It may be that the base member has edges. It may be that the base member has sides. Each side may comprise the edges of the base member which are adjacent to another base member in the blister package assembly. The opposing sides of the base member may be equidistant from the cavity. The sides of the base member may be symmetrical along a centreline of the base member. It may be that the base member has ends. Each end may comprise the edges of the base member that extend between the sides and/or are substantially perpendicular to the sides. The end of the base member which is furthest from the centre of the cavity may be referred to as a first end. The end of the base member which is on the opposite side of the cavity to the first end may be referred to as a second end. The planar surface region may extend between the sides and the first and second ends of the base member. Thus, the top surface of the blister package may be substantially planar apart from the cavity. The planar surface region may extend across the majority of the top surface of the base member.

In the case that each pair of adjacent base members has a single second seal region, it may be that the first axis extends normal to the perimeter of each cavity at the point it intersects the perimeter. In the case that each pair of adjacent base members has a single second seal region, it may be that, for each pair of adjacent blister packages, the first axis extends from the cavity of one of the blister packages of the pair to the cavity of the other of the blister packages of the pair, where the distance between the cavities of the pair is is at a minimum. In that case, it may be that the first axis extends through the centre of each cavity of the blister package assembly.

The seal member may have a length (being its longest dimension) and a width. The seal member may be substantially planar. The seal member may have a thickness very much less than its width and length.

The blister package assembly may be a blister package strip, for example comprising at least five base members. It may be that the base members are arranged along the longitudinal axis (length) of the seal member, for example with their cavities in a line. The or each first axis may extend parallel to the longitudinal axis of the seal member. It may be that the blister packages are arranged side-by-side in the blister package assembly. It may be that each blister package assembly comprises a first end blister package and a second end blister package. It may be that each end blister package is only adjacent to a single blister package (i.e. only has another blister package on one side, being opposite sides for the first and second end blister packages). It may be that each end blister package has only one second seal region and/or the seal member associated with each end blister package has only one second melt region. It may be that each end blister package does not have a region extending away from the first (seal and/or melt) region along the first axis on the opposite side of the cavity to the adjacent blister package and/or extending towards the side of the base member which is at the end of the blister package assembly.

Excluding the seal and/or prior to sealing of the blister package, the base member of each blister package may be spaced apart from the base member of any other blister package, for example along the longitudinal axis. It may be that, excluding the seal and/or prior to sealing of the blister package, there is a gap between the base members of each pair of adjacent blister packages. For example, a gap of at least 0.3 mm, for example at least 0.4 mm, for example of at least 0.5 mm. The minimum distance between adjacent base members may be in the range of from 0.3 mm to 2 mm inclusive, for example from 0.5 mm to 2 mm inclusive. Seals in accordance with the present disclosure may find particular application in blister package assemblies having a gap between adjacent blister packages, as the elongate bridge can provide additional stiffness along the length of the seal member. It may be that the longitudinal axis of the gap (if present) between adjacent blister package extends perpendicular to the first axis and/or the second region. It may be that the second region extends across the gap.

It may be that the base members are initially separate, and it is melting of the base member to form the seal that causes base member material to extend across the gap and thereby allow the second region(s) to extend between the first regions. Thus, it may be that in the gap, the base member material of the second seal region is melted base member material. It may be that only melted base member material is present in the gap. In that case, the melt depth is equal to the thickness of the elongate bridge. In the gap, the melt depth/thickness, may be at least 0.5 mm, for example at least 0.75 mm. It may be that, in the gap, the melt depth is 100% of the thickness of the base member material. It may be that, in the gap, the melt depth is at least 50%, for example at least 75% of the thickness of the base member at the edges of the base member.

The seal member may comprise, for each base member, a pull tab for use in opening the blister package comprising the pull tab and the base member. It may be that the pull tab is a region of the seal member that is not affixed to the base member by the seal. It may be that the pull tab is sized and configured to be held between the thumb and forefinger of a user, such that the user may pull the pull tab in order to open the blister package and/or remove the seal member from the base member. The blister package may be configured such that the user pulls the pull tab along a first pull-axis in order to open the blister package and/or remove the seal member from the base member. The pull-axis may be perpendicular to the first axis along which the second (seal and/or melt) region extends. Thus, it may be that any additional rigidity provided by the second region is in a direction perpendicular to the direction of the force exerted by a user to open the blister package. This may reduce any increase in the force required to open the blister package as a consequence of the presence of the second region. It may be that the pull tab extends from an outer edge of the first region/seal around the cavity towards, for example to, the first end. It may be that the pull tab extends from the edge of the seal closest to the first end towards, for example to, the first end.

It may be that, for each pair of adjacent blister packages, the seal member comprises a series of perforations. It may be that each series of perforations extends perpendicular to the first axis and/or the second (seal and/or melt) region. It may be that each series of perforations extends across the second region(s), for example at a point equidistant from the first regions.

It may be that the minimum width of the seal (i.e. the minimum perpendicular distance between the inner edge of the seal and an opposing outer edge of the seal) around the cavity is located along the centre line of a blister package/base member, for example at 90 degrees to the second (seal and/or melt) region and/or the first axis of each pair. It may be the minimum width of the seal around the cavity is located on the opposite side of the cavity to the first end. The width of the seal may be substantially constant around the majority of the perimeter of the cavity. Other than at the second regions, the width of the seal may be substantially constant around the whole of the perimeter of the cavity.

The distance between the inner edge of the seal and the perimeter of the cavity may be substantially constant around the majority of, for example the whole of the cavity. The distance between the inner edge of the seal and the perimeter of the cavity may vary with respect to angle around the perimeter of the cavity, over a least part of, for example around the whole of the perimeter of the cavity. The distance between the inner edge of the seal and the perimeter of the cavity may vary only within a segment around the perimeter of the cavity, said segment having an angle around the centre of the cavity of from 60 to 130 degrees inclusive, for example from 80 to 110 degrees inclusive, for example from 85 to 95 degrees inclusive. The distance between the inner edge of the seal and the perimeter of the cavity may be greatest on the same side of the cavity as the first end. This may assist in making the blister package easy for a user to open.

The seal around the cavity and/or each first (seal and/or melt) region may comprise a (first) curved region, for example extending over an angle of at least 180 degrees, for example over at least 260 degrees, around the centre of the cavity. The curved region may be a (first) arcuate region (i.e. a region of constant radius with respect to the centre of the cavity). Thus, each first region may comprise a (first) arcuate region, for example extending over an angle of at least 180 degrees, for example at least 260 degrees, around the centre of the cavity. The curved and/or arcuate region may be concentric with the centre of the cavity. The arcuate region may extend around the opposite side of the cavity to the first end. It may be that the arcuate region extends over 360 degrees, i.e. the seal around the cavity and/or the seal region may be an annulus around, for example centred on the cavity.

The seal around the cavity and/or each first region may comprise a connecting region, the connecting region extending between the ends of the (first) curved or arcuate region such that the first region extends around the perimeter of the cavity. The connecting region may extend over less than 180 degrees, for example less 130 degrees, for example from 85 to 95 degrees inclusive, around the cavity.

It may be that the connecting region comprises or is a second arcuate region, for example having a different radius of curvature to the first arcuate region. Thus, the second arcuate region may extend over less than 180 degrees, for example less 130 degrees, for example from 85 to 95 degrees inclusive, around the cavity. It may be the connecting region comprises one or more straight regions, for example in which the seal and/or first region continues as a tangent to the curvature of the seal and/or first region at the end of the (first) curved and/or arcuate region. It may be that the first region, for example the connecting region, comprises two straight regions; one straight region being a tangent to the curvature of the seal/first region at a first end of the (first) curved/arcuate region and the other straight region being a tangent to the curvature of the seal/first region at a second end (e.g. the other end) of the (first) curved/arcuate region. It may be that the two straight regions meet such that the first region extends around the perimeter of the cavity.

It may be that the base member is made of a plastics material, for example a thermoplastic material. It may be that the base member comprises a top surface. For example, a top surface comprising the planar surface region. It may be that the cavity is a recess in the top surface. It may be that the base member comprises a bottom surface, being the surface on the opposite side of the base member to the top surface. It may that, apart from the cavity, the top surface of the base member is substantially planar. The intersection of the cavity and the planar surface region may be referred to as the perimeter of the cavity. The cavity may have a concave interior surface on the top side (i.e. the side of the top surface) of the base member and/or a convex exterior surface on the bottom side (i.e. the side of the bottom surface) of the base member. The cavity may be substantially hemispherical, substantially cylindrical and/or irregular in shape. The cavity may have a sidewall. The cavity may have a base.

The seal is where the seal member is affixed to the base members. It may be that the seal member is fused to the base member at the seal. For example, at the seal, a layer of plastic of the seal member is melted together with the material of the base member. It may be that the seal member is not affixed to the blister packages over the majority of the surface area of the seal member. It may be that the surface area of the seal is less than half of the surface area of the seal member and/or the surface area of the top surfaces of the blister packages to which the seal member is affixed.

The seal member is hermetically sealed to the base member at the seal. The seal member may comprise one or more layers of a plastics material, for example a thermoplastic material. The seal member may comprise one or layers of foil. Said layers may extend across the majority of, for example the whole of, the seal member. For example, the seal member may be a laminated structure including one or more layers of foil and one or more layers of a plastics material. The thickness of the seal member may be from 50 micrometers to 100 micrometers inclusive, for example from 60 micrometers to 70 micrometers inclusive. Suitable materials for the seal member can be obtained from AMCOR (Switzerland). It may be that, when affixed to the blister packages, the seal member covers the majority of, for example the whole of, the top surface of each base member. The seal member may have an area equal to the area of the top surface of the base member. The seal member may have an area greater than the area of the top surface of the base member. The seal member may have an area less than the area of the top surface of the base member. The seal member is joined to the base members to form a seal. It may be that the same seal member is affixed to all the blister packages of the blister package assembly.

It may be that the blister package assembly comprises a plurality of pairs of adjacent blister packages. It will be appreciated that each blister package may be in two pairs, for example one pair in which it is the left-most blister package, and another pair in which it is the right-most blister package.

The seal may be configured to provide a peel strength of less than 15 Newtons (N), for example a peel strength of from 4 N to 14 N inclusive, for example from 6 N to 11 N inclusive, for example from 8 N to ION inclusive. The peel strength can be measured using an INSTRON Model 5943 machine. For purposes of these measurements, the angle of pull is set at 45 degrees. The load cell of the machine is calibrated prior to testing the peel strength. Generally, the operating instructions are set by the manufacturer.

It may be that the minimum width of the second (seal and/or) region varies by less than 0.8 mm, for example less 0.75 mm, for example less than 0.5 mm between each pair of adjacent blister packages.

The contact lens contained in the blister package is preferably a soft contact lens. For example, a contact lens that has an equilibrium water content (EWC) from 10-90%. The contact lens may be a hydrogel contact lens. The contact lens may be a silicone hydrogel contact lens. The contact lens may be an unworn contact lens.

The base member may include two or more stabilising legs. The base member may include three or more stabilising legs. The stabilising legs may extend down from the bottom surface of the base member. The stabilising legs may be vertically aligned with the rim of the blister well. The stabilising legs may extend down from the bottom surface of the base member such that they extend out at least as far as, for example further than, the furthest extent of the cavity. The stabilising legs may extend out far enough to provide stability to the base member when it is placed upright on a flat surface. The stabilising legs may allow a reduction in the weight of the blister package to be achieved while still providing a blister package that is stable when placed upright on a flat surface without the handle formed by the flange having to serve as a stability support and whilst maintaining enough structural integrity to avoid problematic deformation and enough structural integrity to adequately protect a contact lens during transportation and storage.

The base member may include at least two side tabs. It may be that each side tab extending down from the top surface of the base member at an edge, for example a side, of the base member. The side tabs may be positioned on either side of the cavity, for example opposite each other. The side tabs may have a height (being the extent of the tab from the top surface) from 2 mm to 4 mm. The side tabs may have a height from 3 mm to 4 mm. The side tabs may have a height of 3 mm. The side tabs may have a height of 4 mm. The side tabs may have a length along the top surface of the flange of 6 mm to 10 mm. The side tabs may have a length along the top surface of the flange of 7 mm to 9.00 mm. The side tabs may have a length along the top surface of the flange of 8 mm. The side tabs may increase the structural integrity of the base member. The side tabs may reduce the likelihood of problematic deformation of the base member. The side tabs may increase the stability of the base member when it is placed upright on a flat surface. The side tabs may provide a gripping region.

It may be that a through-hole extends through the base member from the top surface to the bottom surface. It may be that the through-hole is located closer to an edge of the base member than to the centre of the cavity. For example, it may be that the through-hole is located closer to the first end of the base member, than to the centre of the cavity. The through-hole may be located at a distance of 10 mm to 30 mm from the centre of the cavity. The through-hole may be located at a distance of 20 mm from the centre of the cavity. The through-hole may have a maximum width (i.e. the greatest width in the case of a non-constant width), a maximum length (i.e. the greatest length in the case of a non-constant length) and a depth. The depth may be the extent of the through-hole through the base member. It may be that the maximum width and the maximum length are greater than the depth. It may be that the maximum width is less than the maximum length. It may be that the through-hole has a maximum width of from 0.5 mm to 1.5 mm inclusive, for example a width of from 0.9 mm to 1.1 mm inclusive. It may be that the through-hole has a maximum length of from 8 mm to 12 mm inclusive, for example from 9 mm to 11 mm inclusive. The through-hole may extend parallel (for example the length of the through-hole may be parallel) to the edge of the base member, for example the first end of the base member.

The first end of the base member may be shaped and configured to be received in the through-hole of a substantially identical base member. The first end and through-hole may be shaped and configured to interlock such that the first end can be inserted into a through-hole of a substantially identical base member by movement of the end relative to the through-hole in a first direction, and then the end and through-hole interlock to retain the end in the through-hole against movement in a second, opposite, direction. For example, the base member may be substantially planar at the first end apart from a protrusion extending from the top or bottom surface at said first end, said protrusion retaining the first end in the through-hole against movement in a second, opposite, direction. Each base member may be configured such that the first end of a first base member can be received in the through-hole of a second base member, while the first end of a third base member is received in the through-hole of the second base member and, optionally, while the first end of a further base member is received in the through-hold of the second base member. The base member may be so assembled when they have been used, i.e. when the seal member, contact lens and contact lens packaging solution have been removed. Thus, the base members can be connected together (after use) to form a used blister package assembly. This may facilitate recycling of the base members.

The cavity may hold a volume of contact lens packaging solution of from 0.4 mL to 1.6 mL inclusive, for example from 0.6 mL to 1.4 mL inclusive, for example from 0.8 mL to 1.2 mL inclusive. The cavity may have a depth (being the maximum extent perpendicular to the planar surface portion of from 5 mm to 8 mm inclusive, for example from 6 mm to 7 mm inclusive, for example 6 mm or 6.7 mm.

The base member may have a length (its longest dimension) from 40 mm to 50 mm inclusive, for example from 43 mm to 47 mm inclusive, for example the base member may have a length of 46 mm. The base member may have a thickness, being the distance between the top and bottom surfaces. The base member may have a width, being its extent perpendicular to the length and thickness. The base member may have and a width of from 25 mm to 35 mm inclusive, for example from 27 mm to 33 mm inclusive, for example from 28 mm to 30 mm inclusive, for example the base member may have a width of 29 mm. It may be that the base member has a weight of 0.72 g or less, for example from 0.40 g to 0.72 g inclusive, for example, a weight of 0.70 g, a weight of 0.72 g. It may be that the base member has a weight of less than 0.70 g, for example a weight of less than 0.65 g.

It may be that the seal comprises a repeating pattern of first and second regions. It may be that the seal comprises one first region for each cavity and one second region for each adjacent pair of blister packages.

Where used herein in connection with a dimension, “substantially constant” refers to a variation of less than two percent, for example less than one percent.

The present disclosure provides, according to a second aspect, a method of manufacturing a contact lens blister package assembly, for example of any other aspect.

It may be that the blister package assembly comprises at least two base members, each base member comprising a cavity holding a contact lens and contact lens packaging solution; and a (planar) surface region surrounding the cavity. It may be that the method comprises: affixing a seal member to each base member to form a seal and thereby contain the contact lens and the packaging solution in the cavity. It may be that the step of affixing comprises pressing the seal member against the base members, for example using a sealing head having a raised region. It may be that heating of the raised region melts the base member to form the seal. It may be that the raised region comprises a plurality of first raised regions, the first raised regions being spaced apart along the sealing head. It may be that the raised region comprises one or more second raised regions, each second raised region connecting (extending between) each pair of adjacent first raised regions. It may be that when the sealing head is pressing the seal member against the base member, each first raised region extends around a perimeter of the cavity on one of the base members. Using a sealing head with second raised regions may enable more precise control of the formation of the seal in the second seal regions/melt regions. It may be that the second raised region melts the thermoplastic material of the base member so as to provide a bridge of base member material between the previously separate base members. It will be appreciated that features of the shape or configuration of the seal and/or melt regions described above or below apply equally to the raised regions.

It may be that the first raised regions have a substantially constant width, wherein the width of the first raised region is the minimum perpendicular distance between the inner edge of the raised profile and an opposing outer edge of the raised region profile around the cavity; and wherein each second raised region extends along a first axis between the first raised regions of a pair; each second raised region has a length, being the minimum extent of the second raised region between the first raised regions, and a width, being the extent of the raised region in a direction perpendicular to the first axis, and wherein the length of the second raised region is at least a third of the minimum width of the second raised region.

The method may comprise placing a contact lens into the cavity of each base member, before affixing the seal member.

The method may comprise placing a volume of liquid contact lens packaging solution into the cavity of each base member, before affixing the seal member.

The method may comprise autoclaving the sealed contact lens blister package assembly to sterilize the contact lens and the packaging solution.

The step of affixing a seal member to the base member may comprise pressing the seal member against the base member, for example against the planar surface region. The step of affixing a seal member to the base member may comprise heating the seal member and base member to melt the seal member and the base member together to form the seal. It may be that said pressing and heating are carried out simultaneously. For example, the step of affixing may comprise melting a melt region of the seal member, while the seal member is pressed against the base member. For example, the step of affixing may comprise melting a region of a plastic layer of a (foil laminate) seal member and a (plastic) base member while the seal member is pressed against the base member. The method may comprise a sealing head (see below) pressing the seal member against the base member. It may be that a raised region of the sealing head presses the seal member against the base member. For example, it may be that the raised region is pressed against a surface of the seal member on the opposite side of the seal member to the base members of the assembly. It may be that the raised region is the only part of the sealing head that contacts the seal member.