Abstract:
In a top garment hanger, through openings are formed in the arms of the hanger relative to a center axis of the hanger body. The provision of the various through openings reduces the total weight of the hanger and the resin material used to mold the hanger. The hanger is accordingly environmentally friendly. The manufacturing cost and the transportation cost of the hanger are reduced, which provide a market advantage for the manufacturer, transporter and retailer of the garment hangers.

Description:
CROSS REFERENCE OF RELATED APPLICATIONS 
       [0001]    Under 35 U.S.C. §119(e), this application claims priority of U.S. Provisional Patent Application Ser. No. 61/149,956 filed Feb. 4, 2009, entitled “LIGHTWEIGHT TOP GARMENT HANGER”, the disclosure of which is hereby incorporated by reference in its entirety for all purposes. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of Invention 
         [0003]    The present invention relates generally to molded plastic garment hangers as are widely used for the purpose of shipping and displaying garments. More specifically, the present invention relates to a lightweight top garment hanger with an improved hanger body, which consumes less material and less energy for processing the material as compared to existing top garment hangers, without compromising the structural integrity and mechanical performance of the hanger. The top garment hanger according to the present invention is environmentally advantageous. 
         [0004]    2. Description of Related Art 
         [0005]    In the area of retail garment sales, so-called Garment-On-Hanger (GOH) programs have become preferred by retailers. In a GOH program, garments are delivered to retail merchants already suspended from hangers, where upon arrival at the retail location the garments are immediately placed on display for sale. One application of the GOH programs is top garments such as T-shirts, polo shirts, jackets and the like. The garments are placed on a hanger and then shipped from the remote destination to the retail establishment 
         [0006]    In particular, retailers have specified particular hangers or hanger characteristics among their several suppliers in order to achieve uniformity on their sales floors. To this end, standards as to hanger size, shape, performance characteristics, etc., are maintained, for example, by organizations such as the Voluntary Inter-industry Commerce Standards Association (VICS). One particular standardized hanger feature is popular across several hanger models, namely a wire hook mated to a plastic hanger. This type of hanger is suitable for suspending, shipping and displaying a wide variety of garments especially top garments, such as shirts, jackets and so on. 
         [0007]    With the continuing consumption of the natural resources, it is popular and necessary in the manufacturing industry to optimize the product design to save materials and energy and concomitantly reduce the manufacturing and transportation costs, without compromising performance of the product. The resultant product under such a material and energy saving concept is recognized as an environmentally friendly product, and is much more market competitive than its prior art counterpart. In the hanger molding industry, millions of plastic top garment hangers are manufactured each year. Thus, an environmentally friendly hanger would provide a significant commercial advantage for the manufacturer, transporter and retailer in the industry. 
         [0008]    Accordingly, there is a need for a novel top garment hanger that uses less material for manufacturing and still maintains its structural integrity and mechanical performance to satisfy industry standards, for example, the VICS standards. 
         [0009]    Accordingly, there is a need for a novel top garment hanger that is lightweight and easy to handle. 
         [0010]    Accordingly, there is a need for a novel top garment hanger that effectively reduces manufacturing and transportation costs and uses less material to enhance the environment. 
         [0011]    Accordingly, there is a need for a novel top garment hanger made from less material while still maintaining performance and the compatibility with the existing garment/hanger conveying mechanism. 
       BRIEF SUMMARY OF THE INVENTION 
       [0012]    Therefore, in order to overcome certain deficiencies of the prior art, provided according to the present invention is a lightweight top garment hanger. The hanger includes a body, a hook member connected to the body, a first arm connected to the body and extending from the body to a first end of the hanger, and a second arm connected to the body and extending from the body to a second end of the hanger. The second arm is substantially symmetrical to the first arm relative to a center axis of the body. The first arm includes a first upper flange, a first lower flange and a first arm web connecting the first upper flange and the first lower flange. The first arm web includes at least one first through opening formed therein. 
         [0013]    In an exemplary embodiment, the second arm also includes a second upper flange, a second lower flange and a second arm web connecting the second upper flange and the second lower flange. The second arm web also includes at least one second through opening formed therein. The first through opening of the first arm can be symmetrical to the second through opening of the second arm relative to the central axis of the hanger body. 
         [0014]    In an exemplary embodiment, the first arm includes a first group of three through openings formed in a first distal portion of the first arm, and the second arm includes a second group of three through openings formed in a second distal portion of the second arm. Each one of the first group of three through openings is substantially symmetrical to a respective one through opening of the second group of three openings. 
         [0015]    In one embodiment, the area of the at least one first through opening accounts for 10-80% of the total area of the first arm web. Specifically, the area of the at least one first through opening accounts for 30-50% of the total area of the first arm web. 
         [0016]    In a further embodiment, the area of the at least one second through opening accounts for 10-80% of the total area of the second arm web. Specifically, the area of the at least one second through opening accounts for 30-50% of the total area of the second arm web. 
         [0017]    In still a further embodiment, the area of the first group of through openings accounts for 10-80% of the total area of the first arm web. Specifically, the area of the first group of through openings accounts for 30-50% of the total area of the first arm web. 
         [0018]    In still a further embodiment, the area of the second group of through openings accounts for 10-80% of the total area of the second arm web. Specifically, the area of the second group of through opening accounts for 30-50% of the total area of the second arm web. 
         [0019]    In still a further embodiment, the height of the hanger body and the hanger arm is reduced to further reduce the material used in the hanger, while still maintaining the mechanical performance of the hanger and satisfying industry standards, such as VICS standards. 
         [0020]    In still a further embodiment, the ratio of the total weight the top garment hanger (excluding the wire hook), according to the present invention, to the total weight of the prior art top garment hanger (excluding the wire hook) is within the range of 60-90%, both hangers satisfying same industry standards. In other words, compared to the prior art top garment hanger, the total weight reduction achieved by the plastic molded part of the top garment hanger according to the present invention is about 10-40% of the prior art hanger. 
         [0021]    In still a further embodiment, the total weight of the plastic molded part of the top garment hanger according to the present invention is about 75% of the total weight of the plastic molded part of the prior art top garment hanger, both hangers satisfying same industry standards. Specifically, the total weight of the plastic material (such as K resin) used for molding the top garment hanger according to the present invention is about 75% of the total weight of the plastic material (such as K resin) used for molding the prior art top garment hanger, both hangers satisfying same industry standards. 
         [0022]    In still a further embodiment, the total weight of the plastic material (such as K resin) for molding the top garment hanger according to the present invention is about 24.5 grams. For example, compared to the standard top garment hanger in the industry requiring 33.0 grams of plastic material (such as a “484” top garment hanger satisfying the VICS standards), the total weight reduction of the plastic material is about 8.5 grams. 
         [0023]    In still a further embodiment, the body of the top garment hanger can further include a hook receiving element depending therefrom, which is molded integrally with the body at a lower portion of the body. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0024]    These and other features, aspects and benefits of the present invention will be made apparent with reference to the following specification and accompanying drawings, where like reference numerals refer to like features across the several views, and wherein: 
           [0025]      FIG. 1  illustrates a front elevation view of a known prior art top garment hanger; 
           [0026]      FIG. 2  illustrates a sectional view of the known top garment hanger along Lines  2 - 2 ; 
           [0027]      FIG. 3  illustrates a front elevation view of a lightweight top garment hanger according to one exemplary embodiment of the present invention; 
           [0028]      FIG. 4  illustrates a top view of the lightweight top garment hanger shown in  FIG. 3 ; 
           [0029]      FIG. 5  illustrates a bottom view of the lightweight top garment hanger shown in  FIG. 3 ; 
           [0030]      FIG. 6  illustrates a local side view showing region A in  FIG. 1 ; and 
           [0031]      FIG. 7  illustrates a sectional view of the lightweight top garment hanger in  FIG. 3  along Lines  7 - 7  in  FIG. 3 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0032]    Referring to  FIG. 1 , illustrated is a top garment hanger  100  as is known in the art. The known garment hanger has a hook member  110 , a central hanger body  120  connected to the hook member  110  substantially at the middle of the body  120 , a first arm  130  connected to a lower side portion of the body  120  and downwardly sloping from the body  120  to a first end  132 , and a second arm  140  connected to another lower side portion of the body  120  and downwardly sloping from the body  120  to a second end  142 . The body  120  generally includes a body web  122  surrounded by a continuous body flange  124 , to define a region  126  suitable for displaying an information indicator. 
         [0033]    The central body  120  includes a centrally located boss  127 , to which the hook member  110  is rotatably mounted for suspending a top garment. The boss  127  is reinforced by a pair of supporting ribs  128  and  129  on opposite sides thereof, which are integrally molded and joined to an upper portion of the body flange  124 . The supporting ribs  128  and  129  are disposed angularly between the boss  127  and the hanger body  120 . 
         [0034]    The hook member  110  is fabricated from wire stock and is inverted into the boss  127 . The removal of the metal hook member is prevented by using any conventional attachment such as a threaded connection. 
         [0035]    The first arm  130  includes a first upper flange  134  and a first lower flange  136 , connected to one another by a first arm web  138 . The first upper flange  134  and the first lower flange  136  are integrally molded with the body flange  124 . The second arm  140  includes a second upper flange  144  and a second lower flange  146 , connected to one another by a second arm web  148 . The second upper flange  144  and the second lower flange  146  are molded with the body flange  124 . 
         [0036]    The hanger  100  further includes a hook receiving loop element  150  depending from, and molded integrally with, the body  120  at a lower portion of the body flange  124 . The hook receiving loop element  150  allows another garment hanger to be suspended therefrom. 
         [0037]    The hanger  100  further includes a first recess  160  defined in the first arm  130 , for receiving a portion of a top garment, such as the shoulder strap of a top garment. The hanger  100  further includes a pair of opposite cantilevers  162  and  164  for partially covering the recess  160 . The cantilevers  162  and  164  prevent the shoulder strap from slipping off the hanger arm  130 . Each of the cantilevers  162  and  164  includes a downwardly extending terminus  166 . Similarly, the second arm  140  includes a second recess  170  and a pair of opposite cantilevers  172  and  174 . Each of the cantilevers  172  and  174  includes a downwardly extending terminus  176 . 
         [0038]    The hanger  100  as shown in  FIG. 1  is a standard prior art top garment hanger satisfying the VICS standards with respect to the dimensions and mechanical performance of the hanger. 
         [0039]      FIG. 2  is a cross sectional view of the top garment hanger  100  along line  2 - 2  in  FIG. 1 , and particularly illustrates details of the construction of the second upper flange  144 , second lower flange  146  and the second arm web  148  of the second hanger arm  140 . As shown, the second upper flange  144 , second lower flange  146  and the second arm web  148  forms an I-beam shaped configuration of the second arm  140 . The first arm  130  has similar configuration, symmetrical to the second arm  140 . As shown in  FIG. 2 , the hanger arm  140  has a first height H 1  defined substantially as the distance from the second upper flange  144  to the second lower flange  146 . The hanger arm  140  further has a first width W 1  defined substantially as the distance from the left side to the right side of the second upper flange  144  and the second lower flange  146 . For the prior art top garment hanger  100  (such as a “484” top garment hanger), the first height H 1  is about 0.75″ and the first width W 1  is about 0.30″. Thus, the ratio between the first height H 1  and the first width W 1  is about 2.50, according to the prior art top garment hanger  100 . 
         [0040]    Referring to  FIG. 3 , illustrated is an exemplary embodiment of a top garment hanger according to the present invention, identified by numeral  200  throughout. 
         [0041]    The top garment hanger  200  includes a hook member  210  and a central body  220 . The hook member  210  is connected to the hook member  210 , substantially at the middle of the body  220 . The hanger  200  further includes a first arm  230  connected to a lower side portion of body  220 . The first arm  230  extends downwardly and outwardly from the body  220  to a first end  232 . The hanger  200  further includes a second arm  240  connected to another lower side portion of the body  220 . The second arm  240  extends downwardly and outwardly from the body  220  to a second end  242 . The first arm  230  and the second arm  240  extend oppositely from one another. 
         [0042]    In the shown embodiment, the first end  232 , which is distal to the central body  220 , is tapered with respect to the portion of the first arm  230  proximate to the central body  220 , to provide a generally pointed arm end. Similarly, the second end  242  is also tapered. The inventor of the present invention has discovered that, compared to the prior art top garment hanger (having distal ends substantially constant with the proximal portion of the hanger arm), the narrowed and tapered distal ends of the hanger arm effectively reduce the resin material used for molding the hanger arm, while maintaining the strength of the hanger arms necessary for supporting top garments. 
         [0043]    As shown in  FIG. 3 , the central body  220  is preferably symmetrical along a central axis X-X′ of the hanger. The first arm  230  and second arm  240  can be symmetrical to one another relative to the central axis X-X′. 
         [0044]    The body  220  includes a body web  222  surrounded by a continuous body flange  224 . Accordingly, a region  226  is defined for displaying an information indicator, such as a plastic placard. 
         [0045]    The central body  220  of the hanger  200  further includes a centrally located boss  227 , to which the hook member  210  is rotatably mounted. The boss  227  is reinforced by a pair of side support ribs  228  and  229 . The side ribs  228  and  229  are disposed at either side of the boss  227 , and are slanted with respect to the boss  227 . The support ribs  228  and  229  can be integrally molded with the body flange  224  of the central body  220 . The ribs  228  and  229  can be symmetrical relative to the central axis X-X′. 
         [0046]    The first arm  230  includes a first upper flange  234  and a first lower flange  236 , connected to one another by a first arm web  238 . The first upper flange  234  and the first lower flange  236  are preferably molded integrally with the body flange  224 . The second arm  240  also includes a second upper flange  244  and a second lower flange  246 , connected to one another by a second arm web  248 . The second upper flange  244  and the second lower flange  246  are preferably molded integrally with the body flange  224 . 
         [0047]    Referring to  FIGS. 4 and 6 , the detailed configuration of the side support ribs  228  and  229  is described. Each of the ribs  228  and  229  includes a top portion  302  connected to the boss  227 , a base portion  304  connected to the body flange  224 , and a middle portion  306  between the top portion  302  and the base portion  304 . The top portion  302 , the base portion  304  and the middle portion  306  are not consistent in their widths. Specifically, the ribs  228  and  229  are tapered upwardly, i.e., the ribs  228  and  229  expand gradually from the top portion  302  to the base portion  304 . The inventor of the present invention has discovered that the tapered ribs use less material as compared to the traditional support ribs having constant width, without compromising the mechanical strength and performance of the ribs and the hanger. 
         [0048]    The hanger  200  further includes a hook receiving loop element  250  depending from and molded integrally with the body  220  at a lower portion of the body flange  224 . The hook receiving loop element  250  allows another ganged garment hanger to be suspended therefrom. Specifically, the hook receiving loop element  250  is narrowed as compared to the hook receiving loop element  150  of the prior art. The inventor of the present invention has discovered that the narrowed hook receiving loop element uses less material as compared to the traditional loop element, without compromising the mechanical performance of the loop element. 
         [0049]    The first arm  230  further includes a first recess  231  extending downwardly from the upper surface of the first arm  230 . For example, the first recess  231  can be formed by partially deforming the first upper flange  234  downwardly. The first recess  231  is configured to accommodate a part of the top garment, such as a strap shoulder of a lady&#39;s top garment. The first arm  230  further includes a pair of first cantilevers  233  and  235 , extending oppositely to each other to partially cover the first recess  231 . The provision of the cantilevers prevents the part of the garment received in the first recess  231 , such as the strap shoulders, from slipping out of the first recess  231 . The pair of first cantilevers  233  are preferably molded integrally and continuously with the upper flange  234  of the first arm  230 . 
         [0050]    Referring to  FIG. 4 , depicting a top view of the top garment hanger  200 , each of the cantilevers  233  and  235  includes a tapered terminal end  237 . Thus, viewed form the top, the cantilevers  233  and  235  both assume a substantially trapezoidal shape. The inventor of the present invention has discovered that the trapezoidal-profiled cantilevers  233  and  235  use less material, as compared to the traditional cantilevers  162  and  164  (shown in  FIG. 1 ) having constant profile and downwardly extending terminus. At the same time, the performance of the cantilevers can be maintained. 
         [0051]    Similarly, the second arm  240  includes a second recess  241  and a pair of second cantilevers  243  and  245 . 
         [0052]    Along a substantial centerline Y-Y′ of the first recess  231 , the first arm  230  is divided into a first distal portion  239  and a first proximal portion  239 ′, relative to the central body  220 . Similarly, along a substantial centerline Z-Z′ of the second recess  241 , the second arm  240  is divided into a second distal portion  249  and a second proximal portion  249 ′, relative to the central body  220 . 
         [0053]      FIG. 7  illustrates a sectional view of the top garment hanger  200  along Lines  7 - 7  in  FIG. 3 . As shown, the first upper flange  234 , the first lower flange  236  and the first arm web  238  provides an I-beam shaped hanger arm configuration. The first arm web  238  is in the form of a vertical wall extending between the first upper flange  234  and the first lower flange  236 . 
         [0054]    As shown in  FIGS. 3 and 7 , the first arm  230  includes at least one through opening  260  formed in the first arm web  238 . In the shown embodiment, the first arm  230  includes a first group of three through openings  260   a - 260   c  provided discontinuously in the first arm web  238 . The first through opening  260   a  and the second through opening  260   b  is divided by a first strut  262 , and the second through opening  260   b  and the third through opening  260   c  is divided by a second strut  264 . 
         [0055]    Provision of the through openings  260   a - 260   c  greatly reduces the resin material used in manufacturing the hanger  200 , and concomitantly, the weight of the hanger  200 . Accordingly, manufacturing and transportation costs of the hangers are significantly reduced, especially considering the millions of hangers manufactured each year. However, this hanger configuration with various openings still maintains the mechanical performance and structural integrity of the hanger satisfying industry standards, for example, the VICS standards. 
         [0056]    The through openings  260   a - 260   c  can assume any suitable shape and profile depending on the structural requirements of the hanger, the preference of the molding process and the appearance of the hanger. Although the shown through openings  260   a - 260   c  are elongated holes substantially in the form of bubbles, as shown in  FIG. 3 , it should be understood that the number and shape of the through openings are not limited to the shown embodiment. The through openings can be of any shape, such as square, triangle or diamond. Furthermore, the through openings  260   a - 260   c  of the first arm  230  can be formed in the first distal portion  239  of the first arm  230 . 
         [0057]    The inventor of the present invention has discovered that the provision of through openings in arm web significantly reduces the resin material used for molding the hanger body, without compromising the mechanical performance and structural integrity of the hanger arm. 
         [0058]    Optionally, the second arm  240  also includes at least one through opening  270  formed in the second arm web  248 . Preferably, the through opening in the second arm is symmetrical to the through opening of the first arm. However, it should be understood by a person of ordinary skill in the art that the through opening  270  formed in the second arm can be asymmetrical to the through opening  260  formed in the first arm, as long as the configuration of various openings maintains the mechanical performance of the hanger arm. 
         [0059]    Preferably, the second arm  240  includes a plurality of through openings  270   a - 270   c . The first through opening  270   a  and the second through opening  270   b  are divided by a first strut  272 ; and the second through opening  270   b  and the third through opening  270   c  are divided by a second strut  274 . More preferably, each of the through openings  270   a - 270   c  is symmetrical to the respective through opening of the through openings  260   a - 260   c . However, it should be understood by a person of ordinary skill in the art that the plurality of through openings in the first arm can be asymmetrical to the plurality of through openings in the second arm. Preferably, the through openings  270   a - 270   c  of the second arm  240  are formed in the second distal portion  249  of the second arm  240 . 
         [0060]    Referring to  FIG. 7 , the I-beam shaped hanger arm  230  has a second height H 2  defined substantially as the distance from the upper flange  234  to the lower flange  236 . The hanger arm  230  further has a second width W 2  defined substantially as the distance from the left side to the right side of the upper flange  234  and the lower flange  236 . For example, the second height H 2  is about 0.50″ and the second width W 2  is about 0.30″. Thus, the ratio between the second height H 2  and the second width W 2  is 1.67, according to the exemplary top garment hanger  200 . 
         [0061]    The following Table 1 presents a comparison of parameters of a hanger according to the present invention vis-à-vis the parameters of a market-accessible prior art hanger (such as a “484/17″” top garment hanger according VICS), both hangers meeting the requirements of the acknowledged industry standards, including the VICS standards. 
         [0000]    
       
         
               
               
               
             
               
               
               
             
           
               
                 TABLE 1 
               
               
                   
               
               
                   
                 Prior Art 
                 Top Garment 
               
               
                   
                 Top Garment 
                 Hanger of the 
               
               
                   
                 Hanger 
                 Present Invention 
               
               
                 Parameters 
                 (having an I beam) 
                 (having an I beam) 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Height of I beam 
                 0.75″ 
                 0.50″ 
               
               
                 Width of I beam 
                 0.30″ 
                 0.30″ 
               
               
                 Height/width ratio of I beam 
                 2.5 
                 1.67 
               
               
                 Weight of metal hook 
                  8.0 g 
                  8.0 g 
               
               
                 Weight of K resin of hanger 
                 33.0 g 
                 24.5 g 
               
               
                 body 
                   
                   
               
               
                 Total weight of hanger 
                 41.0 g 
                 32.5 g 
               
               
                   
               
             
          
         
       
     
         [0062]    Table 1 shows that, compared to the prior art hanger averagely consuming 33.0 g of K resin, the top garment hanger according to the present invention consumes 24.5 g of K resin. In other words, 8.5 g of K resin are saved per hanger, which accounts for about 25.75% of the total resin material of the prior art hanger. With significantly less resin material consumed, the mechanical performances and structural integrity of the top garment hanger according to the present invention are still maintained at a level same as that of the prior art hanger. 
         [0063]    Each year, about 1.0 billion top garment hangers are manufactured in accordance with the VICS standards. Thus, the top garment hanger according to the present invention would reduce the resin material by about 18.7 million pounds annually, which would in turn eliminate about 55.0 million pounds of CO 2  emission for producing the same amount of resin. 
         [0064]    Furthermore, the reduction of resin material leads to less consumption of energy and resources for storing, transporting and handling the hangers. Hence, the top garment hanger according to the present invention helps to preserve environment and resources, while still providing improved products to the consumers. 
         [0065]    The hanger of the present invention can be formed of one or more of may be one or more of polystyrene, SAN, ABS, PPO, nylon, polypropylene (PP), polyethylene, PET, polycarbonates (PC), acrylics, K-resin, and polyvinyl chloride (PVC) among others. 
         [0066]    From the foregoing illustrations it is readily apparent that the present invention is directed to a lightweight molded plastic garment hanger for high volume injection molding. The hangers of the present invention consume less material than the corresponding prior art hangers, while still maintaining the mechanical performance, for example, under the VICS standards. Moreover, the production of such hangers is environmentally advantageous. 
         [0067]    The present invention has been described with respect to certain exemplary embodiments. Certain alterations and/or modifications will be apparent to those skilled in the art, in light of the instant disclosure, without departing from the spirit or the scope of the invention. These embodiments are offered as merely illustrative, and not limiting, on the scope of the invention, which is defined solely with reference to the following appended claims.