# US 11,077,969 B2 · Systems and methods for multi-stage sealing of contact lens packaging

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- Number: US 11,077,969 B2
- Document ID: US11077969B2
- Status: Granted
- Kind: B2
- Application number: 16/998,594
- Filed: 2020-08-20
- Published: 2020-12-03
- Granted: 2021-08-03
- Earliest claimed: 2011-10-18
- Assignees: Menicon Singapore Pte Ltd.
- Applicants: Menicon Singapore Pte Ltd.
- Inventors: Stephen D. Newman
- Web page: https://patentgrep.com/patent/US11077969B2

## CPC

- B65B 25/008: {packaging of contact lenses}
- A45C 11/005: {Contact lens cases (A45C11/046 takes precedence)}
- B29C 65/18: using heated tools
- B29C 65/76: Making non-permanent or releasable joints
- B29C 66/112: {Single lapped joints}
- B29C 66/131: {Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area}
- B29C 66/24245: {forming a square}
- B29C 66/244: {said joint lines being non-straight, e.g. forming non-closed contours}
- B29C 66/305: {Decorative or coloured joints (optical properties of the material of the parts to be joined B29C66/733)}
- B29C 66/3452: {Making complete joints by combining partial joints}
- B29C 66/53461: {joining substantially flat covers and/or substantially flat bottoms to open ends of container bodies}
- B29C 66/81463: {comprising a plurality of single pressing elements, e.g. a plurality of sonotrodes, or comprising a plurality of single counter-pressing elements, e.g. a plurality of anvils, said plurality of said single elements being suitable for making a single joint}
- B29C 66/8161: {said pressing elements being supported or backed-up by springs or by resilient material}
- B29C 66/8322: {Joining or pressing tools reciprocating along one axis}
- B29C 66/8432: {Machines for making separate joints at the same time mounted in parallel or in series}
- B29C 66/849: {Packaging machines}
- B65B 7/2878: {by heat-sealing}
- B65B 51/10: Applying or generating heat or pressure or combinations thereof {(welding of plastics per se B29C65/02; closing plastic tube ends in general B29C57/10)}
- B65B 51/14: by reciprocating or oscillating members (B65B51/148 takes precedence)
- B65B 51/22: by friction or ultrasonic or high-frequency electrical means
- B65D 75/327: {and forming several compartments}
- A45C 2011/006: {for storing a plurality of disposable lens packages}
- B29C 65/04: Dielectric heating, e.g. high-frequency welding {, i.e. radio frequency welding of plastic materials having dielectric properties, e.g. PVC}
- B29C 65/08: using ultrasonic vibrations {(non-plastics element to plastics elements B29C65/645)}
- B29C 65/1412: {Infrared [IR] radiation}
- B29C 65/16: Laser beams
- B29C 66/71: {characterised by the composition of the plastics material of the parts to be joined (welding bar compositions B29C65/125)}
- B29C 66/72321: {consisting of metals or their alloys}
- B29C 66/8242: {Pneumatic or hydraulic drives (using fluid pressure directly acting on the parts to be joined B29C66/8266)}
- B29C 66/8246: {Servomechanisms, e.g. servomotors}
- B29L 2011/0041: {Contact lenses}
- B29L 2031/7164: {Blister packages}
- B65D 2585/545: Contact lenses
- B65B: MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING (bundling and pressing devices for cigars A24C1/44; devices for tensioning and securing binders adapted to be supported by the article or articles to be bound B25B25/00; applying closure members to bottles, jars or similar containers B67B1/00-B67B6/00; concurrent cleaning, filling and closing of bottles B67C7/00; emptying bottles, jars, cans, casks, barrels or similar containers B67C9/00)
- A45C: PURSES; LUGGAGE; HAND CARRIED BAGS
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B65D: CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES

## Abstract

A contact lens package includes a first package layer, a second package layer, a lens receiving area defined between the first and second package layers, and first and second seal portions. The first seal portion extends around a first portion of the lens receiving area. The second seal portion extends around a second portion of the lens receiving area. The second seal portion has different sealing properties than the first seal portion. The first seal portion may include a releasable seal between the first and second package layers, and the second seal portion may include a permanent seal between the first and second package layers.

## Claims

### Claim 1

A method for manufacturing a contact lens package, comprising:
providing a first package layer and a second package layer that define a lens receiving area therebetween;
forming a first seal portion between the first and second package layers around all but a portion of a periphery of the lens receiving area; and
forming a second seal portion between the first and second package layers to completely seal the lens receiving area.

### Claim 2 (depends on 1)

The method of claim 1, wherein forming the second seal portion includes overlapping the second seal portion with the portion of the periphery of the lens receiving area not included in the first seal portion.

### Claim 3 (depends on 1)

The method of claim 1, wherein forming the second seal portion includes forming the second seal portion with a greater seal strength than a seal strength of the first seal portion.

### Claim 4 (depends on 1)

The method of claim 1, wherein forming the first seal portion includes creating a releasable seal between the first and second package layers.

### Claim 5 (depends on 1)

The method of claim 1, wherein forming the second seal portion includes creating a permanent seal between the first and second package layers.

### Claim 6 (depends on 1)

The method of claim 1, wherein forming the second seal portion includes applying at least one of a greater heat and a greater pressure than applied when forming the first seal portion.

### Claim 7 (depends on 1)

The method of claim 1, further comprising removing gases from the lens receiving area before forming the second seal portion.

### Claim 8 (depends on 1)

The method of claim 1, further comprising positioning a contact lens and at least one liquid in the lens receiving area before forming the first and second seal portions.

### Claim 9 (depends on 1)

The method of claim 1, further comprising providing an internal member disc positioned in the lens receiving area, and forming a third seal portion between the internal member and at least one of the first and second package layers.

### Claim 10

A method of manufacturing a contact lens package, comprising:
positioning a first package layer on a first press portion;
positioning a contact lens on the first package layer;
positioning a second package layer on the first package layer and covering the contact lens;
creating a first seal portion between the first and second package layers with a second press portion; and
creating a second seal portion between the first and second package layers with a third press portion;
wherein creating the second seal portion includes creating the second seal portion as a permanent seal between the first and second package layers.

### Claim 11 (depends on 10)

The method of claim 10, wherein the first package layer includes a preformed lens receiving area, and positioning the contact lens includes positioning the contact lens in the lens receiving area.

### Claim 12 (depends on 10)

The method of claim 10, wherein the first and second seal portion have different properties.

### Claim 13 (depends on 10)

The method of claim 10, wherein creating the first seal portion includes creating the first seal portion as a releasable seal between the first and second package layers.

### Claim 14 (depends on 10)

The method of claim 10, wherein creating the second seal portion includes applying at least one of a greater heat and a greater pressure as compared to a heat and pressure used to create the first seal portion.

### Claim 15 (depends on 10)

The method of claim 10, further comprising applying a vacuum to align the second package layer with the first and second press portions.

### Claim 16 (depends on 10)

The method of claim 10, further comprising removing gas from the lens receiving area before creating the second seal portion.

### Claim 17 (depends on 10)

The method of claim 10, further comprising positioning a support disc adjacent to the contact lens between the first and second package layers, and forming a third seal portion between the support disc and at least one of the first and second package layers.

### Claim 18

A method of assembling a contact lens package, comprising:
arranging a first foil package layer and a second foil package layer at least partially overlapping each other with a contact lens positioned there between;
creating a first sealed portion between the first and second foil package layers; and
creating a second sealed portion between the first and second foil package layers.

### Claim 19 (depends on 18)

The method of claim 18, wherein the contact lens is positioned in a lens receiving area defined between the first and second foil package layers, and creating the first sealed portion includes sealing around all but a gap portion of a periphery of the lens receiving area, and creating the second sealed portion includes sealing the gap portion.

### Claim 20 (depends on 18)

The method of claim 18, wherein creating the second sealed portion occurs after creating the first sealed portion.

### Claim 21 (depends on 18)

The method of claim 18, wherein creating the first sealed portion includes creating a releasable seal between the first and second foil package layers, and creating the second sealed portion includes creating a permanent seal between the first and second foil package layers.

### Claim 22 (depends on 18)

The method of claim 18, further comprising positioning a support member between the first and second foil package layers and in contact with the contact lens, and creating a third sealed portion between the support member and at least one of the first and second foil package layers.