Metal working – Method of mechanical manufacture – Roller making
Reexamination Certificate
1999-02-08
2001-03-13
Rosenbaum, I Cuda (Department: 3726)
Metal working
Method of mechanical manufacture
Roller making
C029S895210
Reexamination Certificate
active
06199279
ABSTRACT:
FIELD OF THE INVENTION
This invention relates generally to methods and apparatus for making roller covers by bonding a roller fabric to a thermoplastic tubular form using an intermediate epoxy adhesive.
BACKGROUND OF THE INVENTION
It is generally known to make paint roller covers with thermoplastic cores. Making the cores out of a thermoplastic material has the advantage that the cores will not delaminate even after prolonged soaking as in the case with most cardboard cores. However, it may still be a problem with the roller fabric prematurely separating from thermoplastic tubular forms, either because the adhesive does not provide a very effective bond between the fabric backing and tubular forms, or the adhesive does not hold up after prolonged soaking in certain types of solvents.
One type of adhesive that has been successfully used in the past to adhere the roller fabric to paperboard cores reinforced with a phenolic resin is a two component thermosetting or epoxy adhesive. However, problems have been encountered in obtaining an effective bond between the fabric backing and thermoplastic tubular forms using an epoxy adhesive.
SUMMARY OF THE INVENTION
This invention relates to paint roller covers and method and apparatus for making same by bonding a fabric to tubular forms of thermoplastic core material using an intermediate two component thermosetting adhesive.
In accordance with one aspect of the invention, the exterior surface of the tubular forms of thermoplastic core material is treated prior to the application of the epoxy adhesive to increase the surface tension and polarity of the exterior surface rendering the core material more chemically receptive to adhesion, wetting and bonding.
In accordance with another aspect of the invention, the surface treatment of the tubular forms of thermoplastic core material may include chemical, electronic, plasma or flame treatment.
In accordance with another aspect of the invention, the preferred method of surface treatment is electronic corona discharge, which involves subjecting substantially the entire exterior surface of the tubular core material to a high frequency bombardment of high voltage sparks to alter the molecular structure of the exterior core surface thereby increasing the interaction between the exterior core surface and the adhesive subsequently applied thereto.
In accordance with another aspect of the invention, the exterior surface of the tubular core material is preheated to a temperature of between about 150 to 180° F. immediately prior to the surface treatment step to further enhance the adhesion integrity of the adhesive with the core surface.
In accordance with another aspect of the invention, the ratio of the resin and catalyst that comprise the adhesive is formulated to allow sufficient time (for example 20 to 40 seconds) for the adhesive mixture to penetrate the interstices of the fabric backing before the adhesive mixture cures and sets in order to permanently bond the fabric backing to the exterior surface of the tubular core material.
In accordance with yet another aspect of the invention, the fabric backing is preferably preheated immediately prior to helically winding the fabric onto the plastic core material.
In accordance with still another aspect of the invention, after the adhesive and fabric have been applied to the core material, the fabric covered core material may be further heated using controlled radiant or forced convection heating to further promote the adhesive curing process and then subsequently cooled to normalize the condition of the fabric covered core material prior to cutting the fabric covered core material into a plurality of individual lengths of fabric covered core material.
These and other objects, advantages, features and aspects of the present invention will become apparent as the following description proceeds.
To the accomplishment of the foregoing and related ends, the invention, then, comprises the features hereinafter fully described and particularly pointed out in the claims, the following description and the annexed drawings setting forth in detail a certain illustrative embodiment of the invention, this being indicative, however, of but one of the various ways in which the principles of the invention may be employed.
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Gerardo Serafin J.
Humphrey Dennis D.
Purdy Thomas G.
Cuda Rosenbaum I
Renner , Otto, Boisselle & Sklar, LLP
The Wooster Brush Company
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