Systems and methods for multi-stage sealing of contact lens packaging

Abstract

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

What is claimed is: 
     
         1 . A contact lens package, comprising:
 a first package layer;   a second package layer;   a lens receiving area defined between the first and second package layers;   a first seal portion extending around a first portion of the lens receiving area;   a second seal portion extending around a second portion of the lens receiving area, the second seal portion having different sealing properties than the first seal portion.   
     
     
         2 . The contact lens package of  claim 1 , wherein the first seal portion is a releasable seal between the first and second package layers, and the second seal portion is a permanent seal between the first and second package layers. 
     
     
         3 . The contact lens package of  claim 1 , wherein the first and second seal portions together extend around an entire periphery of the lens receiving area. 
     
     
         4 . The contact lens package of  claim 1 , wherein the first and second package layers comprise foil. 
     
     
         5 . The contact lens package of  claim 1 , wherein the second seal portion overlaps a portion of the first seal portion. 
     
     
         6 . The contact lens package of  claim 1 , wherein the second seal portion provides a greater seal strength between the first and second package layers than a seal strength provided by the first seal portion. 
     
     
         7 . The contact lens package of  claim 1 , further comprising an internal member positioned in the lens receiving area, and a third seal portion between the internal member and at least one of the first and second package layers. 
     
     
         8 . A press adapted to seal a contact lens package, the press comprising:
 a first portion configured to support at least one contact lens package, the contact lens package including a lens receiving area sized to hold a contact lens;   a second portion having at least one first sealer configured to create a first seal portion around only a portion of the lens receiving area;   a third portion having at least one second sealer configured to create a second seal portion around a different portion of the lens receiving area, the second seal portion having different sealing properties than the first seal portion.   
     
     
         9 . The press of  claim 8 , wherein the first portion is defined by a lower sealing head, and the second and third portions are carried by an upper sealing head. 
     
     
         10 . The press of  claim 8 , wherein the first portion includes at least one recess sized to receive the contact lens package. 
     
     
         11 . The press of  claim 8 , wherein the first seal portion defines an unsealed gap at a location around a periphery of the lens receiving area, and the second seal portion overlaps and closes the gap. 
     
     
         12 . The press of  claim 8 , wherein the second seal portion has a greater seal strength than the first seal portion. 
     
     
         13 . The press of  claim 8 , wherein at least one of the second and third portions remove gases from the lens receiving area before creating the second seal portion. 
     
     
         14 . The press of  claim 8 , wherein the first and second portions each include an alignment feature configured to align the contact lens package with the first and second portions. 
     
     
         15 . The press of  claim 14 , wherein the alignment feature is an orifice, and the press is configured to apply a vacuum force to the contact lens package through the orifice. 
     
     
         16 . The press of  claim 14 , wherein at least one of the first, second and third portions is heated. 
     
     
         17 . The press of  claim 8 , wherein the second and third portions are carried by a common press head. 
     
     
         18 . A method for manufacturing a contact lens package, comprising:
 providing first and second package layers that define a lens receiving area there between;   forming a first seal portion around all but a portion of a periphery of the lens receiving area;   forming a second seal portion to completely seal closed the lens receiving area.   
     
     
         19 . The method of  claim 18 , wherein forming the second seal portion includes overlapping the second seal portion with the portion of the periphery of the lens receiving area not included in the first seal portion. 
     
     
         20 . The method of  claim 18 , wherein forming the second seal portion includes forming the second seal portion with a greater seal strength than a seal strength of the first seal portion. 
     
     
         21 . The method of  claim 18 , wherein forming the first seal portion includes creating a releasable seal between the first and second package layers. 
     
     
         22 . The method of  claim 18 , wherein forming the second seal portion includes creating a permanent seal between the first and second package layers. 
     
     
         23 . The method of  claim 18 , wherein forming the second seal portion includes applying at least one of a greater heat and a greater pressure than applied when forming the first seal portion. 
     
     
         24 . The method of  claim 18 , further comprising removing gases from the lens receiving area before forming the second seal portion. 
     
     
         25 . The method of  claim 18 , further comprising positioning a contact lens and at least one liquid in the lens receiving area before forming the first and second seal portions. 
     
     
         26 . The method of  claim 18 , further comprising providing an internal member disc positioned in the lens receiving area, and forming a third seal portion between the internal member and at least one of the first and second package layers. 
     
     
         27 . A method of manufacturing a contact lens package, comprising:
 positioning a first package layer on a first press portion;   positioning a contact lens on the first package layer;   positioning a second package layer on the first package layer and covering the contact lens;   creating a first seal portion between the first and second package layers with a second press portion;   creating a second seal portion between the first and second package layers with a third press portion.   
     
     
         28 . The method of  claim 27 , wherein the first package layer includes a pre-formed lens receiving area, and positioning the contact lens includes positioning the contact lens in the lens receiving area. 
     
     
         29 . The method of  claim 27 , wherein the first and second seal portion have different properties. 
     
     
         30 . The method of  claim 27 , wherein creating the first seal portion includes creating the first seal portion as a releasable seal between the first and second package layers. 
     
     
         31 . The method of  claim 27 , wherein creating the second seal portion includes creating the second seal portion as a permanent seal between the first and second package layers. 
     
     
         32 . The method of  claim 27 , wherein creating the second seal portion includes applying at least one of a greater heat and a greater pressure as compared to a heat and pressure used to create the first seal portion. 
     
     
         33 . The method of  claim 27 , further comprising applying a vacuum to align the second package layer with the first and second press portions. 
     
     
         34 . The method of  claim 27 , further comprising removing gas from the lens receiving area before creating the second seal portion. 
     
     
         35 . The method of  claim 27 , further comprising positioning a support disc adjacent to the contact lens between the first and second package layers, and forming a third seal portion between the support disc and at least one of the first and second package layers. 
     
     
         36 . A method of assembling a contact lens package, comprising:
 arranging first and second foil package layers at least partially overlapping each other with a contact lens positioned there between;   creating a first sealed portion between the first and second foil package layers; and   creating a second sealed portion between the first and second foil package layers.   
     
     
         37 . The method of  claim 36 , wherein the contact lens is positioned in a lens receiving area defined between the first and second foil package layers, and creating the first sealed portion includes sealing around all but a gap portion of a periphery of the lens receiving area, and creating the second sealed portion includes sealing the gap portion. 
     
     
         38 . The method of  claim 36 , wherein creating the second sealed portion occurs after creating the first sealed portion. 
     
     
         39 . The method of  claim 36 , wherein creating the first sealed portion includes creating a releasable seal between the first and second foil package layers, and creating the second sealed portion includes creating a permanent seal between the first and second foil package layers. 
     
     
         40 . The method of  claim 36 , further comprising positioning a support member between the first and second foil package layers and in contact with the contact lens, and creating a third sealed portion between the support member and at least one of the first and second foil package layers.