Methods and systems for contact lens sterilization

Abstract

A method of sterilizing a contact lens includes at least partially sterilizing the contact lens with an application of electrolyzed brine. A system for at least partially sterilizing a contact lens in initial packaging includes a generator for producing electrolyzed brine with biocidal activity, and a dispenser for dispensing a quantity of electrolyzed brine from the generator into the initial packaging with the contact lens.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate various embodiments of the present system and method and are a part of the specification. The illustrated embodiments are merely examples of the present system and method and do not limit the scope of the claims.

FIG. 1 illustrates a process of manufacturing contact lenses including an autoclave sterilization process, according to one exemplary embodiment.

FIG. 2 illustrates a process of manufacturing contact lenses, according to one exemplary embodiment, including a sterilization process using electrolyzed brine according to principles described herein.

FIG. 3 illustrates a portion of a flow-line manufacturing process for contact lenses incorporating electrolyzed brine as a sterilizing agent according to one exemplary embodiment of the principles described herein.

Claims

1. A method of sterilizing a contact lens comprising sterilizing said contact lens with an application of electrolyzed brine.

2. The method of claim 1, wherein said electrolyzed brine is sealed with said contact lens in the initial packaging of said contact lens.

3. The method of claim 2, further comprising heating said initial packaging to seal a foil to a container housing said contact lens and electrolyzed brine, wherein said heating is effective to at least partially sterilize said lens.

4. The method of claim 3, wherein said heating is further effective to promote decomposition of said electrolyzed brine.

5. The method of claim 2, further comprising adding a surfactant to said electrolyzed brine after said brine is electrolyzed to prevent said contact lens from adhering to said initial packaging.

6. The method of claim 2, wherein a material used to form said. contact lens contains a surfactant which leaches into said electrolyzed brine to prevent said contact lens from adhering to said initial packaging.

7. The method of claim 1, wherein said electrolyzed brine also contains a pH buffer.

8. The method of claim 2, further comprising autoclaving said initial packaging to further sterilize said contact lens.

9. The method of claim 3, wherein said container comprises a boat.

10. The method of claim 3, wherein said container comprises a laminated aluminum foil.

11. A system for sterilizing a contact lens in initial packaging, said system comprising: a generator for producing electrolyzed brine with biocidal activity; anda dispenser for dispensing a quantity of electrolyzed brine from said generator into said initial packaging with said contact lens.

12. The system of claim 11, wherein said generator comprises a mixer that mixes salt with water to produce a brine solution that is then electrolyzed by said generator.

13. The system of claim 11, wherein said generator comprises an anode chamber and a cathode chamber separated by a membrane with a system for delivering a quantity of brine solution into each of said anode chamber and said cathode chamber.

14. The system of claim 11, wherein said generator is configured to produce said electrolyzed brine with a pH between 7.20 and 7.70.

15. The system of claim 11, wherein said electrolyzed brine is configured to decompose to an innocuous saline solution in between 2 and 12 hours from generation.

16. A method of sterilizing a contact lens comprising at least partially sterilizing said contact lens with an application of electrolyzed brine.

17. The method of claim 16, further comprising heat sealing said contact lens in a primary package; wherein said heat sealing enhances a rate of biocidal activity of said electrolyzed brine.

18. The method of claim 16, further comprising: packaging said contact lens within a package; andpassing said packaging and said contact lens through an autoclave to further sterilize said contact lens.

19. The method of claim 16, further comprising packaging said contact lens and said electrolyzed brine in a contact lens package, wherein said application of said electrolyzed brine and said packaging of said contact lens in said contact lens package comprises a flow-line process.

20. The method of claim 16, further comprising adding a bicarbonate to said electrolyzed brine.