WO2023111851A1

WO2023111851A1 - Solutionless contact lens packages and methods of manufacture

Info

Publication number: WO2023111851A1
Application number: PCT/IB2022/062147
Authority: WO
Inventors: Sam Jonathan POPWELL; Daniel Graham Ward; Stephen Sams; William Stephen HONEY
Original assignee: Johnson & Johnson Vision Care, Inc.
Priority date: 2021-12-15
Filing date: 2022-12-13
Publication date: 2023-06-22
Also published as: TW202337784A

Abstract

The present invention relates to solutionless contact lens packages and methods of manufacture/assembly. The solutionless package includes a cavity that houses a contact lens and air containing vapor, wherein a relative humidity of the air is greater than 80% when the package is at a typical manufacturing and storage temperature.

Description

SOLUTIONLESS CONTACT LENS PACKAGES AND METHODS OF MANUFACTURE

I. BACKGROUND OF THE INVENTION

In a conventional contact lens package, the contact lens typically sits in a molded plastic base having a cavity (or "bowl") that houses the contact lens in a volume of packaging solution. As a result, the user experience for transferring a contact lens from the package to an eye generally involves the user "fishing" the contact lens out of the bowl with a finger. This process requires touching the lens multiple times, which can transfer contaminants or pathogens from the hand to the lens and ultimately to the eye. Not only is this handling experience unsanitary, but it is also unduly cumbersome, messy, and mechanically stressful to the lens, which can tear, rip, or distort when overly manipulated. Furthermore, such conventional packages generally include a sufficient amount of packaging solution to keep the lens submerged during storage and transit (e.g., about 0.5 to ImL of solution).

In view of the growing awareness of sustainability and around ocular health and the customer demand for a more convenient experience, a need has arisen for contact lens packaging that enables a less messy, more ecologically responsible, and more sanitary contact lens handling experience.

II. SUMMARY

It has now been found that some or all the foregoing and related objects may be attained in a contact lens package having one or more aspects described herein. According to certain embodiments, a solutionless contact lens package can include a cavity that houses a contact lens and air including vapor having a relative humidity that is sufficient to maintain hydration of the contact lens when the package is in an unopened state. In this manner, the contact lens can remain hydrated within the cavity without the need for liquid packaging solution under typical manufacturing and storage temperatures, and the contact lens can be easily removed from the cavity without having to fish the contact lens out of packaging solution. In certain embodiments, the contact lens can be disposed within the cavity in a convex-side-up orientation and, in some embodiments, thereby allowing a single-touch user experience. The present disclosure provides various embodiments of contact lens packages and methods of packaging a contact lens.

These and other aspects and improvements of the present disclosure will become apparent to one of ordinary skill in the art upon review of the following detailed description when taken in conjunction with the accompanying drawings and the appended claims.

III. BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features and advantages of the invention will be apparent from the following, more particular description of certain embodiments of the present disclosure, as illustrated in the accompanying drawings.

FIG. 1A is a top perspective view of an example solutionless contact lens package in accordance with embodiments of the disclosure, showing the contact lens package in an unopened state.

FIG. IB is a cross-sectional side view of the contact lens package of FIG. 1A, taken along line 1B-1B of FIG. 1A, showing the contact lens package in the unopened state.

FIG. 1C is a cross-sectional side view of the contact lens package of FIG. 1A, taken along line 1B-1B of FIG. 1A, showing the contact lens package in an opened state and a user removing a contact lens from a cavity of the contact lens package. IV. DETAILED DESCRIPTION

Reference will now be made in detail to representative embodiments illustrated in the accompanying drawings wherein reference numerals indicate certain elements. The following descriptions are not intended to limit the myriad embodiments to one preferred embodiment. To the contrary, it is intended to cover alternatives, modifications, and equivalents as can be included within the spirit and scope of the described embodiments as defined by the appended claims.

References to "one embodiment," "an embodiment," "some embodiments," "an example embodiment," etc., indicate that the embodiment described may include a particular feature, structure, aspect, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, aspect, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to effect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.

Lens(es) or contact lens(es) refer to ophthalmic devices that reside on the eye. They have a generally hemispheric shape and can provide optical correction, cosmetic enhancement, UV blocking and visible light or glare reduction, therapeutic effect, including wound healing, delivery of drugs or neutraceuticals, diagnostic evaluation or monitoring, or any combination thereof. The term lens includes soft hydrogel contact lenses, which are generally provided to the consumer in a package in the hydrated state, and have a relatively low moduli, which allows them to conform to the cornea. Contact lenses suitable for use with the packages of the present invention include all hydrated contact lenses, including conventional and silicone hydrogel contact lenses.

A hydrogel is a hydrated crosslinked polymeric system that contains water in an equilibrium state, and may contain at least about 25%, or at least 35% water in the hydrated state. Hydrogels typically are oxygen permeable and biocompatible, making them excellent materials for producing contact lenses.

Conventional hydrogel contact lenses do not contain silicone containing components, and generally have higher water content, lower oxygen permeability, moduli, and shape memories than silicone hydrogels. Conventional hydrogels are prepared from monomeric mixtures predominantly containing hydrophilic monomers, such as 2-hydroxyethyl methacrylate ("HEMA"), N-vinyl pyrrolidone ("NVP") or polyvinyl alcohols. United States Patents Nos. 4,495,313, 4,889,664 and 5,039,459 disclose the formation of conventional hydrogels. Conventional hydrogels may be ionic or non-ionic and include polymacon, etafilcon, nelfilcon, ocufilcon lenefilcon and the like. The oxygen permeability of these conventional hydrogel materials is typically below 20-30 barrers.

Silicon hydrogel formulations include balafilcon samfilcon, lotrafilcon A and B, delfilcon, galyfilcon, senofilcon A, B and C, narafilcon, comfilcon, formofilcon, riofilcon, fanfilcon, stenfilcon, somofilcon, kalifilcon and the like. "Silicone hydrogels" refer to polymeric networks made from at least one hydrophilic component and at least one silicone-containing component. Silicone hydrogels may have moduli in the range of 60-200, 60-150 or 80 -130 psi, water contents in the range of 20 to 60%. Examples of silicone hydrogels include acquafilcon, asmofilcon, balafilcon, comfilcon, delefilcon, enfilcon, fanfilcon, formofilcon, galyfilcon, lotrafilcon, narafilcon, riofilcon, samfilcon, senofilcon, somofilcon, and stenfilcon, verofilcon, including all of their variants, as well as silicone hydrogels as prepared in US Patent Nos. 4,659,782, 4,659,783, 5,244,981, 5,314,960, 5,331,067, 5,371,147, 5,998,498, 6,087,415, 5,760,100, 5,776,999, 5,789,461, 5,849,811, 5,965,631, 6,367,929, 6,822,016, 6,867,245, 6,943,203, 7,247,692, 7,249,848, 7,553,880, 7,666,921, 7,786,185, 7,956,131, 8,022,158, 8,273,802, 8,399,538, 8,470,906, 8,450,387, 8,487,058, 8,507,577, 8,637,621, 8,703,891, 8,937,110, 8,937,111, 8,940,812, 9,056,878, 9,057,821, 9,125,808, 9,140,825, 9156,934, 9,170,349, 9,244,196, 9,244,197, 9,260,544, 9,297,928, 9,297,929 as well as WO 03/22321, WO 2008/061992, and US 2010/0048847. These patents are hereby incorporated by reference in their entireties. Silicone hydrogels may have higher shape memory than conventional contact lenses.

Hydrogel lenses are viscoelastic materials. Conventional lens materials, such as polyhydroxyethyl methacrylate-based lenses like etafilcon A or polymacon have low loss modulus and tan delta compared to silicone hydrogels and may form fewer and less severe optical distortions as a result of contact with packaging. The incorporation of silicones (which generally increase the bulk elastic response), wetting agents such as PVP (which generally increase the viscous response) or coatings of conventional hydrogel materials (which may lower the elastic response at the lens interface) can alter the lens viscoelastic properties. Conventional hydrogel contact lenses and silicone hydrogel contact lenses having short or stiff crosslinking agents and or stiffening agent have short shape memories and may be less susceptible to deformation during storage. Viscoelastic properties, including loss modulus and tan delta, can be measured using a dynamic mechanical analysis. The contact lenses can be of any geometry or power, and have a generally hemispherical shape, with a concave posterior side which rests against the eye when in use and a convex anterior side which faces away from the eye and is contacted by the eyelid during blinking.

The center or apex of the lens is the center of the lens optic zone. The optic zone provides optical correction and may have a diameter between about 7mm and about 10mm. The lens periphery or lens edge is the edge where the anterior and posterior sides meet.

Embodiments may include a lens support surrounded by a sealable cavity also interchangeably referred to as a chamber. The cavity may have any convenient form and may comprise a package base and at least a lid, each of which are described in detail below. As used herein, the phrases "the lid", "a lid", "the base" and "a base" encompass both the singular and plural. The lid and package base are sealed to each other to form a cavity which holds the contact lens, support and packaging solution in a sterile state during shipping and storage prior to use. The contact lens package is made from materials which are compatible with the contact lens and solution, as well as retortable and biologically inert.

"Film" or "multilayer film" are films used to seal the package and are often referred to as lidstock. Multilayer films used in conventional contact lens packages may be used in the packages of the present invention as the base, a component of the lid, or both. Multilayer films comprise a plurality of layers, including barrier layers, including foil layers, or coatings, seal layers, which seal the film to the rest of the package, and may also comprise additional layers selected from peel initiation layers, lamination layers, and layers that improve other package properties like stiffness, temperature resistance, printability, puncture resistance, barrier resistance to water or oxygen and the like. The multilayer films form a steam sterilizable (retortable) seal. The multilayer film can include PET, BON or OPP films layers to increase stiffness and temperature resistance, or to EVOH or PVDC coatings to improve barrier resistance to oxygen or moisture vapor.

An "unopened state" or "unopened" as used herein refers to a contact lens package that is closed and houses a contact lens.

An "opened state" or "opened" as used herein refers to a contact lens package after the sterile seal has been broken. Depending on the context described herein, the opened state extends to the state of the package when the user has manipulated the package to cause the lens to be lifted out of the packaging solution for transfer by the user.

A "solutionless contact lens package" as used herein refers to a contact lens package that contains a contact lens and air including vapor but no liquid at at least one temperature in the range of typical manufacturing and storage temperatures. It will be understood that relative humidity changes when temperatures change and because warm air can hold more vapor than cool air, relative humidity of the air in the package will fall when the temperature rises. Likewise, below a given temperature that corresponds with the dew point for the volume of liquid in the vapor, moisture will condense out of the air. Thus, for the purposes of this disclosure, relative humidity in the package shall be understood to mean the relative humidity of the air (including vapor suspended therein) at at least one temperature within the range of typical manufacturing and storage temperatures.

"Typical manufacturing and storage temperatures" refers to a range of temperatures at or between 60 and 80 degrees Fahrenheit. A "wearer" or "user" as used herein refers to a person opening a contact lens package. The user is generally referred to as the person who both opens the package and transfers the contact lens contained therein to their eye. However, the user in some contexts may be a person handling the lens package on behalf of the wearer, such an eye care provider ("ECP") or another individual demonstrating for or assisting the wearer.

"Vapor" as used herein refers to a liquid suspended in air. The liquid that composes the vapor may be a packaging solution, i.e., is any physiologically compatible solution, which is compatible with the selected lens material and packaging. Packaging solutions include buffered solutions having a physiological pH, such as buffered saline solutions. The packaging solution may contain known components, including buffers, pH and tonicity adjusting agents, lubricants, wetting agents, nutraceuticals, pharmaceuticals, in package coating components and the like.

The package base may form the bottom of the package. It can be made from any material suitable for packaging medical devices, including plastic. Examples of suitable materials include polyolefins including polypropylene, and olefin co-polymers, including COPs (Cyclic Olefin Polymer) and COCs, (Cyclic Olefin Co-polymers), and blends thereof.

The packaging lid generally resides at the upper portion the package and seals with the base to form a cavity containing at least a portion of the lens support, lens, and packaging solution. The lid may be made from any material suitable for packaging medical devices, including a molded sheet of foil or plastic, laminate films, or plastic. Packages comprising plastic for one structure and foil or laminated films as the other, or packages comprising foil or laminated films as the outer layer for the lid and base are known in the art and are examples of suitable combinations. In preferred embodiments, the package base and lid are either composed of or include a vapor material, such as a multilayer film to limit the diffusion of vapor through the package materials.

References throughout this description to injection molding processes and the use of materials conventionally applied to injection molding should be understood as exemplary. Those of skill in the art will appreciate that other means of manufacture are possible within the scope of the appended claims, including but not limited to alternative molding processes, thermoforming, 3D printing, and the like. Likewise, references to heat seals and heat sealing are exemplary to embodiments described herein. Other means of securing packaging components will be apparent to those skilled in the art, including the use of adhesive, glue, thermal bonding, welding such as heat, ultrasonic or laser welding, or a mechanical trap, and the like.

Certain aspects of the invention may serve to reduce or prevent significant optical damage to the contact lens due to interactions with air bubbles or the interior of the lens package that may arise during storage or transit due to gravitational or other forces, such as mechanical pressure being applied from outside of the package. As used herein, significant optical damage means a root-mean-squared (RMS) value equal or greater than about 0.08pm.

Referring now to the drawings, FIGS. 1A-1C illustrate an example contact lens package 100 in accordance with embodiments of the present disclosure. As described, the contact lens package 100 may include a base 110, a lid 150, a contact lens 160, and air including vapor 170. "Air," and "air including vapor," are used interchangeably herein and are both understood to mean air that has a humidity, i.e., air that contains vapor suspended therein. The contact lens package 100 may have an unopened state, as shown in FIGS. 1A and IB, and an opened state, as shown in FIG. 1C. When the contact lens package 100 is in the unopened state, the contact lens

160 and the air 170 may be housed within a cavity 140 formed by the base 110 and the lid 150. In this manner, the contact lens 160 may be protected between the base 110 and the lid 150 and exposed to the air 170 until the contact lens package 100 is opened for removal of the contact lens 160. When desired, a user may open the contact lens package 100 by at least partially removing the lid 150 from the base 110 to allow access to the contact lens 160. Such removal of the lid 150 may allow the user to engage and remove the contact lens 160 from a base cavity 122 of the base 110. As described below, when the contact lens package 100 is in the unopened state, a relative humidity of the air 170 within the cavity 140 may be at a level sufficient to maintain hydration of the contact lens 160. In this manner, use of the humid air 170 may avoid the need for liquid packaging solution within the cavity 140, thereby avoiding the drawbacks of certain existing contact lens packages as discussed above.

According to the illustrated example, the base 110 may have a first end 112 (which also may be referred to as a "back end" in certain embodiments) and a second end 114 (which also may be referred to as a "front end" in certain embodiments) disposed opposite one another. As shown, the base 110 may have a first side 116 (which also may be referred to as a "top side" in certain embodiments) and a second side 118 (which also may be referred to as a "bottom side" in certain embodiments) disposed opposite one another and each extending from the first end 112 to the second end 114. The base 110 also may have a pair of lateral sides 120 disposed opposite one another and each extending from the first end 112 to the second end 114. The base 110 may define a base cavity 122 that houses the contact lens 160 and the air 170. The base cavity 122 may have an opening 124 that allows for removal of the contact lens 160 when the contact lens package 100 is in the opened state. As shown, the base cavity 122 may have an elongated shape with a first end 126 (which also may be referred to as a "back end" in certain embodiments) and a second end 128 (which also may be referred to as a "front end" in certain embodiments) disposed opposite one another along a longitudinal axis defined by the base cavity 122.

According to the illustrated example, the base 110 may include multiple different portions that provide different functions. As shown, the base 110 may include a platform 130, a support 132, a bowl 134, and a lens support 136. The platform 130 may serve as a base structure for the support 132 and the bowl 134 and for connection of the lid 160 to the base 110. In some embodiments, as shown, the platform 130 may be formed as a planar member, although other configurations may be used. The support 132 may extend downward from the platform 130 and be configured to stabilize the base 110 when placed on a support surface. In some embodiments, as shown, the support 132 may be formed as a tab extending transverse to the platform 130, although other configurations may be used. The bowl 134 may extend downward from the platform 130 and be configured to receive at least a portion of the contact lens 160 and the air 170 therein. Various shapes and configurations of the bowl 134 may be used. In some embodiments, the configured to have a contact surface area with the lens of less than or equal to 80 percent the surface area of the contact lens such as by incorporating features (not shown), e.g., arms, channels, or segmentations, or discrete elements that contact the lens. Reducing the contact area with the lens may facilitate single-touch transfer of the lens.

The bowl 134 (i.e., the bowl portion of base 110) may define at least a portion of the base cavity 122. In some embodiments, as shown, the base cavity 122 may be defined entirely by the bowl 134. The lens support 136 may include a support surface 138 that supports the contact lens 160 within the base cavity 122 and the overall cavity 140. In some embodiments, as shown, the lens support 136 may be surrounded by the bowl 134 and may be formed as a dome, and the support surface 138 may be a convex surface that engages the concave surface of the contact lens 160, although other configurations may be used. It will be appreciated that various shapes and configurations of the base 110 and respective portions thereof may be used in different embodiments, and that the illustrated embodiment is merely one example. As discussed above, the base 110 may be formed of any suitable material. In certain embodiments, the base 110 may be substantially rigid. In other embodiments, the base 110 may be flexible.

In certain embodiments, the contact lens package 100 may include a lens support that is disposed within the cavity 140 and provided as a separate component from the base 110 and the lid 150. In some embodiments, the lens support may be connected to the base 110. The lens support may include a support surface that supports the contact lens 160 within the cavity 140 in a manner similar to the lens support 136 described above. In some embodiments, the lens support may be formed as a dome, and the support surface may be a convex surface that engages the concave surface of the contact lens 160. In some embodiments, the lens support also may include a bowl that surrounds the support surface and houses at least part of the contact lens 160. In some embodiments, the base 110 may be flexible, the lid 150 may be flexible, and the separate lens support may be substantially rigid. In this manner, the separate, substantially rigid lens support may serve to protect the contact lens 160 when flexible materials are used for the base 110 and the lid 150. As shown, the lid 150 may extend over respective surfaces of the base 110 and seal the contact lens 160 and the air 170 within the cavity 140 when the contact lens package 100 is in the unopened state. In this manner, the base 110 and the lid 150 together may form the sealed cavity 140 for containing the contact lens 160 and the air 170 until a user desires to open the contact lens package 100 and remove the contact lens 160 for use. In some embodiments, as shown, when the contact lens package 100 is in the unopened state, the lid 150 may extend over and cover the base cavity 122 and respective portions of the platform 130. When the contact lens package 100 is in the unopened state, respective portions of the lid 150 may be sealed to respective adjacent portions of the base 110, such as portions of the platform 130 surrounding the opening 124 of the base cavity 122, such that the contact lens 160 and the air 170 are contained within the cavity 140 formed by the base 110 and the lid 150. The seal between the lid 150 and the base 110 may be at least partially broken when the contact lens package 100 is transitioned from the unopened state to an opened state for removal of the contact lens 160. As discussed above, the lid 150 may be formed of any suitable material. In certain embodiments, as shown, the lid 150 may be flexible.

In some embodiments, the base and the lid may be composed of or include a vapor barrier materials, such as a multilayer film. Incorporation of a vapor barrier material may substantially increase the shelf life of the lens because moisture, i.e., vapor in the air within the package, may escape other conventional materials (e.g., polypropylene) overtime and thus lead to dehydration of the contact lens. Base 110 of the embodiment depicted may be formed into the illustrated shape by cold forming a foil material having a thickness (e.g., 1mm) sufficient to remain substantially rigid, i.e., resist significant deformation under normal storage and use. Cold forming foil allows for heat sealing with a foil lid to create a robust vapor barrier surrounding the cavity.

As one example, the base be Cold Forming Foil composed of layers including OPA(Nylon) film 25p, Adhesive, Aluminum Foil 45-60p, Adhesive, and PVC 60p. However, other formed vapor barrier materials and processes capable of achieving a similar effect will be appreciated by those of skill in the art.

As noted above, the air 170 contained within the cavity 140 may be humid air, that is air including vapor (e.g., packaging solution suspended in air), sufficient for maintaining hydration of the contact lens 160 when the contact lens package 100 is in the unopened state. In some embodiments, the relative humidity of the air including vapor 170 may be greater than 80% when the contact lens package 100 is in the unopened state. In some embodiments, the relative humidity of the air including vapor 170 may be greater than 90% when the contact lens package 100 is in the unopened state. In some embodiments, the relative humidity of the air including vapor 170 may be 100% when the contact lens package 100 is in the unopened state. The relative humidity of the air 170 may be selected as appropriate for the particular type of the contact lens 160 provided with the contact lens package 100. Because the package is solutionless, relying only upon vapor to maintain hydration, as compared to certain existing contact lens packages, the contact lens package 100 may drastically reduce the amount solution required and thus reduce waste cost. Moreover, by not including liquid packaging solution within the cavity 140, removal of the contact lens 160 may be less messy and more simplified, as the user does not need to fish the contact lens 160 out of liquid packaging solution.

FIGS. IB and 1C illustrate an example method of opening the contact lens package 100 in accordance with embodiments of the present disclosure. As noted above, the contact lens package 100 may be provided and stored in the unopened state, as shown in FIGS. 1A and IB, until a user desires to open the package 100. With the contact lens package 100 in the unopened state, the user may hold the base 110 and at least partially remove the lid 150 from the base 110. For example, the user may grasp an end region of the lid 150 and pull the lid 150 away from the base 110. In this manner, at least a portion of the seal between the lid 150 and the base 110 may be broken. In some embodiments, the lid 150 may be partially removed from the base 110 such that at least a portion of the base cavity 122 is no longer covered by the lid 150 along the first side 116. In some embodiments, as shown in FIG. 1C, the lid 150 may be entirely removed from the base 110.

After at least partially removing the lid 150 from the base 110, the user may engage the contact lens 160 through the opening 124 of the base cavity 122 with one of the user's fingers while the contact lens 160 resides within the base cavity 122, as shown in FIG. 1C. In some embodiments, as shown, the user may engage the contact lens 160 while the contact lens package 100 is held in the horizontal orientation. According to the illustrated embodiment in which the concave surface of the contact lens 160 faces the base 110, the user may engage the convex surface of the contact lens 160. The user then may remove the contact lens 160 from the base cavity 122 via the engagement through the opening 124, as shown in FIG. 1C. In this manner, the contact lens 160 may be conveniently removed from the base 110 and positioned on the user's finger in the desired concave-side-up orientation, ready for positioning on the user's eye.

Solutionless contact lens packages as disclosed herein may be packaged by first disposing a contact lens and air containing vapor within a cavity of a package, then causing a relative humidity of the air in the cavity to be greater than 80%, and enclosing the cavity such that the relative humidity of the air is maintained greater than 80% when the package is in an unopened state at at least one temperature between 60 and 80 degrees Fahrenheit. One method of creating this environment is by performing the assembling steps within a manufacturing environment, room, or other chamber sized at least to accommodate primary packaging equipment. For example, a commercial humidifier may be supplied with packaging solution and configured to vaporize the solution into the air to achieve the desired humidity, i.e., 80% to 100% relative humidity at at least one temperature between 60 and 80 degrees. In a preferred embodiment, vapor is supplied by the humidifier to achieve a relative humidity of 100% at 70 degrees is produced within an air-and-vapor-sealed primary packaging module of a manufacturing line.

The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that many of the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of the specific embodiments described herein are presented for the purposes of illustration and description. They are not targeted to be exhaustive or to limit the embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.

The Summary and Abstract sections may set forth one or more but not all exemplary embodiments of the present invention as contemplated by the inventors, and thus, are not intended to limit the present invention and the appended claims in any way. The foregoing description of the specific embodiments will so fully reveal the general nature of the invention that others can, by applying knowledge within the skill of the art, readily modify and/or adapt for various applications such specific embodiments, without undue experimentation, without departing from the general concept of the present invention. Therefore, such adaptations and modifications are intended to be within the meaning and range of equivalents of the disclosed embodiments, based on the teaching and guidance presented herein. It is to be understood that the phraseology or terminology herein is for the purpose of description and not of limitation, such that the terminology or phraseology of the present specification is to be interpreted by the skilled artisan in light of the teachings and guidance.

The packages of the present invention may be manufactured using known materials and processes. The packaging materials may be virgin, recycled or a combination thereof. The volume within the package cavity can vary depending on the design selected.

Aspects of some embodiments of the invention are further disclosed by the following clauses:

1. A solutionless contact lens package comprising: a cavity that houses a contact lens and air containing vapor, wherein a relative humidity of the air is greater than 80% when the package is in an unopened state at at least one temperature between 60 and 80 degrees Fahrenheit.

2. The solutionless contact lens package of clause 1, wherein the relative humidity of the air is greater than 90% when the package is in the unopened state at at least one temperature between 60 and 80 degrees Fahrenheit. 3. The solutionless contact lens package of clause 1, wherein the relative humidity of the air is 100% when the package is in the unopened state at at least one temperature between 60 and 80 degrees Fahrenheit.

4. The solutionless contact lens package of any one of clauses 1-3, wherein the base and the lid comprise a vapor barrier.

5. The solutionless contact lens package of clause 4, wherein the base is formed of a substantially rigid foil material.

6. The solutionless contact lens package of clause 4 or clause 5, wherein the base and the lid collectively define the cavity.

7. The solutionless contact lens package of any one of clauses 4-6, wherein the base is substantially rigid, and wherein the lid is flexible.

8. The solutionless contact lens package of any one of clauses 4-6, wherein the base is flexible, and wherein the lid is flexible.

9. The solutionless contact lens package of any one of clauses 4-8, wherein the lid extends over and covers the contact lens when the package is in the unopened state, wherein the lid does not cover the contact lens when the package is in an opened state, and wherein the contact lens is disposed within the cavity such that a convex surface of the contact lens faces the lid when the package is in the unopened state.

10. The solutionless contact lens package of any one of clauses 4-9, wherein the base comprises a base cavity that forms at least part of the cavity, and wherein at least part of the contact lens is housed within the base cavity.

11. The solutionless contact lens package of clause 10, wherein the lid extends over and covers the base cavity when the package is in the unopened state, and wherein the lid does not cover the base cavity when the package is in an opened state, such that the contact lens is accessible to a user through an opening of the base cavity when the package is in the opened state.

12. The solutionless contact lens package of any one of clauses 4-11, wherein the base comprises a lens support comprising a support surface that supports the contact lens within the cavity.

13. The solutionless contact lens package of clause 12, wherein the support surface engages a concave surface of the contact lens. 14. The solutionless contact lens package of clause 12 or clause 13, wherein the support surface is a convex surface.

15. The solutionless contact lens package of any one of clauses 12-14, wherein the base further comprises a bowl that surrounds the support surface and houses at least part of the contact lens.

16. The solutionless contact lens package of any one of clauses 4-11, further comprising a lens support disposed within the cavity, wherein the lens support comprises a support surface configured to have a contact surface area with the lens of less than or equal to 80 percent the surface area of the contact lens.

17. The solutionless contact lens package of clause 16, wherein the lens support is disposed between the base and the contact lens.

18. The solutionless contact lens package of clause 16 or clause 17, wherein the lens support is connected to the base.

19. The solutionless contact lens package of any one of clauses 16-18, wherein the support surface engages a concave surface of the contact lens. 20. The solutionless contact lens package of any one of clauses 16-19, wherein the support surface is a convex surface.

21. The solutionless contact lens package of any one of clauses 16-20, wherein the lens support further comprises a bowl that surrounds the support surface and houses at least part of the contact lens.

22. The solutionless contact lens package of any one of clauses 16-21, wherein the lid extends over and covers the lens support when the package is in the unopened state, and wherein the lid does not cover the lens support when the package is in an opened state.

23. The solutionless contact lens package of any one of clauses 16-22, wherein the base is flexible, wherein the lid is flexible, and wherein the lens support is substantially rigid.

25. A method of packaging a contact lens, the method comprising: disposing a contact lens and air containing vapor within a cavity of a package; causing a relative humidity of the air in the cavity to be greater than 80%; and enclosing the cavity such that the relative humidity of the air is maintained greater than 80% when the package is in an unopened state at at least one temperature between 60 and 80 degrees Fahrenheit. 26. The method of clause 25, wherein the relative humidity of the air is greater than 90% when the package is in the unopened state at at least one temperature between 60 and 80 degrees Fahrenheit.

27. The method of clause 25, wherein the relative humidity of the air is 100% when the package is in the unopened state at at least one temperature between 60 and 80 degrees Fahrenheit.

28. The method of any one of clauses 25-27, wherein the relative humidity in the cavity is established by performing the steps of clause 25 in a humidified chamber.

29. The method of any one of clauses 25-28, further comprising cold forming a base material to form the cavity.

Not all the features described herein need to be incorporated into every package, and those of skill in the art, using the teachings herein, can combine the features to provide a wide variety of improved contact lens packages. In summary, the contact lens packages of the present invention incorporate several novel functionalities which may be combined in a wide variety of combinations as described herein to provide the desired improved and/or single touch packaging. The breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments but should be defined only in accordance with the following claims and their equivalents.

Claims

WHAT IS CLAIMED IS:

2. The solutionless contact lens package of claim 1, wherein the relative humidity of the air is greater than 90% when the package is in the unopened state at at least one temperature between 60 and 80 degrees Fahrenheit.

3. The solutionless contact lens package of claim 1, wherein the relative humidity of the air is 100% when the package is in the unopened state at at least one temperature between 60 and 80 degrees Fahrenheit.

4. The solutionless contact lens package of claim 1, further comprising a base and a lid, wherein the base and the lid comprise a vapor barrier.

5. The solutionless contact lens package of claim 1, further comprising a base and a lid, wherein the base is formed of a substantially rigid foil material.

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6. The solutionless contact lens package of claim 1, further comprising a base and a lid, wherein the base and the lid collectively define the cavity.

7. The solutionless contact lens package of claim 1, further comprising a base and a lid, wherein the base is substantially rigid, and wherein the lid is flexible.

8. The solutionless contact lens package of claim 1, further comprising a base and a lid, wherein the base is flexible, and wherein the lid is flexible.

9. The solutionless contact lens package of claim 1, further comprising a base and a lid, wherein the lid extends over and covers the contact lens when the package is in the unopened state, wherein the lid does not cover the contact lens when the package is in an opened state, and wherein the contact lens is disposed within the cavity such that a convex surface of the contact lens faces the lid when the package is in the unopened state.

10. The solutionless contact lens package of claim 1, further comprising a base and a lid, wherein the base comprises a base cavity that forms at least part of the cavity, and wherein at least part of the contact lens is housed within the base cavity.

11. The solutionless contact lens package of claim 10, wherein the lid extends over and covers the base cavity when the package is in the unopened state, and wherein the lid does not cover the base cavity when the package is in an opened state, such that the contact lens is accessible to a user through an opening of the base cavity when the package is in the opened state.

12. The solutionless contact lens package of claim 1, further comprising a base and a lid, wherein the base comprises a lens support comprising a support surface that supports the contact lens within the cavity.

13. The solutionless contact lens package of claim 12, wherein the support surface engages a concave surface of the contact lens.

14. The solutionless contact lens package of claim 12, wherein the support surface is a convex surface.

15. The solutionless contact lens package of claim 12, wherein the base further comprises a bowl that surrounds the support surface and houses at least part of the contact lens.

16. The solutionless contact lens package of claim 1, further comprising a lens support disposed within the cavity, wherein the lens support comprises a support surface configured to have a contact surface area with the lens of less than or equal to 80 percent the surface area of the contact lens.

17. The solutionless contact lens package of claim 16, wherein the lens support is disposed between a base and the contact lens.

18. The solutionless contact lens package of claim 16, wherein the lens support is connected to a base.

19. The solutionless contact lens package of claim 16, wherein the support surface engages a concave surface of the contact lens.

20. The solutionless contact lens package of claim 16, wherein the support surface is a convex surface.

21. The solutionless contact lens package of claim 16, wherein the lens support further comprises a bowl that surrounds the support surface and houses at least part of the contact lens.

22. The solutionless contact lens package of claim 1, further comprising a base and a lid, wherein the lid extends over and covers the lens support when the package is in the unopened state, and wherein the lid does not cover the lens support when the package is in an opened state.

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23. A method of packaging a contact lens, the method comprising: disposing a contact lens and air containing vapor within a cavity of a package; causing a relative humidity of the air in the cavity to be greater than 80%; and enclosing the cavity such that the relative humidity of the air is maintained greater than 80% when the package is in an unopened state at at least one temperature between 60 and 80 degrees Fahrenheit.

24. The method of claim 23, wherein the relative humidity of the air is greater than 90% when the package is in the unopened state at at least one temperature between 60 and 80 degrees Fahrenheit.

25. The method of claim 23, wherein the relative humidity of the air is 100% when the package is in the unopened state at at least one temperature between 60 and 80 degrees Fahrenheit.

26. The method of claim 23, wherein the relative humidity in the cavity is established by performing the steps of claim 23 in a humidified chamber.

27. The method of claim 23, further comprising cold forming a base material to form the cavity.

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