Heat seal apparatus for lens packages

Abstract

The present invention relates to an apparatus for packaging contact lenses. The apparatus includes a compliant head, improved heater and improved heat seal die.

1 . An apparatus for packaging contact lenses in a plurality of contact lens containers, each container having a recess, a sealing flange about said recess, and a contact lens with said recess, a plurality of said containers being sealed in said apparatus to a contiguous lidstock to form a set of packages, said apparatus comprising: 
 a plurality of lifts;    a plurality of platens located in a lower portion of the apparatus, each of said platens comprising a compliant head that is compliant in more than one direction, each of said platens adjacent to one another, each of said platens being individually supported by one of said lifts;    a plurality of discrete carriers, said carriers being movable within said apparatus onto said plurality of said platens, such that each of said carriers is mounted on a respective one of said platens, a single one of said containers being mounted on a single one of said carriers to provide a plurality of said containers located adjacent to one another;    a lidstock maneuvering system for placing a contiguous lidstock over said plurality of said containers located adjacent to one another; and    a mandrel disposed above said plurality of platens;    wherein pressure is applied to said contiguous lidstock and said flanges of said containers by said mandrel and said plurality of platens to adhere said contiguous lidstock to said plurality of said containers to form a set of packages.    
   
   
       2 . The apparatus according to  claim 1 , wherein each carrier has a cavity, each said recess of said container being received in said cavity of said carrier.  
   
   
       3 . The apparatus according to  claim 1 , wherein said lidstock has a thickness and said container has a thickness, and further wherein said mandrel is selectively moveable between a retracted upper position and an engaged lower position to seal said lidstock to said containers, and wherein in said lower position, a pressure applied by said mandrel against each of said platens is maintained within a predetermined range by the respective lifts, thereby compensating for tolerance differences in the thickness of said containers and the thickness of said lidstock to ensure that an adequate seal is formed between said lidstock and each of said containers.  
   
   
       4 . The apparatus according to  claim 3 , further comprising a pressure transducer being connected to said lifts, and further wherein said lifts apply pressure to said container within a predetermined range, as determined by said pressure transducer.  
   
   
       5 . The apparatus according to  claim 1  wherein said mandrel is heated.  
   
   
       6 . The apparatus of  claim 1 , wherein said lidstock comprises print, and further wherein said lidstock maneuvering system further comprises: 
 a vision alignment inspection system having means for checking the print quality on said lidstock and for simultaneously checking for registration of said lidstock within said apparatus based on the location of said print.    
   
   
       7 . The apparatus of  claim 6 , wherein said lidstock maneuvering system further comprises a printing system and a cutting system, wherein said lidstock is fed from a roll under tension into said printing system and said cutting system, and said vision alignment inspection system is located after said printing system.  
   
   
       8 . The apparatus of  claim 6 , wherein said lidstock maneuvering system further comprises a printing system and cutting system, wherein said lidstock is fed from a roll under tension into said printing system and said cutting system and said alignment inspection system is located between said printing system and said cutting system.  
   
   
       9 . The apparatus of  claim 6 , further comprising a heat seal apparatus, wherein said lidstock is mechanically controlled after said vision alignment inspection system to prevent misregistration of said lidstock in said heat seal apparatus.  
   
   
       10 . The apparatus of  claim 3 , wherein said lidstock is held in position by said lidstock maneuvering system over said container until said mandrel contacts said lidstock in said engaged lower position.  
   
   
       11 . The apparatus of  claim 1 , wherein said apparatus further comprises: 
 said mandrel further comprising a plurality of dies each having a die cylinder;    said dies disposed above each of said carriers;    wherein said cylinders apply pressure, within a predetermined range, to each of said dies    
   
   
       12 - 28 . (canceled)