Systems and methods for producing magnetically receptive layers and magnetic layers for use in surface covering systems

Abstract

The present invention pertains to the art of surface coverings, and, more particularly to a system and method for producing isotropic and anisotropic magnetically receptive layers and magnetized underlayments for use in securing surface covering units supporting surfaces. The present invention relates to an apparatus, method, and method of manufacturing isotropic and anisotropic magnetized floor covering units and magnetized underlays for securing surface covering units.

What is claimed is: 
     
         1 ) A method for producing a magnetically receptive sheet good for use in surface covering systems, 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 at a desired mixing pressure to form a magnetically receptive material; and   extruding the magnetically receptive material at a desired extrusion temperature to form a magnetically receptive sheet good; or   applying a calendaring process to the magnetically receptive layer to form a magnetically receptive sheet good.   
     
     
         2 ) The method of  claim 1 , further comprising annealing the magnetically receptive sheet good. 
     
     
         3 ) The method of  claim 1 , further comprising cold pressing the magnetically receptive sheet good onto a natural material building product. 
     
     
         4 ) The method of  claim 1 , further comprising hot pressing the magnetically receptive sheet good onto a synthetic material building product. 
     
     
         5 ) The method of  claim 1 , further comprising magnetizing the magnetically receptive sheet good. 
     
     
         6 ) The method of  claim 1 , wherein the magnetically receptive layer is magnetized to produce a magnetized underlayment adapted to magnetically engage and support a non-magnetized receptive layer component, the composition of the magnetically receptive material is selected from the group consisting of:
 for use in a calendaring process:
 1) pure iron powder (Fe) or strontium ferrite approximately 89-91%, chlorinated polyethylene elastomer polymer (CPE) approximately 8-9% and epoxidized soybean oil (ESBO) approximately 1-2%; or 
 2) Iron powder (ferrous iron or ferrous ferric oxide, Fe3O4) approximately 89-91%, CPE approximately 8-9% and plasticizer approximately 1-2%; 
   or for use in an extrusion process:
 3) PVC approximately 16.5%, calcium carbonate approximately 39%, iron powder approximately 26.5%, plasticizer approximately 16%, and viscosity depressant & stabilizer approximately 2%. 
   
     
     
         7 ) The method of  claim 1 , wherein the magnetically receptive material is used to produce a non-magnetized receptive component for use opposite a magnetized underlayment component, the composition of the magnetically receptive material is selected from the group consisting of:
 for use in a calendaring process:
 1) Mn—Zn (manganese/zinc) soft ferrite powder approximately 89-91%, CPE approximately 8-9% and plasticizer approximately 1-2%; 
 2) approximately 20 portions of CPE, approximately 150 portions of stainless iron powder, approximately 30 portions of polyvinyl chloride (PVC), approximately 18 portions of dioctyl terephthalate, approximately 200 portions of stainless iron powder; or 
   or for use in an extrusion process:
 3) PVC approximately 16.5%, calcium carbonate approximately 39%, plasticizer approximately 16%, viscosity depressant & stabilizer approximately 2%, and at approximately 26.5% one of: Mn—Zn (manganese/zinc) soft ferrite powder; stainless iron powder; or ferrous oxide or ferric oxide powder. 
   
     
     
         8 ) The method of  claim 1 , wherein the ferrite compound is strontium ferrite, the polymer is chlorinated polyethylene elastomer polymer (CPE), and the plasticizer is epoxidized soybean oil (ESBO). 
     
     
         9 ) The method of  claim 1 , wherein the mixing is performed for approximately 15 minutes, the desired mixing temperature is under 120 degrees Celsius, and the desired mixing pressure is atmospheric pressure. 
     
     
         10 ) The method of  claim 1 , wherein the desired extrusion temperature is 120 degrees Celsius and wherein the magnetically receptive sheet good is extruded at 10 meters per minute. 
     
     
         11 ) The method of  claim 1 , wherein the mixing is performed for 20-30 minutes, the desired mixing temperature is between 90-115 degrees Celsius, and the desired mixing pressure is between 0.4-0.7 MPa. 
     
     
         12 ) The method of  claim 1 , wherein the magnetically receptive sheet good is extruded at 4-10 meters per minute and the desired extrusion temperature is 40-70 degrees Celsius. 
     
     
         13 ) The method of  claim 1 , wherein the ferrite compound is strontium ferrite having a particle size of 38-62 microns. 
     
     
         14 ) A rust resistant and dimensionally stable magnetically receptive sheet good for use in surface covering systems, the sheet good being magnetized to provide a magnetized underlayment for magnetically engaging a non-magnetized receptive layer component, the magnetized underlayment comprising:
 for use in a calendaring process:
 1) pure iron powder (Fe) or strontium ferrite approximately 89-91%, chlorinated polyethylene elastomer polymer (CPE) approximately 8-9% and epoxidized soybean oil (ESBO) approximately 1-2%; or 
 2) Iron powder (ferrous iron or ferrous ferric oxide, Fe3O4) approximately 89-91%, CPE approximately 8-9% and plasticizer approximately 1-2%; 
   or for use in an extrusion process:
 3) PVC approximately 16.5%, calcium carbonate approximately 39%, iron powder approximately 26.5%, plasticizer approximately 16%, and viscosity depressant & stabilizer approximately 2%. 
   
     
     
         15 ) The sheet good of  claim 14 , wherein the ferrite component comprises a particle size of 38-62 microns. 
     
     
         16 ) A rust resistant and dimensionally stable magnetically receptive component for use in surface covering systems, the magnetically receptive component being a non-magnetized receptive layer component for magnetically engaging with a magnetized underlayment, the magnetically receptive component comprising:
 for use in a calendaring process:
 1) Mn—Zn (manganese/zinc) soft ferrite powder approximately 89-91%, CPE approximately 8-9% and plasticizer approximately 1-2%; 
 2) approximately 20 portions of CPE, approximately 150 portions of stainless iron powder, approximately 30 portions of polyvinyl chloride (PVC), approximately 18 portions of dioctyl terephthalate, approximately 200 portions of stainless iron powder; or 
   or for use in an extrusion process:
 3) PVC approximately 16.5%, calcium carbonate approximately 39%, plasticizer approximately 16%, viscosity depressant & stabilizer approximately 2%, and at approximately 26.5% one of: Mn—Zn (manganese/zinc) soft ferrite powder; stainless iron powder; or ferrous oxide or ferric oxide powder.