Contact Lens Packaging Recess Design for Burr Prevention
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Solution Overview
Problem
Existing methods for packaging and manufacturing disposable contact lenses are inefficient, as they require separate processes for lens formation and packaging, leading to increased costs and complexity.
Innovation Solution
A container with a round-shaped central recess, a peripheral groove, a rim, and a tenon is used to form and package contact lenses directly, incorporating a ring-shaped protruding portion to prevent lens displacement and burrs, with a hand-held section for easy handling and sealing with a lid to maintain sterility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate processes are used for lens formation and packaging, then manufacturing precision can be maintained, but device complexity and production cost increase
Solution Approach 1:
The patent combines the lens formation mold and packaging container into a single integrated structure. The container includes a recess that serves dual purposes: as the mold cavity for forming the contact lens and as the final packaging compartment. This eliminates the need for separate molding and packaging operations, directly resolving the contradiction by integrating two previously separate processes into one unified structure.
Solution Approach 2:
The container structure performs multiple functions simultaneously: it serves as the molding mold, the packaging vessel, and the storage container for the contact lens with solution. The recess portion acts as both the mold cavity during manufacturing and the holding compartment during storage and distribution, demonstrating multi-functionality that reduces overall system complexity while maintaining manufacturing precision.
2Manufacturing precision
If a simple container structure is used, then device complexity is reduced, but manufacturing precision and lens quality deteriorate
Solution Approach 1:
The container features localized structural elements precisely where needed: the recess has a specific curved surface geometry that defines the lens optical zone, and a protruding portion positioned at the periphery to prevent lens ejection. These localized features provide the necessary manufacturing precision for lens formation without requiring complex structures throughout the entire container, thus maintaining simplicity while ensuring quality.
Solution Approach 2:
The container is divided into distinct functional zones: the recess portion for lens formation, the protruding portion for lens retention, and the main body for solution storage. This segmentation allows each zone to be optimized for its specific function - the recess provides precise optical surface formation while the protruding portion provides mechanical lens retention - without requiring the entire structure to be complex.
3Ease of manufacture
If the contact lens is formed with a radius of curvature matching the container, then manufacturing is simplified, but the lens cannot be properly removed from the container
Solution Approach 1:
The container design creates an asymmetric fit between the lens and container by providing a protruding portion that extends into the recess. The lens radius of curvature matches the recess curvature for easy formation, but the protruding portion creates a mechanical interference fit that prevents lens ejection during manufacturing while allowing controlled removal when needed, resolving the contradiction between ease of manufacture and ease of operation.
Solution Approach 2:
The protruding portion is designed to preemptively counteract any force that might eject the lens from the container during manufacturing and handling. This preliminary anti-action mechanism ensures the lens remains securely positioned throughout the manufacturing process and storage period, while still allowing for intentional removal by the user when needed, thus balancing manufacturing simplicity with operational control.
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
This method simplifies the production process by integrating lens formation and packaging, reducing costs and ensuring the contact lens is formed without burrs or rough edges, while maintaining sterility and ease of use.
Implementation Method 1
injecting a lens-forming monomer mixture into the central recess to form a contact lens
Data Source
AI summary
This invention provides a method of packaging and manufacturing a contact lens in a container, wherein the container comprises a central recess formed of a curved surface with a ring-shaped protruding portion surrounding the curved surface, the method comprising the steps of: providing the container; injecting a lens-forming monomer mixture into the central recess to form the contact lens along the curved surface of the central recess; combining the container and a hand-held section; pouring a solution into the container to immerse the contact lens in the container; and sealing the container with a lid for sealing the contact lens and the solution in the container; wherein the curved surface of the central recess has one or a plurality of continuous radii of curvature Rrecess less than a radius of curvature Rlens of the contact lens in its hydrous state.