Additive saline dosing system and method for contact lens packaging

Abstract

Additives that could interfere with the sealing of a cover onto a contact lens package are delivered separately from the bulk saline delivered into the lens package, thereby allowing more precise control of the additive delivery, reducing the incidence of additive in the seal area of the lens package, and improving the seal integrity.

1 . A method of packaging a contact lens, said method comprising:
 depositing a contact lens into a container, the container defining a lens-receiving cavity and a sealing surface surrounding the lens-receiving cavity;   dispensing saline solution into the lens-receiving cavity, the saline solution being dispensed at a first delivery rate;   dosing at least one additive into the lens-receiving cavity separately from the saline solution, the at least one additive being dosed at a second delivery rate substantially less than the first delivery rate, and controlled to prevent depositing the at least one additive on the sealing surface surrounding the lens-receiving cavity; and   applying a cover over the lens-receiving cavity in sealing engagement with the sealing surface.   
   
   
       2 . The method of  claim 1 , wherein the at least one additive is delivered into the lens-receiving cavity after the saline solution is delivered into the lens-receiving cavity. 
   
   
       3 . The method of  claim 1 , wherein the at least one additive is delivered into the lens-receiving cavity before the saline solution is delivered into the lens-receiving cavity. 
   
   
       4 . The method of  claim 1 , wherein the at least one additive is delivered into the lens-receiving cavity while the saline solution is delivered into the lens-receiving cavity. 
   
   
       5 . The method of  claim 1 , wherein the at least one additive is delivered into the lens-receiving cavity after the contact lens is deposited therein. 
   
   
       6 . The method of  claim 1 , wherein the second delivery rate is no more than 50% of the first delivery rate. 
   
   
       7 . The method of  claim 1 , wherein the second delivery rate is no more than 25% of the first delivery rate. 
   
   
       8 . The method of  claim 1 , wherein the second delivery rate is no more than 5% of the first delivery rate. 
   
   
       9 . A method for dosing saline solution with an additive during contact lens packaging, comprising:
 introducing saline solution into a contact lens package, the saline solution not containing a specified additive; and   separately introducing the specified additive into the contact lens package to combine the specified additive with the saline solution in the contact lens package.   
   
   
       10 . The method of  claim 9 , further comprising depositing a contact lens into the contact lens package. 
   
   
       11 . The method of  claim 10 , wherein the specified additive is introduced after the contact lens is deposited into the contact lens package. 
   
   
       12 . The method of  claim 9 , wherein the saline solution is introduced into the contact lens package at a first station, and wherein the specified additive is introduced into the contact lens package at a second station. 
   
   
       13 . The method of  claim 9 , wherein the saline solution is introduced into the contact lens package before the specified additive. 
   
   
       14 . The method of  claim 9 , wherein the saline solution is introduced into the contact lens package after the specified additive. 
   
   
       15 . The method of  claim 9 , wherein the saline solution is introduced into the contact lens package simultaneously with the specified additive. 
   
   
       16 . The method of  claim 9 , wherein the saline solution is introduced at a first delivery rate, and the specified additive is introduced at a second delivery rate that is no more than 35% the first delivery rate. 
   
   
       17 . The method of  claim 9 , wherein the saline solution is introduced at a first delivery rate, and the specified additive is introduced at a second delivery rate that is no more than 10% the first delivery rate. 
   
   
       18 . The method of  claim 9 , wherein the saline solution is introduced at a first delivery rate, and the specified additive is introduced at a second delivery rate that is no more than 1% the first delivery rate. 
   
   
       19 . The method of  claim 9 , further comprising sealing a cover onto the contact lens package to hermetically seal the saline solution and the specified additive therein. 
   
   
       20 . A system for packaging contact lenses, said system comprising:
 a conveyor for moving contact lens packages along a contact lens packaging line;   a lens delivery station for placement of contact lenses in the contact lens packages;   a saline dispensing station for delivering saline solution not having a specified additive therein into the contact lens packages;   an additive dosing station for delivering the specified additive into the contact lens packages separately from the saline solution, without depositing the specified additive onto a seal area of the contact lens packages; and   a sealing station for hermetically sealing a cover onto the seal area of each of the contact lens packages.   
   
   
       21 . The system of  claim 20 , further comprising an inspection station for inspecting the contact lenses in the contact lens packages. 
   
   
       22 . The system of  claim 20 , wherein the specified additive is dosed into the contact lens packages after the saline solution is dispensed into the contact lens packages. 
   
   
       23 . The system of  claim 20 , wherein the specified additive is dosed into the contact lens packages after the contact lenses are placed in the contact lens packages. 
   
   
       24 . The system of  claim 20 , wherein the saline dispensing station dispenses saline solution at a first delivery rate, and wherein the additive dosing station doses the specified additive at a second delivery rate that is no more than 10% the first delivery rate. 
   
   
       25 . A contact lens product comprising:
 a primary lens containment package comprising a shell defining a lens-receiving cavity, and a cover for placement over the lens-receiving cavity;   a contact lens removably disposed within the lens-receiving cavity;   a quantity of saline solution disposed within the lens-receiving cavity; and   a quantity of an additive dosed into the lens-receiving cavity separately from the saline solution;   wherein the cover is hermetically sealed to the shell without interruption by any of the additive being deposited between the shell and the cover.