suitable to receive the underside of a contact lens package (e.g., a single contact lens package and / or a contact lens package array). For example, each void 504a-e may be suitable for receiving a corresponding cavity of the contact lens package.Attorney Docket No.: VTN6155WOPCT1

[0049] The body 502 may have an asymmetry to define an orientation of the contact lens package in the holder 500. For example, the body 502 may have a ridge 506 disposed on the upper surface of the body 502 on one side. The ridge 506 may be configured to abut a corresponding side of the contact lens package. For example, the body 502 may have one or more alignment features 508a-e. The alignment features 508a-e may be disposed on at the upper surface of the body 502 on one side (e.g., on a side opposite the ridge). The alignment features 508a-e may be configured to complement a corresponding feature of the contact lens package (e.g., to complement one or more tabs of the contact lens package).

[0050] The holder 500 may include a bottom portion (not shown) suitable for engaging a conveyor. For example, there may be a tongue and / or groove structure integrated into the bottom of the body. The tongue and / or groove structure may be configured to interface with a corresponding groove and / or tongue structure in the conveyor. The body portion may have an asymmetry to define an orientation of the holder to the conveyor.

[0051] The holder 500 (via the body 502, for example) may provide structural support for the contact lens package as they are manipulated by the industrial automation system disclosed herein. For example, the holder 500 (via the body 502, for example) may provide a stabilizing counter force to operations of the manipulation hardware (such as manipulation hardware 114, press 204, gripper 206, and the like)

[0052] FIGs. 6A-C are corresponding block diagrams depicting a first manipulation of the contact lens package. And FIGs. 7A-C are perspective views that illustrate the corresponding operation via an example press 600. The first manipulation may be conducted to create a gap 620 (shown in FIG. 6C) between non-sealed portion of the bottom surface of the sheet 606 and the upper surface of the body 602 along the front of package array 608, before the heat seal. This separation of the bottom surface of the sheet and the upper surface of the package body allows more consistent removal of the lid in the following step.

[0053] FIGs. 6A and 7A show a contact lens package 602 being received for the first manipulation operation (e.g., received into the press 600). The contact lens package 602 may be carried in a holder 604 (configured such as holder 500 is, for example). The contact lens package may have a body 605, a top sheet 606 and a flange 608. The contact lens package may have a cavity 610 received within a void in the holder 604. The contact lens package may be conveyed into position via a conveyor. For example, the contact lens package may be conveyedAttorney Docket No.: VTN6155WOPCT1 to a first station including a press 600. A sensor may be used to indicate that the conveyor, holder 604, and corresponding contact lens package 602 is in position for operation.

[0054] A retaining member 612 (e.g., plate 614) may closely parallel the upper surface of the sheet 606 of the contact lens package 602. The retaining member 612 may be spaced from the upper surface of the sheet 606 such that there is adequate clearance to receive the contact lens package 602 and sufficient closeness to upper surface of the sheet 606 to provide a stabilizing counter force during operation. For example, the retaining member 612 (e.g., the plate 614) may define bottom surface that abuts the upper surface of the sheet 606. The plate 614 may be sized to correspond to the size of the contact lens package 602. In an example, the retaining member 612 maybe fixed (e.g., plate 614 may be a fixed component of the press 600). In an example, the retaining member 612 may be moveable, having for example a loading position with extra clearance for receiving the contact lens package 602 and an active position that abuts (e.g., and / or further presses) the upper surface of the sheet 606. For example, the retaining member 612 may include a robotic end effector that is controllably moveable.

[0055] In FIGs. 6B and 7B, the front section of flange 608 and a corresponding portion of the sheet 606 may be displaced. For example, the flange 608 and a corresponding portion of the sheet 606 may be displaced relative to the cavity 610. In an example, a displacement member 616 (such a pusher bar 618 for example) may displace, relative to the cavity 610, the flange 608 and a corresponding portion of the sheet 606. A displacement member 616 (such a pusher bar 618 for example) may displace, relative to the cavity 610, the flange 608 and a corresponding portion of the sheet 606 by providing an upward force on the flange 608 (either directly to the flange 608 or via a tab 619 of the contact lens package 602), bending the flange and the corresponding portion of the sheet 606 upward at an angle, while the remaining portion of the contact lens package 602 (including, for example, the cavity 610 and / or the other portion of the sheet 606) remains fixed (e.g., fixed between the holder 604 and the retaining member 612, e.g., plate 614). In an example, a displacement member 616 may be configured to displace, relative to the cavity 610, the flange 608 and a corresponding portion of the sheet 606 by providing a downward force on the flange 608, bending the flange and the corresponding portion of the sheet 606 downward at an angle, while the remaining portion of the contact lens package 602 (including, for example, the cavity 610 and / or the other portion of the sheetAttorney Docket No.: VTN6155WOPCT1606) remains fixed (e.g., fixed between the holder 604 and the retaining member 612, e.g., plate 614). In an example, the flange 608 and a corresponding portion of the sheet 606 may be displaced relative to the cavity 610 by stabilizing the flange 608 and the corresponding portion of the sheet 606, and displacing the portion of the contact lens package containing the cavity.

[0056] The displacement member 616 may include any manipulation hardware suitable for displacing the flange 608 and the corresponding portion of the sheet 606 may be displaced relative to the cavity 610. For example, the displacement member 616 may include manipulation hardware such as the pusher bar 616, a moving roller (where a roller moves relative to the secure contact lens package, and an edge of the moving roller interferes and displaces the flange 608 and the corresponding portion of the sheet 606), a stationary roller (where a conveyed contact lens package moves relative to stationary roller, and an edge of the stationary roller interferes and displaces the flange 608 and the corresponding portion of the sheet 606), a robotic end effector, a bending ramp (where a conveyed contact lens package is moved adjacent to a ramp that interferes and displaces the flange 608 and the corresponding portion of the sheet 606), and the like. Force for the pusher bar 618 may be provided by a controllable air cylinder and / or other actuator. The displacement member may also include a bar or wedge which passes between the flange 608 and corresponding portion of the sheet 606.

[0057] The displacement of the flange 608 and a corresponding portion of the sheet 606 may be such that upon removal of the force provided by the displacement member 616 there is an edge separation 620 between the flange 608 and the corresponding unsealed portion of the sheet 606. Because the sheet generally comprises a foil layer, the sheet is malleable and can retain its position after deflection. Thus, to effect an edge separation, the magnitude of displacement may be calibrated to reversibly deflect the flange 608. Upon recovery, the flange 608 may recover its original shape while the sheet 606 remains in an at least partially deflected from its original position. For example, upon recovery, the sheet 606 may recover relatively little of its original shape. For example, upon recovery, the flange 608 may recover most of its original shape. In an example, a vertical displacement of between about 5 mm and about 20 mm may generate the edge separation 620 for typical contact lens packaging materials and / or form factors.

[0058] FIGs. 6C and 7C, illustrate, the edge separation 620 between the flange 608 and a corresponding portion of the sheet 606. Here, the displacement member 616Attorney Docket No.: VTN6155WOPCT1(e.g., pusher bar 618) may disengage. For example, the displacement member 616 (e.g., pusher bar 618) may move to a position that avoids interference with recovery of the flange 608 and the corresponding portion of the sheet 606. For example, the displacement member 616 (e.g., pusher bar 618) may return to an initial position (such as that shown in FIGs. 6A and 7A, for example). For example, the displacement member 616 may move to a position, other than its initial position, that avoids interference with recovery of the flange 608 and the corresponding portion of the sheet 606. With the displacement member 616 disengaged, the displaced flange 608 of the contact lens package may exhibit resilience and recover more than sheet 606, effectively separating the top side of the flange 608 from the bottom side of the sheet 606 at the edge.

[0059] FIG. 8 illustrates an example gripper 800. The gripper 800 may be disposed at a second station, different from the first station housing the press 600. The gripper 800 may be used to remove a sheet from the body of a contact lens package. For example, the gripper 800 may be used to remove a sheet from the body of a contact lens package after an edge separation has been developed between the flange of a contact lens package and the corresponding portion of the sheet (for example, as illustrated in FIGs. 6A-C and 7A-C).

[0060] The gripper 800 may include a first jaw 802 and a second jaw 804. The second jaw 804 may oppose the first jaw 802. The first jaw 802 and the second jaw 804 may be operable to be closed on each other for grasping. The first jaw 802 and the second jaw 804 may be operable to be opened from each other for releasing and / or initial positioning. The opening and closing of the jaws 802, 804 may be controlled by an actuator, such as an air cylinder 806, for example. The gripper 800 may be configured to insert a portion of the first jaw 802 between a flange and the corresponding portion of the sheet at the edge separation as disclosed herein. The gripper 800 may be configured to detach the sheet from the body of a contact lens package.

[0061] The first jaw 802 and the second jaw 804 may be configured to grasp the sheet of a contact lens package and detach it from the corresponding body. The first jaw 802 may define a first face 808. The second jaw 804 may define a second face 810. In an example, the faces 808, 810 of each of the first and second jaws 802, 804 may have complementary profiles, enabling, for example, a flush fit suitable for grasping thin, sheetlike materials. For example, faces 808, 810 of each of the first and second jaws 802, 804 may be configured one with an anvil and the other with a crimper die complementing the anvil and / or being otherwise suitable for gripping the sheet.Attorney Docket No.: VTN6155WOPCT1

[0062] In an example, the first face 808 of the first jaw 802 and / or the second face 810 of the second jaw 804 may be configured with a textured face (e.g., a knurled, roughened or hatched textured) to increase friction with the contact lens package’s sheet. In an example, the first face 808 of the first jaw 802 and / or the second face 810 of the second jaw 804 may have a surface material (e.g., a rubber material) to increase friction with the contact lens package’s sheet.

[0063] The first and second jaws 802, 804 of the gripper 800 may be commonly movable. For example, gripper 800 may be configured to move the first and second jaws 802, 804 such that their position relative to each other is unchanged. For example, the gripper 800 may be configured to move the first and second jaws 802, 804 maintaining the jaws in a closed position. For example, the gripper 800 may be configured to move the first and second jaws 802, 804 maintaining the jaws in an open position. In an example, the first and second jaws 802, 804 may be mounted to a carriage 812. Movement of the carriage 812 may commonly move the first and second jaws 802, 804. As it will be further illustrated, the first and second jaws 802, 804 of the gripper 800 may be commonly movable to detach a grasped contact lens sheet from its corresponding body. For example, first and second jaws 802, 804 of the gripper 800 may be commonly movable in a lateral direction, for example, parallel to the face of the contact lens package. The carriage 812 may be moved by a controllable actuator, such as a servo motor for example.

[0064] In an example, the first jaw 802 may have a bottom surface (e.g., the bottom surface of one or more lateral prongs 814 disposed at distal end of the first jaw 802). The bottom surface of the first jaw 802 may provide an additional stabilizing force on the contact lens package. Likewise, the second jaw may have its own bottom surface (e.g., a portion of the bottom surface of an integrated carriage 812). The bottom surface of the second jaw 804 may provide an additional stabilizing force on the contact lens package.

[0065] The gripper 800 may be disposed relative to a conveyor 816. The conveyor 816 may be configured to convey contact lens package holders 818 (such as holder 500, for example). The conveyor 816 may convey a contact lens package previously manipulated to have a separation between flange and sheet (such as contact lens package 602 in holder 604) to the working space of the gripper. A sensor may be used to detect the proximity of a contact lens package to the working space of the gripper, such that when the contact lens package and / or its corresponding holder is in position, the gripper may manipulate the contact lens package (e.g., detach the sheet from the body).Attorney Docket No.: VTN6155WOPCT1

[0066] FIGs. 9A-F are block diagrams depicting a second manipulation of a contact lens package 602. And FIGs. 10A-F are perspective views illustrating corresponding operation of an example gripper 800. As shown in FIGs. 9A and 10A, the gripper 800 is in an initial position to receive the contact lens package 602 in its holder 604. Here, the first jaw 802 and the second jaw 804 may have an opening distance 902 that is suitable for allowing the conveyor to move the contact lens package 602 into position without interference. The first and second jaws 802, 804 may be disposed parallel to the upper surface of the sheet 606.

[0067] As illustrated in FIGs. 9B and 10B, the second jaw 804 may move (e.g., laterally) such that a bottom surface of the second jaw 804 abuts the upper surface the sheet 606. The bottom surface of the second jaw 804 may provide a stabilizing force on the contact lens package 602. The second jaw 804 may be moved to be proximate to one side of the displaced portion of sheet. For example, the second jaw 804 may be moved to proximate to the vertex in sheet 606, in preparation for closing the first and second jaws 802, 804. In an example, this movement may be a lateral movement common with the first jaw 802. For example, this movement may be driven by moving the carriage 812 laterally. The opening distance 904 may be the same as the opening distance 902. In an example, the opening distance 904 may be different from (e.g., less than) the opening distance 902. The common lateral movement of the first and second jaw may be caused by a servo actuator driving the carriage 812.

[0068] As illustrated in FIGs. 9C and 10C, the first and second jaws 802, 804 may close on the sheet 606. The gripper 800 may be configured to insert a portion (e.g., a bottom edge portion) of the first jaw 802 between the flange 608 and the corresponding portion of the sheet 606 at the edge separation 620. For example, the gripper may be configured such that the first jaw 802 is moved toward the second jaw 804 to grasp the sheet 606. The first jaw 802 and second jaw 804 may be actuated to close on the sheet at the edge separation 620. For example, the first jaw 802 and second jaw 804 may be configured to grasp the sheet 606 at the edge separation 620.

[0069] As illustrated in FIGs. 9D and 10D, common lateral movement of the closed first and second jaws 802, 804 may be used to detach (e.g., peel) the sheet 606 from the body 605 of the contact lens package 602. The common lateral movement of the first and second jaws 802, 804 may be in a direction that is toward an end opposite the edge separation 620 (e.g., toward and / or past the cavity 610) and that is parallel to the upper surface of the flange 608. The common lateral movement of the first and second jaws 802, 804 may cause aAttorney Docket No.: VTN6155WOPCT1 controlled peel of the of the sheet 606. For example, the sheet 606 may develop a fold 906 back over itself during the peel. In an example, the first and second jaws 802, 804 may remain stationary and the holder 604 may provide relative movement to cause the controlled peel. This operation may break the seal between the body 605 and the sheet 606. The speed of the movement may be calibrated to prevent skinning where a portion of sheet is left behind at the seal.

[0070] FIGs. 9E and 10E show the sheet 606 being fully detached from the contact lens package 602. Here, the first and second jaws 802, 804 may be opened and provide an opening distance 908 between them. The opening may free the removed sheet 606 from being grasped. In an example, a controllable air compressor may be used to provide a puff of air to facilitate dislodging the removed sheet 606 from the first and / or second jaws 802, 804.

[0071] The sheet 606 may be received in a first bin. The first bin may be used to collect sheets 606 for subsequent processing. For example, the first bin may be used as input for a corresponding recycling stream, including recycling the sheet 606 via a different stream than the body 605 and flange 608 portions of the contact lens package 602.

[0072] As shown in FIGs. 9F and 10F, the gripper 800 may return to its initial position. For example, the gripper 800 may retract the carriage 812. For example, the gripper 800 may open the jaws 804, 804 to the initial separation 902. The holder 604 with the remaining portions of the contact lens package 602 may be conveyed from the gripper 800 without interference. For example, the remaining portions of the contact lens package 602 may be conveyed for further processing.

[0073] In an example, the contact lens package 602 still containing storage solution and lens(es) in the cavity 610 may be processed. The contact lens package 602 may be resealed with new sheet stock. For example, contact lens package 602 may be resealed with a sheet having different labeling. For example, contact lens package 602 may be resealed with a sheet stock of a different material or composition. For example, contact lens package 602 may be resealed with a general sheet stock for bulk storage, for example.

[0074] In an example, the further processing may include removing the contact lens and / or storage solution from the cavity of the now opened contact lens package. The contact lens and / or storage solution may be removed from the cavity of the now opened contact lens package via, for example, a contact lens picker.Attorney Docket No.: VTN6155WOPCT1

[0075] FIG. 11 is a perspective view of an example contact lens picker 1100. The contact lens picker 1100 may include one or more actuators and manipulation hardware suitable for evacuating storage solution and / or picking a contact lens from an opened contact lens package. For example, the contact lens picker 1100 may include one or more pick heads 1102a-e. Each pick head 1102a-e may include a respective nozzle 1104a-e each mounted to a movable frame 1106. The motion of the frame 1106 may be controlled to move the nozzles 1104a-e into and out of proximity of the open contact lens package. For example, the contact lens picker 1100, when the open contact lens package is conveyed to a working position indicated by a corresponding sensor, may move from an initial position to a working position where the tips of each nozzle are received into corresponding cavities of the open contact lens for operation.

[0076] The nozzles 1104a-e may include one or more orifices 1106 at their tips. The orifices 1108 may include openings in the nozzles connected to tubing and actuators suitable for removing storage liquid and / or picks the contact lens. For example, the nozzles 1104a-e and the orifices 1108 may be configured to remove storage liquid via a vacuum actuator. For example, the nozzles 1104a-e and the orifices 1108 may be configured to provide a vacuum engagement with the contact lens inside of the cavity. In an example, the nozzle 1104a-e may include multiple type orifices 1108, each type being tubed to a different actuator. For example, an orifice 1108 of the first type may be used for storage solution, and an orifice 1108 of the second type may be used for the contact lens picking. The contact lens picker 1100 may include a separator for disposing the collected storage solution into a container. The collected storage solution may be disposed. In a quality control and inspection use case, the storage solution may be individually stored, sampled, and / or tested, for example.

[0077] Once the contact lenses have been removed from the contact lens package, they may be placed by the picker 1100 for further processing. For example, the removed lenses may be placed into different consumer packaging, into a manufacturing working tray, in manufacturing packaging for bulk storage, presented for inspection, disposed into a bin, and the like.

[0078] The remaining empty contact lens package body may be conveyed for further processing. For example, the empty contact lens body may be received in a bin for recycling (e.g., a second bin for a second recycling stream that is different than that for the sheet), may be processed for reuse (e.g., sterilized, replaced with storage solution and lens, and re-sealed), may be processed for storage, may be tested and / or inspected, and the like.Attorney Docket No.: VTN6155WOPCT1

[0079] FIG. 12 is a flow diagram of an example industrial automation method 1200. The method 1200 may be used by a processor of an industrial automation system (such as processor 102 of industrial automation system 100, for example). For example, the method 1200 may be implemented as computer readable instructions that when executed cause the system to perform the method 1200.

[0080] At 1202, a contact lens package may be received. For example, a contact lens package may be received in a holder. For example, the contact lens package may be placed in a holder and received at a conveyor load point. For example, one or more sensors, actuators, and manipulation hardware may be used when receiving the contact lens package.

[0081] At 1204, it may be determined if the contact lens package is at a press station. If the contact lens package is not yet at the station, the conveyor may be actuated to further convey the holder of the contact lens package, at 1206. The presence of the holder and contact lens package at the press station may be indicated by a sensor.

[0082] At 1208, an edge separation between the flange and the corresponding portion of the sheet may be generated. For example, a flange and a corresponding portion of the sheet of the contact lens package may be displaced to generate the edge separation. For example, the flange and the corresponding portion of the sheet of the contact lens package may be displaced relative to the cavity, such that upon recovery there is an edge separation between the flange and the corresponding portion of the sheet. The displacement may be performed by one and more controlled actuations at a press, such as press 600 for example.

[0083] In an example, the edge separation may be generated by a configured actuation of hardware, such a directed air flow to raise the edge of the sheet, a robotic end effector, an articulable vacuum dry picker used to pull the sheet, and the like. Upon completion of this operation, the holder and contact lens package may be conveyed to a subsequent station. In an example, the contact lens package and holder may remain stationary, and the various manipulation hardware may be moved into and out of a working station.

[0084] At 1210, it may be determined if the contact lens package is at a gripper station. If the contact lens package is not yet at the station, the conveyor may be actuated to further convey the holder of the contact lens package, at 1212. The presence of the holder and contact lens package at the gripper station may be indicated by a sensor.Attorney Docket No.: VTN6155WOPCT1

[0085] At 1214, the sheet, at the edge separation, may be grasped. It may be grasped by one or more controlled actuations. For example, it may be grasped by jaws of a gripper. For example, it may be grasped by inserting a first portion of an automated gripper between the flange and the corresponding portion of the sheet at the edge separation and closing the jaws.

[0086] At 1216, the sheet may be detached. For example, the sheet may be detached by one or more controlled actuations, including for example, controlled actuations of a gripper. For example, the sheet may be detached by grasping, via the automated gripper, the sheet at the edge separation and laterally peeling the sheet from the body. For example, a common lateral movement of closed gripper jaws grasping the sheet may detach the sheet.

[0087] At 1218, the sheet and / or the remaining body may be transported. For example, the sheet and / or the remaining body may be transported for further processing. The sheet may be disposed in a bin for recycling for example. The remaining body may be transported to a subsequent lens picker station to evacuate liquid from the cavity and removing the contact lens from the cavity.

[0088] The industrial automation system disclosed herein may provide for safe and efficient handling and manipulation of consumer contact lens packages facilitating any number of use cases. These use cases may enhance sustainability, improving the capacity and efficiency of sustainable practices including recycling, flexible stock storage, repackaging, automated testing / inspection, and the like. Sustainable practices may reduce carbon footprint, more efficiently use natural resources, and produce less waste, which is a benefit for everyone who calls this planet of ours home.

Claims

Attorney Docket No.: VTN6155WOPCT1Claims1. A contact lens package handling device, wherein the contact lens package comprises a body and a sheet, wherein the body comprises a cavity and a flange extending outwardly from the periphery of the cavity; wherein a portion of a bottom side of the sheet is detachably sealed to the body about the periphery of the cavity, and wherein an unsealed portion of the bottom side of the sheet abuts a top surface of the flange, the device comprising:A displacement member configured to displace, relative to the cavity, the flange and the unsealed portion of the sheet such that upon recovery there is an edge separation between the flange and the unsealed portion of the sheet; and a gripper comprising a first jaw and an opposing second jaw, wherein the gripper is configured to insert a portion of the first jaw between the flange and the corresponding portion of the sheet at the edge separation and to detach the sheet from the body.

2. The contact lens package handling device of claim 1 , further comprising a holder to stabilize the body of the contact lens package.

3. The contact lens package handling device of any preceding claim, further comprising a plate to abut an upper side of the sheet to provide a stabilizing counterforce for operation of the press.

4. The contact lens handling device of any preceding claim, wherein the press is configured to displace the flange by displacing the flange in an upward direction.

5. The contact lens handling device of any preceding claim, wherein the actuator is configured to displace the flange by displacing the flange in a downward direction.

6. The contact lens handling device of any preceding claim, wherein the press comprises a corresponding air cylinder and a pusher bar.Attorney Docket No.: VTN6155WOPCT17. The contact lens handling device of any preceding claim, wherein the press and the gripper are at separate stations, and wherein the contact lens package is conveyed from the press to the gripper.

8. The contact lens handling device of claim 7, further comprising a conveyor, wherein the holder is engaged to the conveyor, and wherein the contact lens package is conveyed from the press to the gripper by the conveyor conveying the holder from the actuator to the gripper.

9. The contact lens handling device of any preceding claim, wherein the second jaw advances to the first jaw to grasp the sheet when the first jaw is disposed between the flange and the corresponding portion of the sheet at the edge separation, the second jaw having a bottom surface that is configured to abut the top surface of the sheet at the periphery of the cavity.

10. The contact lens handling device of any preceding claim, wherein the gripper comprises a corresponding air cylinder to supply clamping force for the first and second jaws; wherein the gripper comprises a servo to commonly move the first and second jaws.

11. The contact lens handling device of any preceding claim, wherein first and second jaws commonly move parallel to the upper surface of flange to detach the sheet.

12. The contact lens handling device of any preceding claim, wherein the sheet is detached by laterally peeling the sheet from the body.

13. The contact lens handling device of any preceding claim, further comprising a lens picker comprising an end effector configured to evacuate liquid from the cavity and to remove a contact lens from the cavity.

14. The contact lens handling device of any preceding claim, wherein the contact lens package is part of a lateral contact lens package array with a common flange side.

15. A method comprising:Attorney Docket No.: VTN6155WOPCT1 receiving, in an industrial automation system, a contact lens package, the package comprising a body and a sheet, wherein the body comprises a cavity and a flange extending outwardly from the periphery of the cavity; wherein a bottom side of the sheet is detachably sealed to the body about the periphery of the cavity, and wherein the bottom side of the sheet abuts a top surface of the flange; displacing, relative to the cavity, the flange and a corresponding portion of the sheet such that upon recovery there is an edge separation between the flange and the corresponding portion of the sheet; inserting a first portion of an automated gripper between the flange and the corresponding portion of the sheet at the edge separation detaching, via the automated gripper, the sheet from the body.

16. The method of claim 15, wherein said displacing comprising displacing the flange in an upward direction.

17. The method of any of claims 15 and 16, wherein said detaching comprises grasping, via the automated gripper, the sheet at the edge separation and laterally peeling the sheet from the body.

18. The method of any of claims 15-17, further comprising evacuating liquid from the cavity, via a contact lens picker, and removing a contact lens from the cavity.

19. A contact lens package array handling device, wherein the contact lens package array comprises a connected array of contact lens packages with a unified body and a common sheet, wherein the body comprises, for each package, a corresponding cavity and a corresponding flange extending outwardly from the periphery of the cavity, where each corresponding flange is disposed at a common side of the array, wherein a bottom side of the sheet is detachably sealed to the body about the periphery of each cavity, and wherein the bottom side of an unsealed portion of the sheet abuts a top surface of the flange, the device comprising: a displacement member configured to collectively displace, relative to the cavity, each flange and a corresponding portion of the sheet such that upon recovery there is an edge separation between each flange and the corresponding portion of the sheet.Attorney Docket No.: VTN6f55WOPCTi20. The contact lens package array handling device of claim 19, further comprising a gripper configured to detach the common sheet from contact lens package array, wherein the common sheet is disposed into a first recycling stream and the unified body is disposed into a second recycling stream, different than the first recycling stream.

21. The device of claim 1 or 21 wherein the displacement member is selected from a pusher bar, a moving roller, a stationary roller, a robotic end effector, and a bending ramp.

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