Magnet receptive panels and methods

• US 9,849,649 B2
• Filed: 12/18/2015
• Issued: 12/26/2017
• Est. Priority Date: 02/17/2015
• Status: Active Grant

• Current Assignee: United States Gypsum Company (GEBR Knauf Verwaltungsgesellschaft KG)
• Original Assignee: United States Gypsum Company (GEBR Knauf Verwaltungsgesellschaft KG)
• Inventors: Immordino, Salvatore, Immordino, Vittorio A., Pelot, David D., Moyer, Jr., Kevin W., Rosenstiel, Terry L.
• Primary Examiner(s): Sample, David
• Assistant Examiner(s): Flores, Jr., Donald M
• Application Number:
  US14/974,444
• Publication Number:
  US 20160236444A1
• Time in Patent Office: 739 Days
• Field of Search: None
• CPC Class Codes: B32B 13/06 of metal
• CPC Class Codes: B32B 13/08 of paper or cardboard
• CPC Class Codes: B32B 2307/208 Magnetic, paramagnetic
• CPC Class Codes: B32B 2419/04 Tiles for floors or walls tiles for roofs B32B2419/06
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 27/00 Layered products comprising a layer of synthetic resin fibrous or filamentary layer made of a synthetic resin B32B5/02; particulate layer made of a synthetic resin B32B5/16; foamed layer made of a synthetic resin B32B5/18
• CPC Class Codes: B32B 29/00 Layered products comprising a layer of paper or cardboard
• CPC Class Codes: B32B 3/00 Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
• CPC Class Codes: B32B 37/12 characterised by using adhesives
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: E04C 2/043 of plaster E04C2/049 takes precedence
• CPC Class Codes: E04F 13/00 Coverings or linings, e.g. for walls or ceilings flooring E04F15/00; decoration of surfaces, mosaic work B44, e.g. paper-hanging B44C7/00; made of webs, e.g. of fabrics or wallpaper , as such, or their manufacturing D03D, D04G, D04H, D06N, D21H; construction of false ceilings E04B9/00; roofings or similar water-tight coverings against precipitation E04D
• CPC Class Codes: E04F 13/0883 by magnets
• CPC Class Codes: E04F 13/14 stone or stone-like materials, e.g. ceramics concrete,; of glass or with an outer layer of stone or stone-like materials or glass E04F13/0864 takes precedence; producing shaped elements from concrete, ceramic compositions or other stone-like materials B28B; prefabricated panels in general E04C2/00
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10S 52/04 Magnetic connecting means for building components
• CPC Class Codes: Y10T 428/239 Complete cover or casing
• CPC Class Codes: Y10T 428/24008 including fastener for attaching to external surface

Abstract

Provided are building panels comprising at least one magnet receptive element, methods for making such panels, and kits and methods for attaching objects to a panel without nails or screws.

Claims

1. A building panel comprising a magnet receptive element, wherein the panel comprises a gypsum core covered on at least one side with a paper sheet and the magnet receptive element positioned in at least one of the folowing locations:

embedded in the gypsum core, embedded in the paper sheet, adjacent to at least one surface of the gypsum core, adjacent to at least one surface of the the paper sheet, or a combination thereof; and

wherein

at least one magnet receptive element comprises at least one of the following;

a tape comprising a ferromagnetic material and a paint prepared with a magnet receptive material.

2. The building panel of claim 1, wherein the building panel comprises a plurality of the magnet receptive element that together create a pattern selected from:

a disjointed pattern, discontinuous pattern, continuous pattern, grid, array, geometrically spaced, randomly spaced, spaced in at least one direction, and any combination thereof.

3. The building panel of claim 1, wherein the magnet receptive element comprises a ferromagnetic material selected from the group consisting of iron, nickel, cobalt, alloys with rare earth metals and any combination thereof.

4. The building panel of claim 1, wherein the magnet receptive element is capable of producing a magnetic field.

5. The building panel of claim 1, wherein a cover sheet is applied over the magnet receptive element.

6. The building panel of claim 5, wherein the cover sheet is selected from the group consisting of paper, plastic, coating and any combination thereof.

7. The building panel of claim 1, where the panel is selected from the group consisting of a gypsum fiberboard, gypsum wallboard, cement panel, ceiling tile and plastic panel.

8. The building panel of claim 1, wherein at least two magnet receptive elements create a grid with intersections between magnet receptive elements, and wherein the grid is disjointed and magnet receptive elements do not connect at the intersections.

9. The building panel of claim 1, wherein at least two magnet receptive elements are located so that the angle and distance between the elements can be of any value.

10. The building panel of claim 1, wherein at least one magnet receptive element comprises at least one of the following from the group consisting of:

a magnet receptive tape, magnet receptive sheet, magnet receptive paint, magnet receptive coating, foil, shim, magnetic tape, magnetic sheet, magnetic paint, magnetic coating, and any combination thereof.

11. The building panel of claim 10, wherein the tape is ferrous metal tape, a magnetic field producing material, or any combination thereof.

12. A method for making a building panel, the method comprising positioning at least one magnet receptive element on the building panel;

wherein the panel comprises a gypsum core covered on at least one side with a paper sheet and the magnet receptive element positioned in at least one of the following locations;

embedded in the gypsum core, embedded in the paper sheet, adjacent to at least one surface of the gypsum core, adjacent to at least one surface of the paper sheet, or a combination thereof; and

wherein at least one magnet receptive element comprises at least one of the following;

a tape comprising a ferromagnetic material and a paint prepared with a magnet receptive material.

13. The method of claim 12, wherein the magnet receptive elements are positioned on the building panel by a method selected from the group consisting of:

painting the magnet receptive elements on at least one surface of the building panel;

printing the magnet receptive elements on at least one surface of the building panel;

attaching the magnet receptive elements with an adhesive to at least one surface of the building panel;

attaching magnet receptive elements by using a mechanical attaching design or device to at least one surface of the building panel;

depositing the magnet receptive elements on the surface of the building panel which has not been fully set; and

any combination thereof.

14. The method of claim 12 comprising:

placing the at least one magnet receptive element on a cover paper sheet;

preparing a gypsum slurry;

depositing the gypsum slurry onto the sheet over the at least one magnet receptive element;

forming the slurry into a panel; and

allowing the panel to set.

15. The method of claim 14, wherein the at least one magnet receptive element is adhered to the cover paper sheet with and adhesive.