U.S. patent application number 15/806010 was filed with the patent office on 2018-03-01 for magnet receptive panels and methods.
The applicant listed for this patent is United States Gypsum Company. Invention is credited to Salvatore C. Immordino, JR., Vittorio A. Immordino, Kevin W. Moyer, JR., David D. Pelot, Terry L. Rosenstiel.
Application Number | 20180056627 15/806010 |
Document ID | / |
Family ID | 56621784 |
Filed Date | 2018-03-01 |
United States Patent
Application |
20180056627 |
Kind Code |
A1 |
Immordino, JR.; Salvatore C. ;
et al. |
March 1, 2018 |
MAGNET RECEPTIVE PANELS AND METHODS
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.
Inventors: |
Immordino, JR.; Salvatore C.;
(Trevor, WI) ; Immordino; Vittorio A.; (Trevor,
WI) ; Pelot; David D.; (Chicago, IL) ; Moyer,
JR.; Kevin W.; (Chicago, IL) ; Rosenstiel; Terry
L.; (Vernon Hills, IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
United States Gypsum Company |
Chicago |
IL |
US |
|
|
Family ID: |
56621784 |
Appl. No.: |
15/806010 |
Filed: |
November 7, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
14974444 |
Dec 18, 2015 |
9849649 |
|
|
15806010 |
|
|
|
|
62117204 |
Feb 17, 2015 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 2419/04 20130101;
B32B 7/02 20130101; B32B 29/00 20130101; B32B 13/06 20130101; B32B
13/08 20130101; B32B 27/00 20130101; B32B 3/00 20130101; Y10T
428/239 20150115; E04F 13/0883 20130101; B32B 37/12 20130101; B32B
2307/208 20130101; B32B 2607/00 20130101; Y10T 428/24008 20150115;
B32B 7/12 20130101; Y10S 52/04 20130101; E04C 2/043 20130101; E04F
13/00 20130101; E04F 13/14 20130101 |
International
Class: |
B32B 13/06 20060101
B32B013/06; E04F 13/14 20060101 E04F013/14; B32B 3/00 20060101
B32B003/00; B32B 7/02 20060101 B32B007/02; B32B 7/12 20060101
B32B007/12; B32B 13/08 20060101 B32B013/08; B32B 29/00 20060101
B32B029/00; B32B 37/12 20060101 B32B037/12; E04C 2/04 20060101
E04C002/04; E04F 13/08 20060101 E04F013/08 |
Claims
1. A building panel comprising: a pattern of one or more magnet
receptive elements, the one or more magnet receptive elements
applied to at least one surface of the building panel and/or
embedded into the building panel.
2. The building panel of claim 1, wherein the pattern includes at
least one of a disjointed pattern, a discontinuous pattern, a
continuous pattern, a grid, an array, being geometrically spaced,
randomly spaced, and spaced in at least one direction.
3. The building panel of claim 1, wherein the building panel is a
wallboard panel.
4. The building panel of claim 1, wherein the pattern is a
disjoined grid pattern of at least two rows, a first row of magnet
receptive elements and a second row of magnet receptive elements,
and wherein the magnet receptive elements in the first row and the
magnet receptive elements in the second row differ in their
composition from each other.
5. The building panel of claim 1, wherein the one or more magnet
receptive elements comprise a ferromagnetic material.
6. The building panel of claim 1, wherein the one or more magnet
receptive elements include at least one of magnet receptive tape,
magnet receptive sheet, magnet receptive paint, magnet receptive
coating, foil, shim, magnetic tape, magnetic sheet, magnetic paint,
and magnetic coating.
7. The building panel of claim 1, wherein the one or more magnet
receptive elements are a magnet.
8. The building panel of claim 1, wherein the one or more magnet
receptive elements are attractive to the magnet which comprises at
least one of an alnico magnet, a magnet made from a ferromagnetic
material, a rare-earth magnet, a ceramic magnet, and a neodymium
magnet.
9. The building panel of claim 1, wherein the one or more magnet
receptive elements are at least one of a square, and a
rectangle.
10. The building panel of claim 1, wherein an area of the one or
more magnet receptive elements is in the range from 5 square
millimeters to about 50 square centimeters.
11. The building panel of claim 1, wherein the one or more magnet
receptive elements cover from about 1% to about 100% of the panel
surface.
12. The building panel of claim 1, wherein the one or more magnet
receptive elements are applied to the panel surface in continuous
or discontinued horizontal and/or vertical rows.
13. The building panel of claim 1, wherein a cover sheet is applied
over the one or more magnet receptive elements.
14. The building panel of claim 13, wherein the cover sheet
comprises paper.
15. The building panel of claim 1, wherein the pattern is a
disjointed pattern in which magnet receptive elements are spaced
from each other, and wherein a spacing between two adjacent magnet
receptive elements is smaller in size than a surface of each magnet
receptive element.
16. The building panel of claim 1, wherein the pattern is designed
for use with wireless electricity transmission.
17. A method for making a building panel, the method comprising
attaching one or more magnet receptive elements to a building
panel.
18. The method of claim 17, wherein the step of attaching is
performed by: painting the one or more magnet receptive elements on
at least one surface of the panel; printing the one or more magnet
receptive elements on at least one surface of the panel; attaching
the one or more magnet receptive elements with an adhesive to at
least one surface of the panel; attaching the one or more magnet
receptive elements by using a mechanical attaching design or device
to at least one surface of the panel; imbedding the one or more
magnet receptive elements into the panel; or any combination
thereof.
19. The method of claim 17, wherein the panel comprises a cover
sheet and wherein the one or more magnet receptive elements are
adhered to the cover sheet with an adhesive.
20. A wall, ceiling and/or floor assembly comprising: a building
panel having a pattern of one or more magnet receptive elements,
the one or more magnet receptive elements being applied to at least
one surface of the building panel and/or embedded into the building
panel.
Description
CROSS-REFERNCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority from US
provisional patent application 62/117,204 filed Feb. 17, 2015, the
entire disclosure of which is incorporated herein by reference, and
also from U.S. patent application Ser. No. 14/974,444 filed Dec.
18, 2015, which is also incorporated by reference.
FIELD OF THE INVENTION
[0002] The invention relates to building panels that are magnet
receptive, and methods of making and using the magnet receptive
panels. The invention also relates to magnet panels and methods of
making and using the magnet panels.
BACKGROUND
[0003] Many building panels which are produced from gypsum (calcium
sulfate dihydrate, landplaster) are commonly utilized in building
construction. These panels can be used to construct walls,
ceilings, doors, partitions and in many other applications. Other
panels commonly used in construction include cement panels and
panels made from gypsum and wood fiber.
[0004] As described in patents assigned to United States Gypsum
Company (Chicago, Ill.), including U.S. Pat. No. 8,197,952 and U.S.
Pat. No. 5,643,510, various methods are known for obtaining gypsum
panels. Such methods include those in which gypsum is calcined
first. The calcined gypsum is then mixed with water to form a
gypsum slurry. Other components can be added to the slurry,
including for example, binders, fibers, fillers, surfactants,
defoamers, plasticizers, set accelerators and set retarders. The
gypsum slurry can be sandwiched between two cover sheets and formed
into panels which are then allowed to set. In some applications, at
least one cover sheet is paper. Such gypsum panels are referred to
as wallboard.
[0005] Alternatively, a gypsum slurry can be formulated with fibers
and other components and is shaped into a gypsum panel which is
allowed to set without the use of cover sheets. Such gypsum panels
are known as fiberboards.
[0006] Gypsum panels provide many advantages in construction--they
are light-weight, yet fire-resistant and easy to install. Gypsum
panels can be also formed into various custom shapes and they can
be cut to a particular custom size.
[0007] Because gypsum panels are used as interior walls and
ceilings, there is often a need to attach various objects to the
panels such as for example, pictures, paintings, light fixtures,
mirrors, speakers, various sensors, smoke alarms, and monitors.
Conventionally, attaching an object to a wall or ceiling requires
nails, screws or adhesives. Some of such methods and systems are
provided in U.S. Pat. No. 4,884,375 assigned to USG Interiors, Inc.
After the object is no longer needed and is removed from the gypsum
panel or is moved to a new position, the gypsum panel's surface
remains damaged with an imperfection left in the place where a nail
or screw used to be. Restoring the damaged gypsum panel may require
patching a hole, sanding it and then painting over the patch to
blend the repaired area with the rest of the gypsum panel. However,
and even after all these steps, the damaged gypsum panel may still
continue to look uneven and discolored, especially if the wall
surface was previously decorated. Thus, there is a need for
improved ways for attaching various objects to a wall or ceiling
without the use of nails or screws or adhesives.
SUMMARY
[0008] This invention provides a building panel which enables users
to support objects such as pictures, televisions, shelving,
lighting, equipment, tools, signs, etc. on the panel without the
use of wall-damaging nails or screws.
[0009] One embodiment provides a building panel comprising at least
one magnet receptive element. In some embodiments, 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.
[0010] Further embodiments provide panels in which magnet receptive
elements are arranged into a pattern. Various patterns of magnet
receptive elements are contemplated, including a disjointed
pattern, discontinuous pattern, continuous pattern, grid, array,
geometrically spaced, randomly spaced, spaced in at least one
direction, and any combination thereof. At least some patterns
include those in which at least two magnet receptive elements are
located so that the angle and distance between the elements can be
of any value. A magnet receptive element may comprise a
ferromagnetic material selected from the group consisting of iron,
nickel, cobalt, alloys with rare earth metals and any combination
thereof.
[0011] Magnet receptive elements may be provided as 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. In some embodiments, magnet receptive elements have
magnetic properties and can be function as a magnet.
[0012] Various magnet receptive elements are suitable, including
those comprising a ferromagnetic material selected from iron,
nickel, cobalt, alloys with rare earth metals and any combination
thereof. A magnet receptive element can comprise a tape comprising
a ferromagnetic material and/or a paint prepared with a magnet
receptive material. Some embodiments include a magnet receptive
element which is capable of producing a magnetic field.
[0013] Various building panels include a gypsum fiberboard, gypsum
wallboard, cement panel, ceiling tile and plastic panel. In some
embodiments, a cover sheet can be applied over the magnet receptive
elements and suitable cover sheets include paper, plastic, coating
and any combination thereof.
[0014] Further embodiments provide a method for making a gypsum
panel, comprising positioning at least one magnet receptive element
on the gypsum panel. In some embodiments, magnet receptive elements
are positioned on the gypsum panel by at least one of the following
methods: [0015] painting the magnet receptive elements on at least
one surface of the gypsum panel; [0016] printing the magnet
receptive elements on at least one surface of the gypsum panel;
[0017] attaching the magnet receptive elements with an adhesive to
at least one surface of the gypsum panel; [0018] attaching magnet
receptive elements by using a mechanical attaching design or device
to at least one surface of the gypsum panel; [0019] depositing the
magnet receptive elements on the surface of the gypsum panel which
has not been fully set; and [0020] any combination thereof.
[0021] Further embodiments provide a kit for making a building
panel, the kit comprising an item selected from the group
consisting of: a magnet receptive tape, a magnet receptive sheet, a
magnet receptive paint; an adhesive, a resonator, a magnet
induction (MI) signal repeater, and any combination thereof. The
kit may further comprise a magnet selected from the group
consisting of alnico magnets, magnets made from ferromagnetic
materials, rare-earth magnets, ceramic magnets, neodymium magnets
and any combination thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIGS. 1A and 1B are a front view of a building panel with a
grid of disjointed magnet receptive elements. In FIG. 1A, the
elements in two adjacent horizontal rows are shifted. In FIG. 1B,
the elements in two adjacent horizontal rows are aligned;
[0023] FIG. 2 is a front view of an alternative embodiment for a
building panel with a grid of magnet receptive elements;
[0024] FIG. 3 is a front view of an alternative embodiment for a
building panel with a grid of magnet receptive elements;
[0025] FIG. 4 is a front view of an alternative embodiment for a
magnet receptive building panel;
[0026] FIG. 5 is a cross-sectional view of a building panel with a
grid of magnet receptive elements, with the panel being further
covered with at least one cover layer applied over the grid;
[0027] FIG. 6 is a cross-sectional view of a building panel coated
with a layer of magnet receptive elements, with the building panel
being further covered with a least one cover layer applied over the
layer of magnet receptive elements;
[0028] FIGS. 7A-7F are embodiments of a magnet receptive panel with
a grid of magnet receptive elements. FIGS. 7A-7D depict a magnet
receptive panel with a continuous grid of magnet receptive elements
in which the magnet receptive elements are connected at
intersections. FIGS. 7E-7F depict a magnet receptive panel with a
disjointed grid of magnet receptive elements in which magnet
receptive elements are not connected at intersections; and
[0029] FIGS. 8A-8B are graphs reporting conductivity measurements
for magnet receptive panels of FIGS. 7A-7F. FIG. 8A is a graph for
panels of FIGS. 7A-7D. FIG. 8B is a graph for panels of FIGS.
7E-7F.
DETAILED DESCRIPTION
[0030] The present invention provides a building panel which
comprises a magnet receptive element. Various objects such, as for
example without limitation, pictures, paintings, light fixtures,
mirrors, speakers, various sensors, smoke alarms, and LCD screens
can be attached to the building panel via a magnet and without
nails, screws or adhesives. Thus, various objects can be easily
attached to the building panel, removed from the building panel,
and optionally reattached to another area of the building panel
without damage to the building panel.
[0031] One embodiment provides a magnet receptive substance
connected to a wall, including floors, ceilings, face and/or
backing side of a wall partition, or embedded in a wall so that an
object can be supported at any location on a wall using at least
one magnet. The magnet can be directly or indirectly connected to
the object. In some embodiments, the magnet is connected to the
object with a string or wire.
[0032] Various objects can be secured on the building panel
comprising a magnet receptive element without the need for nails or
screws. Such objects include objects which can be operated with
typical wire and plug electricity or wireless electricity,
including for example, a lamp, radio, screen and fan.
[0033] One embodiment provides a building panel with a pattern of
magnet receptive elements located on at least one surface of the
building panel and/or embedded into the building panel. Various
patterns for the magnet receptive elements are contemplated,
including, but not limited to, discontinuous, continuous,
disjointed, grid, array, geometrically spaced, randomly spaced, or
spaced in one, two, or more directions.
[0034] One embodiment of a magnet receptive panel (10) is shown in
FIG. 1A. Another embodiment of a magnet receptive panel (10) is
shown in FIG. 1B. The magnet receptive panel 10 of FIGS. 1A and 1B
comprises a prefabricated core (12) and a grid of magnet receptive
elements (14) applied to the panel surface (16). In addition to the
embodiments of FIGS. 1A and 1B, a magnet receptive building panel
can be made in any shape with a core of any thickness, length and
shape and a pattern of magnet receptive elements adhered to at
least one surface of the core and/or embedded in the core.
[0035] The core (12) can be a gypsum core formulated and prepared
according to any methods known to a person of skill. In some
embodiments, the gypsum core is prepared from a gypsum slurry which
is formulated from calcined gypsum and water. Additional components
may be added to the gypsum slurry and water. Such components may
include at least one of the following or any combination of the
following: a surfactant, filler, binder, fibers, defoamer, biocide,
set accelerator, plasticizer and set retarder. Suitable surfactants
include, but are not limited to, alkyl sulfates, alkyl ether
sulfates and mixtures thereof. Suitable fillers include, but are
not limited to, any type of clay, sand, cement, calcium carbonate
and any combination thereof. Suitable binders include, but are not
limited to, starch, poly-acrylate and any combination thereof.
Suitable fibers include, but not limited to, paper print, other
cellulosic fibers, glass fiber and mineral wool, and any mixture
thereof. Suitable accelerators include, but are not limited to any
anions that are known as set accelerators, including sulfates,
nitrates and chlorides. Suitable biocides include, but are not
limited, to pyrithiones, such as sodium OMADINE or zinc OMADINE
Suitable plasticizers include, but are not limited to, naphthalene
sulfonate, melamine sulfonate, a polycarboxylate and any mixture
thereof.
[0036] A person of skill will appreciate that while in some
embodiments, a building panel is made with the gypsum core (12), in
other embodiments, a panel core can be made with other materials
such as for example, cement which can be used in combination with
or instead of calcined gypsum for making a panel core. In other
embodiments, a panel can be also made of plastic. A person of skill
will also appreciate that a panel has several surfaces, one of the
surfaces may be facing a room after installation. Any such surface
of the panel is referred to as a front facing surface or simply
facing surface. The surface on the other side of the panel is
called the back surface.
[0037] In some embodiments, the grid of magnet receptive elements
(14) has a disjointed pattern. In some embodiments, the disjointed
grid pattern is made by rows of magnet receptive elements (14A) and
(14B) as shown in FIGS. 1A or 1B. In some embodiments all magnet
receptive elements in the grid (14) are made from the same material
attractive to a magnet. In other embodiments, the magnet receptive
element (14A) may be different in its composition from the magnet
receptive element (14B). A magnet receptive panel with a plurality
of different magnet receptive elements is also contemplated.
[0038] A person of skill will readily recognize that a magnet
receptive element can be made from any material which is attracted
to a magnet. Such magnet receptive materials may include iron,
nickel, cobalt, alloys, and in particular alloys with rare earth
metals, and naturally occurring minerals. While in some
embodiments, the material is magnetically receptive, in other
embodiments a magnetic material can be also used. Thus, at least
some magnet receptive elements have magnetic properties.
[0039] In some embodiments, a magnet receptive element can comprise
a pre-fabricated sheet or tape made from a magnet receptive
material. In some embodiments, a magnet receptive element can
comprise a pre-fabricated sheet or tape made from a ferromagnetic
material. It is also desired in some embodiments that the thickness
of the magnetic receptive tape or sheet is thin or thick. In some
embodiments the thickness of the tape or sheet may be from 1
thousandth of inch to 100 thousandth of inch. In further
embodiments, the magnet receptive tape or sheet may be covered on
one side with paper or joint tape. In some embodiments, the magnet
receptive element can be a tape, paint, sheet, foil, shim, strip or
coating.
[0040] In some embodiments, the magnet receptive elements can be
adhered with an adhesive to the surface of a panel core. In other
embodiments, the magnet receptive elements can be attached or
adhered to the gypsum core before it sets and without the need for
an adhesive. In other embodiments, the magnet receptive elements
can be attached to the gypsum core after the gypsum core sets. In
other embodiments, the magnet receptive elements can be attached to
the panel core after the panel core sets partially.
[0041] In further embodiments, the magnet receptive element (14A)
and/or (14B) comprises a paint prepared with a magnet attractive
material. The grid (14) is then printed or painted on the building
panel surface. In some embodiments, the grid is painted or printed
on the gypsum core surface before the gypsum panel sets. In other
embodiments, the grid is painted or printed on the gypsum core
surface after the gypsum panel sets at least partially.
[0042] In some embodiments, the magnet receptive element (14A)
and/or (14B) comprises a paint, coating, foil, shim, strip, or tape
prepared with a magnet attractive material. The grid can be located
on the inside or outside surface of the outside paper cover sheet
or embedded between plies of paper cover sheets. Paper in this case
refers to either or both the face paper and back paper cover
sheet.
[0043] In some embodiments, the magnet receptive element (14A)
and/or (14B) comprises a paint, coating, foil, shim, strip, or tape
prepared with a magnet attractive material. In will be appreciated
that at least in some embodiments, the magnet receptive elements
have magnetic properties and can be used as a magnet. The magnetic
attractive material is then placed on a non-receptive material such
as plastic or paper then attached to the core or the inside of the
paper or outside of the paper. Paper in this case refers to either
or both the face paper or back paper. The grid of magnet receptive
elements (14) may be suitable for use with at least one type of a
magnet. A person of skill will understand that the term "magnet" is
used in this disclosure broadly and includes any object that
produces a magnetic field. Such magnets include, but are not
limited to, alnico magnets, magnets made from ferromagnetic
materials, rare-earth magnets, ceramic magnets, neodymium magnets
and the like. In some embodiments, suitable magnets may include
flexible magnets. In other embodiments, a magnet may include a
device that produces a magnetic field.
[0044] The size and shape of magnet receptive elements (14A) and
(14B) may vary. In some embodiments, the magnet receptive elements
(14A) and (14B) are of the same shape and size. In other
embodiments, the magnet receptive element (14A) differs from the
magnet receptive element 14B by at least one of the following:
shape or size. Suitable shapes independently for elements 14A and
14B include, but are not limited to, squares, rectangles, stars,
triangles and circles. A person of skill will appreciate that the
shapes can be open or closed. If the shapes are open, they can have
any size opening.
[0045] In some embodiments, an area of a magnet receptive element
is from about 5 square millimeters to about 50 square centimeters.
In some embodiments, an area of a magnet receptive element is from
about 5 square millimeters to about 40 square centimeters. In some
embodiments, an area of a magnet receptive element is from about 5
square millimeters to about 30 square centimeters. In some
embodiments, an area of a magnet receptive element is from about 5
square millimeters to about 20 square centimeters. In some
embodiments, an area of a magnet receptive element is from about 5
square millimeters to about 10 square centimeters. In some
embodiments, an area of a magnet receptive element is from about 5
square millimeters to about 5 square centimeters. In some
embodiments, an area of a magnet receptive element is from about 5
square millimeters to about 1 square centimeter. In some
embodiments, an area of a magnet receptive element is at least 1
square centimeter. In some embodiments, an area of a magnet
receptive element is at least 2 square centimeters. In some
embodiments, an area of a magnet receptive element is at least 3
square centimeters. In some embodiments, an area of a magnet
receptive element is at least 4 square centimeters. In some
embodiments, an area of a magnet receptive element is at least 5
square centimeters. In some embodiments, an area of a magnet
receptive element is at least 6 square centimeters. In some
embodiments, an area of a magnet receptive element is at least 7
square centimeters. In some embodiments, an area of a magnet
receptive element is at least 8 square centimeters. In some
embodiments, an area of a magnet receptive element is at least 9
square centimeters. In some embodiments, an area of a magnet
receptive element is at least 10 square centimeters. In some
embodiments, the size of a magnet receptive element can be
increased to the size of the panel itself such that at least one
surface of the panel is covered almost completely with the magnet
receptive element.
[0046] At least is some embodiments, magnet receptive elements are
applied such that they create horizontal rows with at least two
magnet receptive elements in each row. In some embodiments, magnet
receptive elements from two adjacent horizontal rows may be aligned
in columns as shown in FIG. 1B. In other embodiments, magnet
receptive elements in the second horizontal row are shifted in
comparison to the first horizontal row, as shown in FIG. 1A. In
other embodiments, magnet receptive elements are applied in a grid
with a circle pattern. A person of skill will appreciate that any
disjointed pattern of magnet receptive elements can be suitable in
at least some embodiments.
[0047] As shown in FIG. 1B, magnet receptive elements in the second
horizontal row are aligned under magnet receptive elements in the
first horizontal row. This creates a vertical passage of spaces 18
between magnet receptive elements from two adjacent columns of
magnet receptive elements. The vertical passage of spaces 18
remains free of magnet receptive elements. As can be appreciated
from FIG. 1B, there is also a horizontal passage of spaces 19
between two adjacent horizontal rows of magnet receptive elements.
Thus, embodiments of FIGS. 1A and 1B provide grid patterns in which
magnet receptive elements are disjointed and some panel surface
area between the magnet receptive elements remains free of the
magnet receptive elements. In some embodiments, magnet receptive
elements cover from about 100% to about 1% of a panel surface,
while the rest of the surface remains as spaces (also referred to
as intersections or gaps) between magnet receptive elements, and
magnet receptive elements are not connected at the
intersections.
[0048] In other embodiments, magnet receptive elements from two
adjacent horizontal rows are applied to a gypsum panel surface with
a shift. In some embodiments, a shift is such that the magnet
receptive elements from the two adjacent horizontal rows do not
align, and a grid is created in a chess-board pattern. One of such
embodiments is shown in FIG. 1A.
[0049] It will be appreciated by a person of skill from FIGS. 1A
and 1B that the width (W) of the space (18) between two adjacent
magnet receptive elements situated in the same horizontal row may
or may not be equal to the length of a magnet receptive element. In
some embodiments, the spacing between adjacent magnet receptive
elements can vary within the same row or column or other pattern.
In some embodiments, the width (W) in the space (18) is at least 1
millimeters, but less than 10 centimeters. In other embodiments,
the width (W) of the space (18) may be at least 5 millimeters, but
less than 9 centimeters, less than 8 centimeters, less than 7
centimeters, less than 6 centimeters, less than 5 centimeters, less
than 4 centimeters, less than 3 centimeters, less than 2
centimeters, or less than 1 centimeter. In some embodiments, the
width (W) of the space (18) is 0 and each horizontal row is a
continuous row. In some embodiments, all of the gypsum panel
surface (16) is covered with the grid of magnet receptive elements
(14). In other embodiments, only a portion of the gypsum panel
surface (16) is covered with the grid of magnet receptive elements
(14).
[0050] It will be also appreciated by a person of skill from FIGS.
1A and 1B that the width (D) of the space (19) between two adjacent
magnet receptive elements situated in the adjacent horizontal rows
may or may not be equal to the length of a magnet receptive
element. In some embodiments, the width (D) of the space (19) is at
least 5 millimeters, but less than 10 centimeters. In other
embodiments, the width (D) of the space (19) may be at least 5
millimeters, but less than 9 centimeters, less than 8 centimeters,
less than 7 centimeters, less than 6 centimeters, less than 5
centimeters, less than 4 centimeters, less than 3 centimeters, less
than 2 centimeters, or less than 1 centimeter. In some embodiments
the width (D) of space 19 (19) is equal to the width (W) of space
18 (18).
[0051] In further embodiments, a magnet receptive element is a
magnet receptive tape which is applied in horizontal rows or magnet
receptive paint which is applied in horizontal rows, as shown in
FIG. 2. In this embodiment, a building panel, generally 20,
comprises a grid of magnet receptive elements, generally (24) which
are applied to the panel surface (16) of the panel core (12) in
horizontal rows (24A and 24B), as shown in FIG. 2. In these
embodiments, the distance (29) between two adjacent rows (24A) and
(24B) may vary. In some embodiments, the distance (29) is at least
1 centimeter, but no more than 50 centimeters. In other
embodiments, the distance (29) is at least 1 centimeter, but no
more than 40, 35, 30, 25, 20, 15, 10 or 5 centimeters. The grid of
receptive elements (24) may cover only a portion of the panel
surface (16) or the grid of receptive elements (24) may cover all
of the panel surface (16). Magnet receptive elements in two rows
(24A) and (24B) may be made from the same magnet attractive
material. In alternative embodiments, magnet receptive elements in
two rows (24A) and (24B) may be made from at least two different
magnet attractive materials. A person of skill will appreciate that
in alternative embodiments, magnet receptive elements can be
applied in vertical rows, can be regular, irregular or can arranged
in any other geometric pattern.
[0052] An alternative embodiment for a magnet receptive panel,
generally 30, is shown in FIG. 3. In this embodiment, a grid of
magnet receptive elements, generally (34) is applied to the panel
surface (16) of the panel core (12) in continuous horizontal rows
of magnet receptive elements (34A and 34B) and vertical rows of
magnet receptive elements (34C and 34D), as shown in FIG. 3. In
these embodiments, the distance (39) between two adjacent
horizontal rows of magnet receptive elements (34A) and (34B) may
vary. In some embodiments, the distance (39) is at least 1
centimeter, but no more than 50 centimeters. In other embodiments,
the distance (39) is at least 1 centimeter, but no more than 40,
35, 30, 25, 20, 15, 10 or 5 centimeters.
[0053] The distance (37) between two adjacent vertical rows of
magnet receptive elements (34C) and (34D) may vary. In some
embodiments, the distance (37) is at least 1 centimeter, but no
more than 50 centimeters. In other embodiments, the distance (37)
is at least 1 centimeter, but no more than 40, 35, 30, 25, 20, 15,
10 or 5 centimeters. The grid of receptive elements (34) may cover
only a portion of the panel surface (16) or the grid of receptive
elements (34) may cover all of the gypsum panel surface (16). In
some embodiments, magnet receptive elements in horizontal and
vertical rows (34A, 34B, 34C and 34D) may be made from the same
magnet attractive material. In alternative embodiments, magnet
receptive elements in horizontal rows (34A) and (34B) may be made
from a first magnet receptive material, while magnet receptive
elements in vertical rows (34C) and (34D) may be made from a second
magnet receptive material. Each of the first and second magnet
receptive materials can be independently selected from any
materials which attract magnet.
[0054] An alternative embodiment for a magnet receptive building
panel is shown in FIG. 4. In this embodiment, a suitable magnet
receptive material is applied to the panel surface (16) of the
panel core (12) as a continuous magnet receptive sheet (44). In
some embodiments, the magnet receptive sheet (44) covers the panel
surface (16) completely. In other embodiments, the magnet receptive
sheet (44) covers the panel surface (16) partially.
[0055] A person of skill will appreciate that magnet receptive
panels include fiberboards, wallboards, cement boards, ceilings and
floorings. Some embodiments include fiberboards in which a gypsum
core is made with at least mineral wool, calcined gypsum and
water.
[0056] Other embodiments contemplate wallboards. FIG. 5 is a
cross-sectional view of one embodiment of a magnet receptive
wallboard, generally 50. In this embodiment, a panel core (12) may
be a gypsum core. The wallboard 50 comprises a grid of magnet
receptive elements (54) on at least one surface (16). The building
panel is covered with a cover sheet (52) which is applied over at
least a portion of the grid of magnet responsive elements (54) and
panel surface (16) such that the grid of magnet responsive elements
(54) is sandwiched between the gypsum core (12) and the cover sheet
(52).
[0057] In some embodiments, the cover sheet (52) is a paper cover
sheet. In other embodiments, the cover sheet (52) may be a mat or
screed. At least in some further embodiments, another cover sheet
is applied over the gypsum core surface which is opposite to the
surface (16) such that a magnet receptive gypsum panel is
sandwiched between two cover sheets. In some embodiments, both
cover sheets are made from the same material, for example, both
cover sheets are paper cover sheets. In other embodiments, at least
one cover sheet is a piece of paper, while the other cover sheet
can be a mat or screed.
[0058] Further embodiments include those embodiments in which the
cover sheet (52) comprises a coating. This coating can be applied
over a piece of paper or mat. In alternative, the cover sheet (52)
may comprise a coating which is applied directly over the grid of
magnet receptive elements (54). Various coatings are contemplated
including paints, water-resistant coatings and any combination
thereof. In some embodiments, at least two different coatings can
be applied in sequence. In some embodiments, at least one coating
can be a paint. In some embodiments, plastic can be used as a cover
sheet either alone or in combination with other coatings, cover
sheets and paints.
[0059] While in many embodiments, a magnet receptive panel
comprises a grid of magnet receptive elements, other embodiments
are contemplated as well in which magnet receptive elements are
applied as a continuous layer over a panel. FIG. 6 depicts a
cross-sectional view of one embodiment for a magnet receptive
panel, generally (60). In this embodiment, magnet receptive
elements are applied as a continuous layer (62) over at least a
portion of panel core (12), such that at least a portion of the
surface (16) of the panel (12) is covered with the magnet receptive
layer (62). In some further embodiments, a cover sheet (64) can be
applied over the magnet receptive layer (62). Various cover sheets
can be suitable, including paper cover sheets and polymeric mats.
In some embodiments, a cover sheet can be applied on the front side
of a panel. In other embodiments, a cover sheet can be applied on
the back side of a panel. In further embodiments, a panel can
include a core sandwiched between the back cover sheet and the
front cover sheet. In embodiments with cover sheets, magnet
receptive elements can be located at least in one of the following
locations: on the outside surface of the back cover sheet, embedded
within the back cover sheet, located the back cover sheet and the
panel core, within the panel core, between the panel core and the
face cover sheet, embedded within the face cover sheet and/or on
the outside of the face cover sheet.
[0060] In some embodiments, the magnet receptive layer (62) is a
tape which is attractive to a magnet. This tape can be made from
any material attractive to a magnet. In some embodiments, the tape
is ferrous metal tape. In other embodiments, the magnet receptive
layer (62) is a sheet which is attractive to a magnet. In some
embodiments, this sheet can be adhered to the panel core with an
adhesive. In some embodiments, the sheet is made from ferrous metal
material.
[0061] Further embodiments include methods and kits for making a
magnet receptive building panel. In some methods for making a
magnet receptive building panel, a gypsum slurry is formulated from
calcined gypsum, water and other components selected from at least
one of the following: a binder, filler, fibers, surfactant,
defoamer, set accelerator, set retarder and any mixture
thereof.
[0062] A front cover sheet is continuously fed on a moving conveyer
and a grid of magnet receptive elements is applied over it in any
pattern suitable for a particular purpose. In some embodiments, the
grid is a set of horizontal rows, vertical rows or a combination of
the two. In other embodiments, the grid is a set of disjointed
magnet receptive elements organized in any pattern. In other
embodiments, the grid is a set of disjointed magnet receptive
elements which is not organized in any pattern and applied at
random.
[0063] The gypsum slurry is then continuously deposited over the
grid onto the front cover sheet. A second back cover sheet is
optionally applied such that the gypsum core becomes sandwiched
between the two cover sheets. A magnet receptive gypsum panel is
then allowed to set and is cut to size. In this process, each of a
front cover sheet and back cover sheet can be independently a piece
of paper, plastic mat or screed. In some embodiments, the grid of
magnet receptive elements is created by laying a magnet receptive
tape in any desired pattern over the front cover sheet and prior to
depositing the gypsum slurry over it. In other embodiments, the
grid can be created by applying a magnet receptive paint in a
pattern. At least in some embodiments, the front cover sheet
bearing the grid of magnet receptive elements can be premade and
stored until needed for production of a magnet receptive panel. At
least in some embodiments, the grid of magnet receptive elements is
attached to the front cover sheet with an adhesive.
[0064] Other embodiments include kits which comprise any of the
following: a magnet receptive tape, magnet receptive sheet, magnet
receptive paint, an adhesive, or a magnetic tape. Further
embodiments also include any of the above kits which further
optionally comprise a magnet. The magnet receptive tape can be
applied over a pre-made panel with the adhesive. For example, the
magnet receptive tape can be applied over a building panel, such as
cement or gypsum panel, which has been already installed. A coating
or a cover sheet can be then optionally applied over the magnet
receptive tape. In some embodiments, a magnet receptive tape
further comprises a paper cover sheet applied to one surface of the
tape.
[0065] There are many applications for a magnet receptive building
panel. For example, pictures, paintings, mirrors, speakers, various
sensors, smoke alarms, and LCD screens and other objects can be
attached to the magnet receptive building panel with a magnet and
without the need for nails or screws or adhesives. This protects
the building panel from damage after the objects are removed from
the panel. Some attached objects comprise anti-slip materials such
for example, alongside the magnet, which prevent the objects from
sliding on the wall. At least in some embodiments, a magnet may be
coated or dipped to reduce scuffing or marks.
[0066] The wireless charging technology provides electric current
through a source resonator which induces a specific magnetic field
at a specific frequency. A charged or powered electric device can
be charged wirelessly with the wireless charging technology. Such
devices may include lamps, computers, cell phones and smart phones.
Various light fixtures and liquid crystal displays (LCDs) can be
attached to a magnet receptive panel with a magnet. These devices
can be then charged wirelessly by the wireless charging technology.
In some embodiments, a wireless charging technology resonator can
be set up at a remote location. For example, it can be positioned
behind the wall or ceiling with magnet receptive elements. The
inventors have discovered that a grid of magnet receptive elements
works well in transmitting a signal from a resonator through a
magnet receptive panel, while a solid sheet of magnet receptive
material may interfere with the magnetic field generated by the
resonator. At least in some embodiments, a magnet induction (MI)
signal repeater can be used in combination with a magnet receptive
panel. The magnet induction signal repeater can be used in
combination with a resonator to amplify and project a signal to
different areas of a magnet receptive panel. This allows to
wirelessly install and wirelessly power several light fixtures or
LCDs in different areas of a magnet receptive ceiling or wall,
[0067] While magnet receptive elements are very useful for
attaching various objects to a wall, they may interfere with
transmission of a signal from a resonator. It has been unexpectedly
discovered, that a disjointed grid pattern in which magnet
receptive elements are separated away from each other by some
spaces is a grid pattern which does not interfere significantly and
can be used for devices which will be charged wirelessly. Such
suitable disjointed grid patterns with minimized magnetic field
interference include those shown in FIG. 1A and FIG. 1B.
[0068] Further embodiments provide a building panel with a maximum
number of positions or arrangements for magnet receptive elements
to which an object can be attached with a magnet. These panels are
also designed such that they minimize the interference of wireless
electricity transmission through the panels. When considering both
technologies working in conjunction, such as using magnets to hold
an object to the wall and using wireless electricity to transfer
electricity through a wall, many designs are provided in this
disclosure. First, the maximum amount of available magnetic
positions can simply be achieved by using a metal sheet on or in
the wall; however, this inhibits the wireless electricity
transmission through the wall. Other possible patterns include a
grid of magnet receptive element of any specific size and shape in
strip, diagonal, circular, curved or fractal pattern to accomplish
the optimal distribution for magnet receptive elements needed to
provide a sufficient holding power. Such grid patterns can be
specifically designed for a particular transmitter, receiver, and
power device.
[0069] The inventors have discovered that a disjointed pattern for
magnet receptive elements in which magnet receptive elements are
spaced from each other on a panel increases electricity
transmission through the panel. The spacing between adjacent magnet
receptive elements can be significantly smaller than the size of
magnet receptive elements. In some embodiments, the spacing is less
than 1/8 inch. In some embodiments, sufficient magnet holding power
and only minor interference with electric signal transmission is
achieved with a grid in which the spacing between magnet receptive
elements is smaller than the size of the magnet receptive elements.
This discontinuous grid has an advantage over a continuous grid
because the discontinuity allows for the wireless electricity
transmission to pass through a magnet receptive panel.
[0070] Other technical advantage provided by a building panel in
which magnet receptive elements are organized in a grid with spaces
between magnet receptive elements includes easy installation as
these panels can be cut with a tool commonly used for cutting
conventional gypsum panels.
[0071] Referring to FIGS. 7A-7F, these figures depict various
grids, generally (70) for magnet receptive panels. In these
embodiments, a magnet receptive element is a magnet receptive tape
which is arranged in first set of rows (72) and a second set of
rows (74). As can be appreciated from embodiments in FIGS. 7A-7D,
the tape from the rows (74) and the rows (72) is connected at
intersections (76) in these embodiments. As can be appreciated from
the embodiments of FIGS. 7E-7F, the tape from the rows (74) and the
rows (72) is not connected at intersections (76) in these
embodiments. Thus, the embodiments of FIGS. 7A-7D are continuous
grids, while the embodiments of FIGS. 7E-7F are disjointed grids.
The embodiments of FIGS. 7A, 7B, 7C and 7D differ from each other
by the size of the grid as can be appreciated from a comparative
size of a receiver (78) which overlaps almost completely with the
tape in FIG. 7B, partially in FIGS. 7A and 7C and fits inside the
grid of FIG. 7D. The embodiments of FIGS. 7E and 7F create a grid
of about same size as the embodiments of FIGS. 7A and 7B
respectively, but for no connections at the intersections. Thus,
just like in FIG. 7B, the receiver (78) overlaps almost completely
with the tape in the embodiment of FIG. 7F because this grid in
FIG. 7F is of the same size as the grid in FIG. 7B.
[0072] In conductivity studies through building panels with grids
of FIGS. 7A-7F, it has been unexpectedly discovered that a
significant technical advantage can be achieved with a disjointed
grid. As can be seen from the conductivity graphs in FIGS. 8A and
8B, the panel embodiment with a continuous grid interferes
significantly with electricity transmission when a receiver
overlaps with magnet receptive elements as shown in FIG. 8A. Yet,
the panel embodiment with a disjointed grid in which a receiver
also overlaps with magnet receptive elements does not interfere or
interferes only minimally with conducting the electricity through
the panel, as shown in FIG. 8B. Thus, a disjointed magnet receptive
pattern is more effective at transmitting wireless electricity than
a connected magnet receptive pattern. This allows to position more
magnet receptive elements per a square foot of a magnet receptive
panel in a disjointed grid, which is technically advantageous as
more objects can be attached to such panels because these panels
have a better object holding potential and a greater design
flexibility for positioning objects on the panel.
[0073] Further embodiments provide panels with a pattern of magnet
receptive elements optimized for use in conjunction with wireless
electricity transmission. It is contemplated that the pattern in
these embodiments is designed with consideration of transmission
power, receiver power, transmitter size, receiver size, required
output of receiver, range between transmitter and receiver, and
population of transmitters, repeaters, and receivers.
EXAMPLE 1
Making and Testing Magnetic Panels with Different Grid Patterns
[0074] Two types of magnetic wallboards were prepared. One magnetic
wallboard type had a rudimentary disjointed grid pattern of magnet
receptive elements. The other magnetic wallboard type was prepared
with a continuous grid pattern of magnet receptive elements. In the
continuous grid pattern, magnet receptive tape was used, and a
pattern was created without spaces. In a rudimentary disjointed
grid pattern of magnet receptive elements, two wallboards were
prepared which differ from each other by the size of spaces between
magnet receptive elements.
[0075] All wallboards were tested using the same wireless
electricity transmission device at the same voltage. A multimeter
was used to measure electric voltage transmitted through each
wallboard, and data from these measurements is listed in Table 1
below.
TABLE-US-00001 TABLE 1 Transmission Through Wallboards Conductivity
Through Wallboard Type Wallboard (Volts) Magnet receptive elements
applied in a 0.00 continuous grid pattern Magnet receptive elements
applied in a 4.49 rudimentary disjointed grid pattern with the
width of spaces between two adjacent magnet receptive elements
being 1/4 of the length of a magnet receptive element Magnet
receptive elements applied in a 4.64 rudimentary disjointed grid
pattern with the width of spaces between two adjacent magnet
receptive elements being about 1/2 a magnet receptive element
Control (transmission in a circuit without a 5.16 board)
[0076] As can be seen from Table 1, an electric circuit was created
where a multimeter was detecting a signal of about 5.16 Volts from
a receiver. Various wallboards were placed between a signal
generator and receiver, and the electric voltage in the circuit was
measured again. As can be seen from Table 1, while there was some
interference detected for a wallboard with a rudimentary disjointed
grid pattern (4.64 versus 5.16 and 4.49 versus 5.16), the
significant portion of the voltage (about 70% to 90%) was still
transmitted through these wallboards. In contrast, a magnet
receptive wallboard with a continuous magnet receptive grid has
failed to transmit any signal. It was further noted that the size
of spaces between magnetic receptive elements was important and
grids with larger spaces between magnet receptive elements
transmitted wireless electric signal more efficiently in comparison
to grids with smaller spaces between magnet receptive elements.
Example 2
Comparative Analysis of Magnetic Panels with Connected Grids to
Magnetic Panels with Disjointed Grids
[0077] Magnet receptive panels were prepared with the following 6
grid patterns as shown in FIGS. 7A-7F. In the embodiments of FIGS.
7A through 7D, a magnet receptive element was a metallic tape (1
inch wide, 0.01 inch thick steel shim). This tape was arranged in a
grid with a spacing where the tape was connected at the
intersections. In the embodiment of FIG. 7A, the size of the grid
was 2.times.2 inches. The size of the grid in FIG. 7B was 3.times.3
inches. The size of the grid in FIG. 7C was 4.times.4 inches, and
the size of the grid in FIG. 7D was 5.times.5 inches.
[0078] In the embodiments of FIGS. 7E and 7F, the grid was
disconnected and the magnet receptive tape of FIGS. 7A-7D was
arranged such that the grid spacing was disjointed and the tape was
not connected at the intersections. The size of the grid in
[0079] FIG. 7E was 2.times.2 inches and the size of the grid in
FIG. 7F was 3.times.3 inches.
[0080] All panels were subjected to a test as was described in
Example 1. Each panel was placed between a power source and a
wireless receiver which was connected to a multimeter recoding
voltage from the receiver.
[0081] The wireless receiver is shown in FIGS. 7A-7F as a rectangle
and its position over each of the grids is also shown in each of
the drawings. As can be seen from FIGS. 7A and 7B, the receiver was
overshadowed by the tape. In the embodiment of FIG. 7C, the
receiver overlapped with the tape partially, and in the embodiment
of FIG. 7D, the receiver fitted inside of a space created by the
tape. In the disjointed grid of FIG. 7E, the receiver overlapped
with the tape partially, while in the disjointed grid of FIG. 7F,
the receiver overlapped with the tape almost completely, but for
the intersections in which the tape was not connected.
[0082] In conductivity tests, the receiver was moved away from the
power source to a different distance in the range from 0 mm to 36
mm.
[0083] As can be seen from Table 2, a receiver placed at 0 mm from
a power source over a wallboard with no grid, receives a signal of
5.16 Volts. The signal gradually decreases as the receiver is moved
to the distance of 36 mm from the power source. In contrast to this
control with no grid, a 2.times.2 grid of the embodiment of FIG. 7A
interferes completely with transmission and no current is
transmitted through this panel. The embodiment with a 3.times.3
grid of FIG. 7B still interferes significantly with transmittal.
The embodiments with a 4.times.4 and 5.times.5 grids (FIGS. 7C and
7D) transmit some electricity. The data of Table 2 is plotted as
graphs in FIG. 8A.
TABLE-US-00002 TABLE 2 Wallboards with Connected Grid Spacing 2
.times. 2 grid 3 .times. 3 grid 4 .times. 4 grid 5 .times. 5 grid
No grid (FIG. 7A) (FIG. 7B) (FIG. 7C) (FIG. 7D) Range Percent Range
Percent Range Percent Range Percent Range Percent (mm) Volts of max
(mm) Volts of max (mm) Volts of max (mm) Volts of max (mm) Volts of
max 36 0 0% 40 0 0% 40 0 0% 29 0 0% 36 0 0% 35 4.05 78% 35 0 0% 35
0 0% 28 4.14 80% 35 4.05 78% 34 4.2 81% 30 0 0% 30 0 0% 27 4.36 84%
34 4.2 81% 33 4.39 85% 25 0 0% 25 0 0% 26 4.6 89% 33 4.39 85% 32
4.57 89% 20 0 0% 20 0 0% 25 4.85 94% 32 4.57 89% 31 4.76 92% 15 0
0% 15 0 0% 24 5.1 99% 31 4.76 92% 30 4.96 96% 10 0 0% 10 0 0% 23
5.16 100% 30 4.96 96% 29 5.16 100% 5 0 0% 5 0 0% 22 5.16 100% 29
5.16 100% 0 5.16 100% 0 0 0% 0 0 0% 0 5.16 100% 0 5.16 100%
[0084] As can be seen from Table 3 and unexpectedly, a disjointed
2.times.2 grid of the embodiment of FIG. 7E does interfere with a
current transmission, but still transmits a significant percentage
of the transmission voltage. The embodiment with a disjointed
3.times.3 grid of FIG. 7F also transmits current. The data of Table
3 is plotted as graphs in FIG. 8B.
TABLE-US-00003 TABLE 3 Wallboards with Disjointed Grid Spacing 2
.times. 2 grid 3 .times. 3 grid No grid (FIG. 7F) (FIG. 7F) Percent
Range Percent of Range Percent of Range (mm) Volts of max (mm)
Volts max (mm) Volts max 36 0 0% 35 0 0% 35 0 0% 35 4.05 78% 34
4.14 80% 34 4.14 80% 34 4.2 81% 33 4.32 84% 33 4.3 83% 33 4.39 85%
32 4.52 88% 32 4.49 87% 32 4.57 89% 31 4.72 91% 31 4.67 91% 31 4.76
92% 30 4.93 96% 30 4.86 94% 30 4.96 96% 29 5.4 105% 29 5.06 98% 29
5.16 100% 28 5.16 100% 28 5.16 100% 0 5.16 100% 0 5.16 100% 0 5.16
100%
[0085] The current transmission observed with disjointed grids of
FIGS. 7E and 7F is unexpected. Based on the data obtained with a
continuous grid in the embodiments of FIGS. 7A-7D, a significant
interference is detected for the embodiments in which a receiver
overlaps with magnet receptive elements. Despite this and
surprisingly, the interference can be significantly decreased if
magnet receptive elements are not connected. In comparing FIG. 8A
with FIG. 8B, and Table 2 with Table 3, making a magnet receptive
panel with a disjointed grid pattern unexpectedly decreases
interference. This allows to position more magnet receptive
elements per a square foot of a magnet receptive wallboard and
still obtain a wallboard with only minimum transmission
interference.
* * * * *