CA2428879A1 - Magnetic substrates, composition and method for making the same - Google Patents

Magnetic substrates, composition and method for making the same Download PDF

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Publication number
CA2428879A1
CA2428879A1 CA002428879A CA2428879A CA2428879A1 CA 2428879 A1 CA2428879 A1 CA 2428879A1 CA 002428879 A CA002428879 A CA 002428879A CA 2428879 A CA2428879 A CA 2428879A CA 2428879 A1 CA2428879 A1 CA 2428879A1
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CA
Canada
Prior art keywords
magnetic
layer
printable
article
thickness
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CA002428879A
Other languages
French (fr)
Other versions
CA2428879C (en
Inventor
Randall Boudouris
Raymond S. Richards
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
MagnetNotes Ltd
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to CA2680699A priority Critical patent/CA2680699C/en
Publication of CA2428879A1 publication Critical patent/CA2428879A1/en
Application granted granted Critical
Publication of CA2428879C publication Critical patent/CA2428879C/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/0027—Thick magnetic films
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • G—PHYSICS
    • G09—EDUCATION; CRYPTOGRAPHY; DISPLAY; ADVERTISING; SEALS
    • G09F—DISPLAYING; ADVERTISING; SIGNS; LABELS OR NAME-PLATES; SEALS
    • G09F7/00—Signs, name or number plates, letters, numerals, or symbols; Panels or boards
    • G09F7/02—Signs, plates, panels or boards using readily-detachable elements bearing or forming symbols
    • G09F7/04—Signs, plates, panels or boards using readily-detachable elements bearing or forming symbols the elements being secured or adapted to be secured by magnetic means
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/14—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for applying magnetic films to substrates
    • H01F41/16—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for applying magnetic films to substrates the magnetic material being applied in the form of particles, e.g. by serigraphy, to form thick magnetic films or precursors therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/20—Properties of the layers or laminate having particular electrical or magnetic properties, e.g. piezoelectric
    • B32B2307/208—Magnetic, paramagnetic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/15—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
    • B32B37/153—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state at least one layer is extruded and immediately laminated while in semi-molten state
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/14—Printing or colouring
    • B32B38/145—Printing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31971—Of carbohydrate
    • Y10T428/31993—Of paper

Abstract

A process of making a magnetic assembly (10, 15) having at least one magnetic layer (14) and at least one printable substrate layer (12) including the steps of providing a magnetic composition comprising about 70 wt-% to about 95 wt-%
of at least one magnetic material and about 5 wt-% to about 30 wt- of at least one thermoplastic binder, forming the magnetic composition into a magnetic layer (14), and directly applying the magnetic composition at an elevated temperature in molten form to a printable substrate layer (12), and to the magnetic composition and any articles made therefrom.

Claims (50)

1. A unitary process of forming a magnetic assembly having at least one magnetic layer having dimensions of thickness, width and length, and at least one printable substrate layer having dimensions of thickness, width and length, comprising the steps of:
a) providing a magnetic hot melt composition at an elevated temperature with an extruder, said magnetic hot melt composition comprising from about 70 wt-% to about 95 wt-% of at least one magnetic material and about 5 wt-% to about 30 wt-% of at least one thermoplastic polymer; and b) directly applying said magnetic hot melt composition with a slot die head at an elevated temperature when it is pliable to a printable substrate layer to form at least one magnetic layer.
2. The process of Claim 1 wherein said applying step b) affixes said magnetic layer to said printable substrate layer in dimensions of thickness and width in final form.
3. The process of Claim 1 wherein said applying step b) affixes said magnetic layer to said printable substrate layer in dimensions of thickness, width and length in final form.
4. The process of Claim 1 further comprising subjecting said magnetic assembly to a strong magnetic field sufficient to result in a permanent magnetic effect in the assembly.
5. The process of Claim 4 wherein the magnetic composition is at an elevated temperature while subjecting said magnetic assembly to said magnetic field.
6. The process of Claim 4 wherein said magnetic composition is at ambient temperature.
7. The process of Claim 4 wherein said magnetizing step is accomplished after said applying step during said forming process.
8. The process of Claim 1 further comprising the step of printing said printable substrate.
9. The process of Claim 1 further comprising the step of forming a continuous web of said magnetic assembly into a roll.
10. The process of Claim 1 wherein said magnetic assembly is formed in sheet form.
11. A process for forming a pad article comprising forming a plurality of magnetic sheet assemblies by the process of Claim 1 and layering the sheet assemblies together to form a stacked pad.
12. The process of Claim 11 wherein said plurality are bound together with an adhesive or shrink wrapped.
13. The process of Claim 1 wherein said temperature of application is from about 135°C to about 190°C.
14. The process of Claim 1 wherein said magnetic hot melt composition comprises about 75 wt-% to about 95 wt-% of the at least one magnetic material.
15. The process of Claim 1 wherein said magnetic hot melt composition comprises about 80 wt-% to about 95 wt-% of the at least one magnetic material and about wt-% to about 20 wt-% of said at least one thermoplastic polymer.
16. The process of Claim 1 wherein said magnetic material has the following general formula:
M2+O6Fe2O3 wherein M represents a divalent metal.
17. The process of Claim 16 wherein said divalent metal is barium, strontium, lead or mixture thereof.
18. The process of Claim 1 wherein the at least one thermoplastic polymer comprises at least one member selected from the group consisting of natural rubbers, block copolymers, polyolefins, polyalphaolefins, polyesters, polyamides, nylons, polyurethanes, copolymers thereof, and mixtures thereof.
19. The process of Claim 1 wherein the at least one thermoplastic polymer comprises at least one polyalphaolefin.
20. The process of Claim 19 wherein said at least one polyalphaolefin is an amorphous polypropylene or an interpolymer of ethylene and at least one alphaolefin.
21. The process of Claim 1 wherein said at least one magnetic material has a particle size of about 40 microns or less.
22. The process of Claim 1 wherein said at least one magnetic layer has a thickness of about 50 µ to about 765 µ.
23. The process of Claim 1 wherein said at least one magnetic layer has a thickness of about 50 µ to about 510 µ.
24. The process of Claim 1 wherein said at least one magnetic layer has a thickness of about 50 µ to about 305 µ.
25. The process of Claim 1 wherein said magnetic composition is applied to said printable substrate in the form of at least one ribbon.
26. The process of Claim 25 further comprising the step of pressing said at least one ribbon to said printable substrate.
27. The process of Claim 25 wherein said at least one ribbon is pressed to said substrate with a chill roll.
28. The process of Claim 25 wherein said at least one ribbon has substantially the same length and width as said printable substrate.
29. The process of Claim 26 wherein said at least one ribbon is discontinuous with said printable substrate.
30. The process of Claim 1 wherein said printable layer comprises paper, metal, fabric, or plastic.
31. The process of Claim 1 wherein said printable layer is further treated with a varnish, lacquer, film or mixture thereof.
32. The process of Claim 1 wherein said magnetic layer is further joined to a release liner.
33. The process of Claim 32 wherein said release liner is adhered to an article through the use of an adhesive.
34. The process of Claim 33 wherein said article is a magazine, book, food package, beverage container, envelope or box.
35. The process of Claim 32 further comprising the step of removing said magnetic assembly from said release liner.
36. The process of Claim 32 wherein said magnetic assembly further has an overlaminate over said printable substrate layer.
37. The process of Claim 32 wherein said overlaminate is perforated in substantially the same dimensions as said magnetic assembly.
38. The process of Claim 1 wherein said magnetic assembly is a reminder, business card, greeting card, postcard, label, advertisement, coupon, calendar, schedule, recipe or promotional card.
39. The process of Claim 1 wherein said at least one magnetic layer is continuous with said printable layer.
40. The process of Claim 1 wherein said at least one magnetic layer is applied to said printable layer in a discontinuous pattern.
41. The process of Claim 1 wherein said at least one magnetic layer and said printable layer are of equivalent length and width.
42. An article which is capable of self-adhering to a magnetic metal surface comprising:
a) a first magnetic layer of a magnetic hot melt composition, the hot melt composition comprising from about 5 wt-% to about 30 wt-% of at least one thermoplastic polymer and about 70 wt-% to about 95 wt-% of at least one magnetic material;
b) a second layer of a printable material;
wherein said first layer and said second layer are directly adhered together by the adhesion provided by the hot melt composition.
43. The article of Claim 42 wherein said article is a reminder, a greeting card, postcard, coupon, label, business card, advertisement, calendar, recipe, schedule, or promotional card.
44. The article of Claim 42 wherein said printable material is paper, plastic or metal.
45. The article of Claim 42 wherein said first layer has a thickness of about 50 µ to about 765 µ.
46. The article of Claim 42 wherein said thermoplastic is an amorphous polypropylene or copolymer thereof, or an interpolymer or ethylene and at least one alphaolefin.
47. The article of claim 42 wherein said first magnetic layer comprises about 5 wt-%
to about 25 wt-% of said at least one thermoplastic polymer and about 75 wt-%
to about 95 wt-% of said at least one magnetic material.
48. The article of claim 42 wherein said first magnetic layer comprises about 8 wt-%
to about 20 wt-% of said at least one thermoplastic polymer and about 80 wt-%
to about 92 wt-% of said at least one magnetic material.
49. The article of claim 42 wherein said first magnetic layer comprises about 5 wt-%
to about 10 wt-% of said at least one thermoplastic polymer and about 85 wt-%
to about 90 wt-% of said at least one magnetic material.
50. A unitary process of forming a magnetic assembly having at least one magnetic layer having dimensions of thickness, width and length, and at least one printable substrate layer having dimensions of thickness, width and length, comprising the step of extruding in final form at an elevated temperature a magnetic composition comprising about 70 wt-% to about 95 wt-% of at least one magnetic material and about 5 wt-% to about 30 wt-% of at least one thermoplastic polymer onto a printable substrate layer with a slot die head.
CA2428879A 2000-11-26 2001-11-21 Magnetic substrates, composition and method for making the same Expired - Lifetime CA2428879C (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA2680699A CA2680699C (en) 2000-11-26 2001-11-21 Magnetic substrates, composition and method for making the same

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US25319100P 2000-11-26 2000-11-26
US60/253,191 2000-11-26
PCT/US2001/043316 WO2002042074A1 (en) 2000-11-26 2001-11-21 Magnetic substrates, composition and method for making the same

Related Child Applications (1)

Application Number Title Priority Date Filing Date
CA2680699A Division CA2680699C (en) 2000-11-26 2001-11-21 Magnetic substrates, composition and method for making the same

Publications (2)

Publication Number Publication Date
CA2428879A1 true CA2428879A1 (en) 2002-05-30
CA2428879C CA2428879C (en) 2012-11-06

Family

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Family Applications (2)

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CA2680699A Expired - Lifetime CA2680699C (en) 2000-11-26 2001-11-21 Magnetic substrates, composition and method for making the same
CA2428879A Expired - Lifetime CA2428879C (en) 2000-11-26 2001-11-21 Magnetic substrates, composition and method for making the same

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Country Status (14)

Country Link
US (3) US7128798B2 (en)
EP (1) EP1360071B1 (en)
JP (1) JP2004513785A (en)
KR (1) KR20030086579A (en)
CN (1) CN100344446C (en)
AT (1) ATE315474T1 (en)
AU (1) AU2002232415A1 (en)
BR (1) BR0115626A (en)
CA (2) CA2680699C (en)
DE (1) DE60116669T2 (en)
ES (1) ES2256324T3 (en)
HK (1) HK1063302A1 (en)
MX (1) MXPA03004575A (en)
WO (1) WO2002042074A1 (en)

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