Methods for manufacturing a paint roller with grooved substrate

Abstract

A method for improving strength of the finished product in paint roller manufacturing processes and other continuous processes for producing tubular goods from polymers. The method utilizes a substrate such as a polypropylene strip with grooves on its surface. The grooved substrate is fed onto a mandrel to form a tube. Adhesive is applied upon the grooved surface of the grooved substrate. A cover may be applied about the tube, and the resulting product is then cut into finished-size paint rollers. The hardened adhesive in the grooves may operate to reduce the hoop-force which would otherwise tend to unwind the wound substrate. The method in certain embodiments provides a reduction in cost and weight of the finished product.

What is claimed is: 
     
       1. A method for producing a paint roller comprising the steps of:
 grooving a surface of a substrate, thereby forming a plurality of grooves on the surface,
 wherein an overage is removed while grooving the surface, and 
 wherein the removal of the overage results in a reduction in the weight of the paint roller; 
 
 collecting the overage, wherein the overage is reusable in a subsequent implementation of the method; 
 feeding the grooved substrate about a mandrel; 
 applying a cover about the grooved substrate, thereby creating the paint roller. 
 
     
     
       2. The method of  claim 1 , wherein the cross-section of at least one groove of the plurality of grooves is a section of a shape selected from the group consisting of circle, elliptic, oval, quadrilateral, square, rectangle, rhombus, trapezoid, kite, diamond, triangle, pentagon, hexagon, heptagon, octagon. 
     
     
       3. The method of  claim 1 , wherein the step of grooving the surface of the substrate comprises of the step of:
 feeding the substrate along a plurality of knives/drill bits, wherein the surface of the substrate is grooved by the plurality of knives/drill bits, thereby creating the plurality of grooves. 
 
     
     
       4. The method of  claim 1 , furthering comprising the step of:
 reclaiming the overage, thereby reusing the overage in the subsequent implementation of the method. 
 
     
     
       5. The method of  claim 1 , furthering comprising the step of:
 selling the overage, thereby recouping a portion of an expenditure spent for producing the paint roller. 
 
     
     
       6. The method of  claim 1 , wherein the substrate is a polypropylene strip, and wherein the overage is a polypropylene byproduct. 
     
     
       7. The method of  claim 6 , wherein the step of collecting the overage comprises the steps of:
 vacuuming the polypropylene byproduct, wherein the polypropylene byproduct is grooved out of the polypropylene strip as the strip passes along the plurality of knives/drill bits, wherein a vacuum is adjacent to the plurality of knives/drill bits. 
 
     
     
       8. The method of  claim 6 , wherein the step of feeding the grooved polypropylene strip about the mandrel comprises the steps of:
 feeding a first grooved strip of polypropylene about the mandrel; 
 feeding a second grooved strip of polypropylene about the first grooved strip of polypropylene in offset relation therewith; and 
 applying adhesive upon, at least:
 a portion of the outer surface of one wind of the first grooved strip, 
 an adjacent portion of the outer surface of a subsequent wind of the first grooved strip, and 
 substantially all of the outer surface of a wind of the second grooved strip. 
 
 
     
     
       9. The method of  claim 8 , wherein the step of applying the cover comprises the steps of:
 feeding the cover about the second grooved strip; and 
 applying a compressing force upon the cover urging the cover toward the second grooved strip and simultaneously urging the second grooved strip toward the first grooved strip, thereby creating the paint roller. 
 
     
     
       10. The method of  claim 8 , wherein the plurality of grooves of the first grooved strip are positioned at an offset in relation to the plurality of grooves of the second grooved strip. 
     
     
       11. The method of  claim 8 , wherein the shape of the plurality of grooves of the first grooved strip are a different shape from the shape of the plurality of grooves of the second grooved strip. 
     
     
       12. The method of  claim 9 , further comprising the step of:
 cutting the paint roller into lengths. 
 
     
     
       13. The method of  claim 1 , wherein the strength of the paint roller is not detrimentally compromised by the removal of the overage. 
     
     
       14. A method for producing tubular products comprising the steps of:
 grooving and removing an overage from a raw substrate, 
 wherein the processed substrate has a plurality of grooves, 
 wherein the removal of the overage results in a reduction in the weight of the product; 
 collecting the overage, wherein the overage is reusable in a subsequent implementation of the method; 
 feeding the processed substrate onto a mandrel, thereby positioning the processed substrate on the mandrel; and 
 producing a tubular product using the processed substrate. 
 
     
     
       15. A method of producing a paint roller comprising the steps of:
 helically winding a strip about a mandrel, wherein a surface of the strip has grooves, and wherein the grooves are angled with relation to the longitudinal axis of the strip so that the grooves run parallel to the longitudinal axis of the mandrel as the strip is wound about the mandrel; 
 applying a cover about the grooved substrate strip, thereby creating the paint roller. 
 
     
     
       16. A method of producing a paint roller comprising:
 helically winding a strip about a mandrel, wherein a surface of the strip has grooves, and wherein the grooves are angled with relation to the longitudinal axis of the strip so that the grooves run parallel to the longitudinal axis of the mandrel as the strip is wound about the mandrel;   helically winding another strip about the strip and mandrel;   applying a cover about the grooved strip and the another strip, thereby creating the paint roller.   
     
     
       17. The method of claim 16, further comprising:
 applying adhesive to:
 an outer surface of the strip prior to helically winding the another strip about the strip, and 
 an outer surface of the another strip prior to applying the cover about the grooved strip and the another strip. 
   
     
     
       18. A method of producing a paint roller comprising:
 helically winding a strip about a mandrel, wherein a surface of the strip has dimples, and wherein the dimples form surface reliefs on an outer surface or an inner surface of the strip as the strip is wound about the mandrel;   applying a cover about the dimpled strip, thereby creating the paint roller.   
     
     
       19. The method of claim 18, further comprising applying adhesive to an outer surface of the dimpled strip prior to applying a cover about the dimpled strip. 
     
     
       20. A method of producing a paint roller comprising:
 helically winding a strip about a mandrel, wherein a surface of the strip has dimples, and wherein the dimples form surface reliefs on an outer surface or an inner surface of the strip as the strip is wound about the mandrel;   helically winding another strip about the strip and mandrel;   applying a cover about the dimpled strip and the another strip, thereby creating the paint roller.   
     
     
       21. The method of claim 20, further comprising:
 applying adhesive to:
 an outer surface of the strip prior to helically winding the another strip about the strip; and 
 an outer surface of the another strip prior to applying the cover about the grooved strip and the another strip. 
   
     
     
       22. A method for producing a paint roller comprising:
 helically winding an inner and an outer substrate about a mandrel, wherein at least one surface of each of the inner and outer substrates has a plurality of surface-reliefs;   applying adhesive to an outer surface of the inner substrate and an outer surface of the outer substrate;   applying a paint absorbing and spreading cover about the outer substrate, thereby covering the adhesive on the outer surface of outer substrate; and,   urging the paint absorbing and spreading cover toward the inner and outer substrates, thereby creating the paint roller.   
     
     
       23. The method of claim 22, wherein the cross-section of at least one surface-relief of the plurality of surface-reliefs on the inner substrate is a section of a shape selected from the group consisting of circle, elliptic, oval, quadrilateral, square, rectangle, rhombus, trapezoid, kite, diamond, triangle, pentagon, hexagon, heptagon, octagon. 
     
     
       24. The method of claim 22, wherein the cross-section of at least one surface-relief of the plurality of surface-reliefs on the outer substrate is a section of a shape selected from the group consisting of circle, elliptic, oval, quadrilateral, square, rectangle, rhombus, trapezoid, kite, diamond, triangle, pentagon, hexagon, heptagon, octagon. 
     
     
       25. The method of claim 22, wherein at least one of the inner and outer substrates is a strip comprising polypropylene. 
     
     
       26. The method of claim 25, wherein the at least one relieved surface of the at least one strip comprising polypropylene strip is the outer surface. 
     
     
       27. The method of claim 22, wherein the inner and outer substrates are both strips comprising polypropylene. 
     
     
       28. The method of claim 27, wherein the at least one relieved surface of the inner substrate is the outer surface of the inner substrate, and the at least one relieved surface of the outer substrate is the outer surface of the outer substrate. 
     
     
       29. A method for producing a paint roller comprising:
 helically winding an inner and an outer substrate about a mandrel, each of the inner and outer substrates having an inner and outer surface, and wherein at least one surface of at least one of the inner and outer substrate has a plurality of surface-reliefs;   applying adhesive to an outer surface of the inner substrate and the outer surface of the outer substrate;   applying a paint absorbing and spreading cover about the outer substrate, thereby covering the adhesive on the outer surface of outer substrate; and,   urging the paint absorbing and spreading cover toward the inner and outer substrates, thereby creating the paint roller.   
     
     
       30. The method of claim 29, wherein the cross-section of at least one surface-relief of the plurality of surface-reliefs on the at least one surface is a section of a shape selected from the group consisting of circle, elliptic, oval, quadrilateral, square, rectangle, rhombus, trapezoid, kite, diamond, triangle, pentagon, hexagon, heptagon, octagon. 
     
     
       31. The method of claim 29, wherein at least one of the inner and outer substrates is a strip comprising polypropylene. 
     
     
       32. The method of claim 29, wherein the inner and outer substrates are each strips comprising polypropylene. 
     
     
       33. The method of claim 29, wherein the at least one surface having a plurality of surface-reliefs is the outer surface. 
     
     
       34. The method of claim 29, wherein the at least one surface having a plurality of surface-reliefs is the inner surface. 
     
     
       35. The method of claim 29, wherein at least one surface of each of the inner and outer substrates has a plurality of surface-reliefs. 
     
     
       36. The method of claim 35, wherein the at least one relieved surface of the inner substrate is the outer surface of the inner substrate, and the at least one relieved surface of the outer substrate is the outer surface of the outer substrate.