Patent Application
20070220829
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.
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. Pat. No. 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. Pat. No. 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. Pat. No. 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.
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.
In 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.
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.
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 15 D 64 mm 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
In one optional embodiment, decorative imagery such as facial features 111 may be included on the outer shell. In one particular embodiment, shown in
The compressible product may take any shape. Referring generally to
Turning to
To carry out the method of the present invention, as shown in
Referring generally to
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
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. In 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
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.
