# US 8,771,451 B2 · Methods for manufacturing a paint roller and component parts thereof > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,771,451 B2 - Document ID: US8771451B2 - Status: Granted - Kind: B2 - Application number: 13/431,597 - Filed: 2012-03-27 - Published: 2013-03-28 - Granted: 2014-07-08 - Earliest claimed: 2009-01-08 - Applicants: Chandra Sekar - Inventors: Chandra Sekar - Web page: https://patentgrep.com/patent/US8771451B2 ## CPC - B32B 37/1284: {Application of adhesive} - B29C 53/581: {using sheets or strips consisting principally of plastics material (using profiled sheets or strips B29C53/78)} - B29C 63/105: {continuously} - B29D 23/001: {Pipes; Pipe joints (pleated hoses B29D23/18)} - B29C 48/001: {Combinations of extrusion moulding with other shaping operations} - B29C 48/0012: {combined with shaping by internal pressure generated in the material, e.g. foaming} - B29C 48/09: Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels - B29C 48/151: Coating hollow articles - B29C 48/21: the layers being joined at their surfaces - B29C 48/395: using screws surrounded by a cooperating barrel, e.g. single screw extruders - B29C 53/607: {having driving means for advancing the wound articles, e.g. belts, rolls (B29C53/74 takes precedence)} - B29C 63/0069: {of tubular articles} - B29C 2063/485: {the liquid being an adhesive} - B29C 2793/009: after shaping - B29K 2023/12: {PP, i.e. polypropylene} - B29K 2105/04: cellular or porous - B29L 2023/00: Tubular articles (B29L2024/00 takes precedence {; catheters B29L2031/7542}) - B29L 2031/328: {Paint rollers} - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00) - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES ## Abstract Described are methods of making a thermoplastic core paint roller using a composite cover material having a backing made from a compound comprising a polypropylene-based elastomer and calcium carbonate having between 5% and 50% calcium carbonate by weight. One or various compounds of polypropylene and calcium carbonate having between 5% and 66% calcium carbonate by weight may be used to form portions of one or multiple components that make up the paint roller, including, for example, the thermoplastic strips and/or the adhesives. The materials can be assembled in a continuous manufacturing process. ## Claims ### Claim 1 A method of making a paint roller 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; extruding a polypropylene-based compound to form a smoothly flowing layer of adhesive, the polypropylene-based compound comprising (i) at least 5% but not more than 66% calcium carbonate by weight; and (ii) a polypropylene resin; applying the layer of adhesive onto an outer surface of the wound strip; helically wrapping a strip of composite cover material about the wound strip and over the layer of adhesive, the composite cover material having a backing with a thickness of about 10 to 40 mils and comprising (i) at least 25% but not more than 50% calcium carbonate by weight; and (ii) polypropylene-based elastomer; allowing the adhesive to cool, thereby bonding the strip of cover material to the wound strip. ### Claim 2 (depends on 1) The method of claim 1, wherein the composite cover material backing further comprises up to 50% polypropylene resin by weight. ### Claim 3 (depends on 2) The method of claim 2, wherein the composite cover material backing comprises: (i) at least 10% but not more than 40% calcium carbonate by weight; (ii) at least 40% but not more than 85% polypropylene-based elastomer by weight; and (iii) polypropylene resin. ### Claim 4 A method for continuously producing a multi-strip laminate paint roller comprising the steps of: helically advancing an inner strip of thermoplastic material around a mandrel so as to form a helically wound inner strip, the inner strip having an inner surface and an outer surface; helically winding a second strip of thermoplastic material around a mandrel in offset relation to the inner strip, so as to form a helically wound second strip, the second strip having an inner surface and an outer surface; advancing the wound inner and second strips along the mandrel; extruding a polypropylene-based compound to form a smoothly flowing layer of adhesive, the polypropylene-based compound comprising (i) at least 5% but not more than 66% calcium carbonate by weight; and (ii) polypropylene resin; applying the layer of adhesive onto at least a portion of the outer surface of the wound inner strip and at least a portion of the outer surface of the wound second strip; wrapping a strip of composite cover material about the wound second strip and over the layer of adhesive applied to at least a portion of the outer surface, the composite cover material having an inner surface and an outer surface, the outer surface of the composite cover material comprising a pile fabric, and the inner surface of the composite cover material having a backing with a thickness of about 10 to 40 mils and comprising at least 25% but not more than 50% calcium carbonate by weight and a polypropylene-based elastomer; applying a compressive force from without the composite cover material to urge the composite cover material, the layer of adhesive, and the inner and second strips together, thereby laminating the inner surface of the composite cover material to the outer surface of the second strip and laminating the inner surface of the second strip to the outer surface of the inner strip; and allowing the adhesive to set, thereby creating the multi-strip laminated paint roller. ### Claim 5 (depends on 4) The method of claim 4, wherein the composite cover material backing further comprises up to 50% polypropylene resin by weight. ### Claim 6 (depends on 5) The method of claim 5, wherein the composite cover material backing comprises: (i) at least 10% but not more than 40% calcium carbonate by weight; (ii) at least 40% but not more than 85% polypropylene-based elastomer by weight; and (iii) a polypropylene resin. ### Claim 7 A method for continuously making a laminated paint roller comprising the steps of: helically winding a strip of thermoplastic material around a mandrel so as to form a helically wound strip, the strip having an inner surface and an outer surface; advancing the helically wound strip along the mandrel; extruding a polypropylene-based compound to form a smoothly flowing layer of adhesive, the polypropylene-based compound comprising (i) at least 5% but not more than 66% calcium carbonate by weight; and (ii) polypropylene resin; applying the layer of adhesive onto at least a portion of the outer surface of the wound strip; wrapping a strip of composite cover material about the wound strip and over the layer of adhesive applied to at least a portion of the outer surface of the wound strip, the composite cover material having an inner surface and an outer surface, the outer surface of the composite cover material comprising a pile fabric, and the inner surface of the composite cover material having a backing with a thickness of about 10 to 40 mils and comprising at least 25% but not more than 50% calcium carbonate by weight and a polypropylene-based elastomer; applying a compressive force from without the composite cover material to urge the composite cover material, the layer of adhesive, and the strip together, thereby laminating the inner surface of the composite cover material to the outer surface of the strip; and allowing the adhesive to set, thereby creating the laminated paint roller. ### Claim 8 (depends on 7) The method of claim 7, wherein the composite cover material backing further comprises up to 50% polypropylene resin by weight. ### Claim 9 (depends on 8) The method of claim 8, wherein the composite cover material backing comprises: (i) at least 10% but not more than 40% calcium carbonate by weight; (ii) at least 40% but not more than 85% polypropylene-based elastomer by weight; and (iii) polypropylene resin. ### Claim 10 A method of making a paint roller 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; extruding a thermoplastic compound to form a smoothly flowing layer of adhesive; applying the layer of adhesive onto an outer surface of the wound strip; helically wrapping a strip of composite cover material about the wound strip and over the layer of adhesive, the composite cover material having a backing with a thickness of about 10 to 40 mils and comprising (i) at least 25% but not more than 50% calcium carbonate by weight; and (ii) polypropylene-based elastomer; allowing the adhesive to cool, thereby bonding the strip of cover material to the wound strip. ### Claim 11 (depends on 10) The method of claim 10, wherein the composite cover material backing further comprises up to 50% polypropylene resin by weight. ### Claim 12 (depends on 11) The method of claim 11, wherein the composite cover material backing comprises: (i) at least 10% but not more than 40% calcium carbonate by weight; (ii) at least 40% but not more than 85% polypropylene-based elastomer by weight; and (iii) a polypropylene resin. ### Claim 13 A method for continuously producing a multi-strip laminate paint roller comprising the steps of: helically advancing an inner strip of thermoplastic material around a mandrel so as to form a helically wound inner strip, the inner strip having an inner surface and an outer surface; helically winding a second strip of thermoplastic material around a mandrel in offset relation to the inner strip, so as to form a helically wound second strip, the second strip having an inner surface and an outer surface; advancing the wound inner and second strips along the mandrel; extruding a thermoplastic material to form a smoothly flowing layer of adhesive; applying the layer of adhesive onto at least a portion of the outer surface of the wound inner strip and at least a portion of the outer surface of the wound second strip; wrapping a strip of composite cover material about the wound second strip and over the layer of adhesive applied to at least a portion of the outer surface, the composite cover material having an inner surface and an outer surface, the outer surface of the composite cover material comprising a pile fabric, and the inner surface of the composite cover material having a backing with a thickness of about 10 to 40 mils and comprising at least 25% but not more than 50% calcium carbonate by weight and a polypropylene-based elastomer; applying a compressive force from without the composite cover material to urge the composite cover material, the layer of adhesive, and the inner and second strips together, thereby laminating the inner surface of the composite cover material to the outer surface of the second strip and laminating the inner surface of the second strip to the outer surface of the inner strip; and allowing the adhesive to set, thereby creating the multi-strip laminated paint roller. ### Claim 14 (depends on 13) The method of claim 13, wherein the composite cover material backing further comprises up to 50% polypropylene resin by weight. ### Claim 15 (depends on 14) The method of claim 14, wherein the composite cover material backing comprises: (i) at least 10% but not more than 40% calcium carbonate by weight; (ii) at least 40% but not more than 85% polypropylene-based elastomer by weight; and (iii) polypropylene resin. ### Claim 16 A method for continuously making a laminated paint roller comprising the steps of: helically winding a strip of thermoplastic material around a mandrel so as to form a helically wound strip, the strip having an inner surface and an outer surface; advancing the helically wound strip along the mandrel; extruding a thermoplastic material to form a smoothly flowing layer of adhesive; applying the layer of adhesive onto at least a portion of the outer surface of the wound strip; wrapping a strip of composite cover material about the wound strip and over the layer of adhesive applied to at least a portion of the outer surface of the wound strip, the composite cover material having an inner surface and an outer surface, the outer surface of the composite cover material comprising a pile fabric, and the inner surface of the composite cover material having a backing with a thickness of about 10 to 40 mils and comprising at least 25% but not more than 50% calcium carbonate by weight and a polypropylene-based elastomer; applying a compressive force from without the composite cover material to urge the composite cover material, the layer of adhesive, and the strip together, thereby laminating the inner surface of the composite cover material to the outer surface of the strip; and allowing the adhesive to set, thereby creating the laminated paint roller. ### Claim 17 (depends on 16) The method of claim 16, wherein the composite cover material backing further comprises up to 50% polypropylene resin by weight. ### Claim 18 (depends on 17) The method of claim 17, wherein the composite cover material backing comprises: (i) at least 10% but not more than 40% calcium carbonate by weight; (ii) at least 40% but not more than 85% polypropylene-based elastomer by weight; and (iii) polypropylene resin.