CONTACT LENS PACKAGE AND METHOD AND PACKAGING MACHINE FOR PRODUCING SAME

Abstract

The contact lens package comprises an accommodation element having a cup which contains a contact lens fluid and a contact lens, and a cover film which closes the cup. The accommodation element has, at least in a region of the cup, a coating containing silicon oxide or aluminium oxide. The associated method of production comprises the coating of the accommodation element, at least in the region of the cup, with the coating and the associated packaging machine comprises a coating station for corresponding coating of the accommodation element.

Claims

1. A method for producing contact lens packages, comprising the steps of: forming an accommodation element having at least one cup; coating the accommodation element, at least in a region of the at least one cup, with a coating containing silicon oxide or aluminium oxide; filling the at least one cup of the accommodation element with a contact lens fluid and a contact lens; and applying a cover film to the accommodation element to close the at least one cup.

2. The method of claim 1, wherein the step of forming the accommodation element comprises the steps of: providing a film web; and thermoforming the at least one cup into the film web.

3. The method of claim 2, wherein the step of forming the accommodation element additionally comprises punching the accommodation element out of the film web before the step of coating the accommodation element.

4. The method of claim 1, wherein the accommodation element has, in the region of the at least one cup, a wall thickness which is between 0.05 mm and 0.6 mm.

5. The method of claim 1, wherein the method additionally comprises, before the step of coating the accommodation element, the steps of: grasping the accommodation element by means of a handling device; and inserting the grasped accommodation element into a support by means of the handling device.

6. The method of claim 5, wherein the step of filling the at least one cup of the accommodation element comprises moving the support through a filling station; and the step of applying the cover film to the accommodation element comprises moving the support through a sealing station.

7. The method of claim 1, wherein the method additionally comprises, before the step of coating the accommodation element, arranging the accommodation element in a coating chamber, and the coating of the accommodation element is effected in the coating chamber.

8. The method of claim 7, wherein the method additionally comprises, after the step of arranging the accommodation element in the coating chamber and before the step of coating the accommodation element, the steps of: generating a subatmospheric pressure in the coating chamber; and introducing a process gas into the coating chamber.

9. The method of claim 8, wherein the step of coating the accommodation element comprises: generating a plasma in the coating chamber and, as a result, generating the coating.

10. The method of claim 1, wherein the coating has a layer thickness which is between 10 nm and 250 nm.

11. The method of claim 1, wherein the coating has a layer thickness which is between 20 nm and 80 nm.

12. A contact lens package comprising: an accommodation element which has at least one cup for accommodation of a contact lens fluid and a contact lens; and a cover film which is connected to the accommodation element in order to close the at least one cup; wherein the accommodation element has, at least in a region of the at least one cup, a coating containing silicon oxide or aluminium oxide.

13. The contact lens package of claim 12, wherein the accommodation element has, in the region of the at least one cup, a wall thickness which is between 0.05 mm and 0.6 mm.

14. The contact lens package of claim 12, wherein the coating has a layer thickness which is between 10 nm and 250 nm.

15. The contact lens package of claim 12, wherein the coating has a layer thickness which is between 20 nm and 80 nm.

16. A packaging machine for producing contact lens packages, wherein the packaging machine comprises: a forming station configured to form at least one cup of an accommodation element; a coating station configured to coat the accommodation element, at least in a region of the at least one cup, with a coating containing silicon oxide or aluminium oxide; a filling station configured to fill the at least one cup of the accommodation element with a contact lens fluid and a contact lens; and a sealing station configured to apply a cover film to the accommodation element to close the at least one cup.

17. The packaging machine of claim 16, wherein the forming station comprises a heating device for heating of a film web and a forming device for forming the at least one cup into the film web.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0085] FIG. 1 shows a perspective view of a contact lens package according to the disclosure.

[0086] FIG. 2a-d show a side view of a contact lens package and corresponding intermediate products during a method according to the disclosure.

[0087] FIG. 3 schematically shows a coating chamber for coating of contact lens packages.

[0088] FIG. 4 schematically shows a perspective view of a packaging machine according to the disclosure.

DETAILED DESCRIPTION

[0089] FIG. 1 depicts a perspective view of an embodiment of a contact lens package 2 according to an aspect of the disclosure. A cross-sectional view of the contact lens package 2 can be seen in FIG. 2d. The contact lens package 2 comprises an accommodation element 4 which has at least one cup 6, and a cover film 8 which is connected to the accommodation element 4 in order to seal the at least one cup 6. Moreover, the accommodation element 4 has a flange 10 which surrounds the at least one cup 6 and to which the cover film 8 is attached.

[0090] Preferably, the accommodation element 4 has exactly one cup 6. It is possible for multiple accommodation elements 4 to be connected to one another, for example along their longitudinal and/or transverse sides. Preferably, the accommodation elements 4 are connected to one another such that they are as easily separable as possible, for example by means of a perforated region of the accommodation element 4 and the cover film 8. The accommodation element 4 can also have a plurality of cups 6. The description of preferred embodiments herein therefore applies analogously to embodiments having a plurality of accommodation elements 4 and/or a plurality of cups 6, essentially irrespective of the number of accommodation elements 4 and cups 6.

[0091] The at least one cup 6 serves to accommodate a contact lens fluid 12 and a contact lens 14, as can be seen in the cross-sectional view according to FIG. 2d. In order to avoid diffusion of the contact lens fluid 12 or constituents thereof out of the contact lens package 2, even in the case of a low wall thickness of the accommodation element 4 in the region of the cup 6, the accommodation element 4 has, at least in the region of the cup 6, a coating 16 containing silicon oxide or aluminium oxide. The coating 16 is indicated by a dashed line in FIGS. 2c and 2d. It is self-evident that the coating 16 is preferably continuous.

[0092] Preferably, at least one cup inner surface 6a has the coating 16. The cup inner surface 6a is the side of the cup 6 that, together with the cover film 8, forms a cavity 6b in which the contact lens fluid 12 and the contact lens 14 are accommodated. The cup inner surface 6a is therefore in contact with the contact lens fluid 12 and should therefore be completely provided with the coating 16 in order to provide the necessary barrier effect.

[0093] The accommodation element 4 can also have the coating 16 in the region outside the cup 6 and especially in the region of the flange 10, as shown in FIGS. 2c and 2d. However, it may also be desirable for the accommodation element 4 not to have a coating 16 outside the cup 6 or cup inner surface 6a and especially in the region of the flange 10, for example for better attachment of the cover film 8 to the accommodation element 4.

[0094] The sealing effect of the coating 16 means that the wall thickness of the accommodation element 4 can be minimized, while the seal of the contact lens package 2 is ensured at the same time. The accommodation element 4 can therefore have, in the region of the cup 6 and preferably everywhere, a wall thickness W which is between 0.05 mm and 0.6 mm, more preferably between 0.1 mm and 0.5 mm and even more preferably between 0.2 mm and 0.4 mm.

[0095] The coating 16 preferably has a layer thickness S which is between 2 nm and 500 nm, more preferably between 10 nm and 250 nm and even more preferably between 20 nm and 80 nm. In a particularly preferred embodiment, the layer thickness S of the coating 16 is between 40 nm and 60 nm or between 45 nm and 55 nm. The coating 16 preferably has a uniform layer thickness S, especially on the cup inner surface 6a.

[0096] An embodiment of the method according to an aspect of the disclosure for producing the contact lens package 2 is described below.

[0097] The method first comprises the formation of the accommodation element 4 which has the at least one cup 6. In order to be able to produce a plurality of contact lens packages 2, the method steps can be repeated for each contact lens package 2 or each method step is carried out simultaneously for a plurality of accommodation elements 4 and, if necessary, subsequently repeated for a further plurality of accommodation elements 4. It is self-evident that the following remarks always apply to at least one accommodation element 4 and thus not only to one accommodation element 4 but also to a plurality of accommodation elements 4 which are produced in parallel or consecutively.

[0098] The accommodation element 4 can, in principle, be formed by means of injection moulding or by thermoforming. If the accommodation element 4 is produced by injection moulding, this already gives it the desired shape having the at least one cup 6, as can be seen in FIG. 2b for example.

[0099] However, preference is given to the formation of the accommodation element 4 by thermoforming. As depicted in FIGS. 2a and 2b, the formation of the accommodation element 4 can comprise the provision of a film web 18 and the thermoforming of the at least one cup 6 into the film web 18. The thermoforming, in turn, comprises the heating of the film web 18 and the deep drawing of the at least one cup 16 in the film web 18. The film web 18 can, for example, consist of polypropylene (PP) and have a thickness which substantially corresponds to the wall thickness W of the accommodation element 4 to be formed, in particular the cup 16. The method has maximum efficiency when a plurality of cups 6 is formed into the film web 18 at the same time.

[0100] After the at least one cup 6 has been formed in the film web 18, the formation of the accommodation element 4 preferably comprises punching the accommodation element 4 out of the film web 18. Singularized accommodation elements 4 are present after punching. At the same time, each accommodation element 4 can have one or more cups 6. It is also conceivable that a plurality of inter-connected accommodation elements 4 is punched out.

[0101] The method additionally comprises coating the accommodation element 4, at least in the region of the cup 6, with the coating 16 containing silicon oxide or aluminium oxide. A correspondingly coated accommodation element 4 can be seen in FIG. 2c, the coating 16 being indicated by a dashed line. Coating the accommodation element 4 is effected at least on the cup inner surface 6a, so that the accommodation element 4 has the coating 16 at least on the cup inner surface 6a, as described above. Coating can also be effected in the region outside the cup 6 and especially in the region of the flange 10, as can be seen in FIG. 2c, or solely on the cup inner surface 6a.

[0102] In order to facilitate the handling of the delicate accommodation elements 4 throughout the remainder of the method, to protect them from damage and to make the method as efficient as possible, the method preferably comprises the grasping of the accommodation element 4 by means of a handling device and the insertion of the grasped accommodation element 4 into a support 20 by means of the handling device. The handling device can directly remove the accommodation element 4 from a punching device preferably after punching.

[0103] Suitable handling devices are known to a person skilled in the art, for example as “pick-and-place” devices, and therefore not described in detail. For example, the handling device can be designed as a gripping device or suction device for grasping of respectively one or more accommodation elements 4.

[0104] In the support 20, which is depicted schematically in FIG. 3, the accommodation element 4 can be fed to the further processing steps. Preferably, the support 20 accommodates a plurality of accommodation elements 4 at the same time. The support 20 comprises a seat 22, for example in the form of a receptacle or a through-bore, for each accommodation element 4 to be accommodated or for each cup 16 to be accommodated. At the same time, the accommodation element 4 can be arranged in the support 20 such that the flange 10 rests on the support 20 and the at least one cup 6 is open to the top, as depicted in FIG. 3. However, the accommodation element 4 can also be arranged on the support 20 such that the flange 10 rests on the support 20 and the at least one cup 6 is open to the bottom. The seat 22 is then preferably adapted to the flange 10 and open to the bottom, so that the cup inner surface 6a is accessible for coating. As a result, the accommodation element 4 rests on the support 20 via the regions of the flange 10 that are adjacent to the cup 6, and coating of said regions of the flange 10 can be prevented.

[0105] Coating is preferably effected in a coating chamber 24, which is depicted schematically in FIG. 3. In this case, the method comprises, before the coating of the accommodation element 4, the arrangement of the accommodation element 4 in the coating chamber 24 and subsequently the coating of the accommodation element 4 in the coating chamber 24. The arrangement of the accommodation element 4 in the coating chamber 24 is preferably effected by moving the support 20 into the coating chamber 24.

[0106] After the arrangement of the accommodation element 4 in the coating chamber 24 and before the coating of the accommodation element 4, the method preferably comprises the generation of a subatmospheric pressure in the coating chamber 24 and the introduction of a process gas into the coating chamber 24.

[0107] For this purpose, the coating chamber 24 can have a gas feed 26 for introduction of the process gas into the coating chamber 24. The gas feed 26 is closable and provides a fluid connection to a gas tank. Furthermore, the coating chamber 24 is in fluid connection with a vacuum source 28 for generation of the subatmospheric pressure in the coating chamber 24.

[0108] Furthermore, the method comprises the generation of a plasma in the coating chamber and, as a result, the generation of the coating 16 on the accommodation element 4. For generation of a plasma from the process gas, the coating chamber 24 has a suitable energy source 30. The energy source 30 is, for example, configured for generation of microwaves or comprises suitable electrodes.

[0109] If the accommodation element 4 has been coated with the coating 16, it is supplied to the further method steps, preferably by being guided in the support 20 through relevant processing stations.

[0110] What takes place first after coating is the filling of the at least one cup 6 of the accommodation element 4 with the contact lens fluid 12 and the contact lens 14, both of which can be seen in FIG. 2d. The filling of the at least one cup 6 of the accommodation element 4 preferably comprises moving the support 20 through a filling station.

[0111] If the at least one cup 6 has been filled, what takes place is the application of the cover film 8 to the accommodation element 4 to close the at least one cup 6, as likewise depicted in FIG. 2d. The application of the cover film 8 preferably comprises the adhesive bonding or (heat) sealing of the cover film 8 to the accommodation element 4, especially in the region of the flange 10. Moreover, the application of the cover film 8 can comprise the movement of the support 20 through a sealing station.

[0112] So that the cover film 8 also provides a sufficient barrier effect, it is preferably formed from an aluminium composite film. Such cover films are known to a person skilled in the art and can be connected to the accommodation element 4 in a simple manner and, at the same, easily opened for removal of the contact lens 14.

[0113] If the accommodation element 4 has a plurality of cups 6 and/or if multiple accommodation elements 4 are connected to one another, it may be desirable to be able to detach individual cups 6 or accommodation elements 4. If the cover film 8 has been applied to the accommodation element 4, the method can then additionally comprise the introduction of a material weakening, in particular a perforation or groove, between the individual cups 6 of an accommodation element 4 or between the individual accommodation elements 4.

[0114] Referring to FIG. 4, what is described is a packaging machine 32 according to an aspect of the disclosure for producing the contact lens packages 2, which packaging machine is configured to execute the method described above and to produce contact lens packages 2 described above.

[0115] The packaging machine 32 comprises a forming station 34 which is configured to form the at least one cup 6 of the accommodation element 4. In the preferred exemplary embodiment in which the accommodation element 4 is formed by thermoforming, the forming station 34 comprises a heating device 36 for heating of the film web 18 and a forming device 38 for forming or deep drawing of the at least one cup 6 into the film web 18. The heating device 36 and the forming device 38 are indicated schematically in FIG. 4 as components of the forming station 34. Preferably, a plurality of cups 6 is formed at the same time.

[0116] The efficiency of formation of the at least one cup 6 by thermoforming can be taken advantage of particularly effectively if the film web 18 is provided on a stock roll 40. The long-length film web 18 can be kept in reserve in a space-saving manner on the stock roll 40. Moreover, the film web 18 can be easily fed to the forming station 34.

[0117] In this exemplary embodiment, the packaging machine 32 further comprises an optional punching station 42 for punching of the accommodation element 4 out of the film web 18. Preferably, a plurality of accommodation elements 4 is punched out at the same time. Preferably, the punching by the punching station 42 is effected immediately after the forming of the at least one cup 6 in the forming station 34. The accommodation elements 4 are thereby punched before coating, so that the intactness of the coating 16 can be ensured. However, it is also conceivable to punch the accommodation elements 4 only after coating. The punching station 42 would then have to be arranged at an appropriate point in the packaging machine 32.

[0118] Suitable forming and punching stations 34, 42 are known to a person skilled in the art in the field of package production and therefore not described in detail.

[0119] After punching, the accommodation elements 4 are present in singularized form, but can still have multiple cups 6. For gentle handling, the accommodation elements 4 are then preferably inserted into a support 20 (see FIG. 3) by means of the handling device and fed to the further processing stations.

[0120] The packaging machine 32 additionally comprises a coating station 44 which is configured for coating of the accommodation element 4, at least in the region of the at least one cup 6, with the coating 16 containing silicon oxide or aluminium oxide. The coating station 44 can comprise the coating chamber 24 and the energy source 30, as have been described in detail with reference to FIG. 3.

[0121] It is particularly preferred that the coating station 44 is integrated in the packaging line, the result being that the contact lens packages 2 are producible in a particularly simple and efficient manner. In particular, the accommodation elements 4 can then be guided in the support 20 through both the coating station 44 and subsequent processing stations without the need for further handling or for transfer of the accommodation elements 4. However, this does not mean that the coating station 44 must be arranged and oriented in a line with the other processing stations. For example, it is conceivable that the accommodation elements 4 are moved away from the other processing stations and towards the coating station 44 by means of the handling device, which is, for example, attached to a robot. It is also conceivable that the accommodation elements 4 are first inserted into the support 20 and the support 20 is accordingly guided or moved by means of a robot to the coating station 44.

[0122] In a filling station 46 of the packaging machine 32, the contact lens fluid 12 and the contact lens 14 are filled into each cup 6. Afterwards, the packaging machine 32 additionally comprises a sealing station 48 which is configured to apply the cover film 8 to the accommodation element 4. The filling station 46 and the sealing station 48 can be configured for production of contact lens packages in accordance with known packaging machines and are therefore not described in detail.

[0123] If multiple cups 6 are present in an accommodation element 4 or multiple accommodation elements 4 are integral with one another, material weakenings, in particular perforations or grooves, can be introduced between individual cups 6 of an accommodation element 4 or between the individual accommodation elements 4 in a station (not depicted) which follows the sealing station 48. Material weakenings other than perforations are possible, too.