Dimpled Contact Lens Package Reducing Head Space
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Solution Overview
Problem
Contact lenses interact with their packaging during storage and shipment, leading to issues like folding, inversion, and suction-cupping, which affect user experience and optical properties, and there is a need for effective anti-counterfeiting measures.
Innovation Solution
The implementation of a 'low head space' condition in contact lens packages using a dimpled package design with a concave shape in the foil, reducing the space between the lens and the package cover, and incorporating embossed patterns for anti-counterfeiting verification, achieved through specific dimple shapes and increased saline solution volume without altering the package design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the head space in the package is reduced, then lens folding and inversion are minimized, but the package design becomes more complex
Solution Approach 1:
The patent applies curvature by introducing a dimpled (concave) shape in the foil package cover instead of a flat surface. This curved geometry reduces head space volume and prevents lens folding/inversion by conforming to the lens shape, while the dimple is formed through simple embossing during manufacturing, avoiding complex structural modifications.
2Reliability
If the head space is reduced by increasing solution volume, then lens folding is reduced, but the manufacturing cost increases
Solution Approach 1:
Instead of increasing solution volume to reduce head space, the patent uses a dimpled (curved) foil cover that creates reduced head space geometry. This approach achieves lens stability without adding excess solution, thereby avoiding increased manufacturing costs associated with additional consumable materials.
3Object-generated harmful factors
If a dimpled package design is implemented, then lens suction-cupping is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The dimpled design creates a concave surface that prevents lens suction-cupping to the foil. The dimple is formed through embossing with a die during heat sealing, using existing manufacturing equipment and processes, which minimizes the need for additional precision manufacturing capabilities while effectively reducing harmful lens-package interactions.
Solution Approach 2:
The patent modifies physical parameters of the foil cover by introducing a controlled concave deformation (dimple) with specific geometric characteristics. This parameter change alters the surface geometry to prevent suction-cupping while the dimple dimensions are optimized to work within existing manufacturing tolerances and capabilities.
4Reliability
If embossed patterns are added for anti-counterfeiting, then package security is improved, but device complexity increases
Solution Approach 1:
The patent uses embossed patterns on the foil cover that create visible optical effects (light reflection/refraction variations) to provide anti-counterfeiting verification. These patterns are integrated into the existing dimple formation process through the same heat seal die, adding security features without requiring separate structural components or increasing overall package complexity.
Data Source
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AI summary
The packages described by this invention all have reduced "head space," that is, the distance from lid to lens. Packages contain dimples to achieve this reduced head space. Specifically, packages are designed with dimple sag equal to or less than 1.90-mm, or volume displaced equal to or less than 360µl. Combined with the existing primary packaging, it has been found that such conditions provide for reduction in folded lens rate during shipping and handling. As well, lenses stored or having an extended time in low head space packages in a "foil down" orientation now have characteristics closer lenses stored in a "foil up orientation." The packages finally include a foil 3D pattern at a smaller scale than the dimple, by embossing or other methods allowing reduce lens sticking to the foil as well as an added anti-counterfeiting measure.