Thermoformed blister package

Abstract

A blister package ( 10 ) and method for manufacturing the blister package include an upper wall member ( 14 ) (e.g., front panel), a lower wall member ( 16 ) (e.g., backer) and a printing ( 20 ) (e.g., print, decoration, advertising), where the upper wall member is formed to effectively hold an article ( 12 ) (e.g., toothbrush, razor) preferably by accommodating specific geometry of the article. The lower wall member is preferably formed (e.g., molded, thermoformed) after printing from a flat sheet of material (e.g., plastic) to resemble a cylindrical or cone based final shape linearly along or parallel to the lower wall member's longitudinal axis ( 46 ). The printing is applied to the flat sheet of material without distortion and appears on the final shaped lower wall member without the appearance of distortion.

1 . A blister package for housing an article, comprising:
 a front panel;   a backer molded from a planar film and defining an outline portion laving a longitudinal axis and a convex curve cross-section; and   a printing, on the outline portion;   wherein the outline portion is linear along the longitudinal axis and has not been deformed along or parallel to the longitudinal axis but has only been deformed transversely to the axis, wherein the front panel and the backer are secured together to define a region for holding an article, and wherein the printing is legible on the backer.   
     
     
         2 . The blister package of  claim 1 , wherein the front panel further comprises a first three-dimensional structure and a planar rim; and the backer further comprises a planar flange and a second three-dimensional structure; the first three-dimensional structure protruding from the planar rim a first distance, the second three-dimensional structure protruding, from the planar flange a second distance, wherein the second distance is less than the first distance. 
     
     
         3 . The blister package of  claim 1 , wherein the outline portion is cone shaped. 
     
     
         4 . The blister package of  claim 2 , wherein a radius of curvature of the convex curve cross-section is greater than the second distance. 
     
     
         5 . The blister package of Claim  1 , wherein the outline portion comprises a backer transparent section for visual access to the article. 
     
     
         6 . The blister package of  claim 5 , wherein the article is a toothbrush comprising:
 a head with an elongated handle; and   bristles attached to the head, the backer transparent section allowing visual access to the head of the toothbrush.   
     
     
         7 . The blister package of  claim 1 , wherein the backer comprises an inner surface directed towards the article and an outer surface opposite the inner surface and directed away from the article, the printing being applied to the inner surface of the backer. 
     
     
         8 . The blister package of  claim 1 , wherein the backer comprises an inner surface directed towards the article and an outer surface opposite the inner surface and directed away from the article, the printing being applied to the outer surface of the backer. 
     
     
         9 . The blister package of  claim 1 , wherein the front panel further comprises a planar rim; and the backer further comprises a planar flange, the planar rim secured to the planar flange to define the region. 
     
     
         10 . The blister package of  claim 1 , wherein the outline portion extends across a width of the backer. 
     
     
         11 . A method for making a blister package for housing an article, comprising:
 a) providing a front panel;   b) applying a printing to a planar film, the printing having an appearance free of distortion on the planar film;   c) thermoforming the planar film into a backer to define an outline portion having a longitudinal axis and a convex curve cross-section, with the outline portion linear along the longitudinal axis, the printing thermoformed with the second planar film and maintaining a legible appearance regardless of distortion caused by the thermoforming;   d) placing the article into one of the front panel or the backer; and   e) sealing the front panel and the backer together with the article in between the front panel and the backer;   wherein, during the thermoforming, the outline portion is not deformed along or parallel to the longitudinal axis but is only deformed transversely to the axis.   
     
     
         12 . The method of  claim 11 , wherein the outline portion is cylindrical. 
     
     
         13 . The method of  claim 11 , wherein the front panel further comprises a first three-dimensional structure and a planar rim; and the backer further comprises a planar flange and a second three-dimensional structure; the first three-dimensional structure protruding from the planar rim a first distance, the second three-dimensional structure protruding from the planar flange a second distance, wherein the second distance is less than the first distance. 
     
     
         14 . The method of  claim 13 , wherein the convex curve cross-section has a radius of curvature greater than the second distance. 
     
     
         15 . The method of  claim 11 , wherein the outline portion is cone shaped. 
     
     
         16 . A backer sealed to a front panel to form a blister package for housing an article, the front panel including a first three-dimensional thermoformed structure and a planar rim extending about the periphery of the first three-dimensional thermoformed structure, the first three-dimensional thermoformed structure molded from a first planar film and protruding from the planar rim to define an article receiving portion, the first three-dimensional thermoformed structure including a first transparent section for visual access to the article, the backer comprising:
 a second three-dimensional thermoformed structure;   a planar flange extending about the periphery of the second three-dimensional thermoformed structure; and   a printing,   wherein the second three-dimensional thermoformed structure is molded from a second planar film and protrudes from the planar flange to define an outline portion having a longitudinal axis and a convex curve cross-section, wherein the outline portion is linear along the longitudinal axis and has not been deformed along or parallel to the longitudinal axis but has only been deformed transversely to the axis;   the backer being sealed to the front panel by a bonding of the planar rim to the planar flange to define a sealed region, the first and second three-dimensional thermoformed structures cooperating to form an article receiving pocket for the article, the printing being on the outline portion and being legible on the backer.   
     
     
         17 . The backer of  claim 16 , the outline portion including a backer transparent section for visual access to the article. 
     
     
         18 . The backer of  claim 17 , wherein the article is a toothbrush comprising:
 a head with an elongated handle; and   bristles attached to the head, wherein the backer transparent section allows visual access to the head of the toothbrush.   
     
     
         19 . The backer of  claim 16 , wherein the outline portion extends across a width of the backer between the planar flanges at opposite ends of the width. 
     
     
         20 . The backer of  claim 16 , wherein the first three-dimensional thermoformed structure protrudes from the planar rim a first distance, the second three-dimensional thermoformed structure protrudes from the planar flange a second distance less than the first distance. 
     
     
         21 . The backer of  claim 16 , wherein a radius of curvature of the convex curve cross-section is greater than the protrusion of the second three-dimensional thermoformed structure from the planar flange. 
     
     
         22 . The backer of  claim 16 , wherein the outline portion is cone shaped. 
     
     
         23 . The backer of  claim 16 , wherein the outline portion is cylindrical.