Note: Descriptions are shown in the official language in which they were submitted.
CA 02664974 2013-06-10
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METHODS FOR MANUFACTURING A PAINT ROLLER AND COMPONENT
PARTS THEREOF
FIELD OF THE INVENTION
[0003] This invention pertains to methods and apparatuses 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 a composite cover material for use in a
paint roller
manufacturing process, and to making paint rollers that are formed in a
continuous process
from one or more strips and a composite cover material.
SUMMARY
10003a1 Certain exemplary embodiments can provide a method of making a
composite
cover material having an outer surface comprising pile and a smooth non-porous
inner
surface, the cover material for use in a method of making a laminated paint
roller
comprising the steps of, helically winding a strip of polypropylene material
around a
mandrel so as to form a helically wound strip, the strip having an outer
surface, advancing
the wound strip along the mandrel, applying a layer of polypropylene adhesive
onto an
outer surface of the wound strip, wrapping a strip of cover material about the
wound strip
and over the layer of adhesive and applying compressive force without the
cover material
to urge the cover material, the layer of adhesive and strip of polypropylene
material
together thereby laminating the cover material to the strip, the method
comprising:
advancing a width of pile material having an underside and a pile side,
underside up and
pile side down, beneath a rotating roller; depositing a layer of molten
material, the molten
material comprising polypropylene, on the rotating roller such that the layer
of
molten material comes in contact with and is compressed against the underside
of
the advancing width of pile material as the pile material passes beneath the
rotating
roller and before the layer of molten material has a chance to harden
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and set; permitting the molten material to harden and set while in contact
with the
advancing width of pile material thereby forming a substantially non-porous
backed pile
material; and cutting the non-porous backed pile material into strips of cover
material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] 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:
[0005] Figure 1 is a side view diagrammatic representation of an apparatus for
making
composite cover material in accordance with an embodiment of the present
invention.
[0006] Figure 2 is a side view diagrammatic representation of another
apparatus for
making composite cover material in accordance with an embodiment of the
present
invention.
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CA 02664974 2013-03-20
[0007] Figure 3 is a diagrammatic top view of the apparatus for making
composite
cover material of Figure 2.
[0008] Figure 4 is a side view diagrammatic representation of yet another
apparatus
for making composite cover material in accordance with an embodiment of the
present invention.
[0009] Figures SA and 5B are diagrammatic views of the apparatus for making
composite cover material of Figure 4.
[0010] Figure 6 is a side view diagrammatic representation of still another
apparatus
for making composite cover material in accordance with an embodiment of the
present invention.
[0011] Figure 7 is a side view diagrammatic representation of a further
apparatus for
making composite cover material in accordance with an embodiment of the
present
invention.
[0012] Figure 8 is a side view diagrammatic representation of a still further
apparatus
for making composite cover material in accordance with an embodiment of the
present invention.
[0013] Figure 9 is a side view diagrammatic representation of another further
apparatus for making composite cover material in accordance with an embodiment
of
the present invention.
[0014] Figure 10 is a side view diagrammatic representation of yet another
further
apparatus for making composite cover material in accordance with an embodiment
of
the present invention.
[0015] Figure 11 is a side view diagrammatic representation of still another
further
apparatus for making composite cover material in accordance with an embodiment
of
the present invention.
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[0016] Figure 12 is a diagrammatic representation of an apparatus for making
laminated paint rollers using a composite cover material in accordance with an
embodiment of the present invention.
[0017] Figure 13 is a diagrammatic representation of another apparatus for
making
laminated paint rollers using a composite cover material in accordance with an
embodiment of the present invention.
[0018] Figure 14 is a diagrammatic representation of an apparatus suitable for
making multi-strip laminated paint rollers using a composite cover material in
accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION AND THE PREFERRED
EMBODIMENTS
[0019] Figure 1 shows an apparatus 801 for forming composite cover material
817.
In an embodiment, the apparatus comprises an adhesive applicator 809 that
receives a
supply of adhesive from an adhesive supply 811 via a feeder 810, and a strip
cutter
816.
100201 The composite cover material 817 is formed using a supply of pile
material
802 such as would be suitable for use manufacturing a paint roller cover. The
composite cover material is formed using a continuous supply of pile material
such as
would be suitable for use manufacturing a paint roller cover. Suitable pile
material
802 may be used such as the material that can be manufactured using a sliver
knitting
machine such as the SK-18 available from Mayer Industries Inc. Such knitted
pile
material may be made "in the round," and slit for use as a continuous pile
material.
Once slit, the knitted pile material can be laid flat for further processing.
As an
alternative to the knitted pile material, a woven pile material may be used,
such a
woven pile material, while generally more expensive than the knitted material,
is
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advantageous as its fibers are better locked in during the weaving process
rather than
by later application of an adhesive. The knitted or woven pile material 802 is
usually
sheared (not shown) on the pile side to attain a desired pile height. As an
alternative
to woven or knitted materials, a microfiber material may be used. The material
802 can
have any usable width, such as widths of approximately 32" or 60", and can be
manufactured or sheared to a desired pile height. The material 802 can have
any
usable width, for example, a width of approximately 32" or 60". In an
embodiment,
the material has a pile side (shown facing downwards) and a fabric side (shown
facing
upwards).
[0021] In an embodiment, the material 802 is laid flat with its pile side down
and
moved towards an adhesive layer 820 being dispensed from the adhesive
applicator
809. A tenter (not shown), also known as a tenter frame, or a similar
apparatus may
be used to advance the material 802. In an embodiment, the material 802 is
moved in
a generally horizontal direction with the pile side down.
[0022] The adhesive layer 820 is dispensed from the adhesive applicator 809
onto the
fabric backing of the material 802. The adhesive supply 811 supplies the
adhesive to
the applicator 809 via a feeder 810. In an embodiment, the adhesive is made
predominantly or entirely from polypropylene resin, the adhesive applicator
809 may
be a die head and the supply 811 and feeder 810 are parts of an extruder
suitable for
use to extrude polypropylene resin into the adhesive layer 820. After the
adhesive
layer 820 has been applied to the fabric backing of the material 802 they are
allowed
to set and/or bond together. The setting of the adhesive layer and/or the
bonding
between the adhesive layer 820 and the fabric backing of material 802 may be
affected by control of the environment (e.g., the application of heating or
cooling, or
otherwise) after the adhesive 820 is dispensed from the applicator 809 but
before it
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has set fully. It is within the scope of the invention to permit the setting
of the
adhesive layer 820 and its bonding to the material 802 through the use of
environmental intervention and/or mechanical intervention.
100231 In an embodiment, a polypropylene adhesive layer 820 is applied to the
fabric backing of the material 802 in a molten, or at least partially
liquefied state. For
the purpose of this document, the term polypropylene is not intended to
require that
the adhesive, strip or other material be made solely of polypropylene, that it
is made
predominantly from polypropylene, and may contain some or a substantial
portion of
additives as may be desirable. In an embodiment, after its application to the
fabric
backing of the material 802, the molten polypropylene adhesive layer 802 fill
interstitial spaces or gaps within the fabric backing of the material 802
before setting,
thus integrating the adhesive layer 820 with the material 802, and forming a
composite sheet material 815. The thusly formed composite sheet material 815
is
stiffer than the material 802 absent the integrated materials from the
adhesive layer.
In an embodiment, the fibers of the of the composite sheet material 815 are
locked in
place by the integrated materials from the adhesive layer.
100241 After its application to the fabric backing of the material 802, the
molten
polypropylene adhesive layer 802 can set with an even or smooth the exposed
surface
as it forms the composite sheet material 815 with a generally uniform non-
porous
backing.
100251 The composite sheet material 815 is advanced across cutter 816 to form
composite cover material 817. The cutter 816 may be used to cut the composite
sheet
material 815 into strips of composite cover material 817 in a desired width.
The strips
of composite sheet material 815 do not need to be cut to equal widths. It is
within the
scope of this invention to cut differing width composite cover material 817
from a
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single composite sheet material 815, for example, by varying the spacing of
the
cutting edges of the cutter 816.
[0026] In an embodiment, the strips of composite cover material 817 each have
a
width of approximately 2 7/8 inches, corresponding to a width of cover
material that
may typically be used to manufacture paint rollers. The composite cover
material 817
may be spooled and cut such that it can be transported for use at another site
or on
another machine performing a continuous manufacturing process for laminated
paint
rollers. In another embodiment, the composite cover material may be feed
directly to
an apparatus that uses the material in forming laminated paint rollers. Where
the
composite cover material is spooled, it may be desirable to spool the
composite cover
material 817 while it is still warm and pliable, alternatively, it may be
desirable to
ensure that the composite cover material 817 is fully cooled (i.e., not warm
and
pliable) when it is spooled.
[0027] If the pile on material 802 had not been sheared to the desired height
prior to
the application of the adhesive layer 820, the composite sheet material 815,
or the
composite cover material 817 may be cut by a pile cutter (not shown). The
additional
rigidity of the composite sheet material 815 or composite cover material 817
(as
compared to the material 802) may make the process of shearing to a desired
pile
height easier.
[0028] Figure 2 shows an apparatus 801A for forming composite cover material
817. In an embodiment, the apparatus comprises an adhesive applicator 809, an
environmental control 807 and a strip cutter 816. The adhesive applicator 809
receives a supply of adhesive from an adhesive supply 811 via a feeder 810.
[0029] Composite cover material 817 is formed using a supply of pile material
802
such as would be suitable for use manufacturing a paint roller cover. Pile
material
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802 is a type suitable for use as a paint roller, and in an embodiment may be
knitted or
woven material. The material 802 can have any usable width, for example, a
width of
approximately 32 inches, or of approximately 60 inches. In an embodiment, the
material has a pile side (shown facing upwards) and a fabric side (shown
facing
downwards).
[0030] In an embodiment, the material 802 is laid flat with its pile side down
and
moved towards an adhesive layer 820 being dispensed from the adhesive
applicator
809. A tenter (not shown) or a similar apparatus may be used to advance the
material
802. In an embodiment, the material 802 is moved in a generally horizontal
direction
with the pile side down.
[0031] An adhesive layer 820 is dispensed from the adhesive applicator 809
onto the
fabric backing of the material 802. The adhesive supply 811 supplies the
adhesive to
the applicator 809 via a feeder 810. In an embodiment, the adhesive is made
predominantly or entirely from polypropylene resin, the adhesive applicator
809 may
be a die head and the supply 811 and feeder 810 are parts of an extruder
suitable for
use to extrude polypropylene resin into the adhesive layer 820. Once the
adhesive
layer 820 has been applied to the fabric backing of the material 802 they are
allowed
to set and/or bond together.
[0032] The setting of the adhesive layer and/or the bonding between the
adhesive
layer 820 and the fabric backing of material 802 may be affected by control of
the
environment (e.g., the application of heating or cooling, or otherwise) after
the
adhesive 820 is dispensed from the applicator 809 but before it has set fully.
It is
within the scope of the invention to permit the setting of the adhesive layer
820 and its
bonding to the material 802 through the use of environmental intervention.
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10033] In an embodiment, after the application of the adhesive layer 820 the
material
812 can be fed through an environmental control 807 as it forms the composite
sheet
material 815. The environmental control 807 may be used to affect the bond, or
the
quality or completeness of the bond, between the adhesive layer 820 to the
underlying
material 802, and aid in integrating the adhesive layer 820 with the material
802.
[0034] In an embodiment using an environmental control 807, the control 807
may
employ the application of heat, which may even or smooth the exposed surface
of the
adhesive layer 820.
[0035] In an embodiment using an environmental control 807, the control 807
may
employ the application of heat, which may permit the adhesive in the adhesive
layer
820 to better fill interstitial spaces or gaps within the material 802.
[0036] In an embodiment using an environmental control 807, the control 807
may
employ the application of heat, which may allow more contact between the
adhesive
in the adhesive layer and the fibers making up the pile in the material 802,
thereby
locking fibers in place in the pile as it sets.
[0037] In an embodiment using an environmental control 807, the control 807
may
employ the application of heat, which can provide the ability to control the
speed at
which the adhesive sets and creates the composite sheet material 815.
[0038] In another embodiment using an environmental control 807, the control
807
may employ cooling, such cooling can hasten the hardening or setting of the
adhesive
layer 820.
[0039] It is within the scope of the invention to employ an environmental
control
807 that utilizes both the application of heat and the application of cold,
seriatim, in
any order, and without limitation on the number of applications or the
temperature of
a specific application. Using heat, cooling, multiple applications of heat or
cooling,
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or combinations of both heat and cooling may achieve, among other things, one
or
more of the following: (i) evening or smoothing the exposed surface of the
adhesive
layer 820 to provide a generally uniform non-porous backing; (ii) permitting
the
adhesive in the adhesive layer 820 to better fill interstitial spaces or gaps
within the
material 802; and/or (iii) allowing more contact between the adhesive in the
adhesive
layer and the fibers making up the pile in the material 802; (iv) locking
fibers in the
pile in place as the adhesive sets; and/or (v) hasten or lengthening the
hardening or
setting of the adhesive layer 820.
[0040] Whether or not an environmental control 807 is employed, the composite
sheet material 815 is advanced across cutter 816 to form composite cover
material
817. As discussed above, the cutter 816 may be used to cut the composite sheet
material 815 into strips of composite cover material 817 in a desired width.
The strips
of composite sheet material 815 do not need to be cut to equal widths. It is
within the
scope of this invention to cut differing width composite cover material 817
from a
single composite sheet material 815, for example, by varying the spacing of
the
cutting edges of the cutter 816.
[0041] In an embodiment, the strips of composite cover material 817 each have
a
width of approximately 2 7/8 inches, corresponding to a width of cover
material that
may typically be used to manufacture paint rollers. As discussed above,
composite
cover material 817 may be spooled and cut for transport, or feed directly to
an
apparatus that uses the material in forming laminated paint rollers. The
composite
cover material 817 may be spooled while it is still warm and pliable, or after
it is fully
cooled.
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[0042] If the pile on material 802 has not been sheared to the desired height
prior to
the application of the adhesive layer 820, a pile cutter (not shown) can be
use to shear
the composite sheet material 815 or the composite cover material 817.
[0043] Figure 3 shows a top view is shown of an apparatus 801A for
manufacturing
the composite cover material 817 in accordance with an embodiment of the
invention.
The adhesive applicator 809 applies an adhesive layer 820 to the material 802
as the
material is advanced. In an embodiment, the material 802 may be fed into the
apparatus 801A directly as it is manufactured, or from pre-manufactured
lengths.
[0044] In the embodiment shown in Figure 3, the fabric-backed pile material
802
approximately 32" wide is advanced. A polypropylene adhesive layer 820, which
starts wider at the applicator 809 is narrowed as it is pulled along by the
advancing
material 802. Where the adhesive layer 820 makes contact with the material
802, it
may be between 31 5/8" and 32". The adhesive layer 802 and advancing material
802
passed through environmental control 807. Smooth composite sheet material 815
emerges from the environmental control 807 and is separated into eleven strips
of
composite cover material 817, each being 2 7/8" wide. Twelve separate blades
can be
used in the cutter 816 to form the eleven strips of 2 7/8" each, and two small
waste
strips 31.
[0045] Varying the width of the material 802 is within the scope of the
invention,
thus, in another embodiment, the material 802 can be approximately 60" wide,
and
narrowed width of the adhesive layer 820 where it contacts the material 802 is
between 57.5" and 60" wide. Using this configuration, and twenty-one blades
for
cutter 16, twenty strips of 2 7/8" composite cover material can be made. As
above,
two small waste strips 31 will result.
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[0046] While only two different examples are presented, any desired width of
material 802 may be used. Where the adhesive layer 820 comprises
polypropylene,
and where the applicator 809 is an extruder, one limiting factor on the width
of the
material 802 used is the capabilities of the extruder. It is, however, within
the scope
of the invention to use multiple extruders to apply multiple, non-overlapping
adhesive
layers 802 on the material 802.
[0047] Figure 4 shows an apparatus 801B for forming the composite cover
material
817. In an embodiment, the apparatus comprises an adhesive applicator 809 fed
from
a feeder (not shown) which gets a supply of adhesive from an adhesive supply
(not
shown). An advancing material 802 is deposited by an applicator 809 onto a
roller
880, and runs between the roller 880 and a frame 890 having a flat portion.
The roller
880 may be urged toward the frame 890 by a spring, by gravity or by other
means that
will be apparent to persons skilled in the art.
[0048] Composite cover material 817 is formed using a supply of pile material
802
such as would be suitable for use manufacturing a paint roller cover. The
material
802 is a type suitable for use as a paint roller, and in an embodiment may be
knitted or
woven material. The material 802 can have any usable width, for example, a
width of
approximately 32 inches, or of approximately 60 inches. In an embodiment, the
material has a pile side (shown facing upwards) and a fabric side (shown
facing
downwards).
100491 In an embodiment, the material 802 is supported by a frame 809 such as
a
tenter frame with its pile side down, and moved towards the roller; an
adhesive layer
820 is dispensed from the adhesive applicator 809. The frame or a similar
apparatus
may be used to advance the material 802. The adhesive layer may be any
operable
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thickness. In an embodiment, the adhesive layer 820 is between 0.010' and
0.020" in
thickness.
[0050] Once the adhesive layer 820 dispensed from the applicator 809 contacts
the
roller 880, it travels along on the outside of the roller until it is
sandwiched between
the roller 880 and the material 802. The positioning and angular orientation
of the
applicator 809 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 880. In another embodiment the applicator 809 is within 30 degrees (+/-
) of
vertical, and is positioned to dispense adhesive such that the adhesive layer
820 first
makes contact on the upper half of the roller 880. In yet another embodiment,
the
applicator 809 is within 30 degrees (+/-) of horizontal and is positioned to
dispense
adhesive such that the adhesive layer 820 first makes contact on the lower
half of the
roller 880. Variations in the angular orientation of the applicator 809, 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.
[0051] In an embodiment, the adhesive is made predominantly or entirely from
polypropylene resin and the adhesive applicator 809 may be a die head that is
part of
an extruder suitable for use to extrude polypropylene resin into the adhesive
layer 820.
In such an embodiment, the adhesive has a viscosity as it exits the extruder
in the
form of a sheet of molten polypropylene. The applicator 809 may be placed
relatively
close to the location where the adhesive layer 820 contacts the roller 880 (as
shown);
alternatively, in an embodiment, the applicator 809 may be placed farther
away, or at
another location where the adhesive layer 820 contacts the roller 880 sooner
before it
contacts the material 802, or after it contacts the material 802. Such
variation is
within the scope of this invention, and will be apparent to a person of skill
in the art.
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[0052] As the material 802 and the adhesive layer 820 pass between the roller
880
and the surface of the frame 890 they are urged together. The top or roller-
side of the
adhesive layer 820 may be smoothed or uniformly imprinted (e.g., embossed) as
it
passed underneath the roller 880 forming a uniform or smooth adhesive layer
surface
851. The compressive force of the roller 880 may be sufficient to force
adhesive into
the interstitial spaces or gaps in the fabric backing of the material 802. The
resulting
composite sheet material 815 may be cut by cutter 816 to form the composite
cover
material 817 with a non-porous backing.
[0053] The roller 880 may be heated. Heating of the roller 880 may aid in the
penetration of the adhesive layer 820 into the interstitial spaces or gaps
within the
material 802 as the adhesive layer 820 passes beneath the roller 880.
[0054] The roller 880 may be cooled. Cooling of the roller 880 may hasten the
setting of the adhesive layer 820 or of the uniform or smooth adhesive layer
surface
851, or both. Hastening the setting of the uniform or smooth adhesive layer
surface
851 may yield a crisper imprint or a smoother surface thereon. Even if the
roller 880
is cooled, the compressive force of the roller 880 may be sufficient to force
adhesive
into the interstitial spaces or gaps in the fabric backing of the material
802. Thus, a
cooled roller may provide one or more of the following benefits: providing a
smoother or crisper surface 851; hastening the setting of the adhesive, and
thus the
forming of the composite sheet material 815; improving the contact between the
material 802 and the adhesive used to form the adhesive layer 820; and holding
in
place of the fibers comprising the pile of the material 802.
[0055] The roller 880 may also be operated at ambient temperature, and neither
heated nor cooled. In an embodiment, the roller 880 is of a diameter that will
allow it
to adequately smooth or uniformly imprint the adhesive layer 820 to form the
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smoothed or uniform adhesive layer 851. In an embodiment, the roller 880 has a
diameter between about 14" and 20".
[0056] Figures 5A and 5B show a top view of the apparatus 801B. The material
802 advances
across frame 890 (not shown). The applicator 809 dispenses an adhesive layer
(not
show) on the upper surface of the material 802. The material 802 with the
adhesive
layer thereupon are passed beneath a roller 880 which imparts a compressive
force
thereupon. The top or roller-side of the adhesive layer 820 may be smoothed or
uniformly imprinted as it passed underneath the roller 880 forming a uniform
or
smooth adhesive layer surface 851 while the compressive force of the roller
880 may
be sufficient to force adhesive into the interstitial spaces or gaps in the
fabric backing
of the material 802. The resulting composite sheet material 815 may be cut by
cutter
816 to form the composite cover material 817 with a non-porous backing.
[00571 Figure 6 shows an apparatus 801C that is a variation on the apparatus
801B
shown in Figures 4, 5A and 5B. More specifically, apparatus 801 additionally
includes
roller 881, that acts, together with roller 881, to impart a compressive force
between
the material 802 and the adhesive layer 820. The roller is shown in a modified
frame
891 that allows for the rollers 880, 881 to act together rollers as the
material 802 and
adhesive layer 820 pass beneath the upper roller 880.
[0058] As discussed above with respect to the roller 880, the roller 881 can
be
heated or cooled. It is thus possible to simultaneously heat or cool the
rollers 880,
881. It is also possible to heat or cool one of the rollers, or to heat one of
the rollers,
while cooling the other.
[00591 In an embodiment, the upper roller 880 is cooled while the lower roller
881 is
heated. Cooling the upper roller 880 may provide one or more of the following
benefits: providing a smoother or crisper surface 851; hastening the setting
of the
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adhesive, and thus the forming of the composite sheet material 815; improving
the
contact between the material 802 and the adhesive used to form the adhesive
layer
820; and holding in place of the fibers comprising the pile of the material
802. While
heating the lower roller 881 may aid in the penetration of the adhesive layer
820 into
the interstitial spaces or gaps within the material 802 as the adhesive layer
820 passes
above the roller 881.
100601 Either or both of the rollers may also be operated at ambient
temperature, and
neither heated nor cooled.
100611 Moreover, it is not necessary to modify the frame 890 shown in Figure 4
to
be like the frame 891 shown in Figure 6 to operate rollers 880, 881 in order
to keep
within the scope of the present invention. As will be apparent to one of skill
in the art,
the rollers 880, 881 can be configured to be prior to, or after, an unmodified
frame
890. The applicator 809 can be moved accordingly.
[0062] The rollers 880, 881 may be the same size, or of differing sizes. In an
embodiment, the upper roller 880 is of a diameter that will allow it to
adequately
smooth or uniformly imprint the adhesive layer 820 to form the smoothed or
uniform
adhesive layer 851. In an embodiment, the upper roller 880 has a diameter
between
about 14" and 20". In an embodiment, the lower roller 881 is of a diameter
that will
permit it to operate with the upper roller 880. In an embodiment, the lower
roller 880
has a diameter between about 5" and 20".
100631 In an embodiment, instead of using a tenter to move the material, the
rollers
880, 881 can drive the material therebetween.
[0064] Turning now to Figure 7, an apparatus 801D for forming the composite
cover
material 817 is shown. In an embodiment, the apparatus comprises an adhesive
applicator 809 fed from a feeder (not shown) which gets a supply of adhesive
from an
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adhesive supply (not shown). An advancing material 802 runs between a roller
880
and a surface 890 such as a flat portion of a tenter frame. The roller 880 may
be
urged toward the surface 890 by a spring, by gravity or by other means that
will be
apparent to persons skilled in the art.
[0065] An adhesive layer 820 leaves the applicator 809 and is sandwiched
between
the roller 880 and the material 802 prior to, or as the material passes
beneath the roller
880. In an embodiment, the adhesive forming the adhesive layer 820 is
predominantly polypropylene. The positioning of the applicator 809 may be
varied.
Where the adhesive forming the adhesive layer 820 is polypropylene, the
applicator
809 may be the die head of an extruder. In such an embodiment, the adhesive
has a
viscosity as it exits the extruder that forms a sheet of molten polypropylene.
In an
embodiment, the applicator 809 may be placed at a distance to the location
where the
adhesive layer contacts the material 802 prior to contacting the roller 880
(as shown)
or at substantially the same time it contacts the roller 880; or at another
location,
including where the adhesive layer 820 contacts the roller 880 before it
contacts the
material 802. Such variation is within the scope of this invention, and will
be
apparent to a person of skill in the art.
[0066] As the material 802 and the adhesive layer 820 pass between the roller
880
and the surface 890 they are urged together. The top or roller-side of the
adhesive
layer 820 is smoothed or uniformly imprinted as it passed underneath the
roller 880
forming a uniform or smooth adhesive layer 851, while the contact between the
adhesive and the material 802 under pressure from the roller 880 permits the
adhesive
layer 820 to fill interstitial spaces or gaps within the material 802. The
material 802
and the uniform or smooth adhesive layer 851 may then be passed beneath a
second
roller 881 to form the resulting composite sheet material 815.
16
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[0067] After the material 802 with the applied adhesive layer 820 pass between
the
roller 880 and the surface 890 forming the uniform or smooth adhesive layer
851, the
combination is then passed beneath a second roller 884. As with the first
roller 880,
when the combination passes beneath the second roller 884 it is again urged
together.
The second roller 884 may also smooth or imprint the uniform or smooth
adhesive
layer 851, and in any event, will impart downward pressure upon it, which may
permit the adhesive layer 820 to further fill interstitial spaces or gaps
within the
material 802. The resulting composite sheet material 815 may be cut by cutter
816 to
form the composite cover material 817 with a non-porous backing.
[0068] One or both of the rollers 880, 884 may be heated or cooled, or one may
be
heated while the other is cooled.
[0069] Cooling one or both of the rollers 880 may provide one or more of the
following benefits: providing a smoother external surface or crisper imprint;
hastening
the setting of the adhesive, and thus hastening the forming of the composite
sheet
material 815; improving the contact between the material 802 and the adhesive
used
to form the adhesive layer 820; and holding in place of the fibers comprising
the pile
of the material 802. Heating the rollers 880, 884 may aid in the penetration
of the
adhesive layer 820 into the interstitial spaces or gaps within the material
802 as the
adhesive layer 820 passes beneath the rollers 880, 884 and may permit for
better
imprinting into, or smoothing of, the external surface of the adhesive layer
820.
[0070] Either or both rollers 880, 884 may also be operated without heating or
cooling.
100711 The diameter of each of the rollers 880, 881, and whether each of them
are
heated, or cooled, or neither heated nor cooled, depends upon the specific
function
desired for the roller. Such variations are within the scope of the present
invention.
17
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[0072] Figure 8 shows an apparatus 801E for forming the composite cover
material
817. In an embodiment, the apparatus comprises an adhesive applicator 809 fed
from
a feeder (not shown) which gets a supply of adhesive from an adhesive supply
(not
shown). An advancing material 802 runs between rollers 880, 882, 883 and a
surface
890 such as a flat portion of a tenter frame. The rollers 880, 882, 883 may be
urged
toward the surface 890 by a spring, by gravity or by other means that will be
apparent
to persons skilled in the art.
100731 An adhesive layer 820 leaves the applicator 809 and falls upon the
first roller
880. As the first roller 880 rotates, the adhesive layer 820 comes into
contact with the
material 802. The positioning of the applicator 809 may be varied. In an
embodiment
where the adhesive forming the adhesive layer 820 is polypropylene, the
applicator
809 may be the die head of an extruder. In such an embodiment, the adhesive
has a
viscosity as it exits the extruder that forms a sheet of molten polypropylene.
In an
embodiment, the applicator 809 may be placed above the roller 880 such that it
contacts the roller before the material 802 (as shown); or at another location
where it
will still make contact with the roller 880 before it contacts the material
802. Such
variation is within the scope of this invention, and will be apparent to a
person of skill
in the art.
[0074] In an embodiment, the adhesive forming the adhesive layer 820 is
polypropylene. As the material 802 and the adhesive layer 820 pass between the
rollers 880, 882, 883 and the surface 890 they are urged together. As
discussed above,
each of the rollers 880, 882, 883 may be heated or cooled, or may be neither
heated
nor cooled. Also as discussed above, the rollers 880, 882, 883 may be of the
same
size, or of varying size. In an embodiment, the rollers 880 882, 883 are each
in the
range of 14" to 20". In an embodiment, the first roller 880 is in the range of
14" to
18
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20", while the second and third rollers 882, 883 are smaller than the first
roller 880,
and are in the range of 10" to 18". Selection of the diameters and thermal
characteristics of the rollers 880, 882, 883 may be to achieve desired
results.
100751 The composite sheet material 815 may be cut by cutter 816 to form the
composite cover material 817 with a non-porous backing.
[0076] Figure 9 shows an apparatus 801E for forming the composite cover
material 817. In an embodiment, the apparatus comprises an adhesive applicator
809,
a feeder and adhesive supply (not shown), rollers 850 and strip cutter 816.
After the
adhesive layer 820 leaves the applicator 809, but before it contacts the
material 802,
the rollers 850 smooth the adhesive layer 820 to form a smoothed adhesive
layer 851.
In an embodiment where the adhesive is polypropylene, although smoothed
adhesive
layer 851 may be cooler than it was leaving the applicator 809, it is still
not hardened
or set. Thus, after the smoothed adhesive layer 851 contacts the material 802,
it can
harden and set forming the composite sheet material 815. The composite sheet
material 815 may be cut by cutter 816 to form the composite cover material 817
with
a non-porous backing.
[0077] Figure 10 shows an apparatus 801F for forming the composite cover
material
817. In an embodiment, the apparatus comprises an adhesive applicator 809, a
feeder
and an adhesive supply (not shown), rollers 850, rollers 852 and strip cutter
816.
After the adhesive layer 820 leaves the applicator 809, but before it contacts
the
material 802, the rollers 850 smooth the adhesive layer 820 to form a smoothed
adhesive layer 851. In an embodiment where the adhesive is polypropylene,
although
smoothed adhesive layer 851 may be cooler than it was leaving applicator 809,
it is
still not hardened or set. After the smoothed adhesive layer 851 contacts the
material
802, the rollers 852 apply a compressive force compressing the smoothed
adhesive
19
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layer 851 and the material 802 together to form the composite sheet material
815.
The rollers 852 may also be used to uniformly imprint the smoothed adhesive
layer
851. The composite sheet material 815 may be cut by cutter 816 to form the
composite cover material 817 with a non-porous backing.
[0078] In an embodiment, the rollers 852 are heated to a temperature hotter
than the
temperature of smoothed adhesive layer 851. In an embodiment, the rollers 852
are
cooled to a temperature cooler than the temperature of the smoothed adhesive
layer
851. In an embodiment, the rollers 852 are neither heated nor cooled. In an
embodiment, one of the rollers 852 is heated while the other is cooled.
[0079] Figure 11 shows an apparatus 801G for forming the composite cover
material 817. In an embodiment, the apparatus comprises an adhesive applicator
809,
a feeder and an adhesive supply (not shown), three roller pairs 850, 855, 860
and
strip cutter 816. After the adhesive layer 820 leaves the applicator 809, but
before it
contacts the material 802, the roller pair 850 may smooth the adhesive layer
820 to
form a smoothed adhesive layer 851. In an embodiment the adhesive is
predominantly polypropylene, and although smoothed adhesive layer 851 may be
cooler than it was when leaving applicator 809, it is still not hardened or
set. After
the smoothed adhesive layer 851 contacts the material 802, the second roller
pair 852
applies a compressive force compressing the smoothed adhesive layer 851 and
the
material 802 together while at the same time imparting heat to the
combination. The
third roller pair 860 thereafter applies a compressive force compressing the
smoothed
adhesive layer 851 and the material 802 together, while it may, at the same
time, cool
them. It is believed that the heating by rollers 852 may aid in filling fill
interstitial
spaces or gaps within the material 802 with contacting side of the smoothed
adhesive
layer 851, and that the cooling by the second cooling rollers 860 may hasten
the
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setting of the smoothed adhesive layer. The resulting composite sheet material
815
may be cut by cutter 816 to form the composite cover material 817 with a non-
porous
backing.
[0080] Figure 12 shows a diagrammatic representation of an apparatus 900
suitable
for making laminated paint rollers in accordance with an embodiment of the
invention.
For ease of discussion in this application, the term "downstream" refers to
the
direction further along in the roller manufacturing process, or nearer the fly-
away
cutter 27, while the term "upstream" refers to the direction earlier in the
roller
manufacturing process, or further from the fly-away cutter 27.
[0081] Housing 22 supports mandrel 21. A cooler (not shown) can be used to
cool
the mandrel 21. In an embodiment, inner strip 23 is feed about a the mandrel
21, so it
winds helically. The term helically as used herein means oriented about a
mandrel 21
so as to permit the upstream edge of a given wind of a strip or cover material
to be in
closely-spaced or abutting relation with the downstream edge of the preceding
wind
of the strip. A lubricant such as 5% mineral oil may be applied to the inner
surface of
the inner strip 23 prior to winding on the mandrel 21.
[0082] The head 24 provides a layer of adhesive material 25 from a source of
such
material (not shown), the adhesive material 25 may be polypropylene or a
compound
predominantly made of polypropylene. The source of adhesive material 25 may be
an
extruder, or may be another source of adhesive material, such as a melter. The
head
24 may be any type of head appropriate for providing adhesive material 25 from
the
source, such as a nozzle or a die. Where the source of polypropylene adhesive
material 25 is an extruder, the head 24 is preferably a die.
[0083] In an embodiment a single head 24 supplies an adhesive layer 25 to the
outer
surface of inner strip 23 as it rotates around the mandrel 21. Although the
width of
21
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the adhesive layer may be varied, in an embodiment, the width the adhesive
layer 25
should substantially cover the outer surface of the inner strip 23. The width
of the
adhesive layer 25, however, may not completely cover the outer surface of the
inner
strip 23, or may be sufficient to excess adhesive over the amount required to
completely cover the outer surface of inner strip 23. A strip of composite
cover
material 17 is advanced about the mandrel 21 outside of the inner strip 23 and
adhesive layer 25. In an embodiment, composite cover material 817 comprises an
outer surface of pile and a smooth or uniformly imprinted inner surface or
backing
made of polypropylene or a compound predominantly made of polypropylene.
[0084] The edges of the composite cover material 817 may be offset from the
edges
of the inner strip 23 as the two are advanced along the mandrel 21. It is
believed that
the a stronger product is yielded from having an offset between the edge of
the
composite cover material 817 and the edge of the inner strip 23. An offset of
between
about one-quarter and three-quarters of the width of the inner strip 23 is
found to
achieve acceptable results. Good results may be achieved by having an offset
of
about one-half of the width of the inner strip 23.
[0085] Prior to the hardening and setting of the adhesive material 25, an
inwardly
compressive force applies pressure to the outer pile surface of the composite
cover
material 817, imparting inward forces on the component parts, thus laminating
the
composite cover material 817 and the inner strip 23 as the adhesive layer 25
sets. The
continuous roller 929 is thereby formed about the mandrel 21.
[0086] In an embodiment, the inwardly compressive force is a helical belt
system
formed from rollers 28a, 28b, and a belt 28. In addition to compressing the
component parts and forming the roller, the belt 28 advances the thus-formed
endless
roller 929 along the mandrel 21 and continuously rotates the endless roller,
thereby
22
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also advancing the inner strip 23 and the composite cover material 817 around
and
downstream on the mandrel 21.
[0087] The endless roller 929 may be cut by the fly-away saw 27, into lengths
after
it has sufficiently set. The fly-away saw 27 may be used to cut endless roller
929 into
paint-roller sized lengths ready for finishing, or more typically into sticks
926 of a
fixed length, such as 65", that may be further cut and finished into paint-
rollers.
[0088] It is within the scope of the invention to apply the adhesive layer 25
to the
outer surface of the inner strip 23, the inner smooth or imprinted surface of
the
composite cover material 817, or simultaneously to the smooth or imprinted
inner
surface of the composite cover material 817 and the outer surface of the inner
strip 23,
in any event, such that the adhesive layer 25 is sandwiched between the inner
strip 23
and the composite cover material 817.
[0089] In an embodiment, the head 24 is a die head, and the adhesive layer 25
is
predominantly or entirely from polypropylene. An extruder (not shown) forces
the
thermoplastic through the head 24, thereby dispensing a molten adhesive layer
25.
[0090] The present invention creates a laminated paint roller from a single
strip of
polypropylene 23 (or made predominantly of polypropylene), a single strip of
composite cover material 817, and a single die head 24 that produces a layer
of
adhesive material 25 that is approximately as wide the width of the inner
strip 23.
The simple manufacturing line produces a laminated paint roller, with a low
hoop
force, which does not suffer from being out of round at its ends after being
finished
and cut. The lower hoop force can be demonstrated by slicing the a finished
laminated paint roller lengthwise, and observing that it does not tend to open
flat, but
rather tends to keep its round shape as would an extruded plastic tube. .
23
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100911 In an embodiment: the inner strip 23 has a width of 2 3/4 inches, and a
thickness of between about 0.010" and 0.030"; the composite cover material 817
has
approximately the same thickness, not counting the pile height, and a width of
2 7/8
inches; and the adhesive layer may be between 0.010 inches and 0.030 inches.
Thicknesses selected from the higher values in these ranges will provide paint
rollers
that have a more rigid feel, while thicknesses selected from the lower values
in the
ranges will provide a paint roller that has a softer feel. It is within the
scope of the
invention to independently select each of the thicknesses from these ranges.
The
width and thickness of the inner strip 23, and the width, non-pile thickness
and pile
thickness of the composite cover material 817 may be those that are
appropriate for
manufacture of the desired roller. For example, a typical high quality
laminated roller
having a 1.5-inch diameter core and a 75-wall can be manufactured with the
following
materials:
Width Non-pile Thickness Pile Thickness
Inner Strip 2.750" 0.025" N/A
Adhesive Layer 2.750" 0.020" N/A
Composite cover material 2.875" 0.015" Desired
Pile
100921 As used herein, the term "wall" or "mil" means thickness in thousandths
of
an inch. Such widths and thickness and the methods of determining them will be
apparent to one of skill in the art; almost infinite variation is possible
depending upon
the characteristics of the desired roller.
100931 It is presently believed that the lamination process of the present
invention
will produce commercially acceptable rollers having a 1.5-inch diameter core
manufactured with any of the following combinations of materials:
24
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Width Non-pile Thickness Pile Thickness
Inner Strip 2.750" 0.005" N/A
Adhesive Layer 2.750" 0.010" N/A
Composite cover material 2.875" 0.005" Desired
Pile
[0094] or
Width Non-pile Thickness Pile Thickness
Inner Strip 2.750" 0.010" N/A
Adhesive Layer 2.750" 0.020" N/A
Composite cover material 2.875" 0.015" Desired
Pile
[0095] or
Width Non-pile Thickness Pile Thickness
Inner Strip 2.750" 0.015" N/A
Adhesive Layer 2.750" 0.015" N/A
Composite cover material 2.875" 0.010" Desired
Pile
[0096] Variations of this type with respect to the present invention will be
apparent
to one skilled in the art. The amount of adhesive required is expected to be
less than
may be required in a process bonding a polypropylene strip to cover material
such as
material 802 (Figure 1, et seq.) This is expected because the adhesive layer
bonds
only two smooth (or uniform) non-porous layers rather than a smooth layer with
a
porous material.
[0097] In another embodiment (not shown), the composite cover material 817 can
be
directly fed from a machine producing it (e.g., the apparatus 801B in Figure
4) into a
paint roller manufacturing apparatus 900 for making laminated paint rollers.
It is
within the scope of the invention to combine multiple composite cover material
817
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strips, such as, for example, using a fly-away to cutter to cut the composite
cover
material 817 into fixed-length sections, and using a fastening means to attach
the ends
of such fixed-length sections as the composite cover material 817 is consumed
by the
manufacturing of paint rollers using a paint roller manufacturing apparatus
900. In
this manner, depending on the relative speed of the paint roller manufacturing
apparatus 900, the machine producing the composite cover sheet 815 (see Figure
4),
the manufactured width of composite cover sheet 815 (see Figure 4) and the
desired
width of composite cover material 817 (see Figure 4), multiple paint roller
manufacturing apparati 900 can be supplied from one apparatus 801B making
composite cover material 817.
100981 Figure 13 shows a diagrammatic representation of an apparatus 950
suitable
for making laminated paint rollers in accordance with an embodiment of the
invention.
In an embodiment, the apparatus comprises a first adhesive applicator 809
having a
feeder and an adhesive supply (not shown), rollers 880, 880 and a cutter 816.
The
composite cover material 817 is formed using a supply of pile material 802,
having a
pile side and a fabric side, and suitable for use manufacturing a paint roller
cover.
The pile material 802 is laid flat for processing. The material 802 may be
sheared
(not shown) on the pile side to attain a desired pile height prior to
processing by the
machine 950. The material 802 can be in any convenient width. In an
embodiment,
material 802 has a width of approximately 32".
[0099] In an embodiment, an adhesive layer 820 is applied to the fabric side
of the
material 802 by the adhesive applicator 809. The adhesive supply (not shown)
supplies the adhesive to the applicator 809 by a feeder (not shown). In an
embodiment, the adhesive is made predominantly or entirely from polypropylene
resin, the adhesive applicator may be an extruder comprising a die head 809.
26
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1001001 After the adhesive layer 820 is applied to the fabric side of the
material 802, a compressive force urging the adhesive layer and the material
802
together is imparted by rollers 880, 881. The upper roller 880 smoothes and/or
imprints the exterior surface of the adhesive layer forming a smoothed or
imprinted
layer 851. The thus-formed composite sheet material is then permitted to cool
and set.
Such cooling and setting can be hastened by a cooling system (not shown) which
can
impart cooling to the combined sheet material 815 by any method, including,
without
limitation, a cooled roller or the flow of cool air or other gas or fluids. In
an
embodiment, the adhesive layer 820 comprises predominantly or entirely
polypropylene. The fibers in the material 802 are further held in place by the
adhesive layer 820 after it has cooled and set.
[00101] Either before or after the applied adhesive layer 820 is
completely set,
the composite sheet material 815 is advanced toward a cutter 816. The cutter
816 is
used to cut the composite sheet material into strips of composite cover
material 817
having a pile side and a smooth and/or imprinted side predominantly or
entirely made
of polypropylene. In an embodiment, the strips of composite cover material are
each
approximately 2 7/8 inches wide corresponding to a width of a cover strip that
may be
then used to manufacture paint rollers.
[00102] In an embodiment, eleven strips of composite cover material 817
each
being 2 7/8 inches wide are formed from a width of approximately 32" of the
material
802. This width allows for a relatively small amount of waste on each side of
the
composite sheet material 815 as it is cut by the cutter 816 and thereby
becomes
composite cover material 817.
[00103] Although the composite cover material 815, or the strips of
composite
cover material 817 could be spooled and cut (not shown) for transportation to
another
27
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site or another machine performing a manufacturing process for laminated paint
rollers in accordance with the present invention, in an embodiment, the
composite
cover material 817 is fed directly to a mandrel 21. Housing 22 supports the
mandrel
21. A cooler (not shown) can be used to cool the mandrel 21. In an embodiment,
an
inner strip 23 is made from or predominantly made from polypropylene. The
inner
strip 23 is feed about a the mandrel 21 so it winds helically.
[00104] The head 24 provides a layer of adhesive material 25 from a source
of
such material (not shown). The layer of adhesive material 25 is preferably
polypropylene or made predominately from polypropylene. The polypropylene
material is preferably supplied by an extruder (not shown) to head 24 that is
a die.
1001051 In an embodiment a single head 24 dispenses a layer of adhesive
material 25 to the outer surface of inner strip 23 as it rotates around the
mandrel 21.
Although the width of the layer of adhesive material may be varied, in an
embodiment,
the width the layer of adhesive material 25 should substantially cover the
outer
surface of the inner strip 21. The width of the layer of adhesive material 25,
however,
may not completely cover the outer surface of the inner strip 21, or may in an
embodiment be sufficient to provide excess adhesive over the amount required
to
completely cover the outer surface of inner strip 21. The strip of composite
cover
material 817 is advanced from the cutter 816 toward, and then about the
mandrel 21
outside of the inner strip 23 and the layer of adhesive material 25.
1001061 The edges of the composite cover material 817 may be offset from
the
edges of the inner strip 23 as the two are advanced along the mandrel 21. It
is
believed that the a stronger product is yielded from having an offset between
the edge
of the composite cover material 817 and the edge of the inner strip 23. An
offset of
between about one-quarter (as shown) and three-quarters of the width of the
inner
28
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strip 23 is found to achieve acceptable results. Good results are achieved by
having an
offset of about one-half of the width of the inner strip 23.
[00107] Prior to the hardening and setting of the layer of adhesive
material 25,
an inwardly compressive force applies pressure to the outer surface of the
composite
cover material 817, imparting inward forces on the component parts, thus
laminating
the composite cover material 817 and the inner strip 21 as the adhesive layer
25 sets.
The continuous roller 929 is thereby formed about the mandrel 21.
[00108] In an embodiment, the inwardly compressive force is a helical belt
system formed from rollers 28a, 28b, and a belt 28. In addition to compressing
the
component parts and forming the roller, the belt 28 advances the thus-formed
endless
roller 929 along the mandrel 21 and continuously rotates the endless roller,
thereby
also advancing the inner strip 23 and the composite cover material 817 around
and
downstream on the mandrel 817.
[00109] The endless roller 929 may be cut by the fly-away saw 27, into
lengths after it has sufficiently set. The fly-away saw 27 may be used to cut
endless
roller 929 into paint-roller sized lengths ready for finishing, or more
typically into
sticks 926 of a fixed length, such as 65", that may be further cut and
finished into
paint-rollers.
100110] It is within the scope of the invention to apply the adhesive
layer 25
to the outer surface of the inner strip 23 (shown), the inner surface of the
composite
cover material 817 not shown, or simultaneously to the inner surface of the
composite
cover material 817 and the outer surface of the inner strip 23, in any event,
such that
the adhesive layer 25 is sandwiched between the inner strip 23 and the
composite
cover material 817.
29
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[00111] Figure 14 shows a diagrammatic representation of an apparatus 410
suitable for making laminated paint rollers in accordance with another
embodiment of
the invention. Housing 22 supports mandrel 21. A cooler (not shown) can be
used to
cool the mandrel 21. In an embodiment, inner strip 23 is feed about a the
mandrel 21,
so it winds helically. A lubricant such as 5% mineral oil may be applied to
the inner
surface of the inner strip 23 prior to winding on the mandrel 21. Second strip
423 is
feed about a the mandrel 21 and inner strip 23, so it winds helically, and in
offset
relation to inner strip 23.
[00112] The head 424 provides a layer of adhesive material 425 from a
source
of such material (not shown), the adhesive material 425 preferably is or
comprises
predominately polypropylene. The source of adhesive material 425 is preferably
an
extruder, but may be any source of adhesive material including a melter. The
head
424 may be any type of head appropriate for providing adhesive material 425
from the
source, such as a nozzle or a die. Where the source of the adhesive material
425 is an
extruder, the head 424 is preferably a die.
[00113] In an embodiment a single head 424 supplies an adhesive layer 425
to
the outer surface of portions of two adjacent winds of inner strip 23 and to
all or
substantially all of one wind of second strip 423 as they rotate (helically)
around the
mandrel 21. The width of the adhesive layer may be varied, thus, in an
embodiment,
the width the adhesive layer 425 should substantially cover the outer surface
of the
second strip 423 and should cover approximately the same width on the outer
surface
of inner strip 23, albeit on two adjacent winds of inner strip 23. The width
of the
adhesive layer 425, however, may be insufficient to cover, or may result in
some
excess adhesive over the amount required to completely cover the outer
surfaces of
the strips 23, 423 as discussed. A strip of composite cover material 817
having a non-
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porous backing is advanced about the mandrel 21 outside of the second strip
423 and
adhesive layer 425. In an embodiment, the generally non-porous backing of the
composite cover material is made of, or made predominantly of, polypropylene.
In an
embodiment, the backing of the composite cover material 817 the may be
generally
smooth or may have a uniform imprint thereon.
[00114] The edges of the composite cover material 817 may be offset from
the
edges of the second strip 423 as they are advanced (helically) along the
mandrel 21.
It is believed that the a stronger product is yielded from having an offset
between the
edges of the non-porous layers, i.e., the composite cover material 817, the
inner strip
23 and the second strip 423. An offset of between about one-quarter and three-
quarters of the width of the inner strip 23 is found to achieve acceptable
results. Good
results can be achieved by having an offset of about one-third of the width of
the inner
strip 23 between each of the aforementioned non-porous layers.
[00115] Prior to the hardening and setting of the adhesive material 425,
an
inwardly compressive force applies pressure to the outer surface of the
composite
cover material 817, imparting inward forces on the component parts, thus
laminating
the composite cover material 817, the second strip 243 and the inner strip 23
as the
adhesive layer 425 sets. The continuous roller 20 is thereby formed about the
mandrel 21.
[00116] In an embodiment, the inwardly compressive force is a helical belt
system formed from rollers 28a, 28b, and a belt 28. In addition to compressing
the
component parts and forming the roller, the belt 28 advances the thus-formed
endless
roller 20 along the mandrel 21 and continuously rotates the endless roller,
thereby also
advancing the strips 23, 423 and the composite cover material 817 around and
downstream on the mandrel 21.
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Atty. Docket No.: 043829.012000 PATENT
[00117] The endless
roller 20 may be cut by the fly-away saw 27, into lengths
after it has sufficiently set. The fly-away saw 27 may be used to cut endless
roller 20
into paint-roller sized lengths ready for finishing, or more typically into
sticks of a
fixed length, such as 65", that may be further cut and finished into paint-
rollers.
[00118] It is
possible, without departing from the invention, to use more than
one head to deposit the layer of adhesive material 25 between the composite
cover
material 817 and the second strip 423, and between the second strip 423 and
the inner
strip 23. Regardless of the width or number of heads, in order to produce a
quality
laminated continuous roller, pressure must be applied inwardly upon the
composite
cover material 817 before the layer of polypropylene is permitted to harden
and set.
[00119] A benefit of
certain embodiments of the instant invention is that a
laminated roller can be produced using a narrow head and one strip and a
composite
cover material with a non-porous backing, and more specifically, with one non-
porous
polypropylene strip and one strip of a composite cover material having a non-
porous
backing. It is expected that such a process will be easy and cost efficient to
operate,
and will likely be able to produce rollers quickly. Another benefit of certain
embodiments of the present invention is that it can create a laminated paint
roller
using a narrow head and one strip and a composite cover material with a non-
porous
backing without the rollers being out-of-round at its edges when they are
finished and
cut.
1001201 A benefit of
certain embodiments of the instant invention is that it can
create a high quality laminated roller by using a single head, two thin strips
of
polypropylene and a composite cover material with a non-porous backing.
[00121] The above
embodiments and preferences are illustrative of the present
invention. It is neither necessary, nor intended for this patent to outline or
define
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CA 02664974 2009-04-30
Atty. Docket No.: 043829.012000 PATENT
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.
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