Construction Magnetic Panel and Method of Manufacture

Abstract

A construction magnetic panel is provided having a flexible base formed with front and internal sides and including magnetic particles placed within the body of the panel. The magnetic particles are operated within a working temperature range between −60 and +120° C., whereby the magnetic particles are characterized by the maximum energy product (BH).sub.max within the range between 2,0 and 100,00 kJ/m.sup.3 and are capable of magnetic interaction with external magnetically susceptible materials.

Claims

1. A construction magnetic panel, comprising: a base formed with front and internal sides and having magnetic particles, said magnetic particles operated at a working temperature range between −60 and +120° C., whereby said magnetic particles are characterized by maximum energy product (BH).sub.max within the range between 2,0 and 100,00 kJ/m.sup.3 and are capable of magnetic interaction with external magnetically-susceptible materials.

2. The construction magnetic panel according to claim 1, wherein said magnetic particles are placed at least on a surface of the internal/rear side, wherein said base is solid and selected from the group comprising: a glass, a metal, a compressed craft paper with moisture-proof impregnation, a ceramic, a wood, a plastic, a rubber, a textile, a leather, a stone and any combination thereof (or almost of any both natural or synthetic materials or their combination, or any suitable simple or complex object, including electronic devices.

3. The construction magnetic panel according to claim 1, wherein said magnetic particles are placed at least on a surface of the internal side or within a body the base, wherein said base is a flexible/resilient structure selected from the group comprising: a fabric and a plastic, including polystyrene.

4. The construction magnetic panel according to claim 3, wherein when said resilient/flexible base is made of the plastic, said plastic is a polymer mixture having incorporated said magnetic particles in the form of a magnetic filler including vinyl with magnetic properties characterized by the maximum energy product (BH).sub.max within the range between 2,0 and 100,00 kJ/m.sup.3.

5. The construction magnetic panel according to claim 3, wherein when said resilient/flexible base is made of the fabric, said fabric is a filamentary fabric including acrylate latex with magnetic particles in the form of a dispersed magnetic filler characterized by the maximum energy product (BH).sub.max within the range between 2,0 and 100,00 kJ/m.sup.3.

6. The construction magnetic panel according to claim 2, wherein said magnetic particles are embodied at the inner side of the body of the base in the form of a magnetic powder.

7. The construction magnetic panel according to claim 3, further comprising a decorative ornament is provided at the front of the base wherein the flexible fabric or the plastic incorporates particles having magnetic properties.

8. The construction magnetic panel according to claim 2, wherein a flexible/resilient vinyl base with the magnetic properties is attached to the rigid, generally nonmagnetic trim element, said trim element is selected from the group comprising: a glass, a metal, a compressed craft paper with moisture-proof impregnation, a ceramic, wood, plastic, rubber, textile, leather, stone and any combination thereof, said step of attaching is carried out by means of an adhesive joint characterized by a breaking force which is at least twice greater of a magnetic attraction between external magnetically susceptible materials and the vinyl having the particles with the magnetic properties.

9. The construction magnetic panel according to claim 5, wherein the base made of the flexible fabric is attached to an article selected from the group comprising: glass, metal, compressed craft paper, ceramic, wood, plastic, rubber, textile, leather, stone and any combination thereof, by means of an adhesive compound having a breaking force which is at least twice greater of a magnetic attraction between external magnetically susceptible materials and the filamentary fabric including acrylate latex with magnetic particles in the form of a dispersed magnetic filler.

10. A method of manufacturing of the construction magnetic panel according to claim 2, comprising the following step: embedding at least one said magnetic particle on a surface of the internal/rear side of the base, wherein said at least one magnetic particle is capable of magnetic interaction with external magnetically susceptible materials.

11. The method of manufacturing the construction magnetic panel according to claim 10, further comprising the step of producing the base from a polymer mixture with said at least one magnetic structure in the form of a magnetic filler having resilient/flexible and magnet properties characterized by the maximum energy product (BH).sub.max within the range between 2,0 and 100,00 kJ/m.sup.3.

12. The method of manufacturing the construction magnetic panel according to claim 5, further comprising the step of producing the base from the flexible fabric, wherein said flexible fabric is a filamentary fabric including acrylate latex with magnetic particles in the form of a dispersed magnetic filler characterized by the maximum energy product (BH).sub.max within the range between 2,0 and 100,00 kJ/m.sup.3.

13. The method of manufacturing the construction magnetic panel according to claim 10, further comprising the step of attaching a vinyl with particles having magnetic properties to the rigid base, said rigid base is selected from the group comprising: glass, metal, pressed craft paper, ceramic, wood, plastic, rubber, textile, leather, stone or any combination thereof, said attaching is by means of an adhesive joint, wherein a breaking force of the adhesive joint is at least twice greater of the magnetic attraction force with external magnetically susceptible materials.

14. The method of manufacturing the construction magnetic panel according to claim 10, further comprising the step of embedding the flexible fabric with dispersed magnetic filler by means of an adhesive compound to the solid base, said rigid base is selected from the group comprising: glass, metal, pressed craft paper, ceramic, wood, plastic, rubber, textile, leather, stone or any combination thereof, wherein the breaking force of the adhesive compound is at least twice greater of the magnetic attraction with external magnetically susceptible materials.

15. The method of manufacturing the construction magnetic panel according to claim 10, further comprising the step of implementing in an internal side of the rigid base, said rigid base is selected from the group comprising: glass, metal, pressed craft paper, ceramic, wood, plastic, rubber, textile, leather, stone or any combination thereof, said step of implementing is carried out with the magnetic particles in the form of a magnetic powder with a characteristic maximum energy product (BH).sub.max within the range between 2,0 and 100,00 kJ/m.sup.3.

16. A construction magnetic panel, comprising: a solid base formed with front and internal sides and having magnetic particles placed within a body of the panel, said base is selected from the group comprising: a glass, a plastic, and compressed craft paper with moisture-proof impregnation, said magnetic particles operating at a working temperature range between −60 and +120° C., whereby said magnetic particles are characterized by the maximum energy product (BH).sub.max within the range between 2,0 and 100,00 kJ/m.sup.3 and are capable of magnetic interaction with external magnetically-susceptible materials.

17. A construction magnetic panel, comprising: a flexible base formed with front and internal sides and having magnetic particles placed within a body of the base, said base is selected from the group comprising: a fabric and a plastic, including polystyrene, said magnetic particles operating within a working temperature range between −60 and +120° C., whereby said magnetic particles are characterized by the maximum energy product (BH).sub.max within the range between 2,0 and 100,00 kJ/m.sup.3 and are capable of magnetic interaction with external magnetically-susceptible materials.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0045] In the following drawings, the same parts in the various views are afforded the same reference designators. Referring now to the drawings which are provided to illustrate and not to limit the invention, wherein:

[0046] The accompanying drawings illustrate various embodiments of systems, methods, and various other aspects of the embodiments. Any person with ordinary art skills will appreciate that the illustrated element boundaries (e.g., boxes, groups of boxes, or other shapes) in the figures represent an example of the boundaries. It may be understood that, in some examples, one element may be designed as multiple elements or that multiple elements may be designed as one element. In some examples, an element shown as an internal component of one element may be implemented as an external component in another and vice versa. Furthermore, elements may not be drawn to scale. Non-limiting and non-exhaustive descriptions are described with reference to the following drawings. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating principles.

[0047] FIG. 1 is a general view showing a connection between a magnetic panel and an outer surface of a wall of a building.

[0048] FIG. 2 is an enlarged view of detail A shown in FIG. 1.

[0049] FIG. 3 is a view illustrating attachment of the magnetic panel having a flexible plastic base to an internal surface of the wall of a building.

[0050] FIGS. 4A and 4B illustrate a fragment of the flexible plastic base including magnetic particles.

[0051] FIG. 5 illustrates a fragment of a flexible fabric base with magnetic particles embedded with the size of particles not exceeding 0.05 mm.

[0052] FIGS. 6A and 6B illustrate another embodiment of the flexible base.

[0053] FIGS. 7A and 7B illustrate one embodiment the rigid base made of a glass with implemented magnetic particles.

[0054] FIGS. 8A and 8B illustrate another embodiment of the rigid base made of a metal with the implemented magnetic particles.

[0055] FIG. 9 illustrates a further embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0056] Aspects of the present invention are disclosed in the following description and related figures directed to specific embodiments of the invention. Those of ordinary skill in the art will recognize that alternate embodiments may be devised without departing from the spirit or the scope of the claims. Additionally, well-known elements of exemplary embodiments of the invention will not be described in detail or will be omitted so as not to obscure the relevant details of the invention.

[0057] As used herein, the word exemplary means serving as an example, instance, or illustration. The embodiments described herein are not limiting but rather are exemplary only. The described embodiments are not necessarily to be construed as preferred or advantageous over other embodiments. Moreover, the terms embodiments of the invention, embodiments, or invention do not require that all embodiments include the discussed feature, advantage, or mode of operation.

[0058] Magnet panels could be used for interior and exterior decoration both as single or multilayer products. A single-layer magnetic panel is a soft or hard magnetic base with a print, pattern, or moulded relief applied to its front side, which in essence is a direct part of the magnetic base, or a thin decorative layer applied directly to it. A multilayer magnetic panel is a soft or hard magnetic base with an adhesive composition applied to its front side for fixing over the entire area or only on some part of the magnetic base of mostly non-magnetic soft or hard materials, such as glass or ceramic, or wood, or plastic, or rubber, or textile, or leather, or stone, or metal, or pressed craft paper and any combination thereof (or almost any of both natural or synthetic glueable materials or their combination, or any suitable simple or complex object, including furniture or electronic devices). Also, on the front side of the internal panel could be glued, for example, brackets for hanging small relatively lightweight items on the walls (lamps, paintings, pictures, other decorative elements, bookshelves, small cabinets, LCD or plasma monitors/TVs, fire extinguishers, sensors and cameras, tablets, buttons, sockets, hooks for hanging clothes or bicycles, etc.). With a large area of contact between the suspended element and the wall, the magnetic material can be glued by front side directly to the surface of the object in contact with the wall, for example, over the entire surface of a cabinets or bookshelves. Thus, the number of variants of the products obtained on magnetic bases is practically inexhaustible. On the front side of the magnetic bases for exterior trim panels, in addition to all the suitable materials or items listed above for interior trim panels, could be glued, for example, solar panels, advertising, architectural elements, etc. or brackets for their attachment.

[0059] In addition to structural and architectural enhancements, interior designs can also be supplemented with a variety of components, including but not limited to: (1) Built-in living fixtures, including prefabricated seating, shelving, and storage, kitchen accessories, fireplace, and heating options are only a few, as precast built-in fixtures offer an ideal canvas for many in-home furnishings; (2) Magnetic wall coverings or the more inclusive term “smart surface technology” also provides an innovative component of aspects of this invention. Magnetic Wall coverings are high-performance materials that combine easy installation with various designs, digital prints, textures, and colors. Suitable for residential and commercial interiors, these lightweight wall coverings offer a smooth and seamless surface and can be quickly updated and changed anytime. These innovative magnetic panels can quickly “reinvent” interior space and can be affixed vertically, horizontally, or on curved surfaces, made from environmentally friendly and sustainable materials.

[0060] Referring now to FIGS. 1-9 of the drawings showing various embodiments of a building/construction magnetic panel 10 of the invention. FIGS. 1, 2 and 3 specifically illustrate connection between the magnetic panel 10 and a surface of the wall 15 of a building, including the magnetically susceptible or steel exterior 23. The panel 10 typically consists of a base 12 having an outer side layer 14 and an inner surface layer 16. The base 12 comprises an elastic flexible carrier material.

[0061] In the formation of the panel 10 the magnetic particles 18 are distributed evenly over the surface layer 16 or the entire body/volume 17 of an elastic/flexible carrier material of the base 12. The magnetic particles 18 are provided as a powder of the class of magnetic hexaferrites, such as barium ferrite, or, for example, a powder of the class of magnetic spinels, such as magnetite, or any other powder exhibiting magnetic properties, with the particle size of not more than 0.05 mm with a Curie temperature (point) of at least 300° C. The flexible carrier material of the base 12 can be made, for example, from a material based on polyvinyl chloride with plasticizing additives (including low and high molecular weight), for example, polyethylene chloride (as a high molecular weight additive), The magnetic panel 10 can be produced by, for example, thorough mixing the magnetic powder with the melt of the carrier material to produce a mixture. Further manufacturing steps include profiling the mixture into a roll of film of a relatively soft flexible material having an approximate thickness between 0.3 and 3.0 mm, whereas the roll can be formed having the width of up to 3000 mm. In the formation of the roll of film conventional methods can be utilized, such as for example, calendering. In order to provide the resulting material of the panel 10 with the properties of a permanent magnet characterized by maximum energy product (BH).sub.max within the range between 2,0 and 100,00 kJ/m.sup.3 of the resulting material, such material further undergoes an additional processing, for example, by an external magnetic field.

[0062] The film, in the case of distribution of the magnetic powder over the entire body/volume 17 of the carrier material represents a homogeneous material. In the case of the distribution of the magnetic particles 18 over the surface 16, the carrier material is a two- or more-layer film consisting of the layers having different compositions. For example, the outer side layer 14 may be a non-magnetic elastic film intended for applying images, for example by UV printing.

[0063] In the embodiment of FIGS. 4A and 4B, the material of the base 25 utilizes a flexible plastic film 28 having the properties resembling an elastic, soft linoleum, which is made utilizing a mixture of polymers 36, including vinyl, with the implemented magnetic particles 38. The panel of this embodiment can be utilized for interior finishing and fixing to the surface of a building wall.

[0064] Magnetic particles, which can be, for example, a magnetic powder 38 of the class of magnetic hexaferrites, such as barium ferrite. The magnetic particles can be also a powder of the class of magnetic spinels, such as magnetite, or any other powder exhibiting magnetic properties not exciding 0.05 mm, characterized by maximum energy product (BH).sub.max within the range between 2,0 and 100,00 kJ/m.sup.3. The plastic base 25 can be used within the operating temperature range between −60 and +120° C. The magnetic particles 18 utilized by the invention are capable of a magnetic interaction with external magnetically-receptive materials, such as for example metallic elements of the wall 15 of a building and are typically characterized by maximum energy product (BH).sub.max within the range between 2,0 and 100,00 kJ/m.sup.3. In some embodiments (see FIG. 3) the front side layer 14 of the panel 10 can be provided with a decorative finishing having a predetermined ornament 30. Further, elements of magneto-susceptible materials can be embedded into the wall surface.

[0065] Referring now to the embodiment of FIG. 5, having the base manufactured using the flexible fabric 26, such as a fibrous fabric, for example. In this embodiment the magnetic particles 18 are, for example, in the form of magnetic filler/magnetic particle powder 34 of the class of magnetic hexaferrites, such as barium ferrite, or, for example, a powder of the class of magnetic spinels, such as magnetite, or any other powder exhibiting magnetic properties and not exciding 0.05 mm. The magnetic particles are fixed/attached to the surface of a soft and flexible carrier material, e.g., textile fiber 26 by means of an adhesive, e.g. acrylic latex glue/lacquer. In this process impregnation the fabric with a liquefied acrylic latex composition is involved. The magnetic powder 34 characterized by maximum energy product (BH).sub.max within the range between 2,0 and 100,00 kJ/m.sup.3 can be introduced into the acrylic latex composition, by, for example, by mixing until the particles of the magnetic powder are evenly distributed in the solution of the specified adhesive. This occurs before the resulting mixture is applied to the surface of the material 26. If necessary, after the latex has hardened, the obtained material 26 is treated with an external magnetic field to form the properties of a permanent magnet in the material.

[0066] Referring now to the embodiments of FIGS. 7A and 7B as well as 8A and 8B, wherein the flexible base/elements 25 is produced utilizing the flexible plastic (see also FIGS. 4A and 4B) or the flexible fabric (see also FIG. 5). The base/elements 25 are attached to the sheets of the glass 20 (FIGS. 7A, 7B) or the metal plate 21 (FIGS. 8A, 8B). The magnetic particles in the form of the magnetic powder 34 are implemented into the flexible base 25 by the methods discussed in the application. The base 25 having the magnetic particles is attached to the glass 20 or the metal plate 21 by means of an adhesive joint 32, such as a glue which can be for example one- and two-component polyurethane adhesive or epoxy resin. The breaking force of separation of the adhesive joint 32 is selected to be at least twice higher than the magnetic attraction force to a steel/metal surface of the flexible plastic (vinyl, for example) having the magnetic particles or twice higher than the magnetic attraction force of fibrous fabric with magnetic particles in the form of impregnation with acrylate latex having the dispersed magnetic particles.

[0067] Although the panels 19 and 21 are being described utilizing glass and metal in their structure, it should be understood that the magnetic panels of the invention can utilize various materials such as, for example ceramic, wood, various plastics, rubber, textile, leather, stone, pressed craft paper and any combination thereof. In actuality, any natural or synthetic glueable materials or their combination can be used for the formation and use of the magnetic panels of the invention.

[0068] In the method of manufacturing of the construction magnetic panel of the invention one or more magnetic particles are secured within at least at one of the front side 14 or the inner side 16 of the base by means of an adhesive joint 32, such as a glue which can be for example one- and two-component polyurethane adhesive or epoxy resin. Alternative methods include use of a mechanical fixing device, or by embedding (implementing in the form of a magnetic powder 34) of one or more magnetic particles into the base. Use of other conventional methods or any combination of the above-discussed approaches are within the scope of the invention. To assure a reliable magnetic interaction with third-party magnetically susceptible materials, the magnetic particles 18 are provided characterized by maximum energy product (BH)max within the range between 2,0 and 100,00 kJ/m3.

[0069] The embodiment of FIGS. 6A and 6B illustrate a base 22 made from a pressed craft paper 42 extending between two water resistant layers 40 and impregnated with the magnetic powder 34.

[0070] FIG. 9 illustrates another embodiment of the invention showing a bookshelf 45 attached to a wall 15 having the magnetically susceptible or steel exterior 23 by means of the magnetic panel 25 of the invention and the adhesive joint 32. The adhesive joint 32 is a glue which can be for example one- and two-component polyurethane adhesive or epoxy resin.

[0071] The present invention exhibits a substantial number of advantages compared to the known prior art, for example, by providing simple installation and removal of the panel 10. This makes it possible to change rapidly the appearance of the exterior of the building wall and interior of the premises. Another important advantage of the invention is the absence of the requirement for the highly skilled labor used in the installation of the panels 10 and the need for special equipment. Further advantage of the invention is producing the magnetic panels from a variety of materials and coatings such as for example, paper-layered plastic, glass, metal, ceramic, wood, rubber, textile, leather, stone, pressed craft paper and any combination thereof (practically any natural or synthetic glueable materials or their combination, or any suitable simple or complex object, including electronic devices). The possibility of arranging the magnetic panels in various combinations on a wall of a building is also very beneficial.