Note: Descriptions are shown in the official language in which they were submitted.
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CONTACT LENS SECONDARY PACKAGING AND METHODS
TECHNICAL FIELD
[0001] The present systems and methods relate to contact lens
packaging
and more particularly, to secondary contact lens packaging and related
methods.
BACKGROUND
[0002] 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 used for disposable lenses (both bi-
weekly and
daily) consists of a polypropylene receptacle for the lens (herein after
referred to as a
"boat"), topped by a multi-layer film that may include polyethylene, aluminum,
a
bonding agent and polypropylene. The boat is typically an injection molded
plastic
which has high stiffness and includes a preformed recess. The boat is filled
with a
suitable storage solution, such as saline, and receives a single lens in situ.
The blister
pack is then sterilized, typically by being autoclaved using steam and
pressure, to
terminal sterility. These blister packs are presented to the patient in boxes
of individual
packs or as multiple blister strips.
[0003] The lens is stored in the package for an extended period of
time,
which may include months or years. The lens must be kept hydrated while in the
package. Consequently, 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. During 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.
[0004] The package may be exposed to various potentially detrimental
environmental conditions and damaging forces during shipping, handling and
storing of
the package. As the package becomes smaller, thinner and lighter as a result
of efforts
to reduce material and manufacturing costs, the more susceptible the package
may
become to such environmental conditions and damaging forces. Further, the use
of
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certain materials and constructions for the package may affect the shelf-life
of the
product held in the package.
[0005] In order to protect the package during shipping, handling, and
storage, primary contact lens packages are typically grouped into a usable
quantity and
inserted into a secondary package for storage and transport. Traditionally,
secondary
packages for contact lenses constitute a cardboard box including supplier
information
and directions printed thereon.
[0006] Many contact lens users store their contact lenses in the
bathroom
where they have access to a mirror and a sink to aid in the insertion or
retraction of their
contact lenses. Bathrooms are usually wet environments. However, traditional
secondary packages for Contact lenses are typically made from a paper-based
material
that is inadequate for use in a wet environment.
SUMMARY
[0007] One aspect of the present disclosure relates to a contact lens
package
assembly. The contact lens package assembly includes a sealable first lens
package, at
least one contact lens sealed within the first lens package, and a sealable
second or
secondary lens package. In one embodiment, the secondary package is
waterproof. The
first or primary lens package is sealed within the second or secondary lens
package to
increase a shelf life of the at least one contact lens. The secondary lens
package may be
resealable. The secondary lens package may be configured to retain a plurality
of first
lens packages. The contact lens package assembly may further include at least
one inert
gas sealed within the secondary lens package and outside of the first lens
package.
[0008] Another aspect of the present disclosure relates to a package
system
that includes primary and secondary packages. The primary package is
configured to
hold a product with a finite shelf life. The secondary package portion may be
configured to hold the primary package and provides an inert environment for
the
primary package that maintains or extends the shelf life of the product. The
product
may be, for example, a contact lens or a medicament, and may have a
nutritional value.
[0009] Another aspect of the present disclosure relates to a method
for
manufacturing a contact lens package. The method includes sealing a contact
lens
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within a first or primary package, and sealing the first or primary lens
package within a
secondary lens package, wherein the secondary lens package provides an inert
storage
conditioned for the first or primary lens package. The method may further
include
storing a volume of inert gas within the secondary lens package. The secondary
lens
package may include two foil layers that are secured together to define an
interior sized
to receive the first or primary lens package.
[0010] Another aspect of the present disclosure relates to a method of
forming a secondary contact lens package. The method includes providing first
and
second foil layers, connecting the first and second foil layers together to
define a
secondary package interior, wherein the secondary package interior is
configured to
receive a primary contact lens package that holds at least one contact lens.
The method
also includes creating an inert environment within the secondary package
interior. The
method may include providing a waterproof environment within the secondary
package
interior.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] 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.
[0012] FIG. 1 is a top perspective view of an example contact lens
package
assembly in accordance with the present disclosure.
[0013] FIG. 2 is a partially exploded top perspective view of the
contact
lens package assembly of FIG. 1.
[0014] FIG. 3 is a partially exploded bottom perspective view of the
contact
lens package assembly of FIG. 1.
[0015] FIG. 4 is an exploded top perspective view of the contact lens
package assembly of FIG. 1.
[0016] FIG. 5 is a cross-sectional side view of the contact lens
package
assembly of FIG. 1 taken along cross-section indicators 5-5.
[0017] FIG. 5A is a cross-sectional view of the contact lens package
assembly of FIG. 5 taken along cross-section indicator 5A.
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[0018] FIG. 6 is a cross-sectional view of the contact lens package
assembly
of FIG. 1 taken along cross-section indicators 6-6.
[0019] FIG. 7 is a top perspective view of another example contact lens
package assembly in accordance with the present disclosure.
[0020] FIG. 8 is an exploded top perspective view of the contact lens
package assembly of FIG. 7.
[0021] Throughout the drawings, identical reference numbers designate
similar, but not necessarily identical, elements.
DETAILED DESCRIPTION
[0022] The present disclosure relates to a secondary packaging for use
with
primary contact lens packages. In one example, at least one contact lens is
held in a first
or primary contact lens package, and the first contact lens package is
inserted into and
sealed within a second or secondary contact lens package. The secondary
contact lens
package may provide an inert environment that helps maintain a useful life or
shelf life
of the contact lens held in the primary contact lens package. The secondary
contact lens
package may also provide a waterproof environment within which the primary
contact
lens package is stored. The secondary contact lens package may also provide a
level of
protection for the primary contact lens package during shipping and handling.
[0023] The secondary contact lens package may, according to one
exemplary embodiment, be a resealable package that permits inserting and
removing at
least one primary contact lens package. The secondary contact lens package
may,
according to one exemplary embodiment, include inert materials. The secondary
contact lens package may also, according to one exemplary embodiment, include
layers
of metal-based materials such as foil. The secondary contact lens package may
further
include at least first and second laminate sheets or members that are sealed
together
around a periphery to define an interior sized to receive the primary contact
lens
package that holds at least one contact lens. Each of the laminate sheets may
include a
polymer layer and a metal (e.g., foil) layer.
[0024] The secondary contact lens package may have other uses outside
of
retaining at least one primary contact lens package that holds at least one
contact lens.
Other example uses include, for example, retaining one or more prepackaged
4
medicaments, vitamins, supplements, and other volatile products that would
benefit from storage
within an inert secondary storage environment.
[0025] The secondary package may be used in combination with a support
structure such
as a drawer or tray type structure that retains at least one primary contact
lens package and is
insertable with the primary contact lens package into the secondary package.
The support structure may
provide additional rigidity and resistance to deformation and impact forces
that might otherwise
damage the primary contact lens package and the at least one contact lens
retained therein. In at least
some examples, the secondary contact lens package has a flexible or deformable
construction and the
support structure provides at least some rigidity for a contact lens package
assembly that comprises the
primary and secondary contact lens packages and the support structure. Further
details concerning
example support structures are provided in Singapore Patent Application filed
on 18 October 2011 and
entitled "Support Structure for Shipping and Storage of Replacement Contact
Lenses".
[0026] As disclosed in the above-mentioned Singapore Patent Application
entitled "Support
Structure for Shipping and Storage of Replacement Contact Lenses", the support
structure may be used
to support at least one primary contact lens package during shipping of the
contact lens package.
Similarly, the support structure may be used to carry or support at least one
primary contact lens
package during storage of the contact lens package. The same support structure
may be used for both
shipping and storage of at least one primary contact lens package. The support
structure may have a
greater rigidity property than the primary contact lens package. The support
structure may further
provide at least one of additional strength, support and protection for the
primary contact lens package
during at least one of shipping and storage of the primary contact lens
package.
[0027] The support structure may be insertable into the secondary
contact lens package.
The secondary contact lens package may define an interior sized to receive at
least one support member
carrying at least one primary contact lens package. The support member may be
configured to be
removably positioned within a separate storage case for storage of at least
one primary contact lens
package retained in the support member. According to one exemplary embodiment,
the support
member may
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have a drawer-shaped construction having a cavity or interior sized to receive
at least
one contact lens package. The drawer-shaped support member may slide into and
out of
a storage case having at a least one slot or opening sized to receive the
support member.
The support member may be substantially enclosed within the storage case. A
portion
of the support member may be visible from outside of the storage case when the
support
member is positioned within the storage case.
[0028] The support member may include at least one graphic that is
visible
when the support member is stowed within the storage case. The graphic may
include
information related to the at least one primary contact lens package retained
by the
support member. The graphic of the storage case may also provide information
related
to the at least one primary contact lens package retained by the support
member. The
support member may comprise materials that are recycled from other contact
lens-
related manufacturing processes. For example, the support member may include
materials recycled from the plastic molds used to form the contact lenses that
are held in
the primary contact lens packages. Using such recycled materials may reduce
overall
material waste in the process of manufacturing, shipping and storage of
contact lens-
related products.
[0029] The example secondary packages disclosed herein may have
several
advantages as compared to traditional paper-based secondary packages commonly
used
for storing primary packages. Traditional secondary packaging comprises paper-
based
materials that generally lack sterility and resistance to water/humidity
damage. Further,
traditional secondary packages are bulky and occupy a significant amount of
space. The
example secondary packages disclosed herein may be relatively slim,
lightweight and
take up a smaller volume of space as compared to paper-based secondary
packaging.
Further, the example secondary packaging may be waterproof as discussed above
and
provide an improved sterile environment. The inclusion of foil layers in the
secondary
packaging may help minimize light and oxygen transmission into the secondary
packaging. Further, the secondary packaging may be filled with an inert gas
that
contributes to greater product stability and improved shelf life of the
product held within
the secondary package.
[0030] As used in the present specification and in the appended
claims, the
term "inert" refers generally to something that is not chemically reactive,
or, in other
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words, something that is chemically stable. Typically, the noble gases have
been
considered inert gases because of their perceived lack of participation in any
chemical
reactions. The term inert may be applied in a relative sense to describe the
lack of
chemical reactions for an object under normal or typical environmental
conditions.
[0031] The terms "sterile" and ''sterilize" refer generally to any
material or
combination of materials which may come into physical and fluid contact with a
contact
lens or other object contained within a finally formed package. Although
polypropylene
is commonly used as a sterilizable material in packages, any other material
that is
capable of creating a sterile environment for contact lenses, medical devices,
or dental
devices can be used in the present article and method as well. According to
one
exemplary embodiment, a sterile material may include any material accepted by
the U.S.
Food and Drug Administration (FDA) as suitable for the packaging of sterile
medical
devices.
[0032] The phrases "shelf life" and "useful life" refer generally to a
length
of time that food, drink, medicine, chemicals, and many other perishable items
are given
before they are considered unsuitable for sale, use, or consumption. Shelf
life or useful
life is the recommendation of time that products can be stored, during which
the defined
quality of a specified proportion of the goods remains acceptable under
expected (or
specified) conditions of distribution, storage and display. Most shelf life
labels or listed
expiration dates are used as guidelines based on normal handling of products.
Contact
lenses are a product that is typically subject to a predetermined shelf life.
The shelf life
of a contact lens may be dependent on a number of conditions such as, for
example, the
material of the contact lens, packaging conditions, and storage conditions.
[0033] 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
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embodiment" or similar phrases in various places in the specification are not
necessarily
all referring to the same embodiment.
[0034] Referring now to FIGS. 1-6, an example contact lens package
assembly 1 Otis shown and described. The contact lens package assembly 10
includes a
plurality of first or primary lens packages 14, and a second or secondary lens
package
12. At least one primary lens package 14 may be inserted into and stored
within the
secondary contact lens package 12. In some embodiments, the secondary contact
lens
package 12 is at least partially formed around at least one primary lens
package 14
rather than the primary lens package 14 being inserted into the secondary
contact lens
package 12. The secondary contact lens package 12 may provide an inert
environment
within which the primary lens package 14 is stored. The secondary contact lens
package
12 may, according to one exemplary embodiment, include a pair of foil layers
that are
sealed around a periphery of the secondary contact lens package 12 to define
an interior
or cavity within which the primary lens package 14 is stored. According to one
exemplary embodiment, the secondary contact lens package 12 may define a
flexible,
pliable construction. The secondary contact lens package 12 may also be
resealable.
[0035] The first or primary lens packages 14 may, according to the
exemplary embodiment, each include a plurality of first lens package portions
20A-C
that each include a substrate 26, a cover sheet 28 and a contact lens
receiving portion 30
(see FIGS. 4-6). The first exemplary lens package portions 20A-C may be
separable
along perforation lines 22 (see FIG. 4). The first lens packages 14 may retain
a plurality
of contact lenses 24 that are held within the contact lens receiving portions
30 between
the substrate 26 and cover sheet 28 (see FIG. 4). The present exemplary system
and
method will be described, for ease of explanation only, as incorporating
primary contact
lens packages that include a polypropylene boat for receiving and holding the
lens,
topped by a multi-layer film. However, any primary contact lens packaging
configuration may be secured within the present secondary contact lens package
12,
including, but in no way limited to, primary contact lens packaging disclosed
in U.S.
Pat. No. 7,828,137, which patent is incorporated herein by reference in its
entirety.
[0036] Each of the primary lens packages 14 illustrated in FIG. 4
includes
three primary lens package portions. Other constructions and configurations
are
possible for the primary lens packages 14 including, for example, a
construction having
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a single first lens package portion that retains a single contact lens 24.
Other
embodiments include two or more primary lens package portions that each
includes a
single contact lens 24 for each of the primary lens packages 14.
[0037] The primary lens packages 14 may be relatively thin and have a
relatively low profile. In one example, the first lens packages 14 may have a
maximum
thickness between about .25 to 2 times a sagittal height of the contact lens
24 when the
contact lens 24 is uncompressed and in a state of rest. In another example,
the first lens
packages 14 have a maximum thickness that is less than a sagittal height of
the contact
lens 24 when the contact lens 24 is uncompressed and in a state of rest.
[0038] At least one of the substrate 26 and cover sheet 28 may
comprise a
metal material such as a foil. The metal material of the substrate 26 and
cover sheet 28
may be provided as a layer or sheet of material. At least one of the substrate
26 and
cover sheet 28 may also include a polymer material that is provided in the
form of a
layer or sheet. The polymer material may include, for example, polypropylene.
The
substrate 26 and cover sheet 28 may be sealed together using, for example, a
heat seal or
adhesive. Additionally, according to one exemplary embodiment, the primary
lens
package may assume any configuration, including, but in no way limited to, a
package
formed from a plurality of sheets.
[0039] Storing the first lens packages 14 in an inert environment may
increase the shelf-life or useful life of the contact lenses 24 retained
within the first lens
packages 14. Further, the first lens packages 14 may have a generally
flexible, pliable
construction that may benefit from being stored and shipped within a structure
having
additional rigidity and strength to help protect the contact lenses 24. A
secondary
=
contact lens package 12 may provide such additional protection and support as
well as
an inert environment for the first lens packages 14 containing the contact
lenses 24.
[0040] The secondary contact lens package 12 may include first and
second
sheets or layers 40, 42, first and second ends 44, 46, first and second side
edges 48, 50, a
top surface 52, and a bottom surface 54. The secondary contact lens package 12
may
define an interior 56 having an interior opening 58 at the first end 44 (see
FIG. 2). The
secondary contact lens package 12 may also include a closure assembly 60
positioned at
the first end 40 and associated with the interior opening 58. The closure
assembly 60
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may include first and second closure members 59, 61 that meet together to
releas ably
close the interior opening 58.
[0041] According to one exemplary embodiment, the first and second
sheets
40, 42 may be connected to each other around a periphery. A sealed portion 63
may
extend around a portion of the periphery of the first and second sheets 40,
42, such as,
for example, around all edges except for at the interior opening 58. Separate
sealing
steps or features (e.g., the closure assembly 60) may be used to seal closed
the interior
opening 58. The sealed portion 63 may be defined using a heat sealing method.
Other
methods and forms of connecting the first and second sheets 40, 42 are
possible
including, for example, adhesives, and infrared, ultrasound, and sonic bonding
(see FIG.
4).
[0042] The secondary contact lens package 12 may include a plurality
of
graphics positioned on the top and bottom surfaces 52, 54. FIGS. 1 and 3
illustrate a
first graphic 62 positioned on the top surface 52, and second a third graphics
64, 66
positioned on the bottom surface 54. An additional graphic or reflective
member 70
may be positioned on one of the surfaces, such as the bottom surface 54 as
shown in
FIG. 3. A reflective member support 72 (see FIG. 4) may be included with the
sheet
upon which the reflective member 72 is mounted (e.g., on an internal surface
of the
second sheet 42 opposite a position of the reflective members). Any one or all
of the
first, second and third graphics 62, 64, 66 and the reflective member 72 may
convey
information to a user or provide other functions. For example, the contents of
the
package, directions, logos, and other information may be conveyed through the
first,
second and third graphics 62, 64, 66. One of the first, second and third
graphics 62, 64,
66 and the reflective member 72 may include, for example, a bar code, security
features,
and tracking data.
[0043] According to one exemplary embodiment, the secondary contact
lens
package 12 may be filled with an inert gas that assists in providing an inert
environment
within the interior 56. In an example assembly method, the at least one
primary lens
package 14 is inserted through the interior opening 58 into the interior 56 of
the
secondary contact lens package 12. An inert gas is then injected into the
interior 56 to
expose exterior surfaces of the primary lens package 14 to the inert gas. The
closure
assembly 60 is sealed or otherwise closed to retain the inert gas within the
interior 56.
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An additional method step may include removing air or oxygen from within the
interior
56 prior to, during, or after injecting the inert gas into the interior 56. In
some
arrangements, an additional seal may be formed along the interior opening 58
in
addition to or in place of the closure assembly 60, wherein that additional
seal may be
broken to obtain access to the first lens packages 14. The closure assembly 60
may be
used after breaking the additional seal to provide waterproof releasable
closing of the
interior opening 58.
[0044] Each of the first and second sheets 40, 42 of the secondary
contact
lens package 12 may, according to one exemplary embodiment, include a
plurality of
layers. The first and second sheets 40, 42 may be constructed as laminates.
Referring to
FIG. 5A, the first sheet 40 may include a first foil layer 90 and a first
'polymer layer 92.
The second sheet 42 may include a second foil layer 94 and a second polymer
layer 96.
The first and second polymer layers 92, 96 may be arranged facing each other
so that
application of heat to the first and second sheets 40, 42 bonds the first and
second
polymer layers 92, 96 to form the seal portion 63.
[0045] Each of the first and second sheets 40, 42 may include
additional
materials and layers including, for example, at least one layer that includes
one or more
of the graphic portions 62, 64, 66. The use of foil layers in a secondary
contact lens
package 12 may provide light reflectivity that inhibits the egress of light
into the interior
56, wherein that light may otherwise provide at least some degradation of the
first lens
packages 14 or influence the inert environment within the interior 56. The
polymer
layers 92, 96 of the first and second sheets 40, 42 may include an inert
material such as
polypropylene. Other inert materials may similarly be used to create an inert
environment within the secondary contact lens package 12.
[0046] The foil layers 90, 94 of the secondary contact lens package 12
may
also provide additional strength and durability for the secondary contact lens
package
12. The foil layers 90, 94 may also comprise a corrosive resistant material.
The foil
layers 90, 94 may be encapsulated within other layers of non-corrosive
material such as,
for example, polymer-based layers.
[0047] The material composition of the first and second sheets 40, 42
and
other features of the secondary contact lens package 12 may provide a
waterproof
environment within the interior 56. Providing a waterproof environment may
have
11
advantages when using the contact lens package assembly 10 in a high moisture
environment such as,
for example, within a storage cabinet, on a sink top, or in a cupboard in a
bathroom where contact
lenses are typically stored. The waterproof aspects of the secondary contact
lens package 12 may also
provide benefits when transporting the contact lens package assembly 10 in,
for example, a person's
pocket, purse, wallet, bag, suitcase or other carrying member where the
contact lens package assembly
may be exposed to, for example, perspiration, food or drink, or high humidity
conditions.
[0048] The combination of a foil layer with a polymer layer such as
polypropylene in the
first and second sheets 40, 42 of the secondary contact lens package 12 may
provide improved
resistance to the passage of moisture or gas through a secondary contact lens
package 12 either into or
out of the interior 56. Details concerning the construction, advantages and
manufacturing of a package
layer comprising foil, such as foil-on-foil packaging, and related systems and
methods are disclosed in
U.S. Patent No. 7,828,137. Other features and functionality related to lens
package constructions and
materials are described in Singapore Patent Application filed on 18 October
2011 and entitled
"Packaging for Disposable Soft Contact Lenses Having Pre-Formed Multi-Layer
Structural Laminate".
[0049] As disclosed in the above-mentioned Singapore Patent Application
entitled
"Packaging for Disposable Soft Contact Lenses Having Pre-Formed Multi-Layer
Structural Laminate", a
primary lens package may include a preformed laminate substrate. One layer of
the laminate substrate
is configured to provide sufficient structural rigidity to maintain a shape
(e.g., a lens receiving portion)
that is preformed in the substrate. In one example, the first layer includes a
polymer material such as
polypropylene. Another layer of the laminate substrate may include a second
material that provides
different properties from the first layer such as, for example, light-
reflectivity, strength, and resistance
to water/vapor permeability. The package also includes a cover sheet that is
connected to the substrate
and seals a contact lens within a lens receiving portion formed in the
substrate. The cover sheet may
also be a laminate having at least two layers. The first layer may comprise,
for example, a polymer that
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assists in connecting the cover sheet to the substrate. Another layer of the
cover sheet
may include a material having different properties such as, for example,
greater light-
reflectivity, strength, or resistance to water/vapor permeability.
[0050] A further aspect related to the primary lens package is
directed to a
_
single contact lens package that houses multiple contact lenses. The contact
lens
package may include a plurality of lens receiving portions (e.g., recesses,
depressions or
"boats") formed in the substrate. The lens receiving portions may be arranged
in
multiple directions such as multiple rows, wherein each row includes at least
one
contact lens receiving portion. The rows may be arranged opposite each other
or side-
by-side. Some contact lens packages may provide for separation of at least one
lens
receiving portion from the other lens receiving portions. Other arrangements
may
include a plurality of lens receiving portions that are inseparable from each
other once
the contact lens package is assembled.
[0051] Some primary lens packages may include layers of material for
the
cover sheet and substrate that are added during assembly of the contact lens
package
rather than being provided with the substrate and/or cover sheet as a
laminate. In one
example, at least one layer of light-reflective material or liquid/vapor
impermeable
material is added to the substrate or the cover sheet after sealing a contact
lens within a
lens receiving portion of the substrate.
[0052] The primary lens packages may be created in a single
manufacturing
line. The substrate and sheet may include materials capable of maintaining a
sterile
environment within the package where the lens is disposed. The sterile
environment
may be created by heating the first material of the substrate. Light-sensitive
materials
disposed within the package may also be protected from light to limit
degradation of the
light-sensitive materials. The substrate and cover sheet may comprise
materials that
permit printing of graphics that minimize negative effects on the light-
reflecting
attributes or the sterile environment of the contact lens package. In some
arrangements,
the contact lens package may be configured for use as an insertion aid. The
materials of
the contact lens package may promote improved sealing between the substrate
and cover
sheet layers. For example, the laminate materials used for at least one of the
substrate
and cover sheet may include layers of material in the area where a seal is
formed
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between the substrate and cover sheet that provide improved seals (e.g.,
releasable seals,
permanent seals, hermetic seals, heat seals, etc.).
[0053] The secondary contact lens package 12 disclosed herein may have
other constructions such as a construction wherein one of the first and second
sheets 40,
42 is configured as a substrate that is relatively rigid and the other of the
first and second
sheets 40, 42 is configured as a cover sheet sealed to the substrate to define
an interior
sized to receive at least one of the first lens packages 14. This alternative
embodiment
may provide an inert environment for storage of the first lens packages 14.
The
alternative embodiment may provide a waterproof environment for storage of the
first
lens packages 14. The alternative embodiment may include one or more foil
layers.
[0054] One objective in providing an inert environment within the
interior
56 of the secondary contact lens package 12 (e.g., using an inert gas) is to
improve a
sterility assurance level for the primary lens package 14. Providing an inert
environment within the interior 56 may limit the growth of bacteria. Providing
an inert
environment may also permit storage within the secondary contact lens package
12 of a
primary package (e.g., the primary lens package 14) having lower standards of
water-
resistance, light reflectivity, gas permeability, etc. Furthermore, the
additional
protection against environmental conditions provided by the secondary contact
lens
package 12 may permit reduced standards for the primary lens package 14
relate(' to
strength, durability, and protection against environmental conditions.
[0055] Another application for the secondary contact lens package 12
is for
the storage of non-contact lens products that may be volatile for any number
of reasons
such as, for example, freshness and shelf-life. In one example, the secondary
contact
lens package 12 is referred to generally as a secondary package used to store
pre-
packaged products such as, for example, medications, vitamins, supplements,
and other
food and drug-related products. In at least some instances, both physical and
chemical
aspects of the product being stored may be protected and/or given an extended
shelf life
as a result of storage within the inert environment provided by the secondary
packaging.
[0056] The use of a secondary package for storing of such relatively
volatile
products may be enhanced with the use of a cold sterilization process when
sterilizing
the secondary package after product has been sealed therein. Even after the
secondary
package has been opened to obtain access to the product, providing the
secondary
14
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package with a resealable opening may further extend at least some benefits of
using the
secondary package such as, for example, the waterproof environment, protection
against
physical harm, reduced exposure to light, and protection against egress of
bacteria,
additional oxygen or other debilitating conditions for the stored product.
[0057] In addition to a foil based package, the secondary contact lens
package 12 disclosed herein may be manufactured in according to any number of
manufacturing methods and using a number of materials. Specifically, according
to one
exemplary embodiment, the secondary contact lens package 12 may be an
injection case
molded plastic packaging, a card or paper material that is wax or polymer
coated so as
to be waterproof, a foil or foil composite package, a package made from
materials that
are reeycled from other contact lens-related manufacturing processes such as
plastic
molds used to form the contact lenses that are held in the primary contact
lens packages,
and combinations thereof.
[0058] Referring now to FIGS. 7-8, another example contact lens
package
assembly 100 is shown. The contact lens package assembly 100 includes a first
or
primary lens package 112 stored within a second or secondary lens package 114.
The
first lens package 112 may be held within a support member 182 prior to being
inserted
into and stored within a secondary package 114. The primary lens package 112
may
have the same or similar construction to the primary lens packages 14
described above
with reference to FIGS. 1-6.
[0059] The secondary lens package 114 may include first and second
ends
144, 146, first and second side edges 148, 150, top and bottom surfaces 152,
154, an
interior 156, an interior opening 158, and sealed portions 162 at opposing
ends (see FIG.
7). The secondary lens package 114 may also include an expansion portion 180
along
the first and second side edges 148, 150. The expansion portion 180 may
include a fold
or expandable portion that helps increase a size of the interior 156 to
accommodate, for
example, the support member 182.
[0060] The support member 182 may include a periphery wall 184 and a
recess or cavity 186. The cavity 186 may be sized to receive at least one of
the primary
lens packages 112. A plurality of primary lens packages 112 may be positioned
within
the cavity 186. The support member 182 retaining the primary lens package 112
may be
inserted through the interior opening 158 into the interior 156. An inert gas
may be
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injected into the interior 156 prior to sealing closed the secondary lens
package 114. At
least one of the sealed portions 162 may include a closure assembly that
provides a
resealable opening into the secondary lens package 114.
[0061] Details concerning the support member 182 and its possible
functions related to, for example, carrying and supporting the first lens
package 112
during shipping, storage and use is described in Singapore Patent Application
filed on
18 October 2011 and entitled "Support Structure for Shipping and Storage of
Replacement Contact Lenses", mentioned above.
[0062] The secondary lens package 114 may, according to one exemplary
embodiment, be formed using a single sheet (e.g., a laminate sheet including a
foil
layer) that is folded over and sealed along opposing free edges to create a
tubular-
shaped structure. The tubular-type structure may be sealed at opposing ends to
create
the secondary lens package 114 shown in FIGS. 7 and 8. The expansion portions
180
may be folded or otherwise formed into the secondary lens package 114 prior to
creating
the sealed portions 162. The primary lens package 112 may be inserted into the
secondary lens package 114 before sealing either of the sealed portions.
[0063] In other examples, first and second sheets of material (e.g.,
laminate
sheets each including a foil layer) may be sealed together around a periphery
such as
described above with reference to secondary contact lens package 12. The
sealed
portions 162 may be formed in the first and second ends 144, 146 in separate
sealing
steps. In a still further embodiment, the secondary lens package is formed
using a
continuous, unbroken tubular member that is sealed closed at the first and
second ends
144, 146 to create the sealed portions 162. The expansion portions 180 may be
formed
in the tubular structure prior to or as part of forming the sealed portions
162.
[0064] The materials used for the secondary lens package 114 may have
the
same or similar properties, features, layers, manufacturing methods and
constructions as
described above with reference to secondary contact lens package 12.
[0065] One aspect of the present disclosure relates to packaging with
the
inclusion of some form of inert medium to preserve a desired condition within
the
packaging until the time of opening the packaging. Another aspect relates to
packaging
and other features that may be used to tune or match the internal conditions
of the
packaging to the properties of the product being stored in the packaging to
optimize a
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shelf-life or product-life of that product. Another aspect relates to an
ability to use
thermally-sensitive ingredients, dyes, and material as part of the primary
packaging held
within the secondary packaging because of the inert environment provided
within the
secondary packaging. Another aspect relates to secondary packaging that
provides an
improved storage and/or shipping condition for thermally-sensitive
medications,
vitamins, supplements, and other products. A still further aspect relates to
secondary
packaging and permits the use of primary packaging designs and materials that
have
lower standards of, for example, strength, sterility, shelf-life, and gas
permeability. At
least some of these aspects of the present disclosure are possible or enhanced
with the
use of cold sterilization techniques related to sterilizing the secondary
packaging.
[0066] Some example inert gasses or other gasses that may be used
within
the secondary packaging include, for example, nitrogen, argon, and other
gasses (e.g.,
noble gases) that may, for example, match the properties, attributes, or other
aspects of
the product held in the secondary packaging.
[0067] Example methods in accordance with the present disclosure
relate to
assembly of a contact lens package having at least one first lens package
stored within a
secondary lens package. Other aspects relate to methods of manufacturing or
forming a
secondary lens package. Further aspects relate to creating an inert
environment for
storage of at least one primary lens package. Other aspects relate to methods
of
accessing and storing a plurality of first lens packages within a secondary,
resealable
lens package. Another method relates to storage of a plurality of first lens
packages
within a waterproof secondary lens package. The secondary lens package may be
resealable. Many other methods and aspects of the present disclosure are
possible.
[0068] 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.
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