Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor
Reexamination Certificate
1994-11-22
2001-03-20
Mayes, Curtis (Department: 1734)
Adhesive bonding and miscellaneous chemical manufacture
Methods
Surface bonding and/or assembly therefor
C156S188000, C156S192000, C156S195000
Reexamination Certificate
active
06203648
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates generally to the manufacture of composite thermoplastic products and more specifically to an improved method of manufacturing paint rollers and the product produced thereby. More particularly, the present invention relates to methods for conditioning the surface of a thermoplastic tube to receive a variety of adhesives suitable for adhering a thermoplastic compatible fabric strip to the thermoplastic tube which, for purposes of illustration, will be a thermoplastic paint roller core.
BACKGROUND OF THE INVENTION
Currently in the manufacture of paint rollers, strips of pile fabric are used which are wound around a plastic or cardboard tube or core. More specifically, among the devices currently employed is a type of machine illustrated in Spanish Utility Model No. 293.980, which includes a rotating cylinder over which the cardboard or plastic tube is mounted, and onto which a strip of pile fabric is applied through a guide oriented obliquely and situated on and carried by a carriage which is mounted in fixed fashion over a sliding apparatus. The bonding of the tube and strip of pile fabric is accomplished either by the application of adhesive material in the case of a cardboard tube or, in the case of a plastic tube, gas flame heating by which gas burners heat the tube to bond it to the strip of pile fabric, thereby forming a single body.
In the first case, i.e., where conventional adhesive is used as the means of bonding between the cardboard tube and strip of pile fabric, the manufacture of paint rollers presents significant problems, all resulting from the difficulty of applying the adhesive uniformly, plus the fact that very specific adhesives must be used to produce the bond between the cardboard tube and the strip of pile fabric so that, when the rollers are used, these adhesives do not separate due to the solvents contained in the paint and in the fluids used to clean the roller.
These problems considerably increase the cost of manufacturing paint rollers because of the cost of the adhesives and the time needed for the adhesives to harden.
The second system mentioned above, though a significant advance in the art over what had been earlier used, does present certain problems, all resulting from the increased safety costs required by installations that use gas as a fuel source for the gas flame heating. Further, the heating of the plastic tube can produce undesirable products of combustion and high noise, both effects being potentially harmful for the operators and expensive to eliminate; all of this therefore has the result of raising the cost of the final product.
SUMMARY OF THE INVENTION
The object of the present invention is a procedure for manufacturing paint rollers and the product produced thereby, of the type in which a strip of pile fabric is wound helically over a plastic base structure, such as a tube or core, with a thermoplastic adhesive substance interposed there-between, with the result that the strip of pile fabric and the plastic base structure form a single, integral composite end product.
Specifically, an intermediate thermoplastic adhesive substance is applied onto a plastic tube in the area adjacent to the area of the winding of a fabric strip on the tube, the adhesive substance being heated. If the adhesive substance is molten it may be applied through a nozzle connected to a reservoir where the thermoplastic adhesive is heated, which nozzle is mounted on a carriage on which the pile fabric strip applicator is also located. Suitable adhesives include polypropylene, polyethylene, a mixture of polypropylene and polyethylene, any of a variety of polyamides, polyolefin based compounds, polyester based compounds, polyurethane based compounds, polyamide “hot melt” adhesives sold under the designations HB Fuller Hot Melt 6542-PEL and HL2021, Hot Melt 2167PL and other suitable adhesives compatible with a thermoplastic tube, such as a polypropylene tube, a polyethylene tube, a nylon tube, or a combination of polypropylene and polyethylene, and resistant to the anticipated solvents found in the paint, stain, shellac or varnish and the solvents used to clean the roller. The anticipated solvents include turpentine, mineral spirits, aliphatic compounds, ketones or aromatics in petroleum based solvents including naphtha, chlorinated hydrocarbons, alcohol based solvents, acetone, toluene and water including soapy water and ammoniated water.
Another object of the present invention is the provision of a paint roller which is structurally integral as a result of the bonding of the thermoplastic adhesive with the strip of the pile fabric and the plastic tube.
REFERENCES:
patent: 2647300 (1953-08-01), Thomas et al.
patent: 3226799 (1966-01-01), Grodberg et al.
patent: 3457130 (1969-07-01), Morrison
patent: 4197348 (1980-04-01), Townsend
patent: 4514245 (1985-04-01), Chabrier
patent: 5137595 (1992-08-01), Garcia
patent: 5195242 (1993-03-01), Sekar
Alvarez Garcia Jaime
Barton William W.
Polzin Bruce C.
Shehow Kenneth L.
Foley & Lardner
Mayes Curtis
Newell Operating Company
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