Patent Application
20110283936
This application includes material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent disclosure, as it appears in the Patent and Trademark Office files or records, but otherwise reserves all copyright rights whatsoever.
This invention pertains to methods and apparatus for making paint rollers of the type used for applying paint to walls and the like. More specifically, the invention pertains to methods and apparatus for making component parts for use in a process of making a paint roller, and methods and apparatus for making a paint roller.
In the accompanying drawings forming a part of this specification, and in which like reference characters are employed to designate like parts throughout the same:
Polypropylene is used in the manufacture of paint rollers due to its low cost and resistance to solvents. The inventor has numerous prior and pending patents directed to continuous processes for making paint rollers using thermoplastic strips and/or thermoplastic adhesives that are formed entirely, substantially, or in part from polypropylene. Mr. Sekar's prior patents include, without limitation, U.S. Pat. Nos. 5,195,242 and 5,572,790, each entitled Method of Making a Paint Roller, and U.S. Pat. No. 6,159,134 entitled Method of Making a Paint Roller With Integrated Core and Cover. Mr. Sekar's pending applications include, without limitation, U.S. patent application Ser. No. 12/350,798 filed Jan. 8, 2009, U.S. patent application Ser. No. 12/435,946 filed May 5, 2009, U.S. patent application Ser. No. 12/463,876 filed May 11, 2009 and U.S. patent application Ser. No. 12/687,028 filed Jan. 13, 2010.
Nucleating agents can be used to create nucleated polypropylene. Nucleating agents that can be used with polypropylene to create nucleated polypropylene include talc and carboxylate salts (e.g. sodium benzoate, NaOBz), sorbitol acetals and phosphate ester salts. Nucleated polypropylene is known to have certain properties that differ from non-nucleated polypropylene. For example, a nucleated polypropylene can be purchased from Total Petrochemicals of Houston, Tex. under the trade name TOTAL Polypropylene 4481 WA, which Total Petrochemicals describes in its technical data sheet as follows:
Moreover, while typical polypropylene generally has a heat deflection temperature of around 90-95 degrees centigrade, the technical data sheet for TOTAL Polypropylene 4481WZ identifies its heat deflection temperature as 115 degrees centigrade.
Another nucleated polypropylene can be purchased from Pinnacle Polymers of Garyville, La. under the trade name 2180H, which Pinnacle Polymers describes in its technical data sheet as an 80 melt flow (g/10 min.) medium impact copolymer polypropylene for injection molding. Pinnacle Polymers states that 2180H contains nucleator and antistat. Pinnacle Polymers states in its technical data sheet that the 2180H product provides:
Referring to
Referring now to
The amount of nucleation of the polypropylene used in the strip 145 may be varied without departing from the scope of the present disclosure. The use of nucleated polypropylene in the strip 145 achieves characteristics that, when compared to using non-nucleated polypropylene, will be increased as to stiffness of the finished roller when the roller is at an elevated temperature. Such an elevated temperature may occur if a finished roller is being cleaned, e.g., using hot water, or submerged or used in connection with another hot substance, such as a solvent, at an elevated temperature but not hotter than boiling water. Such an elevated temperature may also occur if a finished roller is being used to apply a heated fluid—fluids at a temperature making paint rollers made from strips of non-nucleated polypropylene undesirable due to softness. Elevated temperature may also occur if a finished roller is being used in a hot environment or for application of fluid to a hot surface.
Increased stiffness when at an elevated temperature may give a paint roller a firmer or stiffer feel, which may improve its performance as a paint roller if used at a higher temperature. Moreover, in many cases, stiffer or firmer paint rollers are typically sold at a higher price. To some degree, stiffness at an elevated temperature can be controlled, or a desired stiffness or range of stiffness can be achieved by varying the nucleation of the polypropylene.
In an embodiment, nucleated polypropylene can also be used in lieu of, or in combination with, non-nucleated polypropylene in the adhesive 135 and/or the backing for the cover 250. When so used, these application too are expected to achieve characteristics that, when compared to using non-nucleated polypropylene, will be increased as to stiffness of the finished roller when it is at an elevated temperature.
Referring to
A strip 145, 345, 348, 445, 448 may be cut lengthwise from a sheet material (not shown) that is manufactured using a compound of nucleated polypropylene and calcium carbonate. The thickness of a sheet of material may be determined by successive rollers. A compound of nucleated polypropylene and calcium carbonate having an appropriate MFI can be run through successive rollers to reach a desired thickness for the sheet material, and thus for the strip.
In an embodiment, the MFI of the polypropylene/calcium carbonate compound is approximately 2. Nucleated polypropylene TOTAL Polypropylene 4481WZ or a similar nucleated polypropylene having a melt flow index of approximately 4 may be compounded with approximately 60% by weight of calcium carbonate to achieve a resulting nucleated polypropylene/calcium carbonate compound having an MFI of approximately 2. This resulting compound can be run through successive rollers to reach a desired thickness for the sheet material. Almost any desired sheet thickness can be attained. In an embodiment, the sheet of polypropylene/calcium carbonate compound material having thickness of approximately 10 mil, 15 mil, 20 mil or 25 mil can be cut longitudinally into one or more strip 145, 345, 348, 445, 448 of a width appropriate for use in making paint rollers.
In an embodiment, the calcium carbonate compounded with the nucleated polypropylene to form a strip 145, 345, 348, 445, 448 should be a relatively fine, powdered form of calcium carbonate. In an embodiment calcium carbonate compounded with nucleated polypropylene to form a sheet which is cut into one or more strips 145, 345, 348, 445, 448 should have a median particle size of 3 micrometers or less. In an embodiment, calcium carbonate compounded with nucleated polypropylene to form a sheet which is cut into one or more strips 145, 345, 348, 445, 448 may be surface treated.
The use of non-refined calcium carbonate, e.g., calcium carbonate that has not been surface treated, in combination with nucleated polypropylene adds strength to a resulting paint roller product when compared to a combination of refined calcium carbonate in combination with nucleated polypropylene. Thus, in an embodiment, the calcium carbonate compounded with nucleated polypropylene to form a sheet which is cut into one or more strips 145, 345, 348, 445, 448 is a non-refined calcium carbonate. In an embodiment, the non-refined calcium carbonate is used in compounding is in a relatively fine, powdered form. In an embodiment the calcium carbonate may have a median particle size of 3 micrometers or less.
In an embodiment, a twin screw extruder (not shown) may be used to compound non-refined calcium carbonate and nucleated polypropylene together and that compound may be used to form a sheet which is cut into one or more strips 145, 345, 348, 445, 448. The twin screw extruder may accept a supply of nucleated polypropylene, e.g., in pellet form, and a separate supply of calcium carbonate, e.g., in powered form.
The cost by weigh of calcium carbonate is expected to be lower than the cost by weigh of nucleated polypropylene, thus the use of a strip 145, 345, 348, 445, 448 comprising a compound of nucleated polypropylene and calcium carbonate is likely to reduce the cost of manufacturing paint rollers made therewith.
Strips 145, 345, 348, 445, 448 comprising a compound of nucleated polypropylene and calcium carbonate having between 5% and 66% calcium carbonate by weight is expected to have higher thermal conductivity than that of strips 145, 345, 348, 445, 448 made from nucleated polypropylene alone. Because of the higher thermal conductivity, using a strip 145, 345, 348 made from a compound of nucleated polypropylene and calcium carbonate having between 5% and 66% calcium carbonate by weight, rather than a strip 145, 345, 348 made from more than 95% nucleated polypropylene, is anticipated that an adhesive 135, 335 will set faster, and thus, an apparatus 100, 300 will operate at higher overall throughput than it would when using a strip 145, 345, 348, 445, 448 comprising more than 95% nucleated polypropylene. Similarly, the apparatus 400 is anticipated to operate at a higher throughput due to the higher thermal conductivity of a strip 445, 448 when one or more of the strips are made from a compound nucleated polypropylene and calcium carbonate having between 5% and 66% calcium carbonate by weight, rather than from more than 95% nucleated polypropylene,
Referring now to
Compounded strip 145 comprising nucleated polypropylene and between 5% and 66% calcium carbonate by weight is wrapped helically about a mandrel 140 held on a base 150. The mandrel may be cooled by a cooler (not shown). An adhesive 135 comprising polypropylene is applied to an outer surface of the strip 145 by applicator 130. A cover 125 is wrapped around the mandrel 150 over the compounded strip 145 and the adhesive 135. A helical belt 120 driven by rollers 120a, 120b applies a compressive force on the cover material and advances the tubular assembly 115 down the mandrel 150. A flyaway saw 105 cuts the tubular assembly into lengths 110 that can be used, or cut and used to produce finished paint rollers.
The amount of nucleation of the polypropylene used in the compounded strip 145 may be varied without departing from the scope of the present disclosure. The use of nucleated polypropylene in the compounded strip 145 achieves characteristics that, when compared to using non-nucleated polypropylene, will be increased as to stiffness of the finished roller when the roller is at an elevated temperature. The use of a compounded strip 145 comprising between 5% and 66% calcium carbonate achieves characteristics that, among other things, when compared to using a strip made without calcium carbonate, will be increased as to stiffness of the finished roller at non-elevated temperature.
Increased stiffness, regardless of the temperature, may give a paint roller a firmer or stiffer feel, which may improve its performance. Moreover, in many cases, stiffer or firmer paint rollers are typically sold at a higher price.
In an embodiment, a compound of nucleated polypropylene and between 5% and 66% calcium carbonate by weight can also be used in lieu of, or in combination with, non-nucleated polypropylene in the adhesive 135 and/or the backing for the cover 250. When so used, these application too achieve characteristics that, when compared to using non-nucleated polypropylene alone, will be increased as to stiffness of the finished roller.
It will be apparent to a person of skill in the art that, in view of the foregoing disclosure, any or all of the thermoplastic component parts of the paint roller, e.g., the adhesive 135 the strip 145 and the backing of the cover 125 may be made from a compound formed from nucleated polypropylene and between 5% and 66% calcium carbonate by weight. When more than one component part is made of a compound of nucleated polypropylene and calcium carbonate having between 5% and 66% calcium carbonate by weight, the percentage of calcium carbonate used in the compound forming the adhesive 135, the strip 145 and the cover 125 backing may be the same, or may differ from one-another. As the percentage of calcium carbonate may be varied, so too may the level of nucleation of the polypropylene.
Referring to
The compound of nucleated polypropylene and calcium carbonate may be formed using a twin screw extruder (not shown) to compound calcium carbonate and nucleated polypropylene together and that compound may be used to supply the applicator 130, 330 directly, or alternatively to form a source for another extruder that supplies the applicator 130, 330. The twin screw extruder may accept a supply of nucleated polypropylene, e.g., in pellet form, and a separate supply of calcium carbonate, e.g., in powered form.
In an embodiment, the calcium carbonate compounded with the nucleated polypropylene to form a strip 145, 345, 348, 445, 448 should be a relatively fine, powdered form of calcium carbonate. In an embodiment, non-refined calcium carbonate, e.g., calcium carbonate that has not been surface treated, is used compounded with nucleated polypropylene. In an embodiment, the non-refined calcium carbonate is used in compounding is in a relatively fine, powdered form. In an embodiment the calcium carbonate may have a median particle size of 3 micrometers or less.
In an embodiment, the MFI of the nucleated polypropylene/calcium carbonate compound forming the adhesive is approximately 35 to provide for flow through the applicator 130, 330. Nucleated polypropylene 2180H or a similar nucleated polypropylene having a melt flow index of approximately 80 may be compounded with approximately 45% by weight of calcium carbonate to achieve a resulting nucleated polypropylene/calcium carbonate compound having an MFI of approximately 35. This resulting compound permits the compound to flow appropriately through the applicator 130, 330 in the process of making paint rollers.
Referring now to
In an embodiment, the adhesive 335 has an MFI of between 20 and 50 to permit it to flow appropriately from the applicator 330. In an embodiment, the adhesive 335 has an MFI of approximately 35 to permit proper flow from the applicator 330 using a typical extruder (not shown).
In an embodiment, nucleated polypropylene 2180H or a similar nucleated polypropylene having a melt flow index of approximately 80 is compounded with approximately 45% by weight of calcium carbonate to achieve a resulting compound having an MFI of approximately 35. This compounded adhesive 335 can flow as adhesive through applicator 330 in the process of making paint rollers. The strips 345, 348 are wrapped helically about a mandrel 340, which may be cooled by a cooler (not shown). The mandrel 340 is held on a base 350. The compounded adhesive 335 is applied to an outer surface of the strips 345, 348 by applicator 330. A cover 325 is wrapped around the mandrel 340 over the strips 345, 348 and the compounded adhesive 335. A helical belt 320 driven by rollers 320a, 320b applies a compressive force on the cover material and advances the tubular assembly 310 down the mandrel 350. A flyaway saw 305 cuts the tubular assembly into lengths that can be used, or cut and used to produce finished paint rollers.
In an embodiment, nucleated polypropylene having a melt flow index of approximately 35 is used as an adhesive 335. The strips 345, 348 are wrapped helically about a mandrel 340, which may be cooled by a cooler (not shown). The mandrel 340 is held on a base 350. The adhesive 335 is applied to an outer surface of the strips 345, 348 by applicator 330. A cover 325 is wrapped around the mandrel 340 over the strips 345, 348 and the adhesive 335. A helical belt 320 driven by rollers 320a, 320b applies a compressive force on the cover material and advances the tubular assembly 310 down the mandrel 350. A flyaway saw 305 cuts the tubular assembly into lengths that can be used, or cut and used to produce finished paint rollers.
It will be apparent to a person of skill in the art that, in view of the foregoing disclosure, any or all of the thermoplastic component parts of the paint roller, e.g., the adhesive 335 the strips 345, 348 and the backing of the cover 325 may be made from a compound formed from nucleated polypropylene and between 5% and 66% calcium carbonate by weight. When more than one component part is made of a compound of nucleated polypropylene and calcium carbonate having between 5% and 66% calcium carbonate by weight, the percentage of calcium carbonate used in the compound forming the adhesive 335, the strips 345, 348 and the cover 325 backing may be the same, or may differ from one-another. As the percentage of calcium carbonate may be varied, so too may the level of nucleation of the polypropylene.
In an embodiment, a cover 125, 250, 325, 425, 520 has a fabric backing and a pile outer surface such as knitted or woven cover materials; such a fabric backing of the cover 125, 250, 325, 425, 520 comprises interstitial pores into which an adhesive 135, 335, or liquefied or tacky base material 445, 540 may flow, especially when compressed by a belt 120, 320, 420. In an embodiment, a cover 125, 250, 325, 425, 520 is made from a microfiber material; such a microfiber cover 125, 250, 325, 425, 520 also comprises interstitial pores into which an adhesive 135, 335, or liquefied or tacky base material 445, 540 may flow, especially when compressed by a belt 120, 320, 420. In an embodiment, a cover 125, 250, 325, 425, 520 is made of a strip of natural skin, such as lambskin, sewn together to form a long strip. Natural skins, such as lambskin, comprises interstitial pores into which an adhesive 135, 335, or liquefied or tacky base material 445, 540 may flow, especially when compressed by a belt 120, 320, 420.
In an embodiment, a cover 125, 250, 325, 425, 520 has a pile, microfiber or fur outer surface and a smooth or uniformly imprinted backing formed from nucleated polypropylene or a compound of nucleated polypropylene and calcium carbonate. In an embodiment, the compound of nucleated polypropylene and calcium carbonate comprises between 5% and 66% calcium carbonate by weight.
In an embodiment, a cover 125, 250, 325, 425, 520 has a pile or microfiber outer surface and a smooth or uniformly imprinted backing formed from nucleated polypropylene or a compound of nucleated polypropylene and calcium carbonate. In an embodiment, the compound of nucleated polypropylene and calcium carbonate comprises between 5% and 66% calcium carbonate by weight.
In an embodiment, the adhesive 210 consists substantially entirely of nucleated polypropylene. Where the adhesive 210 consists substantially entirely of nucleated polypropylene, Pinnacle Polymers 2180H rated with an MFI of 80 may be used.
In another embodiment, the adhesive 210 is a compound of nucleated polypropylene and calcium carbonate having between 5% and 66% calcium carbonate by weight. Where the adhesive is a compound of nucleated polypropylene and calcium carbonate having between 5% and 66% calcium carbonate by weight, the adhesive 210 may be formed by a twin screw extruder sufficient for compounding calcium carbonate with nucleated polypropylene (not shown) from a supply of nucleated polypropylene resin in pellet form. The calcium carbonate used should be relatively non-abrasive to the processing machinery. In an embodiment, 2180H or a nucleated polypropylene having a similar MFI of 80 is compounded with 12% calcium carbonate by weight to achieve a compounded adhesive 210 having an MFI of approximately 70. In an embodiment, a nucleated polypropylene having an MFI of approximately 105 is compounded with 25% calcium carbonate by weight to achieve a compounded adhesive 210 having an MFI of approximately 80.
The cover material 215 is advanced along the frame 230 with its pile side down, and moved beneath the roller 220. In an embodiment, the cover material 215 has a pile side and a fabric backing—the fabric backing being porous and having interstitial spaces sufficient to permit penetration of the adhesive 210. In another embodiment, the cover material 215 lacks a separate fabric backing (e.g., microfiber), but the side opposite the pile side is porous and has interstitial spaces sufficient to permit penetration of the adhesive 210. In yet another embodiment, the cover material 215 has a fur side and a suede side, and the suede side is porous and has interstitial spaces sufficient to permit penetration of the adhesive 210.
An applicator 205 dispenses the adhesive 210. The positioning and angular orientation of the applicator 205 may be varied. In an embodiment, the applicator is angled between 30 degrees and 60 degrees from vertical and positioned within inches of the middle of the roller 220. In another embodiment the applicator 205 is within 30 degrees (+/−) of vertical, and is positioned to dispense adhesive such that the adhesive layer 210 first makes contact on the upper half of the roller 220. In yet another embodiment, the applicator 205 is within 30 degrees (+/−) of horizontal and is positioned to dispense adhesive such that the adhesive layer 210 first makes contact on the lower half of the roller 220. Variations in the angular orientation of the applicator 205, and its distance from and orientation around the roller are within the scope of the invention, and will be apparent to one skilled in the art.
As the cover material 215 and the layer of adhesive 210 pass between the roller 220 and the surface of the frame 230 they are urged together. The roller-side of the adhesive 210 may be smoothed or uniformly imprinted (e.g., embossed) by the roller 220 as it passed underneath, thus forming a uniform or smooth adhesive layer surface 225.
In an embodiment, the roller 220 may be heated. In an embodiment, the roller 220 may be cooled.
In an embodiment, the roller 220 applies a compressive force to urge the adhesive 210 towards the cover material 215. In an embodiment, the compressive force is sufficient to force the adhesive 210 into the interstitial spaces within the fabric backing of the cover material 215. The resulting composite sheet material 235 may be cut by a cutter 240 to trim away any excess materials, and thus to form the compound composite cover material 250 with a non-porous backing.
Apparatus 400 may be operated using a two strips 445, 448 and a composite paint roller cover 415 having a smoothed or uniformly imprinted backing comprising nucleated polypropylene. In an embodiment, the backing additionally comprises between 5% and 66% calcium carbonate by weight. The first strip of material 448 and the second strip of material 445 each generally comprising polypropylene is wrapped helically about a mandrel 440 held on a base 450. The second strip of material 445 being wrapped helically about the first strip 448. The mandrel may be cooled by a cooler (not shown). The heaters 460, 455 which may employ heating elements or heat by open flame, heat the outer surface (vis-ä-vis the wrapping about the mandrel) of the strips 448, 445 respectively. The heat produced by the heaters 460 is sufficient to cause the outer surface of the strips 448, 445 to become tacky, or to liquefy, or to become molten. (Although shown diagrammatically at a distance from the mandrel, in an embodiment, the heaters 460, 455 are placed as close as practicable to the point where the strips 448, 445 contact the mandrel.) A composite paint roller cover 415 having a smoothed or uniformly imprinted backing comprising nucleated polypropylene is also helically wrapped around the mandrel 440 over the outer surface of the second strip 445. A helical belt drive 420 applies an inwardly compressive force on the cover material 415 and advances the assembly down the mandrel 440 so that a flyaway saw 405 may cut the assembly into lengths (not shown) that can be used, or further cut and used to produce finished paint rollers.
It will be apparent to a person of skill in the art that, in view of the foregoing disclosure, any or all of the thermoplastic component parts of the paint roller, e.g., the strips 445, 448 and the backing of the composite paint roller cover 415 may be made from a compound formed from nucleated polypropylene and between 5% and 66% calcium carbonate by weight. When more than one component part is made of a compound of nucleated polypropylene and calcium carbonate having between 5% and 66% calcium carbonate by weight, the percentage of calcium carbonate used in the compound forming each strip 445, 448 and/or forming the composite paint roller cover 425 backing may be the same, or may differ from one-another. As the percentage of calcium carbonate may be varied, so too may the level of nucleation of the polypropylene.
It will be apparent to a person of skill in the art that, in view of the foregoing disclosure, any or all of the thermoplastic component parts of the paint roller, e.g., the core 540 and the backing of the composite cover 520 may be made from a compound formed from nucleated polypropylene and between 5% and 66% calcium carbonate by weight. When more than one component part is made of a compound of nucleated polypropylene and calcium carbonate having between 5% and 66% calcium carbonate by weight, the percentage of calcium carbonate used in the compound forming the core 540 and the backing of the composite cover 520 backing may be the same, or may differ from one-another. As the percentage of calcium carbonate may be varied, so too may the level of nucleation of the polypropylene.
It will be apparent to a person of skill in the art that, in view of the foregoing disclosure, any or all of the thermoplastic component parts of the paint roller may be made using nucleated polypropylene, and the level of nucleation of the polypropylene needn't be constant from one part to anther.
It will also be apparent to a person of skill in the art that, in view of the foregoing disclosure, any or all of the thermoplastic component parts of the paint roller may be made from a compound formed from polypropylene or from nucleated polypropylene, and in either case, between 5% and 66% calcium carbonate by weight. When more than one thermoplastic component of the paint roller is made of a compound comprising between 5% and 66% calcium carbonate by weight, the percentage of calcium carbonate used in the compound forming those several components may be the same, or may differ from one-another.
It is possible, without departing from the scope or spirit of the present disclosure to use nucleated polypropylene in lieu of polypropylene, in whole, or in part, in making paint rollers. In light of this disclosure, other methods for the manufacture of the paint rollers using at least a portion of which are made from nucleated polypropylene will be apparent to persons of skill in the art.
It also is possible, without departing from the scope or spirit of the present disclosure, to use a compound of polypropylene or nucleated polypropylene and calcium carbonate having between 5% and 66% calcium carbonate by weight in lieu of polypropylene in making paint rollers. In light of this disclosure, other methods for the manufacture of the same will be apparent to persons of skill in the art.
Benefits of certain embodiments of the instant invention include: control of thermal conductivity in the component materials leading to faster throughput and/or faster set times; and control of material characteristics such as stiffness for manufacture of harder, more expensive paint rollers.
Benefits of certain embodiments of the instant invention include: control of the heat deflection temperature in the component materials leading to paint rollers able to withstand higher temperatures in use and during cleaning; and control of material characteristics such as stiffness for manufacture of harder, more expensive paint rollers.
The above embodiments and preferences are illustrative of the present invention. It is neither necessary, nor intended for this patent to outline or define every possible combination or embodiment. The inventor has disclosed sufficient information to permit one skilled in the art to practice at least one embodiment of the invention, and has disclosed the ways the inventor now believes are the best ways to practice the invention. The above description and drawings are merely illustrative of the present invention and that changes in components, structure and procedure are possible without departing from the scope of the present invention as defined in the claims below.
In an embodiment, a paint roller is made using a strip formed by compounding TOTAL Polypropylene 4481 WA or another nucleated polypropylene having an MFI of approximately 4 and approximately 60% calcium carbonate by weight.
In an embodiment, a paint roller is made using two strips formed by compounding TOTAL Polypropylene 4481 WA or another nucleated polypropylene having an MFI of approximately 4 and approximately 60% calcium carbonate by weight.
In an embodiment, a paint roller is made using an adhesive formed by compounding Pinnacle Polymers 2180H or another nucleated polypropylene having an MFI of approximately 80 and approximately 45% calcium carbonate by weight.
In an embodiment, a paint roller is made using at least one strip formed by compounding TOTAL Polypropylene 4481 WA or another nucleated polypropylene having an MFI of approximately 4 and approximately 60% calcium carbonate by weight; an adhesive formed by compounding Pinnacle Polymers 2180H or another nucleated polypropylene having an MFI of approximately 80 and approximately 45% calcium carbonate by weight; and composite cover having a backing comprising Pinnacle Polymers 2180H or another nucleated polypropylene having an MFI of approximately 80.
In one embodiment a strip of material is helically wound around a mandrel so as to form a helically wound strip. The strip is formed from nucleated polypropylene. The wound strip is advanced along the mandrel. A layer of adhesive is applied onto an outer surface of the wound strip. A strip of cover material then is helically wrapped about the wound strip and over the layer of adhesive, thereby bonding the strip of cover material to the wound strip for forming the paint roller.
In one embodiment, a strip of material is helically wound around a mandrel so as to form a helically wound strip. The strip is formed from nucleated polypropylene. The wound strip is advanced along the mandrel. A layer of adhesive is applied onto an outer surface of the wound strip. A strip of cover material then is helically wrapped about the wound strip and over the layer of adhesive, thereby bonding the strip of cover material to the wound strip for forming the paint roller.
In another embodiment a strip of material is helically wound around a mandrel so as to form a helically wound strip. The wound strip is advanced along the mandrel. An adhesive formed from nucleated polypropylene. The layer of adhesive is applied onto an outer surface of the wound strip. A strip of cover material then is helically wrapped about the wound strip and over the layer of adhesive, thereby bonding the strip of cover material to the wound strip for forming the paint roller.
In another embodiment a strip of material helically wound around a mandrel so as to form a helically wound strip. The strip is formed from nucleated polypropylene. The wound strip is advanced along the mandrel. An adhesive is made from nucleated polypropylene. A layer of the adhesive is applied onto an outer surface of the wound strip. A strip of cover material then is helically wrapped about the wound strip and over the layer of adhesive, thereby bonding the strip of cover material to the wound strip for forming the paint roller.
In an embodiment an inner strip and an outer strip of material is helically advanced about a mandrel in offset relation. At least one of the strips is formed from nucleated polypropylene. A layer of adhesive is applied between the two strips and on the outer surface of the outer strip. Prior to permitting the layer of adhesive to harden and set, a cover is wrapped around the outer strip and a compressing force is applied upon the cover urging the cover and the two strips toward the mandrel, thereby creating the continuous laminated paint roller.
In another embodiment an inner strip and an outer strip of material is helically advanced about a mandrel in offset relation. An adhesive material is made from nucleated polypropylene. The adhesive material is applied between the two strips and on the outer surface of the outer strip. Prior to permitting the adhesive material to harden and set, a cover is wrapped around the outer strip and a compressing force is applied upon the cover urging the cover and the two strips toward the mandrel, thereby creating the continuous laminated paint roller.
In another embodiment an inner strip and an outer strip of material is helically advanced about a mandrel in offset relation, at least one of the strips being formed from nucleated polypropylene. An adhesive material is also formed from nucleated polypropylene. The adhesive material is applied between the two strips and on the outer surface of the outer strip. Prior to permitting the layer of adhesive to harden and set, a cover is wrapped around the outer strip and a compressing force is applied upon the cover urging the cover and the two strips toward the mandrel, thereby creating the continuous laminated paint roller.
In another embodiment a first width of applicator material is advanced. The cover material has an applicator side and a backing side, wherein the backing on the backing side is porous, having interstitial spaces or gaps. An adhesive is made from nucleated polypropylene. A layer of the adhesive is applied to the backing side of the applicator material. The adhesive layer is allowed to set to form a composite sheet material having an applicator side and a non-porous backing. The composite sheet material is longitudinally cut to form one or more strips of composite cover material in a second width. The formed composite cover material has an inner surface and an outer surface, the outer surface comprising an exposed pile, fur or microfiber, and the inner surface comprising a non-porous layer.
In another embodiment an adhesive material is made from nucleated polypropylene. The adhesive material is applied between a cover material and one or more materials making up the paint roller core. The adhesive material is permitted to harden and set, thereby creating the paint roller.
In another embodiment a strip comprising nucleated polypropylene is helically wound around a mandrel so as to form a helically wound strip, the strip having an outer surface. The wound strip is helically advanced along the mandrel. A layer of adhesive comprising nucleated polypropylene is applied onto the outer surface of the wound strip. A strip of composite cover material is then wrapped about the wound strip and over the layer of adhesive. The composite cover material is formed by method comprising the following steps. A width of porous applicator material is provided having an applicator side and an underside. The width of applicator material is advanced with the underside facing up. A backing layer is made from nucleated polypropylene. The backing layer is applied on the underside of the advancing width of applicator material so that the layer has one side that is in contact with the underside of the advancing material and an other side that is not in contact with the advancing applicator material, the layer being in molten form when it is applied. A compressive force is applied to the other side of the layer before the layer hardens and sets, to smooth the other side of the layer of nucleated polypropylene, and to urge the layer and the underside of the applicator material together, thereby forming a composite material having a smooth or uniformly imprinted non-porous side and an exposed applicator side. In an embodiment, pile is held fast by the set adhesive. The width of composite material is cut into a strip once the backing layer is no longer in molten form, thereby forming a composite cover material having an inner surface comprising a smooth or uniformly imprinted non-porous nucleated polypropylene side and a pile side. The composite cover material produced by the method described above is then used to form a laminated pain roller. A compressive force is applied from without the composite cover material to urge the composite cover material, the layer of adhesive and strip of non-porous nucleated polypropylene material together, thereby laminating the smooth inner surface of the composite cover material to the outer surface of the non-porous nucleated polypropylene strip.
In another embodiment an inner strip of thermoplastic material is helically around a mandrel so as to form a helically wound inner strip, the inner strip having an outer surface. A second strip of thermoplastic material is helically wound around a mandrel in offset relation to the inner strip, so as to form a helically wound second strip, the second strip having an inner surface and an outer surface. The wound inner and second strips are advanced along the mandrel. An adhesive is made from nucleated polypropylene. A layer of the adhesive is applied onto the outer surface of the wound inner strip and the outer surface of the wound second strip. A strip of composite cover material is then wrapped about the wound second strip and over the layer of adhesive applied to the wound second strip. The composite cover material has an inner surface and an outer surface, the outer surface comprising a pile fabric, and the inner surface comprising a smooth generally non-porous backing comprising nucleated polypropylene. A compressive force is then applied from without the composite cover material to urge the composite cover material, the layer of adhesive and inner and second strips together, thereby laminating the inner surface of the composite cover material to the outer surface of the second strip and laminating the inner surface of the second strip to the outer surface of the inner strip.
In another embodiment an inner strip and an outer strip of material is helically advanced about a mandrel in offset relation. At least one of the strips is formed from nucleated polypropylene. The inner strip and the outer strip have an outer surface facing away from the mandrel. The outer surface of the inner and outer strips is heated to cause a layer of the outer surface of the strips to become liquefied. Prior to permitting the liquefied layers to harden and set, a cover around is wrapped around the outer strip and a compressing force is applied upon the cover urging the cover and the two strips toward the mandrel, thereby creating the continuous laminated paint roller.
In another embodiment a cold hard hollow core is provided. The cold hard hollow core is formed from nucleated polypropylene. A mandrel having an external diameter is provided. The mandrel slidably receives and makes contact with the cold hard hollow core. The cold hard hollow core is rotated. The exterior surface of the cold hard hollow thermoplastic rotating core is heated, by application of a single source of heat, to a temperature high enough to cause subsequently applied cover to adhere to said exterior surface. A cover is then to the heated exterior surface of the cold hard hollow thermoplastic core, thereby bonding the cover to the heated exterior surface thereof, and forming a paint roller.
In yet another embodiment a strip of material is helically wound around a mandrel so as to form a helically wound strip. The strip is formed from a compound of nucleated polypropylene and calcium carbonate having between 5% and 66% calcium carbonate by weight. The wound strip is advanced along the mandrel. A layer of adhesive is applied onto an outer surface of the wound strip. A strip of cover material then is helically wrapped about the wound strip and over the layer of adhesive, thereby bonding the strip of cover material to the wound strip for forming the paint roller.
In another embodiment a strip of material is helically wound around a mandrel so as to form a helically wound strip. The wound strip is advanced along the mandrel. An adhesive is compounded from nucleated polypropylene and calcium carbonate. The compound comprises between 5% and 66% calcium carbonate by weight. The layer of adhesive is applied onto an outer surface of the wound strip. A strip of cover material then is helically wrapped about the wound strip and over the layer of adhesive, thereby bonding the strip of cover material to the wound strip for forming the paint roller.
In another embodiment a strip of material helically wound around a mandrel so as to form a helically wound strip. The strip is formed from a compound of nucleated polypropylene and calcium carbonate having between 5% and 66% calcium carbonate by weight. The wound strip is advanced along the mandrel. An adhesive is compounded from nucleated polypropylene and calcium carbonate. The compound comprises between 5% and 66% calcium carbonate by weight. The layer of adhesive is applied onto an outer surface of the wound strip. A strip of cover material then is helically wrapped about the wound strip and over the layer of adhesive, thereby bonding the strip of cover material to the wound strip for forming the paint roller.
In another embodiment an inner strip and an outer strip of material is helically advanced about a mandrel in offset relation. At least one of the strips is formed from a compound of nucleated polypropylene and calcium carbonate having between 5% and 66% calcium carbonate by weight. A layer of adhesive is applied between the two strips and on the outer surface of the outer strip. Prior to permitting the layer of adhesive to harden and set, a cover is wrapped around the outer strip and a compressing force is applied upon the cover urging the cover and the two strips toward the mandrel, thereby creating the continuous laminated paint roller.
In another embodiment an inner strip and an outer strip of material is helically advanced about a mandrel in offset relation. An adhesive material is compounded from nucleated polypropylene and calcium carbonate, the compound comprising between 5% and 66% calcium carbonate by weight. The adhesive material is applied between the two strips and on the outer surface of the outer strip. Prior to permitting the adhesive material to harden and set, a cover is wrapped around the outer strip and a compressing force is applied upon the cover urging the cover and the two strips toward the mandrel, thereby creating the continuous laminated paint roller.
In another embodiment an inner strip and an outer strip of material is helically advanced about a mandrel in offset relation, at least one of the strips being formed from a compound of polypropylene and calcium carbonate having between 5% and 66% calcium carbonate by weight. An adhesive material is compounded from nucleated polypropylene and calcium carbonate. The compound comprises between 5% and 66% calcium carbonate by weight. The adhesive material is applied between the two strips and on the outer surface of the outer strip. Prior to permitting the layer of adhesive material to harden and set, a cover is wrapped around the outer strip and a compressing force is applied upon the cover urging the cover and the two strips toward the mandrel, thereby creating the continuous laminated paint roller.
In another embodiment a first width of applicator material is advanced. The applicator material has an applicator side and a backing side, wherein the backing side is porous, having interstitial spaces or gaps. An adhesive is compounded from nucleated polypropylene and calcium carbonate. The compound comprises between 5% and 66% calcium carbonate by weight. A layer of the adhesive is applied to the backing side of the applicator material. The adhesive layer is allowed to set to form a composite sheet material having an exposed applicator side and a non-porous backing. The composite sheet material is longitudinally cut to form one or more strips of composite cover material in a second width. The formed composite cover material has an inner surface and an outer surface, the outer surface comprising an exposed applicator side, and the inner surface comprising a non-porous layer.
In another embodiment an adhesive material is compounded from nucleated polypropylene and calcium carbonate. The compound comprises between 5% and 66% calcium carbonate by weight. The adhesive material is applied between a cover material and one or more materials making up the paint roller core. The adhesive material is permitted to harden and set, thereby creating the paint roller.
In another embodiment a strip comprising nucleated polypropylene is helically wound around a mandrel so as to form a helically wound strip, the strip having an outer surface. The wound strip is helically advanced along the mandrel. A layer of adhesive comprising nucleated polypropylene is applied onto the outer surface of the wound strip. A strip of composite cover material is then wrapped about the wound strip and over the layer of adhesive. The composite cover material is formed by method comprising the following steps. A width of porous pile material is provided having a pile side and an fabric underside. The width of pile material is advanced with the fabric underside facing up. A backing layer is compounded from nucleated polypropylene and calcium carbonate, the compound comprising between 5% and 66% calcium carbonate by weight. The backing layer is applied on the fabric underside of the advancing width of pile material so that the layer has one side that is in contact with the fabric underside of the advancing material and an other side that is not in contact with the advancing pile material, the layer being in molten form when it is applied. A compressive force is applied to the other side of the layer before the layer hardens and sets, to smooth the other side of the layer of nucleated polypropylene, and to urge the layer and the fabric underside of the pile material together, thereby forming a composite material having a smooth or uniformly imprinted non-porous side and a pile side, and wherein the pile is held fast on the composite material. The width of composite material is cut into a strip once the backing layer is no longer in molten form, thereby forming a composite cover material having an inner surface comprising a smooth or uniformly imprinted non-porous nucleated polypropylene side and a pile side. The composite cover material produced by the method described above is then used to form a laminated pain roller. A compressive force is applied from without the composite cover material to urge the composite cover material, the layer of adhesive and strip of non-porous nucleated polypropylene material together, thereby laminating the smooth inner surface of the composite cover material to the outer surface of the non-porous nucleated polypropylene strip.
In another embodiment an inner strip of thermoplastic material is helically around a mandrel so as to form a helically wound inner strip, the inner strip having an outer surface. A second strip of thermoplastic material is helically wound around a mandrel in offset relation to the inner strip, so as to form a helically wound second strip, the second strip having an inner surface and an outer surface. The wound inner and second strips are advanced along the mandrel. An adhesive is compounded from nucleated polypropylene and calcium carbonate, the compound comprising between 5% and 66% calcium carbonate by weight. A layer of the adhesive is applied onto the outer surface of the wound inner strip and the outer surface of the wound second strip. A strip of composite cover material is then wrapped about the wound second strip and over the layer of adhesive applied to the wound second strip. The composite cover material has an inner surface and an outer surface, the outer surface comprising an applicator side, and the inner surface comprising a smooth generally non-porous backing comprising nucleated polypropylene. A compressive force is then applied from without the composite cover material to urge the composite cover material, the layer of adhesive and inner and second strips together, thereby laminating the inner surface of the composite cover material to the outer surface of the second strip and laminating the inner surface of the second strip to the outer surface of the inner strip.
In another embodiment an inner strip and an outer strip of material is helically advanced about a mandrel in offset relation. At least one of the strips is formed from a compound of nucleated polypropylene and calcium carbonate having between 5% and 66% calcium carbonate by weight. The inner strip and the outer strip have an outer surface facing away from the mandrel. The outer surface of the inner and outer strips is heated to cause a layer of the outer surface of the strips to become liquefied. Prior to permitting the liquefied layers to harden and set, a cover around is wrapped around the outer strip and a compressing force is applied upon the cover urging the cover and the two strips toward the mandrel, thereby creating the continuous laminated paint roller.
In another embodiment a cold hard hollow core is provided. The cold hard hollow core is formed from a compound of nucleated polypropylene and calcium carbonate having between 5% and 66% calcium carbonate by weight. A mandrel having an external diameter is provided. The mandrel slidably receives and makes contact with the cold hard hollow core. The cold hard hollow core is rotated. The exterior surface of the cold hard hollow thermoplastic rotating core is heated, by application of a single source of heat, to a temperature high enough to cause subsequently applied cover to adhere to said exterior surface. A cover is then to the heated exterior surface of the cold hard hollow thermoplastic core, thereby bonding the cover to the heated exterior surface thereof, and forming a paint roller.
These above embodiments and preferences are illustrative of the present invention. It is neither necessary, nor intended for this patent to outline or define every possible combination or embodiment. The inventor has disclosed sufficient information to permit one skilled in the art to practice at least one embodiment of the invention, and has disclosed the ways the inventor now believes are the best ways to practice the invention. The above description and drawings are merely illustrative of the present invention and that changes in components, structure and procedure are possible without departing from the scope of the present invention as defined in the following claims. Thus, while the invention has been particularly shown and described with reference to embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention. The above embodiments are illustrative of the present invention. It is neither necessary, nor intended for this patent to outline or define every possible combination or embodiment.
