GB2463248A

GB2463248A - Biodegradable garment hanger with clay coating

Info

Publication number: GB2463248A
Application number: GB0816123A
Authority: GB
Inventors: Brendan Joyce
Original assignee: Individual
Current assignee: Individual
Priority date: 2008-09-04
Filing date: 2008-09-04
Publication date: 2010-03-10
Anticipated expiration: 2028-09-04
Also published as: GB0816123D0; GB2463248B; WO2010026232A1

Abstract

A biodegradable, recyclable garment hanger 1 comprising a single flat sheet of shaped paper board having first and second surface layers (41, 42, see figure 4) and an intermediate layer (43, see figure 4), wherein the first and second surface layers are clay coated layers and the middle layer is bleached chemical pulp. The centre layer is thicker than the outer layers, and the hanger further comprises a water soluble varnish (44, see figure 4) applied to the surface layer. The hook 3 may be separate to the body 4 of the hanger and attached to it using perforations. The hanger may be made in a die-cutting process. The hanger may receive indicia 6 for advertising. The hanger may also have a trouser support portion (see figure 7).

Description

Garment Hangers

Field of the Invention

[0001] The present invention relates to garment hangers, and in particular, to disposable garment hangers such as biodegradable, for example paperboard, hangers.

Background to the Invention

[0002] In the field of clothing such as in clothing stores, garments are traditionally hung on hangers, which are typically plastic, wire, or plastic and wire, and arranged on rails, with similar garments hung together on a single rail. Clothing stores use a large number of these hangers to display items, Hangers are often given to the customer when a garment is purchased thus increasing the amount required. Hangers are often times simply discarded whether by the store or by the customer. Plastic hangers which tend to break relatively easily are also discarded.

[0003] The same issues also arise in other clothing fields where garment hangers are used such as in dry cleaners, hotels, hospitals, etc. A problem associated with this type of hanger is that, in order to be disposed of in an environmentally friendly way, they must be recycled or otherwise processed. In certain instances, the hangers may be given away for free or at a discounted rate. This can occur if businesses or advertisers want to promote a product.

[0004] There is a need for hanger products that are recyclable, that are manufactured from materials that are renewable and that have sufficient strength to cany garments of considerable mass. To date this has not been achieved as paper-based hanger products have difficulty in supporting large loads. Furthermore most paper-based materials are hygroscopic and have a tendency to lose their mechanical properties over time and in particular in humid environments. One approach to dealing with the hygroscopic properties of paper-based garment hangers is to coat the surface with water resistant synthetic materials. However, these synthetic coatings do not easily biodegrade and they make the recycling of the garment hanger very difficult.

[0005] It is thus desirable to provide alternative hangers to those previously available.

For example, notwithstanding the foregoing, it is desirable to provide hanger products that are manufactured from renewable materials so that they can be recycled by conventional means, that will easily biodegrade (for example by composting) and that can provide the mechanical strength required to support large garments. It is further desirable to provide hangers that can maintain their mechanical properties over time -even in a humid environment.

Summary of the Invention

[0006] The present invention is manufactured from paper-based products. The material used in this invention is made from 100% bleached cellulose fibers. The material contains a relatively low recycled content and contains mostly new (virgin) fibers. The material is applied as a solid flat bleached sulfate (SBS) board. The bleach refers to the chemical process used to remove the color from the cellulose making the individual fibers transparent, appearing as white pigmentation. The board is preferably double-sided board and comprises three layers: a first surface layer, a second surface layer and an intermediate layer. The first and second surface layers preferably comprise at least one layer of clay coat. Preferably the surface layers comprise two or more layers of clay coat. The thickness of the surface layer is preferably greater than 1 micrometer. More preferably the thickness of the surface layer is 3 micrometers or more. The thickness of the surface layer provides the board with a surface that will achieve a superior print finish.

[0007] The intermediate layer comprises a bleached chemical pulp. In one embodiment the intermediate layer comprises a single layer. Preferably the wall thickness of the intermediate layer is greater than 600 micrometers. More preferably the wall thickness is greater than 700 micrometers and most preferably the wall thickness is greater than 800 micrometers.

[0008] In another embodiment, the intermediate layer is composed of multiple layers.

Preferably the board has a wall thickness of greater than 610 micrometers. More preferably the wall thickness is greater than 710 micrometers and most preferably the board has a wall thickness of greater than 810 micrometers.

[0009] The density of the board is preferably greater than 500kg/m3. More preferably the density of the board is greater than 600kg/m3 and most preferably the board has a density of greater than 650kg/m3.

[0010] The design of the hanger of the present invention allows the surface of the board to be used for advertising purposes. The clay coat surface and the bleached fibres create a white background upon which advertisers can print detailed promotional and product graphics. The specifications of the board described above allow for effective print on both sides of the hanger. Without such specifications, the hanger may not take print effectively on both sides of the hanger.

[0011] The shape of the hanger is produced in a one step pressing operation and since this eliminates assembly this is a significant advantage. The hanger of this invention has overcome certain aspects of strengthening and issues of mechanical integrity with a single cut paperboard hanger.

[0012] The flat features of the hanger also lend themselves well to facilitate storage and result in a better capacity than regular wire hangers.

[0013] The hanger's geometry comprises a hook section, a neck section and a body section.

[0014] In an upper hook section of the hanger, there is an upper arch support. The board thickness at this section improves the hanger shear strength.

[0015] The hanger's curved hook section withstands shear and vertical loads, while the inner curve of the hanger with a larger diameter ensures the hanger can be used with a variety of hanger rail diameters.

[0016] The hanger's central upper portion of the neck design gives increased tensile strength to the neck section. It also improves overall shear strength to the neck of the hanger and improves overall strength to the central neck support.

[0017] Varying the dimensions of the neck section can be used to increase the overall neck strength.

[0018] In one embodiment the body section further comprises a central portion and first and second shoulders wherein the vertical height of the central portion is greater than that of the shoulders. For heavy garments such as coats the present inventor has discovered that the height of the central portion is important in preventing buckling of the hanger under the load of the garment.

[0019] The height of the central portion of the hanger is preferably increased by creating an underbelly or pot-belly. This is an effective method of reinforcing the hanger against buckling under heavy garments. The lower middle base of the hanger underbelly also adds additional strength by reducing the tendency of the hanger to fold or bend in the middle due to (vertical) stresses.

[0020] The upper portion of the neck is also strengthened by increasing the width of the neck at different sections and alternatively or additionally rounding out the hook of the hanger.

[0021] The minimum material breakdown required of the paperboard of the clay coat top layers, solid bleach sulfate internal layers, and bottom layer clay coat for a double-sided board comprises of 2 layers of clay coat on both sides with a minimum of 2 micrometers thickness and a minimum inner of 3 layers comprising bleached chemical pulp with a minimum of 805-808 micrometer thickness.

[0022] The design of the hanger is such that when a load is present on the hanger (the hook is hung on a support) the load weight bearing is transitioned to the rest of the hanger.

[0023] The thickness of the paperboard is also key in preventing buckling or shear stresses as described above. A minimum thickness which prevents the shoulders buckling (collapsing or pulling downward) when garments are placed on the hanger is utilised. The height of the central portion of the hanger is preferably increased by creating an underbelly. This is an effective method of reinforcing the hanger against buckling under heavy garments. A lower middle base of the hanger underbelly also adds additional strength by reducing the effect of the hanger from folding or bending in the middle due to vertical or longitudinal stresses.

[0024] Since it has rounded corners (desirably all corners are rounded), it is a safer product than an angular hanger.

[0025] The shoulder strap notches prevent slipping and also provide an area to hang shirts/skirts/dresses.

[0026] By sealing the hanger in a water-based varnish, it reduces the amount of FM (Foreign Materials) typically associated with cartonboard materials and thus can be used in a sterile environment.

[0027] According to the present invention there is provided a garment hanger, having a garment support portion and a hook portion, wherein the hanger comprises a single die cut piece of recyclable (desirably 810 Micrometer) (SBS) solid bleach Sulfate paperboard, with a water-based varnish top layer.

[0028] An especially surprising aspect of the present invention is that the mechanical properties of the hanger can be improved in a humid environment by sealing the outer surfaces of the hanger with a water-based varnish. This water-based varnish is easy to recycle or biodegrade since it is water-soluble and yet it provides humidity resistance to the products of the invention. Hangers based on this concept can be used in humid conditions such as a dry-cleaning environment while maintaining its rigidity, yet by its nature, is still a biodegradable and compostable product.

[0029] The varnish is a water-based overprint varnish and is printed on the finished printed board. It is environmentally safe, non-hazardous. It provides reasonable scuff and water resistance. The coating provides excellent adhesion for label substrates and maintains its integrity after exposure to climatic extremes of> 50°C and> 85% RH such as those which occur in a typical ETO (ethylene oxide) sterilisation process. The material has been tested to ISTA 2A standard to temperature extremes of-iS °C to 60 °C. Specification: Solid content 35-43% Flash point> 100 °C. Another result of the printing and varnishing process is that the board is further strengthened to a more rigid hanger while still maintaining its flexibility.

[0030] The hanger can also be strengthened by dipping the paperboard hanger or parts thereof in a polymer resin.

[00311 An advantage of the present invention is that the hanger is made from a material that biodegrades, so that it is environmentally friendly. The hanger is sufficiently strong and rigid to hang various types of garments.

[0032] The hanger is coated in a water-based environmental friendly varnish. This ensures that the hanger can withstand dry cleaning, as well as the effects of heat, humidity and moisture and also retain its color print without scuffing.

[0033] According to one embodiment of the invention, the garment hanger is substantially flat, so that it comprises a substantially planar front face and a substantially planar rear face. At least one face (or both) of the hanger may be provided with a printable area. An advertisement, logo or image may be printed directly onto the hanger, prior to varnishing. The printable area may comprise a detachable advertising portion, such as a coupon or voucher. The coupon or voucher may be provided with a barcode or RFID.

[0034] An advantage of this arrangement is that the hanger may be used as an advertising medium or for branding purposes. The hanger may, for example, be used to advertise that a particular garment is on sale or special offer. Alternatively, the hanger many be provided with the logo of the store or designer of the garment. Because the hanger is made from board, the advertisement or logo may be printed directly onto the hanger itself using conventional printing processes, which is not possible with currently available plastic or wire hangers.

[0035] The hanger may be used to show the brand of company X. One could die cut the logo, symbol, name within the paperboard hanger that depicts or is associated with the company, without using any print. This is generally known as custom die cutting in printing parlance.

[0036] Embossing is another printing technique to give a raised' surface of a particular part of the printed or die-cut substrate. This area can also then be printed upon. A brand or logo can be embossed to seem textured instead of printing or in addition to printing.

[0037] The hanger may also be laminated or printed on to create a 3D and/or holographic image.

[0038] In one embodiment, the hook portion of the hanger is provided with a printable area. The hook printable area may be printed with a size indication. A variety of hangers having different size indications may be provided, so that each garment may be hung on a hanger having an appropriate size indication.

[0039] An advantage of this arrangement is that the size of the hanging garment may be quickly seen by the user, so that s/he does not have to inspect the swing tags or labels of each garment on a rail in order to find the correct size. Plastic hangers are often provided with a small cuff which may be placed on the hook portion of the hanger by sales staff, to indicate garment size. However, the present invention provides the advantage of allowing the size to be printed directly onto the hanger itself, thereby providing a single piece hanger, not requiring assembly by sales staff [0040] According to one embodiment of the invention, the hanger includes a trouser support portion, comprising: a partially cut-out portion provided at a central area of the garment support portion, the partially cut-out portion having a tab provided thereon; and a slot provided adjacent the partially cut-out portion; wherein the partially cutout portion is foldable to allow the tab to be inserted into the slot, thereby providing more rigid support portion for a trouser.

[0041] According to another embodiment of the invention, the hanger would be a two-piece version comprised of a polymer hook which is connected to the paperboard portion of the hanger comprising the printable area of the hanger. The hanger hook section will comprise of a separate piece made from a polymer. Using a "punch through" section on the polymer, it will clip into the carton board for example in the mid upper section of the hanger. The punch through section may include slots in the paperboard section of the hanger. The overall configuration will provide additional strength and rigidity to the hanger.

[0042] The present invention also relates to a hanger of the type described above comprising a hook and the hook is made of paperboard material and the hanging face of the hook is protected by a plastic reinforcer. The reinforcer may form a (partial) hook shape and have a channel defined therein for receiving the underside of the hook. The reinforcer can be adhered to the hanger. One suitable material comprises of a high impact strength polymer, such as (HIPS) high impact polystyrene. The hanging face of the reinforcer may be profiled to improve movement along a rail, for example may be curved (e.g. formed with a radius). The invention extends to a hanger substantially as described herein with reference to and as illustrated in the accompanying drawings.

Brief Description of the Drawings

[0043] Figure 1 is a front elevation view of a hanger according to one embodiment of the present invention; [0044] Figure 2 is a side elevation view of the hanger of Figure 1; [0045] Figure 3 is a front elevation view of the hanger of Figure 1 showing curvature of the hook; [0046] Figure 4 is a schematic representation of the various layers of material from which a hanger of the invention may be constructed; [0047] Figure 5 is a schematic representation of how graphics or text, for example of a promotional nature may be applied to a hanger of the invention; [0048] Figure 6 is a front elevation view of the hanger of Figure 1 showing how forces from the load of a garment may be transmitted through the hanger; [0049] Figure 7 is a front elevation view of a hanger according to a further embodiment of the present invention; [0050] Figure 8 is a side elevation view of the hanger of Figure 7; [0051] Figure 9 is a front elevation view of a two-part hanger according to a further embodiment of the present invention; [0052] Figure 10 is a side view of the hanger of Figure 9; [0053] Figure 11 is a front elevation view of a hook part of the hanger of Figure 9; [0054] Figure 12 is a side view of the hook part of Figure 11; [0055] Figure 13 shows a side view of a hanger of the invention of the type shown in Figure 1 to which a hook reinforcement has been fitted; and [0056] Figure 14 is a side view of the hook reinforcement of Figure 13.

Detailed Description of the Drawinus

[0057] Figures 1 and 2 show a garment hanger 1 according to a first embodiment of the present invention. The hanger 1 comprises a hook section in the form of a hook portion 3, a neck section 7 and a body section in the form of a garment support portion 2. The neck section 7 joins the hook portion to the garment support portion 2. The hanger 1 is made from a single die-cut piece of solid bleach sulfate (recyclable) board.

A portion 8 of the neck section (the portion proximate the support portion 2) has a wider lateral profile than that of the hook section 3. In particular a portion 8 of the neck section is substantially wider for example at least 1.5, 2 or even 3 times wider than the hook section. As shown in the embodiment it is desirable that a portion of the neck becomes progressively wider moving away from the hook section toward the body section. This forms an upper arch support. The body section comprises a central section 9 and two shoulder sections 10 and the height of said central section is greater than said shoulder section. In particular it will be appreciated that an upper end (or edge)16 of the hanger which runs between the shoulders 10 and the neck section 7 has a neck profile 17 which is profiled to create a substantial incline (which can be considered to deviate substantially from a vertical profile) joining the shoulder 10 and the hook portion 3.

This adds strength to the hanger. It is desirable that at least one profile along the neck joining the hook and main body is substantially inclined. The incline may be linear but desirably it is substantially curved. As shown in the figure it is desirable that the incline is on one side of the hook, that side being the side to which the hook faces. It will be appreciated that this can be varied for strength etc. Varying the dimensions and/or inclination can be utilised to vary the rigidity of the hanger. The neck and/or hook profile can be selected for improved overall strength to the central neck support. As best seen from Figure 2, the garment hanger is substantially flat, so that it comprises a substantially planar front face 4 (and a substantially planar rear face 5). At least one face of the hanger has a printable area 6. This may be confined to a particular area such as seen in Figure 5 where area 6 is illustrated in dashed outline. Any desired text or graphics such as an advertisement, logo or image may be printed directly onto the hanger. Any desired text or graphics may also be formed by the material of the hanger itself, for example in relief such as may be formed by cut-out and/or raised material for example by embossing. Desirably the applied text and/or graphics are applied prior to varnishing. This ensures the text and/or graphics are protected. If desired the varnish may be applied by a printing technique.

[0058] Suitable water-based varnishes and soy-based inks may be used for this application.

[0059] Desirably the central section 9 comprises a reinforcing underbelly 11. The reinforcing underbelly 11 comprises a convex profile between points 12 and 13 on the lower end 14 of the hanger. This provides added strength to the hanger. As can be seen the reinforcing underbelly extends across a substantial portion of the lower end 14 of the hanger. It is desirable that it extends across at least 50% of the width of the hanger. The embodiment illustrates that the lower middle base of the hanger (with the underbelly) also adds additional strength by reducing folding or bending effects on the hanger due to compression from the garment or garments on the hanger shoulders. In particular the design of the hanger is such that the compressive force of the garment is supported by (a) the board thickness (for example 810 micrometers) giving it improved rigidity and (b) the hanger design as it spreads the load across the hanger, this is facilitated further by the curved shape of the base. The overall board area is increased without compromising on aesthetics.

[0060] As also seen in Figure 1 a notch 15 is provided in each shoulder 10 of the hanger. These notches are for catching straps or loops on a garment for example hanging loops such as those found on a dress, skirt or top.

[0061] The neck section 7 of the hanger may comprise an area 19 for application of text or graphics such as a size indication for a garment on the hanger. The area 19 may

be a printable area.

[0062] The hanger desirably has curved elbows 18 (between the base and the shoulders). It may additionally have bevelled edges, thus making it a safer product than an average wire hanger.

[0063] The hook is desirably shaped to accommodate different sizes of hanging rail.

A larger diameter such as can be achieved with hangers of the invention, ensures the hanger can be used with a variety of hanger rail diameters.

[0064] The hanger of the invention has increased tensile strength in the neck section.

It also has improved overall shear strength in the neck section.

[0065] Figure 3 shows some typical radii of curvature of the hook 1. R3 1 indicates an inner radius and R5 1 indicates an outer radius.

[0066] Figure 4 is a schematic representation of the materials making up a hanger of the invention. It will be appreciated that the representation is not drawn to scale. In particular the hanger is made from a shaped paperboard 40. The shaped paperboard 40 comprises first 41 and second 42 surface layers and an intermediate layer 43. This gives a double-sided structure. The intermediate layer 43 comprises bleached chemical pulp.

In particular the intermediate layer 43 comprises solid bleached sulfate paperboard material. Typically the thickness of the intermediate layer is greater than 600 micrometers.

[0067] More particularly there are three distinct layers 43(a)-(c) of paperboard material (comprised of bleached chemical pulp) which form the intermediate layer 43, though the three layers form an integral unit. The first and second layers 41,42 form the surface layers. In the embodiment they are clay coat layers. Desirably a hanger of the invention will comprise 2-3 layers of clay coat on both sides. In the embodiment there are two layers, respectively labelled 41(a)/41(b) and 42(a)/42(b) in each clay coat. The thickness of said surface layers is small relative to said intermediate layer. Each layer of clay coat 41(a)/41(b) and 42(a)/42(b) wilt typically be approx 3-4 micrometers in thickness. The surface layers provide a superior print finish where printed materials are applied.

[0068] The hanger so formed will be coated with a water-based vanish material 44 (applied to the surface layers). Such a finish will improve the board integrity when subjected to the normal ambient temperature and humidity but also will maintain its integrity with increasing humidity and temperature. Varnishes suitable for use are capable of withstanding temperatures in access of 60 ° C and 85% RH (relative humidity).

[0069] Figure 5 illustrates a hanger that is provided with an area 6 (shown in dashed outline) for advertising etc. The area may be a permanent part of the hanger or may comprise a removable part, for example cut-outs such as coupons, peel-offs, or communication or identification tags such as those using RFID. The area 6 can be provided by perforation which allows tear-off The design of the hanger will be such that the overall integrity of the die cut hanger will not be compromised following the removal of any removable part.

[0070] Figure 6 gives a schematic representation of how stresses are distributed in a hanger 1 of the type shown in Figure 5. In particular it gives an overview of how the various forces (indicated by arrows), be they compressive, shear or tensile, are dispersed throughout the hanger. It is believed that the distribution of forces achieved leads to greater robustness in use of a hanger of the invention and in particular making it more sag-resistant when loaded with the weight of a garment. The hanger of the invention thus meets the requirements for everyday use by maintaining its integrity.

[0071] In the embodiment shown in Figure 7 and Figure 8, the hanger 1 (which is similar in construction to the hangers of Figures 1-6) includes a trouser holder section or support portion 27. The trouser or other garment support portion 27 comprises a partially cut-out section or flap 28 provided at a central area of the garment support portion 27. The flap comprises two flap portions respectively labelled 28a and 28b. As shown in Figure 7, the partially cut-out flap 28 (which can be pushed out by a user) is elongate in shape and is cut out along three sides thereof. The fold over section may be created by a cut crease design such as by die-cutting, for example, when the board is die cut to the hanger shape. It is held in place along a fold or hinge line 30 which may be formed by a score/perforation. A pair of tabs 29 are provided along a free edge 31. A matching pair of slots 210 are provided below the cut-out portion 28. An additional fold line 211 is also provided. To assemble the hanger, the cut-out portion is folded along both fold lines 30 and 211 and the tabs 9 are inserted into the slots 210. As best seen from Figure 8, the cut-out portion 28 and in particular the lower portion 28b thus provides a horizontally disposed (rigid) trouser support portion (supported by upper portion 28a and in particular tabs 29 which are engaged in slots 210). Folding out the cut-out portion 28 in this manner leaves a window 32 through the hanger. Trousers or other garments can then be hung from the support portion by insertion through the window 32. It will be appreciated that the hanger has an assembly to fold the trouser section back providing a rigid trouser support.

[0072] The additional surface area provided by this arrangement ameliorates unwanted creasing on the garment imparted by conventional hangers where the garment is supported by the hanger.

[0073] Figure 9 relates to a two-part hanger 1 of the invention. Figure 10 shows a side view thereof In both figures the hanger is in an assembled configuration. The hanger 1 comprises a hook section in the form of a hook portion 103, a neck section 107 and a body section in the form of a garment support portion 102. In this embodiment the hook and neck sections are integrally formed as one piece and separately from the remainder of the hanger. That unitary piece will be referred to as the hook part 105 for simplicity, The neck section 107 joins the hook portion to the garment support portions 102. Figure 11 shows a front view of the hook and neck section (detached from the remainder of the hanger) and Figure 12 shows a side view thereof The hook part 105 is formed by a polymer hook section of one part of the two-piece assemblage of the paperboard hanger. The remainder of the hanger comprises a paperboard material as described above.

[0074] The hook part 105 comprises a series of punch-through members or pins 110 (best seen in Figure 12) for attaching the hook part 105 to the remainder of the hanger.

If desired slots can be provided in the other part of the hanger to receive the pins 110.

The slots may be dimensioned to facilitate a friction fit between the pins and the paperboard.

[0075] Figure 13 shows a side view of a hanger of the invention of the type shown in Figure 1 to which a hook reinforcement 301 has been fitted to the (inner face or) hanging surface 300 of the hook. The hook reinforcement is an attachment for the hook that may be made of a suitable plastics material.

[0076] Figure 14 shows a side view of the hook reinforcement of Figure 13 by itself.

The reinforcement has opposing limbs 302 joined by a curved section 303 to form a substantially u-shaped member. The hook reinforcement is shaped to fit to the underside of the hook as shown in Figure 13. In particular the reinforcement is recessed so that the hook fits into the reinforcement. This provides a mating fit of one to the other. The hook is reinforced for hanging and is less likely to be damaged by a support on which it is hung. The reinforcer can be adhered to the hanger. One suitable material comprises of a high impact strength polymer, such as (HIPS) high impact polystyrene. The hanging face of the reinforcer may be profiled to improve movement along a rail, for example may be curved (e.g. formed with a radius).

Example

[0077] A hanger of the type shown in Figure 1 was made having the following construction: 3 paperboard layers totalling 810 micron thick with first and second surface layers comprising clay coated layers of 3 micron and with an intermediate layer of 804 micron comprising of bleached chemical pulp; water soluble varnish was applied to the surface layers, die cutting was used to punch out the hanger shape of Figure 1.

The so-formed hanger was tested as follows: The hanger was tested to ISTA 2A standard to temperature extremes of-iS °C to 60 °C.

Specification: Solid content 35-43% Flash point> 100 °C.

The coating was found to provide excellent adhesion for label substrates and maintains its integrity after exposure to climatic extremes of> 50°C and> 85% RH such as those which occur in a typical ETO (ethylene oxide) sterilisation process.

Tensile testing: A hanger of the above type was tensile tested also.

Breaking point was found to be at 1 2lbs/in, using a tensile tester (bottom jaw of the tester at the base of the hanger, top jaw of the tester on the hanger hook) with a 20 lb load cell. The hanger was tensile tested to failure.

Real time use: A hanger of the above type was tested by hanging with a weight of 5 lbs at a temperature of 22 °C and humidity 45% and 55%.

The hanger has successfully held the weight in those conditions over a 12 week period with testing ongoing without failure or deformation of the hanger.

Scuff resistance: A rub tester was used to rub two printed surfaces of a hanger of the above type against each other (face-to-face) in the same plane, at the same speed (60 rpm), under a constant rubbing pressure.

The hanger was found to be scuff resistant after 3 minutes on the tester.

[0078] The words "comprises/comprising" and the words "having/including" when used herein with reference to the present invention are used to specify the presence of stated features, integers, steps or components but does not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof [0079] It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination.

Claims

Claims 1. A biodegradable, recyclable garment hanger wherein the garment hanger comprises a single flat sheet of shaped paper board, the shaped paper board comprising first and second surface layers and an intermediate layer, wherein said first and second surface layers comprise clay coated layers and wherein said intermediate layer comprises bleached chemical pulp, and the thickness of said surface layers is small relative to said intermediate layer, the hanger further comprising a water soluble varnish applied to the surface layer.
2. A garment hanger according to Claim 1 wherein the density of said surface layers is greater than the density of said intermediate layer.
3. A garment hanger according to Claim 1 wherein the density of the paperboard is greater than 5 OOkg/m3.
4. A garment hanger according to Claim 3 wherein the density of the paperboard is greater than 600kg/m3.
5. A garment hanger according to Claim 4 wherein the density of the paperboard is greater than 65 Okg/m3.
6. A garment hanger according to any preceding claim wherein the wall thickness of the intermediate layer is greater than 600 micrometers.
7. A garment hanger according to Claim 6 wherein the wall thickness of the intermediate layer is greater than 700 micrometers.
8. A garment hanger according to Claim 7 wherein the wall thickness of the intermediate layer is greater than 800 micrometers.
9. A garment hanger according to any preceding claim wherein the resistance of the board to moisture ingress is improved by the application of a water-based varnish to the outer surfaces of the hanger.
10. A garment hanger according to Claim 9 wherein said water-based varnish improves the mechanical properties of the hanger in a humid environment.
11. A garment hanger according to any preceding claim wherein said bleached chemical pulp comprises 100% solid bleached cellulose fibers.
12. A garment hanger according to any preceding claim wherein said a single flat sheet of shaped paperboard is produced by punching said shape in a die cutting operation.
13. A garment hanger according to any preceding claim wherein the hanger comprises a hook section, a neck section and a body section.
14. A garment hanger according to Claim 13 wherein at least a portion of the neck section is wider than the hook section.
15. A garment hanger according to Claim 12 or Claim 13 wherein the body section comprises a central section and two shoulder sections and the height of said central section is greater than said shoulder section.
16. A garment hanger according to any one of Claims 13 to 15 wherein the central section comprises a reinforcing underbelly.
17. A hanger according to any preceding claim, wherein the water-based varnish is printed on the finished board.
18. A hanger according to Claim 17, wherein the water-based varnish provides scuff resistance and/or provides excellent adhesion for label substrates.
19. A hanger according to Claim 17 or Claim 18, wherein the water-based varnish maintains its integrity after exposure to temperatures of-iS °C to 60 °C.
20. A hanger according to any one of Claims 17 to 19, wherein the water-based varnish maintains its integrity after exposure to at least 85% relative humidity for example during a typical ETO sterilisation process.
21. A hanger according to any preceding claim, wherein the hanger is substantially flat, so that it comprises a substantially planar front face and a substantially planar rear face and wherein at least one face of the hanger is provided with a printable area.
22. A hanger according to Claim 21, wherein the printable area comprises a detachable advertising portion, such as a coupon or voucher.
23. A hanger according to any preceding claim wherein said surface layers comprise 2-3 layers of clay coat on both sides of greater than 2 micrometers in thickness.
24. A hanger according to Claim 23 wherein said surface layers comprise 2-3 layers of clay coat on both sides of between 3 and 4 micrometers in thickness.
25. A hanger according to any preceding claim wherein said intermediate layer comprises two or more layers of bleached chemical pulp.
26. A hanger according to any preceding claim, wherein the hook portion of the hanger is provided with a printable area and the hook printable area is printed with a size indication.
27. A hanger according to any preceding claim wherein the hanger includes a trouser support portion, comprising: a partially cut-out portion provided at a central area of the garment support portion, the partially cut-out portion having a tab provided thereon; and a slot provided adjacent the partially cut-out portion; and the partially cutout portion is foldable to allow the tab to be inserted into the slot, thereby providing a trouser support portion and to add an incongruous ridge to the folded over portion to ensure trousers/garments do not slide off
28. A hanger according to any preceding claim wherein the hanger can also be used as a media or informational platform through visual awareness using a 3D holographic image through a laminated or printed form.
29. A hanger according to any preceding claim wherein the hanger or parts thereof is dipped in a polymer resin to strengthen the original one piece solid recyclable board for further rigidity.
30. A hanger according to any preceding claim wherein at least one surface of the hanger is embossed to use as a media platform with a logo, trademark or other advertising medium.
31. A hanger according to any preceding claim wherein the hanger has cut-outs (for example die cuts) or paper laminates for advertising or branding.
32. A hanger according to any preceding claim wherein the outer surfaces of the hanger are used as a media or informational platform by providing a 3D holographic image on the surface in a laminated or printed form.
33. A hanger according to any preceding claim wherein said hanger is manufactured from a one-piece solid recyclable board.
34. A hanger according to Claim 33 wherein the single die-cut produces a hanger with two opposing shoulders and with two notches one on either shoulder of the hanger to allow a strap to be hung over the notched area, thereby securing a garment that just has shoulder straps.
35. A hanger according to any preceding claim wherein the bottom portion of the hanger is pot-belly shaped.
36. A hanger according to any preceding claim wherein the width of the base of the hook area is increased to provide greater strength to the hanger.
37. A hanger according to any preceding claim wherein the varnish is water based.
38. A hanger according to any preceding claim wherein the hook section comprises a polymer component and said polymer hook section is connected to the body section of the hanger.
39. A hanger according to Claim 38 wherein the hanger hook section is connected to the body section using a punch-through to clip the hook section to the carton board mid upper section of the hanger.
40. A hanger according to any one of Claims 1 to 36 comprising a hook wherein the hook is made of paperboard material and a hanging face of the hook is protected by a plastics reinforcer.
41. A hanger according to Claim 40 wherein the reinforcer forms a hook shape and has a channel defined therein for receiving an underside of the hook.
42. A hanger substantially as described herein with reference to and/or as illustrated in the accompanying drawings.