Method for manufacturing a hanger for supporting clothing and similar devices, starting from a flat paper material layer and comprising at least one concave region

Abstract

1. A method (1) for manufacturing hangers and similar devices for clothes, comprising at least one recessed area, starting from a flat layer of paper material, the method comprising the following steps: a) wetting said flat layer of paper material to increase its humidity percentage relative to a standard humidity percentage at room temperature; b) allowing said layer of paper material to rest for a predetermined period of time so that said moisture percentage is uniformly distributed throughout the thickness of said flat layer of paper material; c) cutting said flat layer of paper material to define a shape suitable for realizing said hanger; d) performing a knurling process on at least one portion of said cut flat paper material layer in which said at least one recessed area is realized; e) shaping the cut flat layer of paper material by introducing it between a mold and an opposing mold and then pressing; f) Stabilizing the hanger to reduce its moisture percentage.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing hangers and similar devices for supporting clothes, starting from a flat paper material layer and including at least one concave region.

[0002] The term similar device means any object for hanging, publicly displaying, and transporting clothing and its accessories.

[0003] The present invention also relates to hangers and similar devices for supporting clothes, including at least one concave region obtained by the above method.

[0004] Furthermore, the present invention relates to a system configured to execute the above method.

Background Art

[0005] As is known with the growing environmental awareness on a global scale, there is an increasing need to replace objects made of plastic materials with biodegradable objects made of natural-derived substances, particularly plant-derived substances, that protect the environment.

[0006] A known solution to this need is the use of so-called "cellulose pulp", which is a natural product overall, whose main component is wood and consists of 45% cellulose, 30% hemicellulose, 23% lignin, and 5% various extracts including resins, terpenes, and fatty acids.

[0007] The cellulose pulp, which appears substantially as wet pulp, is used in a thermoforming process to manufacture various objects such as tableware, general glasses and spectacles, packaging elements like egg boxes, or various objects like shoe lasts or shoe holders.

[0008] However, using the above material to manufacture the object has several significant drawbacks compared to using a plastic material to obtain the same object.

[0009] First, the cost of the "cellulose pulp" raw material is significantly higher than the cost of the compounds used to manufacture plastic objects.

[0010] The document showing the most important technology is JP-A-09-37921, which discloses a method for manufacturing a hanger starting from a flat paper material layer and including one concave region. The method comprises the following steps.

[0011] Cutting the flat paper material layer so as to define a shape suitable for the realization of the hanger. Forming the cut flat paper material layer by introducing the cut flat paper material layer between a mold and a counter mold and then pressing it.

[0012] Also, the following additional technologies are cited: Utility Model Laid-Open No. 07-14978U, JP-A-09-215580, and WO2011 / 010091A2.

[0013] In all of these processes described in the foregoing documents, a further problem lies in the fact that the thickness of the object being operated on is limited by the operating capacity of the device suitable for removing the humidity of the cellulose pulp.

Summary of the Invention

Problems to be Solved by the Invention

[0014] The present invention is intended to overcome all of the above-mentioned drawbacks existing particularly in the devices and processes described in the foregoing documents.

[0015] Furthermore, additional drawbacks are also associated with the manufacturing processes for producing three-dimensional objects using cellulose pulp. This is because these processes are more complex and require a longer time than the processes used to manufacture the same objects from plastic materials.

[0016] In particular, the cellulose pulp being processed must be wet and then dried, which requires long processing times.

[0017] A further problem lies in the fact that the thickness of these objects is limited by the operating capacity of the equipment suitable for removing the humidity of the cellulose pulp.

[0018] The present invention intends to overcome all the above-mentioned drawbacks. More precisely, the present invention relates to a method provided for the use of cellulose pulp, and intends to propose an alternative method for manufacturing hangers and similar tools for biodegradable type clothing support while protecting the environment.

[0019] In particular, the object of the present invention is to propose a method that enables the production of hangers and similar tools for clothing support that protect the environment, are biodegradable, and have a cost equivalent to that of the same products made of plastic.

[0020] Furthermore, the object of the present invention is to propose a method for manufacturing hangers and similar tools for biodegradable type clothing support, and the method is such that the implementation time for manufacturing the object is completely equivalent to the method used for manufacturing the same object with plastic materials.

Means for Solving the Problems

[0021] The above object is achieved by a method for manufacturing hangers and similar tools for clothing according to the main claim.

[0022] Further features of the method of the present invention are described in the dependent claims.

[0023] The above object is also achieved by a system for implementing the method of the invention described in claim 13.

[0024] Finally, a hanger obtained by using the method and obtained by using the system is also described in the claims.

Brief Description of the Drawings

[0025] Along with the advantages mentioned below, the above object is shown in the description of the preferred embodiments of the present invention given by way of non-limiting examples with reference to the accompanying drawings.

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Mode for Carrying Out the Invention

[0026] A method for manufacturing a hanger provided with at least one concave region according to the present invention starts from a flat layer of paper material, is described below according to a preferred embodiment, and is shown as a whole in FIG. 1 using reference numeral 1.

[0027] Furthermore, the method according to the present invention will be described with reference to the hanger shown in FIG. 2 using reference numeral 100.

[0028] Here, the hanger 100 shows an example of a hanger obtained by the method 1 of the present invention and is proposed only for the purpose of explanation.

[0029] However, it is obvious that what will be described later will be applied in a manner similar to hangers of any shape as long as at least one concave region is provided.

[0030] The flat paper material shown by reference numeral 200 in FIG. 3 is preferably composed of a thickness of 0.5 mm to 4.5 mm and is mainly composed of paper fibers recovered by recycling.

[0031] Returning to the preferred embodiment of Method 1 of the present invention, there is provided in the figure the implementation of the first step a) of wetting the aforementioned flat paper material 200, which is preferably a flat layer of fiber cardboard 201 shown in FIG. 3. Thereby, the humidity percentage is increased with respect to the standard humidity percentage presented by the flat layer of the paper material 200 at room temperature.

[0032] Following this wetting step, the method provides for performing a step (b) of pausing the layer of flat paper material 200 for a predetermined time, such that the aforementioned humidity percentage is uniformly distributed throughout its thickness.

[0033] Specifically, according to a preferred embodiment of the present invention, this humidity percentage resulting from the flat layer of paper material 200 passing through steps a) and b) is composed between 10% and 30%, preferably between 15% and 25%, and more preferably 22%.

[0034] Regarding the wetting step a), according to a preferred embodiment, it is performed by applying in vaporized form a substance containing water to at least one surface of the flat paper material 200. Also, this substance can contain a softening compound, such as soap, wax or emollient, in a percentage lower than the amount of water.

[0035] The presence of the aforementioned softening compound softens the fibers and promotes their widening.

[0036] In an alternative embodiment, the aforementioned substance can be applied onto the flat layer of paper material 200 by rolling.

[0037] Regarding the pausing step b), according to a preferred embodiment of the present invention, the layer of paper material 200 is paused at room temperature for between 12 hours and 36 hours, preferably 24 hours.

[0038] The execution of the two steps a) and b) described above advantageously enables the layer of flat paper material 200 to be softer and more malleable than its natural properties, facilitating the subsequent shaping step.

[0039] Continuing with the steps of Method 1 of the present invention, after the layer of flat paper material 200 has been paused once so as to exhibit a humidity percentage that is higher than standard and uniform across its entire thickness, the layer of flat paper material 200 is cut to define an appropriate shape for the realization of the intended hanger 100. As an example considered, this shape of the flat layer of paper material 200 is shown in Figure 4, indicated by reference number 300.

[0040] Said appropriate shape depends on the hanger 100 that is intended to be obtained at the end of the process.

[0041] In fact, in order to obtain the desired shape at the end of the process, it is necessary to continue to perform trials during the development phase.

[0042] According to a preferred embodiment of the present invention following cutting step c), Method 1 of the present invention provides for performing a rolling step c2) on this flat paper material layer in order to facilitate the opening of its fibers.

[0043] However, this step c2) may be omitted in place of the preferred embodiment.

[0044] Following step c) or step c2), Method 1 of the present invention performs a knurling step d) on at least one portion 301 (Figure 5) of the flat layer of cut paper material 300 where the aforementioned concave region 101 will be realized.

[0045] In particular, said knurling operation provides for making incisions with substantially parallel and non-intersecting lines, shown in Figure 5 by reference number 302, in a direction that is substantially orthogonal to the direction of the fold to be made.

[0046] These incisions 302 are preferably made by passing the portion 301 of the flat layer of cut paper material 300 between two toothed rollers.

[0047] Advantageously, these incisions are made with lines 302 that are substantially parallel and non-intersecting, and then, in the region 101 that will be made concave, by partially and alternately thinning the portions 301 of the flat paper material 300 that have been cut, once the shaping has been carried out, it becomes possible to maintain the same thickness of the object 100 in this region 101, which is substantially uniform and regular, avoiding wrinkles and non-uniformities that would structurally weaken the object 100, and in any case it will not be noticeable.

[0048] Subsequently, in step e), a flat layer of the same cut paper material 300 is introduced between the mold 400 and the counter mold 500 (Figs. 11 - 14), and then, by pressing, the cut flat layer of the paper material 300 is given a shape.

[0049] As can be seen from these last four figures, according to the invention, the flat layer 300 will advantageously be held during the shaping process by at least one catch 450 that is integral with the mold 400, so that it adheres firmly to the opposite surface of the counter mold 500, and thus it will be as seen in the sequence of Figs. 12 - 14. The flat layer 300 changes its shape in the desired way while maintaining its fixed position relative to the counter mold 500. It should be noted that in an alternative embodiment, at least one catch 450 may also be integral with the counter mold 500 so that the flat layer 300 adheres firmly to the opposite surface of the mold 400 during the shaping process.

[0050] According to a preferred embodiment of the invention, this forming step e) is thermoforming.

[0051] In particular, the mold and the counter mold are heated to have a temperature between 60°C and 120°C, preferably between 80°C and 100°C, and more preferably 90°C during the press.

[0052] Finally, the method 1 of the invention performs a stabilization step f) on the formed hanger 100 to reduce its humidity percentage.

[0053] In particular, according to a preferred embodiment of the present invention, in this stabilization step f), the hanger 100 is introduced into a tunnel in which cold air circulates and the humidity level is less than 13%.

[0054] It is advantageous for the cold air to flow over the entire surface of the hanger 100, particularly within the aforementioned concave region 101, rapidly reducing the humidity level of the hanger 100 and thus stabilizing its shape.

[0055] However, it is not excluded that this stabilization step is carried out by hot air.

[0056] As described above, the hanger 100 obtained by Method 1 of the present invention also forms part of the present invention.

[0057] Furthermore, starting from a flat layer of paper material 200, a system for manufacturing a hanger 100 provided with at least one concave region 101 also forms part of the present invention, where the system comprises the following: - A station for wetting the flat layer of paper material 200 so as to carry out step a) of the method according to the present invention; - A rest station for resting the flat layer of paper material 200; - A cutting station provided with a cutting matrix configured to carry out step c) of the method of the present invention; - A knurling station provided with at least two toothed rollers configured to carry out step d) of the method of the present invention; - A press-forming step provided with a mold and a counter-mold configured to carry out step e) of the method of the present invention; - A stabilization station configured to reduce the humidity percentage of the hanger 100 following the forming operation.

[0058] As can be seen from FIG. 6, once the hanger 100 is obtained by the process according to the present invention, at least one concave region 101 is provided, and it is necessary to assume the presence of the hook 600. Advantageously, the hook will be made of paper material in the desired shape, but in any case will have a flat structure, so that it can be inserted into a suitable slit 700 provided at the top of the hanger to obtain the structure shown in FIGS. 7 and 8. The hook 600 has a shank 800, has a longitudinal dimension larger than that of the slit 700, and has a form corresponding to the inner surface of the top, so that it is accurately and stably arranged at the top of the hanger to perform its function.

[0059] Alternatively, the hook 600 comprises two arms 1000 and has a shank 900 having a shape corresponding to the hanger 100 (FIGS. 9 and 10), ensuring the reinforcement of the whole hanger in addition to stabilizing the hook 600 in the desired position.

[0060] As can be seen from FIGS. 15 to 18, it is possible to use the hanger 100 having at least one concave region 101 obtained by the above-described method and / or system even with a conventional hook. In fact, as can be seen in said figures, the hook 850 advantageously has a straight segment 950 which is made of a metal material in a known manner per se, rises from the top of the hanger 100 and then continues into a curved portion 1050. In particular, as can be seen in FIG. 18, the straight segment 950 ends at the bottom with a threaded portion 1150 which can be inserted into a through hole 1250 made in the top of the hanger.

[0061] As can be particularly seen from Figure 17, a substantially cylindrical element 2000 having a threaded hole 2001 is disposed inside and where it cannot be seen from the outside of the top, and the threaded portion 1150 can engage with the threaded hole 2001. The element 2000 is disposed between two protrusions 3000 existing in the inner part of the top of the concave region 101 of the hanger 100. Thus, it is clear that when the hook 850 is properly screwed into the threaded hole 2001 of the element 2000, an interengagement is generated between the hook 850 and the element 2000, and thus with the hanger 100.

[0062] Advantageously, the element 2000 will be made precisely of a compostable material so that it can be recycled in the same way as the hanger 100. Conversely, it is clear that it is sufficient for the user to simply loosen the hook 850 from the element 2000 when the hanger has suffered irreparable damage or when the user wishes to dispose of the hanger when no longer using it, and as a result, the hook 850 can be properly disposed of in metal waste.

[0063] From the foregoing description, it can be understood that the methods, objects and systems described above achieve all of the intended purposes.

[0064] More precisely, with regard to the method of using cellulose pulp, the object of proposing an alternative method for manufacturing an environmentally protective and biodegradable type of hanger has been achieved.

[0065] Furthermore, the object of proposing a method for manufacturing a hanger that can protect the environment and realize a biodegradable product at a cost exactly equivalent to that of the same product made of plastic has also been achieved.

[0066] Also achieved is the proposal of a method for manufacturing an environmentally protective and biodegradable hanger that provides an implementation time for realizing a product comparable to the method of manufacturing the same product from plastic material.

Claims

1. A method (1) for manufacturing a hanger (100) for supporting clothing, starting from a flat paper material layer (200) and including at least one concave region (101), comprises the following steps: a) wetting the flat paper material layer (200) so as to increase the humidity percentage with respect to the standard humidity percentage that the flat paper material layer (200) has at room temperature; b) pausing the flat paper material layer (200) for a predetermined period so that the humidity percentage is evenly distributed throughout the thickness of the flat paper material layer (200); c) cutting the flat paper material layer (200) so as to have a shape suitable for the realization of the hanger (100); d) performing knurling on at least one portion (301) of the cut flat paper material layer (300) so that the at least one concave region (101) is realized, the knurling step comprising passing at least one portion (301) of the cut flat paper material layer (300) between two toothed rollers and cutting it with parallel and non - intersecting lines (302) in a direction orthogonal to the direction of the fold to be made; e) introducing the cut flat paper material layer (300) between a mold and a counter - mold and then pressing it to shape the cut flat paper material layer (300); f) performing a stabilization step of reducing the humidity percentage on the hanger (100).

2. The method (1) according to claim 1, characterized in that the cut flat paper material layer (300) is held during the shaping step by at least one catch (450) integrated with the mold (400) or the counter - mold (500) and adheres firmly to the opposing surface of the opposing counter - mold (500) or the mold (400).

3. The method (1) according to claim 1 or 2, characterized in that there is a rolling process c2) for opening the fibers of the cut flat paper material layer (300) between the cutting process c) and the knurling process d).

4. The method (1) according to any one of claims 1 to 3, characterized in that the humidity percentage of the flat paper material layer (200) after the processes (a) and (b) is between 10% and 30%.

5. The method (1) according to any one of claims 1 to 4, characterized in that the wetting process a) applies a substance containing water in a vaporized form to at least one surface of the flat paper material layer (200).

6. The method (1) according to any one of claims 1 to 3, characterized in that the wetting process a) applies a substance containing water to at least one surface of the flat paper material layer (200) by rolling.

7. The method (1) according to any one of claims 1 to 6, characterized in that the rest process b) rests the flat paper material layer (200) at room temperature for a period of between 12 hours and 36 hours.

8. The method (1) according to any one of claims 1 to 7, characterized in that the forming process e) is a hot forming, and the mold and the opposing mold have a temperature between 60°C and 120°C during pressing.

9. The method (1) according to any one of claims 1 to 8, characterized in that the stabilization process f) introduces the hanger (100) into a tunnel where cold air circulates and the humidity is less than 13%.

10. The method (1) according to any one of claims 1 to 9, characterized in that the flat paper material layer (200) is a flat layer of fiber cardboard (201).

11. A system for manufacturing a hanger (100) for supporting clothing, starting from a flat paper material layer (200) and including at least one concave region (101), the system continuously including the following: - A station for wetting the flat paper material layer (200) so as to carry out step a) of the method according to claim 1; - A rest station for resting the flat paper material layer (200); - A cutting station provided with a cutting matrix configured to carry out step c) of the method according to claim 1; - A knurling station provided with at least two toothed rollers configured to carry out step d) of the method according to claim 1; - A forming press provided with a mold and a counter-mold, the forming press being configured to carry out step e) of the method according to claim 1; - A stabilization station configured to reduce the humidity percentage of the three-dimensional object (100) following the forming step.

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