U.S. patent application number 15/211499 was filed with the patent office on 2017-02-09 for magnetically attached building composite.
The applicant listed for this patent is Milliken & Company. Invention is credited to LeAnne O. Flack, Daniel T. McBride, Venkatkrishna Raghavendran, Tim Scott, I, Jacob J. Smrekar, Sudhanshu Srivastava, Kevin Weir.
Application Number | 20170037629 15/211499 |
Document ID | / |
Family ID | 56741170 |
Filed Date | 2017-02-09 |
United States Patent
Application |
20170037629 |
Kind Code |
A1 |
Srivastava; Sudhanshu ; et
al. |
February 9, 2017 |
MAGNETICALLY ATTACHED BUILDING COMPOSITE
Abstract
A magnetically attached building composite containing at least a
first building component and a second building component. The first
building component has an upper surface and a lower surface, where
the lower surface of the first building component comprises
magnetizable or magnetically responsive materials. The second
building component has an upper surface and a lower surface, where
the upper surface of the second building component is adjacent the
lower surface of the first building component, and wherein the
upper and lower surfaces of the second building component comprise
magnetizable or magnetically responsive materials. At least one of
the lower surface of the first building component and the upper
surface of the second building component comprise magnetizable
materials.
Inventors: |
Srivastava; Sudhanshu;
(Boiling Springs, SC) ; Raghavendran; Venkatkrishna;
(Greer, SC) ; McBride; Daniel T.; (Chesnee,
SC) ; Scott, I; Tim; (Greenville, SC) ; Flack;
LeAnne O.; (Greer, SC) ; Smrekar; Jacob J.;
(Rock Hill, SC) ; Weir; Kevin; (Greer,
SC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Milliken & Company |
Spartanburg |
SC |
US |
|
|
Family ID: |
56741170 |
Appl. No.: |
15/211499 |
Filed: |
July 15, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62201143 |
Aug 5, 2015 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04D 2013/0468 20130101;
E04D 3/36 20130101; E04D 1/34 20130101; E04D 13/0459 20130101; E04B
1/625 20130101; E04F 13/0883 20130101; E04D 3/3601 20130101; E04B
1/6803 20130101; E04D 2001/3408 20130101 |
International
Class: |
E04D 1/34 20060101
E04D001/34; E04D 13/04 20060101 E04D013/04; E04B 1/68 20060101
E04B001/68 |
Claims
1. A magnetically attached building composite comprising: a first
building component having an upper surface and a lower surface,
wherein the lower surface of the first building component comprises
magnetizable or magnetically responsive materials; a second
building component having an upper surface and a lower surface,
wherein the upper surface of the second building component is
adjacent the lower surface of the first building component, wherein
the upper and lower surfaces of the second building component
comprise magnetizable or magnetically responsive materials; a third
building component having an upper surface and a lower surface,
wherein the upper surface of the third building component is
adjacent the lower surface of the second building component,
wherein the upper surface of the third building component comprises
magnetizable or magnetically responsive materials; wherein at least
one of the lower surface of the first building component and the
upper surface of the second building component comprise
magnetizable materials and wherein at least one of the lower
surface of the second building component and the upper surface of
the third building component comprise magnetizable materials.
2. The magnetically attached building composite of claim 1, wherein
the first building component comprises plywood.
3. The magnetically attached building composite of claim 1, wherein
the third building component comprises an insulation layer.
4. The magnetically attached building composite of claim 1, wherein
the second building component comprises a roofing tile.
5. The magnetically attached building composite of claim 1, wherein
the first building component is a structural component.
6. The magnetically attached building composite of claim 1, wherein
the second and third building components are non-structural
components.
7. The magnetically attached building composite of claim 1, wherein
the magnetizable materials are ferromagnets or ferrimagnets.
8. The magnetically attached building composite of claim 1, wherein
the magnetizable materials comprise a material selected from the
group consisting of barium ferrites, strontium ferrites and
neodymium.
9. The magnetically attached building composite of claim 1, wherein
the magnetically responsive materials comprise a material selected
from the group consisting of iron oxide, steel, iron, nickel, and
aluminum.
10. A magnetically attached building composite comprising: a first
building component having an upper surface and a lower surface,
wherein the lower surface of the first building component comprises
magnetizable or magnetically responsive materials; a second
building component having an upper surface and a lower surface,
wherein the upper surface of the second building component is
adjacent the lower surface of the first building component, wherein
the upper and lower surfaces of the second building component
comprise magnetizable or magnetically responsive materials; wherein
at least one of the lower surface of the first building component
and the upper surface of the second building component comprise
magnetizable materials.
11. The magnetically attached building composite of claim 10,
wherein the first building component comprises plywood.
12. The magnetically attached building composite of claim 10,
wherein the second building component comprises a fabric.
13. The magnetically attached building composite of claim 10,
wherein the second building component comprises a metal
flashing.
14. The magnetically attached building composite of claim 10,
wherein the second building component comprises paper.
15. The magnetically attached building composite of claim 10,
wherein the second building component comprises a tape.
16. The magnetically attached building composite of claim 10,
wherein the first building component is a structural component.
17. The magnetically attached building composite of claim 10,
wherein the second building component is a non-structural
component.
18. The magnetically attached building composite of claim 10,
wherein the magnetizable materials are ferromagnets or
ferrimagnets.
19. The magnetically attached building composite of claim 10,
wherein the magnetizable materials comprise a material selected
from the group consisting of barium ferrites, strontium ferrites
and neodymium.
20. The magnetically attached building composite of claim 10,
wherein the magnetically responsive materials comprise a material
selected from the group consisting of iron oxide, steel, iron,
nickel, and aluminum.
Description
RELATED APPLICATIONS
[0001] This application claims priority to co-pending U.S.
provisional patent application 62/201,143 filed on Aug. 5, 2015,
which is herein incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention generally relates to attaching various
building components together with the use of magnets.
BACKGROUND
[0003] Buildings (both commercial and residential) contain a large
number of components that are attached together such as weather
barrier systems, insulation, and roofing materials. Currently,
these components are typically attached to the building (and other
components) by glues, screws, nails and/or staples. These
attachment methods are labor intensive, sometimes release VOC
(volatile organic compounds), and are not able to be easily removed
and reapplied. Thus, there is a need for an attachment means to
more easily attach building components to the building structure
and other building components.
BRIEF SUMMARY
[0004] A magnetically attached building composite containing at
least a first building component and a second building component.
The first building component has an upper surface and a lower
surface, where the lower surface of the first building component
comprises magnetizable or magnetically responsive materials. The
second building component has an upper surface and a lower surface,
where the upper surface of the second building component is
adjacent the lower surface of the first building component, and
wherein the upper and lower surfaces of the second building
component comprise magnetizable or magnetically responsive
materials. At least one of the lower surface of the first building
component and the upper surface of the second building component
comprise magnetizable materials.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 illustrates one embodiment of a magnetically attached
building composite containing two building components.
[0006] FIG. 2 illustrates one embodiment of a magnetically attached
building composite containing three building components.
[0007] FIG. 3 illustrates one embodiment of a magnetically attached
building composite containing four building components.
[0008] FIG. 4 illustrates one embodiment of a magnetically attached
building composite being a house wrap system.
[0009] FIG. 5 illustrates one embodiment of a magnetically attached
building composite being a roofing system.
DETAILED DESCRIPTION
[0010] Building components may be attached to building and other
building components through the use of magnets. This may reduce or
eliminate the need for other fixing methods such as adhesive,
screws, nails, and staples. The magnetic fastenings will help
facilitate installation, reduce labor and decrease the penetrations
from nails/staples and other fasteners into the building structure.
For example installing roof waterproofing membranes or applying
thermal barriers such as insulation boards and batts, will be much
easier for laborers to position and install, minimizing the labor,
time and materials required to nail, staple and adhere them. Site
quality and safety can be enhanced. A further advantage of using
magnetic fastening over adhesives is to reduce the release of VOCs.
The new way of fastening may allow to create a whole spectrum of
design possibilities to the building and infrastructure markets.
Building systems are easier to inspect, maintain and replace, with
less landfill due to inefficient removal of damaged components and
products at the end of their useful life.
[0011] Some examples of possible uses of magnetically attached
building components include magnetic roof decking (concrete, metal,
wood other), flashings for parapets and through-deck intrusions,
roof tiles, structural and non-structural building sheathing
material, weather barrier systems such as house wraps, window and
door tapes and flashings, thermal management systems (such as
insulation such as foam boards, rockwool and glass fiber rolls
& batts, and reflective thermal barriers, water management for
roofs, facades, basements, park decks, bridges and other
infrastructure systems, external cladding and siding materials
(metal, wood, plastic, gypsum, glass and the like), rigid and
flexible solar panel attachments, and roofing membranes (such as
TPO, PVC, and EPDM).
[0012] Referring now to FIG. 1, there is shown one embodiment of a
magnetically attached building composite 10 containing a first
building component 100 and a second building component 200. The
building components (including the first building component 100,
second building component, and additional building components
(third, fourth, fifth, etc) may be any suitable building component.
The building components may be structural components meaning that
they are able to sustain their own weight and typically the weight
of other components (such as plywood, I-beams, rafters, and
decking) or may be non-structural components such as membranes,
films, and fabric layers.
[0013] The first building component 100 has a first side 100a and a
second side 100b. In the case of the first building component being
the outermost component in the magnetically attached building
composite 10, then the second side 100b of the first building
component forms the outer surface of the magnetically attached
building composite 10.
[0014] The second building component 200 has a first side 200a and
a second side 200b. In the case of the second building component
being the outermost component in the magnetically attached building
composite 10, then the first side 200a of the second building
component forms the outer surface of the magnetically attached
building composite 10. In the embodiment of FIG. 1 where there are
two building components (100, 200), the second side 100b of the
first building component and the first side 200a of the second
building component form the outer surfaces of the magnetically
attached building composite 10.
[0015] The building components 100, 200 are oriented such that the
first side 100a of the first building component and the second side
200b of the second building component are adjacent and facing each
other. In some embodiments there may be an additional layer or
component between the building components 100, 200. In another
embodiment, there are no elements between the building components
100 and 200 are their surfaces (100a, 200b) are in physical and
intimate contact.
[0016] Referring now to FIG. 2, there is shown another embodiment
of the magnetically attached building composite 10 having three
building components. The first building component 100 has a first
side 100a and a second side 100b. The second building component 200
has a first side 200a and a second side 200b. The third building
component 300 has a first side 300a and a second side 300b.
[0017] In this embodiment, the second surface 100b of the first
building component 100 and the first surface 200a of the second
building component 200 form the outermost surfaces of the composite
10. The third building component 300 is sandwiched between the
first building component 100 and the second building component
200.
[0018] The building components 100, 200, 300 are oriented such that
the first side 100a of the first building component and the second
side 300b of the third building component are adjacent and facing
each other and the first side 300a of the third building component
and the second side 200b of the second building component are
adjacent and facing each other. In some embodiments there may be an
additional layer or component between the building components 100,
200, 300. In another embodiment, there are no elements between the
building components 100, 200, 300 are their adjacent surfaces are
in physical and intimate contact.
[0019] Referring now to FIG. 3, there is shown another embodiment
of the magnetically attached building composite 10 having four
building components. The first building component 100 has a first
side 100a and a second side 100b. The second building component 200
has a first side 200a and a second side 200b. The third building
component 300 has a first side 300a and a second side 300b. The
fourth building component 400 has a first side 400a and a second
side 400b.
[0020] In this embodiment, the second surface 100b of the first
building component 100 and the first surface 200a of the second
building component 200 form the outermost surfaces of the composite
10. The third building component 300 and fourth building component
are sandwiched between the first building component 100 and the
second building component 200.
[0021] The building components 100, 200, 300, 400 are oriented such
that the first side 100a of the first building component and the
second side 300b of the third building component are adjacent and
facing each other, the first side 300a of the third building
component and the second side 400b of the fourth building component
are adjacent and facing each other, and the first side 400a of the
fourth building component and the second side 200b of the second
building component are adjacent and facing each other. In some
embodiments there may be an additional layer or component between
the building components 100, 200, 300, 400. In another embodiment,
there are no elements between the building components 100, 200, 300
are their adjacent surfaces are in physical and intimate contact.
In other embodiments there may be more than 4 building components
stacked together so form the composite 10.
[0022] Within each pair of adjacent surfaces within the composite
10, at least one of the surfaces must be magnetizable. In one
embodiment, one of the surfaces is magnetizable and the other is
magnetically respective. In another embodiment, both of the
surfaces are magnetizable. The methods and materials to form the
magnetizable and the other is magnetically respective are the same
as discussed previously in regards to FIG. 1.
[0023] In this application magnetizable is defined to mean the
particles present in the coating are permanently magnetized or can
be magnetized permanently using external magnets or electromagnets.
Once the particles are magnetized, they will keep their magnetic
response permanently. The magnetizable behavior for generating
permanent magnetism falls broadly under ferromagnets and
ferrimagnets. Barium ferrites, strontium ferrites, neodymium and
other rare earth metal based alloys are some of the examples that
can be applied in the coatings.
[0024] In this application magnetically responsive is defined to
mean the particles present in the coating are only magnetically
responsive in the presence of external magnets. Once the magnetic
field is removed from the vicinity, the particles will become
non-magnetic. The magnetically responsive behavior or responsive
magnetic behavior falls broadly under paramagnets or
superparamagnets (particle size less than 50 nm). Iron oxide,
steel, iron, nickel, aluminum or their alloys that are not included
in ferromagnets are some of the examples that can be applied in the
coatings.
[0025] The surface of the components may be magnetically responsive
or magnetizable in any suitable manner. In one embodiment, surface
is made to be magnetically responsive or magnetizable by applying a
magnetically responsive or magnetizable coating on the surface. In
another embodiment, surface is made to be magnetically responsive
or magnetizable by materials within the component (preferably
located near or close to the surface of the component).
[0026] Barium ferrites, strontium ferrites, neodymium and other
rare earth metal based alloys can be mixed with the appropriate
binder to be coated on the substrate. There are 2 ways the surface
can be permanently magnetized after the curing or during the
curing.
[0027] Process 1: After the coating method, the magnetizable
particles loaded in the film are cured with the appropriate binder
and composition. Then the permanent magnets can be rolled over the
surface coated with the film 1 to 10 times as required by the
inline manufacturing. Depending upon the pole size, strength and
domains on the permanent magnet or electromagnet can magnetize the
magnetizable coating to a value between 10 and 5000 gauss or a
value close to the maximum gauss value of the magnetizing medium.
Once the film is magnetized, it will remain permanently
magnetized.
[0028] Process 2: During the cure, the magnetizable particles are
mixed with the appropriate binder and applied via coating technique
on the substrate to be magnetized. Once the coating is complete,
the particles are magnetized in the presence of external magnets
during the curing process. The coating will be put in a magnetic
field to align the magnetic poles and hold the dipoles in place in
the presence of the magnetic field until the binder is cured.
[0029] The surface(s) of the components (100, 200, 300, 400, etc)
may be made to be magnetic in any suitable method. In one
embodiment, the magnetic material is applied to a surface as a
coating. In another embodiment, the magnetic material is applied as
a separate film that is adhered to the surface of the component. In
another embodiment, the magnetic material is integral (meaning that
it is formed as part of the component and not added after the
component is formed). Some preferred coating methods include knife
coating, padding, painting, spraying, roll-on-roll, troweling,
extrusion, foam coating, pattern coating, printing, and lamination.
The magnetic particles may also be extruded with the component.
[0030] In one embodiment, the magnetic material is applied as an
approximately uniform coating having approximately the same
thickness, magnetic strength, and/or composition across the surface
of the component. In another embodiment, the magnetic material can
vary across the surface(s) of the components. The magnetic material
may be in a gradient or pattern. These patterns may help with
alignment of one component relative to its adjacent components.
[0031] Any type of magnetizable particles can be used, including
but are limited to: BaFe.sub.3O.sub.4, SrFe.sub.3O.sub.4, NdFeB,
AlNiCo, CoSm and other rare earth metal based alloys. Any type of
magnetically responsive particles can be used, including but are
limited to: Fe.sub.2O.sub.3, Fe.sub.3O.sub.4, steel, iron particles
etc (Para or Superpara). In one embodiment, the particle size of
the magnetic particles is between 10 nm to 50 nm (super
paramagnets) or 100 nm and larger (paramagnets or Ferro magnets).
Magnetic behavior is shown at any loading of the above materials,
the response increases as the loading increases. A range 25% to 95%
by weight is preferred for most practical usages.
[0032] The magnetic particles may be any suitable binder system,
including but not limited to urethanes, acrylates, silicones,
thermosets (rubber and others), thermoplastics and other textile
binders. In some embodiments not requiring flexibility, inorganic
binders like cement and geopolymers can also be used.
[0033] In one embodiment shown in FIG. 4, there is shown a
magnetically attached building composite 10 being a house with
house wrap composite 2000. In this embodiment, the substructure of
the house (typically a plywood) would be the first building
component 100 and the house wrap (typically a fabric) would be the
second building component 200. In this embodiment, the outer facing
surface of the first building component 100 (100a using previous
terminology) would be magnetizable and the inner facing surface of
second building component 200 (200b using previous terminology)
would be magnetically respective. Preferably, these magnetic
surfaces would be achieved thorough coatings or adhering a magnetic
film/layer to the surface of the components 100, 200.
[0034] In one embodiment shown in FIG. 5, there is shown a
magnetically attached building composite 10 being a roofing system
3000. In this embodiment, the substructure of the house (typically
a plywood) would be the first building component 100, an insulation
layer 300 would be the third building component, and the roofing
tiles would be the second building component 200. In this
embodiment, preferably the outer facing surface of the first
building component 100 (100a using previous terminology) would be
magnetizable and the inner facing surface of second building
component 200 (200b using previous terminology) would be
magnetically respective. Preferably, these magnetic surfaces would
be achieved thorough coatings or adhering a magnetic film/layer to
the surface of the components 100, 200.
[0035] In one embodiment, the magnetically attached building
composite may be used in a weather barrier or water drainage
system. Weather barrier and water drainage systems protect
structures from wind-driven rain, manage and control moisture
through the building or envelope and drain excess water away from
the structure. Such weather barrier systems include roofing
underlayments; roofing felt paper, polymeric or synthetic roofing
fabrics, self-adhering ice and water shield tapes, facade
protection systems such as housewraps and self-adhered synthetic
tapes window and door flashing tapes. Water drainage systems
include basement drainage products, such as and mechanically fixed
or loose fitting dimpled polymeric membranes, drainage mats or
grooved, sometimes fleece-lined rigid-foam boards.
[0036] Weather barrier systems are typically supplied in 3-10'
rolls or 6-12' tape forms. Housewraps are typically polymeric (eg.
polyethylene or polypropylene) spun, non-woven, or perforated and
coated woven-tape textile structures, or felt impregnated building
paper. They are designed to prevent rot and mold inside walls by
controlling moisture through the structure and improving thermal
efficiency through air flow control.
[0037] Housewraps and felt building paper are typically installed
by 2 contractors. Starting in the bottom corner, the housewrap is
rolled out horizontally in relatively short lengths and fixed with
plastic-capped staples or nails, typically between 12-18 inch
spacing's, horizontally and vertically and a minimum of 9'' from
headers and openings. 6-12'' vertical and horizontal overlaps are
also fixed preferably with 1'' plastic-capped staples and the taped
with 2-3'' pressure sensitive contractors adhesive tape. Window and
door openings are cut out using a sharp knife, trimmed, stapled and
finally taped into the intrusions to provide protection and
drainage of sills and jambs.
[0038] The application of magnetic coatings may allow for a single
contractor to place and position the fabric easily against a
substrate (particularly in high wind scenarios).
[0039] Fixings and intrusions can be significantly reduced or
eliminated. Improper use of mechanical fixings can cause creases
and folds (sometimes termed "fishmouth") which can act as drainage
paths for water towards the interior of the structure. Using
magnetic coatings, creases are more easily smoothed out with hand
pressure. Furthermore, the fabric may be more easily removed and
repositioned to ensure straightness and square, not easily done if
mechanically fixed or with peel and stick pressure sensitive
adhesives. Magnetic coatings may eliminate or reduce the practice
of leaning on ladders with heavy staple guns to attach fixings,
which is a safety hazard. The reduction, even elimination of
mechanical fixings removes undesirable penetrations into the air
and water barrier system, improving barrier performance and energy
efficiency. A secondary job of taping the overlap joints may even
be eliminated.
[0040] Roofing underlayments are made of similar materials to
housewrap products or modified thermoplastic copolymers. They are
typically designed for residential roofs with a pitch >2:12 to
4:12 and used and fixed in a similar way to housewraps, stapled,
nailed or self-adhered. The fabric is staples at 4-8'' OC depending
on wind speeds. The typically 48'' wide rolls are installed
horizontally in "shingle style" fashion with 4'' course overlaps
and 6'' end laps beginning along the eave edge. End laps are offset
in successive courses by 6 feet. For roof valleys, a polymer-backed
self-adhered tape often 6-12'' wide is adhered over the roofing
underlayment for additional sealing and protection.
[0041] In all these cases, the use installation recommendations
with regards to the number, distances and type of staples or nails
used is sometimes abused. Often too many are used, adding to the
number of undesirable penetrations into the protective water
barrier layer that can contribute to roof leaks. Sometimes
insufficient fixings are used, leading to ripping away of the
fabric or felt paper in high wind situations.
[0042] With magnetic coatings, fixings and intrusions can be
significantly reduced or eliminated. Roofing underlayment is easier
to position and apply, particularly in high wind scenarios. Some
manufacturers are marketing primers to promote adhesion between
self-adhered weather barriers and substrates, mainly for cold
weather applications. These need a clean dry deck, are difficult to
apply in cold weather <45 degrees F., difficult to reposition
and may blister in the heat. Magnetic coatings eliminates these
challenges.
[0043] In another embodiment, the magnetically attached building
composite may be used in window and door tapes. Window and door
tapes typically are a self-adhering "peel and stick" roll-goods,
generally 4-12'' wide. A typical tape construction is a plastic
facer; often polyethylene, polypropylene and metalized films,
coated with an asphalt, butyl, acrylic, polyurethane or other
pressure-sensitive adhesive and covered with a polymeric or paper
release lining. To install the product, the tape is cut 12 inches
longer than width of sill rough opening. The self-adhering tape is
applied to the lower horizontal sill or door jamb is by aligning
the edge with the inside edge of sill. Taped are adhered to the
rough opening across sill and up jambs a minimum of 6 inches. In
some cases, the edges may be mechanically fastened at the corners.
6-12'' inch wide strips the self-adhering tape are then applied to
the window and door jambs. A spray-apply primer may be applied to
the top 6 inches of jambs and exposed sheathing. The self-adhering
tape is now attached at opening head using same installation
procedures used at sill, overlapping the jamb flashing a minimum of
2 inches. After positioning the weather barrier head flap across
head flashing, construction tape or a 4-inch wide section of
self-adhering tape is applied over the 45-degree seams to complete
the air barrier.
[0044] Magnetic coatings may help to speed this flashing process.
Peeling of backing paper is eliminated. The need for special
primers to adhere to the substrate is eliminated. The tape may be
applied in all weather and temperatures. Creases ("fishmouth")
during installation is reduced or eliminated. Repositioning is
facilitated.
[0045] In another embodiment, the magnetically attached building
composite may be used in a basement water drainage system. Basement
and foundation water drainage products protect the thin, water
proofing membrane from damage, protects basement insulation from
damage and minimizes insulation water absorption over time,
critical in maintaining its insulation properties. These thick,
robust plastic sheets, often made from Polyethylene, polypropylene
or other plastics and sometimes dimpled, grooved or textured in
order to drain external ground water away from the structure and
keep earth, rocks and water pressure away from the structure. They
typically come in roll or sheet form, often 3-13' wide. The water
drainage system is typically set to a height 3-6'' above the grade
and is fixed using 1-2'' plastic capped nails applied in a zig-zag
fashion at 6'' OC to 16'' OC, depending on the construction,
through the water proofing membrane and into the structure. When
protecting an external insulation layer, longer nails are used.
Sealing tars, rows of drainage plugs, capping materials and
moldings are often used to complete the water draining system at
joints and overlaps. These plastic drainage systems can also be
applied to the interior of the basement, particularly to fix
basement leaks in existing basements, to drain water away from the
basement interior.
[0046] Magnetic coatings may increase speed of installation. The
layer can be easily positioned and can be re-positioned. Mechanical
fixings are reduced or eliminated, reducing undesirable
penetrations and cost. Creases ("fishmouth") are reduced or
eliminated. Capping materials and moldings are easily applied with
minimal or no mechanical fixings.
[0047] Another basement and foundation drainage system uses rigid
boards, often insulation boards. Typically, these are foam boards
because they are water resistant, but fiberglass polyester fiber
and other fibrous insulation boards are used. These rigid
insulation boards are sometimes grooved to allow water to drain
down its surface and away from the structure. They are typically
fixed using suitable adhesives or plastic capped nails, through the
thin water proofing membrane and into the structure. Sometimes they
are temporary fixed and require the soils to keep them permanently
in place. J or Z flashing strips are often applied to the top edge
to prevent debris and soils from getting behind the board.
[0048] Magnetic coatings on the components may allow for a simple,
quick and efficient application of insulated or non-insulated
drainage boards. Positioning and repositioning is easy and the
boards will stay in place in high wind situations without the
application of adhesives and/or undesirable mechanical fixings.
[0049] The magnetically attached building composite may also be
used for internal basement walls which are often insulated to
condition the space for living purposes, increase energy efficiency
and to prevent pipes freezing.
[0050] Typically, wood framing is attached to the structure and
filled with rolled batt insulation such as fiberglass R11, R13, R19
and R30 Insulation Kraft Faced Batts 16 or 23 in..times.48 or
93''). Typically, 1-3'' rigid foam insulation boards can also be
fitted into the framing structure. Gypsum board is screwed to the
wood framing to cover the insulation and leave an interior surface
finish for painting. Another time-saving method of Insulating
basement walls with rigid foam board is to bond the board securely
to the substrate such as a concrete or masonry block wall, using a
structural adhesive. Another method for fixing rigid insulation
board requires no adhesive because the insulation boards have slots
in the long edges designed to receive 1''.times.3'' (2.5
cm.times.7.6 cm) wood furring strips. Or, a 2''.times.3'' (5
cm.times.7.6 cm) furring strip can be used to provide an air space
behind drywall for installation of electrical wiring.
[0051] Magnetic coatings may simplify the insulation process and
reduce costs. Positioning and repositioning of the boards is easy
and boards can be quickly remove for inspection, maintenance and
upgrades. The ability to coat multiple surfaces allows for the foam
to be fixed to the substrate and exterior gypsum board to be fixed
to the foam with fewer or no mechanical fixings. The elimination of
adhesives means no curing time and no additional VOC's.
[0052] In another embodiment, the magnetically attached building
composite may be used in a roofing shingle system. Shingles are
typically made from wood, stone, fiberglass, metal, plastic and in
the US, often paper and glass fiber-reinforced asphalt. Asphalt
shingles are supplied in 10.times.10 ft. squares, on pallets. Each
shingle strip is a tab, typically 3 shingles across. The tabs are
laid in courses usually with each shingle offset from its
neighbors. The first course is the starter course and the last
being a ridge course or ridge slates for a slate roof. The ridge is
often being covered with a ridge cap, board, piece, or roll
sometimes with a special ridge vent material. Typically, 4 nails
are used per shingle and 6 nails on the prevailing windward sides
of the roof, as wind resistance nailing. Some local codes require
the 6 nails on all sides. Typical fasteners include zinc coated
steel or aluminum nails, 10-12 gauge barbed or smooth shank, 3/8'-
7/16'' heads, driven straight and flush through the shingle,
underlayment and roofing deck.
[0053] Roof valleys are extra sensitive to wind, water flow and
ice/snow build up and are typically applied during the shingle
installation process using either a woven, open valley or
closed-cut valley methods, depending on shingle type and thickness.
Typically, valley shingles lie over a self-adhered, polymeric or
felt paper roofing underlayment.
[0054] Magnetic coatings between the components of a roofing
shingle system may increase the speed of applying roofing shingles.
The coatings allows positioning and repositioning of tiles and
anchors the tiles at the overlap. Undesirable mechanical fixings
are reduced or eliminated, reducing water ingress, saving time,
costs and minimizing installation errors
[0055] In another embodiment, the magnetically attached building
composite may be used in a low slope roofing system. Low slope
roofing systems, (typically having slopes of less than 2:12) such
as flat roofs, car park decks etc, have little slope for water
drainage and pose special problems due to pooling water. 1 meter
wide membranes and/or self-adhering base sheets, are fixed to the
low slope deck are finished with a tough, weather resilient cap
sheet.
[0056] Self-adhering products must be installed on a clean, dry
deck, in temperatures above 45 degrees F. Self-adhering sheets have
a backer sheet. To install the membrane, the sheet is folded back
on itself to expose the backing release liner. The release liner is
split and the exposed liner is peeled away exposing the adhesive.
The adhesive layer is pressed firmly onto the deck or
mechanically-fixed base layer (if there is one). The remaining
section is now rolled back and the remaining adhesive layer pressed
firmly to the substrate. Finally, the whole area is rolled to apply
pressure and expel any remaining air pockets that could cause
blisters.
[0057] Mechanically fixed base sheets are polymeric-coated
textiles. The base sheet is nailed, using metal or plastic-capped
nails, into the deck, or adhered to the deck. The cap sheet is
applied starting from the bottom of the roof slope and then
shingled across the roof, overlapping 6'' and ensuring that joints
do not overlap with the base sheet. Metal or plastic drip edges are
adhered and then mechanically fixed to finish the roofing system at
the roof terminations. Typically, the leading edge of fasteners are
1-2'' from the edge and 9'' OC. The next row of fasteners are
typically 14'' from the leading edge and 18'' OC. The third row of
fasteners are 26'' from the leading edge and 18'' OC. Second and
third row fasteners are staggered to minimize wind uplift. Finally,
a self-adhering cap sheet can be installed using similar methods to
the previous self-adhering membrane, ensuring a good bond between
the salvage edge and the adjacent membrane strip and taking care to
add additional sealants, such as SBS adhesives, at top edge and
T-joints, to prevent water ingress and blisters.
[0058] At parapets, flashings are nailed at the top and counter
flashed. Magnetic coatings may simplify the process of installing
roofing membranes in low-slope roofing applications by having
magnetic surfaces between the different components. Positioning and
repositioning of large membrane sheets is easy and minimizes the
potential for air or moisture entrapment and associated blisters.
Post inspection and maintenance is simplified. Undesirable
mechanical fixings which cause intrusions for potential water
damage, are minimized or eliminated. Associated costs are reduced
and installation quality is improved. The need to have a clean, dry
deck for installing self-adhered roofing is eliminate. Magnetic
coating products can be installed in all weathers and temperatures.
Multi-layer magnetic coating more easily facilitates the
application of various layers on top of each other. Finishes such
as parapet flashings are easy to overlap and fix to existing
magnetic layers.
[0059] In another embodiment, the magnetically attached building
composite may be used in a siding and wall cladding system. Siding
and wall cladding is the exterior material applied to the walls of
a house or other building meant to shed water, protect the walls
from the effects of weather, insulate, and is a key in the
aesthetics of the structure. Siding may be made of wood, metal,
plastic (vinyl), masonry, or composite materials. Siding may be
formed of horizontal or vertical boards, shingles, or sheet
materials. It may be attached directly to the building structure
(wood or metal studs), or to an intermediate layer of structural
sheathing material, typically wood (fiber boards, plywood, oriented
strand board). Fiber Cement board is typically installed over
plywood, OSB, or comparable sheathing. Sidings materials can be
installed over braced wood or steel studs in accordance with local
building codes.
[0060] Siding materials typically cover an intermediate air and
moisture barrier such as housewrap or building felt paper. Fiber
cement siding panels must be nailed into structural framing or
structural; sheathing. Typical fixings include nails or screws.
Fixings are commonly applied using a pneumatic nail gun designed
for siding applications is it is faster than hand nailing. Collated
and uncollated screw guns are also used to apply fixings. Nails
must penetrate a minimum of 11/4'' into the structural framing. The
siding and the trim is caulked. Fixings should be a minimum of
3/8'' from the board edges and corners.
[0061] Subsequent courses are overlapped and butt end/joints are
staggered to avoid noticeable patterns. Shapes siding, such as
shingle siding, is installed in similar ways to lap siding, but
care is required to ensure a random look and correct distance
between subsequent layers.
[0062] Magnetic coatings may speed the installation by reducing or
eliminating fixings and thereby improve the quality of siding
installation. Boards can be easily positioned and repositioned and
removed for inspection. Mechanical fixing can cause stress points
that can lead to cracking and undesirable waves in the facade,
which is eliminated with magnetic coatings. The ability to
magnetically coat multiple layers allows fixing of overlapping
layers.
[0063] In another embodiment, the magnetically attached building
composite may be used in a vinyl siding or shakes system. Vinyl
siding and shakes are typically provided in sections 10' to 16'8''
and 32''-4', widths typically 4'-18'' and various thicknesses
depending on the supplier, eg. 0.044-0.125''. They typically
project 3/4'' and 11/4'' for insulated variants. Some variants have
built-in insulation to add thermal efficiency to the home and
impact resistance to the facade. All fasteners must be able to
penetrate a minimum of 3/4'' (19 mm) into framing or furring and
typically the fasteners are nails or screws. If staples are being
used instead of nails or screws, they are typically not be less
than 16-gauge and semi-flattened to an elliptical cross-section.
They must penetrate not less than 3/4'' (19 mm) into framing or
furring and be wide enough in the crown to allow free movement of
the siding (approximately 1/32'' [0.8 mm] away from the nailing
hem.
[0064] Typically, the first course (row of panels) are placed in
the starter strip and securely locked along the entire length of
the siding panel before fastening. Panels are fastened in the
center of the nailing slots, allowing 1/4'' (6.4 mm) gap between
the siding and all corner posts and channels for expansion. Panels
typically overlap by one half the length of the notch at the end of
the panel, or approximately 1''. Siding section end-laps are
staggered so that no two courses (rows of panels) are aligned
vertically, unless separated by at least three courses.
[0065] Magnetic coatings simplify the application and installation
quality of vinyl and other plastic siding. Positioning and
repositioning of the siding is facilitated whilst post-inspection
and maintenance of the building envelope is easier. The requirement
for fixings is reduced or eliminated. The ability to magnetically
coat multiple layers allows fixing of overlapping layers
[0066] In another embodiment, the magnetically attached building
composite may be used in an insulated siding system. Upgrading the
insulation on an external wall is a cost-effective means of
improving energy efficiency in buildings.
[0067] For exterior wall insulation and re-siding, plastic cap
nails with minimum 1/2'' (1.3 cm) diameter washers are used to
fasten insulation boards tightly to the wall. The nails penetrate
the studs by 1'' (2.5 cm), either directly or through old siding.
Nails can be spaced 6'' (15 cm) along the perimeter of the board
and 12''.times.16'' (30 cm.times.41 cm) in the field. The rigid
insulation boards are butted tightly at the edges and installed in
a staggered pattern.
[0068] Magnetic coating allows quick and easy installation of rigid
insulation boards, particularly in windy conditions. Positioning
and repositioning of the boards is simplified and allows easy
inspection and maintenance. The requirement for mechanical fixings
is reduced or eliminated. The need for structural adhesives is
eliminated.
[0069] In another embodiment, the magnetically attached building
composite may be used in an attic insulation system. Attic
insulation in walls and cathedral ceilings, can turn a hot roof
space into a conditioned space and even an extra living space. This
can significantly improve a home's energy efficiency.
[0070] Typically, batt insulation is placed between the rafters
without compacting the batts or blocking the air channel. Often,
1-2'' thick rigid foam Insulation is adhered, or mechanically fixed
using screws or plastic capped nails. To the rafters in order to
cover the entire inside rafter surface. Gypsum board (drywall) is
applied to cover the insulation and rafters to deliver a clean
finish, using 3'' (7.6 cm) drywall screws to penetrate the
insulation boards and 1'' (2.5 cm) into the rafters.
[0071] Magnetic coatings allow the fast installation of rigid
insulation and gypsum boards with minimum or no fasteners. Adhesive
materials used to bond the materials to the substrate are
eliminated along with associated VOC's and long curing times.
Boards can be positioned and re-positioned more easily and simple
removed for inspection and maintenance.
[0072] In another embodiment, the magnetically attached building
composite may be used in an insulated crawl space system.
Insulating crawl spaces improves a buildings energy efficiency,
conditions the space, minimizing moisture and related rot, mold and
mildew issues, and prevents freezing of water pipes.
[0073] The entire underside of the floor and sometimes, the
internal basement walls areas, are covered typically with 2'' (5
cm) thick rigid insulation boards. The boards are staggered and
fixed perpendicular to the joists with mechanical fixings (screws
or plastic-capped nails) or with adhesives. 1/2'' (1.3 cm) layer of
drywall over the insulation boards may be installed for fire
protection. A dirt base may be covered with a 6 mil polyethylene
sheets to prevent moisture from entering the space.
[0074] Using magnetic coatings, the rigid foam boards and heavy
gypsum boards are easily positioned, repositioned and removed for
easy inspection and maintenance. The requirement to apply
mechanical fixings with heavy mechanical tools is eliminated. The
process of applying adhesives is eliminated along with associated
cure times and production of VOC's in and enclosed space.
[0075] In another embodiment, the magnetically attached building
composite is a single ply roofing system. This embodiment would
correspond to 3 or 4 components (FIGS. 2 and 3). The first
component 100 would be the structural deck--(also called the roof
deck) which can be any suitable material such as steel, wood,
concrete, or gypsum board. The purpose of the roof deck is to
provide a consistent level support for the other roofing materials,
provide vertical support to the other layers of the roof, and/or to
be a horizontal diaphragm to transfer horizontal shear loads. The
next layer (component 300) would be insulation. The insulation
layer can be any suitable insulation including polyiso foam,
polystyrene, fiberboard, gypsum, and polyiso coverboards, wood
fiber board, perlite board, cellular glass or a combination of the
above. The purpose of insulation is to provide a thermal barrier
(increase R-value/thermal efficiency). The next component
(component 200 if in a three layer system or component 400 if in a
four layer system) is a membrane which can be made of any suitable
membrane material such as polyester fabric reinforced EPDM, TPO, or
PVC membranes or nonreinforced EDPM, TPO, or PVC. The membrane is
typically welded or seamed together to form a solid unit. The
purpose of the membrane is to provide an impenetrable layer to
withstand long term outdoor conditions including waterproofing,
improve energy efficiency through reflectivity, chemical
resistance, hail resistance, UV resistance, and wind uplift
resistance. The roofing system may optionally contain accessories
such as venting, skylights, etc. Plastic accessories with
preattached membrane flaps can be used to protect the opening and
allow the membrane system to remain impenetrable. The membrane
layer may be the outermost layer or an additional fleece backed
membrane may form the outermost layer. This additional membrane can
be made of polyester fabric reinforced EPDM, TPO, or PVC membranes
or nonreinforced EDPM, TPO, or PVC. A polyester or polypropylene
fleece can be bonded to the membrane to allow a new membrane to be
placed over an existing membrane in a reroofing application.
[0076] There are three main ways typically used to combine the
above elements into a roofing system. A first is to be mechanically
fastened where a combination of fasteners, plates, and screws are
used to join the structural deck, insulation, membrane, and
accessories together. This system is easy to maintain and is light
weight. However is not typically suitable for areas with high
winds. The second method is to fully adhere the system. In this
method, an adhesive is used to join the membrane to insulation
layer. Also adhesives or fasteners and plates are used to join the
insulation to the structural deck. This system provides the highest
wind uplift resistance and horizontal shear resistance but
typically has VOC's in the compound and takes more time and labor
to apply. The third method is to ballast the system. In this
method, a layer of gravel, river stone, pavers, or vegetation is
placed on top of the membrane to weigh it down and hold it in
place. The insulation can be joined to the structural deck loosely
(by the weight of the ballast) or by adhesives, fasteners, or
plates. This method provides an economical choice as labor and time
are significantly reduced to join the various elements however the
loose stone is not suitable for areas prone to high winds.
[0077] The primary purpose of joining the various elements of a
roof system is to improve wind uplift and horizontal shear
resistance. Typically the fully adhered systems using adhesives are
used in areas prone to storms and/or earthquakes as the adhesives
provide the best adhering properties and resistance. The main
negative to using adhesives is the extra labor and time it takes to
apply the adhesive to each surface and wait for it to "set". Also
most adhesives have high VOC content.
[0078] Another method for joining a roof system could be to use
magnetic elements in place of the adhesives, screws, plates, and
fasteners. This magnetized fully adhered system would provide a
greener option as it would reduce the VOC's and off gassing common
with adhesives, reduce installation labor by eliminating the
adhesive application or mechanical fastening step, would be easier
to remove, replace, and reposition, prevent damage/penetrations
inherent in the mechanically fastened system, reduce installation
time by eliminating the need for adhesives to "set", and could be
installed in a wider range of temperatures and weather
conditions.
EXAMPLES
Example 1
[0079] The first example of a magnetically attached building
composite was formed using 3 layers. The layers were as follows (in
order) a wood board base (layer 1), a barrier foam layer (Layer 2)
and a TPO (Thermoplastic polyolefin) (Layer 3). The magnetic
responsive coating was made using Fe.sub.3O.sub.4 bought from
Atlantic Equipment Engineers particles 100 mesh in size mixed with
acrylate binder (AC-115 in aqueous solution) in a 70:30
(Fe.sub.3O.sub.4:AC-115) ratio by weight. Once the Fe.sub.3O.sub.4
particles were added to the binder, the mixture was mixed
vigorously for 15 min to make it homogeneously mixed. The
magnetically responsive coating was then coated on layer 1 and
Layer 3 only on one side, leaving the other side uncoated. The
coatings were cured at 250.degree. F. for 10 min. A permanently
magnetic layer (.about.250 Gauss) purchased from Arnold Magnetics
was glued on both the sides of the foam (Layer 2). All the layers
were assembled by putting layer 1 as the base facing magnetically
responsive coating on top to the bottom of the permanently magnetic
layer 2. For layer 2 permanently magnetic top was put facing the
magnetic responsive coating on the bottom layer of TPO.
Example 2
[0080] The second example of a magnetically attached building
composite was formed using 3 layers. The layers were as follows (in
order) a wood board as base (layer 1), a barrier foam layer (Layer
2) and a PVC (Vinyl Film) (Layer 3). The magnetic responsive
coating was made using Fe.sub.3O.sub.4 bought from Atlantic
Equipment Engineers particles 100 mesh in size mixed with acrylate
binder (AC-115 in aqueous solution) in a 70:30
(Fe.sub.3O.sub.4:AC-115) ratio by weight. Once the Fe.sub.3O.sub.4
particles were added to the binder, the mixture was mixed
vigorously for 15 min to make it homogeneously mixed. The
magnetically responsive coating was then coated on layer 1 and
Layer 3 only on one side, leaving the other side uncoated. The
coatings were cured at 250.degree. F. for 10 min. A permanently
magnetic layer (.about.250 Gauss) purchased from Arnold Magnetics
was glued on both the sides of the foam (Layer 2). All the layers
were assembled by putting layer 1 as the base facing magnetically
responsive coating on top to the bottom of the permanently magnetic
layer 2. For layer 2 permanently magnetic top was put facing the
magnetic responsive coating on the bottom layer of PVC.
Example 3
[0081] To show the concept of sidings and overlaying different
surfaces a wood board (layer 1) was coated with magnetically
responsive coating and then cured as mentioned in Example 1.
Permanently magnetic layer was put on both the sides of the foam as
layer 2 to attach it on the wood base. Magnetically responsive
coating was then put on the vinyl based sidings and laminates to
assemble it on the foam surface or overlaid on each other by
covering only half of the surface.
Example 4
[0082] To show the concept of parapet and flexibility of the
magnetically responsive coatings A wood board (layer 1) was coated
with magnetically responsive coating and then cured as mentioned in
Example 1. A additional wood piece was coated with a permanently
magnetic layer. A permanently magnetic layer was put on both the
sides of the foam as layer 2 to attach it on the wood base facing
magnetically responsive coating. A magnetically responsive coating
was then made on PVC as layer 3. Layer 3 was attached on the wood
board via permanently magnetic layer and then took it over the
attached foam surface on the wood. The flexibility of the magnetic
coating on Layer 3 was enough to attach layer 1 and layer 2 at two
different heights at the same time, without any cracking
issues.
[0083] For each of the examples 1-3, it was found that the 3 layer
system attached with magnetic force was enough to hold together all
the layers in a flat orientation, at 90 degree orientation, and
also in inverted orientation".
[0084] All references, including publications, patent applications,
and patents, cited herein are hereby incorporated by reference to
the same extent as if each reference were individually and
specifically indicated to be incorporated by reference and were set
forth in its entirety herein.
[0085] The use of the terms "a" and "an" and "the" and similar
referents in the context of describing the invention (especially in
the context of the following claims) are to be construed to cover
both the singular and the plural, unless otherwise indicated herein
or clearly contradicted by context. The terms "comprising,"
"having," "including," and "containing" are to be construed as
open-ended terms (i.e., meaning "including, but not limited to,")
unless otherwise noted. Recitation of ranges of values herein are
merely intended to serve as a shorthand method of referring
individually to each separate value falling within the range,
unless otherwise indicated herein, and each separate value is
incorporated into the specification as if it were individually
recited herein. All methods described herein can be performed in
any suitable order unless otherwise indicated herein or otherwise
clearly contradicted by context. The use of any and all examples,
or exemplary language (e.g., "such as") provided herein, is
intended merely to better illuminate the invention and does not
pose a limitation on the scope of the invention unless otherwise
claimed. No language in the specification should be construed as
indicating any non-claimed element as essential to the practice of
the invention.
[0086] Preferred embodiments of this invention are described
herein, including the best mode known to the inventors for carrying
out the invention. Variations of those preferred embodiments may
become apparent to those of ordinary skill in the art upon reading
the foregoing description. The inventors expect skilled artisans to
employ such variations as appropriate, and the inventors intend for
the invention to be practiced otherwise than as specifically
described herein. Accordingly, this invention includes all
modifications and equivalents of the subject matter recited in the
claims appended hereto as permitted by applicable law. Moreover,
any combination of the above-described elements in all possible
variations thereof is encompassed by the invention unless otherwise
indicated herein or otherwise clearly contradicted by context.
* * * * *