BR112021014196A2 - SYSTEMS AND METHODS FOR PRODUCING MAGNETICALLY RECEPTIVE LAYERS AND MAGNETIC LAYERS FOR USE IN SURFACE COATING SYSTEMS - Google Patents

Abstract

systems and methods for producing magnetically receptive layers and magnetic layers for use in surface coating systems. method for producing a surface coating system comprising magnetically receptive layers affixed to surface coating units and magnetized underlayments for use in attaching surface coating units to supporting surfaces. The system includes isotropic magnetized floor covering units and anisotropic magnetized bases to protect surface covering units. The system includes a suite of formulations including ferrites and rare earth materials, oils and plasticizers, and bonding agents to optimize performance and meet design and application criteria.

Description

“SYSTEMS AND METHODS TO PRODUCE LAYERS

MAGNETICALLY RECEPTIVE AND MAGNETIC LAYERS FOR USE IN SURFACE COATING SYSTEMS” Field of the Invention

[001] The present invention pertains to the technique of surface coatings and more particularly to systems and methods for producing magnetically receptive layers and magnetic layers for use in surface coating systems for indoor and outdoor applications. Fundamentals

[002]In the field of modular floor covering unit installation, existing methods of installing such floor coverings typically involve a labor-intensive and material-intensive process. The process involves preparing a supporting surface, e.g., subfloor, and gluing individual floor covering units using an adhesive. Adhesive is heavy, difficult to apply, expensive, difficult to remove and prone to failure. Additional issues include moisture migration, mold, cracking, etc. Using this prior art method, the adhesive should be applied to the entire supporting surface or the entire underside of a floor covering unit. This process is expensive in labor and money and creates additional costs if the floor covering units need to be replaced or removed. Another installation technique involves so-called floating floors, which are susceptible to movement, warping and other problems.

[003] Another method known in the art for installing modular floor covering units involves the use of adhesive connectors to connect the modular floor covering units with adjacent units. Such prior art “connector systems” allow the modular floor covering to “float” on top of the supporting surface. These prior art systems use an adhesive to hold the edges of adjacent floor units together. One such system and method is SYSTEM FOR CARPET TILE INSTALLATION, U.S. Patent. No. 8,434,282, issued May 7, 2013 (Scott et al.). The method described in Scott et al. uses a one-sided pressure sensitive adhesive strip that is approximately 72 mm square that has a removable protective layer to join four sections of modular floor units together. There are several issues with using this method to install a modular floor covering including the replacement of individual floor covering units, the difficulty of installation and the durability of the installation method.

[004] There are also other carpet sewing methods for joining two segments of flooring material along straight, long seams. Such methods include CARPET SEAMING APPARATUS AND METHOD OF UTILIZING THE SAME, U.S. Patent. No. 5,800,664, Issued September 1, 1998 (Covert) and SEAMING APPARATUS AND METHOD, U.S. Patent Application. No. 14/309,632, filed on June 19, 2014, (LeBlanc et al.). There are additional methods for attaching modular floor covering units together in a “floating floor” configuration that overcome the problems and issues presented by the prior art of Scott et al. Such methods include MODULAR CARPET SEAMING APPARATUS AND METHOD, Patent Application U.S. No. 14/618,752, filed February 10, 2015, (Lautzenhiser et al.).

[005] Improvements have been made to these systems and methods for attaching floor coverings including the use of magnetic underlayments with magnetically receptive layers attached or affixed to the floor covering units. In addition to floor covering applications, wall cladding applications, ceiling cladding applications, roof and exterior wall cladding applications have different environmental concerns and considerations that must be taken into account in determining suitable materials having the proper properties for installation and use. For example, outdoor applications will involve exposure to sun, wind, rain, thunderstorms and other weather related conditions. “Surface” coating applications are used to broadly refer to wall and floor coating applications, unless otherwise noted.

[006]Magnetic systems are often anisotropic, meaning they are direction dependent and may require the surface coating component and underlayment component to be arranged in a directional manner. Such purely anisotropic systems suffer from several disadvantages, including the need to place and align components in a defined manner, increasing installation and material complexity and costs. Isotropic materials are direction independent. Plastic binders can be used in the manufacture of flexible magnetic sheets, but this generally results in lower magnetic strength.

[007]Examples of such systems and methods are described in at least U.S. Patent Application. 16/013,902, entitled MODULAR MAGNETICALLY

RECEPTIVE WOOD AND ENGINEERED WOOD SURFACE UNITS AND MAGNETIC BOX SYSTEM FOR COVERING FLOORS, WALLS, AND OTHER SURFACES, filed June 20, 2018, Lautzenhiser et al.; U.S. Patent Application 15/083,255, entitled SYSTEM, METHOD, AND APPARATUS FOR MAGNETIC SURFACE COVERINGS, filed on March 28, 2016, Lautzenhiser et al.; in the U.S. Patent Application. 15/083,231, entitled SYSTEM, METHOD, AND APPARATUS FOR MAGNETIC SURFACE COVERINGS, filed on March 28, 2016, issued as U.S. Pat. 10,189,236 on January 29, 2019, Lautzenhiser et al.; and in the U.S. Provisional Patent Application. 62/522,513, entitled MODULAR

MAGNETIC WOOD AND ENGINEERED WOOD FLOORING UNITS UTILIZING A MAGNET BOX SYSTEM FOR FLOORS, WALLS, AND OTHER SURFACES,

filed on June 20, 2017, LeBlanc et al.

[008] However, with the existing systems and methods for installing floor and wall covering units, and the systems and methods for producing such installation systems, there are problems in combining different types of materials and in producing the necessary system components. Existing systems may not be sufficiently dimensionally or structurally stable to be optimally suited for heavy traffic or usage conditions, such as in commercial applications. The materials and production processes used to manufacture existing floor/wall covering systems may not produce floor covering units and installation materials with the desired durability and stability required for commercial applications and long-term installation. Additionally, with existing systems, including existing magnetic floor covering systems, the receptive and magnetic layers can be too thick or heavy or have too poor magnetic remanence for particular applications.

[009] What is needed is a system and method for producing modular floor covering units that are compatible with a wide range of floor covering materials and supporting surface types and compositions. Additionally, what is needed is a system and method for producing and installing modular floor covering units that are dimensionally and structurally stable, and are lightweight suitable with at least minimal magnetic remanence for particular installation applications.

[010]Also what is needed is a system and method suitable for wallcovering applications having adequate magnetic force or holding force to maintain the positioning of a surface coating component with respect to an underlying component and adhered support underlayment to a wall or other supporting structure.

[011]Also what is needed is a system and method suitable for external wallcovering applications having adequate magnetic force or holding force to maintain the positioning of a surface coating component with respect to an underlying component and supporting underlayment adhered to an external wall or other supporting structure. The magnetic force or holding force of the system must be able to withstand the shear force associated with gravity, as well as wind and other environmental conditions, e.g., cyclones, tornadoes, falling debris and animals.

[012]Also what is needed is a system and method suitable for external roof cladding applications having adequate magnetic force or holding force to maintain the positioning of a roof cladding component with respect to an underlying component and supporting underlayment adhered to an external roof or other supporting structure. The magnetic force or holding force of the system must be able to withstand the shear force associated with gravity, as well as wind and other environmental conditions, e.g., cyclones, tornadoes, falling debris and animals.

[013]Also what is needed is a system and method suitable for wall, floor and ceiling cladding in aircraft applications having adequate magnetic force or holding force to maintain the positioning of a surface cladding component in relation to a component underlying and supporting underlayment adhered to a wall, ceiling or other supporting structure. What is needed is a thin and light system specially adapted for use on airplanes having critical requirements to minimize installation weight and depth.

[014]Also what is needed is a method of fabricating components of magnetic surface coating systems using rare earth materials and adapted to align crystalline structures to increase strength and limit thickness.

Summary of the Invention

[015] The present invention provides a system, apparatus and method for producing magnetically receptive layers and magnetic layers for use in surface coating systems. The present invention provides systems and methods for manufacturing magnetically receptive layers and magnetic layers for use in surface coating systems that address problems with existing magnetic surface coating systems. The present invention comprises a two-component system comprising a magnetized underlay and an attraction floor covering unit.

[016] The present invention provides a system and method for producing magnetically receptive layers and magnetic underlayments as sheet products for use in an interchangeable box system for attaching surface coating units to supporting surfaces. The magnetically receptive layers and magnetic underlayments of the present invention are more suitable for installation in residential and commercial applications than the systems and methods disclosed in the prior art and provide benefits including increased durability, improved dimensional stability and wider material compatibility than those used in known surface coating systems.

[017] The materials, compounds and processes used in the production of the magnetically receptive layers and magnetic underlayments of the present invention provide a significant improvement over prior art systems and methods.

[018] In a first embodiment, the present invention provides an isotropic magnetically receptive layer and an anisotropic magnetic underlayment. The magnetically receptive layer is disposed on the bottom or underside of a surface coating unit. The magnetic underlayment is arranged on a supporting surface. The anisotropic magnetic underlayment is substantially thinner than a similar isotropic magnetic underlayment but retains similar retention characteristics. For example, an anisotropic magnetic underlayment can be as much as 50% thinner while maintaining retention characteristics within 20% of an isotropic magnetic underlayment that is twice as thick.

[019] In another embodiment, the present invention provides a "hybrid" magnetic underlayment. The “hybrid” magnetic underlayment comprises a combination of neodymium and ferrite powder. The “hybrid” magnetic underlayment can be dimensionally similar to a ferrite powder magnetic underlayment, but can have a holding force eight times greater than a ferrite powder magnetic underlayment. The “hybrid” magnetic underlayment may be suitable for applications where greater holding force is required and where the increased cost associated with neodymium powder is not a major concern.

[020] In another embodiment, the present invention provides a system and method for applying a magnetically receptive layer in a lower cost manner. A magnetically receptive ferrite powder blend can be mixed with a UV oil and sprayed onto a surface coating unit. The ferrite powder suspended in the UV oil is then placed with high power UV lights. The hardened combination of ferrite powder and UV oil acts as a magnetically receptive “B” side layer that is permanently attached to the surface coating unit. Other oils or materials, such as PVC oil, can also be used.

[021] The materials, compounds and processes used in the production of the magnetically receptive layers and magnetic underlayments of the present invention provide a significant improvement over prior art systems and methods.

[022] In another embodiment, the present invention provides a system of surface coating components, the system when installed providing a quasi-permanent surface coating, the system comprising: a surface coating unit comprising an isotropic magnetically receptive layer; and an anisotropic magnetic underlayment disposed on a supporting surface.

[023]Anisotropic magnetic underlayment can be 0.5mm thick. The anisotropic magnetic underlayment may further comprise: a magnetizable material; a binder; and an oil. The magnetizable material may comprise one of: ferrous iron powder, strontium ferrite powder, neodymium powder, and a composite of neodymium and ferrous iron. The binder may comprise thermoplastic chlorinated polyethylene elastomer ("CPE"). The oil may comprise epoxidized soybean oil ("ESBO"). The anisotropic magnetic underlayment may be a calendered sheet product. The anisotropic magnetic underlayment may further comprise a magnetizable material having a mesh size of 1 to 2.3 𝜇m.

[024] In another embodiment, the present invention provides a magnetic underlayment layer for attaching magnetically receptive surface coating units to a support surface, the magnetic underlayment layer comprising: a neodymium powder; a binder; and an oil.

[025] The magnetic underlayment layer may further comprise a plasticizer. The oil may comprise epoxidized soybean oil ("ESBO"). The ratio of neodymium powder to binder and oil is less than 91% neodymium powder to 9% binder and oil. The magnetic underlayment layer may further comprise a ferrite powder. The ratio of ferrite powder to neodymium powder can be 50/50.

[026] In another embodiment, the present invention provides a method for applying a magnetically receptive layer to a surface coating unit, the method comprising: adding a combination of receptive material and a compound oil to a mixer; combining the receptive material combination and the compound oil to form a magnetically receptive oil combination; spraying the magnetically receptive oil blend onto a surface coating unit; and placing the magnetically receptive oil blend into the surface coating unit.

[027] The method may further comprise wherein the receptive material combination comprises one of: ferrous iron powder, strontium ferrite powder, neodymium powder, and a composite of neodymium powder and ferrous iron. The method may further comprise wherein the compound oil comprises one of: ultraviolet ("UV") oil and polyvinyl chloride ("PVC") resin. Adjusting the magnetically receptive oil blend may further comprise placing the magnetically receptive oil blend in high intensity ultraviolet ("UV") lights. Adjusting the magnetically receptive oil blend may further comprise bringing the magnetically receptive oil blend to high temperature.

[028] In another embodiment, the present invention provides a method for producing a magnetically receptive sheet product for use in surface coating systems, the method comprising: combining a ferrite compound, a polymer and a plasticizer in a vessel mixing; mixing the ferrite compound, polymer and plasticizer at a desired mixing temperature and at a desired mixing pressure to form a magnetically receptive material; and extruding the magnetically receptive material at a desired extrusion temperature to form a magnetically receptive sheet product.

[029] The method may further comprise annealing the magnetically receptive sheet product. The method may further comprise cold pressing the magnetically receptive sheet product into a natural material construction product. The method may further comprise heat pressing the magnetically receptive sheet product into a synthetic material construction product. The method may further comprise magnetizing the magnetically receptive sheet product. The composition of the magnetically receptive material can be selected from the group consisting of: approximately 84% pure iron (Fe) powder, approximately 15% chlorinated polyethylene elastomer polymer (CPE) and approximately 8% epoxidized soybean oil ( ESBO); 90% iron powder (Fe304), 9% CPE and 1% plasticizer; 90% Mn-Zn (manganese/zinc) soft ferrite powder, 9% CPE and 1% plasticizer; 20 parts CPE, 150 parts stainless iron powder; 30 parts polyvinyl chloride, 18 parts dioctyl terephthalate, 200 parts stainless iron powder; or 16.5% PVC, 39% Calcium Carbonate, 26.5% Iron Powder, 16% Plasticizer and 2% Viscosity Depressor & Stabilizer. The ferrite compound can be strontium ferrite, the polymer can be chlorinated polyethylene elastomer polymer (CPE), and the plasticizer can be epoxidized soybean oil (ESBO). Mixing can be carried out for approximately 15 minutes, the desired mixing temperature can be up to 120 degrees Celsius, and the desired mixing pressure can be atmospheric pressure. The desired extrusion temperature may be 120 degrees Celsius and where the magnetically receptive sheet product may be extruded at 10 meters per minute. Mixing can be carried out for 20 to 30 minutes, the desired mixing temperature can be between 90 to 115 degrees Celsius, and the desired mixing pressure can be from 0.4 to 0.7 MPa. The magnetically receptive sheet product can be extruded at 4 to 10 meters per minute and the desired extrusion temperature can be 40 to 70 degrees Celsius. The ferrite compound may be strontium ferrite having a particle size of 38 to 62 microns.

[030] In another embodiment, the present invention provides a dimensionally stable, rust resistant, magnetically receptive sheet product for use in surface coating systems, the sheet product comprising: a ferrite compound; a plasticizer; and a polymer. The sheet product may further comprise wherein the ferrite compound is strontium ferrite, the polymer is chlorinated polyethylene elastomer polymer (CPE) and the plasticizer is epoxidized soybean oil (ESBO). The sheet product may further comprise wherein the strontium ferrite comprises a particle size of 38 to 62 microns.

[031] In another embodiment, the present invention provides a method for producing a magnetically receptive sheet product for use in surface coating systems, the method comprising: combining a ferrite compound, a polymer and a plasticizer in a vessel mixing; mixing the ferrite compound, polymer and plasticizer at a desired mixing temperature and at a desired mixing pressure to form a magnetically receptive material; and extruding the magnetically receptive material at a desired extrusion temperature to form a magnetically receptive sheet product; or applying a calendering process to the magnetically receptive layer to form a magnetically receptive sheet product.

[032] The method of the above embodiment may further comprise annealing the magnetically receptive sheet product. The method may further comprise cold pressing the magnetically receptive sheet product into a natural material construction product. The method may further comprise heat pressing the magnetically receptive sheet product into a synthetic material construction product. The method may further comprise magnetizing the magnetically receptive sheet product. The magnetically receptive layer may be magnetized to produce a magnetized underlayment adapted to magnetically hold and support a non-magnetized receptive layer component, the composition of the magnetically receptive material is selected from the group consisting of: for use in a calendering process: 1 ) approximately 89 to 91% pure iron (Fe) or strontium ferrite powder, approximately 8 to 9% chlorinated polyethylene elastomer polymer (CPE) and approximately 1 to 2% epoxidized soybean oil (ESBO); or 2) approximately 89 to 91% iron powder (ferrous iron oxide or ferrous ferric, Fe304), approximately 8 to 9% CPE and approximately 1 to 2% plasticizer; or for use in an extrusion process: 3) approximately 16.5% PVC, approximately 39% calcium carbonate, approximately 26.5% iron powder, approximately 16% plasticizer and approximately 2% depressant & viscosity stabilizer.

The magnetically receptive material can be used to produce a non-magnetized receptive component for use as opposed to a magnetized underlayment component, the composition of the magnetically receptive material is selected from the group consisting of: for use in a calendering process: 1) approximately 89 to 91% Mn-Zn (manganese/zinc) soft ferrite powder, approximately 8 to 9% CPE and approximately 1 to 2% plasticizer; 2) approximately 20 parts CPE, approximately 150 parts stainless iron powder, approximately 30 parts polyvinyl chloride (PVC), approximately 18 parts dioctyl terephthalate, approximately 200 parts stainless iron powder; or for use in an extrusion process: 3) approximately 16.5% PVC, approximately 39% calcium carbonate, approximately 16% plasticizer, approximately 2% viscosity depressant & stabilizer, and at approximately 26.5 % um of: Mn-Zn (manganese/zinc) soft ferrite powder; stainless iron powder; or ferrous oxide powder or ferric oxide.

The ferrite compound can be strontium ferrite, the polymer is chlorinated polyethylene elastomer polymer (CPE) and the plasticizer is epoxidized soybean oil (ESBO). Mixing can be carried out for approximately 15 minutes, the desired mixing temperature can be up to 120 degrees Celsius, and the desired mixing pressure is atmospheric pressure.

The desired extrusion temperature can be 120 degrees Celsius and the magnetically receptive sheet product can be extruded at 10 meters per minute.

Mixing can be carried out for 20 to 30 minutes,

the desired mixing temperature can be between 90 to 115 degrees Celsius, and the desired mixing pressure can be between 0.4 to 0.7 MPa. The magnetically receptive sheet product can be extruded at 4 to 10 meters per minute and the desired extrusion temperature is 40 to 70 degrees Celsius. The ferrite compound may be strontium ferrite having a particle size of 38 to 62 microns.

[033] In another embodiment, the present invention provides a dimensionally stable, rust-resistant, magnetically receptive sheet product for use in surface coating systems, the sheet product being magnetized to provide a magnetized underlayment for magnetically engaging a component. non-magnetized receptive layer, the magnetized underlayment comprising: for use in a calendering process: 1) approximately 89 to 91 % pure iron (Fe) or strontium ferrite powder, approximately 8 to 9 % iron elastomer polymer chlorinated polyethylene (CPE) and approximately 1 to 2% epoxidized soybean oil (ESBO); or 2) Approximately 89 to 91% iron powder (ferrous iron oxide or ferrous ferric, Fe304), approximately 8 to 9% CPE and approximately 1 to 2% plasticizer; or for use in an extrusion process: 3) approximately 16.5% PVC, approximately 39% calcium carbonate, approximately 26.5% iron powder, approximately 16% plasticizer and approximately 2% depressant & viscosity stabilizer. The ferrite component may comprise a particle size of 38 to 62 microns.

[034] In another embodiment the present invention provides a dimensionally stable, rust-resistant magnetically receptive component for use in surface coating systems, the magnetically receptive component being a non-magnetized receptive layer component for magnetically engaging with a magnetized underlayment. , the magnetically receptive component comprising: for use in a calendering process: 1)

approximately 89 to 91% Mn-Zn (manganese/zinc) soft ferrite powder, approximately 8 to 9% CPE and approximately 1 to 2% plasticizer; 2) approximately 20 parts CPE, approximately 150 parts stainless iron powder, approximately 30 parts polyvinyl chloride (PVC), approximately 18 parts dioctyl terephthalate, approximately 200 parts stainless iron powder; or for use in an extrusion process: 3) approximately 16.5% PVC, approximately 39% calcium carbonate, approximately 16% plasticizer, approximately 2% viscosity depressant & stabilizer, and at approximately 26.5 % um of: Mn-Zn (manganese/zinc) soft ferrite powder; stainless iron powder; or ferrous oxide powder or ferric oxide.

[035] In a first embodiment relating to another inventive aspect, the invention provides a surface coating system, the system when installed providing a releasably secured surface coating, the system comprising: a magnetic surface coating unit comprising a non-magnetized isotropic magnetic receptive layer; and an anisotropically magnetized underlayment disposed on a supporting surface; wherein the magnetic surface coating unit is adapted to be magnetically attracted and received opposite the anisotropically magnetized underlayment in a fixed installation and to be non-destructively removable from the anisotropically magnetized underlayment subsequent to the fixed installation. Furthermore, the invention may be further characterized by one or more of the following features: the anisotropically magnetized underlayment is 0.5 mm in thickness and comprises a magnetizable material having a mesh size configured to have, when magnetized, enhanced magnetic attraction property and adapted to support the magnetic surface coating unit in a fixed non-horizontal installation, wherein the fixed non-horizontal installation is one of an indoor wall installation, an outdoor wall installation, an aircraft indoor cabin installation, an external roof installation or an internal ceiling installation. The invention may be further characterized by the anisotropically magnetized underlayment comprising: a magnetizable material including an iron powder; a binder component; and an oil having properties considering quick set-up during manufacturing, wherein set-up occurs at a normal line speed in a calendering or extrusion process. The invention may be further characterized in that the magnetizable material comprises one of: ferrous iron powder, strontium ferrite powder, neodymium powder, and a composite of neodymium powder and ferrous iron. The invention may be further characterized by: wherein the binder comprises thermoplastic chlorinated polyethylene elastomer ("CPE"); wherein the oil comprises epoxidized soybean oil ("ESBO"); wherein the anisotropically magnetized underlayment is one of a calendered sheet product or an extruded sheet product; wherein the anisotropically magnetized underlayment comprises a magnetizable material having a mesh size of 1 to 2.3 𝜇m.

[036] In a second embodiment the present invention provides a magnetized underlayment for attaching magnetically receptive surface coating units to a support surface, the magnetized underlayment comprising: a neodymium powder; a binder; and an oil having properties considering quick set-up during manufacturing, wherein set-up occurs at a normal line speed in a calendering or extrusion process.

[037] The invention may be further characterized by one or more of: the magnetized underlayment further comprising a plasticizer; wherein the oil comprises epoxidized soybean oil ("ESBO"); wherein the ratio of neodymium powder to binder and oil is less than 91% neodymium powder to 9% binder and oil; wherein the magnetic underlayment layer further comprises a ferrite powder; wherein the ratio of ferrite powder to neodymium powder is 50/50. The invention may be further characterized in that the ratio of neodymium powder to binder and oil is selected based on application considerations as being one of: about 91% neodymium powder to about 9% binder and oil; about 81% neodymium powder to about 19% binder and oil; about 71% neodymium powder to about 29% binder and oil; about 61% neodymium powder to about 39% binder and oil; or about 51% neodymium powder to about 49% binder and oil.

[038] In a third embodiment, the invention provides a method for applying a magnetically receptive layer to a surface coating unit to produce a magnetically receptive surface coating unit adapted to be magnetically secured opposite a magnetized underlayment, the method comprising : adding a combination of receptive material and a compound oil in a mixer; combining the receptive material combination and the compound oil to form a magnetically receptive oil combination; spraying the magnetically receptive oil blend onto a surface coating unit; and placing the magnetically receptive oil blend into the surface coating unit. The invention may be further characterized by one or more of: wherein the receptive material combination comprises one of: ferrous iron powder, strontium ferrite powder and neodymium powder, and composite of neodymium powder and ferrous iron; wherein the composite oil comprises one of: ultraviolet ("UV") oil and polyvinyl chloride ("PVC") resin; wherein adjusting the magnetically receptive oil blend comprises rapidly adjusting the magnetically receptive oil blend in high intensity ultraviolet ("UV") lights; wherein adjusting the magnetically receptive oil blend comprises bringing the magnetically receptive oil blend to high temperature.

BRIEF DESCRIPTION OF THE DRAWINGS

[039] In order to facilitate a complete understanding of the present invention, reference is now made to the accompanying drawings, in which like elements are referenced with like numerals. These drawings are not to be construed as limiting the present invention, but are intended to be exemplary and for reference.

[040] FIG. 1 is a flow diagram of an embodiment of production process for a magnetized or magnetically receptive sheet product at atmospheric pressure.

[041] FIG. 2 is a flow diagram of an embodiment of a production process for a magnetized or magnetically receptive sheet product at a pressure other than atmospheric pressure.

[042] FIG. 3 is a flow diagram of one embodiment of a production process for a magnetized or magnetically receptive material for use in a layer of support material.

[043] FIG. 4 is an embodiment of a surface coating unit having an isotropic magnetic receptive layer and an anisotropic magnetic underlayment in accordance with the present invention.

[044] FIG. 5 is an embodiment of a surface coating unit with an isotropic magnetic receptive layer and a combination "hybrid" magnetic underlayment of neodymium and ferrite powder in accordance with the present invention.

[045] FIG. 6 is a flow diagram of one embodiment of a production process for a magnetically receptive layer comprising a ferrite powder suspended in a UV hardened oil.

[046] FIG. 7 is a simplified perspective diagram of a modular surface coating unit with a magnetically receptive layer and a magnetic underlayment disposed on a supporting surface.

[047] FIG. 8 is a simplified perspective diagram of a modular surface coating unit with a magnetically receptive layer and a magnetic underlayment disposed on a supporting surface.

[048] FIG. 9 is a simplified diagram of a system for manufacturing a calendered sheet product, such as a magnetic or magnetically receptive sheet product in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION

[049] The present invention will now be described in more detail with reference to exemplary embodiments as shown in the accompanying drawings. While the present invention is described herein with reference to exemplary embodiments, it should be understood that the present invention is not limited to such exemplary embodiments. Those skilled in the art and having access to the teachings herein will recognize the implementations, modifications and additional embodiments, as well as other applications for the use of the invention, which are fully considered herein to be within the scope of the present invention, as disclosed and claimed herein, and with for which the present invention may be of significant utility.

[050]The magnetized material produces a magnetic field that projects a force that pulls or attracts ferromagnetic or ferrimagnetic materials, e.g., iron, ferrite, strontium ferrite, barium, nickel, cobalt, alloys of these and other materials, such as metals of rare earths, including neodymium-based materials. A magnetized component in a surface coating system can be manufactured using a magnetic material which is then magnetized, such as by an external magnetic field applied to it, e.g., passing under one or more strong permanent magnets or an electromagnet, so as to create a permanent or persistent magnetic field having remanence. The processes can be used to apply a strong magnetic field during fabrication to alter the atomic structure and align the internal microcrystalline structure resulting in increased remanence in the absence of an applied magnetic field. In particular, rare earth materials can be processed to align electrons to increase magnetic strength. Depending on the desired result, multiple stages of magnetization and magnetic alignment can be performed on a magnetic material. The magnetic force of a magnetized material can be measured in terms of its magnetization (often denoted as M in A/m (amps/meter) as a vector field), magnetic moment (often denoted as m or 𝜇 in A*m2 as a vector) or magnetic field or flux or flux density (often denoted as B in teslas (T - weber/m2) as a vector field). Materials that can be magnetized are magnetically receptive and attracted to magnets prior to magnetization.

[051]The strength of a magnet can be expressed in terms of its pulling force, i.e., the magnet's ability to move or "pull" magnetically receptive objects. The pulling force exerted by a permanent magnet is Maxwell's Equation expressed as: F = B2A/2µ0 Eq. 1 where F is force in newtons (SI); A is the cross-sectional area in meters*square; and B is the magnetic induction exerted by the magnetized material.

[052] Relatedly, the Maxwell unit of measurement in the CGS system (centimeter(cm)-gram-second) is a unit of magnetic flux (Φ) (which is the total field over an area) and a Maxwell is the flux through a surface of one square centimeter perpendicular to a magnetic field having a force of one gauss, i.e., one Maxwell = one gauss x cm'; and a Maxwell = 10-8 weber (in the International System of SI Units). The gauss (G) is the CGS unit of measurement of magnetic flux density or magnetic induction (B) and one gauss = one 10-4 tesla.

Accordingly, the units and expressions may be in either CGS or SI and it is understood for the purposes of this invention and the claims that both apply equally.

[053] An important consideration when considering the effective use of magnetic surface cladding systems is the applications, e.g., is the cladding component being placed opposite an underlayment in a wall, a floor, a ceiling, a roof, an area strong wind, to meet building codes or classifications, etc. For example, a holding force of a magnet required in the case of a vertical contacting surface is very different from the holding force required in the case of a horizontal contacting surface. An internal horizontal contact surface application, i.e. the contact surface is horizontal or parallel to the ground or earth, has essentially zero shear force operating against the system due to gravity. In contrast, a vertical application with the system perpendicular to the ground has a significant shear force acting due to gravity, creating the potential for the surface covering component to loosen or slip against the underlayment, which may be attached in some way to the vertical wall or another surface. Consequently, greater magnetic force or traction is required given a vertical contact surface due to the weight of the cladding component being placed and supported by the underlayment. In addition, in external conditions, additional forces act on the system to place an even greater load on the system and increase the magnetic force requirements to maintain system integrity.

[054]System Component Receptive Material or “SCRM” refers to a material and/or composition for use in the manufacture of “MRLP” magnetically receptive layer products and underlayment products and may include, for example, a component at powder base or a sheet product, which may also be referred to as “Bulk Iron Material”. In one implementation, SCRM in powder form can be directly pressed or otherwise applied to the receptive layer components to arrive at an MRLP. In an alternative implementation, SCRM can be used to manufacture an intermediate sheet product for combination with the finished surface covering components to arrive at MRLP products, in essence converting a non-magnetically receptive layer product, e.g., a finished product. of wall or floor covering, in an MRLP.

[055] In one way of implementing aspects of the present invention, modular surface coating units comprise a surface coating portion which may be, for example, a decorative floor or tile, a decorative wooden plank, a vinyl plank. decoration or a square rug. Other types, shapes and compositions of floor covering unit materials may be used. The surface cladding unit can be a floor, wall or ceiling cladding unit or it can also be, for example, an ornament or decorative piece other than a cladding unit. In this way, the floor, or other cladding unit, can be used in an “interchangeable box system” in which all cladding units and decorative elements in the system can be easily installed, removed, moved or rearranged in a magnetic underlayment arranged on a supporting surface (i.e. wall, floor, ceiling). Each modular surface coating unit also comprises a magnetically receptive layer. This magnetically receptive layer may be referred to as an "SCRM" layer or a "receptive 'B' side layer". The SCRM layer (receptive "B" side layer) in the interchangeable box system takes many different forms and processes depending on the material of construction and the material composition of said material of construction.

[056] In the present invention, each modular surface covering unit comprises a floor covering portion which may be, for example, a decorative tile, a decorative wooden plank, a decorative vinyl plank or a square rug. Other types, shapes and compositions of floor covering unit materials may be used. Additionally, the floor covering unit may instead be a wall or ceiling covering unit or it may also be, for example, an ornament or decorative piece other than a covering unit. In this way, the floor, or other cladding unit, can be used in an “interchangeable box system” or “magnetic box system” where all the cladding units and decorative elements in the system can be easily installed, removed, moved around. or rearranged into a magnetic underlayment disposed on a supporting surface (i.e. wall, floor, ceiling). Each modular surface coating unit also comprises a magnetically receptive layer, which may be extruded from the surface coating unit, or may be a separate layer affixed to the unit. This magnetically receptive layer may be referred to as a system component receptive material ("SCRM") layer or a "receptive 'B' side layer". The SCRM layer (receptive "B" side layer) in the interchangeable box system takes many different forms and processes depending on the material of construction and the material composition of said material of construction.

MAGNETICALLY ISOTROPIC AND MAGNETIC RECEPTIVE LAYERS:

[057] The SCRM receptive layer of a flooring unit, such as a modular floor covering unit, in the interchangeable box system, can be adhered to organic composite materials such as natural wood or natural stone or ceramic stone. The SCRM receptive layer can also be used with synthetic building materials such as luxury “LVT” vinyl flooring, “LVP” luxury vinyl plank, rubber composite products such as sports surfaces and other similar surface coatings. Since the SCRM layer is used with different surface coating material compositions, it must comprise certain qualities for all applications. However, different materials and processes must be used to manufacture the SCRM layer when it is to be used with surface coating materials having “similar” properties.

[058]The interchangeable housing system - magnetized underlayment, magnetically receptive layer and surface coating unit (e.g. modular floor coating unit) - comprises unique properties and qualities that can be utilized to work with existing building materials. Additionally, other qualities are desired in the system to be compatible with a wider range of materials and in a wider range of applications. These additional qualities include, but are not limited to, oxidation resistance, dimensional stability (i.e., will not expand or contract when exposed to external/internal elements, e.g. changes in temperature or humidity), resistance to aggressive chemicals and solvents ( e.g. cleaning products), oils, heat, flammability, abrasion, rolling loads, heavy loads, vibration, foot traffic and the like. Interchangeable housing system elements must also be receptive to the “A” side magnetized underlayment disposed on the supporting surface which must also comprise the same or similar properties.

[059] In most SCRM applications, where the SCRM layer is bonded to natural, unnatural or synthetic building materials, the production of the SCRM layer comprises the combination of ferrous compounds with a desired polymer (e.g., Chlorinated Polyethylene “CPE”) to provide the SCRM layer with the desired properties described here above. Additionally, a conditioning agent, such as "EPO" epoxidized soybean oil, is used to achieve the desired flexibility and adhesion during manufacturing.

[060] A ferrite is a type of ceramic compound composed of iron(III) oxide (Fe2O3) chemically combined with one or more additional metallic elements (e.g., iron oxide and strontium carbonate stainless iron powder, iron oxide, iron 304 and other metallic compounds). Ferrite compounds are electrically non-conductive and ferrimagnetic, meaning they can be magnetized or attracted to a magnet. Ferrites can be divided into two families based on their magnetic coercivity and their resistance to being demagnetized. Hard ferrites have high coercivity and are difficult to demagnetize. They are used to manufacture magnets, for example in devices such as refrigerator magnets, loudspeakers and small electric motors. Hard ferrites can be used in the production of the magnetic underlayment of the “A” side interchangeable case system. However, other compounds may be used in some applications for magnetic underlayment where other properties are desired. Soft ferrites have low coercivity.

[061] One embodiment of the interchangeable case system of the present invention uses a strontium ferrite compound having a hexagonal crystal structure at a size of 1.9 to 2.3 microns for the “B” side receptive layer and the magnetic underlayment. side “A”. However, the micron size of the “A” side magnetic underlayment can use an increased individual particle surface area to increase the potential magnetization. An exemplary strontium ferrite compound may have the chemical structure SrFe12O19 SrO,6Fe2O3. The mesh size of the magnetic components, as discussed below, can be optimized based on application or other requirements.

[062] Ferrites are produced by heating a mixture of finely pressed powder precursors in a mold. During the heating process, the calcination of carbonates takes place in the following chemical reaction:

MCO3 → MO + CO2

[063]The oxides of barium and strontium are typically supplied as their carbonates, BaCO3 or SrCO3. The resulting mixture of oxides undergoes sintering. Sintering is a high-temperature process similar to firing ceramic items.

[064] Subsequently, the cooled product is ground into particles smaller than 2 µm., small enough that each particle consists of a single magnetic domain. Then the powder is pressed into a shape, dried and re-sintered. Modeling can be performed in an external magnetic field, so as to obtain a preferred orientation of the particles (anisotropy). This can be used to produce an anisotropic sheet product.

[065]Small and geometrically easy shapes can be produced with dry compression. However, in such a process, small particles can agglomerate and lead to poorer magnetic properties compared to a wet compression process. Direct calcination and sintering without regrinding are also possible, but lead to poor magnetic properties.

[066]To allow efficient stacking of the product in a furnace during sintering and to prevent parts from sticking together, the product can be separated using ceramic powder separator sheets. These sheets are available in various materials such as alumina, zirconia and magnesia. They are also available in fine, medium and coarse particle sizes. By matching the material and particle size to the product being sintered, surface damage and contamination can be reduced, maximizing furnace load.

[067] Chlorinated Polyethylene Elastomers (“CPE”) and resins have excellent physical and mechanical properties, such as resistance to oils, temperature, chemicals and weather. CPE polymers, which may be referred to as "marine polymers", can be used to provide a waterproof membrane or waterproofing characteristics to a sheet product produced for the interchangeable box system (e.g., the receptive "B" layer or the “A” layer of magnetized underlayment). CPEs can also exhibit the characteristics of superior compression fit strength, flame retardancy, tensile strength and abrasion resistance, and can provide these characteristics to the magnetic underlayment or magnetically receptive layer.

[068]CPE polymers comprise many materials from rigid thermoplastics to flexible elastomers, making them highly versatile. CPE polymers are used in a variety of end-use applications, such as wire and cable coating, automotive and industrial roofing, hose and tubes, molding and extrusion, and as a base polymer. In a preferred embodiment, a CPE polymer is the desired polymer in the magnetically receptive "B" side and "A" magnetic underlayment layers of the interchangeable case system of the present invention.

[069]CPE polymers combine well with many types of plastics, such as Polyethylene, EVA and PVC, where many building materials, such as Luxury Vinyl Plank and Tile Flooring Products, are composed of such polymer combinations. CPE and other plastics can be formed into end products with adequate dimensional stability without the need for vulcanization. The excellent additive/filler acceptability characteristics of CPE polymers can provide a benefit in combinations where compound performance and economics are critical, such as in the production of magnetically receptive “B” side layers and system “A” magnetic underlayment. interchangeable case of the present invention.

[070]Epoxidized soybean oil (ESBO) is a collection of organic compounds obtained from the epoxidation of soybean oil. It is used as a plasticizer and stabilizer in polyvinyl chloride (PVC) plastics. ESBO is a viscous yellowish liquid. ESBO is made from soybean oil through the epoxidation process. Polyunsaturated vegetable oils are widely used as precursors for epoxidized oil products as they have high numbers of carbon-carbon double bonds available for epoxidation. The epoxide group is more reactive than the double bond and therefore provides a more energetically favorable site for reaction and makes the oil a good hydrochloric acid decontaminant and plasticizer. Usually, a peroxide or peracid is used to add an oxygen atom and convert the -C=C- bond into an epoxide group.

[071]Food products that are stored in glass jars are usually sealed with seals made of PVC. ESBO is typically one of the additives in PVC sealing in this type of application. It serves as a plasticizer and as a decontaminant for the hydrochloric acid released when PVC thermally degrades, e.g. when the food product undergoes sterilization.

[072] Strontium ferrite, CPE and ESBO polymers are used in the fabrication of magnetized “A” underlayment and magnetically receptive “B” side layer for the interchangeable case system of the present invention. The three compounds, strontium ferrite, CPE polymer and ESBO, are used in various formula compositions and also provide unique properties that conventional methods of bonding building materials simply do not have. The use of these compounds ensures that no volatile organic compounds “VOC” are brought into building structures - a common problem with conventional bonding systems (e.g., glue applications).

[073] The interchangeable case system of the present invention may use one of the following formulas for the composition of the magnetized “A” underlayment and magnetically receptive “B” side layer. The specific formula chosen depends on the support surface, surface coating unit, environmental conditions, and use case for the end-user interchangeable housing system. The same formula or "bulk material" can be used for both layers, however, a strontium ferrite based material is desirable for the underlayment layer and a ferrous iron based material is desirable for the magnetically receptive layer." B". The ferrous iron-based material is already at least partially oxidized providing an almost rust-proof layer. Additionally, a stainless iron blend can be used in place of ferrous iron based material.

[074] For a strontium ferrite-based underlayment or a ferrous-iron-based “B” layer, the layers begin in a non-magnetized or receptive state. Strontium ferrite is best suited for a magnetic underlayment, as strontium ferrite-based material performs better as a magnet than as a receptive layer compared to ferrous-iron-based material. Strontium ferrite is receptively weaker than ferrous iron. Ferrous iron (e.g., Fe2O3) is relatively more rust resistant and magnetically receptive than strontium ferrite. A magnetic underlayment layer comprising a mixture of strontium ferrite-based material would typically be approximately 1 mm thick. A magnetically receptive layer, such as a layer of SCRM material, comprising a mixture of ferrous iron-based material would typically be approximately 0.5 mm thick.

[075] Product composition formulas in magnetic sheet or magnetically receptive material include the following: Approximately 84% pure iron (Fe) powder, approximately 15% CPE and approximately 8% soybean oil (ESBO); 90% iron powder (Fe304), 9% CPE and 1% plasticizer (C19H3603 epoxy ester); 90% Mn-Zn (manganese/zinc) soft ferrite powder, 9% CPE and 1% plasticizer; 20 parts CPE, 150 parts stainless iron powder; and

30 parts PVC, 18 parts DOTP, 200 parts stainless iron powder. (Dioctyl terephthalate, commonly abbreviated as DOTP or DEHT, is an organic compound with the formula C6H4 2. It is a non-phthalate plasticizer, being the diester of terephthalic acid and branched-chain 2-ethylhexanol. This colorless viscous liquid can be used as an emollient for PVC plastics).

[076] These formulas are blended and formed into a sheet product that is “hot pressed” into or into an existing building material, such as one consisting of synthetic materials. Natural materials (e.g. natural wood or natural stone) are “cold pressed” into natural materials so as not to damage the natural material. The formulas given above do not comprise the sheet product most receptive to a magnetization process. The above formulas comprise a trade-off for having the strength necessary to retain a building material in a fixed position on a plane (e.g., supporting surface such as a wall or floor), and have the desired qualities set out above.

[077]Depending on the nature of the existing building material in which the magnetically receptive layer “B” or the magnetized underlayment layer “A” is arranged, different compositions may be used and are not necessarily limited to one of the formulas given above. However, the above formulas are the preferred formulas for most building material compositions and installation applications. Furthermore, depending on the material composition for the surface coating unit to which the finished sheet product (e.g., magnetic underlayment or magnetically receptive layer) is to be applied, the formula for the sheet product may change. For example, the formula may comprise mixing different powders, plasticizers and other materials into the composition of the sheet product used in the magnetic underlayment or magnetically receptive layer. Compounds that are not receptively as strong but have already been oxidized, such as ferrous oxide or stainless iron powder, are used so that the sheet product is highly resistant to rust.

[078] Exemplary processes for producing the sheet product for the magnetically receptive layer "B" or the magnetic underlayment "A" are provided in FIGS. 1 and 2. Referring first to FIG. 1, a process 100 for producing the sheet product at atmospheric pressure is provided. First, the components to produce the sheet product, such as strontium ferrite, CPE polymer and ESBO, according to the desired formula, are placed in a mixer at step 102. Then, at step 104, the materials are mixed and combined in a mixer, such as a Banbury mixer, for approximately about 15 minutes at a maximum temperature of 120°C. The blended materials are then pressed and extruded in step 106 as a sheet at a rate of approximately 10 m per minute at a temperature of approximately 80°C. At all stages of process 100, the mixture is exposed to air at atmospheric pressure and not in a vacuum or partial vacuum. An additional annealing process 408 may be performed after the mixture has been extruded as a sheet product. CPE polymers have properties that are better for dimensional stability than other possible materials, but they can still have dimensional stability issues. For formulas incorporating CPE polymers, annealing step 108 will be used, but is not required in all sheet product formulas. In another embodiment, a CPE polymer having a higher melting point can be used. A blend or blend using a higher melting point CPE polymer may require a different binder than a lower melting point CPE polymer. A blend using a high melting point CPE polymer can be blended at approximately 190°C and may also require higher temperatures in the extrusion and compression stages of sheet product formation.

[079]This vulcanize/anneale step 108 is performed before the sheet product is applied to a building material to be used as the surface coating unit. A sheet product test can be performed at the laboratory level to determine the dimensional stability of the sheet product. In order for the sheet product to be used in the attachment of a surface coating unit a desired level of dimensional stability is required. If the sheet product used as a magnetic underlayment layer “A” or magnetically receptive layer “B” is not dimensionally stable, the surface coating unit may not remain installed as desired and the system may fail. For example, in the case of a flooring material, the flooring can have a catastrophic failure due to expansion and contraction and “warp” the building material causing “splits” or “cracks” that are not desirable and would lead to an imperfect installation.

[080]Annealing is a heat treatment that alters the physical and sometimes chemical properties of a material to increase its ductility and reduce its hardness. In annealing, atoms migrate in the crystal lattice and the number of displacements decreases, leading to a change in ductility and hardness. This process makes it more workable. Annealing is used to bring a metal closer to its equilibrium state. In its heated, soft state, the uniform microstructure of a metal will allow for excellent ductility and workability. In order to perform a complete annealing on ferrous metals, the material must be heated above its upper critical temperature for sufficient time to completely transform the microstructure to austenite. The metal must then be cooled slowly, usually allowing it to cool in the furnace, in order to allow maximum transformation of the ferrite and pearlite phases.

[081]Table 1 and Table 2 provided below illustrate the dimensional change, in the length direction in Table 1 and in the width direction in

Table 2, of a sheet product after a 71 hour annealing process.

Table 1 Length Direction Length After C.

Change of % of (mm) (mm) C. (mm) Change of C. 229.16 229.04 -0.12 -0.05 209.71 209.51 -0.20 -0.10 189.44 189.22 -0.22 -0.12 129.47 129.35 -0.12 -0.09 Layer 130.04 130.03 -0.01 -0.01 Receptive, 128.29 128.29 0, 00 0.00 55°C, 71 h. 238.97 238.95 -0.02 -0.01 238.84 238.60 -0.24 -0.10 238.84 238.75 -0.09 -0.04 3400.00 3400.00 0, 00 0.00 2158.00 2156.00 -2.00 -0.09 261.46 261.40 -0.06 -0.02 260.85 260.67 -0.18 -0.07 Underlayment 234.63 234.51 -0.12 -0.05 magnetic, 240.37 240.34 -0.03 -0.01 55°C, 71 h. 231.07 230.95 -0.12 -0.05 2372.80 2370.00 -2.80 -0.12 2366.00 2366.00 0.00 0.00

Table 2 Width Direction Width (mm) After L.

Change % Change (mm) L. (mm) of L.

Layer 215.33 215.23 -0.10 -0.05 Receptive, 239.95 239.88 -0.07 -0.03 55 °C, / / / /

110.99 110.95 -0.04 -0.04 111.45 111.45 0.00 0.00 113.13 113.11 -0.02 -0.02 238.93 138.73 -0.20 -0.08 239.59 239.52 -0.07 -0.03 239.70 239.62 -0.08 -0.03 915.10 915.00 -0.10 -0.01 913.10 915 .00 -0.10 -0.01 259.49 259.40 -0.09 -0.03 259.10 259.09 -0.01 -0.00 Underlayment 239.77 239.71 -0.06 - 0.03 Magnetic, 55°C, 204.79 204.68 -0.11 -0.05 71hrs. 259.88 258.82 -0.06 -0.02 791.90 790.70 -1.20 -0.15 792.00 791.10 -0.90 -0.11

[082] After the annealing step 108, or if the annealing step 108 is not required due to the composition of the formula used for the sheet product, the sheet product is then hot pressed onto a synthetic building material product in the step 110 or cold pressed into a natural building material product at step 120 to form a finished surface coating unit. If the sheet product is not to be used in a surface coating unit and is to be used as a magnetic underlayment, a magnetization step can be performed on the sheet product to form an “A” layer of magnetic underlayment.

[083]To magnetize the “A” layer of underlayment, a magnetic roller can be used. The magnetic roller comprises a plurality of north and south poles positioned in close proximity to each other on the roller. For thicker underlayments, where a large number of north/south poles are not required to achieve a desired magnetic remanence in the material, the north/south poles can be relatively spaced on the roll. In this application, a roller comprising a plurality of magnetic washers pressed together on a rod or shaft can be used. Exemplary systems are described in the U.S. Patent Publication. 2008/0278272, entitled SHEET MAGNETIZER SYSTEMS AND METHODS THEREOF, filed April 15, 2008, Arnold; and in U.S. Patent 7,728,706 entitled MATERIAL MAGNETIZER SYSTEMS, issued June 1, 2010. Reducing the distance between the north and south poles on the roll allows more north/south poles to be magnetized in the “A” layer of magnetic underlayment, thus producing a magnetic underlayment with increased magnetic remanence. This is necessary to produce a thinner magnetic underlayment with the same or greater magnetic remanence than a thicker layer. To magnetize an “A” layer of thinner magnetic underlayment with a roller, a solid roller must be used. The solid roll may be comprised of a ferrite or neodymium metal material.

[084] A solid magnetic roll comprises a plurality of north/south poles etched or etched into the roll. The etched or etched roll is magnetized in a pulse magnetizer which may comprise a magnetic coil and an alignment field. The field in the pulse magnetizer can be set to cause the particles on the roller to point in a particular direction. The etched roller can have etched and pulse magnetized poles positioned between 1 and 2 mm apart, with closer poles being required for thinner magnetic underlayment. Another embodiment may utilize a solid roll without any etching and wherein the underlayment layer to be magnetized comprises the etched north/south poles. This provides even closer north/south poles than with an etched roller. Laser etching can be performed using prisms and gyro-powered laser diodes. The use of gyro-powered lasers maximizes the number of poles that can be transferred or etched onto a hot-pressed underlayment layer.

[085]Referring now to FIG. 2, a process 200 for producing a sheet product under non-atmospheric pressure is provided. First, the components to produce the sheet product, such as strontium ferrite, CPE polymer, ESBO, according to the desired formula are placed in a mixer in the step

202. Then, in step 204, the materials are mixed and blended in a mixer, such as a Banbury mixer, for 20 to 30 minutes at a temperature of 90 to 115°C and a pressure of 0.4 to 0.7 MPa In step 206, the sheet product is extruded at a compression rate into sheet form at a rotation rate of 4.0 to 10 meters per minute and at a temperature of 40 to 70°C. The blend is pressed into a sheet product at step 206 by mutually compacting two rolls to a specified thickness which is typically 0.3 mm in thickness for a magnetically receptive "B" layer. An additional annealing process 208 may be performed after the mixture has been extruded as a sheet product. For formulas incorporating CPE polymers, annealing step 208 will be used, but is not required in all sheet product formulas. After the annealing step 208, or if the annealing step 208 is not necessary due to the composition of the formula used for the sheet product, the sheet product is then hot-pressed onto a synthetic building material product at step 210 or cold pressed into a natural building material product at step 220 to form a finished surface coating unit. If the sheet product is not to be used in a surface coating unit and is used as a magnetic underlayment, a magnetization step can be performed on the sheet product to form an “A” layer of magnetic underlayment.

[086]Both for process 100 in FIG. 1 and for process 200 in FIG. 2, the micron size of strontium ferrite compound is approximately 38 to 62 microns. This size is the preferred micron size in all formulas for the magnetic underlayment “A” layer and magnetically receptive “B” layer.

[087]Referring now to FIG. 3, a process 300 for producing a magnetized or magnetically receptive material for use in a layer of support material is provided. For some building materials, such as carpet tile, the magnetically receptive “B” layer of the interchangeable box system is not made into a sheet product, but is combined directly into the support system which constitutes a building material that uses polymers. similar. An example of such a formula that can be incorporated into a PVC backing carpet board is 16.5% PVC, 39% calcium carbonate, 26.5% iron powder (Fe3O4), 16% plasticizer DOP (Bis2-Ethylhexyl Phthalate) or DINP (Diisononyl Phthalate) and 2% viscosity depressant & stabilizer. In this process, materials to produce the magnetized or magnetically receptive material for use in a layer of support material are introduced into a mixer at step 302. The materials are then mixed in a manner such as is described at step 104 in FIG. 1, or step 204 in FIG. 2. The blended material is then combined on a backing of a surface coating unit at step 306 to produce a finished surface coating unit having a magnetized or magnetically receptive backing layer.

[088]For the processes shown in FIG. 1, FIG. 2 and FIG. 3 , a fabrication system 900 as shown in FIG. 9 can be used. The fabrication system 900 shown in FIG. 9 provides a system for producing a magnetically receptive layer or a magnetized layer. Some elements of the system may be used to produce a type of sheet product, while others may not be used. In the exemplary embodiment shown in system 900 in FIG. 9, system 900 comprises material storage hoppers 902, 904 and 906, mixer 910, first set of rollers 922 and 924, conveyor 950, magnetizing roller 940, an annealing oven 960 and a second set of rollers 926. materials 903, 905 and 907 stored in the respective storage hoppers 904, 906 and 908 may be, for example, a combination of strontium ferrite, a polymer of CPE and ESBO, or may be more generally a combination of a magnetically receptive material, a binder or polymer and a plasticizer. Other materials may be stored in other hoppers or storage tanks as needed and as described herein. Materials 903, 905 and 907 are mixed in mixer 910, which may be a Banbury mixer, at a desired temperature and pressure for a specified period of time, and are then extruded through nozzle 912 through first set of rollers 922 and 924 in a calendered sheet product 908. Additional roll sets in addition to the first roll set 922 and 924 can also be used. A conveyor 950 can transport the calendered sheet product 908 through an annealing oven 960 and through a magnetic roller 940. Where a magnetically receptive sheet product is being produced, the magnetic roller 940 will not be used. A pulse magnetizer or other magnetizing method may be used in place of the magnetic roller 940. The annealing oven 960 may be any oven or heating source suitable for annealing the calendered sheet product 908. After the calendered sheet product 908 has been annealed and magnetized, a surface coating 932 may be unrolled from a roll 930 and hot or cold pressed onto the calendered sheet product 908 by the second set of rolls 926 and 928 to form the finished surface coating 901. Where an underlayment magnet is being produced, this finishing step will not be performed. Other materials may also be pressed onto the 908 calendered sheet product, except material unrolled from a roll.

930. For example, a magnetically receptive layer calendered sheet product 908 can be cut to size and individually pressed onto surface coating units not suitable for storage in a roll form.

[089] In another embodiment, the present invention provides a method for producing a magnetically receptive sheet product for use in surface coating systems, the method comprising: combining a ferrite compound, a polymer and a plasticizer in a vessel mixing; mixing the ferrite compound, polymer and plasticizer at a desired mixing temperature and at a desired mixing pressure to form a magnetically receptive material; and extruding the magnetically receptive material at a desired extrusion temperature to form a magnetically receptive sheet product; or applying a calendering process to the magnetically receptive layer to form a magnetically receptive sheet product.

[090] The method of the above embodiment may further comprise annealing the magnetically receptive sheet product. The method may further comprise cold pressing the magnetically receptive sheet product onto a natural material construction product. The method may further comprise heat pressing the magnetically receptive sheet product onto a synthetic material construction product. The method may further comprise magnetizing the magnetically receptive sheet product. The magnetically receptive layer may be magnetized to produce a magnetized underlayment adapted to magnetically hold and support a non-magnetized receptive layer component, the composition of the magnetically receptive material is selected from the group consisting of: for use in a calendering process: 1 ) approximately 89 to 91% pure iron (Fe) or strontium ferrite powder, approximately 8 to 9% chlorinated polyethylene elastomer polymer (CPE) and approximately 1 to 2% epoxidized soybean oil (ESBO); or 2) approximately 89 to 91% iron powder (ferrous iron oxide or ferrous ferric oxide, Fe3O4), approximately 8 to 9% CPE and approximately 1 to 2% plasticizer; or for use in an extrusion process: 3) approximately 16.5% PVC, approximately 39% calcium carbonate, approximately 26.5% iron powder, approximately 16% plasticizer and approximately 2% depressant & viscosity stabilizer.

The magnetically receptive material can be used to produce a non-magnetized receptive component for use as opposed to a magnetized underlayment component, the composition of the magnetically receptive material is selected from the group consisting of: for use in a calendering process: 1) approximately 89 to 91% Mn-Zn (manganese/zinc) soft ferrite powder, approximately 8 to 9% CPE and approximately 1 to 2% plasticizer; 2) approximately 20 parts CPE, approximately 150 parts stainless iron powder, approximately 30 parts polyvinyl chloride (PVC), approximately 18 parts dioctyl terephthalate, approximately 200 parts stainless iron powder; or for use in an extrusion process: 3) approximately 16.5% PVC, approximately 39% calcium carbonate, approximately 16% plasticizer, approximately 2% viscosity depressant & stabilizer, and at approximately 26.5 % um of: Mn-Zn (manganese/zinc) soft ferrite powder; stainless iron powder; or ferrous oxide powder or ferric oxide.

The ferrite compound can be strontium ferrite, the polymer is chlorinated polyethylene elastomer polymer (CPE), and the plasticizer is epoxidized soybean oil (ESBO). Mixing can be carried out for approximately 15 minutes, the desired mixing temperature can be 120 degrees Celsius, and the desired mixing pressure is atmospheric pressure.

The desired extrusion temperature can be 120 degrees Celsius and the magnetically receptive sheet product can be extruded at 10 meters per minute.

Mixing can be carried out for 20 to 30 minutes, the desired mixing temperature can be between 90 to 115 degrees Celsius, and the desired mixing pressure can be between 0.4 to 0.7 MPa.

The magnetically receptive sheet product can be extruded at 4 to 10 meters per minute and the desired extrusion temperature is 40 to 70 degrees Celsius. The ferrite compound may be strontium ferrite having a particle size of 38 to 62 microns.

[091] In another embodiment, the present invention provides a dimensionally stable, rust-resistant, magnetically receptive sheet product for use in surface coating systems, the sheet product being magnetized to provide a magnetized underlayment for magnetically engaging a component. non-magnetized receptive layer, the magnetized underlayment comprising: for use in a calendering process: 1) approximately 89 to 91 % pure iron (Fe) or strontium ferrite powder, approximately 8 to 9 % iron elastomer polymer chlorinated polyethylene (CPE) and approximately 1 to 2% epoxidized soybean oil (ESBO); or 2) approximately 89 to 91% iron powder (ferrous iron oxide or ferrous ferric oxide, Fe3O4), approximately 8 to 9% CPE and approximately 1 to 2% plasticizer; or for use in an extrusion process: 3) approximately 16.5% PVC, approximately 39% calcium carbonate, approximately 26.5% iron powder, approximately 16% plasticizer and approximately 2% depressant & viscosity stabilizer. The ferrite component may comprise a particle size of 38 to 62 microns.

[092] In another embodiment, the present invention provides a dimensionally stable, rust-resistant magnetically receptive component for use in surface coating systems, the magnetically receptive component being a non-magnetized receptive layer component for magnetically engaging with an underlayment. magnetised, the magnetically receptive component comprising: for use in a calendering process: 1) approximately 89 to 91% Mn-Zn (manganese/zinc) soft ferrite powder, approximately 8 to 9% CPE and approximately 1 to 2% plasticizer; 2) approximately 20 parts CPE, approximately 150 parts stainless iron powder, approximately 30 parts polyvinyl chloride (PVC), approximately 18 parts dioctyl terephthalate, approximately 200 parts stainless iron powder; or for use in an extrusion process: 3) approximately 16.5% PVC, approximately 39% calcium carbonate, approximately 16% plasticizer, approximately 2% viscosity depressant & stabilizer, and at approximately 26.5 % um of: Mn-Zn (manganese/zinc) soft ferrite powder; stainless iron powder; or ferrous oxide powder or ferric oxide.

MAGNETIC AND MAGNETICALLY RECEPTIVE ANISOTROPIC LAYERS:

[093] The magnetic and magnetically receptive layers described above for use in the magnetic box system are isotropic or “non-directional”. For an isotropic magnetic layer, there is no alignment field used in the magnetization process. This means that the underlayment and receptive layers can be installed on a surface in a direction-independent manner. In some implementations of the magnetic box system, a magnetic anisotropic or magnetically receptive sheet product is desired. In an anisotropic layer an alignment field is used in the magnetization process to align all particles in the “A” layer of magnetic underlayment in the same direction. For example, a thinner sheet product with a stronger magnetic bond may be desirable in installations where weight, but not installation directionality, is a concern.

[094] In aviation, or installing surface coating units on floors, fuselage interiors, bulkheads and other interior surfaces of an aircraft, is an application that is particularly sensitive to the weight of materials used. The use of an anisotropic combination is desirable in an aviation application due to aircraft weight concerns. A material component combination that is used for an anisotropic layer is different from that used with the isotropic and magnetically receptive magnetic layers described above, but a similar or greater magnetic force using anisotropic powders is obtained. Additionally, the layer thickness for the anisotropic layer was reduced from 1.0 mm to 0.5 mm compared to isotropic layers of ferrous iron or strontium ferrite. Reducing the thickness by at least 50% compared to isotropic layers provides a weight savings of nearly the same amount as an anisotropic layer having a similar magnetic remanence.

[095]Referring to FIG. 4, an exemplary interchangeable case system 400 comprising an isotropic surface coating unit 410 and a support surface assembly 401 with an anisotropic magnetic underlayment 402 having a thickness of 0.5 mm disposed on a support surface 404 in accordance with the present invention is provided. The isotropic surface coating unit 410 comprises a decorative or top layer 412 and an isotropic magnetically receptive "B" side layer SCRM

414. Isotropic magnetically receptive layer 414 is magnetically attracted to anisotropic magnetic underlayment 402 disposed on a support surface 404.

[096]Existing isotropic underlayments may have a thickness of 1.52 mm. However, for both isotropic and anisotropic underlayments, reducing the mesh size, thereby decreasing the micron size of the particles in the material combination used to produce the magnetic layer, increases the surface area of each individual particle. This produces a greater magnetic force due to an increased surface area per particle because of the particular crystal structures of the smaller particles. This, in turn, provides for reduced thickness and general use of raw material in the magnetic underlayment.

[097]A reduced mesh size for the raw materials used in the production of the magnetically receptive layer and magnetized underlayment provides thinner layers. For example, using a smaller mesh size provides a magnetic underlayment with a thickness of 1.0mm to be used on a flat horizontal support surface (e.g., floor coverings) and a thickness of 0.5mm on support surfaces. vertical planes (e.g. wall coverings). The smaller mesh size provides benefits to magnetically receptive layers and magnetic underlayments comprising combinations of anisotropic and isotropic materials, anisotropic materials only, or smaller mesh size isotropic materials only. The thickness of magnetically receptive or magnetic underlayments can be within +/- 0.5mm of the ideal layer thickness depending on the particular installation application for which the layer will be used and depending on how the layer will be installed or secured to a surface .

[098] The properties for both an isotropic magnetic underlayment layer and an anisotropic magnetic underlayment layer having a mesh size of 1 to 2.3 µm. for one or more of ferrite powders, iron powders and anisotropic powders are given in Table 3 and Table 4, below. Table 3 Isotropic Magnetic Underlayment Thickness ~ 1.0 mm Shore Hardness 52 to 56 Surface Magnetic Force > 410 Gauss Tensile Force > 39 g/cm2 Vertical and Horizontal Absolute Force > 12 N Table 4 Anisotropic Magnetic Underlayment Thickness ~ 0.5 mm Shore Hardness 52 to 56 Surface Magnetic Strength > 360 Gauss

Tensile Force > 24 g/cm2 Absolute Vertical and Horizontal Force >9N

[099]While anisotropic means that the magnetic underlayment is “oriented” in one direction (while isotropic is not), magnetically receptive material is isotropic. Using an anisotropic magnetic “A” layer and an isotropic magnetically receptive “B” layer allows the entire system to still be isotropic, or directionless, in nature (i.e., no fixed installation orientation for surface cladding units having a magnetically isotropic receptive layer on an anisotropic magnetic underlayment layer). Two exemplary formulas for producing the magnetic underlayment layers are provided in Table 5 and Table 6, below. Table 5 Formula 1 Ferrite powder (e.g., Fe3O4) 87% CPE (thermoplastic chlorinated polyethylene elastomer, which is produced by 12% polyethylene chlorination) Epoxidized Soybean Oil (“ESBO”) 0.8% Table 6 Formula 2 Powder of ferrite (e.g., Fe3O4) 89 % Combination of CPE and PVC 9% Plasticizer 0.5 % ESBO 1.5 %

[0100] In Formula 1, ESBO is a collection of organic compounds obtained from the epoxidation of soybean oil. It is used as a plasticizer and stabilizer in polyvinyl chloride plastics. ESBO is a viscous yellowish liquid. For both formulas, the magnetic underlayment is calendered into a sheet product without the use of a fiberglass reinforcement layer. The mixture is first mixed and blended in a Banbury mixer for 25 to 35 minutes, temperature: 120 to 135 °C, pressure: 0.4 to 0.7 MPa. The sheet product is formed by pressing the mixture onto a sheet at a rotation rate of 4.0 to 10 rpm at a temperature of 40 to 80 °C. The mixture is pressed into sheet form by mutually compacting two rolls to the specified thickness, and then placed on a series of molding rolls to adjust the exact thickness of the underlayment sheet to a desired thickness. A final UV (ultraviolet) oil coating can then be applied to a conveyor belt via a spray mist and hardened to set under an ultraviolet light. UV oil is sensitive and reactive to UV light. In this way, the coating has the desired benefit of setting very quickly (quick setting) and setting optimally at the normal speed of the manufacturing line, i.e., the operator does not need to slow down the line to allow for a long cooking or heating time for purposes of adjustment. This quick-setting feature can be included in an extrusion process or a calendering process and for use in setting a layer as an underlayment or in connection with the fabrication of surface coating components. Regarding underlayment fabrication, the magnetic underlayment sheet is then wound onto a spool and cut to the desired roll length.

[0101] In another embodiment, the present invention provides a system of surface coating components, the system when installed providing a quasi-permanent surface coating, the system comprising: a surface coating unit comprising an isotropic magnetically receptive layer; and an anisotropic magnetic underlayment disposed on a supporting surface.

[0102]The target thickness for an anisotropic magnetic underlayment can be 0.5 mm in thickness, e.g., in applications that require low profile (thickness) and low weight, such as internal surface coating for aircraft. The anisotropic magnetic underlayment may further comprise: a magnetizable material; a binder; and an oil. The magnetizable material may comprise one of: ferrous iron powder, strontium ferrite powder, neodymium powder, and a composite of neodymium and ferrous iron. The binder may comprise thermoplastic chlorinated polyethylene elastomer ("CPE"). The oil may comprise epoxidized soybean oil ("ESBO"). The anisotropic magnetic underlayment may be a calendered sheet product. A desired thickness can be a function of the composition of materials included in the extrusion or blending processes (such as a choice of exemplary formulations presented herein), extrusion spray techniques, calendering techniques, target weight, desired magnetic strength, receptivity or attraction. surface component magnetic, wall vs. flooring, and building code requirements, to name a few considerations. The anisotropic magnetic underlayment may further comprise a magnetizable material having a mesh size of 1 to 2.3 µm.

MAGNETIC NEODYM LAYER:

[0103] In another embodiment, a magnetic underlayment can be produced using a combination of neodymium powder and ferrite. An approximately 50/50 combination of neodymium powder and ferrite powder can be used to produce an anisotropic and isotropic sheet for interior or exterior use (e.g. roofing and exterior finishing). This “hybrid” combination of neodymium powder and ferrite powder provides an average eightfold increase in potential magnetic retention over a ferrite powder, but at an increased cost. A magnetic underlayment comprising a combination of neodymium powder and ferrite would be suitable for applications such as roofing, extra heavy exterior cladding, stone slab, where an increase in magnetic remanence over ferrite powder would be required.

[0104]Neodymium is an element of the family of rare earth metals. It has the atomic symbol Nd, atomic number 60 and atomic weight 144.24 g/mol. Neodymium is not found naturally in metallic form or unmixed with other lanthanides, and is usually refined for general use. Although neodymium is classified as a “rare earth”, it is no rarer than cobalt, nickel and copper ore, and is widely distributed in the earth's crust, but mainly mined in China. An “A” layer of “hybrid” magnetic underlayment comprising a combination of neodymium powder and ferrite can support significantly greater sprung weight than a ferrite powder magnetic underlayment. Layer “A” of “hybrid” magnetic underlayment comprising a combination of neodymium powder and ferrite is well suited for use as a complete roof underlayment capable of withstanding hurricane or tornado force winds. Additionally, it can be used as a fastening system for glass solar panels, reducing the cost of installing solar panels, since a significant part of the expense of installing solar panels is the fastening system and labor to install them.

[0105]The combinations of neodymium powder and “hybrid” magnetic underlayment are also suitable for installation applications where weight is a concern. Because a “hybrid” magnetic underlayment has relatively stronger pull than an underlayment combined with ferrous iron or strontium ferrite, a thinner layer can be used to achieve the same pull force. This may be desirable in aircraft and vehicle installation applications where material weight may be a concern.

[0106]The combination of neodymium with other materials in the “hybrid” magnetic underlayment can be 50 to 90% neodymium powder. For example, a composition having 91% neodymium-based material in an underlayment having a thickness of 0.5 mm will provide on the order of a 20-fold improvement in magnetic attraction or force over a 1 mm thick underlayment using non-neodymium ferrite. However, increasing the percentage of neodymium powder in the blend is undesirable as it can lead to the cracking or disintegration of the “hybrid” magnetic underlayment, as an insufficient percentage of bonding material will be present. Accordingly, the invention provides alternative formulations to balance performance characteristics with application requirements. For example, for every 10% decrease in neodymium concentrations, i.e., 91% to 81% to 71%, etc., there is a corresponding drop in magnetic force on the order of 2x, i.e., at 81% the underlayment will be 18 times stronger than a 1 mm non-neodymium-based underlayment, at 71% the underlayment will be 16 times stronger than a 1 mm non-neodymium-based underlayment, at 61% the underlayment will be 14 times stronger than a 1 mm non-neodymium-based underlayment 1mm non-neodymium base, etc. Accordingly, the ratio of neodymium powder to binder, oil and/or other materials can be selected based on application considerations to be one of: about 91% neodymium powder to about 9% binder and oil ; about 81% neodymium powder to about 19% binder and oil; about 71% neodymium powder to about 29% binder and oil; about 61% neodymium powder to about 39% binder and oil; or about 51% neodymium powder to about 49% binder and oil. The techniques described herein minimize the problem of cracking or brittleness associated with the use of neodymium-based materials.

[0107]Referring to FIG. 5, an exemplary interchangeable housing system 500 comprising a surface coating unit 510 and a support surface assembly 501 with a combination neodymium and ferrite "hybrid" magnetic underlayment 502 disposed on a support surface 504 in accordance with present invention is provided. The surface coating unit 510 comprises a decorative or top layer 512 and a magnetically receptive SCRM "B" side layer 514. The magnetically receptive layer 514 is magnetically attracted to the arranged "hybrid" neodymium and ferrite magnetic underlayment 502 on a support surface 504.

[0108] In another embodiment, the present invention provides a magnetic underlayment layer for securing magnetically receptive surface coating units to a supporting surface, the magnetic underlayment layer comprising: a neodymium powder; a binder; and an oil.

[0109]The magnetic underlayment layer may further comprise a plasticizer. The oil may comprise epoxidized soybean oil ("ESBO"). The ratio of neodymium powder to binder and oil is less than 91% neodymium powder to 9% binder and oil. The magnetic underlayment layer may further comprise a ferrite powder. The ratio of ferrite powder to neodymium powder can be 50/50.

ULTRAVIOLET-CURED OIL-BASED MAGNETIC AND MAGNETICALLY RECEPTIVE LAYERS:

[0110] As described above, the magnetically receptive layer, or SCRM, is the “B” side layer of the Interchangeable Housing System (IBS). The SCRM layer can take the form of a sheet product which is applied as the last layer in a building material, for example the raw materials comprising the sheet product can be calendered and then hot pressed, or pressed cold with resin glues as the last layer of a building material. In another embodiment, materials comprising the "B" SCRM layer can be applied to a surface coating using polymer-based oils and resin/glues and infused with ferrite powders.

[0111] However, these existing methods for applying the SCRM magnetically receptive “B” side layer to a surface coating may be cost or weight prohibitive for certain applications. The SCRM layer can be applied to a surface coating while reducing cost and thickness to meet this need using ultraviolet (“UV”) oil. UV oil is a material commonly used by surface coating unit manufacturers as a final protective layer for surface coating. For example, a surface coating unit may comprise a wear layer (i.e., a scratch resistant coating) which is placed on the surface coating unit as a topcoat as a top coat. UV oil is sprayed onto the top layer of the floor/wall unit by a set of nozzles. The sprayed surface coating unit is then carried by the mounting belt and is subjected to ultra-high intensity UV lights that harden the UV oil to set it and permanently fix the UV oil spray application to the top layer as a layer. of wear.

[0112]Referring to FIG. 6, a flowchart of a process 600 for producing a UV oil-based magnetically receptive layer is provided. In step 602, the mixture of ferrite powder and/or SCRM material of the present invention and a UV oil are added to a mixer. In step 604, the mixture of ferrite powder and/or SCRM material of the present invention and the UV oil are mixed together. In step 606, the combined blend of the combination of ferrite and/or SCRM powder material and UV oil is sprayed onto the bottom or bottom layer of the surface coating unit using the same industrial process used to produce the wear layer. The surface coating unit with the ferrite-infused UV oil is then loaded onto the mounting belt to the ultra-high intensity UV lights at step 608 where the UV oil is permanently fixed/hardened to the bottom of the surface coating unit as a completed SCRM magnetically receptive “B” side layer. The UV oil magnetically receptive layer can be less than 0.15mm thick, which is thinner than the thinnest calendered or extruded magnetically receptive sheet product possible.

[0113] A PVC-based resin can also be used in place of UV oil. For example, the combination of ferrite or SCRM powder material can be mixed with the PVC resin, which is then pulverized and then hardened in a high-temperature in-line oven on the assembly belt to fix the powder-infused PVC resin. of ferrite on the bottom of the surface coating unit as a completed SCRM magnetically receptive “B” side layer. The temperature required to set the PVC resin depends on the type of PVC resin used.

[0114]Other suitable polymers, resins, oils, other suitable liquids and other suitable semi-solid material can be sprayed onto a surface coating unit to form a SCRM layer with acceptable retention/absolute strength. The UV oil spray coating does not need to be as thick as the rolled sheet product layer and can be 0.1mm instead of 0.3-0.5mm thick. The holding force of a UV oil sprayed onto the SCRM layer is less than that of a magnetically receptive sheet product, but still sufficient to hold the surface coating unit in place. The substantially reduced cost of spraying onto a UV oil-based magnetically receptive “B” side SCRM layer allows the SCRM layer to be built into each surface coating unit, whether on the surface coating unit installed in a facility with glue or magnetically fixed.

[0115] In another embodiment, the present invention provides a method for applying a magnetically receptive layer to a surface coating unit, the method comprising: adding a combination of receptive material and an oil compound to a mixer; combining the receptive material combination and the oil compound to form a magnetically receptive oil combination; spraying the magnetically receptive oil blend onto a surface coating unit; and adjusting the magnetically receptive oil blend on the surface coating unit.

[0116] The method may further comprise wherein the receptive material combination comprises one of: ferrous iron powder, strontium ferrite powder, neodymium powder, and a composite of neodymium powder and ferrous iron. The method may further comprise wherein the oil compound comprises one of: ultraviolet ("UV") oil and polyvinyl chloride ("PVC") resin. Adjusting the magnetically receptive oil blend may further comprise adjusting the magnetically receptive oil blend by high intensity ultraviolet ("UV") lights. Adjusting the magnetically receptive oil combination may further comprise adjusting the high temperature magnetically receptive oil combination. MAGNETIC BOX SYSTEM:

[0117]Referring now to FIG. 7, a simplified perspective diagram of a surface coating assembly 700 of a modular surface coating unit 710 with a magnetically receptive layer 720 and a magnetic underlayment 730 disposed on a supporting surface 750 is provided. The modular surface covering unit 710 can be, for example, a floor covering unit, such as an LVT, stone floor or a carpet tile. In another embodiment, the surface coating unit 710 can be a rolled wallpaper or other wallcovering with a magnetically receptive layer 720 disposed on one side. In a wallcovering unit, such as a wallpaper, the magnetically receptive layer may be glued or otherwise adhered to the back or reverse side of the wallcovering unit. With the LVT floor covering unit, the magnetically receptive layer 720 would be hot pressed onto the LVT. For a stone floor, the magnetically receptive layer 720 would be cold pressed onto the stone floor as it is a natural material. For the carpet board,

the magnetically receptive layer 720 can be combined with the carpet backing. The magnetic underlayment layer 730 is disposed on a support surface 750 which can be a wall, floor, ceiling or a movable support surface, such as a trade show display, but can also be any other suitable support surface. The magnetically receptive layer 720 of the surface coating unit 710 is magnetically attracted to the magnetic underlayment layer 730 and secures the surface coating unit 710 to the supporting surface 750.

[0118] This embodiment comprises the magnetically receptive layer 720 on the surface coating unit 710 and the magnetic underlayment 730 on the supporting surface 750. However, in an alternative embodiment, the surface coating unit 710, whether a wall, floor or another coating may have a magnetic layer disposed on the back or reverse and a magnetically receptive underlayment may be disposed on the support surface. For example, when installing System 700 in an in-ground pool, a magnetically receptive layer can be glued or otherwise attached to the pool's base concrete layer. The magnetic surface coating units can then be installed almost permanently on the magnetically receptive underlayment in the pool. Alternatively, a combination of magnetically receptive material can be mixed into a fine-tuning type concrete and spread over the basement concrete layer in the pool where magnetic surface coating units can then be installed over the magnetically receptive fine-tuning layer. . Interchangeable housing system 800, described below and as shown in FIG. 8, can also be configured in this alternative way to suit particular installation applications.

[0119]Referring now to FIG. 8, a perspective view of an environment having an interchangeable box system 800 is provided. The 800 Interchangeable Box System combines features of the 860 Wall Cladding System and 810 Modular Floor Covering. The 880 magnetic underlayment on the walls is adapted to receive 870 wall cladding units, 890 trim pieces, and can also be retrofitted to mount additional accessories. such as television 892 directly or by a frame or other supporting structure affixed to the television and magnetically attached to the underlayment 880. The floor of the interchangeable box system 800 comprises the underlayment 812 and a set of floor covering layers 811. An environment that implements the 800 interchangeable box system can take any aspect of the floors or walls, altered and redecorated with minimal effort and would not require demolition or dismantling of existing decorations or fixtures.

To build an environment with the interchangeable box system 800, a support layer 890 would be attached to a wall frame.

The magnetic underlayment 880 can be attached to the backing layer, the backing layer can be impregnated with a magnetic component, a magnetic underlayment 880 can be laminated to the outside of the backing layer 900, or the backing layer 890 can be completely coated in a magnetically attractive coating.

Wallcovering units 870, trim pieces 890 and other accessories can then be magnetically, semi-permanently and detachably attached to the magnetic underlayment 880. Wallcovering units 870 can be individual surface coating units or can be a coating. surface, such as paper or vinyl wallpaper, with a magnetically receptive layer disposed on the back of the wallcovering unit 870. The underlayment 812 for the modular floor covering 810 may be attached to a surface of support as described above.

The 811 floor covering units can then be placed on the 812 underlayment. Additionally, a magnetic underlayment can be attached to a ceiling in a similar manner to the 880 underlayment on walls. Liners can be fixed to ceiling underlayment in a similar way to wall cladding units.

870.

[0120]Magnetic underlayment 880 and underlayment 812 can have the following properties: thickness of 0.060 inches (1.52 mm), hardness of Shore D60, specific gravity of 3.5, a shrinkage of 1.5% caused by heating to 158 °F (70 °C) for seven days, tensile strength of 700 psi (49 Kg/cm^2), and can have parallel poles (north/south) along the length at 2.0 mm intervals. The floor covering unit 811 and the wall covering unit 600 may have a magnetically isotropic receptive material laminated over the surface to be placed in the underlayment 812 or magnetic underlayment 880 respectively. while underlayments may use an anisotropic or isotropically magnetized flexible layer laminated or incorporated into the underlayment at the time of manufacture. Specifically, the manufacturing process described in the U.S. Published Application. US2016/0375673 can be used to manufacture magnetic underlayment for use in the system. Specifically, the process can use pulse magnetization to isotropically magnetize the 812 underlayment or 880 magnetic underlayment. Pulse magnetization uses a coil and set of capacitors to create short “pulse” bursts of energy to slowly increase the magnetic field and to completely penetrate the 812 underlayment or 880 magnetic underlayment. Pulse magnetization can also be used to anisotropically magnetize the 812 underlayment or 880 magnetic underlayment if desired.

[0121]If the magnetically attractive layer is incorporated into the underlayment 812 or underlayment 880, a dry mixture of strontium ferrite powder and rubber polymer resin (e.g., rubber, PVC, or other similar materials to make a thermoplastic binder), it is mixed, calendered and milled, then formed by a series of rolls to provide the correct width and thickness. The material is then magnetized on one side only.

[0122]The magnetic performance of fixed magnets is limited by the amount of polymer used (typically between 20 to 45% by volume), as this significantly dilutes the material's remanence. Furthermore, the molten powder has an isotropic microstructure. The dilution effect is overcome by the incorporation of an anisotropic magnetic powder. By inducing texture in the magnetic powder or grinding it to a fine micrometer scale particle size, and then setting the magnet in an alignment field, the fixed magnet can then have an intensified remanence in a particular direction. Magnetic underlayment, such as underlayment 812 or underlayment 880, is directionally magnetized to provide stronger remanence. However, the magnetically receptive sheet is not pole-oriented and therefore need not be oriented in any direction. The optimum temperature range for long-term durability of underlayment 812 or underlayment 880 is 95 to -40 °C.

[0123]For an extruded flexible magnet, the flexible granular material is heated until it begins to melt and is then forced under high pressure using a screw feed through a hardened mold that has been eroded with wire in an electrical discharge machine (EDM) ) to have the desired shape of the finished profile. Flexible magnets can be extruded into profiles that can be rolled into rolls and applied or combined. The non-magnetized side of a flexible magnet can be laminated with double-sided adhesive tape or laminated with a thin vinyl coating so that a printed layer can be applied. A fixed cushion can also be applied for flooring purposes. Anisotropic permanent flexible magnets can have a Residual Magnetic Flux Density (Br) of T(G): 0.22 to 0.23 or (2250-2350) and a Holding Power (BHC) of 159 to 174 kA/m or 2000 to 2180 (i) while flexible isotropic permanent magnets have a residual magnetic flux density (Br) of 0.14 to 0.15 T or 1400-1550 (G) and a holding power (BHC) of 100 to 111 kA/m or 1250-1400 (Oe). An anisotropic permanent flexible magnet can be 40% stronger in magnetic remanence than an isotropic one.

[0124]For the 811 floor covering units and 870 wall covering units, the magnetically receptive material of the attractive layer or semi-solid composite may have the following properties: a thickness of 0.025 inches (0.64 mm), a hardness of Shore D60, a specific gravity of 3.5, a shrinkage of 1.5% caused by heating to 158°F (70°C) for seven days, a tensile strength of 700 psi (49 kg/cm^2) and a holding force of 140 grams/cm^2.

[0125]In the 800 interchangeable housing system all components are “almost” permanently attached to the underlayment. Due to the immense surface area, magnetic resonance between the 812 underlayment or 880 underlayment and the 811 floor covering unit or 870 wall covering unit, the materials have an extremely strong hold, making the installation “almost” permanent. However, the fixture can be broken by “grabbing” a corner and forcing upwards to break the fixture, thus allowing the 811 Floorcovering Unit or 870 Wallcovering Unit to be changed on demand, something currently unavailable with any existing technology. . In the 800 Interchangeable Housing System, any material of construction with a flat support (for optimal magnetic remanence) can be used in this system. A floor covering unit 811 made of wood, for example, can also be used as a wall covering unit 870 or vice versa.

[0126]The ability to remove any part at any time during the construction process is highly desirable. If an 870 wall panel in the 870 interchangeable box system does not match correctly or needs trimming, as may be the case in many installations, an 870 wall piece can simply be removed and reattached on demand without rebate.

[0127]In the flooring industry, the prevailing method of sewing a rolled carpet requires attaching an adhesive strip to the perimeter of the room, hot melt bonding the seams, and stretching or “tensioning” the rolled floor covering to hold the product together. at the place. This allows for product failure by actual carpet delamination due to stress (primary floor support moving away from secondary support), heat distortion of finished products, joint elevation, etc. There are many ways the conventional method can fail. The 800 system eliminates these flaws and eliminates the need for masking tape as the 811 floor covering unit no longer needs to be tensioned. Magnetic remanence due to the immense surface area prevents the 811 floor covering unit from “lifting up” or moving under stress.

[0128]In the event that an existing wall or a new building wall has a defect; such as a curvature or concavity limiting magnetic remanence, one can simply use a magnetically receptive and double-sided magnetic support shim to alleviate the problem as an accessory to the interchangeable housing system. 811 floor covering units and 870 wall covering units can provide different designs, logos, textures, colors, acoustic properties, reflective properties or design elements in a room. The 810 floor covering units and 870 wall covering units may also incorporate corporate branding or other branding or sponsorship information and may be used for advertising or as signage. Home owners, business owners or designers can change any aspect of any room using the 800 on-demand interchangeable cash system at any time.

[0129]The flexible nature of the 800 interchangeable box system would also provide benefits in the film, television and theater industries. In these industries, TV sets, movie sets and the like are built in a modular fashion and typically emulate a real location in a more cost-effective way. Unfortunately, these scenarios are built for their specific use in a structure and then that structure must be stored for another “similar” use of the same scenario or a new scenario must be built each time to suit the scene. With the 800 interchangeable box system, it would be highly cost-effective and highly beneficial to change the scene from an on-demand environment utilizing the same structures. It's also economical on large studios that must have a western city setting for a first scene and then a New York City setting for another scene. The ability to use the same structures but change the 870 wallcoverings and 810 floorcovering units to simulate what is needed would be desirable and cost effective.

[0130]While the invention has been described with reference to certain preferred embodiments, it should be understood that numerous changes may be made within the spirit and scope of the inventive concept described. Also, the present invention is not to be limited in scope by the specific embodiments described herein. It is fully understood that various other embodiments and modifications of the present invention, in addition to those described herein, will become apparent to those skilled in the art from the foregoing description and accompanying drawings. Thus, other embodiments and modifications are intended to fall within the scope of the following appended claims. Furthermore, although the present invention has been described herein in the context of particular embodiments and implementations, and applications and in particular environments, those skilled in the art will appreciate that its utility is not limited thereto and that the present invention can be applied in a beneficial in various ways and environments for various purposes. Accordingly, the claims set forth below are to be interpreted in view of the full breadth and spirit of the present invention as disclosed herein.

Claims (19)

1. Surface coating system, the system when installed providing a removable fixed surface coating, the system CHARACTERIZED in that it comprises: a magnetic surface coating unit comprising a non-magnetized isotropic magnetic receiving layer; and an anisotropically magnetized underlayment disposed on a supporting surface; wherein the magnetic surface coating unit is adapted to be magnetically attracted and received opposite the anisotropically magnetized underlayment in a fixed installation and to be non-destructively removable from the anisotropically magnetized underlayment subsequent to the fixed installation. 2. System according to claim 1, CHARACTERIZED in that the anisotropically magnetized underlayment is 0.5 mm thick and comprises magnetizable material having a mesh size configured to have, when magnetized, improved magnetic attraction property and adapted to support the magnetic surface cladding the unit in a non-horizontal fixed installation, wherein the non-horizontal fixed installation is one of an indoor wall installation, an outdoor wall installation, an airplane indoor cabin installation, a roof installation outdoor or indoor ceiling installation. 3. System, according to claim 1, CHARACTERIZED in that the anisotropically magnetized underlayment comprises: a magnetizable material including an iron powder; a binder component; and an oil having properties that allow quick adjustment during manufacturing, wherein adjustment occurs at normal line speed in a calendering or extrusion process. 4. System according to claim 3, CHARACTERIZED in that the magnetizable materials comprise one of: ferrous iron powder, strontium ferrite powder, neodymium powder and a composite of neodymium powder and ferrous iron. 5. System, according to claim 3, CHARACTERIZED by the fact that the binder comprises thermoplastic chlorinated polyethylene elastomer ("CPE"). 6. System, according to claim 3, CHARACTERIZED by the fact that the oil comprises epoxidized soybean oil ("ESBO"). 7. System according to claim 1, CHARACTERIZED in that the anisotropically magnetized underlayment is one of a good calendered sheet or a good extruded sheet. 8. System according to claim 1, CHARACTERIZED by the fact that the anisotropically magnetized underlayment comprises a magnetizable material having a mesh size of 1 to 2.3 µm 9. Magnetized underlayment for attaching magnetically receptive surface coating units to a supporting surface, the magnetized underlayment CHARACTERIZED in that it comprises: a neodymium powder; a binder; and an oil having properties that allow rapid adjustment during manufacturing, wherein adjustment occurs at normal line speed in a calendering or extrusion process. 10. Magnetized underlayment, according to claim 9, CHARACTERIZED by the fact that it also comprises a plasticizer. 11. Magnetized underlayment, according to claim 9, CHARACTERIZED by the fact that the oil comprises epoxidized soybean oil (“ESBO”). 12. Magnetized underlayment according to claim 9, CHARACTERIZED by the fact that the ratio of neodymium powder to binder and oil is selected based on application considerations to be one of: about 91% neodymium powder at about 9% binder and oil; about 81% neodymium powder to about 19% binder and oil; about 71% neodymium powder to about 29% binder and oil; about 61% neodymium powder to about 39% binder and oil; or about 51% neodymium powder to about 49% binder and oil. 13. Magnetized underlayment, according to claim 9, CHARACTERIZED by the fact that the magnetic underlayment layer further comprises a ferrite powder. 14. Magnetized underlayment, according to claim 13, CHARACTERIZED by the fact that the ratio of ferrite powder to neodymium powder is 50/50. 15. A method of applying a magnetically receptive layer to a surface coating unit to produce a magnetically receptive surface coating unit adapted to be magnetically affixed opposite a magnetized underlayment, the method CHARACTERIZING that it comprises: adding a mixture of receptive material and an oil compound in a mixer; mixing the receptive material mixture and the oil compound to form a magnetically receptive oil mixture; spraying the magnetically receptive oil mixture onto a surface coating unit; and placing the magnetically receptive oil mixture into the surface coating unit. 16. Method according to claim 15, CHARACTERIZED by the fact that the receptive material mixture comprises one of: ferrous iron powder, strontium ferrite powder and neodymium powder, and composite of neodymium powder and ferrous iron . 17. Method, according to claim 15, CHARACTERIZED by the fact that the oil compound comprises one of: ultraviolet oil ("UV") and polyvinyl chloride ("PVC") resin. 18. Method, according to claim 15, CHARACTERIZED by the fact that the adjustment of the magnetically receptive oil mixture comprises quickly adjusting the magnetically receptive oil mixture by high-intensity ultraviolet (“UV”) lights. 19. Method, according to claim 15, CHARACTERIZED by the fact that the adjustment of the magnetically receptive oil mixture comprises adjusting the magnetically receptive oil mixture by high temperature.