Patent Description:
In commercial retail stores, packages are often displayed for sale while mounted on rods or display supporting elements by the use of a hang tab. A conventional hang tab, which is typically made of polyester or plastic, has a hang portion that includes an aperture or a slot and a support portion that can be attached to a package that is to be displayed. The aperture or the slot of the hang tab is configured to receive and hang from a display supporting element that is attached to a display. The support portion attaches to a package to be suspended from the display supporting element. Particularly when the package or the object is in a rectangular shape, it is desirable for the hang portion to be folded to reduce space needed for shipment or storage.

Moreover, many companies and manufacturers have been trying to reduce the amount of materials used in the packaging of consumer products that are harmful to the environment. However, eco-friendly materials made of biodegradable, degradable, or recyclable materials have been avoided for use in configurations where these eco-friendly materials will receive a load during use. Eco-friendly materials have especially been avoided in cases where a load (e.g., force) will be continually applied to the material for an extended period of time, such as a case where the material is used to support the weight of a hanging consumer product while it is displayed for an extended period of time, such as days, weeks, or months. Typically, the eco-friendly materials, such as plant based pulp containing materials have been found to easily tear and/or break, hard to fold and unfold, and have poor water absorption resistance. With respect to the prior art, reference is made to documents <CIT>, <CIT>, and <CIT>. Document <CIT> relates to a hanger for hanging a product such as a video cassette for display is disclosed. The hanger is in a form of a flat plate, and comprises a bonding section capable of bonding to a product to be hanged, and a folding section having a hanging means such as a hole and is formed integral with the bonding section. The folding section is capable of turning upward by a predetermined angle with respect to its original state in which the bonding section and the folding section are substantially in the same plane. The hanger can be automatically bonded to the product and does not interfere with the automatic packaging of a number of products into a box due to its flat structure. The folding section is folded upward when the product to be displayed and is hanged by the hanging means on a displaying place. Document <CIT> relates to straw jacket is suitable for packaging a straw and comprises a sealing film, two end-sealing embossing, an auxiliary embossing, a hanging zone, and a hanging hole. The sealing film surrounds and defines a containing space for storing the straw. The two end-sealing embossing are pressed on the sealing film at places corresponding to two opposite ends of the straw in the axial direction and enable to confine the straw in the containing space. The auxiliary embossing is away from the straw and disposed at the external side of one of the end-sealing embossing. The hanging zone is located on the sealing film, and limited and defined by the auxiliary embossing and the adjacent end-sealing embossing. The hanging hole is penetrated to form on the sealing film, and located in the hanging zone. With the structurally reinforced hanging hole, the user could sleeve the straw jacket to the straw to avoid environmental pollution resulted from littering. Document <CIT> relates to a structure of a carton, which comprises a carton body and a carton cover, wherein, at least a reinforced ring is tightened and arranged around four side walls of the carton body; lifting holes are arranged at opposite side walls of the carton body, and at least a reinforced ring is tightened and arranged around the peripheral edge of the lifting holes. The reinforced ring is tightened and arranged around the four side walls of the carton body and the peripheral edges of the lifting holes of the side walls of the carton body, therefore, the connection part of each side wall of the carton body is uneasy to be ripped during the load bearing of the carton body, and the peripheral edges of the lifting holes of the side walls of the carton body are also uneasy to be ripped. Compared with the prior art, the improved carton has the advantages that the total strength of the carton body is enhanced, the service life is enhanced, the structure is simple, and the processing is convenient.

Therefore, there is a need for improved materials and structures used to display a consumer product that are eco-friendly and due to the selection of materials and/or structural design are durable, foldable, and/or water resistant.

Embodiments of the disclosure include a hang tab for supporting a package. The hang tab includes a hang portion, a support portion, and a hinge portion that extends in a first direction and is disposed between the hang portion and the support portion. The hang tab may be formed from a fibrous material, and the hang portion includes an opening (e.g., slot) formed therein, and a central region that at least partially surrounds the opening. The central region may include two or more first regions, and a second region that is disposed between each adjacent pair of two or more first regions, wherein at least one physical attribute of each first region is different than a physical attribute of each second region. In some cases, the at least one different physical attribute is selected from a group consisting of a thickness and a mass density.

Embodiments of the disclosure may further include a package that includes one or more walls that are configured to at least partially enclose a consumer product, and a hang tab. The hang tab includes a hang portion, a support portion, and a hinge portion that extends in a first direction and is disposed between the hang portion and the support portion. The hang tab may be formed from a fibrous material, and the hang portion includes an opening formed therein, and a central region that at least partially surrounds the opening. The central region may include two or more first regions, and a second region that is disposed between each adjacent pair of two or more first regions, wherein at least one physical attribute of each first region is different than a physical attribute of each second region. In some cases, the at least one different physical attribute is selected from a group consisting of a thickness and a mass density.

Embodiments of the disclosure may further provide a method forming a package by attaching a hang tab to a first surface of a package that is configured to at least partially enclose a consumer product, wherein the package comprises one or more walls that are configured to enclose the consumer product, and the first surface is formed on one of the one or more walls, and the hang tab.

In the figures and the following description, an orthogonal coordinate system including an X-axis, a Y-axis, and a Z-axis is used. The directions represented by the arrows in the drawing are assumed to be positive directions for convenience. It is contemplated that elements disclosed in some embodiments may be beneficially utilized on other implementations without specific recitation.

Embodiments described herein are generally related to a device used to display a consumer product, which is referred to herein as a hang tab. More specifically, to eco-friendly hang tabs made of biodegradable, degradable, and/or recyclable materials that can be used to display consumer products. In some embodiments, the displayed consumer product is disposed within a package that is used to support and retain the consumer product therein during shipment, storage and while it is on display. According to one embodiment, a package may include one or more walls that are configured to enclose the consumer product, and have a hang tab attached thereto. The hang tab, which is configured to support at least a portion of the weight the package, may include a hang portion that has an opening, also referred to herein as a slot, formed therein to receive a display supporting element, a support portion having a surface that can be attached to the package, and a hinge portion that is disposed between the hang portion and the support portion.

Hang tabs described herein are generally made of biodegradable, degradable, and/or recyclable materials, such as materials made from materials that include plant based materials, such as wood pulp. It is desirable for the hang tabs described herein to be foldable/un-foldable, durable against the stresses applied to portions of the hang tab during folding/un-folding and durable against becoming damaged and/or physically failing due to loads applied during normal use. In some cases, it is also desirable for the material(s) from which the hang tab is made to be useable after being shipped, stored and/or displayed in a humid and/or uncontrolled ambient environment. In some cases, the material(s) from which the hang tab is made are coated or treated with materials such that they do not significantly absorb water, which is referred to herein as being water resistant.

<FIG> is a front view of a hang tab <NUM> according to one or more embodiments. <FIG> are side views of the hang tab <NUM> formed along the sectioning lines "1B-1B" and "1C-1C," respectively. The hang tab <NUM> includes a hang portion <NUM>, a support portion <NUM>, and a hinge portion <NUM> that extends along the X-axis and separates the hang portion <NUM> from the support portion <NUM>. The hinge portion <NUM> protrudes in the Y-direction from the hang portion <NUM> and the support portion <NUM>, forming a U-shape as shown in <FIG>. The hang portion <NUM> and the support portion <NUM> of the hang tab <NUM> can be formed such that their major surfaces are both parallel to a plane (e.g., X-Z plane) when they are unloaded and/or are not in use, as shown in <FIG>.

The hang portion <NUM> of the hang tab <NUM> generally includes a slot <NUM>, a slot reinforcing portion <NUM> that surrounds the slot <NUM>, a central region <NUM>, and a circumference reinforcing portion <NUM>. In some configurations, as illustrated in <FIG>, the slot reinforcing portion <NUM> is surrounded by the central region <NUM>, and the central region <NUM> is surrounded on at least three edges by the circumference reinforcing portion <NUM> and one edge by the hinge portion <NUM>.

The slot <NUM> of the hang portion <NUM> is configured to receive a display supporting element, such as a wire hanger or support hook (e.g., peg-board hook, wall mounted hook, etc.), for example, when a package or an object, to which the hang tab <NUM> is attached, is being suspended from the display supporting element in a retail store for display. In some embodiments, the slot <NUM> is a so-called "Euro style" slot as shown in <FIG>. The slot <NUM> may be a "delta style" slot as shown in <FIG>, a round slot as shown in <FIG>, a "heavy duty style" slot as shown in <FIG>, or an opening having any other desirable shape (e.g., circular, oval, triangular).

The slot reinforcing portion <NUM>, which is formed around the perimeter of the slot <NUM>, is configured to prevent the hang portion <NUM> from ripping or tearing due to the weight of a package, or an object to which the hang tab <NUM> is attached, when it is suspended from a display supporting element.

The circumference reinforcing portion <NUM>, which is formed on the perimeter of the hang portion <NUM> is configured to further prevent the hang portion <NUM> from tearing due to the load provided by the display supporting element and/or structurally degrading (e.g., fraying) due to contact with other external components during shipping or storage. In some configurations, the hang portion <NUM> may have rounded top corners <NUM>.

In some embodiments, the hang portion <NUM> has a length LH in the X-direction of between <NUM> and <NUM> and a width WH in the Y-direction of between <NUM> and <NUM>, the support portion <NUM> has a length LS in the X-direction of between <NUM> and <NUM> and a width WS in the Y-direction of between <NUM> and <NUM>, and the hinge portion <NUM> has a length LG in the X-direction of between <NUM> and <NUM> and a width WG in the Y-direction of between <NUM> and <NUM>. The slot <NUM> may have a length LSLOT in the X-direction of between <NUM> and <NUM>. The slot reinforcing portion <NUM> has a width WSR of between <NUM> and <NUM> and a thickness TSR of between <NUM> and <NUM>. The circumference reinforcing portion <NUM> has a width WCR of between <NUM> and <NUM> and a thickness TCR of between <NUM> and <NUM>. The hang portion <NUM> may have rounded top corners <NUM> having a corner radius of between <NUM> and <NUM>.

In some embodiments, the hang tab <NUM> is attached to a surface of a package <NUM>, <NUM> that is to be suspended from a display supporting element, as illustrated in <FIG> and <FIG>. In general, the package <NUM>,<NUM> may include one or more walls that enclose a consumer product. In some embodiments, the consumer product is disposed within an internal region of the package <NUM>,<NUM> that has a cylindrical, rectangular or other useful external configuration of walls that are formed from various conventional eco-friendly and/or non-eco-friendly materials. Typical, consumer products can include, but are not limited to, durable and non-durable goods, which may include, for example, consumer electronics (e.g., wireless speakers, mice, keyboards, cameras, headphones), business products or other useful product that can be bought and sold.

In some embodiments, the hang tab <NUM> is attached to an inner top surface of a package <NUM> that is to be suspended from a display supporting element, as illustrated in <FIG>. <FIG> are a front view and a side cross-sectional view of the hang tab <NUM> when the hang tab <NUM> is attached to a package <NUM> and unfolded. <FIG> are a front view and a side cross-sectional view of the hang tab <NUM> when the hang tab <NUM> is folded for shipment or storage. In <FIG>, the support portion <NUM> is inserted inside the package <NUM> through a slit <NUM> and optionally adhered to an inner top surface <NUM> of the package <NUM> by one or more adhesives <NUM> disposed on an attachment region <NUM> of the support portion <NUM>. The adhesive <NUM> may include a glue, cement, mucilage, or paste that will allow the attachment region <NUM> to be permanently or semi-permanently affixed to another external body, and may include a pressure sensitive adhesive, contact adhesive, solvent-based adhesive, polymer dispersion adhesive, hot-melt adhesive, anaerobic adhesive, single or multi-part adhesive or other useful material that can be used to bond the attachment region <NUM> to another external body.

When the package <NUM> is suspended from a display supporting element, the hang tab <NUM> is unfolded such that the hang portion <NUM> is oriented, in an upright position, to receive the display supporting element. The hang portion <NUM> and the support portion <NUM> make a non-zero angle. That is, in <FIG>, the hang portion <NUM> and the support portion <NUM> make a right angle or near right angle, such as an angle of about <NUM>°. In this configuration, the hang tab <NUM> is configured to fold along the hinge portion <NUM>, for example, during shipment or storage, such that the hang portion <NUM> faces the support portion <NUM>. That is, the hang portion <NUM> holds against the package <NUM>, when the hang tab <NUM> is attached to the package <NUM>, and thus a space required for shipment or storage of the package <NUM> is reduced. When the hang tab <NUM> is folded, the hang tab <NUM> bends along the hinge portion <NUM> by approximately <NUM>° from the unfolded position in <FIG>. As shown in <FIG>, the hinge portion <NUM> is of a U-shape such that the hang tab <NUM> can bend approximately <NUM>° from the unfolded position.

In some embodiments, the hang tab <NUM> is attached to an inner side surface of a package <NUM> of an object to be suspended from a display supporting element. <FIG> are a front view and a side cross-sectional view of the hang tab <NUM> when the hang tab <NUM> is attached to a package <NUM> and unfolded. <FIG> are a front view and a side cross-sectional view of the hang tab <NUM> when the hang tab <NUM> is folded. In <FIG>, the support portion <NUM> is inserted inside the package <NUM> through a slit <NUM> and optionally adhered to an inner side surface <NUM> of the package <NUM> by the one or more adhesives <NUM> disposed on the attachment region <NUM> of the support portion <NUM>.

When the package <NUM> is being suspended from a support element, the hang tab <NUM> is unfolded such that the hang portion <NUM> and the support portion <NUM> make an obtuse angle, such as an angle of greater than <NUM>° and less than or equal to about <NUM>°. In this configuration, the hang tab <NUM> is configured to fold along the hinge portion <NUM>, for example, during shipment or storage, such that the hang portion <NUM> faces the support portion <NUM>. That is, the hang portion <NUM> holds against the package <NUM>, <NUM>, when the hang tab <NUM> is attached to the package <NUM>, and thus a space required for shipment or storage of the package <NUM> is reduced. When the hang tab <NUM> is folded, the hang tab <NUM> bends along the hinge portion <NUM> by approximately <NUM>° from the unfolded position in <FIG>. As shown in <FIG>, the hinge portion <NUM> is of a U-shape such that the hang tab <NUM> can bend approximately <NUM>° from the unfolded position.

It should be noted that the particular example embodiments described above are just some possible examples of packages to which a hang tab according to the present disclosure can be attached, and do not limit the possible configurations of hang tabs or packages according to the present disclosure. For example, shapes of packages and locations of a package to which a hang tab can be attached are not limited to the particular examples described above. For example, a hang tab <NUM> can be attached to a package or an object of any shape. In another example, the hang tab <NUM> may be attached to an outer surface of a package or an object.

When a package or an object to which the hang tab <NUM> is attached is suspended from a display supporting element, a force F is applied to the hang tab <NUM>, due to the weight of the package or the object that hang tab <NUM> is supporting, as illustrated in <FIG>, may cause ripping or tearing of the hang tab <NUM> starting from the slot <NUM>. The force F illustrated in <FIG> is shown as a single point load, which is aligned in the Z-direction, to represent the reaction force applied to a portion of the slot <NUM> of the hang tab <NUM> by the display supporting element. However, this schematic representation of the force F applied to the hang tab <NUM> is not intended to be limiting as to the scope of the disclosure provided herein since more than one display supporting element may be inserted within the slot <NUM> to support the hang tab <NUM>, and thus apply more than a single point load may be applied to the hang tab <NUM>. The load applied to the hang tab <NUM> by the display supporting element(s) may include a bearing type load that is distributed over a finite length of the slot reinforcing portion <NUM> due to the contact between the display supporting element and a portion of the slot reinforcing portion <NUM> versus the schematically shown single contact point load. Further, ripping or tearing of the hang tab <NUM> from the slot <NUM> due to the applied force F, may propagate to an edge of the hang portion <NUM> and cause breaking of the hang portion <NUM>. Structural degrading (e.g., fraying) due to contact with other external components during normal use, shipping or storage may cause breaking of the hang portion <NUM> from the edge. Repeated folding and unfolding of the hinge portion <NUM> may also cause breaking of the hinge portion <NUM>.

In some embodiments, the hang tab <NUM> includes a hang tab body that includes a material that comprises a fibrous material, such as a lignocellulosic fibrous material, that is formed into a desirable structural shape. The hang tab body generally includes all of the physical elements of the hang portion <NUM>, the support portion <NUM>, and the hinge portion <NUM>. Examples of useful fibrous materials include materials formed from pulp that is prepared by chemical and/or mechanical treatments. Useful fibrous materials include, but are not limited to, materials formed from various types of plant materials, such as wood, straw, bamboo, bagasse, kenaf, flax, hemp, cotton, or the like. Wood currently provides raw material for vast majority of pulp production and contains one or more of the major groups: cellulose, hemicellulose, lignin, and extractives. Depending on the contents, wood can be classified into one of two main families, hardwoods (also referred to as "short-fiber pulp" or "short-fiber wood pulp") and softwoods (also referred to as "long-fiber pulp" or "long-fiber wood pulp"). Overall, hardwoods contain more cellulose and extractives and less lignin than softwoods. For pulp purposes, softwood fibers are, on average, more than three times the length of those contained in hardwoods. Since increasing fiber length usually translates into more inter-fiber bonding, softwood pulps impart greater strength to the products into which they are made, than do hardwood pulps manufactured by the same process. In one example, the hang tab body is formed of long-fiber pulp to promote its ability to support a load for an extended period of time. In the consumer products industry, for example, it is desirable for a single hang tab <NUM> to support a package that has a mass between about <NUM> kilograms (kg) and about <NUM> kgs.

In some embodiments, various physical attributes found within different portions of the hang tab <NUM> may be adjusted to provide the necessary structural support to allow a packaged consumer product to be displayed using the hang tab <NUM>. As discussed herein, the differing physical attributes within a hang tab <NUM> can include the physical shape (e.g., thickness, overall structural shapes formed in the X-Y, X-Z or Y-Z planes, etc.) of different portions of the hang tab <NUM>, materials used in different portions of the hang tab, and different material properties (e.g., mass density, porosity) used in different portions of the hang tab. In some embodiments, the slot reinforcing portion <NUM>, the circumference reinforcing portion <NUM>, and the hinge portion <NUM> have differing material properties or material compositions than other portions of the hang tab <NUM>. In some embodiments, material within the slot reinforcing portion <NUM>, the circumference reinforcing portion <NUM>, and the hinge portion <NUM> have a higher material density (e.g., mass per unit volume) of the fibrous material in other regions of the hang tab body. In some embodiments, the difference in density is formed by the compression of different initial volumes of material during the processes of forming the hang tab <NUM>, thus making the more dense regions more durable against ripping, tearing, or breaking. To further provide tear resistance, the structure and material within the hang tab <NUM> can be processed (e.g., embossed, machined, etc.) to form structural elements within different regions of the hang tab <NUM>.

<FIG> schematically illustrate various types of structural elements that can be formed in the central region <NUM> of the hang portion <NUM> of the hang tab <NUM>. It is believed that by forming the various structural elements, or texture patterns, in the central region <NUM> of a hang tab <NUM> various failure mechanisms commonly found when supporting a package by use of a display supporting element that includes eco-friendly materials can be reduced. The various structural elements generally include structural shapes that are formed by some manufacturing process, and are created to provide tear resistance to prevent failure of the hang tab <NUM> during use. In some embodiments, the structural elements include a one-dimensional (1D) pattern <NUM> of alternating ridge regions <NUM> and channel regions <NUM> within the central region <NUM>, which have a differing thickness in the Y-direction, and extend in the Z-direction as shown in <FIG> is a cross-sectional view of the 1D pattern <NUM> of alternating ridge regions <NUM> and channel regions <NUM> cut along the sectioning line "5B-5B. " In some embodiments, as illustrated in <FIG>, the ridge regions <NUM> are generally thinner than the channel regions <NUM>, and at least a portion of the material within the ridge regions <NUM> has a higher mass density than the channel regions <NUM>. A thickness of the ridge regions <NUM> is between <NUM> and <NUM>. A thickness of the channel regions <NUM> is between <NUM> and <NUM>. In some embodiments, the ridge regions <NUM> each have a width WFLAT of between <NUM> and <NUM> and the channel regions <NUM> each have a WRIB of between <NUM> and <NUM>.

In some embodiments, the central region <NUM> of the hang tab <NUM> includes a 1D pattern <NUM> of alternating ridge regions <NUM> and channel regions <NUM> extend along the X-axis as shown in <FIG>, or in a direction that makes an acute angle with the Z-axis (e.g., direction that force F (<FIG>) is applied) as shown in <FIG>. In some embodiments, the 1D pattern <NUM> of alternating ridge regions <NUM> and channel regions <NUM> extend along a direction that makes an acute angle with the axis of the hinge portion <NUM> (i.e., X-direction in <FIG>). In some embodiments, the formed structural elements include a two-dimensional (2D) array of interleaving ridge regions <NUM> and channel regions <NUM> as shown in <FIG>. It should be noted that the particular example embodiments described above are just some possible examples of patterns of structural elements on the hang portion <NUM> according to the present disclosure, and do not limit the possible configurations, specifications, or the like of hang tabs or packages according to the present disclosure. For example, the number of ridge regions and the number of channel regions can be different from numbers than the ones shown in <FIG>.

In some embodiments, the ridge regions <NUM>, channel regions <NUM>, slot reinforcing portion <NUM>, and the circumference reinforcing portion <NUM> all have at least one different physical attribute, such as, but not limited to, a different thickness, mass density, material composition, or width in X-Y plane. In one embodiment, the slot reinforcing portion <NUM> and the circumference reinforcing portion <NUM> have the same thickness, mass density, material composition, and width in X-Y plane, and the ridge regions <NUM> and channel regions <NUM> have at least one different physical attribute from the slot reinforcing portion <NUM> and the circumference reinforcing portion <NUM>.

<FIG> depicts a flowchart illustrating a method <NUM> of fabricating a hang tab <NUM> according to one embodiment. In a pulping process (block <NUM>), raw material is mixed in aqueous solution of chemical regents at a temperature of between <NUM> and <NUM> degrees C and converted into pulp. The chemical regents include alkali hydrogen peroxide, such as sodium hydroxide in the form of a lye or caustic soda, which removes the lignin that binds fibers, and oxygen that breaks down the chemical structures of the lignin. The chemical regents further include chlorine dioxide and hydrogen peroxide for bleaching the pulp. In some embodiments, raw material is long-fiber wood pulp containing <NUM>% of cellulose, and the aqueous solution includes <NUM>% of sodium hydroxide, <NUM>% of include chlorine dioxide, <NUM>% of hydrogen peroxide, and <NUM>% of oxygen. A concentration ratio of the raw material to the aqueous solution is between about <NUM>:<NUM> and about <NUM>:<NUM>, for example, about <NUM>:<NUM>.

In a forming process (block <NUM>), the pulp is dredged, or separated, from the aqueous solution by sending the mixture through a metal mesh. The metal mesh may be made of stainless steel and have a mesh size <NUM>/<NUM> (e.g., <NUM> openings in <NUM> inch). The pulp is further exposed to a vacuum on one side of the mesh to bind the fibers within the pulp for a time duration of between about <NUM> seconds and about <NUM> seconds, for example, about <NUM> seconds. The dredged pulp is then placed into a bottom mold <NUM>. In <FIG>, side views of a proximity of a concave portion <NUM> (extending in the X-direction) of the bottom mold <NUM> that forms the hinge portion <NUM> of the hang tab <NUM> along the lines A-A' and B-B', respectively, are shown. In some embodiments, the concave portion <NUM> has a depth of between <NUM> and <NUM> and a width of between <NUM> and <NUM>. The bottom mold <NUM> further includes a protrusion <NUM> that forms the slot <NUM>, elevated portions <NUM> around the protrusion <NUM> that form slot reinforcing portion <NUM>, and an elevated portion <NUM> that forms circumference reinforcing portion <NUM>. In some embodiments, as illustrated in <FIG>, the dredged pulp (or uncompressed pulp material) is placed into the concave portion <NUM> of the bottom mold <NUM> to form a material layer <NUM> that has a layer thickness <NUM> having a thickness T<NUM> of between about <NUM> and <NUM> in a first region and a layer thickness <NUM> having a thickness T<NUM> of between about <NUM> and <NUM> in a second region. In some embodiments, as illustrated in <FIG>, one or more regions of the material layer <NUM> disposed over a bottom mold has thickness T<NUM> that is greater than the thickness a thickness T<NUM>. In one example, the thickness T<NUM> is between about <NUM> and about <NUM> times greater than the thickness T<NUM>, such as between <NUM> and <NUM> times greater.

In a shaping process (block <NUM>), the material layer that was placed between the bottom mold <NUM> and a top mold <NUM> during the block <NUM> is then compressed by applying a force of between about <NUM> kgf and about <NUM> kgf, for example about <NUM> kgf, for a time duration of between about <NUM> seconds and about <NUM> seconds, for example, <NUM> seconds. The bottom mold <NUM> and the top mold <NUM> may be made of a metal alloy and heated to a temperature of between about <NUM> and about <NUM>, for example, about <NUM> during the compression step.

In processes that utilize the mold design illustrated in <FIG>, the top mold <NUM> has a convex portion <NUM> that matches the concave portion <NUM> the bottom mold <NUM> and together forms the hinge portion <NUM> of the hang tab <NUM>. The top mold <NUM> further includes a protrusion <NUM> that matches the protrusion <NUM> of the bottom mold <NUM> and together forms the slot <NUM> (i.e. the pulp placed on the protrusion <NUM> is removed), lowered portions <NUM> that match the elevated portions <NUM> of the bottom mold <NUM> and together form slot reinforcing portion <NUM>, and a lowered portion that matches the elevated portion <NUM> and together forms circumference reinforcing portion <NUM>. The mold configuration illustrated in <FIG> can thus be used to form a hang tab <NUM>, which includes the support portion <NUM>, the hinge portion <NUM> and the hang portion <NUM> of a hang tab <NUM>, wherein the hang portion <NUM> includes a slot <NUM>, a slot reinforcing portion <NUM>, a central region <NUM>, and a circumference reinforcing portion <NUM>.

In some embodiments, as shown in <FIG>, during the processes performed during block <NUM>, using the simpler mold configuration shown in <FIG> for ease of discussion purposes only, the layer of the pulp positioned in the concave portion <NUM> is compressed from the original thickness T<NUM> to a thickness T<NUM> of between <NUM> and <NUM> (<FIG>) and the layer <NUM> of the pulp on the remaining portions of the bottom mold <NUM> is compressed from the thickness T<NUM> to the same thickness T<NUM> of between <NUM> and <NUM> (<FIG>), and thus the hinge portion <NUM> (formed from the layer of pulp in the concave portion <NUM>) has higher material density than the remaining portions of the hang portion <NUM>. The increase in density in the hinge portion <NUM> versus other regions of hang tab <NUM> is derived from the increased change in volume created during the compression process. In some embodiments, the density of a first region of the material layer <NUM> is changed from an initial density of <NUM>-<NUM> % of the theoretical maximum density to a compressed density of <NUM>-<NUM> % of the theoretical maximum density, and the density of a second region of the material layer <NUM> is changed from an initial density of <NUM>-<NUM> % of the theoretical maximum density to a compressed density of <NUM>-<NUM> % of the theoretical maximum density. In other embodiments, the density of a first region of the material layer <NUM> is changed from an initial density of <NUM>-<NUM> % of the theoretical maximum density to a compressed density of <NUM>-<NUM> % of the theoretical maximum density, and the density of a second region of the material layer <NUM> is changed from an initial density of <NUM>-<NUM> % of the theoretical maximum density to a compressed density of <NUM>-<NUM> % of the theoretical maximum density.

In a trimming process (block <NUM>), protruding edges of the shaped pulp created during block <NUM> are trimmed to form the hang tab <NUM>. Typically, all of the trimmed scraps are returned to the aqueous solution and reused.

In an optional coating process (block <NUM>), the formed hang tab <NUM> is coated with a material that can bind the fibrous material and/or prevent water absorption when the hang tab <NUM> requires water-proofing or water-resilience. In some embodiments, the coating configured to cover and seal the exposed surfaces of the hang tab <NUM> from the external ambient environment. In some embodiments, the coating may include a polymeric coating that is hydrophobic.

In the example embodiments described above, eco-friendly hang tabs made of biodegradable, degradable, or recyclable materials, such as wood pulp and methods of eco-friendly hang tabs have been shown. Eco-friendly hang tabs are reinforced such that the hang tabs can be folded and unfolded without breaking, can be used to hang a package without tearing.

Claim 1:
A hang tab (<NUM>) for supporting a package, comprising:
a hang portion (<NUM>) comprising:
an opening formed therein; and
a central region (<NUM>) that at least partially surrounds the opening, wherein the central region comprises:
two or more first regions (<NUM>) ; and
a second region (<NUM>) that is disposed between each adjacent pair of two or more first regions, wherein at least one physical attribute of each first region is different than a physical attribute of each second region, wherein the at least one different physical attribute is selected from a group consisting of a thickness and a mass density;
a support portion (<NUM>) having a surface; and
a hinge portion (<NUM>) that extends in a first direction and is disposed between the hang portion (<NUM>) and the support portion (<NUM>),
wherein the hang tab comprises a fibrous material.