A method of packaging a contact lens

Abstract

Systems, methods, and instrumentalities are disclosed for transferring a contact lens from a lens transfer tip configured to support a concave side of the contact lens to a lens transfer tip configured to support a convex side of the contact lens, for example such that the contact lens may be oriented concave-down when released. A concave-down orientation of the contact lens may allow a wearer to apply a contact lens (e.g., place the contact lens onto the eye) from a container more easily.

Description

[0001] Attorney Docket No.: VTN6157WOPCT1

[0002] A METHOD OF PACKAGING A CONTACT LENS

[0003] Related Applications

[0004] [i] This application claims priority to U.S. Provisional Patent Application Serial No.

[0005] 63 / 691,361, filed September 6, 2024, which is incorporated herein by reference in its entirety.

[0006] Background p] Contact lenses are small, delicate, and sensitive optical parts. The handling and transfer of contact lenses, such as during manufacturing and packaging, may involve different operations, in which a contact lens is physically manipulated. Such physical manipulations may be used to orient the lens for packaging. p] The materials used in contact lenses may be highly sensitive to physical contact.

[0007] During handling and / or transfer operations, for example during packaging, forces applied to a contact lens may result in damage to the lens.

[0008] Summary

[0009] [4] Systems, methods, and instrumentalities are disclosed for transferring a contact lens from a lens transfer tip configured to support a concave side of the contact lens to a lens transfer tip configured to support a convex side of the contact lens, for example such that the contact lens may be oriented concave-down when released. A concave-down orientation of the contact lens may allow a wearer to apply a contact lens (e.g., place the contact lens onto the eye) from a container more easily. Manipulation of a contact lens in a concave-down orientation may add significant complexity to the process of packaging the contact lens.

[0010] [5] A method of packaging a contact lens may include removably coupling a first side (e.g., a convex side) of the contact lens with a lens holding tip. The lens holding tip may be aligned with a container (e.g., a blister pack) having a support structure and a floor. In examples, the lens holding tip may be aligned with the support structure. The support structure may be configured to receive and support a second side (e.g., a concave side) of the contact lens above the floor. Based on the alignment of the lens holding tip to the support structure, the contact lens may be Attorney Docket No.: VTN6157WOPCT1 released from the lens holding tip such that the first side of the contact lens may be accessed from the container while the contact lens is supported by the support structure.

[0011] [6] The support structure may include a member configured to act as a fulcrum.

[0012] Releasing the contact lens from the lens holding tip to the support structure may include the contact lens pivoting about the fulcrum. The support structure may be angled with respect to the contact lens (e.g., when aligned). p] A collective tolerance of alignment for the support structure and the lens holding may be satisfied before releasing the contact lens. p] A burst of air may be applied to the first side of the contact lens (e.g., upon releasing the contact lens from the lens holding tip) to direct the contact lens to the support structure. p] The lens holding tip may have an inner suction diameter and an outer diameter, such that the inner suction diameter is configured to maintain a vacuum while releasably coupled to the contact lens, wherein the inner suction diameter is less than one third of the outer diameter.

[0013]

[0010] The lens holding tip may be configured to surround the first side of the contact lens at least partially (e.g., when removably coupled to the contact lens). The lens holding tip may be configured to removably couple the first side of the contact lens via one or more of a vacuum or a Bernoulli gripper.

[0014]

[0011] An optical inspection may be performed. The optical inspection may include a comparison of a base curve radius of the contact lens to a threshold.

[0015] Brief Description of the Drawings

[0016]

[0012] FIG. 1A illustrates a side view of an example contact lens container with a lens support.

[0017]

[0013] FIG. IB illustrates a perspective view of the bowl region of the container of FIG. 1A.

[0018]

[0014] FIG. 2A illustrates a perspective view of the bowl region of a second example contact lens container.

[0019] [is] FIG. 2B illustrates a perspective view of a third example of a contact lens container.

[0020]

[0016] FIGs. 3A-C illustrate an example method of picking up a contact lens from a contact lens container of FIGs. 1. Attorney Docket No.: VTN6157WOPCT1

[0021]

[0017] FIG. 4 illustrates a block diagram of an example transportation module.

[0022] [is] FIG. 5 depicts an example gripper.

[0023]

[0019] FIG. 6 depicts an example array of grippers. po] FIGs. 7A & B depict example lens holding tips. pi] FIGs. 8A-D depict example configurations of lens holding tips.

[0024]

[0022] FIGs. 9A-C depict example configurations of lens holding tips.

[0025]

[0023] FIGs. 10A & B depict an example gripper in a pre-pick position.

[0026]

[0024] FIGs. 11A & B depict an example handoff process of a contact lens between grippers. ps] FIGs. 12A & B depict an example handling process of a contact lens on a gripper.

[0027]

[0026] FIGs. 13A & B depict an example alignment process for transferring a contact lens to a container and a perspective view of an example alignment process, respectively.

[0028] Detailed Description

[0029]

[0027] A contact lens may be packaged in a container (e.g., a storage container, such as a disposable storage container), as disclosed herein. Different types of containers may be used for storage of contact lenses. For example, containers may be durable molded structures structured for storage of the lens after manufacture and prior to use by a wearer. For example, a container may also be a manufacturing tray. Such a tray may serve as an intermediate storage vessel during manufacturing. For example, a contact lens between processing steps in a manufacturing process may be temporarily stored in a container. ps] In an example, a container (e.g., blister pack or package) for contact lenses may include a polypropylene receptacle for the lens (sometimes referred to as a well), which may be sealed by a removable lid (e.g., made of foil). The container may be an injection molded plastic and may include a pre-formed well. The container may be filled with a solution (e.g., saline or a suitable storage solution) and / or may receive a single lens into the well. The well may be sealed and sterilized. Sterilization may be performed, for example using steam and pressure to achieve terminal sterilization as demanded by industrial standard requirements and / or irradiation. The package may be kept sealed and may minimize water vapor Attorney Docket No.: VTN6157WOPCT1 transmission through the well and the seal (e.g., to maximize the shelflife and keep the lens hydrated).

[0030]

[0029] A concave well offers little direct support (e.g., regarding which surface is extended towards the foil cover) to a maintain the contact lens in the concave position. During storage of a blister pack in various orientations, the contact lens may invert or fold in the concave well, which may complicate application and / or lead to incorrect use of the contact lens. The convex side of the lens may also interact with the floor of the well, which can make lens removal from the blister pack more difficult and may create optical distortions in the lens. Removing a contact lens from a concave bowl also requires the use of fingers on both hands, increasing potential contamination of the lens. po] Blister packs having wells comprising convex supports which support the concave surface of the lens (e.g., the surface configured for corneal contact) such that the convex surface of the lens extends towards the film cover have been disclosed in US11,O71,644, US2023 / 0339672, W02023 / 248062, US2022 / 229563. Blister packs with convex supports can reduce the handling necessary to remove and transfer the lens to the eye. However, positioning the lens on the support must be done to much tighter tolerances and transferring the lens from the manufacturing process to the convex lens support is more difficult that transferring the lens into a concave bowl due to the need to correctly place the concave surface of the lens onto the convex support. pi] FIGs. 1A-B and2A-B depict example containers 100 which may include support structure 116 for contact lens 102. FIGs. 3A-3C depict an example removal of contact lens 102 from container 100. Contact lens 102 housed in a container 100 may a soft lens or a rigid gas permeable lens. In examples container 100 may house one or more contact lenses.

[0031]

[0032] Container 100 may be fabricated individually or as part of an array (not shown) comprising a plurality of removably attached blister packs. Container 100 may be fabricated of a material with a high stiffness whilst being capable of limited plastic deflection and water-tight (e.g., such as a plastic). Container 100 may be manufactured with any suitable means, such as injection molding, thermoforming, and / or compression molding. Container 100 maybe formed as a single body.

[0032]

[0033] Container 100 may comprise well 108 configured as a receptacle for contact lens 102. In examples, one or more wells 108 and respective contact lenses 102 may exist in a 1:1 ratio (e.g., there may be only one lens 102 per well 108). Well 108 maybe formed with floor 112 and side wall 114. Floor 112 may be configured as a Attorney Docket No.: VTN6157WOPCT1 substantially disc-shaped reception area a bowl shaped reception area or may comprise a convex dome as shown in FIG. 2B. Side wall 114 may be configured as an upwardly sloping peripheral wall. It should be understood that well 108 may have any three-dimensional configuration that may be suitable for housing a contact lens 102. For example, side wall 114 maybe angled such that, together with floor 112, well 108 may form a generally concave depression as illustrated in FIG. IB. Well 108 maybe filled with a suitable storage solution 106 (e.g., saline) to keep stored contact lens 102 from drying out.

[0033] P4] Container 100 may comprise a support structure 116, for example within well 108. Support structure 116 may support a concave surface of contact lens 102 (e.g., act as a pillar or pedestal for supporting the concave surface). Support structure 116 may be formed separately and then mounted to the container, such as to the well 108 or part of the flange 124 (as shown in FIG. 2B) or it may be integral to well 108 and produced during the injection molding process. Support structure 116 may extend outwardly or upwardly from a first end 116a attached to the interior side of floor 112 to a second end 116b opposite first end 116a, for example to provide a support to a contour of the concave surface (e.g., corneal contact surface) of contact lens 102. Support structure 116 maybe configured to control a contact surface area 126 between contact lens 102 and a user's finger and / or an applicator tool. The support structure may minimize the contact surface area between it and the contact lens 102 to improve the releasability of the contact lens 102 from the support structure to the finger. The support structure may also be designed to provide drainage channels 118 for storage fluid to escape and / or air to enter underneath the contact lens upon opening the package and either removing the packaging solution or withdrawing the lens from the packaging solution. ps] The support structure may be solid or hollow and may have a variety of configurations such as pillars (shown in FIG. IB) or radially spaced fins 200 (shown in FIG. 2A). The support structure may also be separate from the base as is shown with the pivoting support 117 shown in FIG. 2B. As illustrated in FIG. 2A, second end 116d of each fin 200 may be profiled with first profile 202 that may be contoured to generally conform to the curvature of the concave surface of contact lens 102. In examples, each of the plurality of fins 200 may be profiled with second profile 204, which may function as a guide to engage with the edge of contact lens 102. For example, a tolerance may be anywhere between ±0.5 mm to ±1.5 mm (e.g., ±1 mm) from the central axis X-X or apex of contact lens 102. First profile 202 and second profile 204 may cooperate to form a seated region for supporting the Attorney Docket No.: VTN6157WOPCT1 concave side of contact lens 102 (e.g., the convex side of contact lens 102 faces upwardly towards the wearer).

[0034] P6] The perimeter of support structure 116 may define depression area 104 (e.g., such that contact lens 102 may be left unsupported by depression area 104 as shown in FIG. 3A). For example, support structure 116 may be configured to be substantially cylindrical and / or ring-shaped as illustrated in FIGs. 2. Contact surface area 126 between contact lens 102 and an applicator (e.g., index finger or applicator tool) may be dictated by the area defined by the perimeter of support structure 116. When the convex surface of contact lens 102 is depressed by a user, contact lens 102 may be advantageously encouraged to deform about second end 116b of support structure 116 such that surface area of contact lens 102 in contact with the user increases until the area defined by the perimeter of support structure 116 prevents any further increase in contact surface area 126 between the applicator and contact lens 102 as shown in FIGs. 3B and 3C. For example, second end 116b of support structure 116 may act as a fulcrum such that contact lens 102 maybe encouraged to pivot about the fulcrum (e.g., such that contact surface area 126 deforms when pressure may be applied to the portion of contact lens 102 in depression area 104).

[0035]

[0037] Inversion of contact lens 102 may result in the periphery or rim of contact lens 102 sweeping about an arc. However, side wall 114 of well 108 may be angled such that the periphery or rim of contact lens 102 may be resisted from lifting by contacting a point on side wall 114 of well 108. As the rim of the contact lens 102 is resisted from lifting away from floor 112, the portion 126 of the contact lens 102 in the depression area 104 maybe made to deform. As contact surface area 126 of the contact lens 102 increases, the surface tension increases between the applicator tool and contact lens 102. The area defined by the perimeter of the member controls contact surface area 126 between the applicator and contact lens 102 which ultimately controls the degree of surface tension between applicator and contact lens 102. The size and orientation of contact surface area maybe manipulated to improve the ease of application if contact 102 is accurately placed on support structure 116. ps] With continued reference to in FIGs. 3A-3C, support structure 116 may be positioned in well 108 such that depression area 104 may be directly aligned with the apex of contact lens 102 (e.g., allowing the apex of contact lens 102 to be in contact with the finger). If a different portion of contact lens 102 is in contact with the finger causing contact lens 102 to be off center on the finger, contact lens 102 may not correctly transfer to the fingertip or be correctly located on the corneal Attorney Docket No.: VTN6157WOPCT1 surface when placed on the eye. For example, contact lens 102 may be orientated off-center on the surface of the finger causing the lens to fold on the finger or when attempting to place on the eye. Proper positioning of contact lens 102 on the convex support ensures that the lens is maintained in the desired orientation during storage, avoiding damage to the lens and insuring the desired transfer of the lens from the package to the users finger.

[0036]

[0039] When contact lens 102 may be inserted off-center of the defined location by more than a tolerance, the guide urges contact lens 102 towards the center of the support structure 116. The tolerance may be anywhere between about 0.1mm to about 2 mm or about 0.1 to about 0.5 mm from the axial center of contact lens 102. If placed beyond the tolerance, contact lens 102 may be classed as being off-center over depression area 104, which may result in improper positioning of the contact lens 102 on the finger.

[0037]

[0040] Side wall 114 of well 108 maybe configured with spout 120. Spout 120 may permit pouring of fluid (e.g., storage solution 106) from well 108. pi] Container 100 may be fabricated with flange 124. Flange 124 may be a deck extending horizontally from the edge of well 108 and may be configured enable the user to grip the package to enable opening. Flange 124 may also comprise a heat seal region 119 around the perimeter of bowl 108 to enable sealing engage with a closure, cover, and / or or lid 110 which may be a metallic foil and / or foil / plastic laminate. As illustrated in FIG. 2A, second end 116d of each fin 200 maybe profiled with first profile 202 that may be contoured to generally conform to the curvature of the concave surface of contact lens 102. In examples, each of the plurality of fins 200 may be profiled with second profile 204, which may function as a guide to engage with the edge of contact lens 102. For example, a tolerance may be anywhere between about 0.1 to about 2mm, about ±0.5 mm to ±1.5 mm or about 0.1 to about 0.5 mm from the central axis X-X or apex of contact lens 102. First profile 202 and second profile 204 may cooperate to form a seated region for supporting the concave side of contact lens 102 (e.g., the convex side of contact lens 102 faces upwardly towards the wearer).

[0038]

[0042] An additional advantage associated with container 100 may be that contact lens 102 may be held in the correct orientation for insertion into the eye without further manipulation. The reduction of manipulation results in lowered risk of contamination.

[0039]

[0043] In manufacturing (e.g., fabrication, inspection, packaging) of contact lenses, transportation modules maybe used to transport the contact lenses from one Attorney Docket No.: VTN6157WOPCT1 module / container to another. During any transport process, care should be taken that the contact lens is oriented and handled properly (e.g., not overly manipulated so as to induce damage). The contact lens may need to be securely gripped and reliably placed at a particular position in a container (e.g., to avoid damage). For example, if contact lens 102 is placed partially on an upper surface of container 100 (e.g., outside of well 108), contact lens 102 may become sealed between lid 110 and container 100.

[0040]

[0044] FIG. 4 illustrates a block diagram of an example transportation module 300. Transportation module 300 may include processor 302, memory 304, sensor(s) 306, transport system 308, and gripper(s) 310.

[0041]

[0045] Processor 302 may be any programmable device that may accept digital data as input, may be configured to process the input according to instructions or algorithms, and may provide results as outputs. In an embodiment, processor 302 may be a central processing unit (CPU) configured to carry out the instructions of a computer program. Processor 302 may be configured to perform basic arithmetical, logical, and input / output operations. Processor 302 maybe configured to interface with other modules and engines of a production line, such as over a network. In examples, transportation module 300 may include multiprocessor or multi-core configurations. The processor 302 maybe 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 302 may include any hardware suitable for data processing and control in industrial automation. For example, the processor 302 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 302 may be configured with computer readable code to perform the methods disclosed herein.

[0042]

[0046] Memory 304 may comprise volatile or non-volatile memory as required by processor 302. Memory 304 may provide space to execute the instructions or algorithms and / or the space to store the instructions themselves. In examples, volatile memory may include random access memory (RAM), dynamic random access memory (DRAM), or static random access memory (SRAM), for example. Attorney Docket No.: VTN6157WOPCT1

[0043] Non-volatile memory may include read-only memory, flash memory, ferroelectric RAM, hard disk, floppy disk, magnetic tape, or optical disc storage, for example. Memory 304 may comprise data storage as implemented by general purpose database management storage system (DBMS) as implemented by, for example, Oracle, IBM DB2, Microsoft SQL Server, PostgreSQL, MySQL, and SQLite solutions. Memory 304 may comprise flat file data storage. The foregoing examples in no way limit the type of memory that may be used.

[0044]

[0047] In examples, transportation module 300 and / or a complete contact lens production line may be controlled (e.g., partially controlled) by an external server or processor. Central control and decision-making functions may be handled by a remote server or processing unit rather than being distributed across individual machines or controllers on the production line. This approach may offer centralized control, efficient monitoring, remote management, security, consistency, and / or data analysis and optimization.

[0045]

[0048] Transportation module 300 may be involved in various processes (e.g., in a contact lens production line) that may benefit from the integration of sensors 306 to monitor and control the manufacturing process. Sensors 306 may include one or more of the following: vision inspection systems, proximity sensors, temperature sensors, pressure sensors, humidity sensors, force sensors, thickness gauges, color sensors, UV lighting sensors, barcode scanners, infrared sensors, flow sensors, vibration sensors, optical sensors, gyroscopes, or accelerometers.

[0046]

[0049] Vision inspection sensors (e.g., cameras) may be used for quality control and inspection purposes, for example to identify defects, irregularities, and / or deviations in the shape, surface, and dimensions of contact lenses. For example, an optical inspection may be performed by vision inspection sensors while handling a contact lens. Optical inspection may be performed on a particular surface of a contact lens.

[0047] [so] Proximity sensors may detect the presence or absence of an object without physical contact. For example, proximity sensors may be used for automated handling and / or sorting of lenses during different stages of the production process. pi] Barcode scanners may be used for tracking and traceability of lenses throughout the production process. Barcode scanners may be part of an automated system for managing inventory and ensuring the correct labeling of products (e.g., containers). Attorney Docket No.: VTN6157WOPCT1

[0048]

[0052] The specific combination of sensors 306 incorporated into transport module 300 and / or used in a contact lens production line may depend on the complexity of the manufacturing processes, the level of automation, and / or the quality standards required by the manufacturer. Sensors 306 may collectively contribute to maintaining product quality, consistency, and efficiency of transportation modules 300 throughout a production line.

[0049]

[0053] Transport system 308 may be configured to move materials, components, and / or finished products between different stages of the manufacturing process. The choice of transport system 308 may depend on factors such as the layout of the production line, the level of automation, and / or the specific requirements of each stage. Transport system 308 may include one or more of the following: conveyor systems, automate guided vehicles, robotic arms, turntables (e.g., rotary tables), transfer systems (e.g., belts, rollers, or pneumatic systems), shuttle systems, or chutes. Conveyor systems may include conveyor belts, roller conveyors, chain conveyors, and the like to transport materials and products from one production line module (e.g., station) to another. They can be customized for different shapes and sizes of contact lens components. Industrial robots (e.g., robotic arms) may be equipped with grippers 310 or end-effectors to pick up and transport contact lens components or products between various stages of the production process.

[0050]

[0054] The transport system 308 may include one or more controllable actuators. The actuators 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 may include linear actuators and / or rotary actuators. The actuators may include devices such as conveyor motors, servo motors, air cylinders, vacuums, solenoid actuators, and the like. The actuators may include robotic actuators. The processor 302 may control the actuators in accordance with computer-readable code.

[0051]

[0055] The transportation system 308 may depend on the specific needs of each production line, and a combination of transportation systems 308 may be used to Attorney Docket No.: VTN6157WOPCT1 ensure seamless material flow, minimize handling, and / or optimize the overall production efficiency.

[0052]

[0056] Transport system 308 may generally include a drive mechanism, such as a motor. Conveyor systems may be equipped with a control system that manages the operation of the motor and, in some cases, may allow for variable speed control. In examples, transport system 308 may be controlled by processor 302 (e.g., remotely). Sensors 306 may be integrated into transport system 308 for automation, such as detecting the presence of items or signaling when to start or stop transport (e.g., stop a conveyor).

[0053]

[0057] Grippers 310 may be devices designed to grasp and hold objects (e.g., contact lenses). The choice of grippers may depend on the specific requirements of the production line, such as the need for precision, and / or the fragility of the lenses. Grippers 310 may include one or more of the following: vacuum grippers, Bernoulli grippers, mechanical grippers, soft-touch grippers, magnetic grippers, robotic grippers, pneumatic grippers, or parallel jaw grippers.

[0054]

[0058] Vacuum grippers may use suction to hold objects (e.g., contact lenses) securely. Vacuum grippers may include one or more suction cups, which may be made of materials such as rubber or silicone. The vacuum gripper may be connected to a vacuum system (e.g., a vacuum pump or generator). The vacuum system may generate negative pressure (e.g., creating a low-pressure zone within the suction cup). The suction that may be created by the vacuum gripper may generate a lifting force that holds the object against the suction cup. The strength of the grip may be influenced by one or more of: the suction cup design, the vacuum level, and the characteristics of the object's surface. In an example, the gripped object may be released. For example, the vacuum system may be deactivated. For example, the vacuum system may be deactivated releasing the gripped object. For example, a burst of positive pressure may be introduced (e.g., breaking the seal and allowing the object to be released). During contact lens production, vacuum grippers may be employed for picking and placing lenses during different stages of the manufacturing process.

[0055]

[0059] Bernoulli grippers may leverage airflow to generate a lifting force for object manipulation. A Bernoulli gripper may be equipped with a nozzle through which a controlled stream of compressed air may be expelled. As the compressed air flows through the nozzle, it may create a region of low pressure near the nozzle opening. When the Bernoulli gripper is positioned close to an object, such as a contact lens, the low-pressure zone created by the fast-moving air generates a lifting force that Attorney Docket No.: VTN6157WOPCT1 may lift and hold the object. A Bernoulli gripper may release a held object when needed, for example by reducing the airflow and / or introducing a burst of reverse airflow. Bernoulli grippers may enable non-contact handling and adaptability to object shapes but may have a limited lifting capacity (e.g., compared to other types of grippers 310).

[0056]

[0060] Mechanical grippers may use mechanical fingers or jaws to physically grasp and hold contact lenses. Mechanical grippers maybe adjusted to accommodate different lens sizes. Mechanical grippers may be suitable for handling lenses with a more robust structure and may provide a firm grip during various manufacturing processes.

[0057]

[0061] Soft-touch or compliant grippers may be designed with flexible materials to provide a gentle grip on delicate contact lenses. Soft-touch grippers maybe used in applications where avoiding damage or deformation of the lenses is critical.

[0058]

[0062] Pneumatic grippers may use compressed air to actuate a gripping mechanism. Pneumatic grippers may be suitable for high-speed applications in contact lens production where rapid and controlled handling is required.

[0059]

[0063] Grippers 310 may be integrated with transport system 308. The movement of grippers 310 may be determined by the configuration of the transport system 308 in which it is integrated. For example, a gripper 310 may be mounted on a robotic arm or other automated mechanism, and the movement of gripper 310 may be dictated by processor 302.

[0060]

[0064] Grippers 310 integrated with transport system 308 may be configured for one or more of the following: linear movement, rotational movement, vertical movement, articulated arm movement, or pivot (e.g., swivel) movement. For example, in a conveyor system, grippers 310 may be part of a larger system where movement is facilitated by a conveyor (e.g., the gripper may move along the conveyor to transport the contact lens to various processing or inspection stations). Movement of grippers 310 maybe determined using coordinate system navigation and / or vision-based guidance.

[0061]

[0065] The specific movements of a gripper for transporting a contact lens may depend on the requirements of the manufacturing or handling process. The integration of grippers with robotic systems may allow for flexibility and precision in transporting contact lenses within a production environment.

[0062]

[0066] When integrated with transport module 300, an array of grippers 310 may be mounted on a single transport system 308. During quality inspection, an array of Attorney Docket No.: VTN6157WOPCT1 grippers 310 may be used to handle lenses for detailed examination simultaneously. For example, grippers 310 maybe integrated with sensors 306 (e.g., vision systems) to inspect different aspects of the lenses simultaneously, ensuring comprehensive quality control.

[0063]

[0067] Grippers 310 may be specialized for a specific function and / or stage of production. In examples grippers 310 may be configured to grip a particular side of a contact lens having a first side and a second side. The first side of the contact lens may be the convex surface of the contact lens. For example, the first side may be the posterior surface that does not contact the cornea when worn. The second side of the contact lens may be the concave surface of the contact lens (e.g., opposite the convex surface). For example, the second side may be the anterior surface that contacts the cornea when worn.

[0064]

[0068] In examples, grippers 310 may be configured based on the contact lens surface with which interaction is anticipated. For example, grippers 310 maybe configured to grip the convex surface of a contact lens. For example, grippers 310 may be configured to releasably couple the curvature of the posterior contact lens surface (e.g., the curvature of a gripper head may be configured based on the curvature of the posterior contact lens surface). For example, grippers 310 maybe configured to grip the concave surface of a contact lens. For example, grippers 310 may be configured to releasably couple the curvature of the anterior contact lens surface (e.g., the curvature of a gripper head may be configured based on the curvature of the anterior contact lens surface).

[0065]

[0069] Transportation module 300 may be used to remove and transport articles, such as contact lens sections from a manufacturing line to inspection and packaging stations. For example, the lenses may be deposited in a transparent (e.g., transparent plastic) container which may carry the lenses through the inspection station and may become part of the primary package (e.g., when a lid is sealed thereto). po] Grippers 310 may comprise water separators to drain solution from a container, for example to prevent the solution from fouling plumbing, vacuum generators, vacuum pump, flow control valves, and the like. Grippers 310 may be periodically flushed with deionized (DI) water to prevent buildup of residue (e.g., from saline). For example, grippers 310 and associated system(s) (e.g., vacuum and / or blowoff systems) may be flushed at the beginning and end of each day transportation module 300 is used. Water separators may be sized for higher volume throughput to reduce the potential to clog. It may also be desirable to minimize fluid carryover Attorney Docket No.: VTN6157WOPCT1 from a first container (such as a manufacturing tray) to the final package to maintain consistent packaging solution composition package to package. In this example the fluid from the first container may be drained from the pick-up nozzle in each transfer cycle after depositing the lens and before picking up the next lens. pi] In examples, modular water separator, vacuum system, and / or blowoff system may be used to reduce downtime. For example, vacuum and gripper components may be stored in removable / interchangeable cabinets to allow for quick replacement. The components in the cabinets may be disassembled, cleaned, and reassembled offline.

[0066]

[0072] Container indexing may be used to monitor progress of a container and / or contact lens being handled by transportation module 300. For example, a container storing a contact lens, such as container 100, may be tracked by sensors 306 as the container is handled by transport system 308.

[0067]

[0073] Container(s) (e.g., an array of containers) may be securely held in heat seal fixtures and / or transport vessels, which may be referred to as pucks and boats respectively, which are strategically positioned on a moving carrier (e.g., transport system 308). This carrier may travel along a precise bearing track or conveyor (e.g., contributing to the overall precision of the lens transfer process).

[0068]

[0074] To facilitate the loading and unloading of contact lenses (e.g., to and from pucks and / or boats), signals, such as from sensors 306, may facilitate the indexing of the containers through transportation module 300. For instance, a sensor may indicate when a boat carrying containers 100 is at a specific position, such as under a lens transfer tip. ps] Container progression detection may incorporate pins to detect the progression of containers through lens transfer module 300. For example, a boat stop pin may temporarily halt the advancement of a boat during the transfer process.

[0069]

[0076] Robust tracking mechanisms that diligently monitor integrated tools, containers, and contact lenses as they progress through the system may provide detailed production data and operational flexibility, ensuring a seamless and efficient production flow. For example, these features may allow for the adjustment of movements in transport system 308 (e.g., slides and servo drive equipment), optimizing production processes.

[0070]

[0077] FIG. 5 depicts a partial sectional view of an example gripper 400. The gripper 400 may include a lens holding tip 406. The gripper 400 may be moveable. For example, the gripper 400 may have one or more axes of motion. The gripper 400 Attorney Docket No.: VTN6157WOPCT1 may be configured to grip convex surface 402 of contact lens 404. For example, the lens holding tip 406 may grip the convex surface 402 of the contact lens 404. For example, the gripper 400 may be configured to grip convex surface 402 of contact lens 404 via the lens holding tip 406. ps] In an example, the lens holding tip 406 may be configured to conform to the curvature of convex surface 402 (e.g., to ensure a secure and gentle grip without causing deformation or damage to the lens). Lens holding tip 406 may comprise (e.g., be molded of) medical-grade silicone rubber. Lens holding tip 406 may include at least one aperture 410.

[0071]

[0079] Gripper 400 may include channel(s) 408 arranged in an interior of gripper 400. One or more of channel(s) 408 may include one or more of suction channels, overpressure channels, or vacuum detection channels. The distal end of a channel(s) 408 may be tightly arranged in an aperture 410 (e.g., each aperture 410).

[0072] [so] Channel(s) 408 may include suction channel(s) arranged in the interior of gripper 400. Suction channel(s) may be used to apply a negative pressure or suction force within lens holding tip 406, for example to grip contact lens 404 against lens holding tip 406. To release contact lens 404 the suction channel may be deactivated (e.g., breaking a vacuum seal).

[0073] [si] Channel(s) 408 may include overpressure channel(s) arranged in the interior of gripper 400. Overpressure channel(s) may be used to apply a positive pressure within lens holding tip 406, for example to release the lens from lens holding tip 406.

[0074]

[0082] Channel(s) 408 may include detection vacuum channel(s) arranged in the interior of gripper 400. Detection vacuum channel(s) may have a distal end arranged in aperture (s) 410 in an air-tight manner, for example to allow a detection vacuum independent from applied suction or overpressure. Aperture(s) 410 associated with detection vacuum channels (s) may be arranged in the center of lens holding tip 406.

[0075]

[0083] FIG. 6 depicts an example array of grippers 500. The number of grippers 500 in the array may be selected based on the configuration of the manufacturing line or step or the number of packages to be included in the final packaging array. Each gripper 500 may be configured to grip a concave surface of a respective contact lens 502 via lens holding tip 504. Lens holding tip 504 may be configured to conform to the Attorney Docket No.: VTN6157WOPCT1 curvature of the concave surface of contact lens 502. Lens holding tip 504 may include at least one aperture 506.

[0076]

[0084] FIGS. 7A-7B depict perspective views of an example lens holding tip 600. Lens holding tip 600 may include lens holding tip 602 with apertures 604 arranged around central aperture 606. In examples, apertures 604 maybe configured to apply suction (e.g., via a suction channel). Central aperture 606 may be configured for suction (e.g., vacuum) detection, for example to determine if a contact lens is present at lens holding tip 602. In examples, central aperture 606 may be used for suction and / or overpressure. In examples one or more peripheral aperture 604 may be configured for suction (e.g., vacuum) detection or may be used for suction and / or overpressure. In examples, lens holding tip 600 may be removably coupled to a gripper. For example, lens holding tip 600 may include threads 608.

[0077]

[0085] A configuration of apertures 604 may impact the effectiveness, precision, and efficiency of contact lens handling with lens holding tip 600. Apertures 604 of lens holding tip 600 may be configured to manipulate distribution of suction force, which may have implications on reliability. The arrangement, number, and / or size of apertures 604 may be a factor in one or more of the following: occlusion, air leakage, and / or contact lens deformation. For example, an arrangement of apertures 604 may be selected based on an anticipated size or type of contact lenses (e.g., to control alignment and / or orientation of the contact lenses).

[0078]

[0086] In examples, if the contact lens may be in an uncertain location (e.g., not predictably positioned, such as if the contact lens is within a container lacking a support structure), lens holding tip 600 may be configured with one or more of: fewer apertures 604, larger apertures 604, and / or a smaller diameter of a layout / pattern of apertures, for example when compared to other lens transfer tips. For example, lens holding tip 600 may be configured to have a few apertures 604 that are relatively large in diameter to approximate the total surface area of the smaller apertures that may be used (e.g., in other lens traditional tips). These apertures 604 may be placed in a circular pattern. The circular pattern may have a small diameter such that the apertures 604 are towards the center of lens holding tip 600.

[0079]

[0087] FIGS. 8A-8D depict example configurations of apertures 604 of lens holding tips 600 (e.g., for use with grippers 310) that may be configured to grip a concave surface of a contact lens. FIG. 8D incorporates the example configurations of FIGS. 8A-8C on a single lens holding tip 600 (e.g., for comparison). Lens holding tip 600 as shown in FIG. 8A maybe used, for example, when gripping contact lenses having Attorney Docket No.: VTN6157WOPCT1 a smaller diameter and / or when a particular position of a contact lens to be gripped is uncertain. pa] FIGS. 9A-9C depict example configurations of lens holding tips 700. Lens holding tips 700 may be incorporated into a gripper configured to conform to the curvature of the convex surface of a contact lens. The size and / or curvature of lens holding tip 700 maybe configured based on the contact lens to be gripped. Lens holding tips 700 may include at least one aperture 702. The arrangement, number, and / or size of aperture 702 may be a factor in one or more of the following: occlusion, air leakage, and / or contact lens deformation. For example, a diameter of aperture 702 and a size of lens holding tip 700 maybe selected based on a size or a type of contact lenses to be gripped / transported.

[0080]

[0089] Grippers may include tubing 704. Tubing 704 may extend into aperture 702, for example to alter the diameter of a suction channel associated with aperture 702. Tubing 704 may be fixedly coupled to lens holding tip 700, for example such that an end of tubing 704 is flush with an inner surface of lens holding tip 700 (e.g., in aperture 702. po] In examples, lens holding tips 700 may include outer diameter 708. For example, outer diameter 708 may be the diameter of the portion of the lens holding tip 700 in contact with a contact lens. For example, outer diameter 708 may be the distance between a point on the edge of the portion of the lens holding tip 700 in contact with a gripped contact lens to a farthest point on the edge of the portion of the lens holding tip in contact with the gripped contact lens. For example, the outer diameter 708 may include the distance of an imaginary line passing between two points, each at the edge of the portion of the lens holding tip 700 in contact with the gripped contact lens, and through a center axis of the lens holding tip 700. pi] In examples, lens holding tips 700 may be selected based on outer diameter 708. For example, outer diameter 708 may include a diameter based on the size of the contact lens to be gripped. For example, outer diameter 708 may include a diameter based on the type of the contact lens to be gripped. For example, outer diameter 708 may include a diameter from 2mm to 10mm. For example, outer diameter 708 may include a diameter from 4mm to 8mm. For example, outer diameter 708 may include a diameter of 6mm. For example, outer diameter 708 may include a diameter based on a thickness (e.g., center thickness and / or skirt thickness) of the contact lens to be gripped. For example, outer diameter 708 may include a diameter based on the surface area (e.g., the surface area of the portion of the lens holding tip in contact with a contact gripped lens) suitable to hold the Attorney Docket No.: VTN6157WOPCT1 contact lens to be gripped upright. For example, a lens holding tip with an outer diameter of 6mm may provide 2.5 times more surface area than a 4mm outer diameter model. For example, lens holding tip with an outer diameter of 8mm may provide 4 times more surface area than a 4mm outer diameter model.

[0081] P2] In examples, lens holding tips 700 may include inner suction diameter 706. For example, inner suction diameter 706 may be the diameter of aperture 702. For example, inner suction diameter 706 may be the diameter of the suction channel associated with aperture 702. For example, inner suction diameter 706 may include the distance of an imaginary line between two points each at the edge of the portion of lens holding tip 700 in contact with the gripped contact lens and through the center axis of lens holding tip 700.

[0082]

[0093] In examples, lens holding tips 700 may be selected based on inner suction diameter 706. For example, inner suction diameter 706 may include a diameter based on the size of the contact lens to be gripped. For example, inner suction diameter 706 may include a diameter based on the type of the contact lens to be gripped. For example, inner suction diameter 706 may include a diameter from about 0.1mm to about 3mm, about 1 and about 2mm, or about 1.1 to about 1.8mm. For example, inner suction diameter 706 may include a diameter of about 1.5mm.

[0083]

[0094] Lens holding tip to lens holding tip transfer of a contact lens may cause damage to the contact lens if inner suction diameter 706 is not an appropriate size for supporting the contact lens. For example, if inner suction diameter 706 is too small there may be insufficient suction to grip the contact lens. For example, if inner suction diameter 706 is too large, a gripped contact lens or portion thereof may be drawn into aperture 702. Lens holding tip to lens holding tip transfer of a contact lens may cause damage to the contact lens if outer diameter 708 is not an appropriate size for supporting the contact lens. For example, outer diameter 708 may be sized (e.g., sized large enough) to avoid the gripped contact lens from inverting, folding, rolling up, and / or falling off lens holding tip 700. For example, outer diameter 708 may be sized (e.g., sized small enough) to avoid the gripped contact lens from being drawn into aperture 702, which may damage the contact lens. ps] Feature(s) associated with determining an optimal size of lens holding tips 700 are provided herein. Tubing 704 may be used, for example to manipulate the inner diameter of lens holding tips 700. As shown in FIGS. 9B and 9C, tubing maybe used to reduce the inner diameter of 6mm and 8mm lens holding tips 700 (e.g., to the 1.6mm of the 4mm diameter cup). This approach may remedy a shortcoming of Attorney Docket No.: VTN6157WOPCT1 conventional suction cups that generally have a linear relationship between outer diameter and inner diameter (e.g., as larger suction cups are expected to pick up larger items with greater mass). Accordingly, incorporation of tubing 704 and / or reduction of an inner diameter of an inner diameter of lens holding tips 700 may represent an improvement to the ability of grippers to hold and release the convex surface of a contact lens (e.g., with precision and consistency).

[0084] P6] Manipulation of a contact lens, such as transport of the contact lens from a first container to a second container (e.g., for inspection, packaging, etc.), may comprise a handoff of the contact lens from a first lens transfer tip to a second lens transfer tip (e.g., between grippers 310). This type of handoff maybe used to reorientthe contact lens such that a particular surface of the contact lens is accessible. Contact lens handoff between grippers 310 may ensure the secure and stable transfer of the contact lens, for example considering the curvature and fragility of the contact lens.

[0085]

[0097] FIGS. 10A and 10B depict an example gripper 800 in a pre-pick position. Gripper 800 may comprise a lens holding tip configured to engage with a particular surface of a contact lens. For example gripper 800 may comprise lens holding tip 600 configured to grip the concave side of a contact lens. Gripper 800 may be positioned to a pre-pick position above container 802 in preparation for a lens transfer operation of contact lens 804. Gripper 800 maybe configured to grip an exposed surface of contact lens 804, such as the concave surface of contact lens 804. Gripper 800 and or container 802 may be manipulated and / or tracked by a transport module 300 to ensure alignment in the pre-pick position. The alignment of gripper 800 and container 802 may have a tolerance of about 0.1mm to about 1 mm from the center of the container bowl. pa] Gripper 800 may be moved into an aspirate pick position, for example by being lowered into container 802 with contact lens 804. Gripper 800 may enter container 802 with suction turned on to aspirate the solution through the lens holding tip and / or a water separator. The aspirated solution may be drawn to a reservoir (e.g., waste container). The aspiration process may continue until enough solution is determined to have been aspirated, or until no solution is detected.

[0086]

[0099] Gripper 800 may use suction (e.g., a vacuum) to pick up the contact lens from the container. Gripper 800 may lift contact lens 804 from container 802 to a raised position. Transportation module 300 may signal that container 802 is ready to be moved. For example, a stop pin may retract, allowing container 802 to be moved. Attorney Docket No.: VTN6157WOPCT1

[0087]

[0100] In an example, container 802 may include an opened consumer package, such as an opened blister package for example. In an example, container 802 may include a container for intermediate holding during and / or between various manufacturing steps. For example, container 802 may include a manufacturing tray.

[0088]

[0101] FIGS. 11A and 11 B depict an example handoff process of contact lens 804 between gripper 800 and gripper 806. Gripper 806 may comprise a lens holding tip configured to engage with a particular surface of a contact lens. For example, gripper 806 may comprise lens holding tip 700 configured to grip the convex side of a contact lens. In examples, gripper 800 and gripper 806 may be configured to grip opposite sides of contact lens 804.

[0089]

[0102] In examples, alignment of gripper 800 with gripper 806 may include an alignment such as a geometrical alignment, structural alignment, functional alignment, or the like. For example, gripper 800 and gripper 806 may be geometrically aligned. For example, gripper 800 and gripper 806 may have a common center axis. For example, gripper 800 and gripper 806 may be structurally aligned. For example, a position on a lens holding tip of gripper 800 and a position on a lens holding tip of gripper 806 that correspond to the center of the lens may be aligned. For example, gripper 800 and gripper 806 may be functionally aligned. For example, gripper 800 and gripper 806 may be in any physical alignment that enables a handoff between the lens holding tips.

[0090]

[0103] Alignment of gripper 800 with gripper 806 may be determined based on the position of gripper 800 relative to gripper 806. In examples, the position of gripper 800 and / or gripper 806 may be monitored by sensor(s) and / or precisely controlled using a transport mechanism, such as a servo motor. For example, optical markers or indicators may be implemented on gripper 800 and / or gripper 806 (e.g., to aid in alignment). Optical markers maybe detected by sensors, such as a machine vision system, for precise positioning.

[0091]

[0104] In examples, alignment may be achieved by actuation of gripper 800 and / or gripper 806. For example, alignment may be established with a predefined set point. For example, alignment may be established with a physical set point relative to each gripper.

[0092]

[0105] In examples, alignment of gripper 800 with gripper 806 may be achieved via movement of the mechanism(s) to which gripper 800 and / or gripper 806 are attached. For example, the mechanism (s) to which gripper 800 and / or gripper 806 are attached may be moved via actuation of an actuator. Attorney Docket No.: VTN6157WOPCT1

[0093]

[0106] In examples, alignment of gripper 800 with gripper 806 may be established via movement of gripper 800, gripper 806, and / or the mechanism(s) to which gripper 800 and / or gripper 806 are attached with a defined stop. For example, the stop may be a logical stop and / or a physical stop. For example, the stop may be determined based on a sensor and corresponding logic. In examples, alignment of gripper 800 with gripper 806 may be determined by computer vision. For example, alignment of gripper 800 with gripper 806 may be dynamic. For example, alignment of gripper 800 with gripper 806 may be determined based on a vision sensor (e.g., camera) and corresponding control loop that moves gripper 800 and / or gripper 806 until an alignment threshold is satisfied. In an example, a maximum gradient and cost function may be used to determine alignment of gripper 800 with gripper 806.

[0094]

[0107] In examples, a tolerance range for the alignment process may be defined. For example, a tolerance range may specify an acceptable deviation from a desired position. For a tolerance range may specify an acceptable deviation from a desired position along the axis X-X and axis Y-Y (e.g., as shown in FIG. 13A). For example, a tolerance of alignment (e.g., a collective tolerance of alignment across one or more axis) maybe anywhere between ±0.5 mm to ±1.5 mm (e.g., ±1 mm).

[0095] [los] Gripper 806 may comprise a lens holding tip with an ID suitable for precise placement. A small ID may allow transportation module 300 to have a more precise approximation of the position of contact lens 804 when gripped by gripper 806. Gripper 806 may have ID and OD ranges discussed above with respect to FIG. 11A and 11B. Gripper 806 may have an OD of the lens holding tip maybe anywhere between about 4 and about 12mm, about 5 and about 12mm, about 4 and about 10mm, about 5 and 12mm, or about 5 and about 10 mm.

[0096]

[0109] Gripper 800 and / or gripper 806 may be moved to a contact lens handoff position relative to one another. For example, gripper 806 may be positioned directly beneath gripper 800 via a servo actuator.

[0097] [no] The handoff process between grippers 800 and 806 may include vacuum activation / deactivation and / or blow off activation / deactivation. Gripper 806 may activate suction. Gripper 800, which holds contact lens 804 may deactivate its suction (e.g., after the suction of gripper 806 has been activated). Gripper 800 may (e.g., may further) activate a blow-off mechanism. Gripper 806 may move to a postpick position, for example after detecting contact lens 804 (e.g., a vacuum seal with contact lens 804). The blow-off mechanism of gripper 800 maybe turned off. Attorney Docket No.: VTN6157WOPCT1

[0098] [in] In examples, a processor (e.g., processor 302) may be used to control of gripper 800 and / or gripper 806. The processor may be configured to separately and / or concurrently engage a vacuum actuator of gripper 800 and a blow off actuator of gripper 806. The processor may be configured to moveably align the first and second lens holding tips. The processor may be configured to movably actuate the second lens holding tip to deposit the contact lens in a concave-down orientation.

[0099]

[0112] FIGS. 12A and 12B depict an example handling process of contact lens 804 on gripper 806 (e.g., after a handoff process from gripper 800). Gripper 806 may be configured to move into a position to deposit contact lens 804 into a container, such as container 100. Gripper 806 may be configured to rotate around a point 808 while maintaining suction of contact lens 804. A transport system may move gripper 806 and contact lens 804 (e.g., via a servo actuator) to a lens placement position directly above container 810. Container 810 may be a storage container arranged in a puck.

[0100]

[0113] FIGS. 13A and 13B depict an example alignment process for transferring contact lens 804 to container 810.

[0101]

[0114] Transfer module 300 may signal to begin a load process to transfer contact 804 to container 810 (e.g., a puck with container 810). A sensor 306 may be used to detect the presence of support structure 812 of container 810. If no support structure is detected, handoff of contact lens 804 from gripper 800 to gripper 806 maybe unnecessary (e.g., not performed). Dynamic determination of contact lens handoff may allow use of transport system 308 to selectively transfer contact lens 804 to a variety of potential containers and / or grippers.

[0102] [ns] Container 810 may be indexed towards a pre-transfer location. Container 810 may be stopped at the pre-transfer location, for example by a container stop pin. A stop sensor may sense the presence of container 810 in the pre-transfer location. Container 810 may be held at the pre- transfer location until transport module 300 determines a transfer location (e.g., a location relative to gripper 806) is available (e.g., not occupied by another container and / or puck).

[0103]

[0116] Container slide 814 may advance to the pre-transfer location to capture container 810.

[0104]

[0117] The container stop pin at the pre-transfer location may be retracted (e.g., to enable movement of container 810 along container slide 814). Container slide 814 may move container 810 from the pre-transfer location to a transfer location. Attorney Docket No.: VTN6157WOPCT1

[0105]

[0118] A stop sensor may sense the presence of container 810 at the transfer location. A container stop pin at the pre-stop position may be advanced to prevent another container from being transported to the transfer location. A nest locator at the transfer location may advance to secure container 810 (e.g., a puck containing container 810) into the transfer position. The transfer position may be determined relative to gripper 806.

[0106]

[0119] Container slide 814 may retract to release container 810 and return to the pretransfer location.

[0107]

[0120] The transfer process of contact lens 804 from gripper 806 to container 810 may include vacuum activation / deactivation and / or blowoff activation / deactivation of gripper 806. Transport module 300 may align gripper 806 with support structure 812 of container 810 while maintaining suction of contact lens 804. Support structure 812 may comprise support structure 116 and / or be configured to support the concave surface and shape of contact lens 804.

[0108]

[0121] Alignment of contact lens 804 with support structure 812 may be determined based on positioning of container 810. The position of container 810 may be monitored by sensor(s) and / or precisely controlled using a transport mechanism, such as a servo motor. For example, optical markers or indicators may be implemented on gripper 806, contact lens 804, and / or container 810 to aid in alignment. These optical markers may be detected by sensors, such as a machine vision system, for precise positioning.

[0109]

[0122] In examples, alignment of contact lens 804 with support structure 812 may include an alignment such as a geometrical alignment, structural alignment, functional alignment, or the like. For example, contact lens 804 and support structure 812 may be geometrically aligned. For example, contact lens 804 and support structure 812 may have a common center axis. For example, contact lens 804 and support structure 812 may be structurally aligned. For example, a position on a lens holding tip of gripper 806 and a position on support structure 812 that correspond to the center of the contact lens (e.g., a center axis of the contact lens) may be aligned. For example, contact lens 804 and support structure 812 may be functionally aligned. For example, contact lens 804 and support structure 812 may be in any physical alignment that enables a handoff between gripper 806 and support structure 812.

[0110]

[0123] Alignment of contact lens 804 with support structure 812 may be determined based on the position of contact lens 804 relative to support structure 812. In examples, the position gripper 806, contact lens 804, and / or support structure Attorney Docket No.: VTN6157WOPCT1

[0111] 812 may be monitored by sensor(s) and / or precisely controlled using a transport mechanism, such as a servo motor. For example, optical markers or indicators may be implemented on gripper 800 and / or gripper 806 (e.g., to aid in alignment). Optical markers may be detected by sensors, such as a machine vision system, for precise positioning.

[0112]

[0124] In examples, alignment may be achieved by actuation of gripper 806 and / or container 810 (e.g., support structure 812). For example, alignment may be established with a predefined set point. For example, alignment may be established with a physical set point relative to gripper 806 and support structure 812 respectively.

[0113]

[0125] In examples, alignment of gripper 806 with support structure 812 may be established via movement of the mechanism with a defined stop. For example, the stop may be a logical stop and / or a physical stop. For example, the stop may be determined based on a sensor and corresponding logic. In examples, alignment of gripper 806 (e.g., contact lens 804) with support structure 812 may be determined by computer vision. For example, alignment of gripper 806 with support structure 812 may be dynamic. For example, alignment of gripper 806 with support structure 812 may be determined based on a vision sensor (e.g., camera) and corresponding control loop that moves gripper 806 and / or container 810 until an alignment threshold is satisfied. In an example, a maximum gradient and cost function may be used to determine alignment of contact lens 804 with support structure 812.

[0114]

[0126] A tolerance range for the alignment process may be defined, specifying the acceptable deviation from the desired position along the axis X-X and axis Y-Y, as shown in FIG. 13A. For example, a tolerance of alignment may be less than about 2 mm, less than about 1mm or between about 0.5 mm to about 1.5 mm, or about 1 mm.

[0115]

[0127] Gripper 806 may comprise a lens holding tip with an ID suitable for precise placement as described above. A small ID may allow transportation module 300 to have a more precise approximation of the position of contact lens 804 when gripped by gripper 806. Gripper 806 may have ID and OD ranges discussed above with respect to FIG. 11A and 11B.

[0116]

[0128] Gripper 806 may be moved proximate to container 810 (e.g., based on the alignment of contact lens to support structure 812 and / or container 810). Suction of gripper 806 may be turned off. Blowoff of gripper 806 may be momentarily activated. Gripper 806 may be retracted to a position clear of container 810. Attorney Docket No.: VTN6157WOPCT1

[0117] Gripper 806 may rotate (e.g., via point 808) to receive another contact lens, for example from gripper 800.

[0118]

[0129] Although described with respect to suction grippers, it should be appreciated that alternate types of grippers may be used with respect to the processes depicted in FIGS. 10A-13B. For example, Bernoulli gripper(s) maybe used. Additionally, it should be appreciated that multiple contact lenses may be transferred simultaneously, for example from an array of grippers to respective containers on a puck.

Claims

Attorney Docket No.: VTN6157WOPCT1Claims1. A method of packaging a contact lens, comprising: releasably coupling a first side of the contact lens with a lens holding tip; aligning the lens holding tip to a support structure of a container, wherein the support structure is configured to receive and support a second side of the contact lens above a floor of the container, wherein the second side of the contact lens is a concave surface of the contact lens and the first side of the contact lens is a convex surface of the contact lens; and releasing the contact lens from the lens holding tip onto the support structure of the container.

2. The method of claim 1, wherein the support structure comprises a member configured to act as a fulcrum, wherein releasing the contact lens from the lens holding tip to the support structure comprises the contact lens pivoting about the fulcrum.

3. The method of claim 1, further comprising: upon releasing the lens from the lens holding tip, applying a burst of air to the first side of the contact lens to direct the contact lens to the support structure.

4. The method of claim 1, wherein the lens holding tip has an inner suction diameter and an outer diameter, wherein the inner suction diameter is configured to maintain a vacuum while releasably coupled to the contact lens, wherein the inner suction diameter is less than one third of the outer diameter.

5. The method of claim 1, wherein the lens holding tip is configured to, when removably coupled to the contact lens, at least partially surround the first side of the contact lens.

6. The method of claim 1, further comprising: performing an optical inspection, wherein the optical inspection includes a comparison of a base curve radius of the contact lens to a threshold.Attorney Docket No.: VTN6157WOPCT17. The method of claim 1, wherein a tolerance of alignment for the support structure and the lens holding tip is less than about 2mm, less than about 1.5mm or between about 0.5 mm to about 1.5 mm.

8. The method of claim 1, wherein aligning the lens holding tip to the container comprises positioning the contact lens over the support structure while the support structure is angled with respect to the lens.

9. The method of claim 1, wherein the lens holding tip is configured to removably couple the first side of the contact lens via at least one of a vacuum or a Bernoulli gripper.

10. A device for packaging a contact lens, comprising: a movable gripper comprising a lens holding tip, wherein the lens holding tip is configured to releasably coupling a first side of the contact lens, wherein the gripper is configured to align the lens holding tip to a support structure of a container, wherein the support structure is configured to receive and support a second side of the contact lens above a floor of the container, wherein the second side of the contact lens is a concave surface of the contact lens and the first side of the contact lens is a convex surface of the contact lens, and wherein the gripper is further configured to release the contact lens from the lens holding tip onto the support structure of the container.

11. The device of claim 10, wherein the support structure comprises at a member configured to act as a fulcrum, wherein releasing the contact lens from the lens holding tip to the support structure comprises the contact lens pivoting about the fulcrum.

12. The device of claim 10 wherein the gripper is further configured to apply, upon releasing the lens from the lens holding tip, a burst of air to the first side of the contact lens to direct the contact lens to the support structure.

13. The device of claim 10, wherein the lens holding tip has an inner suction diameter and an outer diameter, wherein the inner suction diameter is configured to maintain a vacuum while releasably coupled to the contact lens, wherein the inner suction diameter is less than one third of the outer diameter.Attorney Docket No.: VTN6157WOPCT114. The device of claim 10, wherein the lens holding tip is configured to, when removably coupled to the contact lens, surround a portion of the first side of the contact lens.

15. The device of claim 10, further comprising a vision inspection sensor configured to perform an optical inspection, wherein the optical inspection includes a comparison of a base curve radius of the contact lens to a threshold.

16. The device of claim 10, wherein a tolerance of alignment for the support structure and the lens holding tip is less than about 2mm or between about 0.5 mm to about 1.5 mm, or about 1 mm.

17. The device of claim 10, wherein the gripper is further configured to position the contact lens over the support structure while the support structure is angled with respect to the lens.

18. The device of claim 10, wherein the lens holding tip is configured to removably couple the first side of the contact lens via at least one of a vacuum or a Bernoulli gripper.

19. A device for packaging a contact lens, comprising: a movable gripper comprising a lens holding tip, wherein the lens holding tip is configured to releasably couple a convex surface of the contact lens, wherein the lens holding tip has an inner suction diameter and an outer diameter, wherein the inner suction diameter is configured to maintain a vacuum while the lens holding tip is releasably coupled to the contact lens, wherein the inner suction diameter is less than one third of the outer diameter, and wherein the gripper is configured to release the contact lens from the lens holding tip onto a support structure of a container.

20. The device of claim 19, wherein the gripper is further configured to position the contact lens over the support structure while the support structure is angled with respect to the lens.Attorney Docket No.: VTN6157WOPCT121. The device of any of claims 10 through 20 wherein the lens holding tip comprises an inner suction diameter of about 0.1mm to 3mm, about 1 to about 2mm or about 1.1 to about 1.8mm.

22. The device of any of claims 10 through 21 wherein the lens holding tip comprises an outer diameter of about 2mm to about 10mm, about 4mm to about 8mm or about 6mm.

23. The method of any of claims 1 through 9 wherein the lens holding tip comprises an inner suction diameter of about 0.1mm to 3mm, about 1 to about 2mm or about 1.1 to about 1.8mm.

24. The method of any of claims 1 through 9 or 23 wherein the lens holding tip comprises an outer diameter of about 2mm to about 10mm, about 4mm to about 8mm or about 6mm.

Images