TITLE: Bendable Hanging Device and Method of Making the Same

SPECIFICATION CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to United States Provisional Patent Application No. 62/458853 filed 14 February 2017 to the above named inventor, and is herein incorporated by reference in its entirety.

FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] Not Applicable

SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM

[0003] Not Applicable

FIELD OF THE INVENTION

[0004] The present invention relates to a hanger comprised of multiple materials and, in particular, to a flexible hanger and assembly that has sufficient rigidity to support clothes for hanging and sufficient flexibility to allow a user to deform the shape of the hanger to a desired position during use,

BACKGROUND OF THE INVENTION

[0005] Current hangers as they are found in the prior art are generally comprised of two types: single material and multi -material. Single material hangers are typically comprised of a wire or plastic material formed or molded into a continuous hanger shape. Multi -material hangers are typically formed from a wire or metal hanging hook that is affixed to a wood or plastic body. Some of the more popular multi -material hanging devices are comprised of a chrome metal hanging hook end affixed to a thin plastic body portion that is fl ocked with a velvet-like material. In a typical construction of this type of hanger, the thin plastic body is overmolded (a manufacturing process wherein part of an object is molded over and around another part of the object) over the metal hook/hanging end.

[0006] Accordingly, this hanger type allows the hook/hanging end to rotate within the hanger body, but generally does not provide strength and durability when the

hook/hanging end is deflected or moved laterally. To keep costs down, the standard construction of this hanger type utilizes a thin and cheap plastic material that is unable to resist failure when placed under load. Typically, this hanger type will fail at around the hook and body connection or the arms of the hanger of the body portion will break.

[0007] An additional type of multi -material hanger is disclosed in US Pat. No. 8,720,750 and provides an additional hanger assembly comprised of a non-slip metal wire that is generally a metal wire coated with a non-slip layer that is sufficiently adhered to the metal wire within a single step and mechanically deformable into a fixed shape without damaging the non-slip layer. The non-slip wire of this '750 patent is comprised of a thermoplastic elastomer (TPE) defined as a blend of polyolefms and rubbers wherein within the blend the rubber phase is not cured, called thermoplastic olefins (TPO), and blends of polyolefms and rubbers wherein within the blend the rubber phase has partially cured or fully cured by a vulcanization process, called thermoplastic vulcanizates (TPV), or unvulcanized block-copolymers or blends thereof. In the construction of a hanger, according to the '750 reference, this TPE is applied to the wire through the use of an adhesion layer comprised of a functionaiized polymer containing functional groups selected from carboxylic acids or anhydrides, epoxy groups, amino groups, oxazoline groups and hydroxyl groups, and a compound selected from copolyamides, copolyesters, and polyamides or blends thereof or the adhesion layer is a compound selected from organo functional silanes, organo functional titanates, and organo functional zirconates. Generally this adhesion layer between the metal core wire and the TPE outer coating is necessary to prevent the slippage of the outer coating from the inner wire during use. Over time, an outer TPE coating that is not sufficiently adhered to the metal core will breakdown and fail from torsional strain associated with repeated use.

[0008] Although the '750 reference provides for a generally durable assembly for a hanging device, there are additional assemblies that provide a sufficiently durable assembly without the need to bond the outer coating to the inner wire with a

functionaiized polymer coating acting as an adhesion layer that is comprised of alternate materials and assembly methods that represent an improvement in processing

capabilities, material costs, and product performance. [0009] Further, there is a need in the marketplace for a device that both provides a more durable hanger assembly and that allows for flexibility and provides the user an ability to alter the shape of the hanger to receive a specific size, style, or type of clothing item. Preferably, this hanger is constructed out of multiple materials and includes a deformable metal wire.

SUMM ARY OF THE INVENTION

[0010] A new and improved hanger and methods of making the same is disclosed. The hanger of the present invention is generally comprised of a coated wire formed into a hanger shape and secured within a body portion including a hanging end in the form of a hook. The coated wire of the present invention can be provided in a material that is bendable for manipulation by a user and allowing the user to move and otherwise position the hanger in a desired shape to provide hanging support for an article of clothing. Preferably, this hanger is assembled from a body portion, a hook portion, and a connecting portion. These portions can be comprised of a single material or multiple materials and assemblies, depending upon a given embodiment of the hanger. Preferably, the body portion is bendable and comprised of a wire material that is coated with an elastomeric material, such as a thermo plastic elastomer (TPE), along its length to provide a soft surface with a higher coefficient of friction when compared to bare wire. In alternate embodiments of the invention, the wire may be annealed to improve softness and flexibility.

[0011] In a first embodiment of the hanger and assembly of the present invention, a multi material hanger is formed through an overmolding process to combine an outer coated wire and hook potion with a generally rigid connecting portion. The outer coated wire is preferably a wire having a tensile strength of between 80 ksi (approximately 552 MPa) and 150 ksi (approximately 1034 MPa) with a TPE coating that may generally be coated to the wire wherein the overmolded connecting portion is selected of a material to cohesively bond with the outer coating of the wire during assembly. Accordingly, the overmolded connecting portion and outer coating of the wire are generally selected from a similar class of polyolefin resin, wherein the heat and pressure of the overmolding process secures the outer coating to the overmolded body portion. This overmolded connection and cohesive bond will generally help to secure the wire within the assembly. Preferably, this connecting portion is comprised substantially of a 3 OF GPP polypropylene that cohesively bonds to the wire outer coating substantially compri sed of a thermoplastic olefin (TPO) with the propylene and TPO comprised of the same class of polyolefin resins.

[0012] In a second embodiment of the hanger and assembly of the present invention, a multi material hanger is formed through an overmolding process and a mechanical interlock within the overmold to combine an outer coated wire and hook potion with a generally rigid connecting portion. The outer coated wire is preferably a wire having a tensile strength of between 80 ksi (approximately 552 MPa) and 150 ksi (approximately 1034 MPa) with a TPE coating that may generally be coated to the wire without adhesion and wherein opposed ends of the wire are generally coined or shaped and then placed within a mold wherein the overmolded body portion and coined or shaped end creates an interference lock within the overmold preventing rotation of the wire, the coating on the wire, and the coated wire within the assembly. Additionally, the overmolded body portion and outer coating can generally be selected from a similar class of polyolefin resin, wherein the heat and pressure of the overmolding process in addition to the coining can aide in securing the outer coating to the ovemiolded body portion. This overmolded connection, cohesive bond, and mechanical interference will generally secure the inner wire within the assembly and prevent rotation of the inner wire exclusive of rotation with the outer coating. Preferably, this connecting portion is comprised substantially of a 30FGPP polypropylene that cohesive bonds to an outer coating substantially comprised of a thermoplastic olefin (TPO) with the propylene and TPO comprised of the same class of polyolefin resins.

[0013] In a third embodiment of the hanger and assembly of the present invention, a multi material hanger is formed through a mechanical assembly with the rigid connecting portion generally securing the entirety of the assembly and portions of the hanger. This assembly generally may utilize mechanical fasteners, adhesives, welding, or other similar securing means to secure a pair of halves forming the connecting portion to secure a coated wire and hook portion. Accordingly, this assembly method provides for various types of materials for use in the connecting portion, including but not limited to, injection molded polymers, metals, wood, or similar materials adapted in a pair of halves for securing together to encapsulate the additional hanger portions preventing rotation of the wire, the coating on the wire, and the coated wire within the assembly.

[0014] In a fourth embodiment of the hanger assembly of the present invention, the connecting portion may be adapted and prefabricated to be a generally hollow body sized and shaped to receive the various components of the hanger assembly and a securing means, such as an adhesive or press-fit connection. Accordingly, the connecting portion assembly preventing rotation of the wire, the coating on the wire, and the coated wire within the assembly.

[0015] The embodiments as stated above are generally adapted as assemblies to secure a TPE material to a wire to form a coated wire for use in a hanger without the use of a functionalized polymer.

[0016] Alternate and in combination to the mechanical assemblies comprised of a connecting portion, the TPE material could be could be combined with alternate and non- functionalized polymers to create a bond through the coextaision of dissimilar materials with different characteristics to secure the TPE to the wire. To create a functional product, it is important that the outer coating of the wire is physically or mechanically- adhered to wire to prevent slippage and deformation of the outer cover during use. In an embodiment of the present invention, the wire and polymer co-extrusion may be comprised of an inner wire, a "non-functional" inner polymer coating, and outer TPE polymer layer, wherein the inner polymer layer creates a physical bond between the wire based on the material hardness and shrinkage of the inner layer, as opposed to a cohesive bond with a "functionalized" polymer. Alternately, the metal wire could be coated with a silicone mbber, wherein the silicone rubber is formulated with a functional agent to bond to the wire during extrusion.

[00 7] According to some alternate embodiments of a construction configuration, a low density polyethylene (LDPE) or polypropylene (PP) can be coextruded with the TPE outer layer in combination to surround the wire. Alternately, a very high durometer 72D thermoplastic urethane (TPU) can be coextruded with a low durometer 40D TPU outer layer in combination surrounding the wire. Alternately, a rigid polyvinyl chloride (PVC) inner layer surrounding the wire can be coextruded with a softer PVC outer layer. These

"non functional" polymers do not bond to the inner metal wire without some type of mechanical implementation, such as a pressure tip extrusion crosshead combined with polymer shrinkage and a high flex modulus resin to create a pressure bond to the inner metal wire. Accordingly, this harder inner layer would prevent the softer outer layer from stretching or spinning on the wire and further be locked into place when the coated wire is bent into its final hanger shape.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING (S)

[0018] The accompanying drawings are included to provide a further understanding of the present invention and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present invention and together with the description serve to further explain the principles of the invention. Other aspects of the invention and the advantages of the invention will be better appreciated as they become better understood by reference to the Detailed Description when considered in conjunction with accompanying drawings, and wherein:

[0019] FIG. 1 is a perspective view of a hanger, according to the present invention;

[0020] FIG. 2 is an exploded view of a first method of constructing a hanger, according to the present invention;

[0021] FIG. 3 is an exploded view of a second method of constructing a hanger, according to the present invention, [0022] FIG. 4 is an exploded view of a third method of constructing a hanger, according to the present invention; and

[0023] FIG. 5 is a cross sectional view of wires, according to several embodiments of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0024] The following detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific embodiments in which the invention may be practiced. These embodiments, which are also referred to herein as "examples," are described in enough detail to enable those skilled in the art to practice the invention. The embodiments may be combined, other embodiments may be utilized, or structural, and logical changes may be made without departing from the scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense.

[002S] Before the present invention is described in such detail, however, it is to be understood that this invention is not limited to particular variations set forth and may, of course, vary. Various changes may be made to the invention described and equivalents may be substituted without departing from the tnie spirit and scope of the invention. In addition, many modifications may be made to adapt a particular situation, material, composition of matter, process, process act(s) or step(s), to the objective(s), spirit or scope of the present invention. All such modifications are intended to be within the scope of the disclosure made herein.

[0026] Unless otherwise indicated, the words and phrases presented in this document have their ordinary meanings to one of skill in the art. Such ordinary meanings can be obtained by reference to their use in the art and by reference to general and scientific dictionaries.

[0027] References in the specification to "one embodiment" indicate that the

embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.

[0028] The following explanations of certain terms are meant to be illustrative rather than exhaustive. These terms have their ordinary meanings given by usage in the art and in addition include the following explanations.

[0029] As used herein, the term "and/or" refers to any one of the items, any combination of the items, or all of the items with which this term is associated,

[0030] As used herein, the singular forms "a," "an," and "the" include plural reference unless the context clearly dictates otherwise.

[0031] As used herein, the terms "include," "for example," "such as," and the like are used illustratively and are not intended to limit the present invention.

[0032] As used herein, the terms "preferred" and "preferably" refer to embodiments of the invention that may afford certain benefits, under certain circumstances. However, other embodiments may also be preferred, under the same or other circumstances. [0033] Furthermore, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the invention,

[0034] As used herein, the term "coupled" means the joining of two members directly or indirectly to one another. Such joining may be stationary in nature or movable in nature and/or such joining may allow for the flow of fluids, electricity, electrical signals, or other types of signals or communication between two members. Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature.

[0035] It will be understood that, although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element without departing from the teachings of the disclosure.

[0036] Referring now to FIGS. l~ 5, a coated metal wire for use in a hanging device, assembly, and methods of making the same are disclosed. The hanging device of the present invention is generally referred to as device 10 and adapted and shaped to form a hanger for the resting support and placement of an item of clothing. The hanging device 10 is generally assembled from multiple materials and components to form an inclusive assembly, although the device 10 could be constructed from a single continuous wire and formed to a hanger shape.

[0037] The hanger 10 of the present invention is constructed out of a metal wire 1 1 forming a body portion 100 with a shape generally adapted to receive an item.

Accordingly, the body portion 100 is generally shaped to form a closed perimeter of the hanger with a pair of correspondingly shaped shoulder portions 103 that may allow for repeated bending and shaping to ultimately form a hanger that can be manipulated by a user and bent or deformed into any shape a user prefers. Preferably, the shoulder portions 103 are similarly shaped wherein the device 10 is generally shaped with two halves being a mirror image and wherein the body portion 100 is symmetrical. In an arrangement of a construction of this hanger device 10 materials can be provided allowing a user to curve, bend, move, and othemise manipulate the hanger 10 to conform to a desired position for the support of a clothing item.

[0038] In the preferred embodiments of the present invention, the wire 1 1 is preferably a steel wire having a tensile strength of between 80 ksi (approximately 552 MPa) and 150 ksi (approximately 034 MPa). Further, the wire 1 1 can have its metallurgical properties manipulated, through processes, such as, but not limited to, annealing, to allow for a lack of memory during bending and for positioning into multiple shapes without breaking. Additionally, the wire 1 1 may have its shape generally altered from the typical cylindrical shape, wherein alternate shapes or edges, such as an octagonal shape, may generally allow for a more robust assembly.

[0039] Further and preferably, the metal wire 1 1 of the hanger 10 is coated with a thermoplastic elastomer (TPE) 13 to provide a friction to the wire 11 surface to enable items to be retained on the hanger 10. Although TPE 13 is preferred, the wire 11 can be coated with various other polymers, such as, but not limited to, a thermoplastic olefin (TPO), and other similar materials to provide an improved tactile surface when compared to bare wire.

[0040] The construction of the wire 11 portion of the body 100 can be provided in several manufactured assemblies including, but not limited to, co-extrusion of the wire 1 1 with various layers of polymers and materials. To create a functional product, it is important that the outer coatings 13, 14 as they are applied to the wire 1 are physically or mechanically adhered to wire 11 to prevent slippage and deformation of the outer cover 13 during use.

[0041] In an embodiment of the present invention, the wire 11 forming the body portion 100 and a polymer co-extrusion may be comprised of an inner wire 1 1, a "non-functional" polymer coating forming an inner layer 12, and the outer TPE polymer layer 13, wherein the inner polymer layer 12 creates a physical bond between the wire 11 based on the material hardness and shrinkage of the inner layer 12, as opposed to a cohesive bond with a "functionalized" polymer.

[0042] Alternately, the metal wire 11 could be coated with a silicone rubber 14, wherein the silicone rabber 14 is formulated with a functional agent to bond to the wire 1 1 during extrusion.

[0043] According to some embodiments of a construction configuration for the coated wire of the hanger 10, the inner layer 12 may be a low density polyethylene (LDPE) or polypropylene (PP) coextruded with the TPE outer layer 13 in combination to surround the wire 11. Alternately, the inner layer 12 may be a very high durometer 72D

thermoplastic urethane (TPU) coextruded with a low durometer 40D TPU outer layer 13 in combination surrounding the wire 1 1 . Alternately, the inner layer 12 may be a rigid polyvinyl chloride (PVC) coextruded with a softer PVC outer layer 13. These "non functional" polymers do not bond to the inner metal wire 1 1 without some type of mechanical implementation, such as a pressure tip extrusion crosshead combined with polymer shrinkage and a high flex modulus resin to create a pressure bond to the inner metal wire 11. Accordingly, this harder inner layer 12 would prevent the softer outer layer 13 from stretching or spinning on the wire and further be locked into place when the coated wire 11 is bent into its final hanger shape 10,

[0044] In the preferred construction of a hanger 10 according to the present invention, the hanger 10 is comprised of multiple materials and assembled. Preferably, this hanger 10 is comprised of the body portion 100, a connecting portion 200, and a hook portion 300 assembled together by various alternate methods. The body portion 100 is constructed out of a coated wire of the above configurations and may be adapted with properties that allow for it to be bent and deformed into a desired shape. The body portion 100 includes a first end 101 and second end 102 opposite the first end 101. The distance between the first end 101 and second end 102 defines the shape of the hanger 10 with the first end 101 and second end 102 received within opposed sides of the connecting portion 200 with the body portion 100 including the pair of opposed shoulders 103 adapted for the resting receipt of an item to be hung. Accordingly, the connecting portion 200 is adapted to receive the first end 101, second end 102, and an attached end 302 of the hook portion 300 to complete the main assembly of the hanger 10. The hook portion 300 is preferably comprised of a rigid metal and shaped for receipt on a standard closest rod with a free end 301 of the hook portion 300 defining an opening sized for receipt on a closet rod for hanging. Although metal is preferred for the hook portion 300, the hook portion 300 can be constructed of various rigid materials, including, but not limited to, wood and plastic.

[004S] The hanger 10 body portion 100 inner wire 11 with outer coating 13 may be provided in various metals with alternate properties and sizes adapted for various capabilities including a coated wire material that is deformable or bendable or a coated wire material adapted for a more traditional hanger 10 assembly with a body portion 100 that is not deformable or bendable. Accordingly, this construction would utilize a body portion 100 that is more rigid, but still constructed with the connecting portion 200 and hook portion 300 to form a multi material hanger with improved hanging and aesthetic properties.

[0046] Various methods of construction for the hanger 10 of the present invention are provided to ensure a durable and robust assembly that allows for a multitude of shape manipulations and movements. These methods only represent preferred assemblies and are not intended to represent the only way to construct a hanger 10 having the desired properties herein disclosed.

[0047] Referring now to Fig. 2 of the hanger 10 of the present invention, a construction method is provided that produces a hanger assembly with a robust and durable hook end and connection to a coated wire through a cohesive bond between outer layer 13 and the material selected for the connecting portion 200. Accordingly, this assembly is constructed through forming the connecting portion 200 with an injected molded rigid polymer that is overmolded to the first end 101 and second end 102 of the body portion 100 coated wired and the attached end 302 of the hook 300, Utilizing this method of assembly, the overmolded connecting portion 200 cohesively bonds to the outer layer 13 of the body portion 100 ends 101, 102 to create an assembly structure that does not allow for rotation of the outer coating on the body portion 100 inner wire. In this assembly it is preferred that the body portion 100 outer coating is comprised of a TPE coating.

[0048] Referring now to Fig. 3 of the hanger 10 of the present invention, a second construction method is provided that produces a hanger assembly with a robust and durable hook end and connection to a coated wire through a mechanical interlock.

Accordingly, this assembly is constructed through a mechanical manipulation of the first end 101 and second end 102 of the body portion 100 inner wire to coin or shape the inner wire ends 101, 102 to form a boss 1 10, 120 (enlarged portion at the wire end). The wire ends 101, 102 having a boss 1 10, 120 are then placed into an injection mold to form the connecting portion 200 with an injected molded rigid polymer that is overmolded to the first end 101 boss 110 and second end 102 boss 120 of the body portion 100 coated wired and the attached end 302 of the hook 300. Utilizing this method of assembly, the overmolded connecting portion 200 and first end 101 boss 1 10 and second end 102 boss 120 form an interference lock within the overmold to create an assembly structure that does not allow for rotation of the outer coating on the body portion 100 inner wire. In this assembly it is preferred that the body portion 100 outer coating is comprised of a TPE coating.

[0049] Referring now to Fig. 4 of the hanger 10 of the present invention, a third construction method is provided that produces a hanger assembly with a robust and durable hook end and connection to a coated wire through a mechanical assembly with additional individual components. Accordingly, this assembly is constructed through a securing of the first end 101 and second end 102 of the body portion 100 into the connecting portion 200. The connecting portion 200 can be comprised of several types of materials, including, but not limited to, injection molded polymer, fabricated metal, wood, or other similar material, and provided in two halves wherein the two halves of the connecting portion 200 are secured together to encapsulate the body portion 100 ends 101, 102 and attached end 302 of the hook portion 300. The halves of the connecting portion 200 can be secured with several types of materials and bonds, including, but not limited to, fasteners, adhesives, vibration or ultrasonic welding, clips, rivets, or other similar securing means. In this assembly it is preferred that the body portion 100 outer coating is comprised of a TPE coating.

[0050] In yet another alternate assembly of the hanger of the present invention, the connecting portion 200 may generally be provided of a pre-molded or pre-fabricated hollow body adapted with various sized apertures to receive the ends 101, 102 of the body portion 100 and attached end 302 of the hook, wherein an adhesive is provided within the interior of the connecting portion 200 for securing the inserted or embedded components.

[0051] While the invention has been described with reference to an exemplary embodiment s), it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifi cations may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment(s) but that the invention will include all embodiments falling with the scope of the appended claims.