JP7531064B2 - Pre-packaged contact lenses - Google Patents

Description

The present invention relates to packaged contact lenses. More specifically, but not exclusively, the present invention relates to a sealed blister package that includes a base member and a sealing member joined to the base member to form a blister cavity arranged to hold an unworn contact lens and an aqueous solution.

Soft contact lenses, such as hydrogel and silicone hydrogel contact lenses, are stored in an aqueous solution to keep them hydrated and ready for use. Typically, contact lenses are individually packaged in sealed blister packages. Blister packages provide a suitable sterile and protective environment for unused contact lenses, allowing them to be shipped and stored unhindered until needed by an end user. A conventional blister package comprises a base member made of a plastic material and a sealing member that is sealed to the base member to form a blister cavity. A typical blister package of the prior art has a blister cavity in which an unused contact lens is stored and a handle that can be held between the user's thumb and fingers. The blister cavity is often configured as a well in the base member, which has the capacity to hold a volume of contact lens packaging solution and the contact lens itself.

U.S. Pat. No. 4,691,820 to Martinez discloses a molded blister package for storing and dispensing hydrophilic contact lenses, comprising a base portion including a cavity surrounded by a protruding flange, and a cover sheet sealed to the flange and surrounding the cavity.

EP 1752058 discloses a contact lens storage blister package that includes a base member that includes a gripping area that includes a curved upper surface shaped to receive the thumb and a curved bottom surface shaped to receive the inner curve of the index finger.

International Patent Application No. 2021260353 discloses a blister package for contact lenses comprising a base sheet and a sealing sheet, one comprising a bowl portion and the other comprising a dome portion.

U.S. Patent No. 10,390,593 discloses a blister package including a thermoplastic base member having a gripping portion, a distal end region, a first side region extending from the proximal end region to the distal end region, a second side region opposite the first side region, and a cavity configured to contain a packaging solution and a contact lens.

Japanese Patent No. 2006016049 discloses a blister pack for contact lenses that includes a container body having a hemispherical recessed section, a flange section extending to its outer periphery, and a support section.

International Patent Application No. 03/039969 discloses a package for contact lenses in which the total volume of the package and the internal volume of the lens-holding cavity within the package are minimized.

It is understood that the disclosure of U.S. Pat. No. 1,0390,593 is the immediate prior art. The advantage of the present invention over the disclosure of U.S. Pat. No. 1,0390,593 is that the base member has a female interlocking feature and a male interlocking feature configured to interlock with a corresponding male interlocking feature on a substantially equivalent base member and to mechanically secure the base member to the substantially equivalent base member to form a base member assembly.

During use, a user typically removes the sealing member from the plastic base member, removes the unworn contact lens, and discards the empty blister package in a trash can, in which case the packages will not be recycled. Since plastic recycling processes require the objects to have dimensions larger than specified minimum dimensions, and if these requirements are not met, the recycling line will have a step to remove these smaller objects and not recycle them, each individual plastic base member is too small to be recycled as plastic at a recycling center. That is, small pieces of plastic such as individual plastic base members cannot be recycled due to their small size, even if they are made of recyclable plastic. The material from which the base member of the blister package is made is recyclable, and therefore the above problem needs to be addressed so that contact lens packages can be recycled in the same manner as larger plastic articles.

The technical effect of configuring the female interlocking features to interlock with corresponding male interlocking features on a substantially equivalent base member and mechanically secure the base member to the substantially equivalent base member to form a base member assembly is to form an object large enough to be recycled at a recycling center. The technical problem addressed is how to reduce the environmental impact of the base members disclosed in U.S. Pat. No. 1,039,0593.

U.S. Pat. No. 4,691,820 European Patent No. 1752058 International Patent Application No. 2021260353 U.S. Pat. No. 1,039,0593 Japanese Patent Application No. 2006016049 International Patent Application No. 03/039969

According to a first aspect, the present invention provides a hermetically sealed blister package having the features set out in claim 1 below. Preferred but optional features of the hermetically sealed blister package are set out in dependent claims 2 to 12.

The female and male interlocking features allow multiple base members to be mechanically secured together to form a base member assembly that can be formed by a user when the user is ready to discard the blister pack. A base member assembly can be formed that is of the size and weight required for recycling centers to recycle, thereby allowing the base members to be recycled, which further reduces the environmental impact of the blister pack as these members are not discarded and sent to landfills.

As used herein, the term "substantially equivalent base member" encompasses equivalent base members as well as base members having differences that are not material to the subject matter of the present invention.

The blister well can have a concave inner surface depending from the upper surface of the base member and a convex outer surface depending from the lower surface of the base member. The blister well can have a sidewall.

The flange may be planar. The flange may have a thickness of 0.3 mm to 1.0 mm. The flange may have a thickness of 0.4 mm to 0.7 mm. The flange may have a thickness of 0.5 mm. The flange may have a thickness of 0.55 mm.

The base member may have an outer edge that is symmetrical about a line extending through the center of the handle and the center of the blister well in a plan view.

The sealing member may be a laminated structure including a foil and one or more layers of plastic material. The sealing member may be made of a plastic material. The sealing member may be made of a foil. The thickness of the sealing member may be from about 50 micrometers to about 100 micrometers. The sealing member may be printed with words and numbers. The sealing member may have a thickness of from 60 micrometers to 70 micrometers. Suitable materials for the sealing member may be available from AMCOR (Switzerland). The sealing member may have an area equal to the area of the top surface of the base member. The sealing member may have an area greater than the area of the top surface of the base member. The sealing member may have an area less than the area of the top surface of the base member.

The blister well can be hemispherical or substantially hemispherical in shape. The blister well can be irregularly shaped. The blister well can be cylindrical in shape. The blister well has a wall, referred to herein as a sidewall. The sidewall can include a flat portion that can be adjacent to a handle. The blister well can have a perimeter.

The base member may include two or more stabilizing legs. The base member may include three or more stabilizing legs. The stabilizing legs may extend downwardly from a lower surface of the base member. The stabilizing legs may be vertically aligned with a periphery of the blister well. The stabilizing legs may extend downwardly from a lower surface of the base member to extend to the furthest extent of the blister well. The stabilizing legs may extend downwardly from a lower surface of the base member to extend further than the furthest extent of the blister well. The stabilizing legs may extend far enough to provide stability to the base member when the base member is placed face up on a flat surface. The stabilizing feet can still provide a blister package that is stable when placed face up on a flat surface without requiring the handle formed by the flange to act as a stabilizing support, while still allowing for a reduction in the weight of the blister package to be achieved while maintaining sufficient structural integrity to avoid problematic deformation during shipping and storage, and sufficient structural integrity to adequately protect the contact lens.

The base member may include at least two side tabs. The side tabs may be positioned on either side of the blister well and extend downwardly from the top surface of the base member. The side tabs may have a height of 2.0 mm to 4.0 mm. The side tabs may have a height of 3.0 mm to 4.0 mm. The side tabs may have a height of 3.0 mm. The side tabs may have a height of 4.0 mm. The side tabs may have a length of 6.0 mm to 10.0 mm along the top surface of the flange. The side tabs may have a length of 7.0 mm to 9.00 mm along the top surface of the flange. The side tabs may have a length of 8.0 mm along the top surface of the flange. The side tabs may increase the structural integrity of the base member. The side tabs may reduce the possibility of problematic deformation of the base member. The side tabs may increase the stability of the base member when placed face up on a flat surface. The side tabs may provide a gripping area.

The female interlocking feature may comprise a hole in the flange of the base member. The hole in the flange of the base member may be square. The hole in the flange of the base member may be oval. The hole in the flange of the base member may be circular. The hole in the flange of the base member may be key-shaped. The female interlocking feature may be located at a greater distance from the periphery of the blister well than from the periphery of the handle. The female interlocking feature may be a hole extending through the flange. The hole may be located closer to the outer edge of the handle than the center of the blister well. The hole may be located at a distance of 10.0 mm to 30.0 mm from the center of the blister well. The hole may be located at a distance of 20.0 mm from the center of the blister well. The hole may be a slot having a width of 0.5 mm to 1.5 mm. The hole may be a slot having a width of 1.1 mm. The hole may be a slot having a width of 1.0 mm. The hole may be a slot having a width of 0.9 mm. The width of the hole may be the shorter dimension of the slot. The hole may be a slot having a length of 8.0mm to 12.0mm. The hole may be a slot having a length of 9.0mm to 11.0mm. The hole may be a slot having a length of 9.0mm. The hole may be a slot having a length of 10.0mm. The side or length of the hole may be parallel to the end of the handle. The length of the hole may be perpendicular to the longitudinal axis of the base member. The length of the hole may be parallel to the longitudinal axis of the base member. The length of the hole may be between 5 degrees and 45 degrees from perpendicular to the longitudinal axis of the base member. The female interlocking feature may be a hole that includes a notch in its edge. The hole may include a notch in its longest side. The notch may be centrally located along the length of the hole. The notch may be eccentrically located along the length of the hole. The notch in the edge of the hole may protrude from 0.5mm to 1.5mm. The notch in the edge of the hole can protrude from the hole by 1.1 mm. The notch in the edge of the hole can have a length of 2.0 mm to 3.0 mm. The notch in the edge of the hole can have a length of 2.7 mm. The notch can have a square shape. The notch can have a curved shape. The notch can have an oval shape. The notch can have a circular shape. The female interlocking feature can include only one hole extending through the flange. The female interlocking feature can include more than one hole extending through the flange. One or more holes in the handle can reduce the weight of the base member.

The blister package can contain a contact lens. The contact lens can be a hydrogel contact lens. The contact lens can be a silicone hydrogel contact lens.

The base member can be made from a recyclable thermoplastic material.

The sealing member is hermetically sealed to the base member. The sealing member can be hermetically sealed to the base member at a sealing region. The sealing region can be substantially annular when viewed in a top plan view. The sealing region can be on the base member. The sealing region can be non-annular when viewed in a top plan view (i.e., from above). The sealing region can have an apex adjacent to the handle of the base member. As used herein, an apex is understood to be the part of a geometric shape that has the sharpest turn relative to the rest of the shape. For example, an apex can be a point where two or more line segments intersect. However, it can be understood that if multiple line segments are curved, the intersection points can be intermixed such that there is an area that has a smaller radius than the portion of the line segments located away from the apex. A sealing region with an apex reduces the separation force required to separate the sealing member from the sealing region. If only a low separation force is required to separate the sealing member from the sealing region, the base member can have less structural integrity, i.e., be less rigid (and therefore lighter), without compromising the protection that the blister package provides to the contact lens.

The sealing area can have a width of 1.0 mm to 4.0 mm. The sealing area can have a width of 1.0 mm to 2.5 mm. The sealing area can have a width of 2.0 mm. The sealing area can have a width of 1.0 mm. The sealing area can have a width of 1.7 mm. The smaller width of the sealing area can improve the ease of opening the blister pack while maintaining an airtight seal.

The blister well may hold a volume of contact lens packaging solution from 0.4 mL to 1.6 mL. The blister well may hold a volume of contact lens packaging solution from 0.6 mL to 1.4 mL. The blister well may hold a volume of contact lens packaging solution from 0.8 mL to 1.2 mL. The blister well may hold a volume of contact lens packaging solution from 0.6 mL. The blister well may hold a volume of contact lens packaging solution from 0.7 mL. The blister well may hold a volume of contact lens packaging solution from 0.8 mL. The base member may have a length of 40.0 mm to 50.0 mm and a width of 25.0 mm to 35.0 mm. The base member may have a length of 40.0 mm to 50.0 mm. The base member may have a length of 43.0 mm to 47.0 mm. The base member may have a length of 46.0 mm. The base member may have a length of 46.31 mm. The base member may have a width of 25.0 mm to 35.0 mm. The base member may have a width of 27.0 mm to 33.0 mm. The base member may have a width of 28.0 mm to 30.0 mm. The base member may have a width of 29.0 mm. The base member may have a weight of 2.25 g or less. The base member may have a weight of 1.0 g or less. The base member may have a weight less than 0.90 g. The base member may have a weight less than 0.80 g. The base member may have a weight less than 0.72 g. The base member may have a weight from 0.40 g to 0.72 g. In one example, the base member has a weight of 0.70 g. The base member may have a weight of 0.72 g. The base member may have a weight less than 0.70 g. The base member may have a weight less than 0.65 g. Reducing the weight of the blister package can further reduce the environmental impact of the blister pack by reducing the amount of fossil fuels required to transport the blister package.

The blister well can have a depth of 5.0 mm to 8.0 mm at its center. The blister well can have a depth of 6.0 mm to 7.0 mm at its center. The blister well can have a depth of 6.0 mm at its center. The blister well can have a depth of 6.7 mm at its center.

The flange of the base member can have a thickness that is equal to or less than the thickness of the sidewall of the blister well. The flange of the base member can have a thickness that is equal to or less than 95% of the thickness of the sidewall of the blister well. The flange of the base member can have a thickness that is equal to or less than 90% of the thickness of the sidewall of the blister well. The flange of the base member can have a thickness that is equal to or less than 85% of the thickness of the sidewall of the blister well.

The sidewalls of the blister wells can have a thickness of 0.3 mm to 1.0 mm. The sidewalls of the blister wells can have a thickness of 0.5 mm to 0.7 mm. The sidewalls of the blister wells can have a thickness of 0.6 mm. It is believed that if the sidewalls of the blister wells are too thin, evaporation through the plastic can occur, causing changes in the packaging solution, potentially resulting in the contact lens drying out and becoming unusable. The thickness of the blister well sidewalls can allow for a reduction in the weight of the blister package while still remaining thick enough to avoid any evaporation of the contact lens packaging solution, thereby allowing the lens to remain hydrated until use by the contact lens wearer.

The blister well sidewalls can facilitate retention of the base member within the base member carrier of a heat sealing system or machine. It can be appreciated that slots can be provided within the base member carrier to receive one or more sidewalls to provide a physical fit between the base member and the base member carrier to ensure that the top surface of the base member remains stable and parallel to the surface of a heat sealing die that is pressed against the sealing member over the top surface of the base member to seal the sealing member to the base member.

The flanges of the base member may have a stiffness of 50,000 psi- ^mm2 to 150,000 psi- ^mm2 . The flanges of the base member may have a stiffness of 60,000 psi- ^mm2 to 90,000 psi- ^mm2 . The flexural modulus of the base member material may be 230,000 psi to 276,000 psi. The stiffness of the base member is calculated by multiplying the flexural modulus of the base member material by the square of the flange thickness in mm. The flexural modulus may be measured using conventional equipment such as that supplied by Instron (Norwood, Massachusetts, USA) or may be provided by the plastics manufacturer as part of the plastics technical data. The flexural modulus may be used as determined by ISO 178 test method.

The flange includes a male interlocking feature. The male interlocking feature may include a clip, a barb, or a combination thereof. The male interlocking feature may include a latch. The latch may be configured to interlock with the female interlocking feature. The male interlocking feature may be a protrusion. The male interlocking feature may be a protrusion on an outer end of the handle. The male interlocking feature may be located on a gripping portion of the base member. The protrusion may have a length along the flange of 9.0 mm to 11.0 mm. The protrusion may have a length along the flange of 9.8 mm. The protrusion may extend from the edge of the base member by 2.0 mm to 3.0 mm. The protrusion may extend from the edge of the base member by 2.3 mm. Inserting a male interlocking feature of one base member into a female interlocking feature of a second substantially identical base member may cause the two base members to join together in a particular orientation and prevent the male interlocking feature from being removed from the female interlocking feature.

The male interlocking feature may include a key-shaped protrusion. The key-shaped protrusion may be configured to fit into a notch of a corresponding female interlocking feature on a substantially equivalent second base member. The key-shaped protrusion and notch may be configured such that when the key-shaped protrusion is inserted into the notch of the second base member, the second base member is oriented in a particular manner relative to the base member. The male interlocking feature may be a protrusion that includes a tab. The male interlocking feature may be a square protrusion with a tab extending from its side so that it appears key-shaped. The male interlocking feature may be a square protrusion with a tab extending from its side through its center. The tab may be positioned at an eccentric position along a side of the rectangle. The tab may extend downward from a top surface of the flange. The tab may have a length along the flange of 2.0 mm to 3.0 mm. The tab may have a length along the flange of 2.2 mm to 2.4 mm. The tab can have a length of 2.3 mm along the flange. The tab can have a height of 1.0 mm to 6.0 mm. The tab can have a height of 1.75 mm. The male interlocking feature can include a protrusion that extends down the entire width of the end of the handle. The tab can be sized and configured to fit into a female interlocking feature of a substantially equivalent base member. The male interlocking feature can hook over a female interlocking feature of a substantially equivalent base member to mechanically secure the base member to the substantially equivalent base member. The female interlocking feature can be a hole in the flange. The female interlocking feature can include a notch in the hole in the flange. The male interlocking feature on the base member is configured to interlock with a corresponding female interlocking feature on the substantially equivalent base member. This means that multiple base members can be attached together to form, for example, a base member assembly or a base member recycling unit, i.e., the base members can be accepted for recycling at a recycling center.

The female interlocking feature can be a concave inner surface of the second well. The female interlocking feature can be a convex outer surface of the second well. The male interlocking feature can be a protrusion on the convex outer surface of the second well. The female interlocking feature can be interconnected with a corresponding male interlocking feature on a substantially equivalent base member by an interference fit between the male interlocking feature and the female interlocking feature.

The base member may include three stabilizing legs. The base member may include four stabilizing legs. The base member may include five stabilizing legs. The base member may include three stabilizing legs positioned approximately 120 degrees apart from one another about a vertical axis extending through the center of the blister well. The base member may include four stabilizing legs positioned approximately 90 degrees apart from one another about a vertical axis extending through the center of the blister well. The stabilizing legs may include a planar lower edge. The stabilizing legs may include a rounded lower edge. The stabilizing legs may include a curved lower edge.

The base member, when placed face up on a flat surface, can have more than one contact point with the flat surface. The base member, when placed face up on a flat surface, can have more than two contact points with the flat surface.

The base member, when placed face up on a flat surface, can have more than three contact points with the flat surface. The base member, when placed face up on a flat surface, can have more than four contact points with the flat surface. The multiple contact points between the base member and the flat surface can allow the force that the surface exerts on the base member to be distributed throughout the base member. This distribution can reduce the stiffness required in any individual region of the base member, such as in the blister well, thereby allowing the weight of the material used to make the base member to be reduced. The weight of the material used to make the base member can be reduced without compromising the ability of the blister package to provide adequate protection for a contact lens.

When the underside of a first base member according to an embodiment of the present invention is placed against the underside of a second base member, there can be more than one contact point between the base members. There can be more than two contact points between the base members. There can be more than three contact points between the base members. There can be more than four contact points between the base members. The multiple contact points between the base members can allow the force exerted by the second base member on the first base member to be distributed throughout the first base member, and vice versa. This distribution can reduce the stiffness required by any individual region of the base member, such as the blister well. The reduction in required stiffness can allow the weight of the material used to make the base member to be reduced. The weight of the material used to make the base member can be reduced without compromising the ability of the blister package to provide adequate protection for contact lenses during storage and shipping.

The blister wells can be reinforced with support ribs. The blister wells can be reinforced with two or more supports. The blister wells can be reinforced with three or more supports. The blister wells can be reinforced with supports such that the thickness of the blister well sidewalls can be reduced without compromising the ability of the blister package to provide protection to the contact lens.

The blister well may have a periphery. The periphery of the blister well may be surrounded by a sealing region on the upper surface of the base member.

The male interlocking feature can be a barb configured to be inserted into the female interlocking feature of the second base member from a first direction. The female interlocking feature of the second base member can be configured to prevent the barb from exiting in a second direction opposite the first direction.

The male interlocking feature may include a first end defining a barb and a second end defining a barb. The first barb and the second barb may be configured to be inserted into the female interlocking feature of the second base member from a first direction, and the second female interlocking feature of the second base member may be configured to prevent the first barb and the second barb from exiting in a second direction opposite the first direction.

Those skilled in the art will appreciate that the base member can be made by injection molding a plastic material into a suitably shaped base member cavity in a conventional injection molding machine.

According to a second aspect, the present invention provides a base member assembly according to claim 13. In this case, the base member assembly includes a plurality of base members, the base members being made of a plastic material, having an upper surface and a lower surface, and including a blister well and a handle. The handle is provided by a flange extending from the blister well. The flange includes a female interlocking feature and a male interlocking feature. The female interlocking feature is located between the periphery of the blister well and an edge of the flange. The male interlocking feature is located outside the periphery of the blister well. The female interlocking feature on the base member is configured to interlock with a corresponding male interlocking feature on a substantially equivalent base member to mechanically secure the base member to the substantially equivalent base member to form the base member assembly. The base member assembly includes a plurality of base members, each of which is mechanically interlocked with one or more other base members, each mechanical interlock being between a female interlocking feature on one of the base members and a corresponding male interlocking feature on another of the base members. The base member assembly can include at least 14 base members. The base member assembly can include at least 16 base members. The base member assembly can include at least 20 base members. The base member assembly can have a height of at least 15 cm. The base member assembly can have a height of at least 20 cm.

According to a third aspect, the present invention is realised as follows: a method for producing packaged contact lenses according to claim 14.

The step of sealing the sealing member to the sealing area of the base member can be performed by pressing the foil laminate sealing member against the plastic base member under heat to fuse the plastic layers of the foil laminate and the sealing area of the base member to one another. The step of sealing the sealing member to the sealing area can be performed at a temperature of 210 degrees Celsius to 240 degrees Celsius. The step of sealing the sealing member to the sealing area can be performed by pressing the sealing member to the flange of the base member with a heated die under a pressure of 25 PSI to 60 PSI. The heated die can press the sealing member against the flange for a time of 100 ms to 1100 ms.

Desirably, the sealing region provides a sufficient seal between the base member and the sealing member to withstand the separation forces encountered during the contact lens autoclaving process, and is relatively easy for a user to peel open using their fingers. If less force is required to separate the sealing member from the sealing region, the base member can be made lighter without compromising the protection that the blister package provides to the contact lens.

For example, the sealing region can be configured to provide an average separation force of less than 15 Newtons (N). In some embodiments, the sealing region is configured to provide a separation force of about 4 N to about 14 N. In further embodiments, the sealing region is configured to provide a separation force of about 6 N to about 11 N. In yet further embodiments, the sealing region is configured to provide a separation force of about 8 N to about 10 N.

Peel strength can be measured using an INSTRON Model 5943 testing machine. For the purposes of these measurements, the pull angle is set at 45 degrees. Prior to testing peel strength, the load cell of the testing machine is calibrated. Operating instructions are typically provided by the manufacturer.

The sealing configuration can be adjusted by controlling the temperature of the heat seal head face that is pressed against the sealing member on the upper surface of the base member as described above, by controlling the pressure with which the sealing head is applied to the sealing member, or by controlling the time that the sealing head is applied to the sealing member, or a combination of these.

According to a fourth aspect, the present invention provides a method for recycling sealed blister packages, the method comprising the steps of removing the sealing member from the base member, removing the contact lens from the blister well, removing the liquid contact lens packaging solution from the blister well, and fastening the base member to a substantially equivalent base member by interconnecting female interlocking features on the base member with corresponding male interlocking features on the substantially equivalent base member to form a base member assembly. The method may further comprise the step of mechanically fastening a further base member to the base member assembly to form an assembly comprising at least 14 base members fastened to each other to form a base member recycling unit. Alternatively, the method may comprise the step of mechanically fastening a further base member to the base member assembly to form an assembly comprising at least 20 base members fastened to each other to form a base member recycling unit. The method may further comprise the step of mechanically fastening a further base member to the base member assembly to form a base member recycling unit having a height of at least 15 cm. The method may further include mechanically fastening a further base member to the base member assembly to form a base member recycling unit having a height of at least 20 cm. The method may further include placing the base member recycling unit in a recycling container, thereby allowing the base member to be recycled as the base member recycling unit to have a sufficient volume for recycling.

It will of course be understood that features described in relation to one aspect of the invention may be incorporated in other aspects of the invention. For example, a method of the invention may incorporate any of the features described in relation to an apparatus of the invention, and vice versa.

A number of embodiments of the present invention will now be described, by way of example only, with reference to the accompanying schematic drawings.

1 is a perspective view of a contact lens package base member according to a first embodiment of the present invention; FIG. 1 is a perspective view of a contact lens package including a base member and a sealing member according to a first embodiment of the present invention; FIG. 1B is a top view of the base member shown in FIG. FIG. 1B is a top view of the female interlocking feature of the base member shown in FIG. 1B is a cross-sectional view of the base member taken along line AA shown in FIG. 1A. FIG. 1B is an end view of the base member shown in FIG. FIG. 1B is a perspective view of an assembly of the base member shown in FIG. FIG. 1B is a side view of the base member assembly shown in FIG. 1A. 3A-3D show steps of a method for producing packaged contact lenses according to a second embodiment of the present invention. 5A-5D show steps of a method for recycling contact lens blister packages according to a third embodiment of the present invention. A top perspective view of a contact lens package base member according to a fourth embodiment of the present invention. FIG. 8B is a bottom perspective view of the base member shown in FIG. 8A. FIG. 8B is a perspective view of a base member assembly of the base member shown in FIG. 8A. FIG. 8B is a side view of the base member assembly of the base member shown in FIG. 8A. A top perspective view of a contact lens package base member according to a fifth embodiment of the present invention. FIG. 9B is a bottom perspective view of the base member shown in FIG. 9A. FIG. 9B is a perspective view of the base member assembly shown in FIG. 9A. A top perspective view of a contact lens package base member according to a sixth embodiment of the present invention. FIG. 10B is a bottom perspective view of the base member shown in FIG. 10A. FIG. 10B is a side view of the base member assembly of the base member shown in FIG. 10A. 2 is a top perspective view of a contact lens package base member according to another embodiment of the present invention. FIG. FIG. 11B is a bottom perspective view of the base member shown in FIG. FIG. 11B is a side view of the pair of base members shown in FIG. 2 is a top view of a contact lens package base member according to another embodiment of the present invention.

In several exemplary embodiments of the present invention, the base member is a recyclable plastic material. The base member includes a blister well and a handle. The base member can include stabilizing legs and side tabs. The base member includes a lower surface designed to face downward during use, such as when the blister pack is used to present a hydrated contact lens to a user to be removed from the blister pack, and an upper surface designed to face upward. The blister well has a concave inner surface extending downward from the upper surface of the base member and an opposite convex outer surface projecting downward from the lower surface of the base member. The blister well can have a periphery. The periphery of the blister well can be where the concave inner surface of the blister well meets the planar upper surface of the base member. The periphery of the blister well can be surrounded by a sealing area on the upper surface of the base member. This sealing area in use is the area where the base member of the blister pack is hermetically sealed to the sealing member of the blister pack. A flange extends from the periphery of the blister well to the edge of the base member. At a first end of the base member, the flange can extend out from the periphery of the blister well to a curved edge at a distance. At a second end of the base member, the flange can extend further than at the first end to form a handle suitable for being held between a user's thumb and fingers in use. The flange includes a female interlocking feature and a male interlocking feature. The female interlocking feature is positioned between the periphery of the blister well and the edge of the flange. The male interlocking feature is positioned outside the periphery of the blister well. The blister well is dimensioned to hold a contact lens and a contact lens packaging solution. A plurality of stabilizing legs can extend downwardly from the underside of the flange around the convex outer surface of the blister well. In use, the stabilizing legs can allow the base member to rest with the underside of the base member in contact with a surface without tilting. Side tabs can extend down from the edge of the flange on either side of the blister well, where the side tabs can be symmetrical on either side of a line that extends through the center of the base member from the first end of the base member to the second end of the base member, where the line passes through the center point of the blister well. The female interlocking feature can be a hole that extends through the flange of the base member. The male interlocking feature can be located on the end of the handle of the base member. The male interlocking feature can be a protrusion on the end of the handle. The protrusion can include a tab that extends downward from the underside of the flange of the base member.

The contact lenses contained within the blister package are preferably soft contact lenses. The soft contact lenses may be hydrogel contact lenses in that they have an equilibrium water content (EWC) of 10-90%. Preferably, the soft contact lenses are silicone hydrogel contact lenses (i.e., hydrogel contact lenses comprising polymeric units derived from at least one silicone-containing chemical).

A first exemplary embodiment of the present invention will now be described with reference to FIGS. 1A through 5B. FIG. 1A shows a base member 100 formed from a thermoplastic layer. The base member 100 has a weight of 0.72 g. The base member 100 is made of a recyclable plastic material. The base member 100 has a length of 46.31 mm at its longest point and a width of 29 mm at its widest point. The base member 100 includes a blister well 104 and a handle 106. The blister well 104 is dimensioned to accommodate a contact lens. The blister well 104 has a sidewall 105 (FIG. 3). The blister well 104 has a periphery 101. The periphery 101 departs from a straight portion 154 in a substantially circular manner. The handle 106 provides a gripping portion configured to be held between a user's thumb and fingers. FIG. 3 shows a cross-sectional view of the base member 100.

The base member has a lower surface 132 and an upper surface 130. The lower surface 132 and the upper surface 130 meet at an edge 134 that extends around the perimeter of the base member.

The blister well 104 is formed as a well in the upper surface 130 of the thermoplastic layer and extends downward to form a concave inner surface. The sidewall 105 of the blister well 104 is 0.6 mm thick, i.e., the distance between the upper surface 130 of the base member 100 and the lower surface 132 of the base member in the region of the blister well 104 is 0.6 mm. The depth of the blister well 104 is 6 mm at its maximum point. The blister well 104 is sized to hold a maximum of 1.6 mL of contact lens packaging solution.

1B shows the base member 100 and the sealing member 103. The sealing member 103 is joined to the base member 100 at a sealing area 102, shown in dotted lines to indicate that the sealing member 103 is located between it and the base member 100 and cannot be directly seen from above. The sealing area 102 is used to hermetically seal the base member 100 to the sealing member 103 to form the blister cavity. The sealing area 102 has a width of 1.5 mm. FIG. 2A shows a top view of the base member 100. A flange extends from the periphery of the blister well 104 to the border of the base member 100. A first end 138 of the base member extends to form a curved edge at a distance of 5 mm from the periphery of the blister well 104. At the second end 136 of the base member, the flange extends further to form a substantially planar handle 106 that can be used as a gripping portion. Along the width of the base member 100, a flange extends from the periphery of the blister well 104 to form two flat edges 140 at the border of the base member 100. The flat edges 140 have a length of 8 mm. The distance between the flat edges 140 is 29 mm.

Two side tabs 122 (one of which is visible in FIG. 1A) extend downwardly from an area adjacent the flat edge 140 of the underside 132 (FIG. 3) of the base member 100. The side tabs 122 have a height of 4 mm and a length of 8 mm. These side tabs serve to increase the structural integrity of the base member 100 and provide a graspable portion for a user to grasp between the thumb and fingers when picking up the base member 100. The side tabs 122 also serve to stabilize the base member 100 when it is placed face up on a flat surface.

The handle 106 has a thickness of 0.55 mm. At a distance of 8.0 mm from the second end 136 of the base member 100, there is a hole 110 that extends through the thickness of the flange. The hole 110 is a female interlocking feature. FIG. 2B shows the shape of the female interlocking feature. The hole 110 is a slot that is essentially rectangular in shape with a length 142 of 10.5 mm and a width 143 of 1 mm. The hole 110 has a notch 146 on one side facing the second end 136 of the base member that extends a portion of the long side of the slot. The notch 146 has a length of 2.7 mm and protrudes 1.1 mm from the slot. As shown in FIG. 2A, the handle 106 includes a protrusion 150 at its distal end (the second end 136 of the base member 100) that extends from the edge of the base member 100. The protrusion 150 is a male interlocking feature. The projection 150 has a straight outer edge 152 when viewed from above (as in FIG. 2A). The straight outer edge 152 has a length of 9.8 mm. There is a tab 124 extending downward from the flat outer edge 152 of the projection 150 (FIGS. 3 and 4).

The tab 124 has a length of 2.3 mm and extends 1.75 mm below the top surface of the base member 100. Three stabilizing legs 116a-116c extend below the bottom surface 132 of the base member 100 and are vertically aligned with the periphery 101 of the blister well on the top surface 130 of the base member 100. The three legs 116a-116c are arranged around the convex outer surface of the blister well 104. At the first end 138 of the base member 100, one of the stabilizing legs 116a is positioned in the center of the width of the base member 100. The second leg 116b and the third leg 116c are shown in FIG. 4 and are arranged on either side of a centerline that extends along the length of the base member 100 from the first end 138 to the second end 136. The center points of the three legs 116a-116c are positioned approximately 120 degrees apart around an axis that extends vertically down through the center of the blister well.

5A and 5B show how fourteen base members 100 according to this embodiment can be joined together by inserting the protrusions 150 of one base member 100 into the holes 110 of another base member 100, with the tabs 124 serving to hold each protrusion inside the holes 110 of each base member. The tabs 124 have an inwardly facing surface 121 as shown in FIG. 5B. The inwardly facing surface 121 of the tabs 124 presses against the flange area adjacent the holes 110 of the other base member 100 to prevent the base members 100 from coming apart. Each base member 100 is joined to at least one other base member 100 at approximately a 90 degree angle. The base members 100 are joined in the above manner in an assembly such that half of the base members 100 are parallel to each other and the other half are joined at a 90 degree angle to the first half.

In a method 200 of manufacturing a packaged contact lens according to a second embodiment shown in FIG. 6, a contact lens blister package according to a first aspect of the invention is prepared 202. A contact lens is placed into a blister well of a thermoplastic base member of the blister package 204. A volume of liquid contact lens packaging solution is placed into the blister well of the thermoplastic base member 206. A sealing member is sealed 208 to a sealing region of the thermoplastic base member. Optionally, the method includes the step of autoclaving 210 the sealed contact lens blister package to sterilize the contact lens and packaging solution.

7 shows a method 300 for recycling the contact lens blister package of the present invention according to a third embodiment. The steps of the method are as follows: The sealing member is removed from the thermoplastic base member 312. The contact lens is removed from the blister well 314. The liquid contact lens packaging solution is removed from the blister well in the thermoplastic base member 316. In step 318, the thermoplastic base member is mechanically secured to the substantially equivalent thermoplastic base member by interconnecting female interlocking features on the thermoplastic base member with corresponding male interlocking features on the substantially equivalent thermoplastic base member to form a base member assembly. The thermoplastic base member is interconnected with the substantially equivalent thermoplastic base member by inserting its protrusion into a hole in the substantially equivalent thermoplastic base member such that the tab aligns with the notch in the hole. The two base members come together to form the base member assembly 320. Optionally, the method includes the step 322 of mechanically fastening additional thermoplastic base members to the base member assembly to form an assembly including at least 30 thermoplastic base members bonded together to form a base member recycling unit. Optionally, the method includes the step 324 of placing the base member recycling unit into a recycling bin.

Another exemplary embodiment of the present invention (FIGS. 8A-8D) is similar to the first exemplary embodiment of the present invention, but has some alternative features. Base member 400 includes blister well 404 and handle 406. Blister well 404 has periphery 401. Periphery 401 is surrounded by sealing area 402. A flange extends from the periphery of blister well 404 to the border of the base member. At one end of the base member, the flange extends to form handle 406. Base member 400 has hole 410 that extends through the thickness of handle 406. Hole 410 is a female interlocking feature. Hole 410 is a slot that is essentially rectangular in shape. Hole 410 has an inner side wall 433. Hole 410 has a length 442 of 10.5 mm and a width 440 of 1.0 mm. The long sides of the hole 410 are parallel to a centerline that runs along the length of the base member 400. The hole 410 has a notch 446 on one side that extends a portion of one of the long sides of the slot. The notch 446 is located eccentrically along the length of the rectangle, which gives the hole 410 a key-shaped appearance. The notch has a length of 2.7 mm and protrudes 1.1 mm from the slot. On the top surface of the base member 400 there is a flange area 431 adjacent to the hole 410. On the bottom surface of the base member 400 there is a flange area 429 (FIG. 8B) adjacent to the hole 410. The base member 400 has two larger holes 456a and 456b on either side of the hole 410. The holes 456a and 456b reduce the amount of material required to make the base member 400, thus reducing its weight. The handle 406 includes a protrusion 425 (FIGS. 8B-8D) at the end of the handle furthest from the blister well 404. Protrusion 425 is a male interlocking feature. FIG. 8B shows this protrusion 425 from the underside of the base member 400. Protrusion 425 has a lower surface 437 that is parallel to the underside of the base member 400. A lip 441 (FIGS. 8C and 8D) is parallel to the upper surface of the base member 400. Between the lower surface 437 of protrusion 425 and the lip 441 of protrusion 425 there is a curved portion 439 (FIG. 8B). The protrusion includes a surface 443 that faces away from the base member 400 in the plane of the flange (as shown in FIG. 8C). Surface 443 is perpendicular to lip 441. Protrusion 425 includes a tab 424 that aligns with a notch 446 in hole 410 on a second substantially identical base member. Tab 424 extends from lip 441 in a direction perpendicular to the top surface of base member 400. Protrusion 425 is shaped so that it can be inserted into hole 410 of second base member 400b (FIG. 8C). Protrusion 425 is shaped so that first base member 400a can be placed perpendicular to second base member 400b with protrusion 425 seated in hole 410. In this position, lip 441 of first base member 400a is next to sidewall 433 (see FIGS. 8A and 8B) of hole 410 of second base member 400b. Tab 424 of first base member 400a is aligned with notch 446 (see FIG. 8A) of second base member 400b. The surface 443 perpendicular to the lip of the first base member 400a is adjacent to the area 431 (FIG. 8A) of the flange adjacent the hole 410 of the second base member 400b.

Once the projection 425 of the first base member 400a is aligned with the hole 410 of the second base member 400b, the first base member 400a can be rotated 90 degrees so that the flange of the first base member 400a is parallel to the flange of the second base member 400b, as shown in FIG. 8D. In this position, the lip 441 of the first base member 400a applies pressure against the area 429 (FIG. 8B) of the flange adjacent the hole 410 on the underside of the second base member 400b. The lip 441 of the first base member 400a acts to prevent the projection 425 of the first base member 400a from slipping out of the hole 410 of the second base member 400b. The tab 424 of the first base member 400a is aligned with the notch 446 (FIG. 8A) of the second base member 400b. Thus, the act of rotating the first base member 400a 90 degrees relative to the second base member 400b can lock the two base members together.

Another exemplary embodiment of the present invention (FIGS. 9A-9C) is similar to the first exemplary embodiment of the present invention, but has some alternative features. Base member 500 includes blister well 504 and handle 506. Blister well 504 has a perimeter 501 where its concave inner surface meets the top surface of the base member. The perimeter 501 of blister well 504 is surrounded by a sealing area 502. A flange extends from the perimeter of blister well 504 to the border of base member 500. At one end of base member 500, the flange extends to form handle 506. Base member 500 has hole 510 extending through the thickness of handle 506. Hole 510 is a female interlocking feature. Hole 510 is a slot that is essentially rectangular in shape. Hole 510 has a length 542 of 10.5 mm and a width 540 of 1.0 mm. The long side of the hole 510 is perpendicular to a centerline extending along the length of the base member 500. The handle 506 includes a protrusion 550 extending out of the flange plane at the end of the handle furthest from the blister well 504. The protrusion 550 is symmetrical about a centerline extending along the length of the base member 500. The protrusion 550 has a pair of hooks 551 positioned on either side of the centerline. The hooks 551 have a surface 535 facing the blister well that is in the flange plane.

9B shows the underside of the base member 500. The hook 551 has an oblique outwardly facing surface 523 that faces away from the base member 500 in the flange plane. There is an indentation 525 between the widest point of the hook 551 and the remainder of the flange of the base member 500. At the end of the projection 550 furthest from the well 504 there is a tab 524 that extends downwardly from the underside. The projection 550 and the tab 524 are male interlocking features. The tab 524 comprises the outward end of the projection 521 that faces away from the base member in the flange plane. The tab 524 comprises an inwardly facing surface 527, which is shown in FIG. 9C. The projection 550 and the tab 524 are shaped so that they can be inserted into a hole 510 of a second substantially equivalent base member 500 according to this embodiment. The hole 510 is surrounded by an area 529 of the underside of the flange. The hole 510 is surrounded by an area 531 (FIG. 9A) on the top surface of the flange. The hole 510 is defined by an inner wall 533 (FIG. 9B) of the flange. To insert the projection 550 and the tab 524 into the hole 510 of the second base member, the user must apply pressure between the angled outward surface 523 of the hook and the area 531 (FIG. 9A) on the top surface of the flange that surrounds the hole 510. This pressure application also applies pressure between the end of the projection 521 and the area 531 on the top surface of the flange that surrounds the hole 510. The angled outward surface 523 and the end of the projection 521 will flex slightly under pressure, allowing this surface to pass through the hole 510.

As shown in FIG. 9C, once the projection 550 has been inserted into the hole 510 of the other base member 500, the tab 524 and hook 551 act to prevent the projection 550 from slipping out of the hole 510. The inwardly facing surface 527 of the tab 524 abuts against an area 529 of the underside of the flange surrounding the hole 510, thereby preventing the projection 550 from slipping out of the hole 510. The indentation 525 of the flange of one base member is next to the inner wall 533 (FIG. 9B) of the hole. The surface 535 (FIG. 9A) of the hook facing the blister well of the first base member presses against the flange 529 surrounding the hole on the underside of the base member, preventing the projection 550 from slipping out of the hole 510. Once the male interlocking feature of one base member (protrusion 550 in this embodiment) has been mechanically secured to the female interlocking feature of the second base member (hole 510 in this embodiment), the male interlocking feature of the second base member can be mechanically secured to the female interlocking feature of a third base member. This can be repeated to form an assembly of base members 500. Figure 9C shows how eight base members 500 according to this embodiment can be joined together by inserting the protrusions 550 of one base member 500 into the holes 510 of another base member 500, with the tabs 524 and hooks 551 serving to hold each protrusion inside the holes 510 of each base member 500. Each base member 500 is joined to at least one other base member 500 at approximately a 90 degree angle. The base members 500 are joined in the assembly in the manner described above, so that half of the base members 500 are parallel to each other and the other half is joined at a 90 degree angle to the first half.

Another exemplary embodiment of the present invention (FIGS. 10A-10C) is similar to the first exemplary embodiment of the present invention, but has some alternative features. A base member 600 includes a blister well 604 and a handle 606. The blister well 604 has a perimeter 601 where its concave inner surface meets the top surface of the base member 600. The perimeter 601 of the blister well is surrounded by a sealing area 602. A flange extends from the periphery of the blister well 604 to the border of the base member 600. At one end of the base member 600, the flange extends out to form a handle 606. The base member 600 has a second well 611 extending downward from the top surface of the handle 606 to form a concave top surface and extending downward from the bottom surface of the handle 606 to form a convex bottom surface. The concave top surface of the second well 611 is a female interlocking feature. FIG. 10A shows the concave upper surface of the second well 611. FIG. 10B shows the underside of the base member 600. A protrusion 612 extends down from the convex lower surface of the second well 611. The protrusion 612 is a male interlocking feature. The protrusion 612 is shaped so that it can be pressed into the second well 611 of another base member 600 according to this embodiment and held there by an interference fit. FIG. 10C shows how the protrusion 612 of the first base member 600 fits into the second well 611 of the second base member 600. The interference fit between the protrusion 612 and the second well 611 holds the two base members 600 together. This interference fit can be repeated to form an assembly of base members 600.

Another exemplary embodiment of the present invention (FIGS. 11A-11C) is similar to the first exemplary embodiment of the present invention, but has some alternative features. Base member 800 includes blister well 804 and handle 806. Blister well 804 has a perimeter 801 where its concave inner surface meets the top surface of base member 800. Perimeter 801 is surrounded by sealing area 802. A flange extends from the perimeter of blister well 804 to the boundary of base member 800. The flange extends from the perimeter of blister well 804 to curved edge 821, which is a substantially equal distance from the perimeter of blister well 804 everywhere around well 804. The flange extends from curved edge 821 to form handle 806 on one side of base member. Handle 806 is planar with sealing area 802. Four protrusions 860 extend downward from the top surface of the flange at approximately 90 degree intervals around an axis that runs vertically through the center of the blister well 804. The protrusions 860 are male interlocking features. FIG. 11B shows the protrusions 860 extending downward from the top surface of the base member 800. The end of the protrusion 860 furthest from the top surface of the base member 800 is hooked. FIG. 11C shows the well 804 of one base member 800 being inserted into the well 804 of a second base member 800 according to this exemplary embodiment, with the protrusions 860 fitting over the curved edge 821 of the second base member in a slightly indented region 861. Region 861 is a female interlocking feature. The hooks of the protrusions 860 serve to hold the protrusions in place and keep the two base members 800 joined together. This joining can be repeated to form an assembly of base members.

Another exemplary embodiment of the present invention (FIG. 12) is similar to the first exemplary embodiment of the present invention, but with some alternative features. A base member 900 includes a blister well 904 and a handle 906. The base member 900 has a hole 910 that extends through the thickness of the handle 906. The hole 910 is a female interlocking feature. The hole is a slot that is essentially rectangular in shape. The hole has a length 942 of 10.5 mm and a width 940 of 1.0 mm. The long sides of the hole 910 are perpendicular to a centerline that extends along the length of the base member. The hole 910 has a notch 946 that is centrally positioned along the width of the base member and extends a portion of one of the long sides of the slot. The notch has a length of 2.7 mm and protrudes 1.1 mm from the slot. The handle 906 includes a protrusion 950 that extends in the plane of the flange. The protrusion 950 is a male interlocking feature.

Although the present invention has been described and illustrated with reference to specific embodiments, those skilled in the art will appreciate that the present invention is susceptible to many different variations not specifically illustrated herein.

Wherever the foregoing description refers to integers or elements having known, obvious or foreseeable equivalents, such equivalents are incorporated herein as if individually set forth. Reference should be made to the claims to determine the true scope of the invention, which should be construed to encompass all such equivalents. The reader will also understand that integers or features of the invention described as preferred, beneficial, advantageous, or the like are optional and do not limit the scope of the independent claims. It should further be understood that such optional integers or features, while having potential advantages in some embodiments of the invention, may not be desirable and therefore may be absent in other embodiments.

100 Base member 101 Periphery 102 Sealing area 104 Blister well 106 Handle 110 Hole 122 Side tab 130 Top surface 134 Edge 140 Flat edge 152 Straight outer edge 154 Straight portion 116a Stabilizing legs

Claims (17)

1. A hermetically sealed blister package for a contact lens comprising a base member made of a plastic material and a sealing member joined to said base member to form a blister cavity arranged to hold an unworn contact lens and a contact lens packaging solution,
the base member has an upper surface and a lower surface and includes a blister well and a handle provided by a flange extending from the blister well;
In a hermetically sealed blister package for contact lenses,
the flange includes a female interlocking feature and a male interlocking feature, the female interlocking feature being positioned between a periphery of the blister well and an edge of the flange, and the male interlocking feature being positioned on an outer edge of the handle ;
the female interlocking features on the base member are configured to interlock with corresponding male interlocking features on a substantially identical base member to mechanically secure the base member to the substantially identical base member to form a base member assembly;
the male interlocking feature comprises a clip, a barb, or a combination thereof;
A hermetically sealed blister package for contact lenses. The hermetically sealed blister package for contact lenses according to claim 1, wherein the base member has a weight of 0.4 g to 0.72 g. The hermetically sealed blister package for contact lenses of claim 1 or claim 2, wherein the female interlocking feature comprises a hole in the flange of the base member. The hermetically sealed blister package for contact lenses according to claim 1 or 2, wherein the female interlocking feature is a hole with a notch at its edge. The hermetically sealed blister package for contact lenses of claim 1 or 2, wherein the female interlocking feature is positioned at a greater distance from the periphery of the blister well than from the periphery of the handle. The hermetically sealed blister package for contact lenses according to claim 1 or claim 2, wherein the step of inserting the male interlocking feature of one base member into the female interlocking feature of a second substantially identical base member joins the two base members together in a specific orientation and prevents the male interlocking feature from being removed from the female interlocking feature. The hermetically sealed blister package for contact lenses according to claim 1 or 2, wherein the male interlocking feature includes a rectangular protrusion with a tab extending from a side to give the appearance of a key, the rectangular protrusion configured to fit into a notch of a corresponding female interlocking feature on a substantially identical second base member, and the rectangular protrusion and the notch are configured such that the second base member is oriented in a particular manner relative to the second base member when the rectangular protrusion is inserted into the notch of the second base member. The hermetically sealed blister package for contact lenses according to claim 1 or 2, wherein the blister well is peripheral, and the peripheral portion of the blister well is surrounded by a sealing region on the upper surface of the base member. The hermetically sealed blister package for contact lenses according to claim 1 or 2, wherein the base member further comprises three or more stabilizing legs, the stabilizing legs extending downward from the lower surface of the base member and vertically aligned with the periphery of the blister well. The hermetically sealed blister package for contact lenses according to claim 1 or 2, wherein the base member includes at least two side tabs positioned on either side of the blister well, the side tabs extending downwardly from the top surface of the base member. A base member assembly including a plurality of base members from the blister package of claim 1 or claim 2, wherein each base member is mechanically coupled to one or more other base members within the assembly, each mechanical coupling being between the female coupling feature on one of the base members and a corresponding male coupling feature on another of the base members. The base member assembly of claim 11 , wherein said base member assembly comprises at least 14 of said base members. 12. The base member assembly of claim 11 , wherein said base member assembly has a height of at least 15 cm. 1. A method for producing packaged contact lenses, comprising:
A step of preparing a base member of the blister package for contact lenses according to claim 1 or 2;
placing a contact lens into the blister well of the base member;
placing a volume of liquid contact lens packaging solution into said blister well of said base member;
sealing a sealing member to a sealing area of the base member;
autoclaving the sealed contact lens blister package to sterilize the contact lenses and packaging solution;
The method includes: A method for recycling the sealed blister package for contact lenses according to claim 1 or 2, comprising the steps of:
removing the sealing member from the base member;
removing the contact lens from the blister well;
removing a liquid contact lens packaging solution from said blister well;
mechanically securing the base member to a substantially identical base member by interconnecting the female interlocking features on the base member with corresponding male interlocking features on the substantially identical base member to form a base member assembly;
The method includes: 16. The method of claim 15, further comprising: mechanically fastening additional base members to the base member assembly to form a base member recycling unit comprising at least 14 base members; and placing the base member recycling unit into a recycling bin. 16. The method of claim 15, further comprising the steps of: mechanically fastening a further base member to the base member assembly to form a base member recycling unit having a height of at least 15 cm; and placing the base member recycling unit into a recycling bin.

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