Patent Application
20130255195
The invention relates to a method for the secondary packaging of ophthalmic lenses, e.g. contact lenses, contained in individual primary packages, and to a system for such the secondary packaging of ophthalmic lenses.
Methods for the secondary packaging of contact lenses contained in blister-type primary packages are well-known, in particular for single use contact lenses which are disposed of after use. Such a primary package is known, for example, from EP 0 680 955. In such a primary package a single contact lens is contained in a cavity in a storage solution such as saline. The individual primary packages are closed by a foil in a manner such that a plurality of primary packages is arranged in a row and a foil strip is placed over the so arranged primary packages. The foil strip is then sealed or welded to the packages, so that a strip of primary packages is formed which are connected to one another by the common foil strip. A so formed strip includes a predetermined number of primary packages (the number of the packages arranged in a row) each containing a contact lens. The predetermined numbers of primary packages of such strip, however, limits the secondary packaging flexibility in that the total number of contact lenses contained in a secondary package is determined as being an integer multiple of the predetermined number of primary packages forming a strip. By way of example, in case a strip includes five individual primary packages each containing a contact lens, then the secondary package always contains an integer multiple of five contact lenses.
A method for producing a secondary package containing such arrays (strips) of five primary packages each containing a contact lens is known from EP 1 125 849 A2. As a consequence, the secondary package has a size capable of accommodating one or more such strips of five primary packages. A customization of the primary or the secondary package can be added to the packaging material, like the name of the ophthalmic doctor who has prescribed the lens or the name of the patient, the telephone number of the ophthalmic doctor, or other information. If the customization includes graphics, the graphics are selected/specified at the time the order is given by the customer, for example by the ophthalmic doctor ordering the lenses.
The described procedure of providing strips of primary packages each containing a contact lens as well as the secondary packaging of such strips suffers from some disadvantages. For example, in case the order specifies a number of contact lenses of one particular type and this number is not an integer multiple of five, then the order cannot be strictly adhered to. For example, if only strips of five primary packages are stored at the lens manufacturer it may be possible for the customer to order only multiple integers of five contact lenses which may be dissatisfying for a customer who wants to order twelve contact lenses, for example. Alternatively, the lens manufacturer may send a total of fifteen lenses to the customer without charging the three lenses in excess of the ordered total of twelve lenses which may be dissatisfying for the lens manufacturer from an economic point of view.
As a further alternative, strips of different numbers of contact lenses can be stored at the lens manufacturer. For example, in addition to storing strips of five primary packages it may be possible to additionally store strips of three primary packages. While this allows a little more flexibility as regards the ordered number of contact lenses, it increases the expense at the lens manufacturer. This is because the lens manufacturer must store strips of three primary packages and strips of five primary packages for each single type of contact lens. This increases both the manufacturing expense (strips of three primary packages and of five primary packages must be produced) as well as the storage expense (strips of three primary packages and of five primary packages must be stored) at the lens manufacturer. In addition, different types of secondary packages may become necessary due to having strips of different lengths, which must be packaged in a secondary package. And even with this increased expense it is still not possible to strictly adhere to each incoming order, since an incoming order may still specify a desired number of contact lenses which is neither an integer multiple of five contact lenses nor an integer multiple of three contact lenses nor a combination thereof.
It is therefore an object of the present invention to reduce the manufacturing expense and the stock at the lens manufacturer, and at the same time to increase flexibility in the secondary packaging of contact lenses so that incoming orders can be strictly adhered to. Also, the number of different secondary packages should be kept as small as possible.
The method and the system according to the present invention overcome the afore-described problems and disadvantages. In particular, the method for the secondary packaging of ophthalmic lenses, for example contact lenses, according to the invention allows for a reduced manufacturing expense and stock and for an improved flexibility in the secondary packaging of contact lenses.
According to the present invention, there is provided a method for the secondary packaging of ophthalmic lenses, for example contact lenses, contained in individual primary packages. The method includes the steps of
The single individual primary packages can generally be of any type or material. It is preferred, however, that the primary packages are blister packs, for example blister packs like those described in the above-mentioned EP 0 680 955. The single primary packages are sealed and stored individually, so that it is no longer necessary to store strips of different lengths including one particular type of contact lens. This reduces the manufacturing expense since only single individually sealed blisters must be produced and also reduces the type of stock, since only single individual primary packages must be stored. In addition, having a stock of only single individual primary packages it is possible to exactly provide any desired number of lenses. The number of single individual primary packages to be packed into a secondary package is determined before the secondary package blank is selected. This allows to select a secondary package blank of suitable size which is capable of accommodating the determined number of single individual primary packages. Once the secondary package blank has been selected, the single individual primary packages are placed into the selected secondary package blank, whereupon the secondary package blank containing the single individual primary packages is folded and closed to form the secondary package. The size of the secondary package blanks is generally flexible. However, for an efficient processing, preferably a predetermined number of secondary package blanks of different sizes are provided.
With the method according to the invention, it is possible to provide any desired number of one type of contact lens in one (or more) customized secondary packages. For example, if an ophthalmic doctor has ordered a number of contact lenses for one of his patients, the single individual primary packages containing the lenses for this patient can be provided in one customized secondary package. This secondary package containing exactly the desired number of lenses may be provided with printing such as “Contact lenses for patient John Smith provided by ophthalmic doctor Tom Cross”.
Alternatively, combinations of different types of lenses can be provided in one customized secondary package to the same customer, for example to an ophthalmic doctor who has ordered different types of lenses for different patients. The term “different type of lens” as used in this application refers to ophthalmic lenses which are distinct from other ophthalmic lenses in at least one property, which can be a physical or a chemical property of the lens, the overall size of the lens, the shape, optical correction, material, color, or any other property of the lens which is capable of distinguishing one ophthalmic lens from another ophthalmic lens. In particular, the ophthalmic lenses are contact lenses.
Of course, both the primary packages as well as the secondary packages can be provided with printing such as branding of the lens manufacturer. Also, the primary package may be provided with additional printed information such as data related to the respective lens contained in the primary package (e.g. base curve radius, optical correction, production lot number, etc.).
According to one aspect of the method according to the present invention, the step of providing a plurality of single individual primary packages includes providing a plurality of single individual primary packages containing at least two different types of ophthalmic lenses. This aspect is directed to the afore-mentioned possibility to provide a variety of at least two different types of contact lenses in one secondary package, as mentioned above. For example, an ophthalmic doctor has ordered a number of contact lenses for his patients John Smith, Jeff Miller and Jane Blair. The single individual primary packages containing the different types of contact lenses can be placed together in one or more secondary packages which are then sent to the ophthalmic doctor who has ordered the lenses for his patients. The primary packages containing the different types of contact lenses can be marked individually (e.g. by printing the names John Smith, Jeff Miller or Jane Blair on the primary package containing the lenses for these individuals) so that the ophthalmic doctor can easily identify which lens in the secondary package is dedicated to whom. In addition, the secondary packages can be individually marked with printing such as “Contact lenses for John Smith, Jeff Miller and Jane Blair provided by ophthalmic doctor Tom Cross” so as to allow the ophthalmic doctor to easily identify which secondary package includes the lenses for a respective patient.
Accordingly, in one embodiment of the method of the invention the number and the type of ophthalmic lenses which are contained in the single individual primary packages and which are to be packed into the secondary package is determined by a customer order.
In accordance with a further aspect of the method according to the invention, the step of providing a secondary package blank includes providing a plurality of predetermined different secondary package blanks, the different secondary package blanks having an identical width. By “identical” width what is meant is that the widths of different secondary packages are substantially the same as each other, that is, the widths are the same to a degree that permits handling by automated equipment. This simplifies the process of picking the single individual primary packages and placing them into a secondary package blank with the aid of automatic equipment such as pick-and-place robots prior to folding the blank to form the secondary package, as will be explained in more detail below. Typically, a number of one to twelve single individual primary packages can be packed into a single secondary package, so that only a limited number of secondary package blanks must be provided, as will also be discussed in more detail below.
In accordance with a further aspect of the method according to the invention, it is preferred that the step of placing each single individual primary package into the secondary package blank includes placing each single individual primary package in a corresponding individual cut-out portion formed in the secondary package blank. The number of individual cut-out portions in the secondary package blank defines the maximum capacity of the secondary package blank so that the secondary package blank is selected to have a maximum number of cut-out portions that corresponds to or slightly exceeds the number of single individual primary packages to be packed into the secondary package.
In accordance with a further aspect of the method according to the invention, the single individual primary packages are placed in the corresponding individual cut-out portion of the secondary package blank such that the single individual primary packages are (securely) retained in the respective cut-out portions. This can be achieved for example by a frictional fit due to slightly different sizes of the single individual primary packages and the cut-out portion. In another example, a retaining member can be provided in the cut-out portion to (securely) retain the single individual primary packages in the cut-out portion. The primary packages are thus retained in a fixed position in the secondary package blank once they have been placed into the cut-out portion which is advantageous in that the primary packages are securely retained in the respective cut-out portions as the secondary package blank is folded to form the secondary package.
In a further variant of the present invention, the method includes the step of folding and closing the secondary package blank which includes folding and closing the secondary package blank to form a wallet-type secondary package. The wallet-type secondary package is advantageous in that it allows to arrange a comparatively large number primary packages in the secondary package by folding the package blank such that after folding the curved bowls (cavities containing the contact lenses and the saline) of the primary packages are facing one another but are arranged offset relative to one another in a space-saving manner. Also, the wallet-type secondary package allows to conveniently access the individual primary packages by unfolding that part of the wallet-type secondary package carrying the primary packages.
As already discussed above, a further embodiment of the method according to the invention includes the step of applying images, graphic designs, written information, or the like to the secondary package blank, to the secondary package or to the single individual primary package, or to any combination thereof. The application of images, graphic designs or written information allows the customization and/or personalization of the primary and secondary packages, and also allows for branding etc. Application of the images, graphic designs, written information, or the like can be carried out before or after the secondary package is formed from the secondary package blank. In particular the step of applying images, graphic designs, written information, or the like can be determined by a customer order.
Another aspect of the present invention deals with a system for the secondary packaging of ophthalmic lenses, for example contact lenses, contained in individual primary packages. The system includes a storage unit for providing a plurality of single individual primary packages each containing an ophthalmic lens as well as an input unit for determining a number of single individual primary packages to be taken from the storage unit and to be packed into a secondary package. The system further includes a package blank magazine for providing a secondary package blank, the secondary package blank being capable of accommodating the determined number of single individual primary packages. Still further, the system includes at least one robot for placing each single individual primary package of the determined number of single individual primary packages into the secondary package blank. Finally, the system includes a folding unit for folding and closing the secondary package blank containing the determined number of single individual primary packages to form the secondary package.
The storage unit may, for example, include a rack system in which the single individual primary packages are stored and from which they can be automatically retrieved and transferred for secondary packaging. The input unit may be embodied as a computer receiving information regarding the number and type of lenses to determine the number of single individual primary packages. The computer also may serve for controlling the retrieval and transfer of the respective single individual primary packages as well as the placing of the single individual primary packages into the secondary package blank.
The package blank magazine may contain different secondary package blanks which are already cut to length and which are capable of accommodating a number of single individual primary packages. Alternatively, the package blank magazine may include strips of package blank material which are cut to length only after the number of single individual packages to be placed into the secondary package blank is determined. In any event, the secondary package blanks all have the same width. This enables an easy transport of the secondary package blanks on the same transport line for the secondary package blanks without any adjustments of the transport line being necessary, regardless of the number of primary packages to be placed into the secondary package. In addition, a “pick and place robot” can always perform more or less the same operation since it has to place a respective individual primary package always at a location which is arranged along the transport line at the same lateral position on the transport line.
According to one aspect of the system according to the invention, the storage unit includes at least one tray, and each tray has at least two compartments. The compartments are dimensioned for accommodating at least one single individual primary package, more preferably a plurality of single individual primary packages containing lenses of the same type.
According to a further aspect, the system according to the invention includes an input unit which is adapted for receiving and processing a customer order determining the number of single individual primary packages. The input unit (e.g. computer) may directly receive and process the customer order that determines the number of single individual primary packages which are to be taken from the plurality of single individual primary packages (i.e. from the storage) and which are to be packed into the secondary package. The input unit receives a customer order including information inter alia about the type of contact lens, the number of ordered contact lenses, the customer, etc. This information is processed to determine the size of a secondary package accommodating the single individual primary packages according to the customer order. Thus, the input unit controls at least the storage unit, the robot and the secondary package blank magazine in accordance with the customer order received.
In a further preferred variant of the invention, the package blank magazine is adapted for providing a plurality of predetermined different secondary package blanks having an identical width. As noted above, by “identical” width what is meant is that the widths of different secondary packages are substantially the same as each other, that is, the widths are the same to a degree that permits handling by automated equipment. In this respect, the term “predetermined different secondary package blanks” means, that the secondary package blanks stored in the magazine are already cut to length, however, secondary package blanks of different lengths are provided, with different secondary package blanks being capable of accommodating a different number of single individual primary packages. Typically, 1 to 12 single individual primary packages are packed into one secondary package blank, so that in this case a number of six different sizes (lengths) of secondary package blanks may be stored in the package blank magazine, as will be explained in more detail below.
For placing the single individual primary packages in the secondary package blank, in accordance with a further aspect the system according to the invention includes a plurality of robots arrayed one after the other along first and second transport lines for transporting the trays (containing the individual primary packages) and the secondary package blanks, respectively. Such an arrangement of more than one robot along the transport lines improves the efficiency of the system as it allows a higher throughput, since in case one robot cannot pick an individual primary package from a tray and place it in the secondary package blank due to already being busy, the next robot can perform this action.
In accordance with a further aspect, the system according to the invention includes an application unit which is adapted for applying images, graphic designs, written information, or the like to the secondary package blank, to the secondary package or to the single individual primary package, or to any combination thereof. The application unit can be of any suitable type, for example the application unit may be a printer. The application unit preferably is connected to the input unit such that any information contained in the customer order can be forwarded to the application unit which may then apply the information, if desired. As has already been mentioned, the information contained in the customer order may contain graphics, images, other design or written information which is to be provided on the surface of the secondary package.
Embodiments of the invention are further described below with reference to the accompanying drawings for a more complete understanding of the present invention and advantages thereof.
Returning to
Secondary package blank 1 shown in
A closed secondary package 16 as shown in
In a first step shown in
In a second step shown in
The fourth embodiment of the secondary package blank 1 shown in
The individual primary packages 17 are stored in a plurality of trays 21 which can be retrieved from a rack system 22. Each tray 21 may have one or more compartments. Each single compartment of tray 21 includes a plurality of primary packages 17, however, within one compartment of a tray 21 packages 17 containing only one type of contact lenses are provided, whereas different compartments typically contain primary packages 17 containing different types of contact lenses. To be able to automatically distinguish between the different types of contact lenses an identification mark (such as a bar-code or clear text printing) can be applied to the individual primary packages.
When a customer order comes in, an input means 24 such as a computer is used for determining the total number of single individual primary packages 17 to be packed into one or more secondary packages. The input means 24 may not only determine the total number of single individual primary package from a customer order, it also determines the total number of each type of contact lens and optionally customization information from the customer order.
After having determined how many contact lenses of each type are to be packed (e.g. by a customer order), one or more secondary package blanks 1 capable of accommodating the determined number of single individual primary packages are selected from a secondary package blank magazine 23 and are transferred onto a conveyor belt 25. Magazine 23 may contain different types of secondary package blanks 1. As can be seen in
Once the secondary package blank (or blanks) 1 have been transferred to conveyor belt 25, one or more robots 26 pick the respective primary packages determined by the customer order from the compartments of the trays 21 and place the picked individual primary packages 17 into the cut-out portions 4 (see
Having formed the secondary package 16, the secondary package 16 may be customized by applying design or other information 29, in particular images, graphic designs, written information or the like to a dedicated surface area of the secondary package 16. And while the customization information to be applied is determined by a customer order via the input means 24, as this has been described, alternatively or in addition branding information can be applied by a printer 28 to the secondary package 16 which may contain design or information, in particular images, graphic designs, written information or the like.
While embodiments of the invention have been described many changes, substitutions, variations, alterations, transformations and modifications are conceivable to a person skilled in the art without departing from the spirit and scope of the present invention. Therefore, the embodiments are not intended to limit the invention, but rather the present invention is intended to encompass such changes, substitutions, variations, alterations, transformations and modifications. Accordingly, the scope of the invention is defined by the appended claims.
This application claims the benefit under 35 USC §119 (e) of U.S. provisional application Ser. No. 61/617,785 filed Mar. 30, 2012, incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 61617785 | Mar 2012 | US |
