Contact lens blister packages and methods for recycling same

Abstract

Contact lens packages are provided and each includes a base member having a cavity and a sealing member coupled to the base member. An unworn contact lens is provided in a packaging solution within the sealed cavity. The base member is a thermoplastic or other recyclable material. The base member includes at least one connecting member that can be an interlocking feature and/or a stackable feature. The connecting member is configured to connect to the connecting member of another base member, after the contact lenses are removed from the cavities. A recyclable thermoplastic contact lens assembly is also provided that includes empty contact lens package base members stacked and connected together. A method of manufacturing contact lens packages and a method to recycle used contact lens package base members, such as by curbside recycling, are also provided.

1 . A contact lens blister package, comprising:
 a thermoplastic base member comprising a bowl that defines a blister cavity dimensioned to accommodate a contact lens, and a flange projecting away from the blister cavity, the flange providing a sealing ring region circumscribing the blister cavity, and the flange having a first proximal end providing a gripping portion configured to be held between a thumb and a finger of a contact lens wearer, and a second distal end extending away from the proximal end from the opposite side of the blister cavity;   a liquid contact lens packaging solution provided in the blister cavity;   an unworn contact lens located in the contact lens packaging solution in the cavity; and   a sealing member hermetically sealed to the sealing ring region of the thermoplastic base member to maintain the contact lens in a sterile condition,   wherein the flange comprises at least one connecting feature located between an outer perimeter of the sealing ring region and the proximal end of the flange, the at least one connecting feature being configured to mechanically fasten and interlock the thermoplastic base member to a second thermoplastic base member of another contact lens blister package to form a thermoplastic base member assembly.   
     
     
         2 . (canceled) 
     
     
         3 . The contact lens blister package of  claim 1 , wherein the thermoplastic base member comprises a recyclable plastic material. 
     
     
         4 . The contact lens blister package of  claim 1 , wherein the thermoplastic base member comprises a polypropylene material. 
     
     
         5 . (canceled) 
     
     
         6 . The contact lens blister package of  claim 1 , wherein the sealing ring region has a non-circular configuration that includes a vertex. 
     
     
         7 . (canceled) 
     
     
         8 . The contact lens blister package of  claim 1 , wherein the gripping portion is planar. 
     
     
         9 . The contact lens blister package of  claim 1 , wherein the connecting feature is at least one of an interlocking feature and a stackable feature. 
     
     
         10 . The contact lens blister package of  claim 9 , wherein the connecting feature is the interlocking feature, and the interlocking feature comprises a hole, a clip, a latch, or a combination thereof. 
     
     
         11 . The contact lens of  claim 10 , wherein the interlocking feature comprises the hole on the flange. 
     
     
         12 . The contact lens blister package of  claim 10 , wherein the interlocking feature comprises the hole and the hole is a slot defined through the flange, the slot having a length greater than a width. 
     
     
         13 . (canceled) 
     
     
         14 . The contact lens blister package of  claim 12 , wherein the width of the slot is from 0.5 mm to 1.5 mm and the length of the slot is from 3.0 mm to 13.0 mm. 
     
     
         15 - 17 . (canceled) 
     
     
         18 . The contact lens blister package of  claim 12 , wherein the slot comprises a notch defined at an edge of the slot. 
     
     
         19 . (canceled) 
     
     
         20 . The contact lens blister package of  claim 18 , wherein the notch is off-centered from a center of the length of the slot. 
     
     
         21 - 22 . (canceled) 
     
     
         23 . The contact lens blister package of  claim 12 , wherein the interlocking feature further comprises a clip having dimensions configured to fit through the slot. 
     
     
         24 . The contact lens blister package of  claim 23 , wherein the clip is configured to be inserted into a slot of a second thermoplastic base member such that the thermoplastic base member is interlocked with the second thermoplastic base member. 
     
     
         25 . The contact lens blister package of  claim 23 , wherein the clip further comprises a bottom surface that is angled and defines a barb configured to be inserted into a slot of a second thermoplastic base member from a first direction and the slot of the second thermoplastic base member is configured to prevent the barb from exiting in a second direction, opposite the first direction. 
     
     
         26 . (canceled) 
     
     
         27 . The contact lens blister package of  claim 24 , wherein the clip further comprises a key protruding therefrom, wherein the key is positioned to fit within a notch of a second thermoplastic base member. 
     
     
         28 - 30 . (canceled) 
     
     
         31 . The contact lens blister package of  claim 23 , wherein the clip is defined at a gripping portion end of the thermoplastic base member. 
     
     
         32 . The contact lens blister package of  claim 9 , wherein the connecting member is the stackable feature and comprises a receptacle formed at a top surface of the flange, wherein the receptacle is located on the gripping portion, in between a gripping portion end and the blister cavity. 
     
     
         33 - 41 . (canceled) 
     
     
         42 . The contact lens blister package of  claim 1 , wherein the liquid contact lens packaging solution is present in an amount from 0.4 mL to 1.6 mL. 
     
     
         43 - 48 . (canceled) 
     
     
         49 . The contact lens blister package of  claim 1 , wherein the thermoplastic base member comprises a plurality of tabs depending from the top surface of the flange of the thermoplastic base member. 
     
     
         50 - 51 . (canceled) 
     
     
         52 . The contact lens blister package of  claim 1 , wherein the bowl of the thermoplastic base member has a concave interior surface and a convex exterior surface, and a plurality of stabilizing legs extend from the bottom surface of the flange of the thermoplastic base member and circumscribe the convex exterior surface of the bowl. 
     
     
         53 - 59 . (canceled) 
     
     
         60 . The contact lens blister package of  claim 1 , wherein the connecting feature of the thermoplastic base member and a connecting feature of the second thermoplastic base member are the same. 
     
     
         61 . The contact lens blister package of  claim 1 , wherein the connecting feature of the thermoplastic base member and a connecting feature of the second thermoplastic base member are complimentary to each other. 
     
     
         62 . (canceled) 
     
     
         63 . The contact lens blister package of  claim 1 , wherein the connecting feature is at least one of an interlocking feature and a stackable feature and the thermoplastic base member assembly does not break or separate while being initially processed at a recycling facility. 
     
     
         64 . The contact lens blister package of  claim 1 , wherein the base members will not disconnect from each other due to gravity or due to gripping of the connected base members attached to each other.