WO2018087517A1 - Wall covers - Google Patents

Wall covers Download PDF

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Publication number
WO2018087517A1
WO2018087517A1 PCT/GB2017/053191 GB2017053191W WO2018087517A1 WO 2018087517 A1 WO2018087517 A1 WO 2018087517A1 GB 2017053191 W GB2017053191 W GB 2017053191W WO 2018087517 A1 WO2018087517 A1 WO 2018087517A1
Authority
WO
WIPO (PCT)
Prior art keywords
magnetic
flexible
cover
sheet
wall
Prior art date
Application number
PCT/GB2017/053191
Other languages
French (fr)
Inventor
Richard Anthony CLARKE
Original Assignee
Richard Signs Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Richard Signs Ltd filed Critical Richard Signs Ltd
Publication of WO2018087517A1 publication Critical patent/WO2018087517A1/en

Links

Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00Coverings or linings, e.g. for walls or ceilings
    • E04F13/07Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/18Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements of organic plastics with or without reinforcements or filling materials or with an outer layer of organic plastics with or without reinforcements or filling materials; plastic tiles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B25/00Layered products comprising a layer of natural or synthetic rubber
    • B32B25/04Layered products comprising a layer of natural or synthetic rubber comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B25/08Layered products comprising a layer of natural or synthetic rubber comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B25/00Layered products comprising a layer of natural or synthetic rubber
    • B32B25/10Layered products comprising a layer of natural or synthetic rubber next to a fibrous or filamentary layer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/06Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/065Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
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    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/06Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
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    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/18Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/30Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/30Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/302Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/34Layered products comprising a layer of synthetic resin comprising polyamides
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/36Layered products comprising a layer of synthetic resin comprising polyesters
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/26Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
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    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04Interconnection of layers
    • B32B7/06Interconnection of layers permitting easy separation
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04Interconnection of layers
    • B32B7/12Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00Coverings or linings, e.g. for walls or ceilings
    • E04F13/002Coverings or linings, e.g. for walls or ceilings made of webs, e.g. of fabrics, or wallpaper, used as coverings or linings
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00Coverings or linings, e.g. for walls or ceilings
    • E04F13/07Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/072Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of specially adapted, structured or shaped covering or lining elements
    • E04F13/077Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of specially adapted, structured or shaped covering or lining elements composed of several layers, e.g. sandwich panels
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00Coverings or linings, e.g. for walls or ceilings
    • E04F13/07Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0866Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements composed of several layers, e.g. sandwich panels or layered panels
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00Coverings or linings, e.g. for walls or ceilings
    • E04F13/07Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0885Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements specially adapted for being adhesively fixed to the wall; Fastening means therefor; Fixing by means of plastics materials hardening after application
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F7/00Magnets
    • H01F7/02Permanent magnets [PM]
    • H01F7/0205Magnetic circuits with PM in general
    • H01F7/021Construction of PM
    • H01F7/0215Flexible forms, sheets
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10Inorganic particles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10Inorganic particles
    • B32B2264/105Metal
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00Composition of foam
    • B32B2266/02Organic
    • B32B2266/0214Materials belonging to B32B27/00
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00Composition of foam
    • B32B2266/02Organic
    • B32B2266/0214Materials belonging to B32B27/00
    • B32B2266/025Polyolefin
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00Composition of foam
    • B32B2266/06Open cell foam
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00Composition of foam
    • B32B2266/08Closed cell foam
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/20Properties of the layers or laminate having particular electrical or magnetic properties, e.g. piezoelectric
    • B32B2307/208Magnetic, paramagnetic
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B32B2307/00Properties of the layers or laminate
    • B32B2307/50Properties of the layers or laminate having particular mechanical properties
    • B32B2307/546Flexural strength; Flexion stiffness
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B32B2451/00Decorative or ornamental articles
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/0027Thick magnetic films

Definitions

  • the present invention relates to magnetic wall covers, and in particular magnetic wall tiles which can be applied to walls with protrusions, divots or other imperfections in a planar wall surface, whilst still enabling a substantially planar wall cover.
  • Magnetic paint is relatively expensive and must be applied to the whole of a wall surface in order to look aesthetically pleasing.
  • a wall may not be conducive to receiving magnetic paint, for example highly porous surfaces such as breeze blocks and porous wooden surfaces, unless significant preparation work is undertaken in filling or masking the pores, or applying an under-layer of a different material.
  • An alternative way of ensuring a wall has magnetic character, without applying paint, is to attach one or more tiles or other wall coverings, such as wall-paper, which includes a magnetic material.
  • Known magnetic wall-coverings include vinyl tiles and other flexible substrates which include magnetic particles or are coated in a magnetic paint or other magnetic media.
  • Such known tiles and wall coverings work well on substantially planar and blemish-free walls, but are difficult or impossible to use on walls which include significant defects such as protrusions, ridges and other raised areas, or defects such as pores, holes or score lines.
  • a magnetic wall cover comprising a plurality of layers which comprise, in order: a flexible cover layer, a flexible magnetic sheet, a flexible compressible sheet and an adhesive.
  • the flexible cover layer comprises a polymeric material selected from polyethyleneterephthalate (PET), polyester, polyamide, a vinyl polymer, polystyrene, or a combination thereof.
  • PET polyethyleneterephthalate
  • the material is PET.
  • the flexible cover layer may comprise a melamine resin material.
  • the cover layer may have a thickness of at least 0.01 mm, 0.02 mm, 0.03 mm, 0.04 mm, 0.05 mm, 0.06 mm, 0.07 mm, 0.08 mm, 0.09 mm, 0.1 mm, 0.125 mm, 0.15 mm, 0.175 mm, 0.2 mm, 0.3 mm, 0.4 mm or 0.5 mm, for example.
  • the thickness of the cover layer may be between 0.05 and 0.1 mm, such as between 0.06 mm and 0.08 mm, for example.
  • the cover layer may comprise a dry erase or dry wipe surface.
  • the dry erase or dry wipe surface may be arranged, in use, to enable a user to draw or write on the surface with a suitable drawing or writing implement, such as a pen or marker, and for the resultant image and/or writing to be removed with a dry material, such as a cloth, without recourse to using any solvents or other chemicals.
  • the cover layer may comprise a matte surface and may be a blackboard (otherwise known as chalkboard) surface, suitable for enabling a user to write images and/or words using chalk or other similar media.
  • the flexible magnetic sheet may comprise a polymeric material comprising magnetic particles.
  • the magnetic particles may be present homogeneously throughout the material, or may be present at a higher concentration in one or more areas of the material, such as at or towards the surface of the sheet next to the flexible cover layer.
  • the magnetic particles may comprise ferrous particles, such as iron particles, including micro iron particles for example.
  • the magnetic particles may comprise a ferrite material such as strontium ferrite; barium ferrite, cobalt ferrite, manganese-zinc-ferrite, nickel- zinc-ferrite, or any suitable combination thereof.
  • the flexible magnetic sheet may comprise a polymeric material selected from polyethyleneterephthalate (PET), polyester, polyamide, a vinyl polymer, polystyrene, or a combination thereof. In some embodiments the material is PET.
  • the flexible cover layer and flexible magnetic sheet may be formed from the same material, such as both being formed from PET, for example.
  • the flexible magnetic sheet may have a thickness of at least 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm or at least 1 mm, for example. In some embodiments the flexible magnetic sheet has a thickness of between 0.5 mm and 1 mm, such as between 0.6 mm and 0.8 mm, or around 0.7 mm.
  • the ratio of thickness of the flexible cover layer to flexible magnetic sheet may be between 1:30 and 1:5, and in some embodiments may be between 1:20 and 1: 10, such as around 1: 10. In some embodiments the thickness of the cover layer may be between 0.05 mm and 0.1 mm and the thickness of the flexible magnetic sheet may be between 0.5 mm and 1 mm for example.
  • the flexible compressible sheet may comprise an elastomeric material, such as rubber, for example.
  • the flexible compressible material may comprise a foam or cellular material, such as a polyethylene foam, a polyolefin foam, a polyurethane foam, a cross linked ethylene copolymer foam, a polypropylene foam, a polychloroprene foam, an ethylene vinyl acetate foam, a polyether foam, or any suitable combination thereof, for example.
  • the foam material may comprise a closed pore or closed cell foam or an open pore or open cell foam.
  • the open pores or open cells of the foam may comprise a continuous open network within the foam material.
  • the foam may comprise memory foam.
  • the flexible compressible sheet may comprise a spacer fabric.
  • the flexibility of the magnetic sheet enables the magnetic base sheet to create a substantially planar magnetic surface, while the flexible compressible sheet provides a backing which can conform to imperfections in a surface to which the cover is applied, through compression and expansion of the compressible material within holes, chips or other apertures in the surface; and/or around and on top of bumps, protuberances and other raised areas on the surface.
  • the flexible compressible sheet may have a thickness of at least 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, 1 mm, 1.1 mm, 1.2 mm, 1.3 mm, 1.4 mm or 1.5 mm, for example, such as between 0.75 mm and 1.25 mm, or between 0.9 mm and 1.1 mm, or around 1 mm.
  • the ratio of thickness of the flexible compressible sheet to flexible magnetic sheet may be between 5: 1 and 1:1, such as between 2: 1 and 1: 1 or between 1.5: 1 and 1.3:1, for example.
  • a ratio within this range enables maximum flexibility of the compressible sheet to conform to any imperfections to which the wall tile of the invention is applied, whilst allowing the flexible magnetic sheet to retain a substantially flat profile thereon.
  • the adhesive may comprise a layer applied to the flexible compressible sheet, or may be integral with the flexible compressible sheet.
  • the flexible compressible sheet may comprise a foam material and the adhesive may be located in at least some of the pores or cells of the material, on the outer surface of the flexible compressible sheet not connected to the flexible magnetic sheet.
  • the magnetic wall cover may include a release layer covering the adhesive.
  • the release layer may comprise a silicone release layer, or may be formed from any other suitable material capable of releasably masking the adhesive.
  • the magnetic wall cover may be in the form of a strip of material having a width of at least 25 cm, 30 cm, 35 cm, 40 cm, 45 cm, 50 cm, 60 cm, 70 cm, 80 cm, 90 cm or at least 100 cm, for example.
  • the length of the material will depend on the format of the wall cover.
  • the magnetic wall cover may comprise a long sheet of material, which may have a length of at least 5 m, 6 m, 7 m, 8 m, 9 m or at least 10 m, for example.
  • the sheet may be formed in a roll.
  • the sheet of material may be arranged to be cut into smaller tiles, for example having a length of no more than 1.5 m, lm, 0.75 m or 0.5 m, for example.
  • the flexible cover may be laminated to the flexible magnetic sheet.
  • the flexible magnetic sheet may be laminated to the flexible compressible sheet.
  • the flexible compressible sheet may be laminated to the adhesive. In some embodiments all of the flexible cover and sheets and optionally the adhesive are laminated to their adjacent components.
  • a magnetic wall tile comprising a magnetic wall cover of the first aspect of the invention.
  • the wall tile may have a width of no more than 1 m and a length of no more than 3 m.
  • the wall tile may be any suitable shape such as rectangular or square.
  • the wall tile may comprise a rectangular (including square) tile having a width of at least 50 cm and a length of no more than 3 m, for example.
  • a kit comprising a plurality of wall tiles of the second aspect of the invention.
  • the or each tile may be identical in material and/or size or each tile may independently be a different size or contain different materials.
  • some tiles may comprise a dry wipe cover surface while other tiles may comprise a matte blackboard cover surface.
  • the kit may include one or more ferrous or magnetic attachments, such as ferrous or magnetic sheets, ferrous or magnetic pockets, ferrous or magnetic wallets or ferrous or magnetic containers, which in use may be releasably attached to the wall tiles by a user, in any desired orientation and/or configuration.
  • the kit includes one or more ferrous or magnetic wallets or pockets.
  • a method of applying a wall covering on a wall comprising adhering at least two wall tiles of the second aspect of the invention to a wall, such that the tiles are in register and create a continuous wall cover.
  • the method may comprise selecting two or more tiles from a kit of the third aspect of the invention.
  • Figure 1 illustrates a side sectional view of a magnetic wall covering of the invention
  • Figure 2 illustrates a side sectional view of the magnetic wall covering of the invention adhered to a wall surface.
  • an embodiment of a magnetic wall cover of the invention 2 comprises a flexible cover layer 4, laminated to a flexible magnetic sheet 6, which in turn is laminated to a flexible compressible sheet 8.
  • the flexible compressible sheet 8 includes an adhesive layer 10 applied across the back surface thereof.
  • the flexible cover layer 4 comprises a dry wipe polyethylene terephthalate (PET) with a gloss finish.
  • PET polyethylene terephthalate
  • the flexible cover layer 4 is arranged, in use to enable the user to draw or write on the surface thereof using any suitable writing or drawing implements such as a marker pen.
  • the flexible cover layer 4 has a thickness of approximately 0.7 millimetre.
  • the flexible cover layer 4 may comprise a matte surface and may take the form of a blackboard (otherwise known as a chalkboard) surface, suitable for enabling the user to write or draw images and/or words using chalk or other similar media.
  • the flexible magnetic sheet 6 comprises a vinyl polymer material comprising magnetic particles in the form of micro iron particles homogenously dispersed throughout the material of the flexible magnetic sheet 6.
  • the flexible magnetic sheet 6 has a thickness of approximately 0.7 millimetre, and therefore the ratio of the thickness of the flexible cover layer 4 to the flexible magnetic layer 6 is approximately 1: 10.
  • the flexible compressible sheet 8 comprises an elastomeric foam material formed from polyethylene foam having a continuous network of open pores or cells.
  • the flexible compressible sheet 8 provides a backing for the flexible magnetic base sheet 6 to enable the magnetic wall cover 2 of the invention to conform to imperfections in a surface to which the cover is applied.
  • the flexible compressible sheet 8 moulds around imperfections such as bumps or other protuberances extending from a surface.
  • the magnetic sheet 6 remains substantially planar, and therefore forms a substantially planar surface on the surface for which it is applied.
  • the adhesive 10 in the embodiment shown in Figure 1 comprises a layer of adhesive coated on the back of the flexible compressible sheet 8, which allows the magnetic wall cover 2 to be adhered to a suitable surface.
  • Figure 2 illustrates the flexible magnetic sheet 2 of the invention adhered to a wall 12.
  • the wall 12 includes an imperfection in the form of protruding bumps 14.
  • the flexible compressible sheet 8 moulds around the protuberances 14 whilst the flexible magnetic sheet 6 and flexible cover layer 4 remain substantially planar.
  • the adhesive 10 may be entrained within the flexible compressible sheet 8, rather than applied as a coating or separate layer on the back thereof.
  • the flexible compressible sheet 8 has a thickness of approximately 1 millimetre, and therefore the ratio of thickness of the flexible compressible sheet 8 to the flexible magnetic sheet 6 is approximately 1.4: 1.
  • the adhesive 10 may include a release layer connected thereto, which may be removed in order to expose the adhesive 10 when required.
  • the release layer may comprise a silicone release layer.
  • the magnetic wall cover 2 may be provided as a roll of material which may have a width of approximately 0.5-1 metre, and a length of between 10 metres and 20 metres, for example.
  • the roll of flexible wall cover 2 may be cut to any desired size to provide a flexible wall cover 2 in the form of tiles which may be then be adhered to a surface such as the wall 12 shown in Figure 2.
  • Tiles are particularly advantageous as they may be easily applied by a user and may form a suitable pattern or configuration applicable to the use to which the magnetic wall cover 2 is to be used. For example, two or three tiles of magnetic wall cover 2 having dimensions approximately 0.6 metres by 1 metre may be placed side by side to create a noticeboard or scribble board.
  • the layered nature of the magnetic wall cover 2 enables each tile to be adhered such that the join between each tile is substantially seamless.
  • the magnetic wall cover 2 may therefore be provided as a kit comprising multiple tiles, as an alternative to a larger roll or sheet of material which needs to be cut to size by a user.
  • the magnetic nature of the magnetic wall cover 2 enables various attachments to be releasably connected to the flexible cover layer 4 via magnetic attraction.
  • various information sheets, pockets, wallets or containers may be releasably connected to the flexible cover layer 4 when those attachments include magnetic or ferrous materials including iron magnets, neodymium magnets, ceramic magnets or the like.
  • the magnetic wall cover 2 may therefore be provided in a kit which includes one or more attachments as well as either a roll or sheet of magnetic wall cover 2 or multiple tiles.

Abstract

A magnetic wall cover (2) comprising a plurality of layers which comprise, in order: a flexible cover layer (4), a flexible magnetic sheet (6), a flexible compressible sheet (8) and an adhesive (10).

Description

Wall Covers
Technical Field of the Invention
The present invention relates to magnetic wall covers, and in particular magnetic wall tiles which can be applied to walls with protrusions, divots or other imperfections in a planar wall surface, whilst still enabling a substantially planar wall cover.
Background to the Invention
It is known to provide magnetic wall coverings such as magnetic paint, which may enable a user to then releasably attach magnetic or ferrous articles, such as notices, advertisements and the like. Magnetic paint is relatively expensive and must be applied to the whole of a wall surface in order to look aesthetically pleasing. In addition a wall may not be conducive to receiving magnetic paint, for example highly porous surfaces such as breeze blocks and porous wooden surfaces, unless significant preparation work is undertaken in filling or masking the pores, or applying an under-layer of a different material.
An alternative way of ensuring a wall has magnetic character, without applying paint, is to attach one or more tiles or other wall coverings, such as wall-paper, which includes a magnetic material. Known magnetic wall-coverings include vinyl tiles and other flexible substrates which include magnetic particles or are coated in a magnetic paint or other magnetic media. Such known tiles and wall coverings work well on substantially planar and blemish-free walls, but are difficult or impossible to use on walls which include significant defects such as protrusions, ridges and other raised areas, or defects such as pores, holes or score lines. The relatively planar nature of known magnetic tile materials makes their mounting on non-planar surfaces very difficult, leading to areas of the magnetic tiles not adhering to areas of the wall to which they are adhered; which in turn leads to a greater chance of the wall tiles falling off or being inadvertently pulled off.
There is therefore a need to provide magnetic wall coverings such as tiles, which can be effectively mounted on uneven surfaces and surfaces with protrusions, and which still create a relatively planar contact surface for mounting other magnetic materials.
There is also a need to provide a magnetic wall covering which can be mounted on walls and can be pre-cut to required dimensions and to fit around wall fittings such as light switches and wall hooks, but which can ensure a relatively smooth and planar contact surface for attaching magnetic items to the wall covering.
It is therefore an aim of one or more embodiments of the invention to overcome or mitigate one or more problems of the prior art. Summary of the Invention
According to a first aspect of the invention there is provided a magnetic wall cover comprising a plurality of layers which comprise, in order: a flexible cover layer, a flexible magnetic sheet, a flexible compressible sheet and an adhesive.
In some embodiments the flexible cover layer comprises a polymeric material selected from polyethyleneterephthalate (PET), polyester, polyamide, a vinyl polymer, polystyrene, or a combination thereof. In some embodiments the material is PET. In other embodiments the flexible cover layer may comprise a melamine resin material.
The cover layer may have a thickness of at least 0.01 mm, 0.02 mm, 0.03 mm, 0.04 mm, 0.05 mm, 0.06 mm, 0.07 mm, 0.08 mm, 0.09 mm, 0.1 mm, 0.125 mm, 0.15 mm, 0.175 mm, 0.2 mm, 0.3 mm, 0.4 mm or 0.5 mm, for example. In some embodiments, the thickness of the cover layer may be between 0.05 and 0.1 mm, such as between 0.06 mm and 0.08 mm, for example.
The cover layer may comprise a dry erase or dry wipe surface. The dry erase or dry wipe surface may be arranged, in use, to enable a user to draw or write on the surface with a suitable drawing or writing implement, such as a pen or marker, and for the resultant image and/or writing to be removed with a dry material, such as a cloth, without recourse to using any solvents or other chemicals.
In alternative embodiments the cover layer may comprise a matte surface and may be a blackboard (otherwise known as chalkboard) surface, suitable for enabling a user to write images and/or words using chalk or other similar media. The flexible magnetic sheet may comprise a polymeric material comprising magnetic particles. The magnetic particles may be present homogeneously throughout the material, or may be present at a higher concentration in one or more areas of the material, such as at or towards the surface of the sheet next to the flexible cover layer. The magnetic particles may comprise ferrous particles, such as iron particles, including micro iron particles for example. The magnetic particles may comprise a ferrite material such as strontium ferrite; barium ferrite, cobalt ferrite, manganese-zinc-ferrite, nickel- zinc-ferrite, or any suitable combination thereof.
The flexible magnetic sheet may comprise a polymeric material selected from polyethyleneterephthalate (PET), polyester, polyamide, a vinyl polymer, polystyrene, or a combination thereof. In some embodiments the material is PET.
The flexible cover layer and flexible magnetic sheet may be formed from the same material, such as both being formed from PET, for example.
The flexible magnetic sheet may have a thickness of at least 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm or at least 1 mm, for example. In some embodiments the flexible magnetic sheet has a thickness of between 0.5 mm and 1 mm, such as between 0.6 mm and 0.8 mm, or around 0.7 mm.
The ratio of thickness of the flexible cover layer to flexible magnetic sheet may be between 1:30 and 1:5, and in some embodiments may be between 1:20 and 1: 10, such as around 1: 10. In some embodiments the thickness of the cover layer may be between 0.05 mm and 0.1 mm and the thickness of the flexible magnetic sheet may be between 0.5 mm and 1 mm for example.
The flexible compressible sheet may comprise an elastomeric material, such as rubber, for example. The flexible compressible material may comprise a foam or cellular material, such as a polyethylene foam, a polyolefin foam, a polyurethane foam, a cross linked ethylene copolymer foam, a polypropylene foam, a polychloroprene foam, an ethylene vinyl acetate foam, a polyether foam, or any suitable combination thereof, for example. The foam material may comprise a closed pore or closed cell foam or an open pore or open cell foam. The open pores or open cells of the foam may comprise a continuous open network within the foam material. The foam may comprise memory foam.
The flexible compressible sheet may comprise a spacer fabric. The flexibility of the magnetic sheet enables the magnetic base sheet to create a substantially planar magnetic surface, while the flexible compressible sheet provides a backing which can conform to imperfections in a surface to which the cover is applied, through compression and expansion of the compressible material within holes, chips or other apertures in the surface; and/or around and on top of bumps, protuberances and other raised areas on the surface.
The flexible compressible sheet may have a thickness of at least 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, 1 mm, 1.1 mm, 1.2 mm, 1.3 mm, 1.4 mm or 1.5 mm, for example, such as between 0.75 mm and 1.25 mm, or between 0.9 mm and 1.1 mm, or around 1 mm.
The ratio of thickness of the flexible compressible sheet to flexible magnetic sheet may be between 5: 1 and 1:1, such as between 2: 1 and 1: 1 or between 1.5: 1 and 1.3:1, for example. A ratio within this range enables maximum flexibility of the compressible sheet to conform to any imperfections to which the wall tile of the invention is applied, whilst allowing the flexible magnetic sheet to retain a substantially flat profile thereon.
The adhesive may comprise a layer applied to the flexible compressible sheet, or may be integral with the flexible compressible sheet. In embodiments where the adhesive is integral with the flexible compressible sheet, the flexible compressible sheet may comprise a foam material and the adhesive may be located in at least some of the pores or cells of the material, on the outer surface of the flexible compressible sheet not connected to the flexible magnetic sheet.
The magnetic wall cover may include a release layer covering the adhesive. The release layer may comprise a silicone release layer, or may be formed from any other suitable material capable of releasably masking the adhesive.
The magnetic wall cover may be in the form of a strip of material having a width of at least 25 cm, 30 cm, 35 cm, 40 cm, 45 cm, 50 cm, 60 cm, 70 cm, 80 cm, 90 cm or at least 100 cm, for example. The length of the material will depend on the format of the wall cover. For example the magnetic wall cover may comprise a long sheet of material, which may have a length of at least 5 m, 6 m, 7 m, 8 m, 9 m or at least 10 m, for example. The sheet may be formed in a roll. The sheet of material may be arranged to be cut into smaller tiles, for example having a length of no more than 1.5 m, lm, 0.75 m or 0.5 m, for example.
The flexible cover may be laminated to the flexible magnetic sheet. The flexible magnetic sheet may be laminated to the flexible compressible sheet. The flexible compressible sheet may be laminated to the adhesive. In some embodiments all of the flexible cover and sheets and optionally the adhesive are laminated to their adjacent components.
According to a second aspect of the invention there is provided a magnetic wall tile comprising a magnetic wall cover of the first aspect of the invention. The wall tile may have a width of no more than 1 m and a length of no more than 3 m. The wall tile may be any suitable shape such as rectangular or square. The wall tile may comprise a rectangular (including square) tile having a width of at least 50 cm and a length of no more than 3 m, for example.
According to a third aspect of the invention there is provided a kit comprising a plurality of wall tiles of the second aspect of the invention. The or each tile may be identical in material and/or size or each tile may independently be a different size or contain different materials. For example some tiles may comprise a dry wipe cover surface while other tiles may comprise a matte blackboard cover surface.
The kit may include one or more ferrous or magnetic attachments, such as ferrous or magnetic sheets, ferrous or magnetic pockets, ferrous or magnetic wallets or ferrous or magnetic containers, which in use may be releasably attached to the wall tiles by a user, in any desired orientation and/or configuration. In some embodiments the kit includes one or more ferrous or magnetic wallets or pockets.
According to a fourth aspect of the invention there is provided a method of applying a wall covering on a wall comprising adhering at least two wall tiles of the second aspect of the invention to a wall, such that the tiles are in register and create a continuous wall cover. The method may comprise selecting two or more tiles from a kit of the third aspect of the invention.
Detailed Description of the Invention In order that the invention may be more clearly understood one or more embodiments thereof will now be described, by way of example only, with reference to the accompanying drawings, of which:
Figure 1 illustrates a side sectional view of a magnetic wall covering of the invention; and
Figure 2 illustrates a side sectional view of the magnetic wall covering of the invention adhered to a wall surface.
Referring to Figures 1 and 2, an embodiment of a magnetic wall cover of the invention 2 comprises a flexible cover layer 4, laminated to a flexible magnetic sheet 6, which in turn is laminated to a flexible compressible sheet 8. The flexible compressible sheet 8 includes an adhesive layer 10 applied across the back surface thereof.
The flexible cover layer 4 comprises a dry wipe polyethylene terephthalate (PET) with a gloss finish. The flexible cover layer 4 is arranged, in use to enable the user to draw or write on the surface thereof using any suitable writing or drawing implements such as a marker pen.
The flexible cover layer 4 has a thickness of approximately 0.7 millimetre. In alternative embodiments the flexible cover layer 4 may comprise a matte surface and may take the form of a blackboard (otherwise known as a chalkboard) surface, suitable for enabling the user to write or draw images and/or words using chalk or other similar media.
The flexible magnetic sheet 6 comprises a vinyl polymer material comprising magnetic particles in the form of micro iron particles homogenously dispersed throughout the material of the flexible magnetic sheet 6.
The flexible magnetic sheet 6 has a thickness of approximately 0.7 millimetre, and therefore the ratio of the thickness of the flexible cover layer 4 to the flexible magnetic layer 6 is approximately 1: 10.
The flexible compressible sheet 8 comprises an elastomeric foam material formed from polyethylene foam having a continuous network of open pores or cells.
The flexible compressible sheet 8 provides a backing for the flexible magnetic base sheet 6 to enable the magnetic wall cover 2 of the invention to conform to imperfections in a surface to which the cover is applied. The flexible compressible sheet 8 moulds around imperfections such as bumps or other protuberances extending from a surface. At the same time, the magnetic sheet 6 remains substantially planar, and therefore forms a substantially planar surface on the surface for which it is applied.
The adhesive 10 in the embodiment shown in Figure 1 comprises a layer of adhesive coated on the back of the flexible compressible sheet 8, which allows the magnetic wall cover 2 to be adhered to a suitable surface.
Figure 2 illustrates the flexible magnetic sheet 2 of the invention adhered to a wall 12. The wall 12 includes an imperfection in the form of protruding bumps 14. As shown in Figure 2, when the magnetic wall cover 2 is applied to the wall 12, the flexible compressible sheet 8 moulds around the protuberances 14 whilst the flexible magnetic sheet 6 and flexible cover layer 4 remain substantially planar.
In alternative embodiments the adhesive 10 may be entrained within the flexible compressible sheet 8, rather than applied as a coating or separate layer on the back thereof.
The flexible compressible sheet 8 has a thickness of approximately 1 millimetre, and therefore the ratio of thickness of the flexible compressible sheet 8 to the flexible magnetic sheet 6 is approximately 1.4: 1.
The adhesive 10 may include a release layer connected thereto, which may be removed in order to expose the adhesive 10 when required. The release layer may comprise a silicone release layer.
The magnetic wall cover 2 may be provided as a roll of material which may have a width of approximately 0.5-1 metre, and a length of between 10 metres and 20 metres, for example. In use, the roll of flexible wall cover 2 may be cut to any desired size to provide a flexible wall cover 2 in the form of tiles which may be then be adhered to a surface such as the wall 12 shown in Figure 2. Tiles are particularly advantageous as they may be easily applied by a user and may form a suitable pattern or configuration applicable to the use to which the magnetic wall cover 2 is to be used. For example, two or three tiles of magnetic wall cover 2 having dimensions approximately 0.6 metres by 1 metre may be placed side by side to create a noticeboard or scribble board. The layered nature of the magnetic wall cover 2 enables each tile to be adhered such that the join between each tile is substantially seamless. The magnetic wall cover 2 may therefore be provided as a kit comprising multiple tiles, as an alternative to a larger roll or sheet of material which needs to be cut to size by a user.
The magnetic nature of the magnetic wall cover 2 enables various attachments to be releasably connected to the flexible cover layer 4 via magnetic attraction. For example, various information sheets, pockets, wallets or containers may be releasably connected to the flexible cover layer 4 when those attachments include magnetic or ferrous materials including iron magnets, neodymium magnets, ceramic magnets or the like. The magnetic wall cover 2 may therefore be provided in a kit which includes one or more attachments as well as either a roll or sheet of magnetic wall cover 2 or multiple tiles.
The above embodiments are described by way of example only. Many variations are possible without departing from the scope of the invention as defined in the appended claims.

Claims

1. A magnetic wall cover comprising a plurality of layers which comprise, in order: a flexible cover layer, a flexible magnetic sheet, a flexible compressible sheet and an adhesive.
2. A magnetic wall cover as claimed in claim 1 wherein the flexible cover layer comprises a polymeric material selected from polyethylene terephthalate, polyester, polyamide, a vinyl polymer, polystyrene or a combination thereof.
3. A magnetic wall cover as claimed in claim 1 or 2 wherein the cover layer has a thickness of between 0.05 millimetre and 0.1 millimetre.
4. A magnetic wall cover as claimed in any one of claims 1 to 3 wherein the cover layer comprises a dry erase or dry wipe surface.
5. A magnetic wall cover as claimed in any preceding claim wherein the flexible magnetic sheet comprises a polymeric material in which magnetic particles are homogenously dispersed throughout the material.
6. A magnetic wall cover as claimed in claim 5 wherein the magnetic particles comprise ferrous particles such as iron particles.
7. A magnetic wall cover as claimed in any preceding claim wherein the flexible magnetic sheet comprises a polymeric material selected from polyethylene terephthalate, polyester, polyamide, vinyl polymer, polystyrene, or a combination thereof.
8. A magnetic wall cover as claimed in any preceding claim wherein the flexible magnetic sheet has a thickness of between 0.5 millimetre and 1 millimetre.
9. A magnetic wall cover as claimed in any preceding claim wherein the ratio of thickness of the flexible cover layer to flexible magnetic sheet is between 1 :30 and 1 :5.
10. A magnetic wall cover as claimed in any preceding claim wherein the flexible compressible sheet comprises a foam material.
11. A magnetic wall cover as claimed in claim 10 wherein the foam material is selected from a polyethylene foam, a polyolefin foam, an ethylene vinyl acetate foam, a polyether foam, or any combination thereof.
12. A magnetic wall cover as claimed in claim 10 or 11 wherein the foam material comprises a closed pore foam, closed cell foam, open pore foam or open cell foam.
13. A magnetic wall cover as claimed in any preceding claim wherein the flexible compressible sheet has a thickness of between 0.5 millimetre and 2 millimetres.
14. A magnetic wall cover as claimed in any preceding claim in which each of the flexible cover layer, flexible magnetic sheet, and flexible compressible sheet are laminated to their respective adjacent layer and/or sheet(s)
15. A magnetic wall tile comprising a magnetic wall cover of any one of claims 1 to 14.
16. A magnetic wall tile as claimed in claim 15 having a width of no more than 1 metre and a length of no more than 3 metres.
17. A kit comprising a plurality of wall tiles of claim 15 or 16.
18. A kit as claimed in claim 17 further comprising one or more ferrous or magnetic attachments, arranged in use to be releasably attached to the wall tiles.
19. A method of forming a wall covering comprising adhering at least two wall tiles of claims 15 or 16 to a wall, such that the tiles are in register and create a continuous wall cover.
PCT/GB2017/053191 2016-11-11 2017-10-24 Wall covers WO2018087517A1 (en)

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GB201619073 2016-11-11

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CN112423976A (en) * 2018-06-26 2021-02-26 美国圣戈班性能塑料公司 Compressible sheet
EP4328398A1 (en) * 2022-08-22 2024-02-28 Cuby Technologies Inc. Magnetic construction panel and its method of manufacture

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JP3194605U (en) * 2014-07-23 2014-12-04 ニチレイマグネット株式会社 Composite foam sheet

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CN112423976A (en) * 2018-06-26 2021-02-26 美国圣戈班性能塑料公司 Compressible sheet
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