(19) TZZ Z_T

(11) EP 2 526 808 B1

(12) EUROPEAN PATENT SPECIFICATION

(45) Date of publication and mention (51) Int Cl.: of the grant of the patent: A45C 11/00 (2006.01) B65D 75/32 (2006.01) 21.10.2015 Bulletin 2015/43 A61F 9/00 (2006.01) B65D 83/00 (2006.01) B65D 83/04 (2006.01) A47F 1/00 (2006.01) (2006.01) (2006.01) (21) Application number: 12180336.5 B65D 81/05 B65D 75/58 B32B 1/06 (2006.01) A45C 11/04 (2006.01) B32B 3/08 (2006.01) B65D 75/30 (2006.01) (22) Date of filing: 16.02.2005 B65D 75/42 (2006.01) B65D 77/02 (2006.01) B65D 81/22 (2006.01) B65D 81/32 (2006.01)

(54) Packaging for disposable soft contact lenses Verpackung von weichen Einweg-Kontaktlinsen Conditionnement pour lentilles de contact souples jetables

(84) Designated Contracting States: (72) Inventor: Newman, Stephen D. AT BE BG CH CY CZ DE DK EE ES FI FR GB GR Singapore, SG 469977 (SG) HU IE IS IT LI LT LU MC NL PL PT RO SE SI SK TR (74) Representative: Freeman, Jacqueline Carol (30) Priority: 17.02.2004 US 781321 WP Thompson 27.02.2004 US 789961 55 Drury Lane London WC2B 5SQ (GB) (43) Date of publication of application: 28.11.2012 Bulletin 2012/48 (56) References cited: WO-A-03/016175 JP-U- 54 123 232 (62) Document number(s) of the earlier application(s) in US-A- 5 474 169 US-A- 5 573 108 accordance with Art. 76 EPC: US-B1- 6 474 465 05708539.1 / 1 718 538 • PATENT ABSTRACTS OF JAPAN vol. 1999, no. (73) Proprietor: Menicon Singapore Pte Ltd. 3, 31 March 1999 (1999-03-31) -& JP 10, 313928, Singapore 609925 (SG) A, (HOYA CORP), 2 December 1998 (1998-12-02)

Note: Within nine months of the publication of the mention of the grant of the European patent in the European Patent Bulletin, any person may give notice to the European Patent Office of opposition to that patent, in accordance with the Implementing Regulations. Notice of opposition shall not be deemed to have been filed until the opposition fee has been paid. (Art. 99(1) European Patent Convention). EP 2 526 808 B1

Printed by Jouve, 75001 PARIS (FR) 1 EP 2 526 808 B1 2

Description industry has been to provide preformed stiff packaging which protects the lens from damage from applied load. BACKGROUND Examples of typical prior art blister packs are shown in: U.S. Patent No. 5,704,468; U.S. Patent No. 4,392,569; [0001] The present invention relates to contact lens 5 U.S. Patent No. 5,620,088; U.S. Patent No. 5,620,088; packaging and, more particularly, to an improved eco- U.S. Patent No. 4,691,820; U.S. Patent No. 5,823,327; nomic form of package for a contact lens which satisfies U.S. Patent No. 5,853,085; EP Patent Publication No. 1 lens packaging criteria, including sterility and environ- 092 645 A1; and EP Patent Publication No. 1 092 645. mentally sensitive disposability. The invention relates to One problem with many blister packs is that the force a package that provides an improved method of orienting 10 required to peal off the film layer from the blister has a and presenting the lens. Also described are methods of high peak, followed by a rapid decrease in the amount removing the lens from the package, and contact lens of force required to open the main part of the seal. This packages arranged for improved distribution, travel com- can result in a jerky movement and spilling the contents patibility and/or dispensing. when the blister is opened. 15 [0006] Flexible retort packages are also known, how- PRIOR ART ever, not for use with contact lenses. U.S. Patent No. 4,769,261 discloses a seal layer for use in large institu- [0002] Soft disposable contact lenses are commonly tional sized retort pouches comprising an ABA film struc- contained in disposable packages. As packaging adds ture, wherein the A layers are each composed of a blend to the overall cost of the lens, it should be made as eco- 20 of a minor amount of an elastomer and a major amount nomically as possible but without compromise to the req- of a polyolefin and the B layer is composed of a blend of uisite packaging criteria.The traditionalblister pack pack- a major amount of an elastomer and a minor amount of aging (shown in Figs. 1-3) for disposable lenses (both bi- polyolefin. Retort pouches made with the A film structure weekly and daily) consists of a receptacle as the seal layer exhibit improved impact strength. There for the lens (herein after referred to as a "boat"), topped 25 is no teaching in the ’261 patent to use a retort package by a multi-layer film consisting of , alumi- for housing a contact lens. num, a bonding agent and polypropylene. The boat is [0007] EP Patent Publication No. 0 129 388 describes usually an injection molded which has high stiff- a formed by sealing together an optically trans- ness but is capable of limited elastic deflection and in- parent film so as to enclose a contact lens plus hydration cludes a preformed recess. The boat is filled with a suit- 30 solution. This teaching is however directed at maintaining able storage solution, preferably saline, and receives a the contact lens in its natural equilibrium shape so as to single lens in situ. The blister pack is then autoclaved allow optical measurement to be conducted without using steam and pressure to terminal sterility. These blis- opening the pack. In an additional aspect of this teaching, ter packs are presented to the patient in of indi- the sachet is provided with a holder or support within the vidual packs (Figs. 4-5) or as multiple blister strips. 35 sachet in which the lens is retained to assist in securing [0003] The marketing objective is to present the con- the lens to allow such optical measurements as back tact lens to a patient in an aesthetically pleasing package surface radius of curvature to be made. It is clear there- that both satisfies the statutory requirements for sterility fore that EP ’388 is directed at maintaining a contact lens and stability, and allows the patient to remove the lens in its equilibrium shape. safely and easily. The packaging is used only once and 40 [0008] Japanese Patent Publication No. 6-258603 is discarded after the lens is removed. This impacts the similarly describes a resin film pack for the storage of costs of the lens/package combination. In order to reduce contact lenses. The package is formed from a suitable the overall price of the lens to the patient, the cost of the resin material by sealing three of the four sided together, packaging should be kept to an absolute minimum. In leaving the fourth side open to insert the contact lens addition, disposability of lens packages necessitates45 plus storage solution. Once the lens and solution have conformity with ecological standards. been placed within the package, the fourth side is then [0004] The lens must be kept hydrated while in the heat sealed. There is no provision within this teaching package. The package must be well sealed and should for the opening of the package. Since the contact lens is minimize water vapor transmission through the boat and placed into the pre-formed package through its open end, laminated layer to maximize the and prevent 50 there is no provision for favorably orientating the lens for drying out of the lens contained therein. In use, the user user convenience. removes the laminated material from a flange formed on [0009] A package according to the preamble of claim the boat by peeling back the cover to expose the lens 1 is known from US 5573108. immersed in a hydrating solution. [0010] The prior art contact lens packages thus have [0005] A variety of contact lens packages, particularly 55 a number of disadvantages, which include the following: disposable contact lens packages including preformed blister packs, are taught in the prior art. As exemplified 1. The packages are relatively expensive for daily in the prior art, conventional wisdom in the contact lens disposable packages as they use two types of ma-

2 3 EP 2 526 808 B1 4

terial, one of which is preformed, thus increasing SUMMARY OF THE INVENTION manufacturing costs. Consumers resist packages which contribute to increased cost of a lens. This will [0012] The present invention seeks to ameliorate the become a greater problem as the daily disposable problems of the prior art packages by providing an alter- market grows and becomes more competitive. 5 native and more economical package without compro- 2. Prior art packages are traditionally manufactured mise to statutory and medical requirements of contact from two distinctly different materials, one for the lens packages. boatwhich houses the lens and another for the cover. [0013] According to the present invention there is pro- This can lead to sealing problems with an attendant vided a single use package with a contact lens therein, risk of compromised sterility. Over time, a poorly10 according to claim 1. sealed blister pack could allow its contents to evap- [0014] Preferred embodiments of the invention are ac- orate and render the pack useless. This could cause cording to the dependent claims. stock defects and consequent financial losses to the [0015] The single-use package, in the preferred em- manufacturer. Correction of such defects would like- bodiments described below, offers a number of advan- ly entail the recall of potentially affected batches, and 15 tages over the prior art blister pack concept. First, the would be potentially expensive both financially and single-use package is smaller and slimmer which lends in terms of company product quality reputation. itself to disposability and is ideal for traveling. Addition- 3. A non-sterile lens, due to poor or incomplete pack- ally, the number of packages in a secondary age sealing, may expose a patient to the risk of eye may be increased, yet storage space for that secondary infection andsubsequent ocular compromise,poten- 20 package, may be reduced. The single-use package may tially resulting in litigation. be composed of foil sheets which stabilize light exposure 4. The size of the packaging is a disadvantage as and prevent oxygen transmission. Further, there is no air the receptacle is many times larger than the lens in the package, thus ballasted autoclaving is not required. itself. As a result of the polypropylene blister com- The absence of air in the package likely contributes to ponent, the individual package is somewhat deeper 25 lens stability in the package. Thus, the shelf-life of a con- than the lens from a sagittal perspective, and as tact lens in a single-use package may be extended. Over- such, does not lend itself to a disposable look or con- all, the single-use package is a more convenient and cost venient stacking due to its shape and size. There- effective form of packaging. fore, for the traveling consumer, the lenses may [0016] Conventional wisdom requires a disposable prove to be a bulky item. 30 contact lens package to be stiff and preformed with a 5. The traditional approach to lens packaging has profiled recess to house the lens therein. The preformed been to ensure that the original shape of the lens is recess in the known packages is intended to ensure that maintained in the package. This philosophical ap- the lens shape is maintained and is not deformed by the proach places limitations on package configurations. package. The preferred single-use package according 6. The retort style packaging as taught in the prior 35 to certain embodiments of the present invention is con- art will also suffer from additional disadvantages. trary to conventional wisdom as it does not maintain the Firstly opening a retort package is typically per- lens in an equilibrated position, but instead holds the lens formed by tearing open the end of the package rather in a flattened state. The internal depth of the single-use thanpeeling back theseal area. This clearly presents package is less than the overall natural sagittal depth of the risk of tearing the lens. Secondly removal of the 40 the contact lens. Further, the single-use package may contact lens from an opened retort package will in- be flexible and not preformed, and may contribute to ad- volve either inserting the finger into the package to justments to the shape of the lens in the package. The retrieve the lens, (which again may lead to damage) present invention challenges the long held view that dis- or emptying the entire contents of the package into posable lens packages must be stiff, and for the most the hand. Thirdly, there is no provision for orientating 45 part, rigid and capable of elastic deflection under load. the lens within the package to facilitate orientation Stiffness of the package was previously thought essential of the lens for the convenience of the patient. to protect the lens. However, if wall stiffness is aban- doned as an essential packaging criterion, alternative [0011] There is a long felt need in the disposable con- contact lens packages with significant space economy tact lens industry to provide an economic, space-efficient, 50 may be contemplated. and convenient, disposable contact lens package without [0017] The invention is a single-use package with a compromise to durability, sterility and utility of the lens. contact lens therein, and the package has an internal While some of these needs are met by the packaging for depth which is less than an overall sagittal depth of the disposable contact lenses disclosed in applicant’s prior contact lens when the contact lens is in its equilibrated application PCT/AU02/01105, published as 55 WOform. 03/016175, further improvements have also been invent- [0018] In one embodiment, the invention is a blister ed and are disclosed herein. package with a molded base, a cover and a contact lens therein, and the overall depth of the blister package is

3 5 EP 2 526 808 B1 6 less than the natural sagittal depth of the contact lens gle-use contact lens package from a group of packages, therein. the method comprising: providing a dispensing container [0019] Also described is a method of removing a con- having a plurality of contact lens packages therein; and tact lens from a contact lens package. The method in- removing at least one contact lens package from the dis- cludes the steps of: placing a package with a spring disc 5 penser. and a contact lens on an index finger; pushing the index [0029] Also described is a method for opening a single- finger through a center of the spring disc such that the use contact lens package having an internal depth that contact lens rests on the tip of the index finger; and plac- is less than the overall sagittal depth of an equilibrated ing the contact lens that rests on the index finger into an contact lens therein, the method comprising separating eye. 10 a first barrier layer from a second barrier layer. [0020] The single-use contact lens package may be [0030] Also described is a single-use package capable removably adhered to a card. of holding a contact lens therein. The package has at [0021] Also described is a single use package for re- least one barrier layer of pliable packaging material form- taining a contact lens, with at least one barrier material ing at least first and second opposing surfaces which defining an internal space for holding a contact lens; a 15 define an internal package space in which the contact medium in the space for maintaining lens hydration; and lens is retained; a hydration medium in the space; and means to enable release of the lens from said space; means for enabling release of the contact lens from the where at least one barrier layer is formed from a homog- package; wherein the at least one barrier layer of material enous, pliable material. is flat and is flexible. [0022] Also described is a single-use package capable 20 [0031] Also described is a set of retort-type single-use of holding a contact lens. The package has two sheets packages for holding contact lenses therein. The pack- of material; and a support member between the two ages each comprise: at least one layer of pliable package sheets of material. The two sheets of material are sealed material forming at least first and second opposing sur- andthe lens is confined in the package suchthat isalways faces which define an internal package space in which maintained in the same orientation inside the package. 25 the contact lens is retained; a medium in the space for [0023] Also described is a containing at least maintaining lens hydration; wherein the package material 90 single-use packages each with a contact lens therein, is capable of assuming a generally planar configuration; where each of the packages has an internal depth which and wherein the set is formed by joining at least two the is less than the overall sagittal depth of each the contact packages so that a single package may be tom away lens within the package. 30 from an adjacent package via a frangible connection be- [0024] In another embodiment, the invention is a sin- tween the packages. gle-use package with a contact lens therein, where the [0032] Also described is a retort-type single-use pack- package is configured such that when the package is age comprising an internal space for holding a contact opened, the lens is always oriented in the same position lens and a medium for maintaining lens hydration therein as when it was placed into the package. 35 is provided. [0025] Also described is a contact lens package con- [0033] Also described is a secondary package for a tainer having a plurality of contact lenses therein. The pluralityof contactlens packagescomprising acontainer, contact lens packages are dispensed such that as one where the contact lens packages contained therein have contact lens package is removed, a next contact lens an internal depth that is less than the natural sagittal package to be dispensed is automatically moved into a 40 depth of the contact lens therein; and wherein the con- position to be removed. tainer is a shape selected from the group consisting of a [0026] Also described is a single-use package with a circle, rectangle, square, triangle, oval and symmetrical, contact lens therein which comprises two sheets of ma- asymmetrical and rounded variations thereof. terial sealed together, and at least one of the sheets has [0034] Also described is a contact lens package holder thereon; and at least one corner that is not sealed 45 sheet, upon which one or more contact lens packages so as to serve as an easy-open comer; wherein the con- are affixed. tact lens therein is held in a flattened state while the pack- [0035] Also described is a single-use contact lens age is sealed and returns to its natural state when the package wherein said package has a convex surface and package is opened; and wherein the printing is selected an opposing concave surface and wherein said package from the group consisting of instructions for use and pre- 50 has an internal depth that is less than 3.0 mm. scription information. [0036] Also described is a secondary package for a [0027] Also described is a single-use package with a plurality of single-use contact lens packages comprising contact lens therein which comprises two sheets of ma- a container, wherein each of said single-use contact lens terial sealed together; a spring disc between the sheets; packages contained therein comprises a convex surface and an amount of hydration medium; wherein the lens in 55 and an opposite concave surface, and wherein said sin- maintained in a flattened state while the package is gle-use packages are stacked such that said convex sur- sealed. face of a first package rests upon said convex surface of [0028] Also described is a method of dispensing a sin- a second package.

4 7 EP 2 526 808 B1 8

[0037] Also described is a single-use generally envel- ing the contact lens on a surface of the sheet; dosing the oped shaped package with a soft contact lens therein, surface of the material with a hydration maintenance me- the package comprising at least one sheet of material dium; folding the material back on itself to define a space sealed together, the at least one sheet being a multilayer inwhich thecontact lens isheld; and sealing the laminate, and wherein the package further comprises a 5 so that the contact lens is held in a sealed environment. spring disk which is arched in its equilibrated state, the [0048] Also described is a method of making a single- contact lens resting upon the convex side of the spring use package with a contact lens therein, the method com- disk within the package. prising the following: placing a spring disc over the con- [0038] Also described is a contact lens package com- tact lens; dosing the spring disc and contact lens with a prising two layers of flexible material sealed together with 10 minimum amount of hydration medium; placing one sheet a peal seal and containing a contact lens and a hydrating of material on top of the spring disc and lens and placing medium within a sealed area encompassed by the peal one sheet of material on the bottom of the spring disc seal, the peal seal being configured such that it includes and contact lens; and sealing the top and bottom sheet a lead-in section that results in the peak force required of material. to begin opening the seal to be no more that 150% of the 15 [0049] Also described is a method of making a single- lowest force needed to open the remainder of the seal use package with a contact lens therein, wherein the [0039] Also described is a contact lens travel pack package has a depth which is less than the overall sagittal comprising a container with a and a base, a plurality depth of the contact lens, the method comprising the of contact lenses packages and a handle. steps of placing the lens and a minimum amount of hy- [0040] Also described is a storage for a plurality 20 dration medium between two sheets; and sealing the of contact lenses comprising a cover, a container for a sheets together sterilizing the envelope and contents; plurality of contact lenses wherein the container compris- allowing access to said lens by splitting, peeling or divid- es a lift-out insert. ing said package along at least one edge. [0041] Also described is a dispensing case for a plu- rality of contact lenses comprising a cylindrical container 25 BREIF DESCRIPTION OF THE DRAWINGS wherein each of the two ends of the container open to dispense the contact lenses. [0050] Figure 1 is a plan view of a typical prior art dis- [0042] Also described is a storage stand for a plurality posable blister contact lens package. of contact lens packages comprising a base and a wall [0051] Figure 2 is a side elevation of the package of extending from the base, wherein the wall comprises a 30 Figure 1 with the lid peeled away to release the contact means for the lenses to be attached thereto. lens therein. [0043] Also described is a storage means for a plurality [0052] Figure 3 is a perspective view of the partially of contact lenses has a plurality of contact lens holder opened package of Figure 2. sheets with a narrow open slot; a plurality of contact lens- [0053] Figure 4 is a side elevation view showing a es attached to the holder sheets; at least one container 35 stacking arrangement for two identical prior art contact comprising a base with a narrow open guide and lid with lens packages. a narrow open slot; and a stand comprising a base and [0054] Figure 5 is a perspective view showing a plu- a central extension. The holder sheets are stored within rality of blister packs stacked as in Figure 4 and contained the container and the container slides onto the base. in a carton. [0044] Also described is a contact lens delivery pack- 40 [0055] Figure 6 is a perspective view of a single-use age comprising an aluminum coated envelope, a plurality package opened to show embossing on the bottom sheet of contact lens packages, and nitrogen gas, wherein the which has a convex indentation. envelope is filled with the nitrogen gas prior to sealing. [0056] Figure 7 is a perspective view of a single-use [0045] Also described is a single-use package for re- package like that of Figure 6, but showing embossing on taining a contact lens therein, the package comprising at 45 the top sheet which has a concave indentation. least one package wall defining an internal space for [0057] Figure 8 is a cross-sectional view of the single- holding the contact lens; a medium in the space for main- use package of Figure 6. taining lens hydration; means to enable release of the [0058] Figure 9 is a cross-sectional view of the single- lens from said space; wherein the at least one wall is use package of Figure 7. formed from a homogenous or multi-layer, pliable mate- 50 [0059] Figure 10 is an example of embossing that can rial. be used in the packages of Figures 6-9, in an abstract [0046] Also described is a kit of jointed single use pli- pattern. able retort-type single use packages for each holding a [0060] Figure 11 is an example of embossing that can contact lens is provided. Each single-use package is con- be used in the packages of Figures 6-9, in a grid pattern. nected to at least one adjacent package. 55 [0061] Figure 12 is an example of embossing that can [0047] Also described is a method of producing a dis- be used in the packages of Figures 6-9, with a logo. posable contact lens package. The method comprises [0062] Figure 13 is a perspective view of a single-use the steps of taking a single sheet of pliable material; plac- package made from two dissimilar, transparent materials

5 9 EP 2 526 808 B1 10 and illustrating a method of opening the package having lease the hydration medium. a depression which contains the contact lens. [0084] Figure 35 is a plan view of a single-use package [0063] Figure 14 is a perspective view of a single-use of the present invention with a first space for a contact package made from two similar, opaque materials and lens and a second space for hydration medium, both of illustrating a method of opening the package having a 5 which have foil covers. depression which contains the contact lens. [0085] Figure 36 is a plan view of the single-use pack- [0064] Figure 15 is a perspective view of a partially age of Figure 35 without the cover that encloses the lens. opened single-use package constructed with a support [0086] Figure 37 is a side elevation view of the single- member. use package of Figure 35 with the cover peeled away [0065] Figure 16 is an exploded side view of the single- 10 from the first space. use package of Figure 15. [0087] Figure 38 is a side elevation view of the single- [0066] Figure 17 is an exploded perspective view of use package of Figure 35 with the cover removed from the single-use package of Figure 15. both the first and second spaces. [0067] Figure 18 is an exploded perspective view of [0088] Figure 39 is a side elevation view of the single- the single-use package of Figure 15 with a netting. 15 use package of Figure 35 with the cover starting to be [0068] Figure 19 is a plan view of the single-use pack- peeled away from the second space. age of Figure 15 showing its tear drop shape. [0089] Figure 40 is a perspective view of the single- [0069] Figure 20 is a plan view of a single-use package usepackage of Figure 35 showing thecover being peeled like that of Figure 15 in a figure-eight shape. away from either the first or second space. [0070] Figure 21 is a plan view of a single-use package 20 [0090] Figure 41 is a plan view of two single-use pack- like that of Figure 15 in an asymmetrical tear drop shape. ages, each having a first and second space, and con- [0071] Figure 22 is a plan view of a single-use package nected by a frangible joint. with a first space for a contact lens having a foil covering [0091] Figure 42 is a plan view of one of the single-use and a second space for hydration medium with a cap. packages of Figure 41 without the covering. [0072] Figure 23 is a plan view of the single-use pack- 25 [0092] Figure 43 is a perspective view of one of the age of Figure 22 without the cover that encloses the lens. single-use packages of Figure 42 showing the cover be- [0073] Figure 24 is a plan view of a tear drop shaped ing peeled away from the first space containing a contact single-use package with a first space for a contact lens lens. having a foil covering and a second space for hydration [0093] Figure 44 is a side view of the single-use pack- medium with a cap. 30 age of Figure 42 with a contact lens therein with a cover [0074] Figure 25 is a plan view of the single-use pack- that is intact. age of Figure 24 without the cover that encloses the lens. [0094] Figure 45 is a side view of the single-use pack- [0075] Figure 26 is a side elevation view of the single- age of Figure 42 with the cover peeled away and the use package of Figure 22 with the cover intact. contact lens in its equilibrated state. [0076] Figure 27 is a side elevation view of the single- 35 [0095] Figure 46 is a side view of a prior art blister pack use package of Figure 22 with the cover partially peeled with a contact lens therein that is folded. off. [0096] Figure 47 is a side view of a prior art blister pack [0077] Figure 28 is a perspective view of the single- with a contact lens therein that is stuck to the side. use package of Figure 22 showing the cover being peeled [0097] Figure 48 is a side view of a prior art blister pack off. 40 with a contact lens therein that is inverted. [0078] Figure 29 is a plan view of a single-use package [0098] Figure 49A is an exploded perspective view of of the present invention with a first space for a contact a sachet type single-use package. lens having a cover and a second space for hydration [0099] Figure 49B is a cross-sectional view of the sin- medium that has a channel to release hydration medium gle-use package of Figure 49A. once separated from the single-use package. 45 [0100] Figure 50A is an exploded perspective view of [0079] Figure 30 is a plan view of the single-use pack- a polypropylene and foil type single-use package. age of Figure 29 with the cover removed. [0101] Figure 50B is a cross-sectional view of the sin- [0080] Figure 31 is a perspective view of the single- gle-use package of Figure 50A. use package of Figure 29 showing the cover being par- [0102] Figure 51A is an exploded perspective view of tially removed. 50 an all polypropylene type single-use package. [0081] Figure 32 is a side elevation view of the single- [0103] Figure 51B is a cross-sectional view of the sin- use package of Figure 29. gle-use package of Figure 51A. [0082] Figure 33 is a side elevation view of the single- [0104] Figure 52 is a side view of the single-use pack- use package of Figure 29 with the cover partially peeled age of the present invention showing the internal depth off. 55 of the single-use package. [0083] Figure 34 is a perspective view of the single- [0105] Figure 53 is a plan view of one embodiment of use package of Figure 30 showing the first and second a single-use package with an island-like protuberance space of the single-use package being separated to re- upon which the contact lens rests.

6 11 EP 2 526 808 B1 12

[0106] Figure 54 is a cross-sectional view of the single- [0129] Figure 75 is a plan view of another spring disc. use package of Figure 53 taken along line 54-54 showing [0130] Figure 76 is a plan view of another spring disc. the contact lens resting on the island-like protuberance. [0131] Figure 77 is a plan view of another spring disc. [0107] Figure 55 is another cross-sectional view of the [0132] Figure 78 is a plan view of another spring disc. single-use package of Figure 53 taken along line 55-55 5 [0133] Figure 79 is a plan view of another spring disc. showing the contact lens resting on the island-like pro- [0134] Figure 80 is a plan view of another spring disc. tuberance. [0135] Figure 81 is a plan view of another spring disc. [0108] Figure 56 is a plan view of a tear shaped poly- [0136] Figure 82 is a plan view of another spring disc. propylene support member with a cut out in the handle. [0137] Figure 83 is a plan view of another spring disc. [0109] Figure 57 is a cross-sectional view of a single- 10 [0138] Figure 84 is a plan view of another spring disc. use package with the support member of Figure 56 that [0139] Figure 85 is a plan view of another spring disc. is opaque. [0140] Figure 86 is a perspective view of a single-use [0110] Figure 58 is a cross-sectional view similar to package with the spring disc of Figure 70A with a contact that of Figure 57 but with the cover peeled back. lens thereon. [0111] Figure 59 is a plan view of the front of a single- 15 [0141] Figure 87 is a cross-sectional view of a contact use package containing the support member of Figure lens and spring disc in a flattened state in a sealed single- 56. use package. [0112] Figure 60 is a plan view of the back of a single- [0142] Figure 88 is a cross-sectional view of a contact use package containing the support member of Figure lens and spring disc in an equilibrated state in a single- 56. 20 use package of Figure 87 with the cover removed. [0113] Figure 61 is a plan view of a polypropylene [0143] Figures 89A-E are perspective views of a sin- spring disc for use in a single-use package. gle-use package with a spring disc and contact lens ther- [0114] Figure 62 is a plan view of another polypropyl- eon with an index finger pushing through the spring disc ene spring disc for use in a single-use package. such that the contact lens rests upon the tip of the index [0115] Figure 63 is a plan view showing the inside of 25 finger and the index finger extends through the opening a single-use package containing another polypropylene of the single-use package so that the contact lens may spring disc and contact lens. be placed in the eye. [0116] Figure 64 is a cross-sectional view of an alter- [0144] Figure 90 is a plan view of a single-use package native single-use package similar to that shown in Figure with an oval shape and a tear notch. 63, showing a polypropylene spring disc and a contact 30 [0145] Figure 91 is a plan view of the single-use pack- lens in a flattened state. age of Figure 90 with the cover removed to show the [0117] Figure 65 is a plan view of the front of the single- spring disc and contact lens therein. use package of Figure 63 with reliefs within the foil on [0146] Figure 92 is a plan view of a single-use package either side of the single-use package for easy opening. with a rounded rectangle shape and a tear notch. [0118] Figure 66 is a plan view of the back side of the 35 [0147] Figure 93 is a plan view of a single-use package single-use package of Figure 63. with an oval shape and a peel open hinge-type cover. [0119] Figure 67 is a cross-sectional view of the single- [0148] Figure 93A is a perspective view of the single- use package of Figure 63 showing a contact lens and use package of Figure 93 showing the hinge-type cover polypropylene spring disc inside a single-use package, being opened. in a flattened configuration. 40 [0149] Figure 94 is a plan view of a single-use package [0120] Figure 68 is a cross-sectional view of the single- with an asymmetrical tear shape and two tear notches use package of Figure 63 with the cover beginning to be at the narrow end. peeled back and the spring disc and contact lens in an [0150] Figure 95 is a plan view of two of the single-use equilibrated state. packages of Figure 94 packaged together. [0121] Figure 69 is an exploded perspective view illus- 45 [0151] Figure 96 is a plan view of a square shaped trating the construction of a single-use package contain- sachet-type single-use package with a tear notch. ing another spring disc. [0152] Figure 97 is a plan view of a rounded corner [0122] Figure 70A is a plan view of another spring disc. square sachet-type single-use package with a tear-off [0123] Figure 70B is a side view of the embodiment of end and cut out tabs that enhance visibility of the tear- Figure 70A showing the spring disc and contact lens in 50 off end. a flattened state. [0153] Figure 98 is a plan view of an embodiment of a [0124] Figure 70C is a side view of the embodiment of sachet-type single-use package, half being oval shaped Figure 70A showing the spring disc and contact lens in and half being a rounded square shape with a half-moon an equilibrated state. tear-off end. [0125] Figure 71 is a plan view of another spring disc. 55 [0154] Figure 99 is a plan view of a sachet-type single- [0126] Figure 72 is a plan view of another spring disc. use package with a rounded square shape and a finger [0127] Figure 73 is a plan view of another spring disc. shaped tear-off end. [0128] Figure 74 is a plan view of another spring disc. [0155] Figure 100 is a plan view of two sachet-type

7 13 EP 2 526 808 B1 14 single-use packages of Figure 99 showing the finger single-use packages strips. shaped tear-off end of one fit into the finger shaped tear- [0174] Figure 119 is a plan view of a secondary pack- off end of the other. aging for a plurality of single-use packages in which there [0156] Figure 101 is a perspective view of a double are six stacks of five single-use packages in separate curved-shape single-use package with the cover being 5 compartments. peeled back to expose the lens therein. [0175] Figure 120 is a cross-sectional view of the sec- [0157] Figure 102 is a perspective view of a plurality ondary packaging of Figure 119. of the single-use packages of Figure 101 stacked togeth- [0176] Figure 121 is a perspective view of two of the er. secondary packages of Figure Figure119 stacked on top [0158] Figure 103 is a perspective view of a molded 10 of each other, providing a 30 day supply of daily contact single-use package with a pull-top opening that has been lenses for each eye. peeled back to expose the inner space and contact lens [0177] Figure 122 is a perspective view of six of the therein. secondary packages of Figure 119, providing a 90 day [0159] Figure 104 is a perspective view of one embod- supply of daily contact lenses for each eye. iment of a pull-top single-use package with a handle de- 15 [0178] Figure 123 is a perspective view of twelve of tail. the secondary packages of Figure 119, providing a 180 [0160] Figure 105 is a perspective view of the single- day supply of daily contact lenses for each eye. use package of Figure 104 with the top pulled back and [0179] Figure 124 is a plan view of a travel pack with the base bent to expose the contact lens therein. two single-use packages. [0161] Figure 106 an exploded perspective view of a 20 [0180] Figure 125A is a plan view of secondary pack- single-use package with a cover and base that lifts up. aging in which there are three compartments each con- [0162] Figure 107 is a perspective view of the single- taining ten single-use packages. use package of Figure 106 with the cover and base lifted [0181] Figure 125B is a cross-sectional view of the sec- up. ondary packaging of Figure 125A. [0163] Figure 108 is a perspective view of a single-use 25 [0182] Figure 126 is a plan view of a transparent travel package in which there is a pointed edge that breaks package for a plurality of single-use packages. open the top cover. [0183] Figure 127 is a front elevation view of the travel [0164] Figure 109 is a perspective view of the single- package of Figure 126. use package of Figure 108 with the top cover broken [0184] Figure 128 is a side elevation view of the travel open. 30 package of Figure 126. [0165] Figure 110 is a cross-sectional view of a single- [0185] Figure 129 is a plan view of the travel package use package with a polypropylene spring disc and a of Figure 126 showing the inside of an open travel pack- break-open edge. age holding a plurality of single-use packages, a sliding [0166] Figure 111 is a perspective view of the cross- guide for the single-use package compartment and a mir- section of the single-use package of Figure 110 showing 35 ror. the break-open edge being broken. [0186] Figure 130 is a side elevation view of the open [0167] Figure 112 is a perspective view of the polypro- travel package of Figure 129 illustrating a means of hang- pylene spring disc used in the embodiment of Figure 111 ing the travel package on a hook. and contact lens thereon. [0187] Figure 131 is a plan view of a travel package [0168] Figure 113 is a cross-sectional view of the sin- 40 similar to that of Figure 126 but made of opaque material. gle-use package of Figure 110 with a break-open edge [0188] Figure 132 is a plan view of an alternative to the that has been broken and has the foil cover peeled away, travel package of Figure 129 with a stationary guide for allowing the polypropylene disc and contact lens to re- maintaining the single-use packages in compartments equilibrate. marked as "L" for left and "R" for right. [0169] Figure 114 is a perspective view of a retort-type 45 [0189] Figure 133 is a side elevation view of a package single-use package. capable of holding enough single-use packages for 90 [0170] Figure 115 is a perspective view of the retort- days of contact lens use for both right and left eyes, and type single-use package of Figure 114 with the contact a travel package attached to the 90 day package. lens exposed by peeling a layer. [0190] Figure 134 is a side elevation view of the 90 day [0171] Figure 116 is a plan view of a strip of retort-type 50 package of Figure 133 without the travel package at- single-use packages. tached. [0172] Figure 117 is a plan view of the strip of retort- [0191] Figure 135 is a side elevation view of the side type single-use packages of Figure 116 including a hy- of the 90 day package of Figure 133 showing that the dration medium pack. travel pack may be slid onto the cover of the 90 day pack- [0173] Figure 118 is an exploded perspective view of 55 age and then snapped into place. an envelope, containing a plurality of retort-type single- [0192] Figure 136 is a side elevation view of the 90 day use packages, packaged in a secondary package con- package with the travel pack of Figure 133 showing that taining a large number of holding retort-type the 90 day package may be used as a sunglass case

8 15 EP 2 526 808 B1 16 when all of the single-use packages have been removed. [0211] Figure 152 is plan view of a donut-shaped sin- [0193] Figure 137 is a side elevation view of the 90 day gle-use package holder sheet. package of Figure 134 showing that the insert containing [0212] Figure 153 is an exploded perspective view of the single-use packages may be lifted up and out of the a plurality of the holder sheets of Figure 152 being placed package using the handle, once the cover to the 90 day 5 into a round . package has been removed. [0213] Figure 154 is a perspective view of a stand for [0194] Figure 137A is an exploded perspective view of containing a plurality of the boxes of Figure 153. a rubber that prevents the insert containing the [0214] Figure 155 is a perspective view of a secondary single-use packages from slipping down into the 90 day package having an eye-mask shape and containing a package. 10 plurality of round single-use packages of the present in- [0195] Figure 138 is a side elevation view of the back vention. of a 90 day package showing that a tab and strip of single- [0215] Figure156 is a planview of two single-usepack- use packages being lifted out of the 90 day package. ages clipped onto a sheet for easy transport. [0196] Figure 138A is a plan view of a tab that indicates [0216] Figure 157 is a plan view of another single-use there are only 30 contact lenses remaining in the 90 day 15 package with a rounded triangle shape. package, as well as prescription and re-order informa- [0217] Figure 158 is a plan view in which a circular tion. secondary packaging container holds a 30 day supply of [0197] Figure 138B is a plan view of a tab that indicates oval shaped single-use packages arranged in a circular there are only 10 lenses remaining in the 90 day package configuration. as well as prescription and re-order information. 20 [0218] Figure 159 is a plan view in which a rectangular [0198] Figure 139 is a perspective view of the single- secondary packaging container holds a 30 day supply of use package secondary packaging container with a plu- single-use packages arranged in two parallel rows. rality of single-use packages therein. [0219] Figure 160 is a perspective view of a secondary [0199] Figure 140 is a plan view of the front of a single- box for delivery of a plurality of single-use packages. use package holder sheet for a plurality of single-use 25 [0220] Figure 161 is a perspective view of a stand for packages wherein the single-use packages are arranged a 90 day supply of round single-use packages. in a circular configuration. [0221] Figure 162 is a perspective view of a delivery [0200] Figure 141 is a plan view of the back of the hold- package comprising an aluminum-coated envelope with er sheet of Figure 140. a plurality of single-use packages therein. [0201] Figure 142 is a plan view of the front of a single- 30 [0222] Figure 163 is a perspective view of a single-use use package holder sheet for a plurality of single-use package dispensing case. packages wherein the single-use packages are arranged [0223] Figure 164 is a perspective view of the single- in two parallel rows. use package dispensing case of Figure 163 with one end [0202] Figure 143 is a plan view of the back of the hold- opened and a single-use package removed. er sheet of Figure 142. 35 [0224] Figure 165 is a side elevational view of a storage [0203] Figure 144 is a plan view of a blister-type single- container and a plurality of single-use contact lens pack- use package. ages stacked therein. [0204] Figure 145 is a side elevation view of a stack of [0225] Figure 166 is a plan view of another single-use the blister-type single-use packages of Figure 144. package with a rounded rectangular shape. [0205] Figure 146 is a plan view of a secondary pack- 40 [0226] Figure 167 is a plan view of the single-use pack- aging container for a plurality of the blister-type single- age of Figure 166 showing the seal areas within the pack- use packages of Figure 144 arranged in a circular con- age. figuration. [0227] Figure 168 is a plan view of the single-use pack- [0206] Figure 147 is an exploded perspective view of age of Figure 166 showing a spring disc in place, but the the secondary packaging container of Figure 146 also 45 top sheet of the package removed. showing a lid. [0228] Figure 169 is a perspective view of the single- [0207] Figure 148 is a cross-sectional view of the sec- use package of Figure 166 showing the package starting ondary packaging container of Figure 147 in which there to be opened. is a 30 day supply of contact lenses. [0229] Figure 170 is a perspective view of the single- [0208] Figure 149 is a cross-sectional view of a sec- 50 use package of Figure 166 showing the package fully ondary packaging container like that of Figure 147 in opened. which there is a 90 day supply of contact lenses. [0230] Figure 171 is across-sectional view of the lam- [0209] Figure 150 is a plan view of a single-use pack- inate used to make the single-use package of Figure 166, age of the present invention with a rounded asymmetrical taken along line 171-171 of Figure 170. triangle shape. 55 [0231] Figure 172 is a graph showing typical traces of [0210] Figure 151 is a plan view of a combination of opening forces for a prior art blister package and an ex- six of the single-use packages of Figure 150 in a circular emplarysingle use package likethat shownin Figure166. arrangement.

9 17 EP 2 526 808 B1 18

DETAILED DESCRIPTION OF THE DRAWINGS AND be seen from Figure 4 that although two packs conven- PREFERRED EMBODIMENTS OF THE INVENTION iently inter-fit, they take up a thickness greater than the thickness (or depth) of two packs. Ideally, a lens package [0232] The present invention will now be described should take up as little space as possible considering the with reference to the accompanying illustrations. In the 5 relatively small size of a contact lens. Economy of storage following passages, different aspects of the invention are space is a critical issue where lenses are mass produced. defined in more detail. Each aspect so defined may be The existing blister packs take up a disproportionate combined with any other aspect or aspects unless clearly amount of space relative to the size of the lens, leading indicated to the contrary. In particular, any feature indi- to increased handling and storage costs. Figure 5 shows cated as being preferred or advantageous may be com- 10 a plurality of like blister packs 12 stacked as in Figure 4 bined with any other feature or features indicated as be- and retained in a carton 13. This bulky, inconvenient, and ing preferred or advantageous. materials-intensive form of lens packaging exists as a [0233] These are also described and illustrated exam- result of conventional wisdom which suggests that lenses ples of packaging as background to the invention as can only be stacked in rigid which isolate the claimed. 15 lens from external load. [0234] The term "internal depth" means the depth of a [0240] As noted above, preferred embodiments of the contact lens holding area within the contact lens package invention provide a single-use package with a contact determined by subtracting the height of the combined lens therein, and the package has an internal depth which opposing wall layers making up the contact lens holding is less than an overall sagittal depth of the contact lens area of the package from the total height of the contact 20 when the contact lens is in its equilibrated form Several lens holding area of the package when the package is embodiments use two flat sheets of material sealed to- lying on a flat surface. gether, or sealed with a support member between them, [0235] The term "sagittal depth" means the total height and clearly display the feature that the internal depth of of a contact lens resting in a relaxed state on a flat sur- the package is less than the sagittal depth of the contact face. 25 lens. [0236] Referring to a contact lens in its "equilibrated [0241] In some embodiments shown in Figures 6-9, state" means that the contact lens is in a resting state the single-use contact lens packages 18 may be stacked unrestricted by any external forces affecting its shape or such that they interfit with one another like stacked height. spoons. That is, the convex surface of a first package [0237] Throughout the specification the term homog- 30 rests upon the concave surface of a second package enous refers to a package wall formed from a single layer when stacked on top of each other. The single-use pack- (i.e. non-laminated layer) of the same material. Many of ages 18 of this embodiment have first and second sheets the packages described as being made from a homog- 14, 15, both of which are indented. Therefore, when the enous single layer material may also be made from a single-use package 18 is sealed, there is a concave sur- multi-layer, laminated, material which may be formed 35 face and a convex surface and the contact lens is held from a combination of suitable or a combination between these surfaces. Either of the top or bottom sur- of suitableplastics and ametallic layer as described here- faces of the single use package may be convex or con- in. cave; however, in a preferred embodiment, the top sur- [0238] Referring to Figures 1 and 2, there is shown a face of the package is concave and the bottom side of typical prior art disposable blister contact lens package 40 the package surface is convex. This type of single-use 1 which is formed in two parts. The package 1 comprises contact lens package 18 stacking is referred to herein as a blister pack member 2 which is sealed by a membrane "spooning" and is economical in terms of space as well 3 forming a lid on the package 1 and which may be peeled as the amount of secondary packaging required. Addi- away to release a contact lens 4 therein. In Figure 3, the tional embodiments of the single-use packages that may package of Figure 2 is shown with the membrane 45 3 be stacked in this manner are shown in Figure 165. Sin- peeled away to expose the contact lens 4. Typically, the gle-use packages of this type may hold the contact lenses member 2 will be a preformed blister pack and include a in a somewhat flattened state, in an equilibrated state, profiled recess 5 which provides a recess in which a lens or anywhere along the continuum there between. How- may be placed. The member 2 is typically injection mold- ever, a common feature of the single-use packages of ed and the package is completed with a sealing mem- 50 this embodiment is that they all have an internal depth brane 3 which mates with a flange 6 to create a sterile that is between 0.1 and 3.0 mm, more preferably between seal. The contact lens 4 is immersed in a solution 7 which 0.2 and 1.5 mm, and most preferably between 0.2 and keeps the lens hydrated until it is removed from the pack. 0.5 mm. In this instance it is clear that the definition of The injection molded preform makes this an expensive internal depth of a contact lens package will obviously package to manufacture, with the result that the contact 55 be construed to mean the depth of a contact lens holding lens will inevitably be more expensive for the consumer. area within the contact lens package, defined by the dis- [0239] Figure 4 shows a stacking arrangement for two tance between the opposing wall layers making up the identical prior art contact lens packages 10 and 11. It can contact lens holding area of the package. The distance

10 19 EP 2 526 808 B1 20 is usually measured at the center of the contact lens hold- polyethylene naphthalate (PEN), ing area. When the package has a concavity and an op- (COC), or fluorinated ethylene propylene (FEP), or other posite face that is also concave in the same direction similar material. The support member 20 does not (see Figs 6-9 and 165 for example), the "internal depth" change the flat profile of the single-use package 156. will obviously be the distance between the walls of the 5 Further, the thickness of the support member 20 is such contact lens package on a line that is normal to the center that the single-use package 156, when sealed, still has of the lens when the lens is in its normal rest position a depth that is less than the natural sagittal depth of the within the package. The internal depth may be deter- contact lens 4. The support member 20 may also serve mined by drawing a line through the center of the lens as a handle 21 (Figure 15) to assist in moving or opening within the contact lens package that is perpendicular to 10 the single-use package 156. The handle area 21 may the face of the lens at its center point, and then measuring optionally have a cut out 24 that further assists gripping the distance along that line where the package walls in- the single-use package 18 as shown in Figure 17. tersect the drawn line. The distance measured is the in- [0245] As illustrated in Figure 18, the support member ternal depth of the contact lens package. 20a has mesh-like netting 22. The netting 22 serves as [0242] In one embodiment of the single-use package 15 an additional support for the contact lens 4 as the lens of the present invention, shown in Figures 6 and 8, the rests upon the netting 22 when in the single-use package single-use package 18, has an internal depth of between 157. The netting 22 may be composed of any suitable 0.2 and 0.5 mm and comprises a first sheet 14 and a polymeric material such as: polypropylene (PP), polypro- second sheet 15 of material sealed together. In this em- pylene copolymer (PPCO), (TPX), bodiment, one of the two sheets 15 is embossed 16 and 20 (PC), polysulphone (PSF), polyethylene also has a convex indentation 19. The embossing 16 aids naphthalate (PEN), cyclic olefin copolymer (COC), or the release of the lens 4 as it prevents the lens 4 from fluorinated ethylene propylene (FEP), or other similar adhering to the embossed sheet 15, as shown in Figure material. 8. Therefore, it is possible to have the contact lens 4 [0246] The single-use package, with or without the present in a predictable orientation upon opening of the 25 support member 20, may have a variety of shapes. For single-use package 18. As shown in the alternate em- example, the single-use package may be a square, rec- bodiment 18a of Figures 7 and 9, the embossed surface tangle, oval, round, tear drop shaped, figure eight, trian- 16a may alternatively be on the top sheet 14a, which in gle, and combinations thereof, all of which may be sym- this example, also has a concave indentation 19a, while metrical, asymmetrical, straight edged or rounded. Two bottom sheet 15a has a convex shape. As shown in Fig- 30 additional shapes of contact lens packages 158 and 159 ure 9, there is a contact lens package having an internal are shown in Figures 20 and 21. Additional shapes are depth that is between about 0.2 mm and about 0.5 mm. acceptable as long as they may accommodate a soft con- The contact lens in this example adheres to the bottom, tact lens. non-embossed sheet. [0247] As shown inFigures 22-45,the single-use pack- [0243] The embossing 16 may take numerous forms, 35 age may have a first space 34 for a contact lens and a for example, abstract patterns, grids and logos, as shown second space 32 for hydration medium 32. This arrange- in Figures 10-12. Alternatively, Figures 13 and 14 show ment may take on a variety of configurations, some of embodiments in which the single-use packages 18c and which allow the second space for hydration medium to 18d have no embossing. The sheets 14 and 15 may be be flat, bulbous and optionally to serve as a handle. Fig- opaque, transparent or colored, such as white or light 40 ures 22 and 28 illustrate that the second space 32 for green. If the sheets are colored, one preferred embodi- hydration medium may be attached to the first space 34 ment is to have the color displayed inwardly toward a for the contact lens and the two spaces are separated contact lens so that the lens may be easily visualized. In by a seamed connection 31 between the two sheets com- addition, the sheets 14 and 15 may have printing thereon. prising the single-use package 160. The connection 31 Such printing may include, for example, symbols (such 45 may be flexible and frangible and thus the second space as text, diagrams, drawings), prescription, instructions, 32 may snap off as in Figure 34, or be torn away from and manufacture information. This printing may be on the first space 34 as in Figures 22, 28, 35 and 36. The the outside of the package, or more preferably, displayed second space 32 for the hydration medium may have a inwardly toward the contact lens (when the package is cap 30. The cap 30 may be removed by pulling, twisting, sealed), which will aid visualization of the contact lens. 50 or snapping off. Alternately, the second space 32 may [0244] As shown in Figures 15-17 and 19, the single- remain connected to the first space 34 as shown in the use package 156 includes a support member 20. The single use package 161 of Figures 24-25. The first space support member 20 encircles the contact lens 4 within 34 and second space 32 may be opened at the same the single-use package 156. The support member 20 time or different times. In one example, the first space may be flexible or rigid and may be, for example, com- 55 34for the contact lens isopened prior to thesecond space posed of any suitable polymers such as polypropylene for the hydration medium 32. In an alternative example, (PP), polypropylene copolymer (PPCO), polymethylpen- the second space 32 for the hydration medium may be tene (TPX), polycarbonate (PC), polysulphone (PSF), opened prior to the first space 34 for the contact lens.

11 21 EP 2 526 808 B1 22

The first and second space may be opened by the same single-use package 164 is removed, it engages a second or different means. The first and second space 34, 32 similar single-use package 164, thus making the second may both be opened by peeling