Contact lens blister package with double layer foil component
A blister package for a contact lens is provided that includes a body and a seal, one or both of which is made up of a double layer foil component. The double layer foil component can be a seal component made of a sheet of material folded upon itself and defining a seal, a flap, and a fold. The seal and the flap intersect at the fold and the flap can be pulled away from the seal to form a pull tab useful to peel back the seal and open the bowl. The body can also, or instead, be made of a double layer foil component that forms at least the bowl such that the bottom of the bowl is double-walled. The double-walled bowl exhibits improved strength and can be provided with strengthening features such as ribs, ridges, channels, or grooves.
1. A blister package for a contact lens, the blister package comprising:
a body, the body comprising a handle, a bowl, and a body top surface, wherein the bowl has a depth, is recessed from the body top surface, and has a top opening, the body comprises a double wall of a foil material defining a sidewall and bottom of the bowl such that the bottom of the bowl is double-walled, the handle extends away from the bowl and terminates at a distal end, and the body top surface defines a perimeter sealing surface surrounding the top opening of the bowl; and
a seal contacting the perimeter sealing surface and sealing the bowl.
2. The blister package of claim 1 , where the seal comprises a double layer foil component comprising a sheet of material folded upon itself and defining a seal portion, a flap, and a fold, the seal portion and the flap intersecting at the fold, wherein the seal portion contacts the perimeter sealing surface around the perimeter of the bowl and seals the top opening of the bowl, the flap is configured to be pulled away from the seal to form a pull tab, and the pull tab is configured to be pulled so that the seal portion can be separated from the perimeter sealing surface and the bowl can be opened.
3. The blister package of claim 2 , wherein the entire seal portion is adhered to the body top surface, except for in an area above the bowl, and the fold contacts the body between the bowl and the distal end of the handle.
4. The blister package of claim 1 , wherein the entire body comprises a double layer of foil material including an inner layer and an outer layer, the inner layer defining the bowl and having a top surface that defines an inner surface of the bowl, the outer layer comprising strengthening ribs and defining a bowl support indentation for receiving the bowl formed of the inner layer.
5. The blister package of claim 1 , wherein the blister package further comprises a contact lens and contact lens solution in the bowl.
6. The blister package of claim 1 , wherein the entire body comprises a double layer of foil material including an inner layer and an outer layer, the inner layer defining the bowl and having a top surface that defines an inner surface of the bowl, the outer layer comprising channels, grooves, ridges, or other strengthening features and defining a bowl support indentation for receiving the bowl formed of the inner layer.
7. A method of forming a blister package, the blister package comprising a body and a seal, wherein
the body comprises a handle, a bowl, and a body top surface, the bowl having a depth, being recessed from the body top surface, and having a top opening, the body comprising a double wall of a foil material defining a sidewall and a bottom of the bowl such that the bottom of the bowl is double-walled, the handle extending away from the bowl and terminating at a distal end, and the body top surface defining a perimeter sealing surface surrounding the top opening of the bowl, and the method comprises:
placing a contact lens and contact lens solution in the bowl; and
sealing the seal against the perimeter sealing surface to seal the bowl.
8. The method of claim 7 , further comprising forming the body from a single piece of material, the forming comprising
forming the inner body layer comprises forming the bowl in a first section of the single piece of material,
forming the outer body layer comprises forming the bowl support indentation in a second section of the single piece of material, adjacent to the first section, and
folding the first section against the second section at a fold formed at an intersection between the first section and the second section, such that (1) the bowl formed in the inner body layer is received in the bowl support indentation of the outer body layer, and (2) together the inner body layer and outer body layer form a double-walled body including the double-walled bowl.
9. The method of claim 7 , further comprising peeling the seal away from the perimeter sealing surface to open the bowl.
10. The method of claim 7 , wherein the body comprises a double wall of a foil material defining a sidewall and a bottom of the bowl such that the bottom of the bowl is double-walled.