Patent Publication Number: US-2021191160-A1

Title: Method and apparatus for storing, preserving and cleaning contact lenses

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of co-pending U.S. application Ser. No. 16/738,931, filed Jan. 9, 2020. U.S. application Ser. No. 16/738,931 was a continuation of U.S. application Ser. No. 16/164,565, filed Oct. 18, 2018 (issued as U.S. Pat. No. 10,578,890 on Mar. 3, 2020) which was a nonprovisional of, and claimed priority to, U.S. Provisional Application Ser. No. 62/574,072, filed Oct. 18, 2017. This application claims priority to each of the above applications, and hereby incorporates by reference the entire disclosures of each of the above applications. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to methods and apparatus for storing, cleaning and preserving contact lenses and other apparatus which may be used on the ocular surface, without specialized chemicals. 
     BACKGROUND 
     The current conventional method for cleaning, sterilization and storage of contact lenses generally requires chemicals. Chemical cleaning and sterilization is both inconvenient and can cause adverse reactions in users with sensitivities to the chemicals. The inconvenience of selecting and purchasing chemical solutions which are compatible with the particular lenses and do not cause adverse reactions in the users, over long timespans, leads to users sometimes running out of the solutions and/or using incorrect solutions, which can lead to infections and/or adverse reactions in the users. Inadequate maintenance practices also shorten the useful life of lenses. Bacterial and viral populations in and on the lenses can develop resistance to chemicals. In addition, the requirement to use specific chemicals in specific order can lead to errors by users, which again lead to adverse results. For example, failure to properly clean lenses prior to chemical sterilization can lead to incomplete sterilization in areas where mucus and protein buildup can shield bacteria and viruses underneath those layers from the sterilizing chemicals, creating danger of infections and irritation of the eyes. Reliance on chemical methods is unreliable on a systemic level. 
     There is a need for compact, simple, reliable apparatus and methods which are essentially failsafe and easy for ordinary consumers to use, and which avoid growth of chemical-resistant bacteria and viruses. 
     SUMMARY AND ADVANTAGES 
     An apparatus for storing, preserving and cleaning contact lenses, includes a base housing; a first lens bowl configured to retain a first contact lens and volume of lens-compatible fluid, the first lens bowl composed of material transparent to a selected range of UV light wavelengths, the first lens bowl coupled to the base housing; a first UV light source proximate the first lens bowl and oriented to direct UV light into the first lens bowl; a removable cover, the cover configured to enclose and seal around at least the first lens bowl, the lens cover substantially opaque to the UV light; a first closure sensor disposed to sense the removable cover in a closed or a not-closed status; a power supply; and, a controller, the controller including software instructions, the controller in control communication with at least the UV light source, the power supply and the first closure sensor, wherein the controller causes the first UV light source to cease emitting when the first closure sensor indicates the removable cover is in the not-closed status. 
     The apparatus may include a first IR light source proximate the first lens bowl and oriented to direct IR light into the first lens bowl; the first lens bowl material additionally transparent to IR light; and, the controller additionally in control communication with the first IR light source. 
     The apparatus may include a first UV reflector disposed within the removable cover above the first lens bowl, the first UV reflector disposed to reflect the selected band of UV light toward the first lens bowl. 
     The apparatus may include a second lens bowl configured to retain a second contact lens and volume of lens-compatible fluid, the second lens bowl composed of material transparent to the selected range of UV light wavelengths, the second lens bowl coupled to the base housing; a second UV light source proximate the second lens bowl and oriented to direct UV light into the second lens bowl; the removable cover additionally configured to enclose and seal around the second lens bowl; and, the controller additionally in control communication with at least the second UV light source. 
     The apparatus may include a second IR light source proximate the second lens bowl and oriented to direct IR light into the second lens bowl; and, the controller additionally in control communication with the second IR light source. 
     The apparatus may include a plurality of closure sensors; and, the controller additionally in control communications with the plurality of closure sensors. 
     The apparatus provide for short term disinfection and/or long term storage. 
     The invention provides many advantages over existing apparatus and methods, including: (1) UV and JR cleaning is less likely to lead to chemically-resistant bacterial and viral strains; (2) the apparatus is compact and safe for home use; (3) it reduces need for chemical agents which may be used ineffectively by consumers and/or which can adversely affect sensitive eye tissues; (4) alleviates concern for out-of-date cleaning solutions; (5) reduced danger that air pockets trapped inside contact lenses will lead to incomplete cleaning due to lack of chemical cleaner contact; (6) use of LEDs provides for precise control of wavelength, intensity and heat addition; (7) design conserves energy usage allowing for compactness and portability; (8) automatic cycles, system monitoring and interlocks require less attention and interaction by the user, so enhance reliability of hygiene overall; and (9) it is noncontact, so improves sterility. 
     Additional advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims. Further benefits and advantages of the embodiments of the invention will become apparent from consideration of the following detailed description given with reference to the accompanying drawings, which specify and show preferred embodiments of the present invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings, which are incorporated into and constitute a part of this specification, illustrate one or more embodiments of the present invention and, together with the detailed description, serve to explain the principles and implementations of the invention. 
         FIG. 1  shows an exploded view of a First Embodiment. 
         FIG. 2  shows a top perspective view of a First Embodiment, with cover closed. 
         FIG. 3  shows a partial exploded view of a First Embodiment base housing and power supply. 
         FIG. 4  shows a top perspective view of a base housing and power supply of a First Embodiment. 
         FIG. 5  shows a top perspective view of a PCB mounting board of a First Embodiment. 
         FIG. 6  shows partial exploded view of a First Embodiment PCB mounting board and electronic housing base. 
         FIG. 7  shows a partially disassembled view of a base housing of First Embodiment with power supply and PCB mounting board installed. 
         FIG. 8  shows a partial exploded view of a First Embodiment optical housing portion. 
         FIG. 9  shows a top perspective view of a First Embodiment without the cover. 
         FIG. 10  shows a partial exploded view of a cover of a First Embodiment. 
     
    
    
     REFERENCE NUMBERS USED IN DRAWINGS 
     Turning now descriptively to the drawings, in which similar reference characters denote similar elements throughout the several views, the figures illustrate the present invention. With regard to the reference numerals used, the following numbering is used throughout the various drawing figures:
           10  First Embodiment     12  Base Housing     14  Rechargeable Power Supply     16  Controller     18   a  First UV Light Source     18   b  Second UV Light Source     20   a  First IR Light Source     20   b  Second IR Light Source     22   a  First Closure Sensor     22   b  Second Closure Sensor     22   c  Third Closure Sensor     22   d  Fourth Closure Sensor     24  Optical Housing     26  Cover     28  Micro-USB Port     30   a  First Cover Closure Magnet     30   b  Second Cover Closure Magnet     30   c  Third Cover Closure Magnet     30   d  Fourth Cover Closure Magnet     32   a  First Magnetically Permeable Fastener     32   b  Second Magnetically Permeable Fastener     32   c  Third Magnetically Permeable Fastener     32   d  Fourth Magnetically Permeable Fastener     34  First Lens Bowl     36  Second Lens Bowl     38   a  IR LED Element     38   b  IR LED Element     38   c  IR LED Element     38   d  IR LED Element     38   e  IR LED Element     38   f  IR LED Element     38   g  IR LED Element     38   h  IR LED Element     40   a  IR LED Element     40   b  IR LED Element     40   c  IR LED Element     40   d  IR LED Element     40   e  IR LED Element     40   f  IR LED Element     40   g  IR LED Element     40   h  IR LED Element     42   a  First Optical Housing Fastener Aperture     42   b  Second Optical Housing Fastener Aperture     42   c  Third Optical Housing Fastener Aperture     42   d  Fourth Optical Housing Fastener Aperture     44   a  First Lens Bowl Aperture     44   b  Second Lens Bowl Aperture     46   a  First Lens Bowl Aperture Perimeter Ledge     46   b  Second Lens Bowl Aperture Perimeter Ledge     48   a  First Lens Bowl Perimeter Horizontal Flange     48   b  Second Lens Bowl Perimeter Horizontal Flange     50   a  First Lens Bowl Perimeter Vertical Flange     50   b  Second Lens Bowl Perimeter Vertical Flange     52  Cover Top/Outer Surface     54  Cover Bottom/Interior Surface     56   a  Cover First Sealing Flange     56   b  Cover Second Sealing Flange     58   a  First Closure Magnet Recess     58   b  Second Closure Magnet Recess     58   c  Third Closure Magnet Recess     58   d  Fourth Closure Magnet Recess     60   a  Cover First Finger Tab     60   b  Cover Second Finger Tab     62  PCB Mounting Board     64  Electronic Housing Base     66  PCB Mounting Board Alignment Aperture     68  PCB Mounting Board Alignment Pin     70  Power Supply Cavity     72   a  First Loop Extension     72   b  Second Loop Extension     72   c  Third Loop Extension     72   d  fourth Loop Extension     74   a  First UV Light Source Sidewall     74   b  Second UV Light Source Sidewall     76   a  First UV Cover Reflector     76   b  Second UV Cover Reflector       

     DETAILED DESCRIPTION 
     Before beginning a detailed description of the subject invention, mention of the following is in order. When appropriate, like reference materials and characters are used to designate identical, corresponding, or similar components in differing figure drawings. The figure drawings associated with this disclosure typically are not drawn with dimensional accuracy to scale, i.e., such drawings have been drafted with a focus on clarity of viewing and understanding rather than dimensional accuracy. 
     In the interest of clarity, not all of the routine features of the implementations described herein are shown and described. It will, of course, be appreciated that in the development of any such actual implementation, numerous implementation-specific decisions must be made in order to achieve the developer&#39;s specific goals, such as compliance with application- and business-related constraints, and that these specific goals will vary from one implementation to another and from one developer to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking of engineering for those of ordinary skill in the art having the benefit of this disclosure. 
     Referring to  FIGS. 1-11 , a first embodiment of an apparatus for storing, preserving and cleaning contact lenses are shown. Referring to  FIG. 1 , an exploded view of a first embodiment  10  is shown. First embodiment  10  includes a base housing  12 , a power supply  14 , an on-board controller  16 , first and second IN light sources  18   a  &amp;  18   b , first and second IR light sources  20   a  &amp;  20   b , closure sensors  22   a ,  22   b ,  22   c  &amp;  22   d , optical housing  24 , and cover  26 . 
     In the First Embodiment, power supply  14  is a rechargeable lithium ion battery, coupled to micro-USB charging port  28  which includes a waterproof enclosure. A rechargeable power supply permits portability and flexibility. In the Embodiment, the apparatus  10  is usable both with the device unplugged and operating solely on battery power, or plugged in to another continuous power source—for example a wall outlet or power source in a vehicle. Rechargeable power supply  14  stores sufficient power for at least one complete cleaning cycle. Base housing  12  includes a power supply cavity  70  defining a space to retain rechargeable power supply  14 . 
     Cover  26  includes a sealing engagement portion, and closure magnets  30   a ,  30   b ,  30   c  &amp;  30   d  mounted within cover  26 . Closure magnets help align cover  26  for proper closing and sealing, and magnetically couple to closure sensors  22   a - d . Cover  26  may be made from a UV-absorbing material to prevent transmission of harmful levels of UV light, or may incorporate a UV-reflective surface. In the embodiment, cover  26  may also include first and second reflectors  76   a  &amp;  b , within first and second sealing flanges  56   a  &amp;  56   b . In the embodiment, first and second reflectors  76   a  &amp;  b  are reflectors fixed to interior surface  54  within scaling flanges  56   a  &amp;  b , respectively, and having polished aluminum surfaces. First and second reflectors  76   a  &amp;  b  may be coated to prevent corrosion and/or leaching. Reflectors may also be provided as applied reflective coatings on the interior surfaces. 
     Magnetically permeable fasteners  32   a ,  32   b ,  32   c  &amp;  32   d  are provided, which perform two functions—engage with closure magnets, and provide magnetic coupling path for closure magnets to closure sensors  22   a - d . In the embodiment, sensors  22   a - d  are Hall effect sensors, which require low power and produce low heat, are solid state, and noncontact, so easily sealed within the plastic casing, and will not interfere with the UV and IR LEDs. Fewer or more closure sensors could be used depending on the particular shape and configuration of the housing and cover, and closure sensors could be configured to sense the status of the cover as either the presence (i.e. closed and sealed status) or the absence (i.e. not completely closed or sealed status) of the cover. If at least one of closure sensors  22   a - d  senses the status of cover  26  as not-closed status, then the controller  16  will cause the UV light sources  18   a  &amp;  b  and the IR light sources  20   a  &amp;  b  to cease emitting. The apparatus could be programmed to permit operation with fewer than all closure sensors sensing a closed status where sufficient redundancy exists that fewer sensors would indicate complete closure. 
     In the Embodiment, first and second UV light sources  18   a  &amp;  b  are hermetically sealed LEDs producing light in a narrow portion of the UV-C band, within a range of approximately 255 nm to 280 nm wavelength (which maximizes lethality to bacteria). The dosage absorbed by microorganisms within the storage compartment is a function of UV light intensity (or fluence rate) and exposure time, shown by the equation: Dose (μw-s/cm 2 )=Intensity (μw/cm 2 )×time (s). The required dosage to achieve 99% kill rate varies with the type of bacterial or virus, but typically a dose of approximately 8,000 μw-s/cm 2  would be required, with a minimum of 2,500 μw-s/cm 2 . Use of sterile storage solution will reduce the dosage required to achieve and maintain satisfactory disinfection (i.e. the minimum microbial load). UV light sources  18   a  &amp;  b  may include multiple UV LED elements. In the Embodiment, UV light sources  18   a  &amp;  b  include first and second enclosing internally UV reflective sidewalls  74   a  &amp;  b , respectively, which contain and direct UV light into the respective first and second lens bowls  34 ,  36  but retain high transmittance for the selected IR wavelength band (in the described Embodiment, concentrated around the 650 nm wavelength). 
     In the embodiment, IR disinfection is combined with the UV disinfection to achieve optimum results. Each of first and second lens bowls  34  and  36  is centered within first and second IR light sources  20   a  &amp;  b , respectively, each of which includes eight IR LED elements,  38   a - h  and  40   a - h , respectively, distributed evenly along a circular circumference. IR LED elements  38   a - h  and  40   a - h  produce light concentrated around the 650 nm wavelength to heat the water volume and any microbes and viruses therein. In the embodiment, the eight low power LED elements  38   a - h  and  40   a - h  distributed around each lens bowl  34  and  36  provide even heating of the compartment, while reducing the danger of structural damage/plastic melting from a lower number of higher power LED elements. IR LED elements  38   a - h  and  40   a - h  are selected to achieve a steady state operating temperature of at least 45 C-50 C (113 F-122 F) during the cleaning cycle. The IR LED elements  38   a - h  and  40   a - h  are deenergized prior to the end of the cleaning cycle, in order to allow the storage solution (and hence, the lenses) to cool to a comfortable temperature prior to removal. In the embodiment, IR LED elements  38   a - h  and  40   a - h  are relatively low power, each IR light source  20   a  &amp;  b  sufficient to warm lens bowls  34  and  36  at steady state but not sufficient to damage the apparatus or lenses even if energized continuously, so as to obviate the need for complicated temperature feedback control. The total IR LED element power will be determined by the wall thickness of the specific materials selected and shape of the device to account for balancing heat losses. 
     In the Embodiment, controller  16  is an integrated circuit module mounted to PCB mounting board  62 , which includes the L.E.D. drivers which control power to UV light sources  18   a  &amp;  b  and IR light sources  20   a  &amp;  b , and monitor their operation, as well as the battery charging and management subsystem. Controller  16  also includes software instructions in the programmable memory which, among other functions, control the process cycle, including the power level of the LED elements, timing, sequence and ramp up, system power management, safety interlock inputs, alarms and warnings, and system operation logs. 
     In the Embodiment, optical housing  24  is a planar element having fastener apertures  42   a ,  42   b ,  42   e  &amp;  42   d  to receive magnetically permeable ferrous fasteners  32   a - d , and first and second lens bowl apertures  44   a  &amp;  b , to receive first and second lens bowls  34  &amp;  36 . Lens bowl apertures  44   a  &amp;  b , are aligned to center lens bowls  34  &amp;  36  over first and second JV light sources  18   a  &amp;  b , respectively. Lens bowl apertures  44   a  &amp;  b  include perimeter ledges  46   a  &amp;  b , respectively. First and second lens bowls  34  &amp;  36  are curved hemispherical or hyperbolically shaped bowls, each including a perimeter horizontal flange  48   a  &amp;  48   b , respectively, which couples with first and second lens bowl aperture perimeter ledges  46   a  &amp;  b , respectively. They may be sealed in place by, for example, gluing, or thermal or sonic welding. Lens bowls  34 ,  36  are made from optically clear, IN-C-transparent material, for example quartz-glass or UV-C-transparent acrylics, which have at least 80% transmittance at the selected wavelength or at least at the most desired wavelength within the selected range. In the embodiment, lens bowls  34 ,  36  themselves act as refractive lenses, in order to focus the UV light through a contact lens held within it and provide uniform UV transmittance and heat distribution. First and second lens bowl perimeter vertical flanges  50   a  &amp;  b  extend upward from first and second lens bowls  34 ,  36 , respectively, to engage cover  26 . The shape and dimensions of lens bowls  34  and  36  are configured to receive a selected type and size of contact lens. In the Embodiment, lens bowls  34  and  36  are configured to receive the standard range of contact lenses used by people. Contact lenses used for animals may be larger or smaller than those used by people, and potentially shaped differently, so the dimensions of the bowls would be configured for the anticipated range of sizes and shapes for the type of use. 
     Cover  26  goes over the top of the apparatus to both seal lens bowls  34  &amp;  36 , and to shield a user from UV light sources  18   a  &amp;  b . In the Embodiment, cover  26  is substantially planar, having a top/outer surface  52  and a bottom/interior surface  54 , and includes first and second sealing flanges  56   a  &amp;  56   b  projecting from bottom/interior surface  54  to sealingly engage first and second lens bowl perimeter vertical flanges  50   a  &amp;  b  and perimeter horizontal flanges  48   a  &amp;  b , respectively. Cover  26  also includes first, second, third and fourth closure magnet recesses  56   a ,  56   b ,  56   e  and  56   d  to retain closure magnets  30   a - d , respectively. Closure magnet recesses  56   a - d  are located in a pattern matching magnetically permeable fasteners  32   a - d  to magnetically couple to them. Cover  26  includes first and second finger tabs  60   a  &amp;  60   b  extending outward from its perimeter to provide easier grip for removal/installation. 
     In the Embodiment, UV light sources  18   a  &amp;  b , IR light sources  20   a  &amp;  b , micro-USB port  28 , and associated controllers, drivers and circuitry, are mounted to a single planar PCB mounting board  62 , which is sealed to prevent moisture damage. Closure sensors  22   a - d  are disposed proximate the four corners of PCB mounting board  62 , aligned to be proximate to fastener apertures  42   a - d . Micro-USB port  28  provides connection to external power, programming and monitoring/diagnostic devices. 
     PCB mounting board  62  is mounted onto electronic housing base  64 , and includes an alignment aperture  66  to receive a corresponding alignment pin  68  therethrough to ensure proper positioning of closure sensors  22   a - d  and the UV &amp; IR light sources  18   a  &amp;  b  and  20   a  &amp;  b.    
     The apparatus could be configured as a single lens device as well, for example by omitting the second lens bowl and associated elements, and could be configured with more than two lens bowls for higher volume applications; however, typical applications would likely be a dual-lens configuration. 
     Those skilled in the art will recognize that numerous modifications and changes may be made to the preferred embodiment without departing from the scope of the claimed invention. It will, of course, be understood that modifications of the invention, in its various aspects, will be apparent to those skilled in the art, some being apparent only after study, others being matters of routine mechanical, chemical and electronic design. No single feature, function or property of the preferred embodiment is essential. Other embodiments are possible, their specific designs depending upon the particular application. As such, the scope of the invention should not be limited by the particular embodiments herein described but should be defined only by the appended claims and equivalents thereof.