Patent Grant
7938255
Soft disposable contact lenses are commonly contained in disposable packages. As packaging adds to the overall cost of the lens, it should be made as economically as possible but without compromise to the requisite packaging criteria.
The traditional blister pack packaging (shown in
The marketing objective is to present the contact lens to a patient in an aesthetically pleasing package that both satisfies the statutory requirements for sterility and stability, and allows the patient to remove the lens safely and easily. The packaging is used only once and is discarded after the lens is removed. This impacts the costs of the lens/package combination. In order to reduce the overall price of the lens to the patient, the cost of the packaging should be kept to an absolute minimum. In addition, disposability of lens packages necessitates conformity with ecological standards.
The lens must be kept hydrated while in the package. The package must be well sealed and should minimize water vapor transmission through the boat and laminated layer to maximize the shelf life and prevent dehydration of the lens contained therein. In use, the user removes the laminated material from a flange formed on the boat by peeling back the cover to expose the lens immersed in a hydrating solution.
There is a long felt need in the disposable contact lens industry to provide an economic, space-efficient, and convenient, disposable contact lens package without compromise to durability, sterility, and utility of the lens.
The accompanying drawings illustrate various embodiments of the principles described herein and are a part of the specification. The illustrated embodiments are merely examples and do not limit the scope of the claims.
Throughout the drawings, identical reference numbers designate similar, but not necessarily identical, elements.
The present specification provides an economical package without compromise to statutory and medical requirements of contact lens packages.
The single-use package, in the embodiments described below, offers a number of advantages over the prior art blister pack concept. First, the single-use package is smaller and slimmer which lends itself to disposability and is ideal for traveling. Additionally, the number of packages in a secondary container may be increased, yet storage space for that secondary package may be reduced.
Further, the present exemplary economical package may be designed to incorporate any number of materials, colors, and/or surface finishes while still conforming to statutory and medical requirements.
The exemplary single-use package may be composed of foil sheets attached to either side of a substrate which stabilize light exposure and prevent oxygen transmission. Further, in some embodiments there is no air in the package, thus non-ballasted autoclaving is not required. The absence of air in the package contributes to lens stability in the package. Thus, the shelf-life of a contact lens in a single-use package may be extended. Overall, the exemplary single-use package is a more convenient and cost effective form of packaging.
Conventional contact lens packages are typically stiff and preformed with a profiled recess to house the lens therein. The preformed recess in the known packages is intended to ensure that the lens shape is maintained and is not deformed by the package. According to one exemplary embodiment, a contact lens package disclosed herein does not maintain the lens in an equilibrated position, but instead holds the lens in a flattened or compressed state. In this embodiment, the package has an internal depth which is less than an overall sagittal depth of the contact lens when the contact lens is in its equilibrated form. A contact lens can be compressed or otherwise confined in the package such that the lens is always maintained in a consistent orientation inside the contact lens orifice. According to one exemplary embodiment, the lens is maintained with its front surface oriented toward the top sealing material.
To aid in the restoration of the contact lens to its uncompressed profile, an internal member may be inserted under the contact lens such that when the package is open, the internal member exerts restoring force on the contact lens. Further the internal member can aid in the user locating and picking up the contact lens. In many packaging configurations, the contact lens adheres to the packaging due to hydrophobic interactions, surface tension, or other forces. This makes removal of the lens by the user difficult. As the user attempts to remove the lens from the packaging, the lens can be lost, damaged, or contaminated. Including an internal member that prevents the lens adhering to its surroundings and presents the lens in a consistent orientation can greatly ease the removal of the contact lens by the user. Various geometries of internal members contained in contact lens packages are disclosed in co-pending application (reference 40361-0067) which is hereby incorporated in their entirety.
Another embodiment is a single-use package with a contact lens therein. The package comprises two sheets of material sealed on each side of a substrate defining an orifice, a restoring member in the form of a foam disc is disposed between the sheets in the orifice, and an amount of hydration medium, wherein the lens in maintained in a flattened state while the package is sealed. A package for contact lenses and a method for manufacturing the contact lens packaging are described herein. More specifically, a package with a substrate having a sheet on both the top and bottom surfaces is disclosed herein. According to one exemplary embodiment, the package is smaller than traditional packages. Further, a method for manufacturing the above-mentioned package is disclosed as well as a method for providing a seal that is both easy to open and more secure to environmental breach when compared to traditional seals.
As used in the present specification and in the appended claims, the term “contactable material” refers generally to any material which may come into physical and fluid contact with a contact lens. A contactable material should be free of potentially toxic or irritant extractable or leachable materials, particularly if subject to forcing conditions such are experienced during steam sterilization at 121° C. Although polypropylene is commonly used as a contactable material in contact lens packages, any other material that is capable of maintaining a sterile environment for contact lenses can be used in the present article and method as well. According to one exemplary embodiment, a contactable material may include any material accepted by the Food and Drug Administration (FDA) as suitable for the packaging of sterile medical devices, or in direct food contacting applications.
Additionally, as used in the present specification and the appended claims, the term “sagittal depth” and “sagittal depth in a relaxed state” when referring to a contact lens shall be interpreted as the height of a contact lens in an equilibrated state. In other words, the saggital depth of a contact lens shall be interpreted as a designed saggital depth of a contact lens in an equilibrated state.
In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present systems and methods. It will be apparent, however, to one skilled in the art that the present apparatus, systems and methods may be practiced without these specific details. Reference in the specification to “an embodiment,” “an example” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment or example is included in at least that one embodiment, but not necessarily in other embodiments. The various instances of the phrase “in one embodiment” or similar phrases in various places in the specification are not necessarily all referring to the same embodiment.
Referring to
Exemplary Articles
Similarly,
According to one exemplary embodiment, the exemplary top sheet (150) and the exemplary bottom sheet (160) may include a foil. This foil may include, but is in no way limited to, a bottom or innermost layer comprising a homogeneous contactable material such as polypropylene. Above the inner layer may be, according to one exemplary embodiment, a layer of metal foil such as aluminum that provides strength and flexibility. Above the aluminum layer, a top layer may be formed including a polymer, such as polyethylene.
The exemplary bottom sheet (160) may also include a foil according to one exemplary embodiment. As mentioned above, the top or innermost layer of the bottom sheet (160) which is in physical or fluid contact with the lens includes a contactable material. The bottom sheet (160) is otherwise designed to maintain the integrity of the packaging during handling, and may comprise the same layers as the top sheet (150), as mentioned above. The bottom sheet (160) does not need to be opened and thus may be permanently attached to the substrate (110), such as through a high temperature heat seal or other substantially permanent coupling. In an exemplary embodiment, the foil is shorter in length than the substrate so that the bottom sheet covers and is attached to body end of the substrate, but not to the handle portion. Words and images may also be printed on the bottom foil.
As shown by the bottom perspective view of
According to one exemplary embodiment, the foam restoration member may be fixed to the substrate (110) or to the bottom film (160) to prevent the foam from being accidentally lifted out of the orifice by the user. In another embodiment the foam restoration member (190) is free floating within the orifice (180).
Similarly, the foam restoration member (190) is made of a contactable material that ensures the lens is maintained free of potentially toxic or irritating leachables. Further it may be desirable that the foam restoration member 190 absorb and retain the contact lens solution, expand quickly when the package is opened, and be made of a very soft material such that the risk of damage to the surface of contact lens is minimized.
By way of example and not limitation, the foam restoration member may be selected from a group comprising homopolymers or copolymers of acrylic acid, polyvinyl alcohol, polyurethanes, polypropylene, polyvinylformal or regenerated cellulose. These soft materials also permit a disinfectant to be effectively fixed thereto. Further since these soft materials have a sufficiently high degree of the absorption of water and retention of water, the foam restoration member helps maintain the hydration of the contact lens. Also, it is desirable that the foam is a soft and pliable support that does not damage surface of the soft contact lens. In selecting a material for a foam restoration member (190) a preference is given to FDA approved materials, including polyvinyl alcohol (PVA) or polypropylene.
In one embodiment, the foam restoration member (190) is made from polyvinyl alcohol. Polyvinyl alcohol foam can be manufactured as a synthetic sponge with a three dimensional open cell structure similar to that of natural sea sponges such that each cell is interconnected with other surrounding cells. Major advantages of this three dimension open cell structure include high filtering efficiency and impressive retention and wicking properties. A PVA sponge absorbs up to 12 times its dry weight of water or water-based solution. The wet volume is about 20% greater than the dry volume. When saturated with water or water based solution, the foam becomes even more flexible and soft. PVA foam also exhibits mechanical strength and abrasion resistance equal to or greater than other synthetic sponge material. The foam pore size and shape can vary to meet specific applications. Further, than material withstands the action of dilute acids and solutions of common detergents. Untreated, the PVA foam does not contribute to the growth of bacteria nor molds. Foam that is packaged wet may be chemically treated to inhibit bacterial or mold growth.
The PVA foam shape restoration members may be constructed from in any number of manufacturing processes. By way of example and not limitation, the PVA foam shape restoration member may be manufactured by a particle replacement process or a whipped air process. In the particle replacement process for manufacturing PVA foam, starch granules can be interspersed in the PVA structure and then subsequently processed out, leaving very consistent, evenly sized pores. Whipped air technology also can be used to form the PVA pores. In this process, air alone is used to form the pores, resulting in a somewhat less even pore size. However, it is possible in this process to produce much larger pore size than the particle replacement technique. Further, whipped air manufacturing doesn't require any particles to be processed out.
The advantages of PVA foam include ultrafine pore sizes which minimize adhesion, continuous open pore structure which results in superior softness, smaller compressed size is allow for higher volumes of foam restoration members to be used, extremely fast wicking properties which absorb lens solution quickly. PVA foam is biocompatible, nontoxic, and FDA approved for surgery and medical uses.
Alternatively, closed cell foam may be used as a shape restoration member. Specifically, closed cell foam will provide a high restoration force once compressed. The gasses contained within the cells of a closed cell foam will not escape when compressed, thereby increasing the internal pressure of the closed cell foam. When a package containing the closed cell foam is opened, the internal pressure will force a shape restoration on the foam shape restoration member.
In
The substrate layer (110) contains a cavity (180), configured to receive contact lens (200) and any other additional packaging materials. The substrate also has a package end (210) and a gripping end (220). The gripping end (220) can be designed with any number of features that increase the friction between the user's fingers and the substrate body to ensure a secure grip by the user during the process of opening the package. A contact lens (200) is then inserted into the cavity formed by the orifice (180) and the top sheet (150). Beneath the contact lens (200) is the foam restoration member (190). The lens, foam restoration member, and lens solution are sealed into the package by bottom film member (160). The process of assembling an exemplary contact lens package (100) is described in more detail in
Prior to grasping the contact lens, best practice dictates that the contact lens user washes the fingers that will touch the lens to prevent contamination of the lens surface. Typically, the contact lens user will grasp the contact lens between a thumb and a forefinger of one hand as shown in FIGS. 19 and 20. Other methods of grasping the contact lens include, but are not limited to, placing a moistened forefinger in contact with the upper surface of the contact lens, which then preferentially adheres to the forefinger. The foam restoration member (190) facilitates this method of lifting the contact lens from the packaging by minimizing the surface tension and suction forces that would ordinarily prevent the lifting of the contact lens (200) from the package (100). The foam restoration member also minimizes surface tension by reducing the surface contact area (by virtue of its porous nature) between the underside of the contact lens and the foam, and by absorbing excess solution that might form a bond between the foam and the contact lens. The foam restoration member reduces the suction forces by providing air channels that allow the motion of air underneath the contact lens as it is lifted. The air channels may be provided by the geometry of the foam restoration member and/or through the open cell structure of the foam.
When the contact lens is grasped between the thumb (400) and the forefinger (410) as shown in
After the user's thumb (400) and forefinger (410) make contact with the lens (200), the thumb and forefinger are brought together as shown in
The foam restoration member (190) as shown in
Turning now to the exemplary shapes and features of the foam restoration member as shown in
Foam restoration members that have hollow undersides or hollow cross-sections may have the advantage of using less of the bulk material that makes up the foam substrate. Further, the reduced cross-section geometries have less solid thickness, allowing them to be compressed into thinner contact lens packages. Solid foam restoration members can have the advantage of exerting greater restoring force on the contact lens and absorbing additional contact lens solution. In addition to the exemplary embodiments shown in
Additionally, the foam could contain markings or colorants that convey information to the user or assist the user in visually locating the contact lens. Information that could be conveyed by markings could include a marking that designates a specific orientation of an asymmetric contact lens, such as a lens that is designed to correct astigmatism. Other information that could be conveyed by the markings or colorants could include a symbol or color that designates which eye, the right or the left, into which the contact lens is to be inserted. The foam restoration member could also change color to convey information about the condition of the packaging or contact lens that it supports. By way of example and not limitation, the foam restoration member could change color if there is inadequate contact lens solution in the package to keep the contact lens properly hydrated. Typically, this would indicate a breach in the packaging that allowed at least some of the contact lens solution to escape and may have also allowed the entry of contaminates such as dust or bacteria. The user would be notified of the breach in the packaging and could dispose of the contact lens before inserting it into their eye. Alternatively, the user could take additional precautions before inserting the lens into their eye, such as washing or hydrating the lens. In an alternative embodiment, the foam could change color or other characteristics in directly in response to the presence of microorganisms or other contaminates.
The color or other characteristics of the foam could be also be chosen to assist the user in identifying the location of the contact lens. This could be particularly helpful for users because, as they are manipulating the packaging to insert the contact lens, they have less than perfect visual acuity. The color or other characteristics could be chosen such that the foam restoration member was visually distinct from the interior of the contact lens packaging upon which it rests and/or visually distinct from the contact lens itself. By way of example and not limitation, the center of the foam restoration member could be pigmented while the rest of the foam restoration member and the surrounding packaging were not. The center of the foam restoration member could be easily viewed by the user through the transparent contact lens. It would then be a straight forward matter to identify the location of contact lens within the packaging. Reliable visual identification of the contact lens enables the user to grasp the lens with more certainty, reducing fumbling in which the contact lens could be damaged, contaminated, or lost.
Another potential benefit of the foam restoration member could include binding antibacterial agents directly into the foam, such that the antibacterial agents do not migrate into the solution or onto the contact lens. Thus configured, the large surface area created by the open cell foam would act as an anti-bacterial agent, by destroying any micro-organisms that come into contact with the foam. This could reduce the need for anti-microbial and anti-bacterial agents in the contact lens solution. The anti-microbial and anti-bacterial agents in the contact lens solution have a greater potential to be transferred into the eye with the contact lens, potentially causing irritation or allergic reaction.
The foam restoration member also provides additional protection to the lens after the lens is packaged. During shipping, handling, and particularly as the package is transported by the user, the contact lens package can be compromised. One primary mechanism for compromising the lens package occurs when the package is brought into contact with a sharp object. The sharp object penetrates the protective foil layers allowing the lens solution to escape, contaminates to enter, and potentially directly damaging the lens itself. The foam provides a compliant support to the lens that allows the lens and protecting film to yield to the intruding object while providing some resistance to the penetrating force. If a penetrating force pierces the film from a side of the package where the foam restoration member is between the film and the lens, the object must penetrate the foam before it can directly damage the lens itself. Additionally, if the lens package is compromised, the foam member retains a portion of the lens solution, reducing the amount of fluid which might escape into the surroundings, such as the user's purse, pocket, or luggage.
After all of the individual components have been manufactured, the top sheet (150,
Once the top sheet member (150,
Once the lens (200,
According to one alternative exemplary embodiment, the bottom foil is attached the foam restoration member by surface tension or otherwise. The lens (200,
Because the packaging is not filled with a large quantity of saline as is common in traditional packaging, saline fluid does not squirt out of the packaging when it is opened, as commonly happens when traditional packaging is opened. Also, because the lens is confined to one location and orientation and can be easily located by the consumer in many embodiments, the lens can be easily removed from the packaging by placing a finger, or fingers, on only outside surface of the lens, leaving the other side (which will rest on the eye) sterile. Thus the common occurrence in traditional packaging in which both sides of the lens are touched in an effort to find the lens in the saline fluid in the boat, or the lens is pushed up against the boat and may touch the un-sterile upper rim of the boat. It is also easier to orient the lens on the finger for insertion on to the eye than in traditional packaging, where the lens may be floating in various orientations in the boat.
In conclusion, the present contact lens packaging is superior to traditional packaging in many ways. It is much less bulky and can easily be stacked together. This allows for less expensive shipping and is more convenient for consumers to store and carry. The packaging keeps the contact lens in a fixed orientation and position so that the customer can easily remove the lens without searching for it or touching the eye contact surface of the lens with a finger or other un-sterile surface. The manufacturing process is superior to traditional processes because it creates a wider seal to the foil that has less risk of contamination and peels back more uniformly.
Internal members within the contact lens packaging can produce a variety of desirable results for the contact lens user. For example, the internal member can facilitate the return of the contact lens to its relaxed state after it has been packaged in a compressed state. The internal member may hold the contact lens in a consistent location and orientation, allowing the user to grasp the lens easily by the desired surface. The internal member may also be visually distinctive, allowing the user to more easily locate the contact lens within the packaging. When the internal member is constructed from a foam material, the foam member can facilitate assembly of the package by holding the desired amount of lens solution internally. The foam member can also provide additional support and protection for the lens during shipping and handling. When the package is opened the foam member can absorb a portion of the lens solution, preventing it from spilling onto the surroundings.
The preceding description has been presented only to illustrate and describe exemplary embodiments of the system and process. It is not intended to be exhaustive or to limit the system and process to any precise form disclosed. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of the system and process be defined by the following claims.
This application is a continuation-in-part of U.S. patent application Ser. No. 11/404,200 filed Apr. 13, 2006 titled “Packaging for Disposable Soft Contact Lens”, U.S. Pat. No. 7,828,137, which is a divisional application of U.S. patent application Ser. No. 10/789,961, filed on Feb. 27, 2004, U.S. Pat. No. 7,086,526, which is a continuation-in-part of U.S. patent application Ser. No. 10/781,321, filed Feb. 17, 2004, now abandoned, which is a continuation-in-part of PCT Patent Application No. PCT/AU02/01105, filed Aug. 17, 2002, designating the United States, both of which are hereby incorporated by reference in their entirety.
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| Number | Date | Country | |
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| Parent | 10789961 | Feb 2004 | US |
| Child | 11404200 | US |
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| Parent | 11404200 | Apr 2006 | US |
| Child | 11931955 | US | |
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| Child | 10789961 | US | |
| Parent | PCT/AU02/01105 | Aug 2002 | US |
| Child | 10781321 | US |
