Packaged product and method of manufacture

Abstract

A compressible product such as a stuffed toy is formed of a memory type stuffing, such as hollow conjugate siliconized polyester fibers, optionally surrounded by an outer shell, that has an uncompressed shape at ambient atmospheric pressure. The compressible product is positioned in a packaging envelope and a pressure differential is created to deform the product into a deformed shape substantially smaller than the uncompressed shape. Optionally, a graphic on the outer shell that is visible in the uncompressed shape is obscured in the deformed shape. The packaging envelope is sealed with the compressible product in the deformed shape. When the seal is broken, the stuffing and outer shell cooperate to substantially reform the compressible product into its uncompressed shape.

1 . A packaged product comprising: 
 a compressible product comprising a flexible outer shell and a stuffing, said stuffing formed from a compressible memory material such that said outer shell and said stuffing cooperate to form said compressible product into an uncompressed shape under ambient atmospheric pressure; and    an airtight packaging envelope including a sealable opening such that when said compressible product is placed within said packaging envelope, a pressure differential is created to reduce the pressure inside said packaging envelope below ambient atmospheric pressure, and said opening is sealed, said compressible product assumes a deformed state substantially smaller than said uncompressed shape, and when said seal is opened, said outer shell and said stuffing cooperating to substantially reform said compressible product to said uncompressed shape.    
   
   
       2 . The packaged product of  claim 1  wherein said deformed state includes compressing said compressible product.  
   
   
       3 . The packaged product of  claim 1  wherein said deformed state includes folding said compressible product.  
   
   
       4 . The packaged product of  claim 1  wherein said outer shell includes a graphic thereon that is unobscured in said uncompressed shape such that when said compressible product is placed within said packaging envelope, said product is positioned to obscure said graphic on said outer shell and when said seal is opened, said outer shell and said stuffing cooperating to substantially reform said compressible product to said uncompressed shape with said graphic unobscured.  
   
   
       5 . The packaged product of  claim 4  wherein said compressible product in said uncompressed shape includes a body, a head extending from to said body, and at least one limb extending from said body.  
   
   
       6 . The packaged product of  claim 5  wherein said graphic appears on said body, and said body is positioned in said packaging envelope with one of said head or said limb folded to obscure said graphic.  
   
   
       7 . The packaged product of  claim 1  wherein said stuffing is hollow conjugate siliconized polyester fiber.  
   
   
       8 . A packaged product comprising: 
 a compressible product comprising a flexible outer shell and a stuffing, said stuffing formed from a compressible memory material such that said outer shell and said stuffing cooperate to form said compressible product into an uncompressed shape under ambient atmospheric pressure, said outer shell including a graphic thereon that is unobscured in said uncompressed shape; and    an airtight packaging envelope including a sealable opening such that when said compressible product is placed within said packaging envelope with said product positioned to obscure said graphic on said outer shell, a pressure differential is created to reduce the pressure inside said packaging envelope below ambient atmospheric pressure, and said opening is sealed, said compressible product assumes a deformed state substantially smaller than said uncompressed shape with said graphic obscured, and when said seal is opened, said outer shell and said stuffing cooperating to substantially reform said compressible product to said uncompressed shape with said graphic unobscured.    
   
   
       9 . The packaged product of  claim 8  wherein said deformed state includes compressing said compressible product.  
   
   
       10 . The packaged product of  claim 8  wherein said compressible product in said uncompressed shape includes a body, a head extending from to said body, and at least one limb extending from said body.  
   
   
       11 . The packaged product of  claim 10  wherein said graphic appears on said body, and said body is positioned in said packaging envelope with one of said head or said limb folded to obscure said graphic.  
   
   
       12 . The packaged product of  claim 8  wherein said stuffing is hollow conjugate siliconized polyester fiber.  
   
   
       13 . A method for packaging a product, comprising: 
 providing a flexible outer shell;    stuffing said outer shell with a stuffing, said stuffing formed from a compressible memory material such that said outer shell and said stuffing cooperate to form a compressible product in an uncompressed shape under ambient atmospheric pressure;    providing an airtight packaging envelope including an a sealable opening;    placing said compressible product into said packaging envelope;    creating a pressure differential to reduce the pressure inside said packaging envelope below ambient atmospheric pressure; and    sealing said opening such that said compressible product assumes a deformed state inside said packaging envelope substantially smaller than said uncompressed shape wherein the packaging envelope and compressible product in a deformed state form a compressed packaged product, and when said seal is opened, said outer shell and said stuffing cooperate to substantially reform said compressible product to said uncompressed shape.    
   
   
       14 . A compressed packaged product manufactured by the method of  claim 13 .  
   
   
       15 . The method of  claim 13  wherein said step of creating a pressure differential includes compressing said compressible product.  
   
   
       16 . The method of  claim 13  wherein said step of placing said product into said packaging envelope includes folding said compressible product.  
   
   
       17 . The method of  claim 13  wherein said outer shell includes a graphic thereon that is unobscured in said uncompressed shape, said method further comprising positioning said compressible product in said packaging envelope to obscure said graphic on said outer shell such that said product is and when said seal is opened, said outer shell and said stuffing cooperating to substantially reform said compressible product to said uncompressed shape with said graphic unobscured.  
   
   
       18 . The method of  claim 17  wherein said compressible product in said uncompressed shape includes a body, a head extending from to said body, and at least one limb extending from said body.  
   
   
       19 . The method of  claim 18  wherein said graphic appears on said body, said method further comprising folding one of said head or said limb to obscure said graphic after placing said compressible product in said packaging envelope.  
   
   
       20 . The method of  claim 13  wherein said stuffing is hollow conjugate siliconized polyester fiber.