CN113795641A

CN113795641A - System and method for producing magnetic receptive and magnetic layers for surface covering systems

Info

Publication number: CN113795641A
Application number: CN202080022340.8A
Authority: CN
Inventors: S·S·勒布朗; L·L·劳岑海泽; M·勒布朗
Original assignee: Golconda Holdings LLC
Current assignee: Golconda Holdings LLC
Priority date: 2019-01-18
Filing date: 2020-01-20
Publication date: 2021-12-14
Also published as: EP3911817A4; WO2020150719A1; AU2020208653A1; ZA202105932B; BR112021014196A2; EP3911817A1; CA3133567A1

Abstract

A method for producing a surface covering system comprising a magnetically receptive layer secured to a surface covering element and a magnetized backing layer for securing the surface covering element to a support surface. The system comprises isotropically magnetized floor covering elements and an anisotropically magnetized mat for fixing the surface covering elements. The system includes a set of formulations including ferrite and rare earth materials, oil and plasticizer, and binders to optimize performance to meet design and application criteria.

Description

System and method for producing magnetic receptive and magnetic layers for surface covering systems

Technical Field

The present invention relates to the field of surface coverings, and more particularly, the present invention relates to systems and methods for producing magnetic receptive and magnetic layers for surface covering systems for interior and exterior applications.

Background

In the field of modular floor covering unit installation, existing methods of installing such floor coverings typically involve very labor and material intensive methods. The method involves preparing a support surface, such as a sub-floor, and separately bonding the floor covering units together using an adhesive. Adhesives are heavy, difficult to apply, expensive, difficult to remove, and prone to failure. Additional problems include moisture migration, mold, cracking, and the like. With this prior art method, the adhesive must be applied to the entire support surface or the entire underside of the floor covering unit. This method is expensive, both in terms of labor and money, and creates additional costs if the floor covering unit is to be replaced or removed. Another installation technique involves so-called floating floors, which are prone to movement, bending and other problems.

Another method known in the art for installing modular floor covering units involves the use of adhesive connectors to connect the modular floor covering units with adjacent units. Such "connector systems" of the prior art allow modular floor coverings to "float" on top of a support surface. These prior art systems use an adhesive to hold the edges of adjacent floor elements together. One such system and method is that granted 5 months and 7 days in 2013 (ScottEt al) SYSTEM FOR CARPET TILE instatalation of U.S. patent No. 8,434,282.ScottMethod described by the et alA single-sided pressure sensitive adhesive sheet of about 72 square millimeters is utilized with a releasable protective layer to join the four portions of the modular flooring unit together. There are several problems with using this method to install modular floor coverings, including replacement of individual floor covering units, difficulty in installation, and durability of the installation method.

Other carpet stitching methods also exist for joining two lengths of floor covering material together along a long, straight seam. Such methods include those authorized at 9/1/1998: (Covert) CARPET SEAMING APPATUS AND METHOD OF UTILIZING THE SAME OF US Patent No. 5,800,664 AND filed 6/19/2014 (LeBlancEt al) of U.S. patent application No. 14/309,632, SEAMING appatatus AND METHOD. There are additional methods for securing modular floor covering units together in a "floating floor" configuration that overcomeScottAnd the problems and difficulties posed by the prior art. Such METHODs include MODULAR CARPET SEAMING APPATUS AND METHOD, filed on 2, 10/2015: (LautzenhiserEt al) U.S. patent application No. 14/618,752.

Improvements have been made to these systems and methods for securing floor coverings, including the use of magnetic underlayments with a magnetically receptive layer secured (secure) or secured (affix) to the floor covering elements. In addition to floor covering applications, wall covering applications, ceiling covering applications, roofing and exterior wall covering applications all have different environmental concerns and considerations that must be factored into determining suitable materials with suitable properties for installation and use. For example, external applications will involve exposure to the sun, wind, rain, storms, and other weather-related conditions. "surface" covering applications broadly refer to wall and floor covering applications unless otherwise indicated.

The magnetic systems are generally anisotropic, meaning that they are directionally dependent, and may require that both the surface covering component and the cushion component be arranged in an oriented manner. Such purely anisotropic systems suffer from several disadvantages, including the need to place and align components in a defined manner, which increases complexity and cost of installation and materials. The isotropic material is directionally independent. Plastic adhesives can be used to make flexible, flexible magnetic sheets, but this generally results in lower magnetic strength.

Examples of such systems and methods are described at least inLautzenhiserU.S. patent application 16/013,902 entitled MODULAR MAGNETICALLY RECEPTIVE WOOD AND ENGINEERED WOOD SURFACace UNITS AND MAGNETIC BOX SYSTEM FOR COVERING FLOORS, WALLS, AND OTHER SURFACES, filed on 20/6/2018;LautzenhiserU.S. patent application 15/083,255 entitled SYSTEM, METHOD, AND APPATUS FOR MAGNETIC SURFACace COVERINGS, filed on 28.3.2016;LautzenhiserU.S. patent application 15/083,231 entitled SYSTEM, METHOD, AND APPATUS FOR MAGNETIC SURFACace COVERINGS, filed 3, 28, 2016 (granted as U.S. patent 10,189,236, 1, 29, 2019); andLeBlancU.S. provisional patent application 62/522,513, entitled MODULAR MAGNETIC WOOD AND ENGINEERED WOOD FLOORING UNIT UTILIZING A MAGNET BOX SYSTEM FOR FLOORS, WALLS, AND OTHER SURFACES, filed on 20/6.2017.

However, using existing systems and methods for installing floor and wall covering units, as well as systems and methods for producing such installation systems, presents problems when combining different material types and when producing the necessary system components. Existing systems may not be sufficiently dimensionally or structurally stable to be optimally suited for high flow rates or use conditions, such as commercial applications. The materials and production methods used to manufacture existing floor/wall covering systems may not be capable of producing floor covering units and installation materials with the desired durability and stability required for commercial applications and long-term installation. Furthermore, with existing systems (including existing magnetic floor covering systems), the receptive layer and the magnetic layer may be too thick or heavy or have too weak a remanence for a particular application.

There is a need for a system and method for producing modular floor covering units that is compatible with a wide variety of floor covering materials and support surface types and compositions. Further, there is a need for a system and method for producing and installing modular floor covering units that is dimensionally and structurally stable and suitably lightweight with at least a minimum remanence for a particular installation application.

There is also a need for systems and methods suitable for wall covering applications that have suitable magnetic or holding strength to maintain the positioning of the surface covering assembly relative to the underlying and supporting underlayment assemblies adhered to the wall or other support structure.

There is also a need for systems and methods suitable for exterior wall covering applications that have suitable magnetic or retention strength to maintain the positioning of the surface covering assembly relative to an underlying and supporting underlayment assembly adhered to an exterior wall or other support structure. The magnetic strength or holding strength of the system must be capable of withstanding the shear forces associated with gravity as well as wind and other environmental conditions (e.g., hurricanes, tornadoes, falling debris, animals).

There is also a need for systems and methods suitable for use in exterior roof covering applications that have suitable magnetic or holding strength to maintain the positioning of the roof covering assembly relative to an underlying and supporting underlayment assembly that is adhered to an exterior roof or other support structure. The magnetic strength or holding strength of the system must be capable of withstanding the shear forces associated with gravity as well as wind and other environmental conditions (e.g., hurricanes, tornadoes, falling debris, animals).

There is also a need for a system and method suitable for wall, floor and ceiling coverings in aircraft applications that has suitable magnetic or retention strength to maintain the positioning of the surface covering assembly relative to an underlying and supporting underlayment assembly that is adhered to a wall ceiling or other support structure. There is a need for a thin, lightweight system that is particularly suited for aircraft having stringent requirements for minimizing installed weight and depth.

There is also a need for a method of manufacturing a magnetic surface covering system component using rare earth materials and which is suitable for aligning crystal structures to increase strength and limit thickness.

Disclosure of Invention

The present invention provides systems, devices and methods for producing magnetic receptive and magnetic layers for surface covering systems. The present invention provides a system and method for manufacturing a magnetic receptive layer and a magnetic layer for a surface covering system that solves the problems of existing magnetic surface covering systems. The present invention comprises a two-component system comprising a magnetized underlay and an attractive floor covering unit.

The present invention provides systems and methods for producing a magnetic receptive layer and a magnetic underlayment as a sheet article for attaching a surface covering unit to a support surface in an interchangeable case system. The magnetic receptive layer and magnetic underlayment of the present invention are more suitable for installation in residential and commercial applications than the systems and methods disclosed in the prior art, and provide benefits including increased durability, improved dimensional stability and wider material compatibility than those used in known surface covering systems.

The materials, compounds and methods used to produce the magnetic receptive layer and magnetic underlayer of the present invention provide significant improvements over prior art systems and methods.

In a first embodiment, the present invention provides an isotropic magnetic receptive layer and an anisotropic magnetic underlayer. The magnetic receptive layer is disposed on the bottom or underside of the surface covering unit. The magnetic cushion is disposed on the support surface. An anisotropic magnetic underlayer is much thinner than a similar isotropic magnetic underlayer, but retains similar retention characteristics. For example, the anisotropic magnetic underlayer can be thinner by up to 50% while maintaining the retention characteristics within 20% of a twice as thick isotropic magnetic underlayer.

In another embodiment, the present invention provides a "hybrid" magnetic underlayer. The "hybrid" magnetic backing layer comprises a blend of neodymium and ferrite powders. The "hybrid" magnetic underlayment may be similar in size to the ferrite powder magnetic underlayment, but may have a retention strength eight times greater than the ferrite powder magnetic underlayment. A "hybrid" magnetic underlayer may be suitable for applications where increased holding strength is desired and the increased cost associated with neodymium powder is not a primary concern.

In another embodiment, the present invention provides a system and method for applying a magnetic receptive layer in a less costly manner. The magnetically receptive ferrite powder blend may be mixed with UV oil and sprayed onto the surface covering unit. Ferrite powder suspended in UV oil is then solidified with high power UV light. The hardened UV oil-ferrite powder blend serves as a magnetically receptive "B" side layer that is permanently bonded to the surface covering unit. Other oils or materials, such as PVC oil, may also be used.

In another embodiment, the present invention provides a system of surface covering components that provides quasi-permanent surface covering when installed, the system comprising: a surface covering unit comprising an isotropic magnetic receptive layer; and an anisotropic magnetic cushion layer disposed on the support surface.

The thickness of the anisotropic magnetic underlayer may be 0.5 mm. The anisotropic magnetic underlayer may further comprise: a magnetizable material; a binder; and oil. The magnetizable material may comprise one of the following: ferrous powder, strontium ferrite powder, neodymium powder, and a composite of neodymium and ferrous. The binder may comprise a thermoplastic chlorinated polyethylene elastomer ("CPE"). The oil may comprise epoxidized soybean oil ("ESBO"). The anisotropic magnetic underlayment may be a calendered sheet article. The anisotropic magnetic underlayer may further comprise a magnetizable material with a mesh size of 1-2.3 μm.

In another embodiment, the present invention provides a magnetic spacer for securing a magnetically receptive surface covering unit to a support surface, the magnetic spacer comprising: neodymium powder; a binder; and oil.

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

In another embodiment, the present invention provides a method for applying a magnetically receptive layer on a surface covering unit, the method comprising: adding a blend of a receiving material and an oil compound to a mixer; blending the receptive material blend and the oil compound to form a magnetically receptive oil blend; spraying the magnetically receptive oil blend onto a surface covering unit; and solidifying the magnetically receptive oil blend onto the surface covering unit.

The method may further comprise wherein the receptive material blend comprises one of: ferrous powder, strontium ferrite powder, neodymium powder, and a composite of neodymium and ferrous powder. The method may further comprise wherein the oil compound comprises one of: ultraviolet ("UV") oils and polyvinyl chloride ("PVC") resins. The solidifying of the magnetically receptive oil blend may further comprise solidifying the magnetically receptive oil blend by high intensity ultraviolet ("UV") light. The solidifying of the magnetically receptive oil blend may further comprise solidifying the magnetically receptive oil blend by an elevated temperature.

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

The method may further include annealing the magnetically receptive sheet article. The method may further comprise cold pressing the magnetically receptive sheet article onto a natural material building product. The method may further comprise hot pressing the magnetically receptive sheet article onto a synthetic material building product. The method may further comprise magnetizing the magnetically receptive sheet article. The composition of the magnetically receptive material may be selected from: pure iron powder (Fe) about 84%, chlorinated polyethylene elastomeric polymer (CPE) about 15%, and epoxidized soybean oil (ESBO) about 8%; iron powder (Fe3O4) 90%, CPE 9% and plasticizer 1%; Mn-Zn (manganese/zinc) soft ferrite powder 90%, CPE 9% and plasticizer 1%; 20 parts of CPE and 150 parts of stainless iron powder; 30 parts of polyvinyl chloride, 18 parts of dioctyl terephthalate and 200 parts of stainless iron powder; or 16.5% of PVC, 39% of calcium carbonate, 26.5% of iron powder, 16% of plasticizer and 2% of viscosity reducer and stabilizer. The ferrite compound may be strontium ferrite, the polymer may be chlorinated polyethylene elastomer polymer (CPE), and the plasticizer may be epoxidized soybean oil (ESBO). The mixing may be performed for about 15 minutes, the desired mixing temperature may be at 120 ℃, and the desired mixing pressure may be atmospheric pressure. The desired extrusion temperature may be 120 ℃, and wherein the magnetically receptive sheet article may be extruded at 10 meters per minute. The mixing may be performed for 20-30 minutes, the desired mixing temperature may be between 90-115 ℃, and the desired mixing pressure may be 0.4-0.7 MPa. The magnetically receptive sheet article may be extruded at 4-10 meters per minute and the desired extrusion temperature may be 40-70 ℃. The ferrite compound may be strontium ferrite having a particle size of 38-62 microns.

In another embodiment, the present invention provides a rust resistant and dimensionally stable magnetically receptive sheet article for a surface covering system, the sheet article comprising: a ferrite compound; a plasticizer; and a polymer. The sheet article may further comprise wherein the ferrite compound is strontium ferrite, the polymer is chlorinated polyethylene elastomer polymer (CPE), and the plasticizer is epoxidized soybean oil (ESBO). The sheet article may further comprise wherein the strontium ferrite comprises a particle size of 38-62 microns.

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

The method of the above embodiment may further comprise annealing the magnetically receptive sheet article. The method may further comprise cold pressing the magnetically receptive sheet article onto a natural material building product. The method may further comprise hot pressing the magnetically receptive sheet article onto a synthetic material building product. The method may further comprise magnetizing the magnetically receptive sheet article. The magnetically receptive layer may be magnetized to produce a magnetized underlayer suitable for magnetically engaging and supporting a non-magnetized receptive layer assembly, the magnetically receptive material having a composition selected from the group consisting of: for the calendering process: 1) about 89-91% pure iron powder (Fe) or strontium ferrite, about 8-9% chlorinated polyethylene elastomeric polymer (CPE) and about 1-2% epoxidized soybean oil (ESBO); or 2) iron powder (ferrous iron or ferroferric oxide Fe3O4) about 89-91%, CPE about 8-9% and plasticizer about 1-2%; or for extrusion processes: 3) about 16.5% PVC, about 39% calcium carbonate, about 26.5% iron powder, about 16% plasticizer, and about 2% viscosity reducer and stabilizer. The magnetically receptive material may be used to produce a non-magnetized receptive component for use in opposition to a magnetized backing component, the magnetically receptive material having a composition selected from the group consisting of: for the calendering process: 1) about 89-91% Mn-Zn soft ferrite powder, about 8-9% CPE and about 1-2% plasticizer; 2) about 20 parts CPE, about 150 parts stainless iron powder, about 30 parts polyvinyl chloride (PVC), about 18 parts dioctyl terephthalate, about 200 parts stainless iron powder; or for extrusion processes: 3) about 16.5% PVC, about 39% calcium carbonate, about 16% plasticizer, about 2% viscosity reducer and stabilizer, and about 26.5% of one of the following: mn — Zn (manganese/zinc) soft ferrite powder; stainless iron powder; or ferrous oxide or ferric oxide powder. The ferrite compound may be strontium ferrite, the polymer is chlorinated polyethylene elastomer polymer (CPE), and the plasticizer is epoxidized soybean oil (ESBO). The mixing may be performed for about 15 minutes, the desired mixing temperature may be at 120 ℃, and the desired mixing pressure is atmospheric pressure. The desired extrusion temperature may be 120 ℃, and the magnetically receptive sheet article may be extruded at 10 meters per minute. The mixing may be performed for 20-30 minutes, the desired mixing temperature may be between 90-115 ℃, and the desired mixing pressure may be between 0.4-0.7 MPa. The magnetically receptive sheet article may be extruded at 4-10 meters/minute and the desired extrusion temperature is 40-70 ℃. The ferrite compound may be strontium ferrite having a particle size of 38-62 microns.

In another embodiment, the present invention provides a rust resistant and dimensionally stable magnetically receptive sheet article for a surface covering system, the sheet article magnetized to provide a magnetized backing layer for magnetically engaging a non-magnetized receptive layer assembly, the magnetized backing layer comprising: for the calendering process: 1) about 89-91% pure iron powder (Fe) or strontium ferrite, about 8-9% chlorinated polyethylene elastomeric polymer (CPE) and about 1-2% epoxidized soybean oil (ESBO); or 2) iron powder (ferrous iron or ferroferric oxide, Fe3O4) about 89-91%, CPE about 8-9% and plasticizer about 1-2%; or for extrusion processes: 3) about 16.5% PVC, about 39% calcium carbonate, about 26.5% iron powder, about 16% plasticizer, and about 2% viscosity reducer and stabilizer. The ferrite assembly may comprise a grain size of 38-62 microns.

In another embodiment, the present invention provides a rust resistant and dimensionally stable magnetic receiver assembly for a surface covering system, the magnetic receiver assembly being a non-magnetized receiver layer assembly for magnetic engagement with a magnetized underlayer, the magnetic receiver assembly comprising: for the calendering process: 1) about 89-91% Mn-Zn soft ferrite powder, about 8-9% CPE and about 1-2% plasticizer; 2) about 20 parts CPE, about 150 parts stainless iron powder, about 30 parts polyvinyl chloride (PVC), about 18 parts dioctyl terephthalate, about 200 parts stainless iron powder; or for extrusion processes: 3) about 16.5% PVC, about 39% calcium carbonate, about 16% plasticizer, about 2% viscosity reducer and stabilizer, and about 26.5% of one of the following: mn — Zn (manganese/zinc) soft ferrite powder; stainless iron powder; or ferrous oxide or ferric oxide powder.

In a first embodiment relating to another aspect of the invention, the invention provides a surface covering system which when installed provides a removably secured surface covering, the system comprising: a magnetic surface covering unit comprising a non-magnetized isotropic magnetic receptive layer; and an anisotropically magnetized underlayer disposed on the support surface; wherein the magnetic surface covering unit is adapted to be magnetically attracted and relatively received by the anisotropically magnetized mat in a fixed installation and to be non-destructively removable from the anisotropically magnetized mat after the fixed installation. Furthermore, the invention may be further characterized by one or more of the following features: the anisotropically magnetized underlayment is 0.5mm thick and comprises a magnetizable material having a mesh size configured to have enhanced magnetic attraction properties when magnetized and adapted to support the magnetic surface covering unit in a non-horizontal fixed installation, wherein the non-horizontal fixed installation is one of an interior wall installation, an exterior wall installation, an aircraft interior cabin installation, an exterior roof installation or an interior ceiling installation. The invention may be further characterized in that the anisotropically magnetized underlayer comprises: a magnetizable material comprising iron powder; an adhesive assembly; and an oil having properties that allow for rapid solidification during manufacturing, whereby solidification occurs at normal line speeds in calendering or extrusion processes. The invention may be further characterized in that the magnetizable material comprises one of the following: ferrous powder, strontium ferrite powder, neodymium powder, and a composite of neodymium and ferrous powder. The invention may be further characterised in that: wherein the binder comprises a thermoplastic chlorinated polyethylene elastomer ("CPE"); wherein the oil comprises epoxidized soybean oil ("ESBO"); wherein the anisotropically magnetized underlayer is one of a calendered sheet article or an extruded sheet article; wherein the anisotropically magnetized blanket comprises a magnetizable material having a mesh size of 1-2.3 μm.

In a second embodiment, the present invention provides a magnetized spacer for securing a magnetically receptive surface covering element to a support surface, the magnetized spacer comprising: neodymium powder; a binder; and an oil having properties that allow for rapid solidification during manufacturing, whereby solidification occurs at normal line speeds in calendering or extrusion processes.

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

In a third embodiment, the present invention provides a method for applying a magnetic receptive layer on a surface covering element to produce a magnetic receptive surface covering element adapted to be magnetically pinned relative to a magnetized underlayer, the method comprising: adding a blend of a receiving material and an oil compound to a mixer; blending the receptive material blend and the oil compound to form a magnetically receptive oil blend; spraying the magnetically receptive oil blend onto a surface covering unit; and solidifying the magnetically receptive oil blend onto the surface covering unit. The invention may be further characterized by one or more of the following: wherein the receptive material blend comprises one of: ferrous powder, strontium ferrite powder, neodymium powder and a compound of neodymium and ferrous powder; wherein the oil compound comprises one of the following: ultraviolet ("UV") oils and polyvinyl chloride ("PVC") resins; wherein the solidifying of the magnetically receptive oil blend comprises rapidly solidifying the magnetically receptive oil blend by high intensity ultraviolet ("UV") light; wherein the solidifying of the magnetically receptive oil blend comprises solidifying the magnetically receptive oil blend by an elevated temperature.

Drawings

To facilitate a thorough understanding of the present invention, reference is now made to the accompanying drawings, in which like elements are designated with like numerals. These drawings should not be construed as limiting the present invention, but are intended to be exemplary and for reference.

Fig. 1 is a flow diagram of an embodiment of a method of producing a magnetized or magnetically receptive sheet material article at atmospheric pressure.

Fig. 2 is a flow diagram of an embodiment of a method of producing a magnetized or magnetically receptive sheet material at a pressure other than atmospheric pressure.

Fig. 3 is a flow chart of an embodiment of a method for producing a magnetized or magnetically receptive material for a layer of backing material.

Fig. 4 is an embodiment of a surface covering unit having an isotropic magnetic receptive layer and an anisotropic magnetic underlayer according to the present invention.

FIG. 5 is an embodiment of a surface covering unit having an isotropic magnetic receptive layer and a neodymium and ferrite powder blend "mixed" magnetic underlayment in accordance with the present invention.

Fig. 6 is a flow chart of an embodiment of a method for producing a magnetically receptive layer comprising ferrite powder suspended in hardened UV oil.

FIG. 7 is a simplified perspective view of a modular surface covering unit having a magnetic receptive layer and a magnetic underlayer disposed on a support surface.

FIG. 8 is a simplified perspective view of a modular surface covering unit having a magnetic receptive layer and a magnetic underlayer disposed on a support surface.

Fig. 9 is a simplified diagram of a system for manufacturing calendered sheet articles (e.g., magnetically or magnetically receptive sheet articles) in accordance with one embodiment of the present invention.

Detailed Description

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

The magnetized material generates a magnetic field that projects a force that pulls or attracts a ferromagnetic or ferrimagnetic material, such as iron, ferrite, strontium ferrite, barium, nickel, cobalt, alloys of these materials, and other materials, such as rare earth metals including neodymium-based materials. Magnetized components in the surface covering system may be made using magnetic materials that are then magnetized, for example by applying an external magnetic field thereto, for example by passing under one or more strong permanent magnets or electromagnets, so as to generate a permanent or permanent magnetic field with a remanence. Methods may be employed to apply strong magnetic fields during fabrication to alter the atomic structure and align the internal crystallite structure, resulting in greater remanence in the absence of an applied magnetic field. In particular, rare earth materials may be treated to align electrons to increase magnetic strength. Depending on the desired result, multiple stages of magnetization and magnetic alignment can be performed on the magnetic material. The magnetic strength of a magnetized material may be dependent on its magnetization (usually expressed as M in amperes/meter as a vector field), magnetic moment (usually expressed as a M ×)²Is shown asmOr mu as a vector) or a magnetic field or flux density (usually in Tesla (T-Weber/m)²) Denoted B as vector field). The magnetizable material is magnetically acceptable and is attracted to the magnet prior to magnetization.

The strength of a magnet can be expressed in terms of its pulling force, i.e., the ability of the magnet to move or "pull" on a magnetically receptive object. The pulling force exerted by the permanent magnet is maxwell's equation, expressed as:

F=B ² A/2µ ₀ Eq. 1

whereinFForce in newtons (SI);Ais the cross-section of an area in square meters; andBis the magnetic induction exerted by the magnetized material.

Relatedly, Max in CGS (centimeter (cm) -gram-second) systemsThe units of measure for the flux (Φ), which is the integral of the field over an area, and 1 maxwell is the total flux over a surface of 1 square centimeter perpendicular to the magnetic field with 1 gauss strength, i.e., 1 maxwell =1 gauss × cm²(ii) a And 1 maxwell =10^-8Weber (in SI international unit system). Gauss (G) is CGS unit of measurement of magnetic flux density or magnetic induction (B), and 1 gauss =10^-4Tesla is carried out. Thus, the units and expressions may be CGS or SI, and it should be understood that both are equally applicable for the purposes of the present invention and the claims.

When considering the efficient use of magnetic surface covering systems, one key consideration is the application, e.g., covering assemblies placed against a mat on a wall, floor, ceiling, roof, high wind area, to meet building codes or classifications, etc. For example, the holding strength of the magnet required in the case of a vertical contact surface is very different from that required in the case of a horizontal contact surface. Internal horizontal contact surface applications (i.e., the contact surface is horizontal or parallel to the ground or earth) operate with substantially zero shear force for the system due to gravity. In contrast, vertical applications of the system perpendicular to the ground have significant shear forces acting due to gravity, creating the possibility of the surface covering assembly breaking away or sliding against a backing layer that may be secured in some manner to a vertical wall or other surface. Thus, greater magnetic strength or pull is required given the vertical contact surface due to the weight of the cover assembly placed and supported by the blanket. In addition, under external conditions, additional forces act on the system to place a greater burden on the system and increase the magnetic strength required to maintain system integrity.

System component receiver material or "SCRM" refers to materials and/or compositions used to make magnetic receiver layer products "MRLP" and cushion layer products, and may include, for example, powder-based components or sheet items, which may also be referred to as "bulk iron material. In one implementation, SCRMs in powder form can be directly pressed or otherwise applied to the receiving layer assembly to achieve MRLP. In an alternative implementation, SCRM can be used to manufacture intermediate sheet articles for incorporation with a finished surface covering assembly to arrive at an MRLP product, essentially converting a non-magnetic receptive layer product (e.g., a finished wall or floor covering) to MRLP.

In one way of carrying out aspects of the present invention, the modular surface covering unit comprises a surface covering portion, which may be, for example, a decorative floor or wall tile, a decorative wood panel, a decorative vinyl wood panel, or a carpet tile. Other floor covering unit material types, shapes and compositions may be used. The surface covering unit may be a floor, wall or ceiling covering unit or may also be, for example, a decorative or ornamental piece other than a covering unit. In this way, the floor or other covering unit may be used in an "interchangeable box system" in which all covering units and decorative elements in the system may be easily installed, removed, moved or rearranged on a magnetic mat provided on a supporting surface (i.e. wall, floor, ceiling). Each modular surface covering unit further comprises a magnetic receptive layer. This magnetic receptive layer may be referred to as the "SCRM" layer or "receptive 'B' side layer". The SCRM layer (the receiving 'B' side layer) in the interchangeable box system takes many different forms and methods depending on the building material and the material composition of the building material.

In the present invention, each modular surface covering unit comprises a floor covering portion, which may be, for example, decorative floor tiles, decorative wood panels, decorative vinyl wood panels, or carpet tiles. Other floor covering unit material types, shapes and compositions may be used. Further, the floor covering unit may alternatively be a wall or ceiling covering unit, or may also be, for example, a decorative piece or a decorative piece in addition to the covering unit. In this way, the floor or other covering unit may be used in an "interchangeable box system" or a "magnetic box system" in which all the covering units and decorative elements in the system may be easily installed, removed, moved or rearranged on a magnetic mat provided on a support surface (i.e. wall, floor, ceiling). Each modular surface covering unit also contains a magnetically receptive layer that may be extruded over the surface covering unit or may be a separate layer secured to the unit. This magnetically receptive layer may be referred to as a system component receptive material ("SCRM") layer or "receptive 'B' side layer". The SCRM layer (the receiving "B" side layer) in the interchangeable box system takes many different forms and methods depending on the building material and the material composition of the building material.

Isotropic magnetic receptive and magnetic layer:

in an interchangeable box system, the SCRM receptive layer of a covering unit (e.g., a modular floor covering unit) may be adhered to an organic compound material (e.g., natural wood or natural stone or ceramic stone). SCRM receptive layers may also be used with synthetic building materials such as luxury vinyl tiles "LVT", luxury vinyl wood boards "LVP", rubber compound products (like sports surfaces) and other similar surface coverings. Since the SCRM layer is used with different surface covering material compositions, it must contain certain qualities for all applications. However, when the SCRM layer is used with a surface covering material having "similar" properties, different materials and methods must be used to fabricate the SCRM layer.

The interchangeable box system (magnetized underlayment, magnetic receptive layer, and surface covering unit (e.g., modular floor covering unit)) includes unique properties and qualities that can be used to work with existing building materials. In addition, other qualities are desirable in the system to be compatible with a wider range of materials and a wider range of applications. These additional qualities include, but are not limited to, oxidation resistance, dimensional stability (i.e., will not grow or shrink when exposed to external/internal elements, such as changes in temperature or humidity), resistance to harsh chemicals and solvents (e.g., cleaning products), oil, heat, flammability, wear, rolling load, heavy load, vibration, foot traffic, and the like. The elements of the interchangeable box system must also be able to accept a blanket of "a" side magnetization disposed on the support surface, which must also contain the same or similar properties.

In most SCRM applications, where SCRM layers are joined with natural, non-natural or synthetic building materials, the production of SCRM layers involves blending a ferrous iron compound with a desired polymer (e.g., chlorinated polyethylene "CPE") to provide an SCRM layer having the desired properties described above. In addition, a conditioning agent (e.g., epoxidized soybean oil "EPO") is used during manufacture to achieve the desired flexibility and adhesion.

Ferrites are ceramic compounds composed of iron (III) oxide (Fe2O3) chemically combined with one or more additional metal elements, such as iron oxide and strontium carbonate stainless iron powder, iron oxide 304 and other metal compounds. Ferrite compounds are non-conductive and ferrimagnetic, meaning that they can be magnetized or attracted to a magnet. Ferrites can be classified into two categories based on their magnetic coercivity and their resistance to demagnetization. Hard ferrites have a high coercivity and are difficult to demagnetize. They are used in the manufacture of magnets, for example for devices such as refrigerator magnets, loudspeakers and small motors. Hard ferrites may be used to produce the "a" side interchangeable box system magnetic underlayment. However, other compounds may be used in some applications where other properties of the magnetic underlayer are desired. Soft ferrites have a low coercivity.

One embodiment of the interchangeable box system of the present invention uses a strontium ferrite compound having a hexagonal crystal structure with dimensions of 1.9-2.3 microns for the "B" side receiving layer and the "a" side magnetic underlayer. However, the "a" side magnetic underlayer micron size can use increased individual particle surface area to increase the potential magnetization. An exemplary strontium ferrite compound may have a chemical structure SrFe12O19 sro.6fe 2O 3. The mesh size of the magnetic assembly as discussed below may be optimized based on the application or other requirements.

Ferrites are produced by heating a mixture of fine powder precursors that are pressed into a mold. During the heating process, the calcination of the carbonate occurs in the following chemical reaction:

MCO3 → MO + CO2

barium and strontium oxides are commonly supplied as their carbonates BaCO3 or SrCO 3. The mixture of oxides obtained undergoes sintering. Sintering is a high temperature process similar to the firing of ceramic articles.

The cooled product is then ground into particles smaller than 2 μm, which are small enough that each particle consists of a single magnetic domain. The powder is then press formed, dried, and re-sintered. To achieve a preferred orientation (anisotropy) of the particles, shaping can be carried out in an external magnetic field. This can be used to produce anisotropic sheet goods.

Small and geometrically easy shapes can be produced with dry pressing. However, in such a process, small particles may agglomerate and result in inferior magnetic properties compared to the wet pressing process. Direct calcination and sintering without further grinding are also possible, but result in poor magnetic properties.

In order to allow the products to be efficiently stacked in the furnace during sintering and to prevent parts from sticking together, ceramic powder separator sheets may be used to separate the products. These sheets are available in a variety of materials, such as alumina, zirconia, and magnesia. They are also available in fine, medium and coarse particle sizes. By matching the material and particle size to the product being sintered, surface damage and contamination can be reduced while maximizing furnace loading.

Chlorinated polyethylene elastomers ("CPE") and resins have excellent physical and mechanical properties, such as oil resistance, temperature resistance, chemical resistance, and weather resistance. CPE polymers (which may be referred to as "marine polymers") may be used to provide waterproofing membrane or waterproofing properties to sheet goods produced from interchangeable box systems (e.g., receiving a "B" layer or a magnetized underlayment "a" layer). CPE may also exhibit excellent compression set resistance, flame retardancy, tensile strength, and abrasion resistance properties, and may provide these properties to the magnetic underlayment or magnetic receptive layer.

CPE polymers can comprise materials ranging from rigid thermoplastics to flexible elastomers, making them highly versatile. CPE polymers are used in a variety of end use applications such as wire and cable jacketing, roofing, automotive and industrial hoses and pipes, molding and extrusion, and as base polymers. In a preferred embodiment, the CPE polymer is the desired polymer in the magnetic receptive "B" and magnetic underlayment "a" side layers of the interchangeable box system of the present invention.

CPE polymers blend well with many types of plastics (e.g., polyethylene, EVA, and PVC) that many building materials (e.g., luxury vinyl wood and tile flooring products) comprise. Blends of such CPE polymers and other plastics can be formed into end products with sufficient dimensional stability without the need for vulcanization. The excellent additive/filler acceptability characteristics of CPE polymers can provide benefits in blends where compound performance and economy are critical, for example in the production of the magnetically receptive "B" and magnetic underlayment "a" side layers of the interchangeable box system of the present invention.

Epoxidized soybean oil (ESBO) is a collection of organic compounds obtained from the epoxidation of soybean oil. It is used as a plasticizer and stabilizer in polyvinyl chloride (PVC) plastics. ESBO is a yellowish viscous liquid. ESBO is made from soybean oil by an epoxidation process. Polyunsaturated vegetable oils are widely used as precursors for epoxidized oil products because they have a large number of carbon-carbon double bonds available for epoxidation. The epoxy groups are more reactive than the double bonds and therefore provide a more energetically favorable reaction site and make the oil a good hydrochloric acid scavenger and plasticizer. The oxygen atom is typically added using a peroxide or peracid (peraclid) and converts the-C = C-bond to an epoxide group.

Food stored in glass jars is typically sealed with gaskets made of PVC. ESBO is typically one of the additives in PVC gaskets in such applications. It acts as a plasticizer and scavenger of hydrochloric acid released when PVC is thermally degraded, for example when foodstuffs are subjected to sterilization.

Strontium ferrite, CPE polymer and ESBO are used to make the magnetized underlayer "a" and magnetically receptive "B" side layers for the interchangeable box system of the present invention. Three compounds (strontium ferrite, CPE polymer and ESBO) were used in various formulation compositions and also provided unique properties that conventional methods of adhesion of building materials simply did not have. The use of these compounds ensures that no volatile organic compounds "VOCs" enter the building structure, which is a common problem with conventional adhesive systems (e.g., glue application).

The interchangeable box system of the present invention may use one of the following formulations for the composition of the magnetized underlayer "a" and the magnetically receptive "B" side layers. The specific formulation selected depends on the support surface, the surface covering unit, the environmental conditions, and the end user's use of the interchangeable box system. The same formulation or "bulk material" can be used for both layers, however, strontium ferrite based materials are desired for the underlayer and divalent iron based materials are desired for the magnetically receptive "B" layer. The divalent iron-based material has been at least partially oxidized providing a nearly rust-inhibiting layer. In addition, a stainless iron mixture may be used instead of the divalent iron-based material.

For both strontium-accepting ferrite-based underlayers or divalent iron-based "B" layers, the layers begin in a non-magnetized or accepting state. Strontium ferrite is more suitable for the magnetic underlayer because strontium ferrite based materials perform better as magnets than as receptive layers compared to ferrous based materials. Strontium ferrite is acceptably weaker than ferrous iron. Ferrous iron (e.g., Fe2O3) is relatively more rust resistant and more magnetically acceptable than strontium ferrite. The magnetic underlayment comprising the strontium ferrite based material mixture is typically about 1 mm thick. The magnetically receptive layer comprising a mixture of divalent iron-based materials (e.g., a layer of SCRM material) is typically about 0.5mm thick.

The magnetic or magnetic receptive sheet material composition formulation includes the following:

pure iron powder (Fe) about 84%, CPE about 15%, and soybean oil (ESBO) about 8%;

iron powder (Fe3O4) 90%, CPE 9%, plasticizer 1% (C19H36O3 epoxy ester);

90% of Mn-Zn (manganese/zinc) soft ferrite powder, 9% of CPE and 1% of plasticizer;

20 parts of CPE and 150 parts of stainless iron powder; and

30 parts of PVC, 18 parts of DOTP and 200 parts of stainless iron powder. (Dioctyl terephthalate, commonly abbreviated DOTP or DEHT, is an organic compound having the formula C6H42, is a non-phthalate plasticizer, is a diester of terephthalic acid and branched 2-ethylhexanol.

These formulations are mixed and formed into sheet goods that are "hot pressed" into or onto existing building materials (e.g., building materials comprising synthetic materials). Natural materials (e.g., natural wood or natural stone) are "cold pressed" into natural materials so as not to damage the natural materials. The formulations provided above do not include the most suitable receiver sheet articles for the magnetization process. Each of the above formulations involves a compromise to have the desired strength to hold the building material in a fixed position on a flat surface (e.g., a support surface such as a wall or floor) and to have the desired qualities described above.

Depending on the nature of the existing building material on which the magnetically receptive "B" layer or magnetized underlayment "a" layer is to be disposed, different compositions may be used and need not be limited to one of the formulations provided above. However, for most building material compositions and installation applications, the above formulation is the preferred formulation. In addition, the formulation of the sheet article may vary depending on the material composition of the surface covering unit onto which the finished sheet article (e.g., magnetic underlayment or magnetic receptive layer) is to be applied. For example, the formulation may include mixing different powders, plasticizers, and other materials for the composition of the sheet article in the magnetic underlayment or magnetic receptive layer. The use of less strongly accepted compounds that have been oxidized, such as ferrous oxide or stainless iron powder, makes the sheet article highly rust-resistant.

An exemplary method for producing a sheet article for a magnetically receptive "B" layer or magnetic underlayment "a" is provided in fig. 1 and 2. Referring initially to fig. 1, a method 100 for producing a sheet article at atmospheric pressure is provided. First, in step 102, the components (e.g., strontium ferrite, CPE polymer, ESBO) used to produce the sheet goods are placed in a mixer according to the desired formulation. The materials are then mixed and blended in step 104 in a mixer (e.g., a banbury mixer) at a maximum temperature of 120 ℃ for about 15 minutes. The mixed material is then compressed and extruded at a rate of about 10 meters/minute at a temperature of about 80 ℃ in step 106. In all steps of the method 100, the mixture is exposed to air at atmospheric pressure, rather than vacuum or partial vacuum. After the mixture is extruded into a sheet article, an additional annealing process 408 may be performed. CPE polymers have properties that are dimensionally stable over other possible materials, but may still have dimensional stability issues. For formulations incorporating CPE polymers, an annealing step 108 will be used, but is not required in all sheet article formulations. In another embodiment, CPE polymers with higher melting points may be used. Using a blend or mixture of higher melting CPE polymers may require a different binder than the lower melting CPE polymers. Blends using high melting CPE polymers may be mixed at about 190 ℃, and may also require higher temperatures during the extrusion and compression stages to form sheet articles.

This curing/annealing step 108 is performed before applying the sheet article to the building material to be used as a surface covering unit. Testing of the sheet article can be performed at a laboratory level to determine the dimensional stability of the sheet article. For sheet items to be used in stationary surface covering units, a desired level of dimensional stability is required. If the sheet article used as the magnetic underlayment "A" layer or the magnetic acceptance "B" layer is dimensionally unstable, the surface covering unit may not remain installed as desired and the system may fail. For example, in the case of flooring, the flooring may have catastrophic failure due to "peaks" or "gaps" caused by expansion and contraction and "warping" of the building material, which is undesirable and will result in installation imperfections.

Annealing is a heat treatment that changes the physical properties of a material and sometimes the chemical properties of the material to increase its ductility and decrease its hardness. During annealing, atoms migrate in the crystal lattice and the number of dislocations is reduced, resulting in changes in ductility and hardness. This approach makes it more feasible. Annealing serves to bring the metal closer to its equilibrium state. In its soft state when heated, the uniform microstructure of the metal will allow excellent ductility and workability. To perform a full anneal in ferrous metal, the material must be heated above its upper critical temperature for a time sufficient to fully transform the microstructure into austenite. The metal must then be cooled slowly, typically by cooling it in a furnace, to allow for maximum ferrite and pearlite transformation.

Tables 1 and 2 provided below illustrate the dimensional changes in the length direction in table 1 and the width direction in table 2 of the sheet article after the 71-hour annealing process.

TABLE 1

TABLE 2

After the annealing step 108, or if the annealing step 108 is not required due to the formulation used for the sheet article, the sheet article is hot pressed onto a synthetic building material product in step 110, or cold pressed into a natural building material product in step 120 to form a finished surface covering unit. If the sheet article is not used on a surface covering unit but is used as a magnetic cushion layer, a magnetization step may be performed on the sheet article to form a magnetic cushion layer "a" layer.

To magnetize the underlayer "a" layer, a magnetic roller may be used. The magnetic roller comprises a plurality of north and south poles positioned very close to each other on the roller. For thicker mats where a large number of north/south poles are not required to achieve the desired remanence in the material, the north/south poles may be relatively spaced on the roller. In this application, a roller comprising a plurality of magnetic washers compressed together on a rod or shaft may be used. An exemplary system is described in the title SHEET MAGNETIZER SYSTEMS AND METHODS THEREOF filed on 15.4.2008ArnoldAnd U.S. patent publication 2008/0278272 and U.S. patent 7,728,706 entitled MATERIAL model SYSTEMS, granted on 6/1/2010. Reducing the distance between the north and south poles on the roller provides more north/south poles to be magnetized on the magnetic underlayer "a" layer, producing a magnetic underlayer with greater remanence. This is required to produce a thinner magnetic underlayer with the same or greater remanence as the thicker layer. In order to magnetize the thinner magnetic underlayer "a" layer with a roller, a solid roller must be used. The solid rollers may comprise a ferrite material or a neodymium metal.

The solid magnetic roller contains a plurality of north/south poles etched or engraved on the roller. The etched or engraved roller is magnetized in a pulse magnetizer, which may contain magnetic coils and an alignment field. The field in the pulsed magnetizer may be configured to cause the particles in the roller to point in a particular direction. The etched roller may have etched and pulsed magnetized poles positioned at a spacing between 1-2 mm, with a thinner magnetic backing layer requiring a closer pole. Another embodiment may employ a solid roller without any etching and wherein the underlayer to be magnetized comprises etched north/south poles. This provides a north/south pole that is closer than the etched roller. Laser etching may be performed using a prism and a gyroscope moving laser diode. The use of a gyroscope moving laser maximizes the number of poles that can be transferred or etched onto the thermally compressed underlayer.

Referring now to fig. 2, a method 200 for producing a sheet article at non-atmospheric pressure is provided. First, in step 202, the components (e.g., strontium ferrite, CPE polymer, ESBO) used to produce the sheet goods are placed in a mixer according to the desired formulation. The materials are then mixed and blended in a mixer (e.g., a banbury mixer) at a temperature of 90-115 ℃ and a pressure of 0.4-0.7MPa for 20-30 minutes in step 204. In step 206, the sheet article is extruded into sheet form at a compression rate at a rotational speed of 4.0-10 meters/minute and at a temperature of 40-70 ℃. In step 206, the mixture is compressed into a sheet article by pressing the two rollers against each other to a specified thickness, which is typically 0.3mm thick for the magnetically receptive "B" layer. After the mixture is extruded into a sheet article, an additional annealing process 208 may be performed. For formulations incorporating CPE polymers, an annealing step 208 will be used, but is not required in all sheet article formulations. After the annealing step 208, or if the annealing step 208 is not required due to the formulation composition used for the sheet article, the sheet article is hot pressed onto a synthetic building material product in step 210, or cold pressed into a natural building material product in step 220 to form a finished surface covering unit. If the sheet article is not used on a surface covering unit but is used as a magnetic cushion layer, a magnetization step may be performed on the sheet article to form a magnetic cushion layer "a" layer.

For both the method 100 in fig. 1 and the method 200 in fig. 2, the micron size of the strontium ferrite compound is about 38-62 microns. In all formulations of the magnetic underlayer "a" layer and the magnetic receptive "B" layer, this dimension is the preferred micrometer dimension.

Referring now to fig. 3, a method 300 for producing a magnetized or magnetically receptive material for a layer of backing material is provided. For some building materials, such as carpet tiles, the magnetically receptive "B" layer of the interchangeable box system is not made into a sheet article, but is directly blended into a backing system that constitutes the building material using a similar polymer. An example of one such formulation that may be incorporated into a PVC backed carpet tile is 16.5% PVC, 39% calcium carbonate, 26.5% iron powder (Fe3O4), 16% plasticizer DOP (di-2-ethylhexyl phthalate) or DINP (diisononyl phthalate) and 2% viscosity reducing and stabilizing agents. In this method, in step 302, a material for producing a magnetized or magnetically receptive material for a layer of backing material is introduced into a mixer. The materials are then mixed in a manner such as described in step 104 in fig. 1 or step 204 in fig. 2. The mixed materials are then blended into the backing of the surface covering unit in step 306 to produce a finished surface covering unit having a magnetized or magnetically receptive backing layer.

For the methods shown in fig. 1, 2, and 3, a manufacturing system 900 as shown in fig. 9 may be used. The manufacturing system 900 shown in FIG. 9 provides a system for producing a magnetically receptive layer or magnetized layer. Some elements of the system may be used to produce one type of sheet material article while other elements may not be used. In the exemplary embodiment shown in the system 900 of fig. 9, the system 900 comprises

material storage hoppers

902, 904, and 906, a mixer 910, a first set of

rollers

922 and 924, a conveyor 950, magnetized rollers 940, an annealing lehr 960, and a second set of rollers 926. The

materials

903, 905 and 907 stored in the

respective storage hoppers

904, 906 and 908 may be, for example, strontium ferrite blends, CPE polymers and ESBO, or more generally, magnetically receptive material blends, binders or polymers and plasticizers. Other materials may be stored in other hoppers or storage tanks as desired and as described herein.

Materials

903, 905 and 907 are mixed in mixer 910 (which may be a banbury mixer) at a desired temperature and pressure for a specified period of time and then extruded through nozzle 912 through a first set of

rollers

922 and 924 into calendered sheet article 908. Other sets of rollers besides the first set of

rollers

922 and 924 may also be used. The conveyor 950 can pass the calendered sheet article 908 through an annealing lehr 960 and through magnetic rolls 940. In the case of producing magnetically receptive sheet articles, magnetic roller 940 will not be used. A pulse magnetizer or other magnetization method may be used instead of the magnetic roller 940. The annealing furnace 960 can be any furnace or heating source suitable for annealing the calendered sheet article 908. After the calendered sheet article 908 has been annealed and magnetized, the surface covering 932 may be unwound from the roll 930 and hot or cold pressed onto the calendered sheet article 908 by a second set of

rolls

926 and 928 to form the finished surface covering 901. In the case of producing a magnetic underlayer, this finishing step will not be performed. In addition to material unwound from the roll 930, other materials may also be pressed onto the calendered sheet article 908. For example, the magnetically receptive layer calendered sheet article 908 may be cut to size and pressed individually onto a surface covering unit that is not suitable for storage in roll form.

The method of the above embodiment may further comprise annealing the magnetically receptive sheet article. The method may further comprise cold pressing the magnetically receptive sheet article onto the natural material building product. The method may further comprise hot pressing the magnetically receptive sheet article onto the composite building product. The method may further comprise magnetizing the magnetically receptive sheet article. The magnetically receptive layer may be magnetized to produce a magnetized underlayer suitable for magnetically engaging and supporting the non-magnetized receptive layer assembly, the magnetically receptive material having a composition selected from the group consisting of: for the calendering process: 1) about 89-91% pure iron powder (Fe) or strontium ferrite, about 8-9% chlorinated polyethylene elastomeric polymer (CPE) and about 1-2% epoxidized soybean oil (ESBO); or 2) iron powder (ferrous iron or ferroferric oxide, Fe3O4) about 89-91%, CPE about 8-9% and plasticizer about 1-2%; or for extrusion processes: 3) about 16.5% PVC, about 39% calcium carbonate, about 26.5% iron powder, about 16% plasticizer, and about 2% viscosity reducer and stabilizer. The magnetically receptive material may be used to produce a non-magnetized receptive component for use in opposition to a magnetized backing component, the magnetically receptive material having a composition selected from the group consisting of: for the calendering process: 1) about 89-91% Mn-Zn soft ferrite powder, about 8-9% CPE and about 1-2% plasticizer; 2) about 20 parts CPE, about 150 parts stainless iron powder, about 30 parts polyvinyl chloride (PVC), about 18 parts dioctyl terephthalate, about 200 parts stainless iron powder; or for extrusion processes: 3) about 16.5% PVC, about 39% calcium carbonate, about 16% plasticizer, about 2% viscosity reducer and stabilizer, and about 26.5% of one of the following: mn — Zn (manganese/zinc) soft ferrite powder; stainless iron powder; or ferrous oxide or ferric oxide powder. The ferrite compound may be strontium ferrite, the polymer is chlorinated polyethylene elastomer polymer (CPE), and the plasticizer is epoxidized soybean oil (ESBO). Mixing may be performed for about 15 minutes, the desired mixing temperature may be at 120 ℃, and the desired mixing pressure is atmospheric pressure. The desired extrusion temperature may be 120 ℃, and the magnetically receptive sheet article may be extruded at 10 meters/minute. The mixing may be carried out for 20-30 minutes, the desired mixing temperature may be between 90-115 ℃ and the desired mixing pressure may be between 0.4-0.7 MPa. The magnetically receptive sheet article may be extruded at 4-10 meters/minute and the desired extrusion temperature is 40-70 ℃. The ferrite compound may be strontium ferrite with a particle size of 38-62 microns.

Anisotropic magnetic and magnetic receptive layers:

the magnetic and magnetically receptive layers described above for the magnetic box system are isotropic or "non-directional". For isotropic magnetic layers, no alignment field is used in the magnetization process. This means that the backing layer and the receiving layer can be mounted on the surface in a directionally independent manner. In some implementations of the magnetic box system, an anisotropic magnetic or magnetic receptive sheet article is desired. In the anisotropic layer, an alignment field is used in the magnetization process to align all the particles in the magnetic underlayer "a" layer in the same direction. For example, in installations where weight is a concern rather than directionality of the installation, thinner sheet items with stronger magnetic bonds may be desirable.

The installation of surface covering units in aviation or on floors, fuselage interiors, bulkheads and other interior surfaces of aircraft is an application that is particularly sensitive to the weight of the materials used. Due to weight concerns for aircraft, the use of anisotropic blends is desirable in aerospace applications. The anisotropic layer uses a different blend of material components than the isotropic magnetic and magnetic receptive layers described above, but uses anisotropic powders to achieve similar or greater magnetic strength. In addition, the layer thickness of the anisotropic layer is reduced from 1.0mm to 0.5mm compared to a ferrous or strontium ferrite isotropic layer. At least a 50% reduction in thickness compared to the isotropic layer provides nearly the same amount of weight reduction in anisotropic layers with similar remanence.

Referring to fig. 4, an exemplary interchangeable box system 400 according to the present disclosure is provided that includes an isotropic surface covering unit 410 and a support surface assembly 401 having a 0.5mm thick anisotropic magnetic shim 402 disposed on a support surface 404. The isotropic surface covering unit 410 comprises a decorative or top layer 412 and an isotropic magnetically receptive SCRM "B" side layer 414. Isotropic magnetic receptive layer 414 is magnetically attracted to anisotropic magnetic underlayer 402 disposed on support surface 404.

The thickness of the existing isotropic shim may be 1.52 mm. However, for both isotropic and anisotropic underlayers, the mesh size is reduced, thereby reducing the micron size of the particles in the material blend used to produce the magnetic layer, increasing the surface area of each individual particle. Due to the specific crystal structure of the smaller particles, the surface area of each particle is increased, which results in a higher magnetic strength. This in turn provides for reduced thickness and overall raw material usage in the magnetic underlayer.

The reduced mesh size of the raw materials used to produce the magnetically receptive layer and the magnetized underlayer provide a thinner layer. For example, using a smaller mesh size provides a magnetic underlayment with a thickness of 1.0mm for use on a horizontal planar support surface (e.g., floor covering) and a magnetic underlayment with a thickness of 0.5mm for use on a vertical planar support surface (e.g., wall covering). Smaller mesh sizes provide benefits to both the magnetic receptive layer and the magnetic underlayment layer comprising a blend of anisotropic and isotropic materials, only anisotropic materials, or only isotropic materials of smaller mesh sizes. The thickness of the magnetically receptive or magnetic underlayer may be within +/-0.5 mm of the desired layer thickness, depending on the particular mounting application in which the layer is to be used and depending on how the layer is to be mounted or secured to the surface.

The properties of both the isotropic and anisotropic magnetic underlayers are provided in tables 3 and 4 below, with a mesh size of 1-2.3 μm for one or more of ferrite powder, iron powder, and anisotropic powder.

TABLE 3

TABLE 4

The magnetically receptive material is isotropic, although anisotropic means that the magnetic underlayer is "oriented" in one direction (whereas isotropic is not). An anisotropic magnetic "a" layer and an isotropic magnetic receptive "B" layer are used and provide that the overall system is still isotropic or non-directional in nature (i.e., there is no fixed mounting orientation for the surface covering unit with the isotropic magnetic receptive layer on the anisotropic magnetic underlayer). Two exemplary formulations for producing magnetic underlayments are provided in tables 5 and 6 below.

TABLE 5

TABLE 6

In formulation 1, ESBO is a collection of organic compounds obtained from the epoxidation of soybean oil. It is used as a plasticizer and stabilizer in polyvinyl chloride plastics. ESBO is a light yellow viscous liquid. For both formulations, the magnetic underlayment was calendered into a sheet article without the use of a fiberglass scrim layer. The mixture is first mixed and blended in a banbury mixer for 25-35 minutes at a temperature: 120 ℃ and 135 ℃, pressure: 0.4-0.7 MPa. Forming a sheet article by compressing the mixture into a sheet at a temperature of 40-80 ℃ and a rotational speed of 4.0-10 rpm. The mixture is compressed into sheet form by pressing two rolls against each other to a specified thickness and then placed into a series of forming rolls to fine tune the precise thickness of the blanket sheet to the desired thickness. The final UV (ultraviolet) oil coating may then be applied by spraying onto a conveyor belt and baked under ultraviolet light to set. UV oils are sensitive and reactive to UV light. In this way, the coating has the desired benefit of very fast setting (fast setting), and sets optimally at normal manufacturing line speeds, i.e., the operator does not have to slow down the line speed to allow extended baking or heating for setting purposes. The rapid solidification feature may be included in an extrusion process or a calendaring process and used to solidify a layer as a backing layer or in connection with the manufacture of a surface covering component. In connection with mat manufacturing, the sheet of magnetic mat is then wound onto a reel and cut to the desired roll length.

The target thickness of the anisotropic magnetic underlayment can be 0.5mm thick, for example, in applications requiring low profile (thickness) and low weight, such as interior surface coverings for aircraft. The anisotropic magnetic underlayer may further comprise: a magnetizable material; a binder; and oil. The magnetizable material may comprise one of the following: ferrous powder, strontium ferrite powder, neodymium powder, and a composite of neodymium and ferrous. The binder may comprise a thermoplastic chlorinated polyethylene elastomer ("CPE"). The oil may comprise epoxidized soybean oil ("ESBO"). The anisotropic magnetic underlayment may be a calendered sheet article. The desired thickness may be a function of the extrusion or blending process (e.g., selection of the exemplary formulations described herein), the extrusion spray technique, the calendering technique, the target weight, the desired magnetic strength, the desired magnetic acceptance or attraction of the surface component, the composition of the wall relative to the material included in the flooring application and building code requirements, to name a few considerations. The anisotropic magnetic underlayer may further comprise a magnetizable material with a mesh size of 1-2.3 μm.

A neodymium magnetic layer:

in another embodiment, the magnetic underlayment may be produced using a blend of neodymium and ferrite powders. An approximately 50/50 blend of neodymium powder and ferrite powder may be used to produce anisotropic and isotropic sheets for interior or exterior applications such as roofing and exterior finishing. This "mixed" blend of neodymium powder and ferrite powder provided an average eight-fold increase in potential magnetic retention over ferrite powder, but at an increased cost. A magnetic underlayment comprising a blend of neodymium and ferrite powders would be suitable for applications such as roofing, extra heavy coatings on the exterior, slate, where an increased remanence would be required over ferrite powders.

Neodymium is a rare earth metal element. It has the atomic symbol Nd, an atomic number of 60 and an atomic weight of 144.24 g/mol. Neodymium is not naturally found in metallic form or unmixed with other lanthanides, and it is usually refined for general use. Although neodymium is classified as "rare earth," it is not as rare as cobalt, nickel and copper ores and is widely distributed in the earth crust, but is largely mined in china. A "hybrid" magnetic underlayment "a" layer comprising a blend of neodymium and ferrite powders may support a much greater hanging weight than a ferrite powder magnetic underlayment. A "hybrid" magnetic underlayment "a" layer comprising a blend of neodymium and ferrite powders is well suited for use as a complete roofing underlayment capable of withstanding the high winds of hurricanes or tornadoes. In addition, it can be used as a fastening system for glass solar panels, reducing the cost of installing solar panels, since a significant part of the cost of installing solar panels is the fastening system and the labor of installing them.

Neodymium powder blends and "mixed" magnetic underlayers are also suitable for installation applications where weight is a concern. Because the "hybrid" magnetic underlayment has a relatively stronger pull than a ferrous or strontium ferrite blend underlayment, thinner layers can be used to achieve the same pull strength. This is desirable in installation applications in aircraft and vehicles where the weight of the material may be a concern.

The blend of neodymium with other materials in the "mixed" magnetic underlayer may be 50-90% neodymium powder. For example, a composition having 91% neodymium-based material in a 0.5mm thick underlayer would provide a 20-fold improvement in magnetic attraction or strength over a 1 mm thick underlayer using a non-neodymium ferrite material. However, it is undesirable to increase the percentage of neodymium powder in the blend, as it can lead to cracking or crumbling of the "mixed" magnetic cushion layer, as an insufficient percentage of binding material will be present. Thus, the present invention provides alternative formulations to balance performance characteristics with application requirements. For example, for every 10% decrease in neodymium concentration, i.e., 91% to 81% to 71%, etc., the magnetic strength decreases by a factor of 2 accordingly, i.e., 18 times stronger for an 81% underlayer than a 1 mm non-neodymium underlayer, 16 times stronger for a 71% underlayer than a 1 mm non-neodymium underlayer, 14 times stronger for a 61% underlayer than a 1 mm non-neodymium underlayer, etc. Thus, the ratio of neodymium powder to binder, oil, and/or other materials may be selected to be one of the following based on application considerations: about 91% neodymium powder to about 9% binder and oil; about 81% neodymium powder to about 19% binder and oil; about 71% neodymium powder to about 29% binder and oil; about 61% neodymium powder to about 39% binder and oil; or about 51% neodymium powder to about 49% binder and oil. The techniques described herein minimize cracking or brittleness problems associated with the use of neodymium-based materials.

Referring to fig. 5, an exemplary interchangeable box system 500 according to the present disclosure is provided that includes a surface covering unit 510 and a support surface assembly 501 in which a neodymium and ferrite blend "hybrid" magnetic underlayer 502 is disposed on a support surface 504. The surface covering unit 510 includes a decorative or top layer 512 and a magnetically receptive SCRM "B" side layer 514. Magnetic receptive layer 514 is magnetically attracted to neodymium and ferrite blend "mixed" magnetic underlayer 502 disposed on support surface 504.

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

Uv cured oil based magnetic and magnetic receptive layers:

as described above, the magnetic receptive layer or SCRM layer is the "B" side layer of the Interchangeable Box System (IBS). The SCRM layer may be in the form of a sheet article applied as the last layer in the building material, e.g. the raw material comprising the sheet article may be calendered and then hot pressed, or cold pressed with a resin glue as the last layer of the building material. In another embodiment, the material comprising the SCRM "B" layer may be applied to the surface covering using oil and polymer based resin/glue and impregnated with ferrite powder.

However, these existing methods for applying the SCRM "B" side magnetic receptive layer to the surface covering may be cost or weight prohibitive for certain applications. The SCRM layer can be applied to the surface covering while reducing cost and thickness to meet this need for using ultraviolet ("UV") oil. UV oil is a material commonly used by manufacturers of surface covering units as a final protective layer for surface covering. For example, the surface covering unit may comprise a wear layer (i.e. a scratch resistant coating) which is placed as a top layer on the surface covering unit as a finishing spray. The UV oil is sprayed onto the top layer of the floor/wall unit through a set of nozzles. The sprayed surface covering unit is then brought onto the assembly belt and subjected to ultra-high intensity UV light which bakes the UV oil to solidify it and permanently bonds the UV oil spray application to the top layer as an abrasion resistant layer.

Referring to fig. 6, a flow chart of a method 600 for producing a UV oil-based magnetic receptive layer is provided. In step 602, the ferrite powder and/or SCRM material blend of the present invention and UV oil are added to a mixer. In step 604, the ferrite powder and/or SCRM material blend of the present invention is mixed together with UV oil. In step 606, the blended mixture of ferrite powder and/or SCRM material blend and UV oil is sprayed onto the last or bottom layer of the surface covering unit using the same industrial process as used to produce the wear layer. Then in step 608, the surface covered unit with ferrite infused UV oil is carried on the mounting strip to the ultra high strength UV light, where the UV oil is permanently bonded/baked onto the bottom of the surface covered unit as a complete SCRM "B" side magnetic receptive layer. The thickness of the UV oil magnetically receptive layer may be less than 0.15 mm, which is thinner than the thinnest possible magnetically receptive sheet article that is calendered or extruded.

PVC-based resins may also be used instead of UV oils. For example, ferrite powder or SCRM material blend can be mixed into PVC resin, then sprayed onto the mounting tape, and then baked in a linear oven at high temperature to bond the ferrite powder infused PVC resin to the bottom of the surface covering element as a complete SCRM "B" side magnetically receptive layer. The temperature required to set the PVC resin depends on the type of PVC resin used.

Other polymers, resins, oils, other suitable liquids, and other suitable semi-solid materials may be sprayed onto the surface covering unit to form an SCRM layer with acceptable holding/shear strength. The UV oil sprayed coating need not be as thick as the rolled sheet article layer and may be 0.1 mm thick instead of 0.3-0.5 mm thick. The retention strength of the UV oil sprayed on the SCRM layer is lower than that of the magnetically receptive sheet article, but still sufficient to hold the surface covering unit in place. The significantly reduced cost of spraying on the UV oil-based SCRM "B" side magnetically receptive layer enables SCRM layers to be built into each surface covering unit, whether the surface covering unit is mounted with glue or is magnetically fixed.

In another embodiment, the present invention provides a method for applying a magnetically receptive layer on a surface covering unit, the method comprising: adding a blend of a receiving material and an oil compound to a mixer; blending a receptive material blend and an oil compound to form a magnetically receptive oil blend; spraying the magnetically receptive oil blend onto the surface covering unit; and solidifying the magnetically receptive oil blend onto the surface covering element.

Magnetic box system:

referring now to fig. 7, a simplified perspective view of a surface covering assembly 700 of modular surface covering unit 710 having a magnetic receptive layer 720 and a magnetic underlayer 730 disposed on a support surface 750 is provided. Modular surface covering unit 710 may be, for example, a floor covering unit such as a LVT, a stone tile, or a carpet tile. In another embodiment, the surface covering unit 710 may be a rolled wallpaper or other wall covering with a magnetically receptive layer 720 disposed on one side. In a wall covering unit (e.g. wallpaper), the magnetically receptive layer may be glued or otherwise adhered to the back or reverse side of the wall covering unit. The magnetically receptive layer 720 may be heat pressed onto the LVT using a LVT floor covering unit. For stone tiles, the magnetically receptive layer 720 may be cold pressed onto the stone tile because it is a natural material. For carpet tiles, the magnetically receptive layer 720 may be blended into the carpet backing. The magnetic underlayment 730 is disposed on a support surface 750, which may be a wall, floor, ceiling, or movable support surface (e.g., trade show display), but may be any other suitable support surface. The magnetically receptive layer 720 of the surface covering unit 710 is magnetically attracted to the magnetic backing layer 730 and secures the surface covering unit 710 to the support surface 750.

This embodiment comprises a magnetically receptive layer 720 on a surface covering unit 710 and a magnetic underlayer 730 on a support surface 750. However, in alternative embodiments, the surface covering unit 710 (whether a wall, floor or other covering) may have a magnetic layer disposed on the back or reverse side, and a magnetically receptive underlayment may be disposed on the support surface. For example, when the system 700 is installed in a buried swimming pool, the magnetically receptive layer may be glued down or otherwise secured to the base concrete layer of the pool. The magnetic surface covering unit can then be quasi-permanently mounted on a magnetically receptive underlayment in the pool. Alternatively, a blend of magnetically receptive materials may be mixed into a thiset type concrete and spread over a base concrete layer in a pool, with a magnetic surface covering unit then installed over the magnetically receptive thiset layer. The interchangeable box system 800 described below and shown in fig. 8 may also be configured in this alternative manner to suit a particular installation application.

Referring now to fig. 8, a perspective view of a room having an interchangeable box system 800 is provided. The interchangeable box system 800 combines the features of the wall covering system 860 and the modular floor covering 810. The magnetic underlayment 880 on the wall is adapted to receive the wall covering unit 870, the trim piece 890, and may also be adapted to mount additional securing devices (e.g., a television 892) directly or to be secured to the television by a frame or other support structure and magnetically secured to the underlayment 880. The floor of the interchangeable box system 800 includes a cushion layer 812 and a set of floor coverings 811. The room in which the interchangeable box system 800 is implemented may have any aspect of changing and re-decorating the floor or walls with minimal effort, and will not require removal or tearing off of existing decorative or fixed devices. To construct a room with the interchangeable box system 800, the support layer 890 would be attached to the wall frame. The magnetic underlayer 880 may be attached to a support layer, the support layer may be impregnated with the magnetic components, the magnetic underlayer 880 may be laminated to the outside of the support layer 900, or the support layer 890 may be completely coated with a magnetically attractive coating. The wall covering unit 870, trim 890 and other securing devices may then be magnetically, semi-permanently and releasably secured to the magnetic mat 880. The wall covering unit 870 may be a separate surface covering unit, or may be a rolled surface covering, such as paper or vinyl wallpaper, with a magnetically receptive layer disposed on the back of the wall covering unit 870. The underlayment 812 for the modular floor covering 810 may be secured to a support surface as described above. The floor covering unit 811 may then be placed on the mat layer 812. Additionally, the magnetic underlayment may be attached to the ceiling in a manner similar to the underlayment 880 on the wall. The ceiling tiles may be secured to the ceiling underlayment in a manner similar to the wall covering unit 870.

Magnetic underlayer 880 and underlayer 812 can have the following properties: 0.060 inch (1.52 mm) thick, a Shore D60 hardness, a specific gravity of 3.5, a shrinkage of 1.5% by heating at 158F for 7 days, and a tensile strength of 700 psi (49 Kg/cm)²) And may have parallel poles (north and south poles) at 2.0mm intervals along the length. The floor covering element 811 and the wall covering element 600 may have a magnetically isotropic receptive material laminated to the surface to be placed on the underlayment 812 or magnetic underlayment 880, respectively, and the underlayment may be manufactured using an anisotropically or isotropically magnetized flexible layer laminated to or incorporated into the underlayment. In particular, the manufacturing method described in U.S. published application US2016/0375673 may be used to manufacture magnetic underlayers for use in systems. Specifically, the method may use pulsed magnetization to isotropically magnetize underlayer 812 or magnetic underlayer 880. Pulsed magnetization utilizes a coil and a set of capacitors to generate a short "pulse" burst of energy to slowly increase the magnetic field and completely penetrate the underlayer 812 or magnetic underlayer 880. Pulsed magnetization can also be used to anisotropically magnetize underlayer 812 or magnetic underlayer 880, if desired.

If a magnetically attractable layer is incorporated into backing layer 812 or backing layer 880, a dry mixture 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 formed through a series of rollers to give it the correct width and thickness. The material is then magnetized on only one side.

The magnetic properties of the bonded magnets are limited by the amount of polymer used (typically between 20-45 vol%) as this significantly dilutes the remanence of the material. In addition, the melt-spun powder has an isotropic microstructure. The dilution effect is overcome by the incorporation of anisotropic magnetic powder. Bonded magnets can then have enhanced remanence in a particular direction by inducing texture in the magnetic powder or grinding it to fine micron-scale particle sizes and then preparing the magnet in an alignment field. The magnetic underlayer (e.g., underlayer 812 or underlayer 880) is magnetized directionally to give it a stronger remanence. However, the magnetic receptive sheeting is not polar oriented and therefore need not be oriented in any one direction. The optimum temperature range for long term durability of the cushion layer 812 or the cushion layer 880 is 95 ℃ to-40 ℃.

For extruded flexible magnets, the flexible granular material is heated until it begins to melt, and then forced under high pressure using screw feed through a hardened die that has been eroded by an Electrical Discharge Machining (EDM) wire to have the desired shape of the final profile. The flexible magnet may be extruded into a profile that may be wound into a roll and applied or combined. The non-magnetized side of the flexible magnet may be laminated with double-sided tape or with a thin vinyl coating so that a printed layer may be applied. The attached underlayment may also be applied for flooring purposes. The residual flux density (Br) of the anisotropic permanent flexible magnet may be t (g): 0.22-0.23 or (2250-. The remanence of an anisotropic permanent flexible magnet can be 40% stronger than an isotropic permanent flexible magnet.

For the floor covering units 811 and the wall covering units 870, the magnetically receptive material of the attraction layer or semi-solid compound may have the following properties: 0.025 inch (0.64mm) thick, Shore D60 hardness, specific gravity of 3.5, by heating at 158F for 7 daysThe shrinkage rate was 1.5% and the tensile strength was 700 psi (49 Kg/cm)²) And a holding strength of 140g/cm²。

In the interchangeable box system 800, all components are "quasi" permanently affixed to the mat. Due to the large surface area of magnetic resonance between the underlayment 812 or underlayment 880 and the floor covering unit 811 or the wall covering unit 870, the material has a very strong bond, making the installation "quasi" permanent. However, the bond may be broken by "grabbing" a corner and prying upward to break the bond, thereby allowing the floor covering unit 811 or the wall covering unit 870 to be changed as needed, which is not currently possible with any prior art. In the interchangeable box system 800, any building material with a flat backing (for optimal remanence) can be used in the system. For example, a floor covering unit 811 made of wood may also be used as the wall covering unit 870, or vice versa.

The ability to remove any part at any given time during the construction process is highly desirable. If a wall panel 870 in an interchangeable box system 870 does not properly match or requires finishing, as is the case in many installations, the wall panel 870 may simply be removed and reattached as needed without removal.

In the flooring industry, the popular method of sewing rolled up carpets requires securing an adhesive strip to the perimeter of the room, hot melt taping, and stretching or "tightening" the rolled up floor covering to hold the product in place. This causes the product to fail due to actual carpet stripping due to tension (primary backing of the floor pulls away from the secondary backing), thermal deformation of the finished article, peaking of the seam, etc. There are many ways in which conventional methods may fail. The system 800 eliminates these failures and eliminates the need for temporary tie bars (tapstrips) since the floor covering unit 811 no longer has to be tightened. The residual magnetism due to the large surface area prevents the floor covering unit 811 from "peaking" or moving under stress.

In the event that an existing wall or a new construction wall has a defect; such as arcuate or concave shape to limit remanence, one can simply use a double-sided magnetic receptor and magnetic back-shim to alleviate the problem of being an accessory to an interchangeable case system. The floor covering unit 811 and the wall covering unit 870 may provide different designs, logos, textures, colors, acoustic properties, reflective properties, or design elements in the room. The floor covering units 810 and wall covering units 870 may also incorporate corporate or other branding or sponsorship information, and may be used for advertising or as signage. A homeowner, business owner, or designer may use the interchangeable box system 800 at any time to change any aspect of any room as desired.

The flexible nature of the interchangeable box system 800 will also provide benefits in the movie, television, and theater industries. In these industries, televisions, movie machines, etc. are built in a modular fashion and often simulate real locations in a more cost effective manner. Unfortunately, these settings are built for their specific use on the framework, and then the framework must be stored for another "similar" use of the same setting, or new settings must be built each time to accommodate the scenario. With the interchangeable box system 800, it would be highly cost effective and highly beneficial to change the scene of a room with the same framework as needed. This is also cost effective in large studios where a western town must be set for a first scenario and then new york city for another scenario. The ability to use the same frame, but change the wall covering 870 and floor covering unit 810 to simulate the desired situation would be desirable and cost effective.

Although 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. Furthermore, the scope of the present invention is not limited by the specific embodiments described herein. It is fully contemplated that other various embodiments of and modifications to the present invention, in addition to those described herein, will become apparent to those of ordinary skill 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. Moreover, although the invention has been described herein in the context of particular embodiments and implementations and applications and in particular environments, those of ordinary skill in the art will appreciate that its usefulness is not limited thereto and that the invention can be beneficially applied in any number of ways and environments for any number of purposes. 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

1. A surface covering system that provides removably secured surface covering when installed, the system comprising:

a magnetic surface covering unit comprising a non-magnetized isotropic magnetic receptive layer; and

an anisotropically magnetized underlayer disposed on the support surface;

wherein the magnetic surface covering unit is adapted to be magnetically attracted and relatively received by the anisotropically magnetized mat in a fixed installation and to be non-destructively removable from the anisotropically magnetized mat after the fixed installation.

2. The system of claim 1, wherein the anisotropically magnetized underlayment is 0.5mm thick and comprises a magnetizable material having a mesh size, the magnetizable material configured to have enhanced magnetic attraction properties when magnetized and adapted to support the magnetic surface covering unit in a non-horizontal fixed installation, wherein the non-horizontal fixed installation is one of an interior wall installation, an exterior wall installation, an aircraft interior cabin installation, an exterior roof installation, or an interior ceiling installation.

3. The system of claim 1, wherein the anisotropically magnetized underlayer comprises:

a magnetizable material comprising iron powder;

a binder component; and

an oil having properties that allow for rapid solidification during manufacture, whereby solidification occurs at normal line speeds in a calendering or extrusion process.

4. The system of claim 3, wherein the magnetizable material comprises one of: ferrous powder, strontium ferrite powder, neodymium powder, and a composite of neodymium and ferrous powder.

5. The system of claim 3, wherein the binder comprises a thermoplastic chlorinated polyethylene elastomer ("CPE").

6. The system of claim 3, wherein the oil comprises epoxidized soybean oil ("ESBO").

7. The system of claim 1, wherein the anisotropically magnetized mat is one of a calendered sheet article or an extruded sheet article.

8. The system of claim 1, wherein the anisotropically magnetized underlayer comprises a magnetizable material with a mesh size of 1-2.3 μ ι η.

9. A magnetized spacer for securing a magnetically receptive surface covering element to a support surface, said magnetized spacer comprising:

neodymium powder;

a binder; and

10. The magnetized underlayer of claim 9, further comprising a plasticizer.

11. The magnetized underlayment of claim 9 wherein the oil comprises epoxidized soybean oil ("ESBO").

12. The magnetized underlayer of claim 9, where the ratio of the neodymium powder to the binder and the oil is selected based on application considerations to be one of: about 91% neodymium powder to about 9% binder and oil; about 81% neodymium powder to about 19% binder and oil; about 71% neodymium powder to about 29% binder and oil; about 61% neodymium powder to about 39% binder and oil; or about 51% neodymium powder to about 49% binder and oil.

13. The magnetized underlayer of claim 9, where the magnetic underlayer further comprises ferrite powder.

14. The magnetized underlayer of claim 13, where the ratio of the ferrite powder to the neodymium powder is 50/50.

15. A method for applying a magnetic receptive layer on a surface covering element to produce a magnetic receptive surface covering element adapted to be magnetically pinned relative to a magnetized underlayer, the method comprising:

adding a blend of a receiving material and an oil compound to a mixer;

blending the receptive material blend and the oil compound to form a magnetically receptive oil blend;

spraying the magnetically receptive oil blend onto a surface covering unit; and

solidifying the magnetically receptive oil blend onto the surface covering unit.

16. The method of claim 15, wherein the receptive material blend comprises one of: ferrous powder, strontium ferrite powder, and neodymium powder and neodymium and ferrous powder composites.

17. The method of claim 15, wherein the oil compound comprises one of: ultraviolet ("UV") oils and polyvinyl chloride ("PVC") resins.

18. The method of claim 15, wherein the solidifying of the magnetically receptive oil blend comprises rapidly solidifying the magnetically receptive oil blend by high intensity ultraviolet ("UV") light.

19. The method of claim 15, wherein the solidifying of the magnetically receptive oil blend comprises solidifying the magnetically receptive oil blend by an elevated temperature.