Blister package for contact lenses

Abstract

A contact lens blister package comprising: (a) a thermoplastic base member that has (i) a receptacle portion that defines a blister cavity, the receptacle portion having an interior surface that is recessed from a rim and includes a convex protrusion that projects into the blister cavity but does not extend to the rim, the thermoplastic base member having a weight that is in a range of from 0.40 g to 1.50 g; and (ii) a flange that projects away from the blister cavity and can be gripped by a user; (b) a sealing member that covers the receptacle portion and is hermetically sealed to a portion of the thermoplastic base member; (c) a liquid contact lens solution provided in the blister cavity; and (d) a single unworn contact lens arranged in the blister cavity and over the convex protrusion such that an anterior surface of the contact lens faces the sealing member.

Description

BLISTER PACKAGE FOR CONTACT LENSESCross-Reference to Related Applications

[0001] This application claims the earlier filing date benefit of U.S. Provisional Application No. 63 / 564,173, filed on March 12, 2024, the entirety of which is incorporated by reference herein.Background

[0002] Disposable contact lenses are typically packaged in single-use blister packages. The blister package can include a hard thermoplastic piece with a receptacle portion that can hold a single contact lens immersed in a sterile contact lens solution. The receptacle portion can be covered with a lidding material that is hermetically sealed to the thermoplastic piece around the receptacle portion.

[0003] Blister packages allow individual contact lenses to be stored in a sealed, sterile environment until use, at which point a user can break the seal, remove the contact lens from the packaging with their fingers, and place the lens directly on their eye. The user will typically then discard the opened blister package in the trash.

[0004] There have been various efforts to mitigate the environmental impacts of single-use blister packaging, e.g., by reducing the amount of materials that are part of the packaging or by making some of the materials recyclable. However, these types of modifications can create risks that the structural integrity of the package is reduced and thereby causes the hermetic seal to break during sterilization, shipping, storage, or handling, or that the lens can become displaced or folded in the cavity and is difficult for the user to remove and safely apply without too much handling.

[0005] As described in detail below, the inventors have developed an improved contact lens blister package that allows a user to easily remove a contact lens stored within the blister package and apply it to their eye without requiring the user to touch the inner (posterior) surface of the lens. The blister package can also reduce exposure of the lens to air while the blister package is sealed. The blister package is designed to have a relatively low profile, reduced weight, and good rigidity.

[0006] According to one aspect, this disclosure provides a contact lens blister package that includes a thermoplastic base member that has a receptacle portion that defines a blister cavity, and a flange that projects away from the blister cavity and can be gripped by a user. The receptacle portion has an interior surface that is recessed from a rim and includes a convex protrusion that projects into the blister cavity but does not extend to the rim. The thermoplastic base member having a weight that is in a range of from 0.40 g to 1.50 g. The blister package further includes a sealing member that covers the receptacle portion and is hermetically sealed to a portion of the thermoplastic base member, a liquid contact lens solution provided in the blister cavity, and a single unworn contact lens arranged in the blister cavity and over the convex protrusion such that an anterior surface of the contact lens faces the sealing member.

[0007] According to another aspect, this disclosure provides a contact lens blister package that includes a thermoplastic base member that has a receptacle portion that defines a blister cavity, the receptacle portion having an interior surface that is recessed from a rim, a sealing region that circumscribes the rim, and a flange that projects away from the blister cavity and can be gripped by a user. The thermoplastic base member having a weight that is in a range of from 0.40 g to 1.50 g. The blister package further includes a sealing member that covers the receptacle portion and is hermetically sealed to the sealing region of the thermoplastic base member, the sealing member having a convex protrusion that projects into the receptacle portion of the thermoplastic base member, a liquid contact lens solution provided in the blister cavity, and a single unworn contact lens arranged in the blister cavity such that a posterior surface of the contact lens faces the convex protrusion.

[0008] According to yet another aspect, this disclosure provides a contact lens blister package that includes a thermoplastic base member that has a receptacle portion that defines a blister cavity having a length dimension extending in a longitudinal direction that is larger than a width dimension extending in a lateral direction, and a flange that projects away from the blister cavity and can be gripped by a user. The receptacle portion has an interior surface that is recessed from a rim and includes a convex protrusion that projects into the blister cavity but does not extend to the rim, and the convex protrusion has a width dimension extending in the lateral direction that is larger than a length dimension extending in the longitudinal direction. The blister package further includes a sealing member that covers the receptacle portion and is hermetically sealed to a portion of the thermoplastic base member, a liquid contact lens solution provided in the blister cavity, and a single unworn contact lens arranged in the blister cavity and over the convex protrusion such that an anterior surface of the contact lens faces the sealing member. And the width dimension of the convex protrusion is at least half of a diameter of the contact lens.

[0009] Fig. 1A is a top view of a sealed contact lens blister package, and Fig. 1B is a cross-sectional side-view of the contact lens blister package; Fig. 2A is a perspective view of a contact lens blister package without a sealing sheet, Fig. 2B is a top view of the contact lens blister package, Fig. 2C is a side view of the contact lens blister package, Fig. 2D is a cross-sectional view of the contact lens blister package through cross-section A-A, and Fig. 2E is a cross-sectional view through a widthwise cross-section B-B of the contact lens blister package; Fig. 3A is a perspective view of a contact lens blister package without a sealing sheet, Fig. 3B is a top view of the contact lens blister package, Fig. 3C is a side view of the contact lens blister package, Fig. 3D is a cross-sectional view of the contact lens blister package through cross-section A-A, and Fig. 3E is a cross-sectional view through a widthwise cross-section B-B of the contact lens blister package; Fig. 4A is a cross-sectional side view of a contact lens blister package, and Fig. 4B is a top view that schematically shows features of the blister package; Figs. 5A-5E are schematic diagrams illustrating the plan view patterns for the protrusion area(s) of sealing members for various blister packages; Fig. 6 is a cross-sectional side view of a contact lens blister package; and Fig. 7A is a side view of a contact lens blister package according to another embodiment, and Fig. 7B is a top view of the contact lens blister package.

[0010] This disclosure provides an improved contact lens blister package that can be made with reduced materials while improving the ease in which a user can remove and apply the contact lens, while still maintaining the structural integrity of the packaging and the hermetic seal. For example, in embodiments, a convex protrusion can be formed in the receptacle portion which enables the lens to be easily removed from the package and improves the rigidity of the thermoplastic base member while allowing less thermoplastic material and less contact lens solution to be used.

[0011] Figs. 1A and 1B illustrate a contact lens blister package 10 that is sealed with an unused contact lens 40. Fig. 1A is a top view of the blister package 10 and Fig. 1B is a cross-sectional side view of the blister package 10 taken through line A-A in Fig. 1A.

[0012] The blister package 10 includes a receptacle portion 20 and a flange portion 25 that are formed from a thermoplastic base member 70. The thermoplastic base member 70 is made from a thermoplastic material. Based on considerations including, e.g., mass production and cost in manufacturing, ease of handling, strength, rigidity, durability, etc., the thermoplastic base member can be made from one or more synthetic resin materials that also have good chemical resistance. Suitable resins include, for example, fluororesin, polyamide, polyarylate, polyethylene, polyethylene terephthalate, polyvinyl chloride, amorphous polyolefin, polycarbonate, polysulfone, polybutylene terephthalate, polypropylene, polymethylpentene, etc., or combinations of the foregoing. The thermoplastic base member can be integrally molded by injection molding, vacuum forming, pressure forming, etc., The thermoplastic base member can also be made of composites of these synthetic resins, or of multilayered structures having layers respectively made from different ones of the resin materials.

[0013] A blister cavity 24 is formed in the receptacle portion 20 between a sealing member (e.g., sealing sheet 30) and an upper side of the thermoplastic base member 70. The thermoplastic base member 70 includes a recessed surface 72 that is recessed with respect to a rim 71 that circumscribes blister cavity 24. A sealing ring 87 extends around the rim 71, and sealing sheet 30 forms a hermetic seal with the sealing ring 87. In this case, the sealing sheet 30 covers the receptacle portion 20 and most of the flange portion 25.

[0014] At least an end part 32 of the sealing sheet 30 that covers the flange portion 25 is not sealed or adhered to the thermoplastic base member 70 so that a user can grip the flange portion 25 with one hand and peel back the sealing sheet 30 with the other hand to open the blister package 10. The blister package 10 can be connected to a plurality of like blister packages along its edges 91, by a perforated section of the sealing sheet 30, for example.

[0015] As shown in Fig. 1A, from a top view, the blister cavity has a perimeter formed by rim 71 that has an oval shape. The blister cavity 24 could alternatively be formed to be circular, elliptical, or polygonal, for example. The sealing sheet 30 covers the blister cavity 24 over length L1 and width W1, and over an area L1 x W1. By way of example, L1 can be 10 mm to 50 mm, from 20 mm to 40 mm, or from 30 mm to 35 mm. Designing the blister cavity with a sufficient length within these ranges can help prevent the contact lens from contacting the air bubble in the blister cavity even when the blister package is stored or transported at a 90 degree angle (i.e., where the length direction is oriented in the direction of gravity). W1 can be from 10 mm to 40 mm or from 15 mm to 25 mm. Fig. 1A shows a geometric center C of the blister cavity 24.

[0016] The blister cavity 24 includes an unused contact lens 40, which may be a hydrogel contact lens such as a silicone hydrogel contact lens, for example. The blister cavity 24 also includes an aqueous hydrating liquid 50, such as a saline solution or buffer solution, in which the contact lens 40 is submerged. The blister cavity also includes a bubble 60, such as an air bubble, that is formed when the blister cavity 24 is sealed.

[0017] The thermoplastic base member 70 can include bumps 77 on the flange portion 25, which can improve the user's grip on the flange portion 25 while the user peels the sealing sheet 30 to open the blister package 10. An underside or exterior side 75 of thermoplastic base member 70 can be formed with a lower pedestal 78, which supports the blister package 10 when it is rested on a level surface. The underside 75 can also include a level portion 76 formed in a relatively longitudinally (i.e., lengthwise) forward part of the blister package 10, which can likewise support the blister package 10 when it is rested on a level surface.

[0018] As can be seen in Fig. 1B, the thermoplastic base member 70 is formed so that, in cross-section, a longitudinally rearward portion (i.e., closer to flange portion 25) of the recessed surface 72 declines in a straight path from the rim 71 toward a longitudinally forward section of the receptacle portion 20 until it reaches a rearward inflection point 83, at which point an upwardly projecting surface 80a projects from the recessed surface 72 toward the sealing sheet 30 until it reaches a maximum height at peak portion 89. As used herein, the word "peak" refers to the highest part of the convex protrusion, and does not connote any particular shape. For example, the peak portion can be flat, curved, or pointed. Although Fig. 1B only illustrates a single peak portion 89 in cross-section, the convex protrusion 74 is formed with two peak portions that are laterally offset from the longitudinal axis and separated by a valley portion 90, similarly to the configuration shown in Fig. 2A. The peak portion 89 abuts an upwardly projecting surface 80b, which extends upwardly from forward inflection point 85. Thus, the inflection points 83, 85 form a base of the convex protrusion 74 from which upwardly projecting surfaces 80a, 80b extend towards peak 89. The valley portion 90 also abuts upwardly projecting surface 80a, 80b and has a lower height than the height h1 of the peak portion 89.

[0019] The base of the convex protrusion 74 has a width (based on the longest dimension that extends in a lateral direction of the blister cavity) of at least 50% of the diameter of the contact lens, from 70% to 100% of the diameter of the contact lens, or from 75% to 99% of the diameter of the contact lens, or from 80% to 98% of the diameter of the contact lens, or form 85% to 95% of the diameter of the contact lens, for example. The base of the convex protrusion 74 has a length (based on the longest dimension that extends in a longitudinal direction of the blister cavity) that is at least 40% of the diameter of the contact lens, or from 50% to 85% of the diameter of the contact lens, or from 60% to 75% of the diameter of the contact lens, for example. The width of the convex protrusion 74 can be larger than its length, such as from 1.1 to 3 times larger, from 1.2 to 2.5 times larger, or from 1.3 to 2 times larger, for example. In this embodiment, the convex protrusion 74 is positioned to overlap with the geometric center C of the blister cavity 24.

[0020] The convex protrusion 74 can also be formed so that the rearward inflection point 83 is closer in a direction normal to an inner surface of the sealing sheet 30 than the forward inflection point 85. The thermoplastic base member 70 forms a substantially level surface 97 at a bottom of the blister cavity 24, forward of inflection point 85, before joining with an opposite side of the recessed surface 72. Thus, as can be seen in Fig. 1B, the interior surface of the receptacle portion 20 has a cross-sectional shape in a longitudinal direction of the blister package that is not arc-shaped. In this embodiment, an underside 81 of the convex protrusion 74 is formed so that it is concave on the underside 75 of thermoplastic base member 70.

[0021] The lens 40 can be arranged in the blister cavity 24 so that the posterior side 44 of lens 40 (i.e., the concave side) faces the convex protrusion 74 and the anterior side 42 of the lens 40 faces generally upwardly toward an inner surface of the sealing sheet 30. The contact lens 40 has an optical zone 95 that is positioned relatively closer to the inner surface of sealing sheet 30 as compared to a periphery of the contact lens 40.

[0022] The convex protrusion 74 can be smaller than the lens 40, and lens 40 can be positioned in the blister cavity 24 so that, when the blister cavity is positioned in an upright position with the convex surface of the lens facing generally upwardly in the direction of gravity, the contact lens covers the entire convex protrusion 74, and likewise covers and is spaced away from the rearward inflection point 83 and the forward inflection point 85. The convex protrusion 74 has a contour that is different from a contour of a posterior surface 44 of the contact lens 40. The nearest distance from the inner surface of the sealing sheet 30 to the convex protrusion 74 is shown as d1. The convex protrusion 74 has a maximum height h1 that can be measured as vertical distance from a peak 89 of convex protrusion 74 to its lowest point, in this case the forward inflection point 85. The maximum height h1 of the convex protrusion 74 defines and corresponds with the extent to which it projects into the blister cavity 24. While Fig. 1B depicts h1 and d1 as extending through a longitudinal center axis of the blister package 10, it will be understood that the location of the peak(s) of the convex protrusion can vary, and in Figs. 2 and 3 embodiments the maximum height of the convex protrusion does not extend through the longitudinal center axis, and therefore likewise the nearest distance from the inner surface of the sealing sheet to the convex protrusion does not extend through the longitudinal center axis.

[0023] It has been discovered in connection with this invention that the formation of a convex protrusion in the blister package is beneficial because a user can more easily remove the contact lens by pinching the sides of the lens toward the convex protrusion. And since the lens is oriented so that the anterior of the lens is facing upward, the user can remove the lens and apply it to their eye without touching the inner surface of the lens. In general, the convex protrusion can have a height that is selected so that the convex protrusion projects into the blister cavity a distance that is less than a sagittal depth of the contact lens, such as from 25 % to 150 % of the sagittal depth of the contact lens, from 30% to 130% of the sagittal depth of the contact lens, from 40 % to 110% of the sagittal depth of the contact lens, or from 60% to 99% of the sagittal depth of the contact lens, for example. Thus, the height of the convex protrusion can either be smaller, larger, or the same as the sagittal depth of the contact lens. The height of the convex protrusion is measured from the lowermost point of the blister cavity, e.g., h1 is measured from level surface 97 in Fig. 1B. The convex protrusion can have a height h1 that is from 1 to 6 mm, such as from 2 mm to 5.5 mm, or from 3 mm to 5 mm, for example. The convex protrusion can also be configured in the blister cavity so that a nearest distance between the inner surface of the sealing sheet and the convex protrusion (e.g., d1 in Fig 1B), at a normal angle from the inner surface, is 6 mm or less or 3 mm or less, for example.

[0024] The convex protrusion also improves the rigidity of the receptacle portion, which enables less thermoplastic material to be used on the base member 70. As compared to a thermoplastic base member that has no protrusions and forms a blister cavity with a relatively flat bottom surface (or with a large radius of curvature), the thermoplastic base member 70 with a convex protrusion increases the section modulus and the moment of inertia of the cross-section, which increases stiffness and reduces torsional and other deformations in the base member. The ability to produce a more rigid base member in turn enables the production of a lighter and more environmentally sustainable package. For example, the thermoplastic base member can have a weight that is in a range of from 0.40 g to 1.50 g, 0.50 g to 1.05 g, from 0.60 g to 0.80 g, or from 0.50 g to 0.70 g, and can have an average wall thickness that is in a range of from 0.1 mm to 0.9 mm or from 0.4 mm to 0.7 mm. The blister package can also be made to have a relatively low profile, and a nearest distance between the inner surface of the sealing member and the optical zone of the contact lens, at a normal angle from the inner surface, can be 4 mm or less, 2 mm or less, or 1 mm or less, for example.

[0025] Both the convex protrusion and the air bubble take up volume in the blister cavity so that less aqueous fluid needs to be added to the blister cavity. As the air volume increases, the amount of liquid that is needed is reduced, but there is a corresponding increase in risk that the air will damage the lens, especially the optical zone of the lens (e.g., 95 in Fig. 1B). Conversely, as the air volume decreases (and the liquid volume increases), the liquid is more likely to come into contact with the sealing sheet during the process of sealing the blister package, which will wet the lower surface of the sealing sheet and can cause improper sealing. In general, the blister cavity can have a volume when sealed that is in a range of from 0.5 mL to 5 mL, from 1 mL to 3 mL, or from 1.5 mL to 2.5 ml, for example. The air bubble can occupy from 1% to 20% of the volume of the sealed blister cavity, or from 2% to 15% of the volume of the sealed blister cavity, for example. The amount of air can also be selected so that, when the blister package is in an upright state (i.e., the anterior surface of the lens is facing vertically upward), the air forms one or more bubbles that contact the inner surface of the sealing sheet over an air contact area that is from 1 to 50 % or from 2 to 25% of the area of the inner surface of the sealing sheet that covers the blister cavity.

[0026] The position of the air bubble can also be controlled. As can be seen in Fig. 1B, the air bubble 60 can be positioned in the blister cavity 24 forwardly of the optical zone 95 of lens 40 in a longitudinal direction of the blister package 40 and at a location where the bubble 60 does not contact the lens 40 when the blister package 10 is in an upright position. Alternatively, the bubble 60 could be positioned rearward of the optical zone 95 at a location where it does not contact the lens 40 when the blister package 10 is in an upright position.

[0027] The description in Figs. 1A-1B is intended to be general to the embodiments in Figs. 2-5, which incorporate the most of the features described above. Thus, a detailed explanation of like features is omitted in the description below.

[0028] Figs. 2A-2D show various views of a blister package 210. In these figures, the blister package 210 is shown without a sealing sheet, without a contact lens, and without contact lens fluid for purposes of illustration. As shown in these figures, the thermoplastic base member 270 forms a receptacle portion 220 and flange portion 225. The receptacle portion 220 has a blister cavity 224 in which an unused contact lens can be placed. The receptacle portion includes rim 271, sealing ring 287, and recessed surface that is recessed from rim 271. Figs. 2A and 2C illustrate that the blister package 210 can include side flanges 263. Fig. 2C illustrates that the underside of thermoplastic base member 270 includes pedestal 278 and a substantially level portion 276 that are together configured to support the blister package 210 on a level surface.

[0029] The receptacle portion 220 includes convex protrusion 274 that has upwardly projecting surfaces 280a, 280b that respectively project upwardly from rearward inflection point 283 and forward inflection point 285 into the blister cavity 224. Here also, the convex protrusion 274 is positioned to overlap the geometric center of the blister cavity 224. In this embodiment, the convex protrusion 274 includes two peaks 289a, 289b that are separated in the widthwise direction by a depressed region 290 that is depressed relative to the peaks 289a, 289b (i.e., a valley). As shown in Fig. 2E, the convex protrusion 274 has an "M" shape. In other embodiments, the convex protrusion can have only a single peak or can have more than two peaks. On an underside of the thermoplastic base member 270, the convex protrusion 274 has a convex underside 281 with corresponding contours. The convex protrusion 274 has side walls 288a, 288b flanking the peaks 289a, 289b in the widthwise direction, and which project upwardly from side inflection point 282a, 282b. A side level portion 294 separates the convex protrusion from the recessed surface 272 on the widthwise sides of the blister package 210.

[0030] In this embodiment, the receptacle portion 220 can include elongate concave recesses or grooves 266a, 266b that are formed in an arcuate shape in plan view in the recessed surface 272 along the sides of the convex protrusion 274.

[0031] As shown by the stippling in Figs. 2A-2C, at least a portion 272a of the recessed surface 272 that defines blister cavity 224 can be embossed or otherwise formed with surface features that increase the surface roughness. Embossing or increasing the surface roughness of the inner surface defining the blister cavity can help prevent the contact lens from adhering to the inner surface and deforming. This embossing or surface roughness can optionally be applied to the entire inner surface of the receptacle portion that defines the blister cavity or to only part of inner surface. For example, the embossing can be applied to at least 40% of the inner surface area of the thermoplastic base member that defines the blister cavity, such as from 50% to 90%, or from 60% to 85%, for example. As shown in Fig. 2A, in this embodiment, a portion 272b of the recessed surface 272 extending below rim 271 is not embossed or is otherwise is made to have a smoother surface than surface portion 272a. For example, portion 272b can have a mirror-finish surface. Portion 272b is an upper part of the receptacle portion, adjacent to rim 271, and can extend below the rim 271 a distance of 0.5 mm to 4 mm, from 1 mm to 3 mm or from 1.25 to 2 mm, for example. A smooth finish on this portion 272b, in particular a mirror-finish, can cause the meniscus formed by the liquid to flatten (i.e., larger radius of curvature) so that the meniscus has a lower height than it would if the portion 272b were embossed. This helps prevent wetting of the lower surface of the sealing sheet during the sealing process, which can cause improper sealing as explained above. And, since the height of the blister cavity rim should generally be higher than the top of the liquid meniscus, the smooth finish on the upper part of the blister cavity enables the thermoplastic base member to have a lower overall height for a given volume of liquid since the meniscus is flattened. This enables the production of a thinner blister package with a lower overall basis weight, which uses less plastic material.

[0032] The surface with the smooth finish can have a surface roughness of from 0.8 μm or less, from 0.7 μm or less, such as from 0.01 μm to 0.6 μm, from 0.02 μm to 0.55 μm, or from 0.03 μm to 0.5μm, for example. The embossed surface can have a surface roughness that is greater than 1.0 μm, greater than 1.2 μm, such as from 1.4 μm to 2.5 μm, for example. As used herein, surface roughness is an average surface roughness of the surface as measured by shape measuring laser microscope VK-X200 (Keyence Corporation).

[0033] In this embodiment, the convex protrusion 274 is not embossed or otherwise is made to have a smoother surface than surface portion 272a, which can make it easier for the user to remove the lens from the package. However, in other embodiments, the convex protrusion 274 could be embossed. On the flange portion 225, to improve grip, the external surface 233 is not embossed or made to includes features that impart surface roughness (with the exception of bumps 277, which are much larger than the surface features formed by embossed surface portion 272a).

[0034] The convex protrusion 274 has a length l2 that extends from the rearward inflection point 283 to the forward inflection point 285, a width w2 that extends between the side inflection points 282a, 282b, and a height h2. The relationship of the height h2 or width w2 to the lens and / or sealing sheet in the package, and the relationship of the width w2 to the length l2, is the same as described above in connection with Fig 1, and the various dimensions of the blister package components can be the same as described above.

[0035] Figs. 3A-3D illustrate another embodiment of a blister package 310 that is shown without a sealing sheet, without a contact lens, and without contact lens fluid for purposes of illustration. The blister package 310 is formed similarly to the embodiment in Figs. 2A-2D with additional surface features in the receptacle portion as explained below.

[0036] The blister package 310 has a thermoplastic base member 370 that forms a receptacle portion 320 with a blister cavity 324 for holding an unused contact lens. As above, a convex protrusion 374 projects from a recessed surface 372. The convex protrusion 374 includes two peaks 389a, 389b and a depressed portion 390, but could alternatively only include a single peak or could include more than two peaks. Here also, the convex protrusion 374 is positioned to overlap the geometric center of the blister cavity. The convex protrusion 374 includes length l3, width w3, and height h3 dimensions that are have the same relationships as described above in connection with other embodiments. The receptacle portion 320 also includes elongate concave recesses or grooves 366a, 366b that are formed in an arcuate shape in plan view in the recessed surface 372 along the sides of the convex protrusion 374.

[0037] In this embodiment, the receptacle portion 320 includes three elongate grooves. Rearward elongate grooves 367a, 367b extend rearward from a rear base of the convex protrusion 374 and are depressed with respect to the surrounding surface. Forward elongate groove 369 extends forwardly from a front base of the convex protrusion 374. As shown in Fig. 3B the grooves can extend lengthwise generally in the longitudinal direction of the blister package 310 and can be longer than the length l3 of the convex protrusion 374. As shown in Fig. 3C, on an underside of the thermoplastic base member 370, the grooves can form corresponding projections. The grooves can be dimensioned and positioned so that the grooves overlap the contact lens in plan view and at least a portion of each groove extends beyond the edge of the contact lens when the lens is sealed in the blister cavity. The addition of grooves in the receptacle portion can improve the rigidity of the receptacle portion, which can enable the production of a blister package with less thermoplastic material. The grooves also help prevent the lens from adhering to the inner surface of the receptacle portion. The grooves also allow the liquid to spread sufficiently underneath the lens when filling the blister cavity, which will push air out from under the lens and can prevent air bubbles from collecting under the lens (which may deform the lens). The recessed surface 372 is not embossed in this embodiment, although the invention contemplates that all or a portion of recessed surface 372 can be embossed in a similar manner described above in connection with Fig. 2.

[0038] Fig. 4A illustrates a blister package 410 that is configured similarly to the above embodiments but with a variation in the shape of the sealing member. As can be seen, the blister package 410 holds a lens 440 that is submerged in contact lens fluid 450. The blister package includes a sealing sheet 430 that seals the contents of the blister package 410. The sealing sheet 430 includes a peripheral region 432 that extends along a periphery of the blister cavity and a central region 433. As can be seen, the peripheral region 432 of the sealing sheet 430 is bulged outwardly with respect to the central region 433. The air bubble 460 can be positioned at the periphery of the blister cavity so that it fits under the bulging peripheral region 432 of the sealing sheet 430 when the blister package 410 is in an upright position, which can help prevent (i) the contact lens from being exposed to air; (ii) at least the optical zone of the contact lens from being exposed to air; (iii) the contact lens from touching the film that surrounds and defines the air bubble 460; and / or (iv) at least the optical zone of the contact lens form touch the film that surrounds the air bubble 460.

[0039] Fig. 4B is a plan view of blister package 410 that schematically illustrates the peripheral region 432 that protrudes or bulges outwardly and the central region 433 that is recessed relative to the peripheral region 432. As can be seen, in this embodiment, the bulging peripheral region 432 surrounds the central region 433. However, any suitable pattern of creating one or more relatively protruding areas of the sealing member can be used to facilitate a desirable positioning of the air bubbles.

[0040] Other examples of suitable patterns are shown in Figs. 5A-5E, which are plan views of blister package 510 showing areas of the sealing member 532 that protrude outwardly relative to other areas 533 of the sealing member. For example, in Fig. 5A the protruding area 532 is located on a peripheral area of the blister cavity that is located opposite the flange, and the relatively recessed area 533 is located on the side nearest the flange. In Fig. 5B the protruding areas 532 are positioned on lateral opposite sides of an elongate relatively recessed area 533. In Fig. 5C, the protruding area 532 is located on a peripheral of the blister cavity nearest the flange, and the relatively recessed area 533 is located on the side opposite the flange. In Fig. 5D, the protruding area 532 borders the relatively recessed area 533 on three sides, and the center of relatively recessed area 533 is offset laterally from the longitudinal axis. In Fig. 5E, there are two relatively recessed areas 533 located at opposite longitudinal end areas of the blister cavity and the protruding area 532 separates the recessed areas 533 in the center of the blister cavity and occupies both lateral end areas of the blister cavity.

[0041] Fig. 6 illustrates a blister package 610 that is configured similarly to the above embodiments but is shaped so that it tilts upward in a resting position. Here also, the blister package 610 holds a lens 640 that is submerged in contact lens fluid 650 and is sealed with a sealing sheet 630. The blister package includes a flange portion 625 with a downwardly projecting tail 617 that contacts level surface 646 when the blister package 610 is rested in an upright position. The underside 676 of the receptacle portion further includes a forward pedestal 619 that also contacts level surface 646 when the blister package 610 is rested in an upright position. The shapes and dimensions of the tail 617 and the forward pedestal 619 can be selected so that plane 645, in which the sealing sheet 630 extends, forms a non-zero angle with respect to flat surface 646. For example, the angle can be an acute angle α, which can be 2° to 45°, from 3° to 25° or from 5° to 15°, for example. In this embodiment, as can be seen, the blister package 610 is configured so that the forward end is tilted upwardly with respect to the rear end. The use of pedestal structures and / or a downwardly projecting tail are not strictly necessary to achieve the desired degree of tiling, and a desired degree of tiling can be achieved in other ways, such as designing the shape of the blister cavity to impart a tilt. Since the bubble 660 is positioned forwardly of the lens 640 in this embodiment, the tilted configuration causes the bubble 660 to be located as far away as possible from the lens 640 when the blister package 610 is in an upright position, which reduces contact of the air with the lens. Alternatively, the blister package could be arranged so that the rear end is tilted upwardly with respect to the forward end, and the air bubble could be positioned rearwardly of the contact lens 640.

[0042] Figs. 7A and 7B illustrate an embodiment of a contact lens blister package in which a convex protrusion is formed as part of the sealing member. The contact lens blister package 700 includes a thermoplastic base member 770 that forms a bowl 773 with an interior concave surface 772. The sealing member 730 includes a dome-shaped projection 765 and a sealing ring 787 that circumscribes the dome and is configured to form a hermetic seal with a corresponding part of the thermoplastic base member 770. The dome-shaped projection 765 supports an unused contact lens 740 so that a posterior surface of the lens 740 faces the dome-shaped projection 765. The dome-shaped projection includes a plurality of holes 768 and a larger center hole 772 positioned at the apex of the dome. The dome-shaped projection 765 can be formed integrally with or otherwise bonded to the sealing member 730, which can be made of a laminate of metal foil with one or more plastic sheets, for example. The dome-shaped projection is configured to protrude into the bowl 773 when the thermoplastic base member 770 is sealed to the sealing member 730 as shown in Fig. 7B. The sealing member 730 can be sealed to the thermoplastic base member 770 to form a blister cavity 724 that contains the contact lens 740 and contact lens fluid (not pictured).

[0043] A user can open the blister package 700 by peeling one side of the thermoplastic base member 770 from the sealing member 730 to expose the lens 740. Here also, the lens 740 is positioned so that the user can remove the lens by gripping the anterior side of the lens 740 and can apply it onto their eye without needing to touch the posterior surface of lens 740. An interior of the dome shaped projection 765 can have a cavity that is at least partially empty or filled with air even when the blister package 700 is sealed. The holes 768 and 772 in the dome-shaped projection 765 are designed to absorb the contact lens fluid when the blister package 700 is opened to reduce leakage of the fluid. The holes 768 and 772 also enable the production of a blister package with a reduced weight.

[0044] Although the disclosure herein refers to certain example embodiments, those embodiments are presented by way of example and not by way of limitation. The intent of the foregoing detailed description, although discussing example embodiments, is to be construed to cover all modifications, alternatives, and equivalents of the embodiments as may fall within the scope of the invention as defined by the claims.

Claims

1. A contact lens blister package comprising: (a) a thermoplastic base member that has (i) a receptacle portion that defines a blister cavity, the receptacle portion having an interior surface that is recessed from a rim and includes a convex protrusion that projects into the blister cavity but does not extend to the rim, the thermoplastic base member having a weight that is in a range of from 0.40 g to 1.50 g; and (ii) a flange that projects away from the blister cavity and can be gripped by a user; (b) a sealing member that covers the receptacle portion and is hermetically sealed to a portion of the thermoplastic base member; (c) a liquid contact lens solution provided in the blister cavity; and (d) a single unworn contact lens arranged in the blister cavity and over the convex protrusion such that an anterior surface of the contact lens faces the sealing member.

2. The contact lens blister package according to claim 1, wherein the convex protrusion has a height that is from 25 % to 150 % of a sagittal depth of the contact lens as measured from a lowermost surface of the blister cavity.

3. The contact lens blister package according to claim 1, wherein the convex protrusion has a height that is from 60 % to 99 % of a sagittal depth of the contact lens as measured from a lowermost surface of the blister cavity.

4. The contact lens blister package according to claim 1, wherein the convex protrusion has a height that is more than 1 mm as measured from a lowermost surface of the blister cavity.

5. The contact lens blister package according to claim 1, wherein the convex protrusion has a width dimension, extending laterally in the blister cavity, that is at least half of a diameter of the contact lens.

6. The contact lens blister package according to claim 1, wherein the convex protrusion has a width dimension extending laterally in the blister cavity and a length dimension extending longitudinally in the blister cavity, and wherein the width dimension of the convex protrusion is greater than the length dimension of the convex protrusion.

7. The contact lens blister package according to claim 1, wherein the convex protrusion has (i) a first projecting surface that projects from a first inflection point on the interior surface of the receptacle portion, and (ii) a second projecting surface that projects from a second inflection point on the interior surface of the receptacle portion, and wherein the first inflection point is located closer to the sealing member than the second inflection point in a direction normal to an inner surface of the sealing member.

8. The contact lens blister package according to claim 7, wherein the first inflection point is located relatively nearer to the flange in a longitudinal direction of the blister package than the second inflection point.

9. The contact lens blister package according to claim 1, wherein the convex protrusion has at least two peaks that are separated by a valley portion.

10. The contact lens blister package according to claim 1, wherein the convex protrusion is positioned to overlap a geometric center of the blister cavity.

11. The contact lens blister package according to claim 1, wherein a nearest distance between an inner surface of the sealing member and the convex protrusion, at a normal angle from the inner surface, is 6 mm or less.

12. The contact lens blister package according to claim 1, wherein a nearest distance between an inner surface of the sealing member and an optical zone of the contact lens, at a normal angle from the inner surface, is 4 mm or less.

13. The contact lens blister package according to claim 1, wherein an exterior side of the convex protrusion has a concave shape.

14. The contact lens blister package according to claim 1, wherein the interior surface of the receptacle portion has one or more grooves.

15. The contact lens blister package according to claim 1, wherein the one or more grooves are elongate and extend in a lengthwise direction of the blister package from a base of the convex protrusion.

16. The contact lens blister package according to claim 1, wherein the sealing member has a peripheral region that covers a periphery of the blister cavity and a central region that covers a center of the blister cavity, and wherein the peripheral region of the sealing member is bulged outwardly from the blister cavity relative to the central region of the sealing member.

17. The contact lens blister package according to claim 1, wherein the blister package is configured to have an upright resting position when an exterior of the thermoplastic base member is rested on a level surface, and wherein, in the upright resting position, a plane in which an upper surface of the sealing member extends forms an acute angle with the level surface.

18. The contact lens blister package according to claim 17, wherein the blister package is configured so that, in the upright resting position, the acute angle is in a range of from 2° to 45°.

19. The contact lens blister package according to claim 1, wherein the blister cavity further includes air, and an inner surface of the sealing member is in contact with both the air and the liquid contact lens solution, and wherein the air occupies from 1% to 20% of a volume of the blister cavity.

20. The contact lens blister package according to claim 19, wherein the air forms an air bubble that is positioned in the blister cavity on a side of the contact lens that is farther from the flange.

21. The contact lens blister package according to claim 19, wherein an inner surface of the sealing member has a first area that covers the blister cavity, and the air contacts the inner surface over an air contact area, and wherein, when the contact lens blister package is in an upright state, the air contact area is from 1 to 50 % of the first area.

22. The contact lens blister package according to claim 19, wherein an inner surface of the sealing member has a first area that covers the blister cavity, and the air contacts the inner surface over an air contact area, and wherein, when the contact lens blister package is in an upright state, the air contact area is from 2 to 25 % of the first area.

23. The contact lens blister package according to claim 1, wherein an exterior surface of the receptacle portion has one or more protrusions.

24. The contact lens blister package according to claim 1, wherein the convex protrusion has a contour that is different from a contour of a posterior surface of the contact lens.

25. The contact lens blister package according to claim 1, wherein the thermoplastic base member has a weight that is in a range of from 0.40 g to 1.05 g.

26. A contact lens blister package comprising: (a) a thermoplastic base member that has (i) a receptacle portion that defines a blister cavity, the receptacle portion having an interior surface that is recessed from a rim; (ii) a sealing region that circumscribes the rim; and (iii) a flange that projects away from the blister cavity and can be gripped by a user, the thermoplastic base member having a weight that is in a range of from 0.40 g to 1.50 g; (b) a sealing member that covers the receptacle portion and is hermetically sealed to the sealing region of the thermoplastic base member, the sealing member having a convex protrusion that projects into the receptacle portion of the thermoplastic base member; (c) a liquid contact lens solution provided in the blister cavity; and (d) a single unworn contact lens arranged in the blister cavity such that a posterior surface of the contact lens faces the convex protrusion.

27. The contact lens blister package according to claim 26, wherein the convex protrusion is shaped like a dome.

28. The contact lens blister package according to claim 26, wherein the convex protrusion is attached to an interior surface of the sealing member.

29. The contact lens blister package according to claim 26, wherein the convex protrusion includes one or more holes that can drain the liquid contact solution and reduce leakage when a user opens the sealing member to remove the contact lens.

30. The contact lens blister package according to claim 26, wherein the thermoplastic base member has a weight that is in a range of from 0.40 g to 1.05 g.

31. A contact lens blister package comprising: (a) a thermoplastic base member that has (i) a receptacle portion that defines a blister cavity having a length dimension extending in a longitudinal direction that is larger than a width dimension extending in a lateral direction, the receptacle portion having an interior surface that is recessed from a rim and includes a convex protrusion that projects into the blister cavity but does not extend to the rim, the convex protrusion having a width dimension extending in the lateral direction that is larger than a length dimension extending in the longitudinal direction; and (ii) a flange that projects away from the blister cavity and can be gripped by a user; (b) a sealing member that covers the receptacle portion and is hermetically sealed to a portion of the thermoplastic base member; (c) a liquid contact lens solution provided in the blister cavity; and (d) a single unworn contact lens arranged in the blister cavity and over the convex protrusion such that an anterior surface of the contact lens faces the sealing member, and wherein the width dimension of the convex protrusion is at least half of a diameter of the contact lens.

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