PACKAGED PRODUCTANDMETHOD OFMANUFACTURE

Field of the Invention

The present invention relates to packaged products and methods of manufacture. More specifically, the present invention relates to methods and devices for manufacturing and packaging deformable products.

Background of the Invention It has long been recognized that one of the primary factors in the costs of shipping and storing of merchandise is the volume required on a vehicle or vessel, in a warehouse, or on a store shelf. As more and more powerful engines are used in

transportation, and stronger material are used for construction, weight is becoming

less of a critical factor, and manufacturers are looking for ways to miniaturize, items, in both their eventual usage form, and the form in which they are shipped and stored prior to, or in between, usage.

Some items may be reduced in size by simply packaging less. Miniature toiletry kits, office desk sets, and snack foods have been marketed to great success

for many years. Some items may be reduced in size by making more effective

component parts. The current wave of personal electronic items comes immediately

to mind. Some items may be reduced in size by merely packing them better, and it is

in this arena that the present invention is directed.

Shrink wrapping of goods is a technique well known in the art. Taunton,

U.S. Patent Number 2,778,171 disclosed "a method of evacuating an envelope"

more than fifty years ago. Other inventions followed to address the method of

evacuation and the preparation of the containers, bags, and envelopes. None of

these, however dealt with the items to be contained in these containers, bags, and envelopes, nor with the configuration into which they would be placed.

Compression of the item itself to reduce volume is also a technique well known in the art Merry, U.S. Patent Number 5,172,629 discloses "a method of compacting a sheet article" such as a shirt or underwear, made of woven fabric, to reduce the volumetric requirement. Earlier, Hammon, U.S. Patent Number 2,659,935 disclosed a method of making compressed sponges.

Such prior art, however, has dealt primarily with the method of evacuation or compression and the apparatus to perform such evacuation or compression, rather than with the item to be evacuated or compressed. Items were assumed to be either

formless, such as underwear or t-shirts, or capable of retaining their general shape when compressed. There is a need in the art for a method and device for the

compression of items to reduce their space requirements, where subsequent shape recovery would be automatic and fast. Likewise, there is a need in the art for a

method and device for the compression of items to reduce their space requirements, where the item being compressed has one, predetermined, shape when compressed, and a second, also predetermined, shape when released from compression.

Summary of the Invention

The present invention includes a packaged product and a method for

packaging a product. A packaged product includes a compressible product with a

flexible outer shell and a stuffing. The stuffing is formed from a compressible

memory material such that the outer shell and the stuffing cooperate to form the

compressible product into an uncompressed shape under ambient atmospheric

pressure. In one optional embodiment, the stuffing may be hollow conjugate

siliconized polyester fiber.

A packaged product also includes an airtight packaging envelope. The packaging envelope includes a sealable opening. The compressible product is

placed within the packaging envelope. When a pressure differential is created inside the envelope and the opening is sealed, the compressible product assumes a deformed state substantially smaller than the uncompressed shape. Optionally, the deformed state includes compressing and/or folding the compressible product. When the seal is opened, the outer shell and the stuffing cooperating to substantially

reform the compressible product to the uncompressed shape. hi an optional embodiment, the outer shell includes a graphic thereon that is unobscured in the uncompressed shape. When the compressible product is placed

within the packaging envelope, the product is positioned to obscure the graphic on the outer shell. Consequently, when the seal is opened, the outer shell and the

stuffing cooperating to substantially reform the compressible product to the uncompressed shape with the graphic unobscured. For example, in one optional embodiment, the compressible product in the uncompressed shape includes a body, a

head extending from to the body, and at least one limb extending from the body. In one such optional embodiment, the graphic appears on the body, and the body is

positioned in the packaging envelope with the head and/or the limb folded to

obscure the graphic.

The present invention also includes a method for packaging a product and a

product manufactured according to the method. According to an embodiment of the

method, a flexible outer shell is provided. The outer shell is stuffed with a stuffing

, formed from a. compressible memory material. Optionally, the stuffing is hollow

conjugate siliconized polyester fiber. The outer shell and the stuffing cooperate to

form a compressible product in an uncompressed shape under ambient atmospheric pressure.

An airtight packaging envelope including an a sealable opening is provided. The compressible product is placed into the packaging envelope and a pressure differential is created inside the envelope. Optionally, in placing the compressible

product into the packaging envelope, the compressible product may be folded and in creating a pressure differential, the compressible product may be compressed. The

opening is sealed such that the compressible product assumes a deformed state inside the packaging envelope substantially smaller than the uncompressed shape.

The packaging envelope and compressible product in a deformed state form a compressed packaged product. When the seal is opened, the outer shell and the

stuffing cooperate to substantially reform the compressible product to the uncompressed shape.

As above, in one optional embodiment, the outer shell may include a graphic thereon that is unobscured in the uncompressed shape. In one such optional

embodiment, the method includes positioning the compressible product in the packaging envelope to obscure the graphic on the outer shell such that the product is

and when the seal is opened, the outer shell and the stuffing cooperating to substantially reform the compressible product to the uncompressed shape to reveal

the graphic. For example, in one optional embodiment, the compressible product in

the uncompressed shape includes a body, a head extending from to the body, and at

least one limb extending from the body. The graphic appears on the body and when

the compressible product is placed in the packaging envelope, ^' the head and/or the

limb are folded to obscure the graphic.

Brief Description of the Drawings

FIG. 1 is a front view of a compressible product in an uncompressed shape according to an optional embodiment of the present invention;

FIG. 2 is a left side view of a compressible product in an uncompressed

shape according to the optional embodiment of FIG. 1 ;

FIG. 3 is a front view of a packaged product with a compressible product according to the optional embodiment of FIG. 1 in a deformed shape;

FIG. 4 is a left side view of a packaged product according to the optional embodiment of FIG. 3; FIG. 5 is a front view of a compressible product in an uncompressed shape according to an optional embodiment of the present invention;

FIG. 6 is a front view of a packaged product with a compressible product

according to the optional embodiment of FIG. 5 in a deformed shape;

FIG. 7 is a flow chart of a method according to an optional embodiment of

the present invention.

Description

Reference is now made to the figures wherein like parts are referred to by

like numerals throughout. The present invention is a packaged product 500 that

includes a compressible product 100 and a packaging envelope 380. FIGS. 1 and 5 show optional embodiments of a compressible product 100 according to the current

invention. The compressible product 100 may take many different forms such as a

stuffed animal or toy or other plush object. However, it is contemplated that the

compressible product 100 maybe any item of a deformable nature.

The compressible product 100 includes a compressible stuffing having an

uncompressed shape. The stuffing is formed from a compressible memory material. By compressible memory material, a material is contemplated that may be deformed

and compressed, but returns to its uncompressed shape when released. In one optional embodiment, the stuffing is hollow conjugate siliconized polyester fibers, such as 15D 64mm Hollow Conjugate Siliconized A grade polyester fibers. However, in alternate optional embodiments, other material may be used, as long as

such material is readily deformable and compressible, and capable of resuming its uncompressed shape when released. Optionally, the stuffing is stuffed into a flexible outer shell 121 and the stuffing and outer shell 121 cooperate to form the uncompressed shape. In such an optional embodiment, the outer shell 121 could take any form. In an optional

embodiment in which the compressible product is a stuffed animal or other plush toy, the outer shell 121 may be fabric, textile, fur, or other outer covering.

At ambient atmospheric pressure, the outer shell 121 and stuffing cooperate to form a compressible product 100 in an uncompressed shape. This uncompressed shape is distinguished from a deformed shape that is discussed in greater detail

below and shown in FIGS. 3, 4, and 6.

In one optional embodiment, decorative imagery such as facial features 111 may be included on the outer shell. La one particular embodiment, shown in FIGS. 5

and 6, a graphic 170 maybe visible, i.e. unobscured, on the outer shell 121. The

graphic 170 may take many different forms, but in an optional embodiment the

graphic is a message, such as "Happy Birthday" or "Get Well Soon," an image, or ■

other visually perceptible graphic 170 that is displayed in a graphic area on the outer

shell 121.

The compressible product may take any shape. Referring generally to FIGS.

1-6, in an optional embodiment the compressible product 100 consists of a body 140

connected to a head 110 and one or more limbs 120, 130, 150, 160, such as a left arm 120, a right arm 130, a.left leg 150, and a right leg 160. The body 140 may optionally a graphic in a designated graphic area 170. hi this optional embodiment,

the limbs 120, 130, 150, 160 and the head 110 are disposed about the body 140 as would be expected for the semblance of a person, an animal, or a similar creature. The head 110 exhibits facial features 111 intended to resemble eyes and a mouth, hi alternate optional embodiments, facial features 111 may differ, being more or less detailed, may exhibit different details, or may be omitted.

Turning to FIGS. 3 and 4, in the optional embodiment illustrated, the

packaged product 500 also includes a packaging envelope 380. hi one optional embodiment, the packaging envelope 380 is a plastic bag, sheath, tube, or other

container that can be sealed in an airtight fashion, hi an optional embodiment, the packaging envelope 380 is formed from a flexible plastic ply that will conform to the shape of the compressible product 100 placed inside it.

To carry out the method of the present invention, as shown in FIG. 7, the compressible product 100 provided 700 is placed 704 in the packaging envelope 380

provided 702. hi placing the 704 compressible product 100 in the packaging

envelope 380, the compressible product 100 may be simply inserted or, in an optional embodiment, may be positioned within the packaging envelope 380. For

example, in one optional embodiment, shown in FIG. 6, the compressible product

100 may be folded inside the packaging envelope 380 so it is held in a folded

configuration as discussed in greater detail below, hi one such optional embodiment, a compressible product having a graphic 170 thereon is placed in the

packaging envelope 380 with the graphic 170 obscured or hidden. Thus, in the example discussed above in which a compressible product 100 includes a body 140

with a head 110 and limbs 120, 130, 150, 160 extending therefrom, a graphic 170 on the compressible product 100, such as the body 140, may be obscured by folding the

head 140 and/or one or more limbs 120, 130, 150, 160 across the body.

Referring generally to FIGS. 3, 4, 6, and 7, a pressure differential is created 706 to reduce the pressure inside the packaging envelope 380 below ambient atmospheric pressure. The pressure differential inside the packaging envelope 380 causes the packaging envelope 380 to collapse, and allows ambient air pressure to

compress the compressible product 100 into a deformed shape substantially smaller than the uncompressed shape. Optionally, the pressure differential is created by evacuating air from the packaging envelope 380 through an opening. For example,

air may be evacuated through the opening using a vacuum pump.

For example, in an optional embodiment in which hollow conjugate

siliconized polyester fibers fill a textile outer shell, one may anticipate that the compressible product 100 will be reduced in volume by approximately 80% when in its deformed shape compared to its uncompressed shape. However, it is noted that this is exemplary only and, in alternate optional embodiments, such compression

ratio may be higher or lower. While the optional embodiment illustrated anticipates

that the airtight package 380 will be highly evacuated, such evacuation is not

essential and in alternate optional embodiments evacuation may be to a lesser degree

or omitted.

With continued reference to FIGS. 3, 4, 6, and 7, to maintain the pressure

differential, the packaging envelope 380 is sealed 708. As maybe appreciated, if the compressible product 100 is positioned before the pressure differential is created, the

packaging envelope 380 will hold the compressible product 100 in position when the packaging envelope 380 collapses around the compressible product 100. The seal

382 may take many different forms, including adhesive, an interlocking seam,

mechanical fasteners, or the like, hi an optional embodiment in which the packaging envelope 380 is a flexible plastic ply, a seal may be created by heating and crimping opposing surfaces until the ply melts and forms a seal.

When the seal 382 is broken, the pressure inside and outside the packaging

envelope 380 reaches equilibrium and the outer shell 121 and stuffing cooperate to substantially reform the compressible product 100 to its uncompressed shape. For

example, in one optional embodiment in which the packaging envelope 380 is heat sealed, the seal 382 may be broken by cutting the airtight package 380. In alternate optional embodiments, the airtight package 380 may be resealable or reformable, so that the airtight package 380 may be reused, hi the optional embodiment illustrated,

the compressible product 100, once removed from the airtight package 380,

substantially reforms itself from its deformed shape to its uncompressed shape. For example, once removed from the airtight package 380 and released, the memory-

type stuffing of which the compressible product 100 substantially reforms its uncompressed shape, so that the compressible product 100 in its deformed shape in

FIGS. 3 and 4 reforms itself into its uncompressed shape as shown in FIGS. 1 and 2, just as the compressible product 100 in its deformed shape in FIG. 6 reforms itself

into its uncompressed shape as shown in FIG. 5. hi an optional embodiment of

FIGS. 5 and 6 in which a graphic 170 is included on the outer shell 121, the

reforming of the uncompressed shape serves to reveal the graphic 170 that was

obscured in the deformed shape.

It contemplated that the compressible product 100 may be constructed to allow repeated compression and decompression of the compressible product 100.

While certain embodiments of the present invention have been shown and

described it is to be understood that the present invention is subject to many modifications and changes without departing from the spirit and scope of the claims

presented herein.