Methods and component parts for manufacturing foam paint rollers

Abstract

Described is a paint roller cover strip for use in manufacturing paint rollers. The paint roller cover strip being formed from a length of foam base shaped in a trapezoidal cross section with two parallel sides, the foam base having a scrim affixed along the length of the narrower one of the two parallel sides. The paint roller cover optionally comprising a microfiber lamination along the length of the wider of the two parallel sides. Also described are methods of making a paint roller having a foam cover. On or two strips of material are helically advanced about a mandrel, a layer of adhesive is placed on the strip(s), and a cover material having the trapezoidal cross section is helically wound about the adhesive. Prior to permitting the layer of adhesive to set, the cover material having the trapezoidal cross section is helically wrapped around the outer strip, and an inward compressive force is applied upon the cover material urging the cover material and the strip(s) toward the mandrel, forming the paint roller having a foam cover. The materials can be assembled in a continuous manufacturing process and the foam base has the shape of a trapezoid with one or more angles sufficient to eliminate gaps between the outer surface of successive helical winds on a finished paint roller.

1 . A method for continuously producing a multi-strip laminate paint roller having a foam cover, the method comprising the steps of:
 helically advancing an inner strip and an outer strip of material about a mandrel in offset relation;   applying a layer of adhesive between the two strips and on the outer surface of the outer strip;   prior to permitting the layer of adhesive to set, wrapping a cover material comprising a foam base, the foam base having a trapezoidal cross section, around the outer strip and applying a compressing force upon the cover material urging the cover material and the two strips toward the mandrel, thereby creating the continuous multi-strip laminated paint roller having a foam cover;   wherein the foam base has an inner surface and an outer surface, and wherein the method further comprises a step of extruding a layer of polypropylene such that it is in molten form when applied onto the inner surface of the foam base prior to wrapping the cover material about the wound strip and over the layer of adhesive.   
     
     
         2 . The method for continuously producing a multi-strip laminate paint roller having a foam cover claimed in  claim 1 , wherein the foam base has a inner surface and an outer surface, the width of the inner surface being smaller than the width of the outer surface, and wherein the cover material further comprises scrim bonded to the inner surface of the foam base. 
     
     
         3 . The method for continuously producing a multi-strip laminate paint roller having a foam cover claimed in  claim 2 , wherein the cover material further comprises microfiber lamination on the outer surface of the foam base. 
     
     
         4 . The method for continuously producing a multi-strip laminate paint roller having a foam cover claimed in  claim 1 , wherein the foam base has a inner surface and an outer surface, the width of the inner surface being smaller than the width of the outer surface, wherein the cover material further comprises microfiber lamination on the outer surface of the foam base. 
     
     
         5 . The method for continuously producing a multi-strip laminate paint roller having a foam cover claimed in  claim 1 , wherein
 the trapezoidal cross section has one pair of parallel sides, and one pair of non-parallel sides, and   the one pair of non-parallel sides has a perpendicular side and a non-perpendicular side,   the perpendicular side being perpendicular to the pair of parallel sides, and   the non-perpendicular side is not perpendicular to the one pair of parallel sides.   
     
     
         6 . The method for continuously producing a multi-strip laminate paint roller having a foam cover claimed in  claim 5 , wherein
 the one pair of parallel sides have a outer side and an inner side, and   the outer side is wider than the inner side, and   the non-perpendicular side is angled at between 45 and 80 degrees with respect to the outer side.   
     
     
         7 . The method for continuously producing a multi-strip laminate paint roller having a foam cover claimed in  claim 6 , wherein the non-perpendicular side is angled at between 50 and 55 degrees with respect to the outer side. 
     
     
         8 . A method of making a paint roller having a foam cover, comprising the steps of:
 helically winding a strip of material around a mandrel so as to form a helically wound strip;   advancing the wound strip along the mandrel;   applying a layer of adhesive onto an outer surface of the wound strip; and   helically wrapping a strip of cover material comprising a foam base, the foam base having a cross section of a trapezoid, 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;   wherein the foam base has an inner surface and an outer surface, and wherein the method further comprises a step of extruding a layer of polypropylene such that it is in molten form when applied onto the inner surface of the foam base prior to helically wrapping the cover material about the wound strip and over the layer of adhesive.   
     
     
         9 . The method of making a paint roller having a foam cover claimed in  claim 8 , wherein the foam base has an inner surface and an outer surface, the width of the inner surface being smaller than the width of the outer surface, and wherein the cover material further comprises scrim bonded to the inner surface of the foam base. 
     
     
         10 . The method of making a paint roller having a foam cover claimed in  claim 9 , wherein the cover material further comprises microfiber lamination on the outer surface of the foam base. 
     
     
         11 . The method of making a paint roller having a foam cover claimed in  claim 8 , wherein the foam base has a inner surface and an outer surface, the width of the inner surface being smaller than the width of the outer surface, wherein the cover material further comprises microfiber lamination on the outer surface of the foam base. 
     
     
         12 . The method of making a paint roller having a foam cover claimed in  claim 8 , wherein
 the trapezoidal cross section has one pair of parallel sides, and one pair of non-parallel sides,   the one pair of non-parallel sides has a perpendicular side and a non-perpendicular side,   the perpendicular side being perpendicular to the pair of parallel sides; and   the non-perpendicular side not being perpendicular to the one pair of parallel sides.   
     
     
         13 . The method of making a paint roller having a foam cover claimed in  claim 12 , wherein
 the one pair of parallel sides have a outer side and an inner side, and   the outer side is wider than the inner side, and   the non-perpendicular side is angled at between 45 and 80 degrees with respect to the outer side.   
     
     
         14 . The method of making a paint roller having a foam cover claimed in  claim 13 , wherein the non-perpendicular side is angled at between 50 and 55 degrees with respect to the outer side. 
     
     
         15 . A paint roller cover strip for use in manufacturing paint rollers, the paint roller cover strip comprising:
 a length of foam base having a trapezoidal cross section, the foam base having an outer side, an inner side a perpendicular side and a non-perpendicular side, wherein the outer side wider than the inner side, the perpendicular side is perpendicular with the outer side and the inner side and the non-perpendicular side is not perpendicular with the outer side or the inner side; and   a length of scrim affixed along the length of the inner side of the foam base.   
     
     
         16 . The paint roller cover strip for use in manufacturing paint rollers claim in  claim 15 , further comprising a microfiber lamination on the outer surface of the foam base. 
     
     
         17 . The method of making a paint roller having a foam cover claimed in  claim 8 , wherein the foam base has an inner surface and an outer surface, and wherein the cover material further comprises a layer of polypropylene bonded to the inner surface of the foam base. 
     
     
         18 . (canceled) 
     
     
         19 . The method of making a paint roller having a foam cover claimed in  claim 8 , wherein the foam base has an inner surface and an outer surface, and wherein the cover material further comprises a layer of fiberglass bonded to the inner surface of the foam base. 
     
     
         20 . The method of making a paint roller having a foam cover claimed in  claim 8 , wherein the foam base has an inner surface and an outer surface, and wherein the cover material further comprises a layer of polyester bonded to the inner surface of the foam base. 
     
     
         21 . The method of making a paint roller having a foam cover claimed in  claim 8 , wherein the foam base has a cross section of an isosceles trapezoid. 
     
     
         22 . The method of making a paint roller of  claim 8 , wherein said step of extruding the layer of polypropylene comprises a step of extruding the layer of polypropylene directly onto the inner surface of the foam base. 
     
     
         23 . The method of making a paint roller of  claim 1 , wherein said step of extruding the layer of polypropylene comprises a step of extruding the layer of polypropylene directly onto the inner surface of the foam base.