Automated system for sizing hangers with an indicating means

Abstract: The specification discloses a system for producing and distributing index coded hangers (11) to a plurality Of locations, wherein the index indicia (17) is correlated to the characteristics of the garment to be hung from the hanger at each of the plurality of locations. A unique hanger and index cap is disclosed, along with a method and means of making the same that is particularly adapted to high volume semi-automated operation. A device for assembling the index cap and hanger at the time the garment is hung is also disclosed. The system contemplates the localized production of the index caps (17) for improved control of batch color and other characteristics, with remote molding and assembly of the hangers (11) at said plurality of remote locations.

Description: The present invention relates to a system and a method for producing a plurality of hangers, having index-coded caps of the type as described in the preambles of claims 1 and 10. It is known to affix an indicating means to a hanger to assist the buyer, in locating a garment of a particular size from a plurality of like garments arranged adjacent thereto on a display rack. Consumer taste and fashion have dictated a desire for mass produced, but well fitted garments. For example, men's suits, commonly sold by chest measurement are now available for short, regular, tall, and extra tall proportions for a given size, thereby providing four different "attributes" for a given garment size, i.e., 42S, 42R, 42T, 42XT respectively. The manufacturers of women's garment, particularly those who manufacture bra and panty sets, have also experienced a comparable increase in the number of attributes allocated to a given garment, in addition to its size. For example, a bra with a chest size of 36 may be available in five different cup sizes (A-DD), and for certain types of lingerie, may be matched with one or more corresponding panty sizes. For this reason, the trade has developed a variety of indexing means to further sub-divide garments by their appropriate attributes, all of which are today, manually affixed. Garment hangers having index-coded caps of the type as defined in the preamble of claims 1 and 10, are known from WO90/09651. The index-coded cap is to be attached to the top of the hook of the garment hanger, and is provided with the plurality of indexing indicia each relating to a specific characteristic of a garment to be hung on the hanger. The caps are described to be attached to the hangers by an automatic system and/or method; the specific system and method used, however, is not described. U.S. Patent 4,322,902 discloses an indicator for garment hangers, which is currently assigned to the assignee of the present application, and which further discloses a first indicator which may be snapped over the wire hook of a hanger, and a second indicator, disclosed in Figures 3-6 which may be attached to either a wire hanger, or a plastic hanger as illustrated in Figures 4 and 6. U.S. Patent 4,137,661 discloses an "identification procedure for suspended articles of clothing and carrier for application of the procedure." In this patent, the marking of data with respect to size, quality, color, manufacturing data, delivery, pattern or price is affixed to a label member 5 and removably secured to the hanger. U.S. Patent 3,024,953 discloses a rectangular plastic guard which is adapted to be secured to the wire hook of a clothes hanger, and which extends upwardly therefrom to assist in preventing the clothes hangers from becoming entangled with one another. U.S. Patent 1,099,261 discloses a clothes hanger particularly adapted for hanging sets of furs, with a metal rectangular plate 10 which receives an index card describing the furs suspended therefrom. U.S. Patent 4,115,940 discloses a garment hanger with a size indicator in which the indicia or carry tab is visible when the garment is hung on the hanger. Design Patent 302,214 discloses a garment hanger in three embodiments, two of which disclose indexing indicia. Design Patent 302,214 is also assigned to the assignee of the present invention. Design Patent 244,197 discloses an ornamental design for size indicator for a garment hanger that is intended for attachment to a garment hanger. Each of these devices is manually affixed, and further, may include additional steps of printing, writing, or otherwise creating the desired indicia to be attached to the hanger. The present invention includes an automatic system for sizing hangers with an indicating means that is directly related to some attribute of the garment suspended from the hanger. The indicating means is sequentially attached to the hanger at the time the garment is hung or suspended from the hanger. The invention further includes a method for manufacturing the indicating means, and then distributing them to a plurality of locations around the world for attachment to the garment hangers at the time the garments are suspended therefrom. The system and method of the present invention are characterized by the features of independent claims 1 and 10, and provide a colorful, easy to read, visual display of one or more attributes of the garment which could be easily discerned by the customer when a plurality of like garments are suspended from a display rack. The sizing indicator is attached above the hook of the hangar to be easily visible above the hangers, even when a plurality of like garments are suspended adjacent one another on a longitudinal rail. By imprinting the size in an Arabic numeral, i.e, 44, and a garment attribute in a color, it is possible for the customer to select the desired garment quickly and easily. When plural garments are involved, such as a bra and panty set, the bra size can be imprinted on one side of the indexing means, while the panty size can be printed on the opposing side of the indexing means. The present invention includes a system for producing a plurality of hangers, each of which has an index coded cap which is related to a specific characteristic of the garment hung from the hanger wherein the individual hangers are produced at a plurality of locations, and the index coded caps are produced at a central location. This system is particularly adapted to the manner in which garments are currently manufactured, distributed and sold in international trade. Large national retailers of clothing generally contract with a plurality of clothing manufacturers to produce uniform standardized clothing which is essentially identical from batch to batch, even though manufactured by different entities. These plurality of manufacturers in turn produce the clothing at their own plants, or in many cases sub-contract the production of the garments to far eastern manufacturers based in Hong Kong, Taiwan, Singapore and South Korea. It is desirable to maintain a consistent appearance for the indexing features of the hanger. It is also desirable to locally produce the hanger at the remote manufacturing location to avoid the shipping costs associated with the bulk shipment of millions of hangers from the United States to far eastern locations. Therefore, the present invention is particularly suited to the production of uniform indexing caps in the United States, and the shipment of those caps to a plurality of garment manufacturing locations, wherein the caps may be automatically attached to the garment hangers, at the time the garment hanger is dispensed for securing the clothing thereto. The use of such a hanger facilitates the "rack ready" production of clothing articles wherein the clothing articles are manufactured and suspended from hangers in the far east, together with the retail store's price tag, and mounted in intermodal containers for shipment to the United States whereupon the "rack ready" clothing may be transferred from the intermodal container to the display rack in the retail store without any additional labor input. To facilitate this system, the system of the present invention also includes a means for aligning and stacking the index coded caps in a predetermined relationship to one another, so that the caps may be loaded in a machine for automatically affixing the index coded caps to the garment hanger. The present invention also includes means for transporting the stacked cap and in a preferred embodiment a bundle which maintains said predetermined relationship to the plurality of locations for which the stacked caps are to be attached to the hangers. Finally, an embodiment of the system of the present invention includes automatic means for sequentially affixing the index coded caps to the garment hangers at each of the plurality of locations wherein the index coded caps are secured to the hanger automatically at the time the garment is hung from the hanger. An embodiment of the system of the present invention also includes a mechanized means for manufacturing a bundle of stacked indexing caps for subsequent attachment to a plurality of hangers wherein the individual index coded caps are injection molded in a plurality of colored batches. The mechanized means further includes a centrifugal means for aligning the caps from each batch in a predetermined stacked relationship to one another, and a means for binding the caps into a bundle for transport to a plurality of remote locations. The system of the present invention also includes a garment hanger having an indexing cap for identifying at least one characteristic of the garment hanging therefrom. The garment hanger includes a hook adapted to engage a rod or other supporting means, and art upstanding flange extending from the hook for receiving one of a plurality of different indexing caps, said flange extending and projecting above the top contour of the hook. The hanger also includes a snap fit engagement means defined by the upstanding flange, and a generally planar and stackable indexing cap having a recess formed therein for receiving the flange of the hanger therewithin. The indexing cap also defines a through opening which facilitates stacking the indexing cap in a bundle of stacked caps during transport, and which receives the snap fit engagement means when the indexing cap is attached to the hanger. An embodiment of the system of the present invention also includes an automatic means for assembly of the indexing coded cap and the hanger at the time the clothing is hung from the hanger. This means includes a magazine for receiving a bundle of stacked caps, a separate magazine for receiving a plurality of stacked hangers, and a reciprocal means for simultaneously dispensing one of the index caps from the magazine and securing said cap to the hanger at the time the hanger is presented to the operator for attaching the clothing thereto. In the accompanying drawings: Figure 1 is a plan view of one side of a bra and panty garment hanger having an index coded cap relating to an attribute of a bra to be suspended therefrom; Figure 2 is an exploded view of the opposite side of the bra and panty hanger illustrated in Figure 1 with the index coded cap separated from the hanger and displaying an attribute of a panty to be suspended therefrom ; Figure 3 illustrates a cross-section of the index coded cap taken along section line 3-3' of Figure 2 ; Figure 4 represents a corresponding cross section of the hanger taken along section line 3-3' of Figure 2; Figure 5 illustrates an end-view of the indexing cap illustrated in Figure 1; Figure 6 illustrates a top view of the indexing cap and hook illustrated in Figure 1; Figure 7 is an isometric view of a mechanized means for producing a bundle of stacked index caps in accordance with the present invention; Figure 8 is a top view of a means for aligning and stacking said index and coded caps; Figure 9 is a diagrammatic view taking along cord section 9-9' of Figure 8 ; Figure 10a is a diagrammatic view of an air jet separator means taken along section line 10-10' in Figure 9; Figure 10b is a diagrammatic illustration of an air jet separator means also taken along section line 10-10' in Figure 9 ; Figure 11 is a cross-sectional view taken along section line 11-11' of Figure 8; Figure 12 is a partially cross-sectioned isometric view of an index coded cap manufactured in accordance with the present invention; Figure 13 is partially cross-section planar view of the stacking means of the present invention; Figure 14 is a top plan view of the magazine of the present invention; Figure 15 is a plan view of a bundle of stacked index coded caps prepared in accordance with the present invention; Figure 15a is an alternate embodiment of a portion of the invention illustrated in Figure 15; Figure 16 is an isometric plan view illustrating the means for assembling the index and coded caps and hangers at the time the hangers are dispensed; Figure 17 is a top plan view of the means for assembling illustrated in Figure 16, illustrating a second operating position in dotted lines; Figure 18 is an isometric plan view of a manual means for assembling index coded caps and hangers; Figure 19 is a top plan view of a portion of the invention illustrated in Figure 18; Figure 20 is a side plan view of the element illustrated in Figure 19. Figures 1-6 illustrate a garment hanger and the index coded cap of the present invention. While the invention will be described and illustrated with respect to a single bra and panty hanger, it is understood that the invention is equally applicable to other types of garment hangers. As illustrated in Figures 1 and 2, the garment hanger is a bra and panty hanger having bra hanger strap clips 12a-12b and panty hanger clips 13a, 13b arranged at either end of central support 14. The hanger presents a first side in Figure 1, and the opposite side in Figure 2, with the index cap positioned for attachment in Figure 2. Hanger 11 also includes a hook member 15 having an upstanding flange 16 (illustrated in Figure 2) for receiving one of a plurality of different indexing caps, one of which is illustrated at 17 in Figures 1-6. The flange 16 projects above the top contour of hook 15. A snap fit engagement means 18 is defined on the upstanding flange 16 as illustrated in Figure 2. The index coded cap 17 is generally planar and stackable and has a recess 19 formed therein (illustrated in Figure 3) for receiving the upstanding flange 16 therewithin. The indexing cap 17 defines a through opening 20 (illustrated in Figures 1-3 and 12) which receives the snap fit engagement means 18 when the index cap is fitted to the upstanding flange. This through opening is also used to form a bundle of stacked caps as will be hereinafter later described with respect to Figures 13-15. The hook member further defines a horizontal flange 21 which cooperates with the snap fit engagement means 18, and a first 16a and second 16b edge of flange 11 to engage the recess 19 defined within the index cap in a wedging manner. Edges 16a and 16b extend upwardly and inwardly in an angular fashion to assist in centering the cap for engagement of the snap fit engagement means 18. Hook member 15 also includes an inner flange 22 which extends from the tip 15a of the hook to the intermediate frame member 14 to strengthen the hook and to provide a larger load bearing surface when the hanger engages a rod or other supporting means during use. Hook member 15 also includes a second reinforcing rib 23 which extends upwardly from central support member 14 to strengthen the hook and to resist twisting or flexure of the hook 15 then the garment hanger is in use. Flanges 22, 23 join with similarly defined upper flange 24, defined by central support member 14. Central support member 14 includes upper and lower flanges 24, 25 and a center medial flange 26 which serves to stiffen the hanger. By choosing a relatively resilient plastic material for the hanger 11, and a relatively stiff plastic material for the cap, the snap fit engagement can be made relatively permanent, since once the index coded cap is secured by snap fit engagement barbs 18, it is necessary to bend or flex the side walls 17a, 17b beyond barbs 18 before the cap can be removed. The stiffness of the plastic material used to form the cap thereby determines the degree of difficulty one encounters in removing the cap. Further, the fit and cooperation of the flat edge 17c of the cap and the horizontal flange 21 mares it difficult to insert a screw driver, or other means, with which to pry the side walls apart for removal of the cap. As illustrated in Figures 1-6, the index cap includes several indexing features. The cap is color coded to denote a specific attribute of the garment suspended from the hanger. In addition, the indexing cap 17 carries on one side the legend 44DD as illustrated at 26 to denote a bra size suspended from the hanger. On the opposite side of the cap, as illustrated at 27 in Figure 2, a panty size "6" is indicated for a hypothetical bra and panty set. In this instance, the color coding could relate to a certain grade and quality of garment, a certain style of garment, or to visually reinforce one of the printed indicia such as cup size or panty size. This color attribute would assist the purchaser in selecting the appropriate garment for his or her intended use. The index cap 17 is planar, having a first and second planar side 17a, 17b which facilitate stacking of the caps for shipment as a bundle of stacked caps. The bottom portion of the cap 17c defines a flat edge, while the top edge of the cap 17d is rounded. The flat configuration 17c and rounded configuration 17d assist the sorting and stacking mechanism in automatically aligning and stacking the caps in a predetermined manner as will be hereinafter illustrated and described with respect to Figures 8-11. As illustrated in Figure 6, the top of the indexing cap 17d is unadorned in the preferred embodiment and is somewhat wider than the internal flange 15a and 15b. It should be noted that as illustrated in Figure 6, flanges 22 and 23 are not visible, and that horizontal flange 21 is substantially the same length as the indexing cap 17, and therefore not visible in Figure 6. The garment hanger illustrated in Figures 1 and 2 also includes a center strengthening rib 26. The use of ribs 22-26 allow the central web of the hanger to be reduced in thickness and weight, thereby reducing the material cost for the hanger and the shipping cost during transit from the various remote manufacturing facilities to the United States. In the preferred embodiment, the hanger is formed of Styrene which provides a clear, virtually transparent hanger for maximum display of bras and panties suspended therefrom. Alternately, the hanger could be formed from K Resin, H.I. Styrene and Polypropylene or other suitable thermoplastics. Figure 7 is an isometric view of a mechanized means for manufacturing a bundle of stacked indexing caps (illustrated in Figure 15). The means includes an injection molding machine 30 having a supply of pelletized thermoplastic through an air conveyor system 31 and a pair of opposing mold cavities, generally indicated at 32. In one embodiment of the invention, the injection molding machine is manufactured by various supplies around the world. In operation, the mold cavities 32 are first filled with thermoplastic at elevated temperatures and pressure to form multiple index coded caps in a single cycle. The number of index coded caps formed during each cycle is a function of the capacity of the injection molding machine and the mold configuration. As the injection mold 32 is separated, the index coded caps, and molding sprues fall from the cavities onto conveyor belt 33 which travels beneath the injection molding machine. The index coded caps and molding sprues are then discharged into an open hopper 34 of a sprue separator 35 which discharges the index caps through an upper opening onto intermediate conveyor 36 and the molding sprues into a waste collection box 37. The accumulated sprues may then be shredded and re-introduced into the product stream at 31 as desired. The sprue separator 35 is a device, manufactured by Alliance Equipment Co. of Starling, Mass. and uses counter rotating brushes to direct the index coded caps-through the upper opening 38 onto conveyor 36. The caps deposited on conveyor 36 are then transferred to a second conveyor 39 for transport to an aligning and stacking machine generally indicated at 40. While belt conveyors are illustrated in Figure 7, it should be understood that air conveyors or other suitable means for transport of the index coded caps could be used to move the caps from the injection molding location to the aligning and stacking station. The aligning and stacking machine includes a central hopper 41 equipped with a shut-off valve and vibrating magnet to assist in controlling the flow of caps from the injection molding machine 30, to the aligning and stacking machine 40. As the index coded caps are discharged from hopper 41, they are deposited into a circular chamber generally indicated in Figure 7 at 42 which aligns the caps in a serial fashion as will be hereinafter further illustrated and described with respect to Figures 8-11. The index coded caps are randomly oriented during all stages of the transport from the injection molding machine 30 to the circular chamber 42. The aligning means provides a serial stream of index caps which exit the circular chamber 42 along conveyor 43 in sequential serial alignment with all caps aligned in the same direction and orientation. The output of conveyor 43 feeds a stacking mechanism 44 which creates a bundle of stacked caps from the serial sequential stream arriving from conveyor 43, as will be further illustrated and described with respect to Figures 13-15. When 100 caps or any other desired number, have been stacked in a stacking mechanism 44, a plastic ribbon is inserted through the opening 20 defined in the index coded caps to create a bundle of stacked caps, which are then lifted from the magazine for transport to a plurality of garment assembly locations. The use of a central location for injection molding machine 30, assures that the respective batches of index coded caps are all of the same color and appearance. The different colors of plastic may be maintained in separate silos (not shown in Figure 7) and directed to the injection molding machine 30 through an air conveyor system as illustrated at 31. When a first batch of caps is completed, the mold cavities 32 are changed to prepare molds with the new indicia, and the air conveyor system will draw a different colored plastic from a separate silo. The rest of the mechanized system remains essentially unchanged, thereby providing quick, convenient and rapid ability to produce a plurality of different batches of stacked index coded caps. As illustrated in Figure 8, the aligning and stacking mechanism 40 includes a circular chamber 42 having a stationary inner circular wall 45 and a rotating circular bowl 46. As the stacked caps are dropped into the circular chamber by hopper 41, they are rotated in a counter-clockwise direction by the rotating bowl 46, and the centrifugal force generated by the rotating bowl. The inverted and downwardly beveled slope of the bowl, illustrated in Figure 9, forces the jumble of stacked caps outwardly against stationary outer wall 45. A ramp 47 extends from the rotating bowl 46 upwardly to an annular band 48 which extends around the inner lower portion of side wall 45. As the jumble of stacked caps encounters ramp 47, the centrifugal force drives selected caps upwardly along the ramp, with a preference for those that are aligned along the circumferential path defined by the annular band 48. The aligned caps are driven upwardly along ramp 47 by other caps from the rear and are held against the annular band 48 by the centrifugal force exerted by more inwardly directed caps in the jumbled pile of caps. A transition plate 50 is positioned parallel to the upper edge of annular band 48 to assist the caps in making the radial transition from the radius defined by ramp 47 to the radius defined by annular band 48. A separator plate 51 is adjacent to ramp 47 and begins with the entry point of ramp 47, but continues upwardly past the elevation of the upper shelf defined by annular band 48, and extends inwardly to contact annular band 48 as ramp 47 tapers off underneath. The separator plate 51 is much thinner than ramp 47, while ramp 47 and annular band 48 are both the approximate width of one of these stacked caps. As the stacked caps emerge from the separator plate 51 along the top of annular band 48, they encounter first and second air jets 52, 53. The motive force for the caps is a push from the rear generated by the jumble of stacked caps advancing upwardly along ramp 47. As illustrated in Figure 10b, air jet 52 is directed downwardly across the upper outer periphery of the advancing row of index coded caps 17. The curved lower portion 17d creates instability on the part of the cap if the cap is oriented upside-down. Air jet 52 strikes the inner recess 19 and drives the stacked cap off the wall in the direction of arrow A. On the other hand, a properly aligned cap will advance under the air jet as illustrated in Figure 10a, and the rounded top portion 17b thereby reduces the impact area from jet 52. A second air jet 53 is provided to displace all caps from the annular band 48 in the event the conveyor mechanism 43 and stacker mechanism 44 are full. The air jet 53 is activated when light from photo diode 54 is no longer received by photo resistor 55 as indicated in Figure 8 because the column of stacked caps has completely filled the conveyor 43 and stacking mechanism 44. As the row of aligned caps passes air jet 53, it encounters guides 56, 57 which maintain the caps in an aligned relationship as they are fed in the conveyor means 43. In addition to the centrifugal force generated by rotating bowl 46, additional air jets may be provided as indicated at 58 and 59 to create an inner vortex of air which swirls around the inner wall 45 of the chamber. A second air jet 59 is directed somewhat inwardly to assist the caps in the transition from ramp 47 to annular band 48. While it would be possible to combine ramp 47 and band 48 in a single unitary structure, it has been found less expensive to use a singular annular band 48, and a short ramp 47 which is fitted therewith. The remaining jumble of stacked caps is swept in a circular manner against annular band 48 by rotating bowl 46, and the centrifugal force generated by the circular movement of the caps. When the jumble of caps has accumulated to a predetermined height, the jumble strikes a feeler probe 60 illustrated in Figure 11. The feeler probe 60 is suspended from gantry 61 which spans both the inner wall 45 and outer wall 62 of the circular chamber 42. When deflected by the jumble of stacked caps, a micro switch (not shown) attached to feeler probe 60 actuates a shut-off valve in hopper 41 to stop the flow of index caps until the jumble is reduced to the predetermined level. As the feeler probe 60 returns to its normal position, the outlet valve on hopper 41 is opened, and an electromagnet is energized which vibrates the hopper 41 to assist in releasing supply of caps into the circular chamber 42. The alignment mechanism also includes a twisted guide 65 which receives the row of stacked caps in a vertical alignment as defined by guides 56, 57 and annular band 48 (illustrated in Figure 9) and rotates them 90° to a flat horizontal position as illustrated in Figure 8. The lower portion of guide 65 is cut away to receive a conveyor belt 43 which is powered by motor 44 to assist in driving the caps to the stacking mechanism 44. The driving force which transports the caps through the twisted portion of guide 65 is generated by the jumble of stacked caps circulating on rotating bowl 46 and is transmitted end to end through each of the caps aligned in serial fashion along the top shelf of annular band 48. As illustrated in Figure 13, the conveyor means 43 includes an endless belt 66 which is tensioned by idler roller 67 and driven by motor means 44 (illustrated in Figure 8). As illustrated in Figure 13, two caps, 17 and 17' are shown exiting guide means 65. The first cap 17 is driven inwardly by the conveyor means until it strikes the outer wall of magazine 70. A fiberoptic photodiodephotoresistor mechanism indicated at 71 senses the arrival of the new cap 17, a control means (not shown) actuates pneumatic motor 72 which drives plunger 73 and platform 74 upwardly, thereby elevating the cap 17 to the position illustrated by cap 17'' in Figure 13. As the cap is elevated upwardly, a pair of beveled dogs 75 and 76 are displaced outwardly by means of their beveled edge, (one of which is illustrated at 77 in Figure 13), until the cap has passed beyond the upper face of the dogs. As soon as cap 17 is in position, spring means 78,79 urge the dogs 75 and 76 inwardly, thereby suspending cap 17 in the new position illustrated by cap 17'' in Figure 13. While the plunger 73 is in an extended position, a skirt 80 prevents the entry of any additional cap, such as cap 17', until the plunger has retracted to the position illustrated in Figure 13. The operation of pneumatic motor 72 is controlled by a timer, actuated by fiberoptics 71 connected to a photoresistorphotodiode arrangement, and by fiberoptic arrangement 82 which is arranged at the top of the stacking arrangement to generate an interrupt signal for the control means when the magazine 70 is fully loaded. Magazine 70 is defined by a pair of complementary U-shaped channels 70a, 70b as illustrated in Figure 14. A weighting mechanism 83 is dimensioned to travel within the guides 70a, 70b and exert a downward force on the stacked caps as the stacking mechanism 72 is operating. The weighting means 83 is connected to a vertical rod 84 by means of offset arm 85 which maintains the weight 83 in alignment, and provides for the easy removal of the weight when the magazine 70 is filled. In addition, a friction guide 86 is mounted on weight 83, and contains a thumbscrew 87 which can exert a vertical drag on weight 83, which drag acts to offset the force of pneumatic cylinder 72. It has been found in practice, that the force and speed of pneumatic cylinder 72, when coupled with the light weight of the index cap 17, will cause the index caps to flip in magazine 70, unless restrained by a weight such as that indicated at 83. When the magazine is filled, the stacked caps, one of which is illustrated at 17''' will interrupt a light beam emitted by a photodiode in fiberoptic array 82, and will generate an interrupt signal for the control means which controls pneumatic cylinder 72. At that time, the operator can remove the weight 83 and swing it around its axis on guide 84, and insert a plastic strand 90 through the aligned through holes 20 defined by the stack of aligned caps. The plastic band 90 is rectangular in cross-section as illustrated in Figure 15a, and matches the rectangular configuration of through hole 20 defined in each of the stacked caps, to thereby maintain the caps in their initial alignment during transport. The plastic strand 90 may include one-way barbs 92, 93 as illustrated in Figure 15a, or a round plastic ball 94 as illustrated in Figure 15. Ball means 94 defines a circular inner opening which receives the rectangular cross-section of strand 90 in a binding engagement. The binding engagement may be further enhanced by serrations 95 formed on the outer surface of the lower portion of plastic strand 90. As illustrated in Figure 12, the index caps 17 include first 17a and second 17b generally planar side walls which facilitate their stacking as a bundle of stacked caps as illustrated in Figure 15. The through hole 20 defined in both side wall 17a, 17b, is configured to match the rectangular configuration of the plastic strand 90 illustrated in Figure 15a. The index cap may include a variety of indicia such as "44DD" illustrated at 17e and various design ornamentation as indicated at 17f. As can be seen from Figure 12 and Figure 3, the inner cavity 19 is tapered to snugly engage the upstanding flange 16 defined by the hook 15 of hanger 11. With respect to the rate of supply of the index coded caps to the stacking mechanism illustrated in Figure 13, it should be noted that the bowl speed of rotating floor 46, the vibration of hopper means 41, the speed of conveyor means 43, and the repetition rate of pneumatic motor 72 are all independently controllable to ensure maximum throughput of the device. Figures 16 and 17 illustrate an automatic means for assembly of hangers and indexing caps at the time the clothing is hung from the hangers. The device is a modified Hangermatic 589 manufactured by Trim-Master, 4860 North 5th Street Highway, Temple, Pennsylvania 19560. The original Hangermatic machine includes a pair of magazine towers 101 and 102 which are dimensioned to contain a vertical stack of hangers therebetween. The hangers rest on a platen member 104 and are selectively engaged by a reciprocating plate 105 which selectively engages the lower most hanger and urges it outwardly to stop means 106a when actuated. As it reaches the stop means, it displaces the outer platen 106 as illustrated in Figure 17, which opens a pneumatic bleed port mounted in the face of platen 104. As long as the outer platen 106 is in its extended position, the pneumatic motor means remains stationary. When the operator has fitted a garment to the extended hanger and removes the hanger, the outer platen 106, which is spring loaded, returns to the inner platen 104, thereby sealing the pneumatic bleed port, and activating a control means (not shown) for pneumatic motor 103 to return reciprocating plate 105 to its original position. When set to fully automatic operation, the pneumatic motor 103 will immediately begin a return stroke for plate 105 which will pick up another hanger from magazines 101, 102, and advance it outwardly against eccentric stops 106a. In the present invention, a third magazine 108 has been added which receives the bundle of stacked caps illustrated in Figure 15, and the configuration of reciprocating plate 105 has been altered to provide a cut-out 105a which conforms to the exterior dimension of the index coded cap 17. Immediately adjacent cut-out 105a, are alignment cams 109. The ends of 111a, 111b of reciprocating plate 105 have also been altered to provide a spring loaded tip for engagement of the hanger 11. In addition, the magazines 101 and 102 are now independently adjustable by means of bracket 110 and support 112 to configure the Hangermatic machine to a wide variety of hanger configurations. Each of the magazines 101, 102 and 108 have cut-outs 101a, 102a which allow the hangers and index caps to be withdrawn from the magazines as plate means 105 reciprocates forwardly as illustrated in Figure 16. Stand-off legs 113-115 are used to elevate the Hangermatic above the employee work bench, to assist the operator in draping the article of clothing about the hanger before the hanger is withdrawn from the Hangermatic machine. Alternately, the individual legs can be altered in length to provide a slanted configuration which will facilitate hanging clothes therefrom. As illustrated in Figure 17, the Hangermatic machine is loaded with a bundle of stacked caps indicated at 117 which are loaded into magazine 108. Magazine 108 is suspended above the reciprocating plate 105 and platen 104 by brackets 116, 117. Prior to engagement with the hanger 11 the spring loaded tips 111a, 111b of reciprocating plate 105 are fully distended. As plate 105 moves forward, or downwardly as illustrated in Figure 17, it first engages an index cap from the stack of caps 117 within recess 105a. The alignment surface 109 centers the hook 15 within reciprocating plate 105 so that the index cap is properly aligned with the upstanding flange 16 during attachment. As indicated earlier, the upwardly and inwardly directed edges 16a, 16b of flange 16 also assist in centering the index cap as it is attached to hook 15. Plate 105 is dimensioned such that the index cap is seated on hook 15 by the impact of plate 105 as the floating spring loaded tips 111a, 111b engage the center portion of hanger 11. The hanger is then driven forwardly, or downwardly as illustrated in Figure 17 out of the magazines 101, 102 to the position illustrated by the dotted lines in Figure 17. As illustrated in Figure 17, the hanger engages pivoted eccentric stops 106a and displaces the end portion of platen 104 outwardly as illustrated in Figure 17. The spring loaded tips 111a and 111b compensate for irregularities in hanger molding, and reduce the impact of the reciprocating plate 105 on the central portion 14 of the hanger. This substantially eliminates the broken and shattered hangers normally encountered in this type of device. As the pneumatic cylinder 103 drives plate 104, the spring loaded tips 111a, 111b are compressed, and the spring loaded platen 107 is extended, thereby opening the pneumatic bleed line positioned between platen 104, and platen 107. As illustrated in Figure 17, the hanger is now presented to the operator with the clips 12a-12c suspended above the work space, and free from any immediately adjacent encumbrances, so that the operator may quickly and easily attach a bra strap thereto. As the article of clothing is attached to the hanger, it is lifted free of the spring loaded tips 111a, 111b of platen 105, which allows platen 107 to close, thereby actuating the control mechanism for the Hangermatic machine, to return reciprocating plate 105 back to its original starting position as illustrated in Figure 17. If set on automatic, as soon as the plate 105 has reciprocated to its fully retracted position, it is reciprocated forward to automatically dispense another index coded cap and hanger. Figure 18 illustrates a manual means for affixing the index caps to hanger 11. As illustrated in Figure 18, a stationary platen 125 is fitted with guide means 126, 127 which are secured to platen 125 by screws and elongated slots 128 which enable the means to be adjusted for a variety of hanger hook sizes. A backet means 129 suspends an index cap magazine 130 above platen 125, the approximate distance of the width of one index coded cap. Immediately under magazine 130 is an opening 131 which is aligned with the through hole 20 defined in the index cap. Immediately below the opening 131 is a reciprocating fork 132 which has both horizontal and vertical fork tines as illustrated in Figures 19 and 20. In operation, a bundle of stacked caps, such as that illustrated in Figure 15, is dropped into the magazine 130, such that the serrated end 95 and ball closure means 94 extend through opening 131. Reciprocating fork 132 is then driven inwardly in the direction illustrated by arrow B in Figure 18 to engage ball means 94 as illustrated in Figures 19 and 20. As illustrated in Figure 19, the strap 90 is frictionally engaged within ball 94. As soon as the ball is engaged by the fork means 132, the strap 90 is withdrawn from the top of the magazine, and the operator is then free to insert a hanger such that the hook of the hanger engages the lowermost index coded cap in the magazine 130. In operation, the operator lies the hanger flat on platen 125, and reciprocates it inwardly in the direction of arrow A until the hanger hook has firmly seated within the index coded cap. The hanger and cap are then withdrawn from the stack, and another index coded cap is present for attachment. Legs 133-135 are provided to position platen 125 at a comfortable working height for the operator. As will be understood from the foregoing, the present invention includes a system for producing a plurality of hangers having index coded caps which are automatically affixed to the hanger at a plurality of remote locations. The index coded caps may be mass produced in a mechanized means and method of injection molding, aligning, stacking and binding of the caps into a stack bundle for shipment. When the bundle of stacked caps has arrived at its end destination, it is inserted into a magazine 108 or 130 and the caps are subsequently attached to a locally produced hanger.

Claims: A system for producing a plurality of hangers (11) having index-coded caps (17) each of which is related to specific characteristics of a garment to be hung from said hanger (11); said system comprising a plurality of said garment characteristic indexing caps (17) with a plurality of indexing indicia, with each index relating to a specific characteristic of a garment to be hung on said hanger (11); characterised by said plurality hangers (11) being produced at each of a plurality of locations, means (40) for aligning and stacking said caps (17) in a predetermined relationship to one another, means (90) for transporting said stacked caps (17) to a plurality of hanger locations; and means for sequentially affixing said caps (17) to said hangers (11) at each of said plurality of locations, said caps (17) being secured to said hanger (11) at the time a garment is hung from said hanger (11). A system as claimed in claim 1, wherein said indexing indicia is a colour of said cap (17). A system as claimed in claim 1 or 2, wherein said hangers (11) are locally produced at a plurality of locations. A system as claimed in claim 2 or 3, wherein all of said caps (17) are manufactured at a central location to achieve uniformity of colour and then are shipped to a plurality of locations to be affixed to said hangers (11). A system as claimed in any one of claims 1 to 4, wherein said stacked caps (17) are bundled and then transported. A system as claimed in claim 5, wherein each of said caps (17) define a through hole (20), and said means for transporting said stacked caps further includes an angular ribbon (90) which extends through said through holes (20) of a plurality of caps (17) to secure said plurality of caps (17) as a bundle of stacked caps. A system as claimed in any one of claims 1 to 6, wherein the means for affixing said caps (17) to said hangers (11) is an automatic dispenser which affixes said caps (17) as it dispenses a hanger (11). A system as claimed in claim 7, wherein said means for affixing said caps (17) includes a magazine (101, 102) of stacked hangers (11) and a reciprocating member (105) adapted to engage a cap (17) from a stack of caps and to forcibly slide said cap (17) onto a hanger (11) as the hanger (11) is expelled from said magazine (101, 102) of stacked hangers. A system as claimed in any one of claims 1 to 6, wherein said means for sequentially affixing said caps (17) is manual and the caps (17) are stacked in a magazine (130) and secured to said hanger (11) when a hanger (11) is inserted into a recessed cavity at the bottom of said magazine (130). A method for producing a plurality of hangers (11) having index-coded caps (17) each of which are related to specific characteristics of a garment to be hung from said hanger (11); said method comprising moulding a plurality of garment characteristic-related indexing caps (17) with a plurality of indexing indicia, with each index relating to a specific characteristic of a garment to be hung on said hanger (11); characterised by said plurality of hangers (11) being produced by injection moulding at each of a plurality of locations, and by the steps of aligning and then stacking said caps (17) in a predetermined relationship to one another; transporting said stacked caps (17) to said plurality of hanger locations; affixing said caps (17) to said hangers (11) at each of said plurality of locations, each cap (17) being secured to each hanger (11) at the time a garment is hung from said hanger (11). A method as claimed in claim 10, wherein the caps (17) are moulded in different colours. A method as claimed in claim 10 or 11, wherein said hangers (11) are moulded locally at a plurality of locations. A method as claimed in claim 11 or 12, wherein all of said caps (17) are moulded at a central location to achieve uniformity of colour and then shipped to a plurality of locations to be secured to said hangers (11). A method as claimed in any one of claims 10 to 13, which further includes a step of binding said stacked caps (17) in a bundle with a ribbon binding means (90) to form a bundle of stacked caps (17) prior to transporting said stacked caps (17) to a plurality of locations. A method as claimed in any one of claims 10 to 14, wherein said caps (17) are automatically affixed to said hanger (11) as the hanger (11) is dispensed for hanging a garment therefrom. A method as claimed in claim 10, wherein the caps (17) are automatically affixed to said hangers (11), said method further including the steps of loading said caps (17) into a magazine (108), loading said hangers (11) into a separate magazine (101, 102), and reciprocating a place (105) between said magazines (108, 101, 102) to automatically affix said caps (17) to said hangers (11). A method as claimed in any one of claims 10 to 14, wherein the step of affixing said caps (17) to said hangers (11) is manual. A method as claimed in claim 17, wherein the step of affixing the caps (17) further includes the step of manually inserting a hanger (11) into a recess formed at the bottom of a magazine (130) of stacked caps (17) and then manually removing said cap and hanger combination. A system of any one of claims 1 to 9 including an automatic means for assembly of hangers (11) and indexing caps (17) at the time clothing is hung from said hangers (11), said means comprising: means (108) for receiving a bundle of stacked caps (17); means (101,102) for receiving a separate plurality of stacked hangers(11); reciprocal means (105) for simultaneously dispensing said cap (17) and securing said cap (17) to said hanger (11) to define an indexed hanger; wherein an index defined by the secured cap (17) is correlated to a specific characteristic of a garment hung thereon. A system as claimed in claim 19 wherein said hanger (11) and said index cap (17) to be secured are positioned in a common plane. A system as claimed in claim 19 or 20 wherein said means for receiving a bundle of stacked caps (17) is a magazine (108). A system as claimed in any one of claims 19 to 21, wherein said means for receiving a plurality of hangers (11) is a magazine (101, 102). A system as claimed in any one of claims 19 to 22, wherein said reciprocal means includes a plate (105) defining a first cut-out (105a) which defines the size and shape of said index cap (17) and second cut-out (109) which is arcuate and extends from said first cut-out (105a) to a leading edge (111a, 111b) of said plate (105), said first and second cut-outs (105a, 109) aligning said index cap (17) and hanger (11) prior to engagement. A system as claimed in any one of claims 19 to 23, wherein said reciprocal means (105) reciprocates along a common plane with said cap (17) and said hanger (11) to remove a cap from said magazine (108) and thereafter secure said cap (17) to said hanger (11) as the hanger (11) and cap (17) are dispensed from said hanger magazine (101, 102). A system of any one of claims 1 to 9 including a manual means for assembly of hangers (11) and indexing caps (17) at the time clothing is hung from said hangers (11) said indexing caps (17) being secured in a stacked bundle of caps by a plastic ribbon (90) and a releasable clamp (92, 93, 94), said manual means comprising: means (130) for receiving a bundle of stacked caps (17); means (132) for removing said releasable clamp (92, 93, 94); alignment means (126, 127) for aligning said hanger (11) with said cap (17) to assist an operator in inserting said hanger (11) into said indexing cap (17). A system for assembly as claimed in claim 25, wherein said means for receiving a bundle of stacked caps (17) is a magazine (130). A system for assembly as claimed in claim 25 or 26, wherein said means (132) for removing said releasable clamp disengages a plastic barb (92, 93). A system for assembly as claimed in claim 26 or 27, wherein said magazine (130) defines an opening at its bottom end whereby after a hanger (11) has been inserted into the recess of a cap (17) said cap (17) may be removed from said magazine (130) by withdrawing said hanger (11).

Inventors: GOULDSON STANLEY, MAICORCA ROBERT, MARSHALL DAVID J, OLK OLAF, GOULDSON, STANLEY, MAICORCA, ROBERT, MARSHALL, DAVID J., OLK, OLAF
Applicants: SPOTLESS PLASTICS PTY LTD, SPOTLESS PLASTICS PTY. LTD.
Application year: 1992
Main classification: B65C7
IPC codes: A47G25, B65C7