Contact Lens Blister Packaging Using Temporary Liquid Securing

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Solution Overview

Problem

The movement of dry contact lenses during packaging leads to uncertainty in position, potential eversion, and quality risks due to static electricity and frictionless conditions, complicating hydration and sterilization processes.

Innovation Solution

The lenses are temporarily secured in blister packaging using an electric charge or a droplet of hydrating liquid at a central location, ensuring stable positioning during transport and hydration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a dry contact lens is placed in a well during packaging, then the lens can be transported and processed, but the lens moves freely within the well due to lack of friction and static electricity

Engineering Contradiction:

Improvepackaging process efficiencyVSAvoidlens position stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

A droplet of liquid is applied to the well surface before placing the lens, creating preliminary adhesion that prevents lens movement during transport and processing. This preliminary action ensures the lens remains stationary at the desired location throughout the packaging process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A liquid droplet is introduced as an intermediary substance between the well surface and the lens. This liquid mediator creates adhesive forces that hold the lens in place, resolving the contradiction between needing the lens to be stationary and the natural tendency of dry lenses to move freely.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If static electricity is present in the well, then the lens may be repelled and bounce out or float above the well surface, but using static neutralizing devices adds process complexity

Engineering Contradiction:

Improvelens positioning accuracyVSAvoidpackaging process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The liquid droplet serves as an intermediary that eliminates static electricity effects between the well surface and the lens. By introducing this liquid medium, the electrostatic repulsion problem is resolved without requiring additional static neutralizing devices, thus maintaining reliability while avoiding increased complexity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The introduction of liquid changes the physical and electrical parameters of the well surface, transforming it from a dry, statically-charged surface to a wet, conductive surface. This parameter change naturally dissipates static electricity and prevents lens repulsion without additional equipment.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If the lens moves within the well during transport, then quality risks increase including eversion and sliding out, but securing the lens permanently would prevent hydration

Engineering Contradiction:

Improvelens position stabilityVSAvoidlens hydration process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The securing mechanism is made dynamic rather than static. The liquid droplet provides adhesion during transport (when needed) but can be removed or evaporated later to allow hydration. This dynamic approach enables the system to transition from a secured state to an unsecured state as process requirements change.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The securing and releasing of the lens occurs in periodic stages: first secured with liquid during transport, then released when hydration is needed. This periodic action pattern allows the lens to be held stationary when required and freed when required, resolving the contradiction between stability and manufacturability.

Inventive Principle:

Principle #19Periodic action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Reduces movement-related quality risks and ensures consistent lens positioning, preventing eversion and enhancing the reliability of the packaging process.

Implementation Method 1

depositing an electric charge at a location in the cavity, securing the contact lens to the blister packaging at the location with the electric charge

Methodology Applied

Scientific EffectStatic electricity: Electrostatics

Implementation Method 2

injecting a lens hydrating liquid into the cavity whereby the lens is hydrated

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Data Source

PatentUS12384577B2Methods for selectively controlling movement of a contact lens during a packaging process

Publication Date: 2025.08.12 BAUSCH & LOMB IRELAND LIMITED

AI summary

A method of selectively controlling movement of a contact lens in blister packaging comprising a cavity, the method comprising depositing an electric charge at a location in the cavity, securing the contact lens to the blister packaging at the location with the electric charge, and after the step of securing the contact lens, injecting a lens hydrating liquid into the cavity whereby the lens is hydrated and the securing terminated. A method of selectively controlling movement of a contact lens in blister packaging comprising a cavity, the method comprising depositing a droplet of a first lens hydrating liquid in the cavity, securing the contact lens to the blister packaging with the droplet, and after the step of securing the contact lens, injecting a second lens hydrating liquid into the cavity whereby the lens is hydrated.