Method for producing hangers and similar devices for clothing support, comprising at least one concave area, starting from a flat layer of paper material
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Solution Overview
Problem
The production of hangers using cellulose pulp is limited by high material costs, complex and time-consuming processes, and restricted thickness due to humidity removal capacity, making it less efficient compared to plastic materials.
Innovation Solution
A method involving a flat layer of paper material, where the paper is wetted, rested, cut, knurled, and formed using a mould and counter-mould, with controlled humidity reduction to produce biodegradable hangers with equivalent costs and production times to plastic hangers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cellulose pulp is used to produce hangers, then the hangers are ecological and biodegradable, but the material cost is significantly higher than plastic
Solution Approach 1:
The invention changes the physical-chemical parameters of the paper material by controlling humidity levels during processing. The paper is wetted to a specific humidity range (40-70%) before forming, which transforms its mechanical properties to become more pliable and easier to form into three-dimensional shapes, thereby reducing processing complexity and cost while maintaining the ecological benefits
Solution Approach 2:
The invention applies preliminary wetting action to the paper material before the forming process. By pre-humidifying the paper to optimal levels, the material becomes more susceptible to forming operations, reducing the energy and time required during actual production, thus lowering overall manufacturing costs while preserving biodegradability
2Reliability
If cellulose pulp is used to produce hangers, then the hangers are ecological and biodegradable, but the production process is more complex and requires longer time than plastic
Solution Approach 1:
The invention performs preliminary wetting of the paper material before forming operations. This pre-treatment optimizes the material's plasticity in advance, allowing faster and more efficient forming processes, thereby reducing overall production time while maintaining the ecological advantages of cellulose-based materials
Solution Approach 2:
The invention optimizes the humidity parameter of the paper material during processing. By maintaining humidity within the 40-70% range during forming, the material achieves optimal workability, enabling faster production cycles without compromising the biodegradable nature of the product
3Reliability
If cellulose pulp is used to produce hangers, then the hangers are ecological and biodegradable, but the thickness is limited by the humidity removal capacity
Solution Approach 1:
The invention applies preliminary wetting to achieve optimal humidity levels (40-70%) before forming thick sections. This pre-treatment ensures that even thick paper material maintains appropriate plasticity during forming, and the controlled humidity state facilitates more efficient moisture removal during drying, enabling production of thicker hangers while preserving ecological properties
Solution Approach 2:
The invention changes the humidity parameter of the paper material to an optimized range (40-70%) that balances plasticity for forming with moisture removal efficiency. This parameter optimization enables the production of thicker hanger sections that would otherwise be difficult to process, while maintaining the biodegradable characteristics of cellulose material
4Manufacturing precision
If paper material is wetted and dried to produce hangers, then the hangers have uniform thickness and good formability, but the processing time increases
Solution Approach 1:
The invention optimizes the humidity parameter to a specific range (40-70%) during forming operations. This optimized parameter range provides the best balance between material plasticity for achieving uniform thickness and moisture content for efficient drying, thereby reducing overall processing time while maintaining high manufacturing precision and thickness uniformity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method enables the production of biodegradable hangers with uniform thickness and reduced processing time, achieving costs and efficiency comparable to plastic hangers while using recycled paper fibers.
Implementation Method 1
carrying out a first step a) of wetting the flat layer of paper material so as to increase the humidity percentage
Implementation Method 2
introducing the hanger into a tunnel in which cold air circulates with a humidity level less than 13%, so as to rapidly decrease the humidity level of the hanger
Data Source
Figure 1
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Figure 4~10
AI summary
It is a method (1) for producing hangers and similar devices for clothing, comprising at least one concave area, starting from a flat layer of paper material, that provides for the following steps: a) wetting said flat layer of paper material so as to increase the humidity percentage with respect to the standard humidity percentage at room temperature; b) leaving said layer of paper material to rest for a predetermined period of time so that said humidity percentage is uniformly distributed throughout the entire thickness of said flat layer of paper material; c) cutting said flat layer of paper material so as to define an appropriate shape for the realization of said hanger; d) carrying out a knurling operation on at least one portion of said cut flat layer of paper material in which said at least one concave area will be realized; e) forming said cut flat layer of paper material by means of the introduction of said cut flat layer of paper material between a mould and a counter-mould and subsequently through pressing; f) carrying out a stabilisation operation of said hanger, reducing the humidity percentage thereof.