CN107849848B - Systems, methods, and apparatus for magnetic surface coverings - Google Patents

Abstract

The present invention relates to the field of floor coverings, and more particularly to an apparatus for securing a floor covering unit to an underlay and a method of manufacturing the floor covering unit and the underlay. More particularly, the present invention relates to methods of making magnetized floor covering units and magnetized underlays for securing magnetized floor covering units.

Description

Systems, methods, and apparatus for magnetic surface coverings

Technical Field

The present invention relates to the field of floor and wall coverings, and more particularly to apparatus for securing floor covering units to underlayment and methods of making the same, as well as systems and methods for securing wall covering units to underlayment and methods of securing underlayment to wall panels.

Background

A magnet is a material that can exert a perceptible force on other materials without actually contacting the other materials. Such forces are known as magnetic forces and may attract or repel. While all known materials exert some magnetic force, for most materials, the force is too small to be easily perceived. For other materials, the magnetic force is much larger, and this material is called a magnet. Some magnets, called permanent magnets, exert a force on an object without any external influence. Iron magnetite, also known as natural magnetite, is a natural permanent magnet. Other permanent magnets may be made by subjecting certain materials to magnetic forces. These materials retain their own magnetic properties when such force is removed. These materials are generally considered to be permanently magnetized and are known as permanent magnets, although thermomagnetic properties may change over time or at elevated temperatures.

All magnets have two locations with the strongest magnetic forces. These two sites are called poles. For a rectangular or cylindrical bar magnet, the poles would be at opposite ends. One pole is called north or north and the other pole is called south or south. This term reflects one of the earliest uses of magnetic materials, such as natural magnetite. When suspended by a string, the north pole of these primary original compasses will always "look" or point north. This helps the seaman judge the direction of travel to reach the remote continents and return.

Current magnet applications include compasses, electric motors, microwave ovens, coin-freed vending machines, photographic illuminometers, automotive horns, televisions, speakers, and tape recorders. Both simple refrigerator notes and complex medical magnetic resonance imaging devices utilize magnets.

When making magnets, raw materials tend to be more important than the manufacturing process. The materials used in permanent magnets (sometimes referred to as hard materials, reflecting the early use of the alloy steels for these magnets) are different from the materials used in electromagnets.

In the field of modular floor covering unit installation, existing methods of installing such floor coverings typically involve very labor and material intensive processes. This process involves individually sticking the floor covering units using an adhesive. Adhesives are heavy, difficult to apply, costly, difficult to remove, and prone to failure. If the prior art method is used, the adhesive must be applied to the entire support surface or the entire underside of the floor covering unit. This process is laborious and expensive and creates additional costs if the floor covering unit is to be replaced or removed.

Another method for installing modular floor covering units known in the art involves the use of adhesive connectors to connect the modular floor covering units with adjacent units. This prior art "connector system" allows the modular floor covering to "float" on top of the support surface. These prior art systems use adhesive to hold the edges of adjacent floor elements together. There are several problems with using this method to install modular floor coverings.

Modular floor units are generally of a heavier nature and the bond between the brick (tile) connector and the modular floor unit is relatively weak compared to conventional adhesives. In prior art tile connectors, the connector is formed of an inert plastic coated with an adhesive. Although the connector is waterproof, it is not completely watertight. This may cause the connector to fail in some cases. The ground covering units are constantly subjected to moisture. With prior art tile connectors, the connector is waterproof because the connector has adhesive on only one side (the side facing up), making the connector less susceptible to moisture from the underlying floor. However, this ignores the adhesive failure caused by the moisture source above the connector. For example, a business such as a hotel may steam clean floor covering units connected by a prior art tile connector type adhesive connector. Further, the ground may have liquid spilled thereon frequently, and may experience wet winter weather. This "wetting" starts from above and moisture seeps down onto the face of the prior art connector, making it very susceptible to moisture and possibly causing the connector to fail.

The prior art tile connectors have high failure rates in areas that are frequently accessed and along the joints of the modular paving units. Frequent traffic from office equipment, walking, chairs, etc. places strain on these connectors. Strain forces from the high frequency of traffic may cause the connector to fail in one or more ways.

The first failure with prior art tile connector type adhesive connectors is that the glue will stretch or fail under the force of the weight created when such a chair is rolled or otherwise moved over a floor covering. To address this problem, modular floor covering installers may supplement this type of adhesive connector system with a canned spray adhesive to impart additional strength to the seams of the modular floor covering. However, doing so would lose most of the advantages of this type of connector system and introduce volatile organic chemicals ("VOCs") into the mounting area. The presence of VOCs in the installation area requires minimal additional ventilation and may also require installation of modular floor coverings during off-hours when an area is often less popular.

A second failure occurs if there is excessive force in one direction. If such a force is applied on the connector, the adhesive connectors will fail together and "bunch up" under the modular floor unit, causing a "profile" to appear under, which can be seen from above the surface of the modular floor unit.

Furthermore, prior art connectors of the prior art tile connector type can only be used with modular floor covering units having a dedicated backing (e.g., a combination glass backing) used in the manufacturing process.

Other carpet bonding methods also exist for joining two lengths of floor covering material together along a long straight seam.

Additionally, there are problems in manufacturing modular floor covering units. All flooring coverings are cut into sections. The sections may be strips of 12 inches in length and 1 to 2 inches in width, square carpet tiles of 24 "x 24", or carpet strips or carpet tiles having other standardized or customized lengths and widths. Flooring, particularly commercial flooring, may be modular flooring units (e.g., carpet vinyl resilient flooring (vinyl composition brick (VCT), Luxury Vinyl Flooring (LVF), luxury vinyl brick (LVT) or luxury vinyl substrate (LVP)), and hardwood boards) or carpet strips) due to the presence of any amount of pressure at the seams under constant pressure conditions at the seams. The pressure may include sub-surface moisture and leakage, cement degradation, stress caused by weight movement, excessive walking, temperature changes, or other environmental factors.

Current modular flooring blankets (and in some cases wide width blankets) are typically made from a layer of flocked carpet, a layer of scrim (scrim), and a layer of bonding agent. First, the binder is produced by first blending a proprietary or standardized blend of raw materials that can be made into granules or powders or both. The type of material used may vary depending on the intended use of the carpet, but may include PVC, polypropylene, rubber, fiberglass, graphite, or various other composites. The carpet for the carpet layer or the modular carpet is typically flocked and further comprises a primary backing as part of the carpet layer. First, the carpet comprises a flocked fabric with a primary backing. The carpet enters the manufacturing line for pre-flocking and may be in the form of a roll of 12 'or 15'. The roll of carpet is then passed through a series of rollers to stretch it to the desired tension. This tensioning reduces the likelihood of wrinkles forming in the finished carpet when the secondary backing is later bonded to the flocked fabric and the primary backing during the manufacturing process.

Simultaneously with tensioning the flock fabric, a roll of backing fabric tape, which may comprise a fiberglass backing fabric tape, is also tensioned. The particle and powder mixture described above is also blended and heated to form a semi-solid compound that may have a similar viscosity and consistency as the interstitial material. The glass fiber-based backing fabric strip, which is under tension and stretched straight on the assembly line, is constantly moved through the assembly process at a set forward speed.

The blended semi-solid composite was sprayed directly from the nozzle onto a glass fiber based backing fabric belt and then brushed (squeegee) to the desired height and thickness. The wiping process is guided by a set of edge dividers (edge dividers). This process results in the semi-solid composite bonding with and pressing into the fiberglass scrim tape, forming a single fiber tape and semi-solid composite layer. The glass fiber backing fabric with the semi-solid compound is then extruded under the aforementioned flocked fabric through a series of rollers to form a sandwich of flocked fabric, primary backing, semi-solid compound, and glass fiber backing fabric strip. After the components have been joined or bonded together, the layers are baked at a constant temperature in an oven, while still moving along the assembly line. After the baking process, one or more coatings may be applied to the now completed backing system and carpet roll. After the pressing and baking stage of the process, the now finished carpet continues to move to be laser cut. The edges of the cut carpet are also sanded to remove stray fabric flocking and scrim crumbs or "burrs" from the cut carpet. The above-mentioned manufacturing process is typically used to manufacture modular flooring carpet units.

Partly due to the process involved in the manufacture of the carpet, the carpet manufactured according to the above mentioned process is subjected to curling forces at its edges. This crimping stress adds external stress to the carpet seam. This type of crimping stress is particularly problematic in applications of modular flooring materials. Typically, as part of the manufacturing process, the broad width carpet or modular flooring material is subjected to a heating and cooling process in an ambient chamber after the initial assembly of the carpet or modular flooring unit has been completed, i.e., after the carpet has been extruded, baked and cut. The environmental chamber may change the relative humidity and temperature from one extreme to another, e.g., from high to low or from low to high, causing the carpet to curl in a particular direction. Depending on the direction in which the carpet curls, the carpet piece will be subjected to a treatment in which the exact opposite curl will be applied to the carpet. Applying this type of treatment and curling process to the carpet reduces the chance of curling the edges of the carpet upwards at the seams after mounting the carpet.

Additionally, with existing magnetic floor covering systems, the floor covering must be installed in a particular direction relative to the underlayment because the system is anisotropic and can only be installed in one particular orientation.

In the field of wall coverings, the process of constructing wall coverings is time consuming, expensive, and cumbersome. In both residential and commercial buildings in general, the interior walls are framed. A set of gypsum, plaster board or drywall boards is typically hung from the frame. These drywall boards are attached to a framing, which may be metal or wood, with screws or nails. These plates must then be finished before painting. Finishing processes for drywall panels typically involve mud sealing and taping (typing). Mud sealing involves applying a wet mix compound to a web or tape that has been applied to the seam of the drywall panels. The seams and edges must then be sanded prior to finishing. Finishing of drywall panels typically involves priming a surface with a primer-type paint and then painting the final wall covering over the primed surface. This process produces particulate dust contamination that is difficult to clean and control. This process also produces undesirable chemical odors due to the presence of volatile organic compounds, "VOCs," in paints, primers, and drywall boards.

Other methods of finishing walls include: the use of wood or plate elements, including "grooved-lap" type elements; applying stone, masonry or brick; applying wallpaper and decorative paper rolls using glue; applying a wall decoration; and fixing the thin wooden boards and applying the plaster coating. For any of these methods, it may also be desirable to insulate the wall by placing a layer of thermal or acoustic insulation behind the finished wall. The insulation process is an additional step that must be completed before the wall is finished and can be time consuming and cumbersome.

For all of the above mentioned methods, changing the cover can be difficult and time consuming. For example, replacing masonry wall coverings requires extensive demolition and cleaning. Changing wallpaper may require changing the drywall board to which the wallpaper is secured. Many of the above methods require destructive removal for replacement.

Additionally, due to the environment, people, etc., fitness facilities, tennis courts, parks, recreation and any other similar facilities have problems of being constantly worn and consumed, and it is difficult to perform proper maintenance and cleaning. They also typically have only one purpose and cannot be used for any activity other than the given activity for which the surface is designed. The padding may have a peel and stick backing, or an attached cushion for some sports needs, or an attached cushion for sports fields to meet ASTM standards.

Furthermore, in current countertop devices, whether the countertop is granite, stone, brick, laminate or any other material, it is common to apply it by using concrete-like substances, resins or permanently sticky substances. Typically, plywood is cut to the shape of the bottom cabinet and bolted into the cabinet. Then, if the tile floor product is to be used as a finishing layer, the concrete slab is screwed into the base plate. Then, the decor product is placed on the single ply or double ply substrate according to the decor product. In this manner, the countertop is permanently attached to the cabinet. If the end user wishes to change their countertop, the countertop must be torn away from the cabinet to accomplish this. In this process there is a great likelihood of damage to the underlying cabinet and the process is a time consuming process, making the kitchen area unusable for a long period of time.

Additionally, in existing roofing systems, whether the roof is covered with shingles, sheet metal, terracotta, or other stone material, the roof is installed over wood and adhesive type composite panels having "tar" paper or other underlayment type materials to provide moisture protection. The materials tend to overlap each other and rain-proofing materials are put into the corners and caulking-like materials are put around the vents to create a water-tight roof. Shingled roofs are almost entirely made of petrochemical (petroleum) based products with gravel-like sand that has been dried to a specific pattern. If problems occur in these roofing systems, it can be very expensive to find the problem because the finishing coating "overlaps" to ensure a seal against water. This is a permanent product and if there is a failure (e.g. a leak) a large area must be removed and replaced all the way down to the substrate. It is often difficult to matingly repair the remaining roof structure so that it appears seamless.

What is needed is: a direction independent method for installing modular floor covering units that does not require gluing to the floor covering units so that simple replacement and reuse of the modular floor covering units is provided whether the floor covering units are carpets, vinyl flooring, resilient flooring, or hardwood flooring, and a system and method for installing modular wall covering units that does not require the use of difficult to install materials and is simple to replace. Additionally, what is needed is a magnetic direction independent underlayment that can be configured in a variety of configurations suitable for individual installations, and a magnetically receptive top coat that is quasi-permanent but easily removed when cleaning of the top coat is required, has an extended service life, or requires modification during use. What is also needed is a modular roofing system with magnetic bonding that allows the roof to conform in strength to various building codes, be lighter in weight, and be made from other "more environmentally friendly" materials. Further, what is needed is a quasi-permanent bond that is strong enough to hold the finished tabletop material in place, but can also be removed with little to no marking.

Disclosure of Invention

The present invention provides systems, apparatus and methods for mounting directionally independent magnetized modular floor covering units on a magnetized underlay. The present invention provides a system and method of manufacturing a magnetic floor, and a method of installing a floor covering system, which solves the seaming and installation problems of prior art installation methods. The present invention comprises a two-part system comprising a magnetized underlay and an attractive floor covering unit. The present invention also provides a direction independent modular magnetic wall covering system as a "complete construction system". The modular magnetic wall covering system of the present invention can be used to finish a wall without the need for additional components or layers.

Typically, when the modular floor covering units are installed on a sub-floor, the modular floor covering units are applied directly to the sub-floor, which may be a concrete base plate, or to a vapour barrier underlayment that has been applied to the sub-floor. The modular floor covering units are then attached to any underlying floor using one of a variety of methods. In a first method, the modular floor covering units are completely glued to the underlying floor; this is the most common approach. In the second method, a clip connector (clip connector) system is used, which may be referred to as "floating ground". Examples of floating ground systems include Scott et al and Lautzenhiser et al, described previously. In the floating floor installation method, the floor covering unit is not adhered or attached to the base plate or the underlying floor, but is attached to an adjacent floor covering unit using a connector (e.g., a carpet clip). The present invention uses a magnetic backing that may comprise two or three layers of underlayment, but may also comprise other layer configurations.

The invention may also be used in the automotive industry where floor coverings are to be cut into a desired pattern, heated and then placed into a mold. The floor covering is then cooled to set its shape to the specifications of a particular manufacturer's car. The actual floor covering unit will be passed over powerful electromagnets on the conveyor belt before the floor covering unit is heated, cut, placed in a mould and then cooled. The carpet mat, which is located on top of the carpet in the car, has a backing. In the backing treatment, a powdered alloy may be added to the mixture. With this system, a molded floor covering unit in the car will ensure that the car mat will remain in place. This can significantly increase passenger safety, as many accidents involve the car mats suddenly bunching up as the driver moves his/her feet, resulting in the car mats bunching up under the car brakes, clutches, and accelerator pedal.

Currently, advertising on ground cover units is not cost effective in the ground cover unit industry. Due to the installation costs and the time required for changes, it is no longer sensible to use ground cover units for advertising.

Using the floor covering and underlay of the present invention, for example, a department store may use modular or roll-good floor covering units and print the advertiser's brand onto the finished surface, overlay or surface of the floor covering unit. The carpet itself, which is designed to be spun into a flocked fabric, may also be laid to form a design, pattern, text, etc. or bricks or carpet strips of different colors or patterns, vinyl flooring, resilient flooring, or hardwood flooring. When an advertising campaign is over, or when a store wishes to show another advertiser or to market another product or brand, the floor covering unit can be easily replaced with another one, and the original floor covering unit can be stored for later reuse.

Another application of the invention may be in home use. For example, if a homeowner likes a particular sports team, or a child likes a certain "favorite" movie or television character, floor covering units having patterns, colors, or designs can be easily installed at home, and can be easily replaced when the state of the homeowner changes. With conventional floor covering units, homeowners cannot so thoroughly customize their homes because of the high labor costs and the need for installation knowledge about conventional carpets and floor coverings. Stylized floors with specific designs are only used in situations such as the floors of soccer team lockers or particularly in certain department store chains. Using the method and system of the present invention, only the ground covering unit needs to be changed. The same magnetized underlayment is utilized each time a new floor covering unit is changed. Outmen who do not have carpet mounting technology can also change the floor covering unit without the help of professional installers. With this rapid and inexpensive use of the floor covering unit, commercial branding or media sales using the floor covering unit can be obtained for the first time in a cost-free manner.

For example, a girl would like to use a "Disney fairy" floor covering for her room at 4 years of birth. Her taste may change by age 6, her favorite character may now be "little bear viny" and later at age 12, may be her favorite pop band. With the floor covering of the present invention, only the top floor covering needs to be replaced, and the underlayment can be used all the time. The homeowner would not need to call for the floor covering professional installer to change the floor covering each time the taste changes. Since the present invention does not require any seaming operation by a professional, the homeowner can replace the floor covering unit by himself.

The modular magnetic wall covering system of the present invention is advantageous to the construction industry and is an improvement over the prior art because it eliminates the need for drywall. Drywall is an imperfect product. In construction, the mandatory fire rating must meet local and city-level regulations, sound insulation must be provided, and the drywall must be properly finished. Drywall must accomplish all of these things and must be a finished wall (finished wall) among the finished walls. By using wall panels composed of lighter, more fire resistant materials, such as mineral wool, the modular magnetic wall covering system of the present invention eliminates the need for drywall and all of its associated costs. The present invention greatly reduces the problems of mold and moisture caused by moisture carried under flooring materials. In high-altitude construction, current wall construction can only be started after the building has been hung with exterior glass, cladding or casting material. This is because gypsum drywall has a paper layer that is organic in nature. In a building system, moisture may be contained in the floor covering and seep into the walls. The gypsum absorbs moisture and the absorbed moisture may cause mold growth. If a building has a burst of water pipes, mold can grow on the wall within a few hours. With the system of the present invention, the materials used for wall and floor coverings have little to no organic material. By having a smaller organic material composition, the present invention greatly reduces or eliminates the obvious and costly moisture problems. Furthermore, dehumidifiers and/or heaters must be used during the construction of gypsum walls in winter/summer, which provide conditions that eliminate mold growth and dry the gypsum drywall joints within an acceptable time frame. The ability to treat the interior of a building before completing the exterior of the building amounts to significant time and money savings in the construction project.

Common contractors and construction companies using the modular magnetic wall covering system of the present invention can provide residential and commercial real estate developers with safer products, green signage, heating and cooling efficiencies, and lower construction costs with fire ratings much higher than those available with drywall-type construction, while at the same time providing consumers with the ability to customize the "fully interchangeable enclosures (box)" in which they work and live. The present invention may provide a semi-permanent or removable wall unit and may be used in applications such as gatherings and showrooms that utilize a versatile customized wall covering system to quickly change temporary wall structures.

Another benefit of the modular magnetic wall covering system of the present invention is that it will enable a "fully interchangeable enclosure" system to be used for wall, floor and ceiling coverings. The systems and methods of the present invention may be used with the modular magnetic wall covering system of the present invention to provide a "fully interchangeable cubicle" room or house to a consumer that can be easily and quickly customized. Additionally, the use of magnetic underlayers on multiple surfaces will reduce the cost of the magnetic sheet to an extent that any other material is not comparable.

The construction industry is moving towards modular construction. The finished goods are modularized in the factory and then brought to the construction site. The modular magnetic wall covering unit of the present invention is easier to construct, easier to transport, and easier to find errors than existing wall finishing or covering methods. There is a large market for modular magnetic wall covering systems.

In one embodiment, the present invention provides a system for finishing a wall, the system comprising: a set of modular wall covering units comprising an inner attracting layer and a decorative outer layer; a magnetic liner comprising an anisotropic or isotropic magnetic sheet; and a support layer including a wall plate, an insulating layer, and a cover layer.

The system of the above embodiment may further comprise a frame. The system may further comprise: wherein the supporting layer is arranged on the frame. The system may further comprise: wherein the decorative layer is adapted to simulate the appearance of brick, plaster, wood, slate, granite, painted walls, wallpaper, Venetian plaster, siding, decorative wood, trademarks, logos, or artwork. The system may further comprise: wherein the magnetic underlayment is permanently bonded to the support layer. The system may further comprise: wherein the magnetic underlayment is attached to the support layer by an adhesive or by fastening means. The system may further comprise: wherein the magnetic underlayment is supported by the fastening device. The system may further comprise: wherein a set of modular wall covering units is adapted to be releasably attached to a magnetic underlayment. The system may further comprise: wherein the wall panel comprises mineral wool. The system may further comprise: wherein the cover layer comprises a flame retardant outer layer. The system may further comprise: wherein the insulating layer comprises flame retardant glass fibers. The system may further comprise: wherein the support layer does not require modification (fining).

In another embodiment, the present invention provides a method for decorating a surface, comprising: securing a magnetic backing to the surface; and releasably attaching a set of modular wall covering units to the magnetic underlayment. The method may further comprise: a support layer is attached to the frame and a magnetic underlayment is adhered to the support surface.

In another embodiment, the present invention provides a method for manufacturing a magnetic floor underlay, the method comprising: blending a bonding compound, the bonding compound comprising a plasticizer and a metal-containing compound; stretching the base-lining fabric layer; heating the binding composition to a semi-solid state; extruding a bonding compound over the base fabric layer; uniformly spreading the bonding compound over the base fabric layer; heating the bonding compound and the scrim layer to cure the bonding compound to a solid state; and magnetizing the substrate.

In this embodiment, the metal-containing composite may comprise iron or steel particles or powder or any suitable ferromagnetic composite. The bonded composite may include PVC, polypropylene, rubber, fiberglass, graphite, or any other suitable composite blend or bonded composite. The scrim layer may be a fiberglass scrim tape. The spreading may be performed by a squeegee guided by a set of edge dividers. The vapor barrier may be a silicone vapor barrier. The scrim layer may be stretched by a set of rollers. The steam resistance may be tensioned by a set of rollers. The vapor barrier may be pressed into the bonding compound and the base fabric layer by a set of nip rollers. The substrate may be magnetized by a set of magnetic rollers. The magnetic rollers may comprise neodymium iron boron (NdFeB or NIB), samarium cobalt (SmCo), alnico, ceramic or ferrite, or super magnet type magnets. Heating of the bonding compound and the scrim layer may be performed by an oven.

In another embodiment, the present invention provides a method for manufacturing a floor covering, the method comprising: blending a bonding compound, the bonding compound comprising a plasticizer and a metal-containing compound; stretching the base-lining fabric layer; heating the binding composition to a semi-solid state; extruding a bonding compound over the base fabric layer; uniformly spreading the bonding compound over the base fabric layer; laminating a floor covering to the bonding compound and the base fabric layer; and heating the bonding composition, the scrim layer, and the floor covering to cure the bonding composition to a solid state.

In this embodiment, the metal-containing composite may comprise iron or steel particles or powder or any suitable ferromagnetic composite. The bonding compound may include PVC, polypropylene, rubber, fiberglass, graphite. The scrim layer may be a fiberglass scrim tape. The spreading may be performed by a squeegee guided by a set of edge dividers. The floor covering may be a flocked carpet layer with a primary backing. The base backing fabric may be stretched by a set of rollers. The ground cover may be tensioned by a set of rollers. The floor covering may be laminated to the bonding compound and the base fabric layer by a set of nip rollers. Heating of the floor covering, bonding compound, and base fabric layer may be performed by an oven. The floor covering may be cut into a set of floor covering units or the floor covering may be rolled into a roll. The cutting may be performed by a laser, ceramic scissors, or other suitable cutting method.

In another embodiment, the present invention provides a system for manufacturing a magnetic substrate, the system comprising: a roll of base liner web material; a set of tensioning rollers adapted to tension the base fabric material as it is being unwound; a roll of vapor barrier material; a set of tensioning rollers adapted to tension the vapor barrier material as it is unrolled; a hopper adapted to store a heated bonded composite, the bonded composite having a metal-containing component; a nozzle adapted to dispense a bonding compound on the backing fabric material; a squeegee adapted to uniformly distribute the bonding compound; an oven adapted to heat the scrim material and the bonding compound to cure the bonding compound; a set of rollers adapted to press the vapor barrier material into the bonding compound and the scrim material; a magnetizer adapted to magnetize the metal-containing compound in the binding material.

In a further embodiment, the present invention provides a system for manufacturing a floor covering adapted for use with a magnetic underlay, the system comprising: a roll of base liner web material; a set of tensioning rollers adapted to tension the base fabric material as it is being unwound; a roll of floor covering material; a set of tensioning rollers adapted to tension the floor covering as it is being deployed; a hopper adapted to store a heated bonded composite, the bonded composite having a metal-containing component; a nozzle adapted to dispense a bonding compound on the backing fabric material; a squeegee adapted to uniformly distribute the bonding compound; a set of rollers adapted to press the floor covering material into the bonding compound and the base fabric material; an oven adapted to heat the scrim material and the bonding compound to cure the bonding compound.

In a further embodiment, the present invention provides a method for installing a floor covering, the method comprising: placing a substrate on the underlying floor, the substrate having been magnetized during the manufacturing process; and placing a floor covering on the magnetized underlay, the floor covering comprising a metal-containing composite embedded in the floor covering during the manufacturing process. The underlayment may be placed in a floating floor configuration on the sub-floor or may be glued directly onto the sub-floor in areas of constant or heavy wear.

In yet another embodiment, the present invention provides a system for installing a floor covering, the system comprising: a primary backing on the underlying floor, the primary backing having been magnetized during manufacture; and a floor covering adapted to be placed over the magnetized underlay, the floor covering comprising a metal-containing composite embedded in the floor covering during manufacture.

In one embodiment, the present invention provides a method for making an isotropic backing, the method comprising: blending a bonding compound, the bonding compound comprising a plasticizer and an isotropic metal-containing compound; heating the binding composition to a semi-solid state; uniformly spreading the binding complex; and heating the bonded composite to cure the bonded composite to a solid state.

The method may further comprise: stretching the base-lining fabric layer; extruding a bonding compound over the base fabric layer; uniformly spreading the bonding compound over the base fabric layer; and laminating the vapor barrier to the bonding compound and the scrim layer. The method may further comprise: and carrying out isotropic magnetization on the bottom lining. The method may further comprise: wherein the spreading of the binding compound may be performed by a set of consecutive rollers. The method may further comprise: wherein the metal-containing compound comprises one of iron powder, iron particles, steel powder, isotropic powder, or strontium ferrite powder, and wherein the bonding compound comprises PVC, polypropylene, rubber, fiberglass, or graphite. The method may further comprise: wherein the scrim layer comprises a fiberglass scrim tape, and wherein the scrim layer is stretched by a set of rollers. The method may further comprise: wherein the spreading may be performed by a squeegee guided by a set of edge dividers. The method may further comprise: wherein the vapor barrier comprises a silicone vapor barrier, and wherein the vapor barrier is tensioned by a set of rollers and is pressed into the bonding compound and the scrim layer by a set of nip rollers. The method may further comprise: wherein the substrate is magnetized by one of the following means: neodymium iron boron (NdFeB or NIB) magnetic rollers, samarium cobalt (SmCo) magnetic rollers, alnico magnetic rollers, ceramic magnetic rollers, ferrite magnetic rollers, super magnet magnetic rollers, or pulse magnetizers.

In another embodiment, the present invention provides a method for making an isotropic floor covering comprising: blending a bonding compound, the bonding compound comprising a plasticizer and an isotropic metal-containing compound; stretching the base-lining fabric layer; heating the binding composition to a semi-solid state; extruding a bonding compound over the base fabric layer; uniformly spreading the bonding compound over the base fabric layer; laminating a floor covering to the bonding compound and the base fabric layer; and heating the bonding composition, the scrim layer, and the floor covering to cure the bonding composition to a solid state.

The method may further comprise: wherein the metal-containing composite comprises one of iron powder, iron particles, steel powder, isotropic powder, or strontium ferrite powder, and wherein the bonding composite comprises PVC, polypropylene, rubber, fiberglass, or graphite. The method may further comprise: wherein the scrim layer comprises a fiberglass scrim tape stretched by a set of rollers. The method may further comprise: wherein the spreading is performed by a squeegee guided by a set of edge dividers. The method may further comprise: wherein the floor covering comprises a flocked carpet layer with a primary backing, and wherein the floor covering is tensioned by a set of rollers. The method may further comprise: wherein a set of clip-on rollers laminate the floor covering into the bonding compound and the base fabric layer. The method may further comprise: wherein the floor covering is laser cut into one of a set of floor covering units or rolls.

In another embodiment, the present invention provides a system for manufacturing an isotropic magnetic substrate, the system comprising: a roll of base liner web material; a set of tensioning rollers adapted to tension the base fabric material as it is being unwound; a roll of vapor barrier material; a set of tensioning rollers adapted to tension the vapor barrier material as it is unrolled; a hopper adapted to store a heated bonded composite, the bonded composite having an isotropic metal-containing component; a nozzle adapted to dispense a bonding compound on the backing fabric material; a squeegee adapted to uniformly distribute the bonding compound; an oven adapted to heat the scrim material and the bonding compound to cure the bonding compound; a set of rollers adapted to press the vapor barrier material into the bonding compound and the scrim material; a magnetizer adapted to magnetize the metal-containing compound in the binding material.

In another embodiment, the present invention provides a system for making an isotropic floor covering suitable for use with a magnetic underlay, the system comprising: a roll of base liner web material; a set of tensioning rollers adapted to tension the base fabric material as it is being unwound; a roll of floor covering material; a set of tensioning rollers adapted to tension the floor covering as it is being deployed; a hopper adapted to store a heated bonded composite having an isotropic metal-containing component; a nozzle adapted to dispense the bonding compound on the backing fabric material; a squeegee adapted to uniformly distribute the bonding compound; a set of rollers adapted to press the floor covering material into the bonded composite and a base fabric material; and an oven adapted to heat the scrim material and the bonding compound to cure the bonding compound.

In another embodiment, the present invention provides a system for manufacturing a calendered isotropic bottom web, the system comprising: a polymer mixture and a metal-containing composite mixture; a blender adapted to mix the polymer mixture and the metal-containing composite mixture to form a gasket mixture; a melter adapted to heat the cushion mixture; a set of forming rollers adapted to form the dunnage mixture into a sheet of dunnage of a desired thickness; and a final set of rollers adapted to form a surface finish on the backing sheet.

The system may further comprise a pulse magnetizer adapted to isotropically magnetize the backing sheet. The system may further include a roll of adhesive sheet material adapted to be pressed onto the trimmed backing sheet material.

In another embodiment, the invention provides a system for manufacturing a floor covering adapted for use with an isotropic magnetic underlay, the system comprising: a roll of base liner web material; a set of tensioning rollers adapted to tension the base fabric material as it is being unwound; a roll of floor covering material; a set of tensioning rollers adapted to tension the floor covering as it is being deployed; a hopper adapted to store a heated bonded composite having an isotropic metal-containing component; a nozzle adapted to dispense the bonding compound on the backing fabric material; a squeegee adapted to uniformly distribute the bonding compound; a set of rollers adapted to press the floor covering material into the bonded composite and a base fabric material; and an oven adapted to heat the scrim material and the bonding compound to cure the bonding compound.

In another embodiment, the present invention provides a system for manufacturing an isotropic floor covering suitable for use with a magnetic underlay, the system comprising: a set of modular floor covering units; an isotropic magnetically receptive bottom liner; means for attaching a magnetic receiving underlay to each modular floor covering unit of a set of modular floor covering units.

The system may further comprise: wherein the modular floor covering unit comprises a floor covering type selected from the group consisting of: vinyl composition blocks (VCT), luxury vinyl blocks (LVT) or luxury vinyl tile (LVP) blocks, ceramic blocks, stone blocks, hardwood blocks, composite wood blocks, engineered hardwood blocks, and ceramic blocks.

In another embodiment, the present invention provides a method for installing an isotropic floor covering, the method comprising: placing a substrate on the underlying floor, the substrate having been magnetized during the manufacturing process; and placing a floor covering on the magnetized underlay, the floor covering comprising a magnetically receptive composite.

Drawings

In order to facilitate a thorough understanding of the present invention, reference is now made to the accompanying drawings. In the drawings, like elements are represented by like reference numerals. The drawings should not be construed as limiting the invention but are intended to be exemplary and for reference.

Figure 1 is a side cross-sectional view of an embodiment of the carpet layer and magnetic underlay of the present invention.

Fig. 2 is a cross-sectional plan view of an embodiment of the carpet layer and magnetic underlay of the present invention.

Figure 3 is a detailed cross-sectional view of the carpet layer and magnetic backing of the present invention.

FIG. 4 is a simplified diagram of an embodiment of a process for making the magnetic substrate of the present invention.

Fig. 5 is a simplified diagram of an embodiment of a process for making the magnetized carpet layer of the present invention.

Fig. 6 is a side cross-sectional view of an embodiment of the wall frame, support layer, magnetic underlayment, and wall covering unit of the present invention.

Fig. 7 is an elevation view of three stages in the installation process of the present invention.

Fig. 8 is a perspective view of an interchangeable enclosure system including modular floor and wall covering units according to the present invention.

Figure 9 is a front view of a billboard having a magnetic layer and a plurality of modular decorative panel members in accordance with the invention.

Figure 10 is a perspective view of a swimming pool with a magnetic underlayment and modular liner panel according to the present invention.

FIG. 11 is a perspective view of a typical row of houses and a row of houses having modular magnetic wall and roof shingles according to the present invention.

Fig. 12 is a perspective view of a cabinet assembly having a magnetic layer for securing a countertop with a magnetically attractable backing layer in accordance with the invention.

Fig. 13 is a perspective view of a sports field having a magnetic underlayment and a plurality of modular floor panel members in accordance with the present invention.

Fig. 14 is a perspective view of a compartment having magnetically attractable wall panels and modular trim panels according to the invention.

Detailed Description

The invention will now be described in detail with reference to exemplary embodiments shown in the drawings. While the present invention is described herein with reference to exemplary embodiments, it should be understood that the invention is not limited to such exemplary embodiments. Additional embodiments, modifications and examples, as well as other uses of the invention, will occur to those skilled in the art upon learning of the teachings herein, and all such embodiments, modifications and examples, and uses are contemplated herein as falling within, and being of significance to, the invention disclosed and claimed herein.

Referring now to FIG. 1, a side cross-sectional view of an embodiment of an installed floor covering unit 100 including a floor covering 110 and a magnetic underlay 120 is provided. The top layer is a ground cover layer 110. The floor covering 110 is placed on top of the magnetic underlay 120. The magnetic underlayer 120 includes a magnetization layer 122 and a vapor barrier 126. An embodiment of a process for producing the magnetic underlay layer 120 is shown in detail in fig. 4 and an embodiment of a process for producing the floor covering 110 is shown in detail in fig. 5.

Referring now to FIG. 4, an embodiment of a process 400 for fabricating a magnetic underlayer 120 is provided. The three main components include: magnetic underlayer 120: a fiberglass scrim portion 123 from a fiberglass scrim roll 410, as shown in fig. 3, a vapor barrier portion 126 from a silicone vapor barrier roll 420, and a semi-solid liquid blend 124 from a hopper 430, as shown in fig. 3.

According to the process 400, the magnetic liner 120 may be magnetized to a set number of magnetic poles. First, a base fabric layer 123 made of fiberglass or various other suitable compounds and blends commonly used in the industry is unwound from a roll 410 by a set of rollers 412 that stretch the base fabric layer 123 and apply a tensioning force to the base fabric layer 123. In this process, the bottom layer may be the vapor barrier 126 that is unwound from the roll 420. Vapor barrier 126 provides vapor barrier properties to the gasket 120. The above-described compounds for making the carpet layer, such as PVC, polypropylene, rubber, fiberglass, graphite, and various other compounds, are blended in hopper 430. In the hopper 430, additional "metal", metal-containing compounds, or ferromagnetic compounds that may include extremely fine particles of iron powder or stainless steel powder or any other ferromagnetic alloy, are also combined with the mixture.

The bottom liner 120 is assembled by first stretching the base fabric 123 via rollers 412 and then transferring the base fabric over a conveyor belt 414 to a hopper 430 and one or more nozzles 432 containing the composite blend. The blended raw material composite and additional blended alloy components are heated to a semi-solid form in hopper 430 and sprayed through one or more nozzles 432 onto the base lining fabric layer 123. This heated composite layer is shown in fig. 3 as composite layer 124. The base fabric layer 123 and the composite layer 124 pass under a wiper (squeegee) 434 to evenly distribute the composite layer 124 over the base fabric layer 123. Squeegee 434 can also press semi-solid composite layer 124 into base fabric layer 123. Alternatively, another set of rollers may press the layers 123 and 124 together to form a tightly bonded layer of both the base fabric 123 and the composite 124. The scrim layer 123 and the composite layer 124 then pass through an oven 440 to cure the semi-solid composite layer 124. The mat is baked at a set temperature and passed through oven 440 at the speed of the assembly line conveyor, causing composite layer 124 and scrim layer 123 to fuse together into a scrim and composite layer 127 as shown in fig. 3 and transition to a solid state.

After passing through the oven 440, the vapor barrier 126, unwound from the roll 420 and tensioned by the roller 422, is combined with the scrim and the composite layer 127 by the nip roller 452. The "complete" liner 120 thus far then passes over the high-strength electric magnet roller(s) 450, the magnet rollers 450 may comprise neodymium iron boron (NdFeB or NIB), samarium cobalt (SmCo), alnico, ceramic or ferrite, or super magnet type magnets. In another embodiment, the powered magnet roller 450 may be a pulse magnetizer. The alloy powder carried in the now solid raw material of the composite layer 124 and the base fabric layer 123 is polarized by passing it through the magnetizing roller 450. The completed magnetized underlayment 120 may then be rolled and/or modularized.

Referring now to fig. 5, an embodiment of a process 500 for making a magnetized carpet layer 110 is provided. First, the binder is created by first blending a proprietary or standardized blend of raw materials that may be pelletized or powdered or both in the hopper 530. The type of material used will vary and depend on the intended use of the carpet, but may include PVC, polypropylene, rubber, fiberglass, graphite, or various other composites. Metal alloy components are also added to the composite blend. The alloy composition may be any iron, steel, or other suitable ferromagnetic composite. The carpet or modular carpet for the carpet layer 112 is typically flocked and also includes a primary backing as part of the carpet layer. Initially, the carpet 112 includes a flocked fabric with a primary backing. The carpet enters the manufacturing line for pre-flocking and may be in the form of a roll 520 of 12 'or 15'. The carpet 112 is unwound from the roll 520 by a series of rollers 522 to stretch it out to a desired tension. This tensioning reduces the likelihood of wrinkles forming in the finished carpet 110 when bonding the secondary or primary fabric layer 114 to the flocked fabric and primary backing of the carpet layer 112.

The scrim layer 114 is unwound from a roll of scrim 510 while the flocked fabric 112 is tensioned by a roller 522, the roll of scrim 510 may comprise a fiberglass scrim tape, and the scrim layer 114 is tensioned by the roller 512. In the hopper 530, the pellet and powder mixture described above is also blended and heated to form a semi-solid compound that may have a similar viscosity and consistency to the caulk. The fiberglass based scrim tape 114, which is under tension and stretched flat on the assembly line 514, is constantly moving through the assembly process at a set forward speed.

The blended semi-solid composite is ejected from the one or more nozzles 532 directly into the composite layer 116 onto the fiberglass-based scrim tape 114 and then scrubed to a desired height and thickness with a squeegee 534. The wiping process may be guided by a set of edge dividers. This wiping process causes the semi-solid compound 116 to bond with the fiberglass based backing fabric tape 114 and press it into the fiberglass based backing fabric tape 114, thereby forming a single fiber tape and semi-solid compound layer 115. The glass fiber-based backing fabric with the semi-solid compound layer 115 is then extruded by a series of rollers 552 beneath the flocked fabric layer 112 to form a sandwich of flocked fabric and primary backing 112, semi-solid compound 116, and glass fiber-based backing fabric strip 114. After the parts have been joined or bonded together by the rollers 552, the layers are baked at a constant temperature in the oven 550 while still moving the layers along the assembly line.

The process 500 combines the alloy into the backing of the finished floor covering unit 110. However, after baking in the oven 550 in the process 500, unlike after baking in the process 400, the carpet layer 110 will not pass through a strong electric magnet, such as the magnet 450. After the baking process, one or more coatings may be applied to the now completed backing system and carpet roll. The finished product 110 may be held in a roll or it may be cut into modular floor covering units. After the pressing and baking stages of the process, the now finished carpet 110 may be laser cut. The edges of the cut carpet may also be sanded to remove stray fabric flock and scrim crumbs or "burrs" from the cut carpet.

In another embodiment, the primary backing 120 or primary backing 112 and semi-solid composite 114 may be produced as a sheet of material that may be hot pressed or otherwise combined with a top layer to produce a magnetic backing layer or magnetic receptive layer that may be applied to or combined with any other layer. In this embodiment, the backing layer or the magnetically receptive layer may be produced by a calendaring (calendaring) process. A calender is a device for processing a polymer melt into a sheet or film. The method can be used to fabricate a magnetically receptive layer.

Calenders distribute heat-softened polymer (e.g., rubber, PVC) between two or more rolls to form a continuous sheet. To start the process, the polymer is first blended and melted. Blending is a process that produces the desired polymer, and a melting process heats the blended polymer and imparts the desired consistency. The polymer is then processed through a calender and extruded at a thickness determined by the size of the gap between the last set of rollers. The last set of rollers also defines a surface finish (e.g., gloss, texture). A double-sided peel-and-stick layer or other adhesive layer may also be added to the backing layer or magnetically receptive layer produced by the calendering process. A buffer layer or other insulating layer may also be attached to the backing layer or magnetic receptive layer resulting from the calendering process. The backing layer or magnetically receptive layer resulting from the calendering process may be combined with another layer in a similar manner to that shown in fig. 4 and 5.

When a calendering process is used to create the magnetic underlayment, a blend of materials that can be magnetized must be added to the polymer mixture prior to forming the layer. One of iron powder, iron particles, steel powder, anisotropic powder, isotropic powder, or strontium ferrite powder may be added to the polymer mixture. After the calendered layer is formed, it may be magnetized. The calendered layers can then be magnetized by a pulse magnetizer or by a set of magnetic rolls.

Referring to fig. 1 and 2, a method of installing a modular floor covering 110 using a magnetized underlayment 120 on an underlying floor may be as follows.

The underlayment 120 may be first placed on the underlying floor. The underlayment 120 may float (i.e., not fixed) or may be glued directly to the underlying floor. The vapor barrier 126 may be placed closest to the underlying floor with the magnetized base fabric layer 122 facing upward away from the underlying floor. A carpet layer 110 with an embedded magnetic attraction layer is placed or laid over the underlayment 120, the carpet layer 110 may be a carpet layer in roll form or a set of modular flooring units. Due to the alloy powder in the backing on the blanket layer 110, the blanket layer 110 will be significantly magnetically attracted to the backing 120. In this way, the finished flooring material 100 need not be joined at all using seams. The installation method according to the present invention omits the use of seams to engage (or hold in place) the carpet layer 110, which may be a modular flooring unit or a longer roll carpet.

The use of the magnetized liner 120 to mount the carpet layer 110 provides several benefits over the prior art. First, it solves the problem of floor bricks and wide carpet curling. The carpet layer 110 will remain flat at all times due to the magnetic attraction between the padding 120 and the carpet layer 110. Whether the carpet layer 110 is a modular floor covering unit or a wide roll carpet, there is no need to "stitch" two carpet layers 110 together. In case of sufficient magnetism, the carpet layer 110 will resist the tensile forces from walking, furniture, machinery etc. in three axes.

This method of manufacture is useful for most floor covering applications and is not limited to carpet-based floor covering units. The method can be used with, for example, magnetized underlayment and vinyl flooring materials with minor modifications; the powdered alloy may be applied to the backing or it may be added to the vinyl blend during the manufacturing process. A plasticizer or other compound or chemical may be added to the composite layer to enable the composite layer to adhere to or be embedded in the floor covering unit. The system may also be used in vinyl composition bricks (VCT), luxury vinyl bricks (LVT) or luxury vinyl tile (LVP) bricks, and other various floor covering units, including: ceramic bricks, stone bricks, hard wood boards, composite wood boards, engineering hard wood boards and porcelain bricks. Similar modified methods may also be used to make hardwood floor coverings with embedded magnetic or magnetized composites or with magnetic or magnetized backings. The magnetic or magnetized composite or backing described herein may be applied to any suitable floor covering. These non-carpet floor coverings with magnetic layers, backings, or embedded composites can be installed in a manner similar to that used to install carpet floor coverings.

Referring now to fig. 6, a side cross-sectional view of an embodiment of a modular magnetic wall covering system 600 of the present invention including a wall frame 1000, a support layer 900, a magnetic underlayment 800, and a wall covering unit 800 is provided.

The modular magnetic wall covering system 600 may use a support layer 900, the support layer 900 including a wall panel 910, the wall panel 910 not requiring finishing nor being made of plaster. The wall panel 910 of the present invention may be comprised of a lighter, thinner panel, and in a preferred embodiment, the wall panel 910 is comprised of mineral wool. Mineral wool is a high quality insulation product made from volcanic rock that melts at high temperatures and is spun into a fine fiber mat or batting. Mineral wool burns only at temperatures in excess of 850 degrees celsius, so the fire protection is very good and provides a fire barrier for roofs, walls or floors. The mineral wool siding 910 provides a significant improvement in fire rating and sound insulation R value over conventional gypsum drywall. The support layer 900 does not require modification, unlike drywall boards would require. Thus, the support layer 900 may comprise a different material than typical drywall boards. The support layer 900 may include: wall panel 910, which may include mineral wool; a cover layer 930 that may include a fire-blocking web (webbing); and an insulating layer 920 that may include a sound dampening stock sheet. The cover layer 930, insulation layer 920, and wall panel 910 may be combined into a single sheet as support layer 900 because, unlike drywall, which must be hung, finished, primed, textured, and ultimately painted, the support layer 900 need not be a "finish coat".

The magnetic underlayment 800 is disposed between the support layer 900 and the wall covering unit 700 and abuts the cover layer 930 of the support layer (if one is used) or the wall panel 910 (if the insulation layer 920 or the cover layer 930 is not used). The magnetic underlayment 800 may be attached to the wall panel by fasteners such as nails, hook and loop, screws, or clips, or by adhesives such as glue, silicone adhesive, or the like. The magnetic underlayment may also be fastened to the support layer 900 and/or the wall frame 1000 by the fastening means 600 shown in fig. 2. The magnetic underlayment 800 may be an anisotropic or isotropic magnetic sheet material. A magnetic underlayment 800 is applied over the support layer 900. Alternatively, the magnetic underlayment 800 may be incorporated into the support layer 900 as a single sheet, thereby eliminating the need to separately attach, hang, or adhere the magnetic underlayment to the support layer 900. The combination of the support layer 900 and the magnetic underlayment 800 together as a single sheet has a high R value and substantially reduces undesirable noise pollution and echo.

In the support layer 900, mineral wool with a stiffening additive (such as glass fibers) may be used to give the board a stiffness comparable to gypsum board. Not only does mineral wool have the desired acoustic properties, but the magnetic underlayment 800 is also another acoustic resistance in the system, and the magnetic underlayment 800 may include anisotropic powders for stronger remanence, but may be isotropically independent of the magnetically receptive material. Mineral wool is an inert material and, when used in building construction, provides a number of advantages. The mineral wool insulation may be made of basalt, a rock pulp.

The supporting layer 900, which consists mainly of mineral wool or slag wool, will eliminate most of the problems of mildew and/or moisture caused by moisture present under the flooring material. In high-altitude construction, current wall construction can be started only after the building has been hung with external glass and casting material. This is because of the problems caused by the commonly used gypsum-based walls. Furthermore, during the winter/summer, during the construction of gypsum walls, dehumidifiers and/or heaters must be used to remove conditions that allow mold growth and provide a joint that allows the gypsum board to dry in an acceptable time frame. The ability to treat the inside of the building before the outside is completed by using a mineral wool support layer 900 will result in time and money savings during construction.

The outer layer is the wall covering unit 700 and the wall covering unit 700 is a "topcoat". The wall covering unit 700 may be manufactured in a similar manner to the resilient flooring product. The wall covering unit 700 may have an attraction layer 720, and the attraction layer 720 is thermally pressed as a backing into the decorative surface layer 710. The top or outer layer of the modular magnetic wall covering system 600 is a decorative surface layer 710 ("dcor" layer). The decorative surface layer 710 may be made to mimic the appearance of any surface or covering type. The finishing pattern (finish) of the decorative surface layer 710 may be virtually any finishing pattern desired by the end user, such as brick, plaster, wood, slate, granite, glossy or matte, wallpaper, Venetian plaster, traditional siding and decorative wood, trademarks, artwork, and the like. Since the modular wall covering unit 700 is not subject to traffic, it can be made thinner than a similarly sized modular floor covering unit.

Referring now to fig. 7, a front view of three stages in the installation of the modular magnetic wall covering system 600 of the present invention is provided. The wall frame 1000, which includes a set of wooden, metal or plastic frame members 510, is a support structure for the modular magnetic wall covering system 600. The support layer 900, including only the wall panel 910, is secured to the frame using fasteners 940 (which may be screws, nails, staples, or other suitable fastening means). The magnetic underlayment 800 is attached to the support layer 900 and will be disposed on the front side of the surface layer 900 and behind the back side of the modular wall covering unit 700. As described herein, the magnetic underlayment may be attached to the support layer 900 by a fastener (such as the fastening unit 600) or by an adhesive. The fastening unit 1100 may be preferred over adhesive to provide additional support for the weight of the magnetic underlayment 800 and the wall covering unit 700 to prevent sagging or drooping. After attaching the magnetic underlayment 800 to the support layer 900, the wall covering unit 700 with the decorative outer layer 710 may be placed on the magnetic underlayment 800. Additional trim pieces, such as trim piece 1200, may be used to conceal seams, provide additional support, or provide a decorative effect. The trim piece 1200 may be placed anywhere along the magnetic underlayment 800, including being placed at the middle as a wall panel or a chair rail (chair rail), at the top as a crown molding (crown molding), or at the bottom as a base plate.

The modular magnetic wall covering system 600 of the present invention is not limited to use on boards such as the supporting layer 900 or in new construction. The modular magnetic wall covering system 600 of the present invention may be used on any suitable magnetic underlayment 800. The magnetic underlayment 800 may be installed on an existing wall panel (such as a drywall) or on a ceiling or other existing wall or surface. For example, the magnetic underlayment 800 may be mounted on a collapsible wall of the exhibitively central divider or over a door, opening, or walkway. The wall covering unit 700 can then be easily placed on the magnetic underlayment 800 and removed from the magnetic underlayment 800 as desired.

Referring now to fig. 8, a perspective view of a room with an interchangeable enclosure system 1300 is provided. The interchangeable box system 1300 combines the features of the wall covering system 600 and the modular floor covering 100. The magnetic underlayment 800 on the wall is adapted to receive the wall covering unit 700, the trim piece 1200, and may also be adapted to mount additional fixtures (such as a television 1300), either directly or through a frame or other support structure attached to the television and magnetically secured to the underlayment 800. The floor of the interchangeable box system 1300 includes a pad 120 and a set of floor coverings 110. A room implementing the interchangeable enclosure system 1300 may change and re-decorate any aspect of the floor or wall with minimal effort and yet will not require removal or tearing off of existing decoration or fixtures. To construct a room with the interchangeable box system 1300, a support layer 900 may be attached to the wall frame as shown in fig. 7. The magnetic underlayment 800 may be attached to the support layer, the support layer may be impregnated with a magnetic component, the magnetic underlayment 800 may be laminated to the exterior of the support layer 900, or the support layer 900 may be completely coated with a magnetically attractive coating. The wall covering unit 700, trim piece 1200, and other securing devices may then be magnetically, semi-permanently, and releasably secured to the magnetic underlayment 800. The underlayment 120 for the modular floor covering 100 may be secured to a support surface, as described above. The floor covering unit 110 may then be placed on the underlayment 120. Additionally, the magnetic underlayment may be attached to the ceiling in a similar manner to the underlayment 800 on the wall. The ceiling bricks may be fixed to the ceiling underlayment in a similar manner as the wall covering unit 700.

The magnetic underlayment 800 and the underlayment 120 may have the following properties: 0.060 inch (1.52 mm) in thickness, Shore D60 hardness, 3.5 specific gravity, 1.5% shrinkage when heated at 158F for seven days, and 700 psi (49 Kg/cm) tensile strength²) And may have parallel holes spaced 2.0 mm apart along the length (north-south). The floor covering unit 110 and the wall covering unit 600 may have an isotropic magnetically receptive material laminated to the surface for placement on the underlayment 120 or the magnetic underlayment, respectively800, while the underlayment may use an anisotropic or isotropically magnetized flexible layer that is laminated to or incorporated into the underlayment at the time of manufacture. In particular, the manufacturing process described above in fig. 4 and 5 may use pulsed magnetization to isotropically magnetize the shim 120 or the magnetic shim 800. Pulsed magnetization utilizes a coil or set of capacitors to produce a short "pulse" energy burst to slowly increase the magnetic field and completely penetrate the shim 120 or the magnetic shim 800. If desired, the liner 120 or magnetic liner 800 may also be anisotropically magnetized using pulsed magnetization.

If a magnetically attractable layer is incorporated into the backer 120 or backer 800, a dry blend of strontium ferrite powder and a rubber polymer resin (e.g., rubber, PVC, or other similar material to make a thermoplastic binder) is mixed, calendered, and ground, then shaped by a series of rollers to give it the correct width and thickness. The material is then magnetized on only one side, as shown in fig. 4.

The magnetic properties of the bonded magnets are limited by the amount of polymer used (typically between 20 and 45 volume percent) as this significantly dilutes the remanence of the material. Additionally, melt-spun powders (melt-spun powder) have an isotropic microstructure. This dilution effect is overcome by the inclusion of anisotropic magnetic powder. By introducing texture into the magnetic powder or grinding it to a fine micron-scale particle size, and then placing the magnet in a magnetic field orientation (aligning field), the bonded magnet can have an enhanced remanence in a particular direction. In the present invention, a magnetic liner (such as liner 120 or liner 800) is magnetized directionally to impart a stronger remanent magnetization. However, the magnetically receptive sheet is not oriented with the magnetic poles, and therefore does not need to be oriented in either direction. The optimal temperature range for the long term durability of either the gasket 120 or the gasket 800 is 95C to-40C.

For extruded flexible magnets, the flexible granular material is heated until it begins to melt, and then passed through a hardening die that has been eroded by an Electrical Discharge Machine (EDM) wire using a screw feeder under high pressure to have the desired shape of the finished profile. The flexible magnets may be extruded into profiles that may be coiled into a coil as shown in fig. 4 and 5 and may be applied or combined. The printed layer may be applied by laminating the non-magnetized face of the flexible magnet with a double-sided adhesive tape, or laminating a thin vinyl overlay. Additional cushions may also be applied for flooring purposes. The anisotropic permanent flexible magnet may have a residual flux density (Br) of T (G) of 0.22 to 0.23 or (2250 to 2350) and a holding power (BHC) of 159 to 174 kA/m or 2000-2180 (Oe), while the isotropic permanent flexible magnet has a residual flux density (Br) of 0.14 to 0.15T or 1400-1500 (G) and a holding power (BHC) of 100 to 111 kA/m or 1250 to 1400 (Oe). The remanence of an anisotropic permanent flexible magnet may be 40% stronger than the remanence of an isotropic permanent flexible magnet.

For the floor covering unit 110 and the wall covering unit 700, as shown in fig. 6 and 3, respectively, the magnetically receptive material of the attracting layer 720 or the semi-solid compound 116 may have the following properties: 0.025 inch (0.64 mm) thick, Shore D60 hard, 3.5 specific gravity, shrinkage of 1.5% when heated at 158F for seven days, and tensile strength of 700 psi (49 Kg/cm)²) And the power is kept at 140 gram/cm²。

In the interchangeable box system 1300, all components are "quasi" permanently affixed to the pad. The material has a strong binding force due to the magnetic resonance of the very large surface area between the underlayment 120 or underlayment 800 and the floor covering unit 110 or the wall covering unit 700, making the installation "quasi" permanent. However, such a bond may be broken by "grabbing" the corner and prying it upward to break the bond, thereby allowing the floor covering unit 110 or the wall covering unit 700 to be changed as desired, which is currently not possible with any of the prior art. In the interchangeable box system 1300, any build material with a flat backing (to achieve optimal remanence) can be used in the system. It is also possible to use a floor covering unit 110 made of, for example, wood as the wall covering unit 700 or vice versa.

The ability to remove any one piece at any given time during the construction process is highly desirable. If the wall panels 700 in the interchangeable enclosure system 700 are not properly matched or require trimming, one can simply remove the wall panels 700 and reattach without loss (abatement) as may be the case in many installations.

In the flooring industry, the common method of joining rolled carpets using seams requires attaching nailing strips (tack strips) to the perimeter of the room, heat sealing the seams, and stretching or "tensioning" the rolled floor covering to hold the product in place. This allows product failure due to actual carpet delamination caused by tension (primary backing of flooring material is pulled away from secondary backing), thermal deformation of the finished product, lifting of the seam, etc. The traditional method has many failure modes. The system 1300 eliminates all of these failures and eliminates the need for nailing strips because the floor covering unit 110 no longer has to be tensioned. Residual magnetism due to the extremely large surface area prevents the floor covering unit 110 from "cocking" or moving under stress.

Under the condition that the existing wall or the newly constructed wall has defects; such as a crown or pit that limits remanence, one can simply use a double-sided magnetically receptive and magnetic backed shim (shim) as an attachment to an interchangeable enclosure system to alleviate this problem. The floor covering unit 110 and the wall covering unit 700 may provide different designs, logos, textures, colors, acoustic properties, reflective properties, or design elements within the room. The floor covering units 110 and the wall covering units 700 may also include business or other brand or sponsor information and may be used for advertising or as a guide sign. The homeowner, business owner, or designer can use the interchangeable box system 1300 at any time to change any aspect of any space as desired.

The flexible nature of the interchangeable box system 1300 will also provide benefits in the movie industry, television industry and theatrical industry. In these industries, televisions, movie equipment, etc. are built in modular form and often mimic real locations in a more cost effective manner. Unfortunately, for a particular use, the devices are built on a frame and the frame must be stored for another "similar" use of the device, or a new device must be built each time to satisfy the scenario. With the interchangeable enclosure system 1300, it would be more cost effective and highly beneficial to change the scene of the room by using the same frame as needed. It is also cost effective for a large studio where one western town must be set for a first scene and then new york city for another scene. The ability to use the same frame but change the wall covering 700 and the floor covering units 110 to simulate what is needed would be desirable and cost effective.

Referring now to fig. 9-14, several additional embodiments of the present invention are provided.

Figure 9 provides a front view of a billboard 1400 having a frame 1410 supported by support posts 1430. One or more magnetically attractive plates 1420 are secured to frame 1410. A plurality of modular magnetic decorative panels 1440, 1442, and 1440 may be mounted on magnetically attractive panel 1420. Magnetically attractive plate 1420 may be constructed in a similar manner to support plate 900 and magnetic underlayment 800 described above, and modular magnetic trim plates 1440, 1442, and 1440 may be similar to wall plate 700 or modular floor covering unit 110. When modular magnetic decorative panels 1440, 1442, and 1440 are placed on attractive panel 1420, one or more designs 1450 will be formed from the outward facing surfaces of modular magnetic decorative panels 1440, 1442, and 1440. In a typical billboard, a poster board is affixed to a billboard frame. Once the advertising campaign is over or the panels need to be replaced, the poster panels are overlaid with the next advertising image. The hand-painted billboard is painted on a plywood sheet fixed to a frame. Once the activity is over, the plywood pieces are whitewashed in preparation for the next design. Changing the design or image on an existing billboard can be time consuming and costly and requires constant maintenance. The billboard 1400 of the present invention provides a magnetically interchangeable system that uses residual magnetism to allow for stronger binding. The flexible magnetic sheet may be attached to the base substrate, laminated to the substrate as a plate or any other suitable configuration to form plate 1420. Flexible, magnetically receptive sheets with drawable vinyl or other suitable materials attached thereto include modular magnetic trim panels 1440, 1442, and 1440.

The strong remanence provided by the present invention reduces the likelihood of failure due to the strength of the magnetic bond. The billboard 1400 may also include LEDs, OLEDs, LCDs, or electro-luminescent elements embedded in the thermoplastic binder of the modular magnetic trim panels 1440, 1442, and 1440 and controlled by a controller board in the billboard 1400. This may enable the local illumination and sequencing of artwork, logos, etc. in modular magnetic trim panels 1440, 1442, and 1440.

Fig. 10 provides a perspective view of a swimming pool 1500 having a modular liner panel 1530 and a magnetic underlayment 1520 placed on an outer surface 1510 of the swimming pool 1500. A ferrite material encased in a polymer binder may also be added to the structure of the outer surface 1510 to eliminate the need for the magnetic underlayment 1520. In such a configuration, the liner panel 1530 would need to be magnetically attractive. Magnetic underlayment 1520 may be laminated into surface 1510 itself or attached as an inner liner to surface 1510. The sheet 1530 may have a magnetic receiving type sheet as a base layer of a flexible sheet, and may be made of printable vinyl or any other material. The plate 1530 may also confine the ferrite in the extruded mixture (trap) in a polymer so that the ferrite is not affected by corrosion or any other material configuration. Plate 1530 may also have a design that mimics traditional brick, pattern, brand, artistic word, or any other feature that a consumer may desire. Plate 1530 may also include LEDs, OLEDs, LCDs, or electroluminescent devices embedded in a thermoplastic binder.

FIG. 11 provides a perspective view of a typical house row 1600 having a standard exterior 1602 and a house row 1700 having an exterior 1702 with a modular facade 1712 and a modular roof 1720. One or more modular boards 1710 may be used on modular facade 1712. Plate 1710 may include a magnetically receptive layer, and facade 1712 may include a flexible magnetic sheet attached to a support structure or may include a support surface with an embedded ferromagnetic layer. The modular roof 1720 may include flexible magnetic sheets attached to a support structure or may include a support surface with an embedded ferromagnetic layer. Roof building tiles 1730 may be magnetically secured to roof 1720. Additionally, magnetically affixed flashing 1734 and gutters or gutters 1732 can also be attached to the modular roof 1720. Roof 1720 may include a magnetic layer adhesively secured to a substrate or a substrate layer having magnetic properties, such as a mineral wool board with a magnetic cladding. The magnetic or outer surface of roof 1720 is waterproof due to the thermoplastic binder encapsulating the strontium ferrite powder in a backing or finish. The magnetic sheet thickness of the roof 1720 is determined based on the desired remanence. For example, wind shear strength against a five-stage hurricane before failure. The modular roof 1720 would be made of a safer, environmentally friendly product and could be easily recycled. Constructors and users will be able to obtain a "green" credit (credit) to the construction system which is not only safer to construct, easier to install (on the installation side), easier to replace, but also cleaner to the environment, thus enabling end users to have a myriad of choices of products with a total price that is better than currently available.

Fig. 12 provides a perspective view of the cabinet system 1800 with the cabinet system 1800 having a magnetic layer 1810, the magnetic layer 1810 for securing a countertop 1820 with a magnetically attractive backing layer. The system 1800 may also include a magnetic layer 1812 for securing the tailgate 1822 and a plurality of cabinet doors 1852, which doors 1852 may have a magnetically attractive layer on the exterior of the doors. Sink notch 1824 can be placed in table 1820 and magnetic layer 1810. The top of the cabinet 1850 may be laminated with orientation independent magnetic sheets to form the magnetic layer 1810 as a plate system, or the magnetic layer 1810 may be glued independently of the substrate or any other configuration. If a brick product is used, the orientation independent magnetic sheet of the magnetic layer 1810 can be attached as a unit to the top of the cabinet 1850. If a ceramic block product is used, a non-sand based mud (which would provide additional support to the block deck) may be used. In the event that removal is required for retrofitting or the bricks are about to break, then a non-sand slurry between the bricks can be cut with a knife and individual bricks or the entire table 1820 can be removed in a simple, quick and non-destructive manner. A magnetically receptive sheet may be applied to the back side of table 1820, whether the layer is a solid piece of graphite, a brick, a fermi card furniture plastic overlay, or any other material that constitutes the finished table. Due to the large surface, the magnetic bond will have sufficient remanence to hold a large weight in place. This enables table 1820 to be replaced by merely replacing table 1820 in a "non-destructive" manner, so as to avoid damage to any base substrate(s) and cabinet 1850. The cabinet system 1800 enables end users to modernize their countertops 1820 with minimal effort, saving significant installation time, and providing interchangeability capabilities not currently available with conventional bonding and installation methods.

Fig. 13 provides a perspective view of a modular sports surface 1900 having magnetic underlayment 1910 and a plurality of modular floor panels 1920 forming a floor pattern 1922. For example, if a sports center has a playing surface, they currently know the size of the space. With modular magnetic surface 1900, this space can be utilized for a variety of purposes. For example, a sports facility may make an indoor tennis court from modular floor panel members 1920 having particular colors, textures, brands, logos, artistic words, and lines, all in a rolled sheet (as in a resilient flooring product or sheet product) or in a set of modular panel members 1920. When the time of use or use of the area is over, the floor panels 1920 may be rolled up or removed for storage and an entirely new set of floor panels 1920 may be quickly installed, for example, for a basketball court or any other desired configuration. This ability to have a set of "quasi" permanent floors 1920 that can be changed to meet the needs of the desired facility would be highly beneficial. The playing surface 1900 may also be rubberized for use in a playground or amusement park.

Fig. 14 provides a perspective view of a compartment 2000, the compartment 2000 having magnetically absorptive interior and exterior walls 2020, 2022 attached to a frame 2010, and a modular trim panel 2030. Compartment 2000 may also include a tabletop 2040, a cabinet 2050, partitions 2052, and drawers 2054. The compartments are usually made of alloy, are designed to be modular, have supporting legs, wiring ducts, and the cells can be configured in a variety of ways and can be adapted to changing office needs. The plates may be independent or directly attached ready made. Existing panel surface options provide a sound deadening, visible and nailable surface with a fabric or laminated covering. In the compartment 2000 of fig. 14, isotropic separate magnetic sheets are applied to the outside of the inner wall 2020 and the outer wall 2022 comprising the individual components of the compartment 2000. In existing compartments, the covering that typically glues the fabric to the frame or the outside is a permanent laminated composite. As described with respect to fig. 8, the independent magnetic orientation of the sheet may be by gluing, or otherwise directly attached to walls 2020 and 2020, or directly fastened to frame 2010, which is magnetically receptive in nature. The compartment 2000 enables a business, company or individual to change the look and feel and office environment to suit their needs, or business changes, activities, etc. in signage and design. An individual working inside the compartment will be able to design the inside with any covering that can be fixed to the magnetic walls 2020 and 2022. For example, a company employee may print a photograph, secure the photograph to the magnetically receptive thin sheet, and then secure the photograph to the interior wall 2020. The business or corporation may alter the outer wall 2022 of the compartment 2000 to meet the needs and desires of business uniformity.

While the invention has been described with reference to certain preferred embodiments, it should be understood that numerous changes could be made within the spirit and scope of the inventive concepts described. Also, the scope of the invention is not limited by the specific embodiments described herein. It is fully contemplated that various other embodiments and modifications of the present invention, in addition to those described herein, will be apparent to those skilled in the art from the foregoing description and accompanying drawings. Accordingly, such other embodiments and modifications are intended to fall within the scope of the appended claims. Further, although the present invention has been described herein in the context of particular examples, implementations, and applications in a particular environment, those of ordinary skill in the art will appreciate that its usefulness is not limited thereto and that the present invention can be beneficially applied in any number of ways and in environments directed to any number of uses. Accordingly, the claims set forth below should be construed in view of the full breadth and spirit of the present disclosure as disclosed herein.

Claims (41)

1. A method for manufacturing a magnetized underlay adapted to be placed in situ on a surface substrate and adapted to fixably receive and support a plurality of removable, magnetically receptive modular surface covering units installed in situ, the method comprising:

blending a binding compound comprising a plasticizer and a magnetizable metal-containing compound;

heating the binding complex to a semi-solid state;

uniformly dispersing and spreading the binding compound over a surface associated with a conveyor;

magnetizing the magnetizable metal-containing composite in the uniformly extended binding composite;

rolling the magnetized bonding compound into a roll, and

heating the roll of magnetized bonding compound to cure the bonding compound to a solid state;

providing a vapor barrier material;

wherein the bonding compound in the solid state provides a dimensionally stable substrate that can be placed on a surface substrate to magnetically receive a magnetically receptive surface covering component in a fixed but removable and replaceable manner, and

wherein the backing provides a vapor barrier to prevent moisture migration from the surface matrix through the backing to protect a magneto-receptive surface covering unit disposed on the backing.

2. The method of claim 1, further comprising:

a. stretching the base-lining fabric layer;

b. extruding the bonding compound over the base fabric layer;

c. uniformly spreading the bonding compound over the base fabric layer; and

d. a vapor barrier laminate is laminated to the bonding compound and the base fabric layer.

3. The method of claim 1, wherein magnetizing the magnetizable metal-containing composite in the binding composite comprises: the magnetizable metal-containing complexes in the binding complex are isotropically magnetized.

4. The method of claim 1, further comprising: wherein the dispersion and spreading of the bonded composite is performed by a set of continuous rollers in a calendering process that includes dispersing the bonded composite between two or more rollers to form a continuous sheet having a desired width and/or thickness.

5. The method of claim 1, further comprising: wherein the metal-containing composite comprises one of iron powder, iron particles, steel powder, isotropic powder, or strontium ferrite powder, and wherein the bonding composite comprises PVC, polypropylene, rubber, fiberglass, or graphite.

6. The method of claim 2, further comprising: wherein the scrim layer comprises a fiberglass scrim tape, and wherein the scrim layer is stretched by a set of rollers.

7. The method of claim 1, further comprising: wherein the spreading is performed by a squeegee guided by a set of edge dividers.

8. The method of claim 1, further comprising: wherein the vapor barrier material comprises a silicone vapor barrier layer, and wherein the vapor barrier layer is tensioned by a set of rollers and laminated into the bonded composite by a set of nip rollers.

9. The method of claim 1, further comprising: wherein the substrate is magnetized by one of the following means: neodymium-iron-boron magnetic rollers, samarium-cobalt (SmCo) magnetic rollers, alnico magnetic rollers, ceramic magnetic rollers, ferrite magnetic rollers, neodymium supermagnet magnetic rollers, or pulse magnetizers.

10. A method for manufacturing a non-magnetized magnetically receptive surface covering component adapted for removable placement in situ on a separate backing component placed over a surface substrate, the method comprising:

blending a bonding compound comprising a plasticizer and a non-magnetized magnetic metal-containing compound;

heating the binding complex to a semi-solid state;

extruding the binding complex over and on an unmodified bottom surface of a surface covering layer;

uniformly dispersing the binding complex over the unmodified bottom surface of the surface covering layer; and

heating the bonding compound and the surface covering layer to cure the bonding compound into a solid state to obtain a surface covering component;

whereby, with the surface covering component mounted over the magnetized backing component, the bottom surface faces toward the magnetized backing and support matrix, and a modified top surface of the surface covering component is exposed and faces away from the magnetized backing and support matrix.

11. The method of claim 10, further comprising: wherein the metal-containing composite comprises one of iron powder, iron particles, steel powder, isotropic powder, or strontium ferrite powder, and wherein the bonding composite comprises PVC, polypropylene, rubber, fiberglass, or graphite.

12. The method of claim 10, further comprising: a stretched scrim layer comprising a fiberglass scrim tape stretched by a set of rollers.

13. The method of claim 10, further comprising: wherein the spreading is performed by a squeegee guided by a set of edge dividers.

14. The method of claim 10, further comprising: wherein the surface covering comprises a flocked carpet layer with a primary backing, and wherein the surface covering is tensioned by a set of rollers.

15. The method of claim 12, further comprising: wherein the surface covering is laminated into the bonding compound and the scrim layer by a set of nip rollers.

16. The method of claim 10, further comprising: wherein the surface covering is laser cut into one of a set of surface covering units or rolls.

17. A system for manufacturing a magnetized underlay adapted to be placed in situ on a surface substrate and adapted to fixably receive and support a plurality of removable, magnetically receptive modular surface covering units installed in situ, the system comprising:

a blender adapted to blend a set of materials to form a bonded composite, the set of materials including a plasticizer and a magnetizable metal-containing composite;

a first heater adapted to heat the binding complex to a semi-solid state;

a dispersion member adapted to disperse the semi-solid binding compound onto the transfer member;

a spreader adapted to spread the binding composition uniformly over a surface associated with the transfer member;

a magnetizer adapted to magnetize the magnetizable metal-containing composite in the uniformly extended binding composite;

a winder adapted to roll the magnetized bonding compound into a roll;

a second heater adapted to heat the roll of magnetized bonding compound to cure the bonding compound to a solid state; and

wherein the bonding compound in the solid state provides a dimensionally stable substrate that can be placed on a surface substrate to magnetically receive a magnetically receptive surface covering component in a secured but removable state.

18. A system for manufacturing a non-magnetized magnetically receptive surface covering component adapted for removable placement in situ on a separate undercushion component that is placed over a surface substrate, the system comprising:

a blender adapted to blend a bonding compound comprising a plasticizer and a non-magnetized magnetic metal-containing compound;

a first heater adapted to heat the binding complex to a semi-solid state;

a dispersion member adapted to uniformly disperse the semi-solid binding complex over the unmodified bottom surface of the surface covering;

a second heater adapted to heat the bonding compound and surface covering to cure the bonding compound to a solid state and permanently secure the bonding compound to the surface covering to form a surface covering component;

whereby, with the surface covering component mounted over the magnetized backing component, the bottom surface faces toward the magnetized backing and support matrix, and a modified top surface of the surface covering component is exposed and faces away from the magnetized backing and support matrix.

19. The system of claim 18, wherein:

the first heater comprises a melter adapted to heat the bonded composite;

the spreader includes a set of forming rollers adapted to form the bonded composite into a sheet of dunnage of a desired thickness; and

a set of dressing rollers adapted to form a surface finish on the backing sheet.

20. The system of claim 19, wherein the magnetizer comprises a pulse magnetizer adapted to isotropically magnetize the backing sheet.

21. The system of claim 19, further comprising a roll of adhesive sheet material adapted to be pressed onto the backing sheet material.

22. The system of claim 18, wherein the surface cover component comprises a ground cover type selected from the group consisting of: vinyl composition blocks (VCT), luxury vinyl blocks (LVT) or luxury vinyl tile (LVP) blocks, ceramic blocks, stone blocks, hardwood blocks, and composite wood blocks.

23. The system of claim 20, wherein the magnetized underlayment sheet is adapted to be secured to a ground surface.

24. The system of claim 20, wherein the magnetized underlayment sheet is adapted to be secured to a wall.

25. The system of claim 18, wherein the surface covering component comprises a ground covering unit.

26. The system of claim 18, wherein the surface covering component comprises a wall covering unit.

27. The system of claim 20, wherein the isotropic magnetic backing is produced in a calendaring process.

28. The system of claim 20, wherein the isotropically magnetized backing sheet comprises a calendered magnetic sheet.

29. The system of claim 20, wherein the isotropically magnetized backing sheet is magnetized by a pulsed magnetization process.

30. A method for manufacturing a magnetized surface underlay adapted to be placed in situ on a surface substrate and adapted to fixably receive and support a plurality of removable, magnetically receptive modular surface covering units installed in situ, the method comprising:

blending a bonding compound, the bonding compound comprising a plasticizer and a metal-containing compound;

heating the binding complex to a semi-solid state;

extruding the binding compound over a surface of a conveyor belt;

spreading the binding compound uniformly over the surface of the conveyor belt;

directionally magnetizing the bonding compound to provide a strong remanence adapted to magnetically receive and support a magnetically receptive cover member that is not oriented with magnetic poles to provide a mounting configuration that is oriented independent of a magnetic direction;

rolling the magnetized binding complex into a roll of magnetized binding complex; and

heating the rolled, magnetized bonding composite at 158 degrees Fahrenheit to cure the bonding composite to a solid state to achieve a shrinkage of 1.5% and a tensile strength of 700 psi (49 Kg/cm)²）。

31. The method of claim 30, further comprising: wherein the metal-containing composite comprises one of an iron powder, an iron particle, a steel powder, an anisotropic powder, an isotropic powder, or a strontium ferrite powder.

32. The method of claim 30, further comprising: wherein the bonding compound comprises PVC, polypropylene, rubber, fiberglass, or graphite.

33. The method of claim 30, further comprising: a scrim layer located on a surface of the conveyor belt and receiving the extruded, semi-solid, bonded composite, and wherein the scrim layer comprises a fiberglass scrim belt.

34. The method of claim 30, further comprising: wherein the spreading is performed by a squeegee guided by a set of edge dividers.

35. The method of claim 30, further comprising: a vapor barrier is laminated to the bonding compound to prevent moisture migration from the surface matrix through the backing to protect the magneto-receptive surface covering unit disposed on the backing.

36. The method of claim 33, further comprising: wherein the base fabric layer is stretched by a set of rollers.

37. The method of claim 35, further comprising: wherein the vapor lock is tensioned by a set of rollers.

38. The method of claim 35, further comprising: wherein the vapor barrier is pressed into the bonding compound by a set of nip rollers.

39. The method of claim 30, further comprising: wherein the substrate is magnetized by a set of magnetic rollers.

40. The method of claim 39, further comprising: wherein the set of magnetic rollers comprises neodymium iron boron, samarium cobalt (SmCo), alnico, ceramic or ferrite, or a neodymium supermagnet type magnet.

41. The method of claim 30, further comprising: wherein the heating of the bonded composite is performed by an oven.

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