Multi-Layer Laminate Contact Lens Packaging with Metal Foil

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Solution Overview

Problem

Conventional contact lens packaging is economically inefficient due to high material costs and bulkiness, which increases the overall cost of contact lenses while compromising on space efficiency and durability, and there is a need for a packaging solution that maintains sterility and stability without adding unnecessary weight or bulk.

Innovation Solution

A contact lens package utilizing a multi-layer laminate substrate with a polymer and metal layer combination, featuring pre-formed lens receiving portions and a removable cover sheet, which provides structural integrity, light-reflectivity, and improved sealing properties, allowing for reduced thickness and weight while maintaining sterility and ease of use.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional polypropylene boats with significant thickness are used, then the lens is protected from damage and liquid transmission is limited, but the packaging weight and material costs increase

Engineering Contradiction:

Improveprotection from damage and liquid transmissionVSAvoidpackaging weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent replaces the traditional single-material polypropylene boat with a multi-layer laminate structure consisting of a polypropylene layer and a metal foil layer (aluminum or stainless steel). This composite structure provides equivalent or superior protection against damage and liquid transmission while significantly reducing the overall thickness and weight of the packaging. The metal foil layer contributes to both the mechanical strength and the barrier properties against liquid and vapor transmission.

Inventive Principle:

Principle #40Composite materials

2Reliability

If traditional polypropylene boats with significant thickness are used, then the lens is protected from damage and liquid transmission is limited, but the packaging bulk increases

Engineering Contradiction:

Improveprotection from damage and liquid transmissionVSAvoidpackaging bulk

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The multi-layer laminate structure with metal foil integration allows the packaging to achieve the required protective functions with reduced thickness. The metal layer provides high strength-to-thickness ratio and excellent barrier properties, enabling a thinner overall structure that occupies less volume while maintaining equivalent protection against damage and liquid transmission.

Inventive Principle:

Principle #40Composite materials

3Reliability

If traditional multi-layer film cover sheets with multiple layers are used, then sterility and sealing are achieved, but the packaging cost increases

Engineering Contradiction:

Improvesterility and sealingVSAvoidpackaging cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent integrates the cover sheet function directly into the laminate structure by incorporating a metal foil layer that serves as both the boat material and part of the sealing system. This eliminates the need for a separate multi-layer film cover sheet, reducing material costs while maintaining sterility and sealing integrity. The metal foil provides an effective barrier against contamination and can be sealed effectively with appropriate sealing structures.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The invention merges the functions of the boat and the cover sheet into a single integrated laminate structure. The polypropylene layer provides structural support and the metal foil layer provides barrier properties and sealing capability, combining multiple functions into one component that reduces overall packaging complexity and cost.

Inventive Principle:

Principle #5Merging (Combining)

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

The solution results in a more economical, space-efficient, and functional contact lens package that reduces material costs and weight while ensuring the lens remains sterile and stable, facilitating easier handling and storage.

Implementation Method 1

The substrate has sufficient structural integrity to maintain a shape of the lens receiving portion

Methodology Applied

Scientific EffectStructural rigidity:

Implementation Method 2

Methodology Applied

Scientific EffectLight reflection: Reflection

Implementation Method 3

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Data Source

PatentUS11412824B2Packaging for disposable soft contact lenses having pre-formed multi-layer structural laminate

Publication Date: 2022.08.16 MENICON SINGAPORE PTE LTD

AI summary

A contact lens package includes a multi-layer laminate substrate and a cover sheet. The multi-layer laminate substrate includes a first polymer layer, a first metal layer and at least one pre-formed lens receiving portion that is sized to hold at least a portion of a contact lens. The cover sheet is removably secured to the substrate and configured to seal a contact lens within the at least one lens receiving portion. The substrate has sufficient structural integrity to maintain a shape of the lens receiving portion.