Paint roller with integrated core and cover and method and apparatus for production of same

Abstract

An apparatus and method for the production of a thermoplastic tubular structure is disclosed. The apparatus comprises a stationary mandrel, a first and second feeder for feeding a first and a second strip to a mandrel at a first location and second location respectively, and a third feeder for feeding a cover strip to the mandrel at a third location, the third location being downstream of the second location. A transport system adapted to wind and advance the strips as they are being fed to the mandrel is used to helically wind the fed strips around the mandrel. A head for dispensing a width of a liquefied thermoplastic material is also disclosed. The head is oriented to dispense the width of the liquefied thermoplastic material on at least part of a winding of the first strip and part of a winding of the second strip. A cutter is used for cutting the thermoplastic tubular structure into predetermined sizes.

Description

[0001] This invention pertains to a method and apparatus for making paint rollers of the type used for applying paint to walls and the like. More specifically, the invention pertains to a method and apparatus for making paint rollers having thermoplastic (and preferably polypropylene) cores that are formed in a single-step 1G3 continuous process.Prior Art[0002] Paint rollers are widely used by professionals and amateurs for applying paint to walls, ceilings, and other surfaces. Typically the roller is used with an applicator having a handle terminating in a rotatable member to which the roller is secured. The roller itself generally comprises a paint absorbing and spreading cover affixed to a generally cylindrical core. The covers may be made from materials such as wool or polyester, and other cover materials that are well known in the art.[0003] Years ago paint rollers were manufactured using a paper or chipboard core. Some manufacturers still make such paper core paint rollers. Th...

AI Technical Summary

Benefits of technology

[0011] It is an object of the present invention to provide an improved and less complex method for forming a reusable paint roller comprising a laminated core and a fully integrated cover.

[0012] It is another object of the present invention to provide a simplified process for manufacturing paint rollers having a laminate core formed from two polypropylene strips.

[0013] It is another object of the present invention to provide a method and apparatus for the manufacture high quality paint rollers in an extremely compact assembly area.

Problems solved by technology

Such cores, however, and the paint rollers made out of them, would often fall apart during use or during cleaning, especially during cleaning with paint solvents (such as, for example, turpentine or mineral spirits, such paint solvents are well known in the art).

The obvious drawback of reusable cores formed in this manner is that they require a long assembly line, due to the need of a heater, and because the phenolic must be heated to a predetermined temperature, there is an obvious trade off between the number of heater stages and the speed of the line.

Additionally, while the resulting rollers are termed reusable because they do not separate when placed in paint solvents, any prolonged exposure to such solvents, does result in breakdown of the paint roller and / or separation of the layers.

Moreover, the manufacturing process for making phenolic core rollers is environmentally unfriendly.

For one, while prior art techniques use rolls of, e.g., chipboard or paper, the Garcia process requires preformed thermoplastic tubular cores which are considerably bulkier than rolls, more expensive to transport, and more difficult to handle.

Another drawback is the anticipated speed limit of the Garcia process dictated by the necessity that the heater, which advances along the core just in front of the fabric strip, move slow enough to insure softening of the polypropylene core, in the absence of which the fabric cover will not bond.

In addition, the application of direct heat to the preformed polypropylene core presents manufacturing hazards from the heat source and from the fumes and / or chemicals released during the heating process.

As a result, the process was difficult to set up, and required many continuous adjustments in its operation.

The resulting roller, however, is somewhat inferior- More specifically, a defect present in all such rollers, manifest itself as a weak point, often sticking out from the ends of a cut roller, or making the ends of the cut roller appear "out of round."

The application of fluidized polypropylene to a mandrel has concomitant complications in synchronization and in the problems inherent in working with consistency of application of a fluidized layer in forming a polypropylene core.

It is, however, believed that no such system has gone into practical use, possibly because of the difficulties associated with controlling the shrinkage variation which inevitably occurs in the matching of what is essentially a through heated core blank or strip blank and a cold (i.e., room temperature, for example) pile fabric.

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