Note: Descriptions are shown in the official language in which they were submitted.
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ENHANCED-RIGIDITY MAGNETIC SHEET SYSTEMS
BACKGROUND
This invention relates to providing a system for improved control of
mechanical flexibility in
magnetic sheets and the development of printable coatings for such sheets.
More particularly, this
invention relates to providing coated magnetic sheets with controlled
mechanical flexibility and
rigidity for improved handling during printing and other manufacture
processes. Magnetic sheets
comprising laminated coatings derive increased mechanical rigidity by
interactions with the
laminate. In contrast, thin, fluid-applied coatings contribute minimal
mechanical rigidity to the
magnetic sheet products to which they are applied. Inadequate mechanical
rigidity frequently leads
to poor handling during processes (printing, cutting, tipping, inserting,
etc.) required for the
manufacture of printable/writable magnetic sheet products employing such thin,
fluid-applied
coatings. Hence, there is a need to enhance the mechanical rigidity of
magnetic sheets employing
such thin, writable coatings.
OBJECTS AND FEATURES OF THE INVENTION
A primary object and feature of the present invention is to provide a system
overcoming the
above-mentioned problem.
It is a further object and feature of the present invention to provide such a
system for
providing magnetic sheets with enhanced mechanical rigidity. It is a further
object and feature of
the present invention to provide such a system for providing magnetic sheets
comprising a favorable
balance of rigidity and flexibility for improved handling with commercial
printers, cutting tools, and
other processing equipment required for the manufacture of such magnetic
sheets.
Another object and feature of the present invention is to provide a set of
chemical
formulations for magnetic sheets which provide such a favorable balance of
rigidity and flexibility
to such magnetic sheets. Another object and feature of the present invention
is to provide such a set
of chemical formulations for magnetic sheets comprising a surfactant. Yet
another object and
feature of the present invention is to provide such a set of chemical
formulations for magnetic sheets
comprising at least one stiff binder to provide stiffening properties to such
magnetic sheets.
Yet another object and feature of the present invention is to provide a set of
chemical
formulations for magnetic sheets employing a surfactant to mediate the
interaction between at least
one stiff binder and a magnetizable material present in such magnetic sheets.
Yet another object and
feature of the present invention is to provide a set of chemical formulations
for magnetic sheets
employing a surfactant to enhance the loading-capacity for a magnetizable
material in such magnetic
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sheets. Yet another object and feature of the present invention is to provide
a set of chemical
formulations for magnetic sheets employing at least one surfactant to enhance
the loading-capacity
for stiff binders in such magnetic sheets.
Another object and feature of the present invention is to provide a set of
chemical
formulations for magnetic sheets comprising a flexible binder to provide
flexibility to such magnetic
sheets. Yet another object and feature of the present invention is to provide
a set of chemical
formulations for magnetic sheets comprising an elastomeric binder to provide
elastomeric properties
to such magnetic sheets. Another object and feature of the present invention
is to provide a set of
chemical formulations for magnetic sheets which provide enhanced tear
resistance.
A further primary object and feature of the present invention is to provide
such a system that
is efficient, inexpensive, and handy. Other objects and features of this
invention will become
apparent with reference to the following descriptions.
SUMMARY OF THE INVENTION
In accordance with a preferred embodiment hereof, this invention provides a
system, relating
to providing at least one magnetic sheet, comprising: at least one
magnetizable sheet structured and
arranged to provide at least one permanent magnetic field upon magnetization
by at least one
magnetic-field source; wherein such at least one magnetizable sheet comprises
at least one
magnetizable-material structured and arranged to be magnetized by such at
least one magnetic-field
source; wherein such at least one magnetizable sheet further comprises at
least one binder structured
and arranged to bind such at least one magnetizable-material in such at least
one magnetizable sheet;
wherein such at least one magnetizable sheet further comprises at least one
interfacial-tension-
reducer structured and arranged to reduce the interfacial tension between such
at least one
magnetizable-material and such at least one binder; wherein such at least one
binder comprises at
least one first stiffener structured and arranged to stiffen such at least one
magnetizable sheet;
wherein such at least one magnetizable sheet provides a favorable balance of
stiffness and flexibility
for enhancing the handling of such at least one magnetizable sheet with
commercial printers, cutting
tools, and processing equipment required for the manufacture of such at least
one magnetizable
sheet.
Moreover, it provides such a system wherein such at least one interfacial-
tension-reducer
comprises at least one magnetizable-material-loading-capacity-enhancer
structured and arranged to
enhance the capacity for loading such at least one magnetizable-material in
such at least one
magnetizable sheet. Additionally, it provides such a system wherein such at
least one interfacial-
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tension-reducer further comprises at least one binder-capacity-loading-
enhancer structured and
arranged to enhance the capacity for loading of such at least one binder in
such at least one
magnetizable sheet. Also, it provides such a system wherein such at least one
interfacial-tension-
reducer further comprises at least one disperser structured and arranged to
disperse such at least one
magnetizable-material in such at least one magnetizable sheet. In addition, it
provides such a system
wherein such at least one interfacial-tension-reducer comprises at least one
elongation-enhancer
structured and arranged to enhance the ability to elongate such at least one
magnetizable sheet. In
addition, it provides such a system wherein such at least one interfacial-
tension-reducer comprises at
least one tear-resistance-enhancer structured and arranged to enhance the
ability of said at least one
magnetizable sheet to resist tearing. And, it provides such a system wherein
such at least one
interfacial-tension-reducer comprises at least one polyester resin derived
from soy. Further, it
provides such a system wherein such at least one interfacial-tension-reducer
is selected from the
group consisting of at least one polyester resin derived from soy, stearic
acid, calcium stearate, at
least one abeitic acid ester, at least one rosin ester, at least one terpene
phenolic ester, at least one
styrene-acrylate copolymer, and at least one acrylate copolymer resin.
Even further, it provides such a system wherein such at least one magnetizable
sheet further
comprises: at least one indicia-acceptor structured and arranged to accept at
least one indicia on at
least one surface of such at least one magnetizable sheet; wherein such at
least one indicia-acceptor
is applied to such at least one surface of such at least one magnetizable
sheet. Moreover, it provides
such a system wherein such at least one polyester resin is present from about
one-tenth of a percent
to about ten percent, by weight, in such at least one magnetizable sheet.
Additionally, it provides
such a system wherein such at least one interfacial-tension-reducer is present
from about one-tenth
of a percent to about ten percent, by weight, in such at least one
magnetizable sheet. Also, it
provides such a system wherein such at least one interfacial-tension-reducer
further comprises at
least one adhesion-promoter structured and arranged to promote the adhesion of
such at least one
indicia-acceptor to such at least one surface of such at least one
magnetizable sheet.
In addition, it provides such a system wherein such at least one first
stiffener is selected from
the group consisting of low-density polyethylene, linear low-density
polyethylene, and at least one
mixture of such low-density polyethylene and such linear low-density
polyethylene. And, it
provides such a system wherein such at least one first stiffener is present
from about ten percent to
about forty percent, by weight, in such at least one magnetizable sheet.
Further, it provides such a
system wherein such at least one first stiffener is obtained from post-
manufacture plastic bag waste.
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Even further, it provides such a system wherein such at least one binder
further comprises at least
one second stiffener structured and arranged to stiffen such at least one
magnetizable sheet.
Moreover, it provides such a system wherein such at least one second stiffener
comprises at
least one ethylene vinyl acetate copolymer. Additionally, it provides such a
system wherein such at
least one ethylene vinyl acetate copolymer is present from about twelve to
about twenty-two
percent, by weight, in such at least one magnetizable sheet. Also, it provides
such a system wherein
such at least one binder further comprises at least one elastomeric-binder
structured and arranged to
provide elastomeric properties to such at least one magnetizable sheet. In
addition, it provides such
a system wherein such at least one elastomeric-binder is selected from the
group consisting of at
least one ethylene-octene copolymer, and least one propylene-based elastomer,
and at least one
mixture of such at least one ethylene-octene copolymer and such at least one
propylene-based
elastomer. And, it provides such a system wherein such at least one
elastomeric binder is present
from about eight percent to about thirty percent, by weight, in such at least
one magnetizable sheet.
Further, it provides such a system wherein such at least one binder further
comprises at least
one flexible-binder structured and arranged to provide flexibility to such at
least one magnetizable
sheet. Even further, it provides such a system wherein such at least one
flexible-binder comprises at
least one chlorinated polyethylene elastomer. Even further, it provides such a
system wherein such
at least one chlorinated polyethylene elastomer is present at about forty
percent, by weight, in such
at least one magnetizable sheet. Even further, it provides such a system
wherein such at least one
magnetizable-material comprises at least one ferrite powder selected from the
group consisting of
strontium ferrite and barium ferrite.
In accordance with another preferred embodiment hereof, this invention
provides a system,
relating to providing at least one magnetic sheet, comprising: at least one
magnetizable sheet
structured and arranged to provide at least one permanent magnetic field upon
magnetization by at
least one magnetic-field source; wherein such at least one magnetizable sheet
comprises at least one
magnetizable-material structured and arranged to be magnetized by such at
least one magnetic-field
source; wherein such at least one magnetizable sheet further comprises at
least one binder structured
and arranged to bind such at least one magnetizable-material in such at least
one magnetizable sheet;
wherein such at least one magnetizable sheet further comprises at least one
interfacial-tension-
reducer structured and arranged to reduce the interfacial tension between such
at least one
magnetizable-material and such at least one binder; wherein such at least one
binder comprises at
least one first-stiffener structured and arranged to stiffen such at least one
magnetizable sheet;
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wherein such at least one interfacial-tension-reducer comprises at least one
magnetizable-material-
loading-enhancer structured and arranged to enhance the loading of such at
least one magnetizable-
material in such at least one magnetizable sheet; wherein such at least one
interfactial-tension-
reducer further comprises at least one binder-loading-enhancer structured and
arranged to enhance
the loading of such at least one binder in such at least one magnetizable
sheet; wherein such at least
one interfacial-tension-reducer comprises at least one polyester resin derived
from soy; wherein such
at least one first-stiffener is selected from the group consisting of low-
density polyethylene, linear
low-density polyethylene, and at least one mixture of such low-density
polyethylene and such linear
low-density polyethylene; wherein such at least one first-stiffener is
obtained from post-manufacture
plastic bag waste; wherein such at least one binder further comprises at least
one second stiffener
structured and arranged to stiffen such at least one magnetizable sheet;
wherein such at least one
second stiffener comprises at least one ethylene vinyl acetate copolymer;
wherein such at least one
binder further comprises at least one elastomeric-binder structured and
arranged to provide
elastomeric properties to such at least one magnetizable sheet; wherein such
at least one elastomeric-
binder is selected from the group consisting of at least one ethylene-octene
copolymer, and least one
propylene-based elastomer, and at least one mixture of such at least one
ethylene-octene copolymer
and such at least one propylene-based elastomer; wherein such at least one
binder further comprises
at least one flexible-binder structured and arranged to provide flexibility to
such at least one
magnetizable sheet; wherein such at least one flexible-binder comprises at
least one chlorinated
polyethylene elastomer; wherein such at least one magnetizable-material
comprises at least one
ferrite powder selected from the group consisting of strontium ferrite and
barium ferrite; and
wherein such at least one magnetizable sheet provides a favorable balance of
stiffness and flexibility
for enhancing the handling of such at least one magnetizable sheet with
commercial printers, cutting
tools, and processing equipment required for the manufacture of such at least
one magnetizable
sheet.
In accordance with another preferred embodiment hereof, this invention
provides a system,
relating to providing at least one magnetic sheet, comprising: magnetizable-
sheet means for
providing at least one permanent magnetic field upon magnetization by at least
one magnetic-field
source; wherein such magnetizable-sheet means comprises magnetizable-material
means for being
magnetized by such at least one magnetic-field source; wherein such
magnetizable-sheet means
comprises binder means for binding such magnetizable-material means in such
magnetizable-sheet
means; wherein such magnetizable-sheet means comprises interfacial-tension-
reducer means for
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reducing the interfacial tension between such magnetizable-material means and
such binder means;
wherein such binder means comprises first-stiffener means for stiffening such
magnetizable-sheet
means; wherein such magnetizable-sheet means provides a favorable balance of
stiffness and
flexibility for enhancing the handling of such at least one magnetizable sheet
with commercial
printers, cutting tools, and processing equipment required for the manufacture
of such at least one
magnetizable sheet.
In accordance with another preferred embodiment hereof, this invention
provides a system,
relating to providing at least one magnetic sheet, comprising: at least one
magnetizable sheet
structured and arranged to provide at least one magnetic field upon
magnetization by at least one
magnetic field source, comprising at least one magnetizable material selected
from the group
consisting of barium ferrite and strontium ferrite, from about one-tenth of a
percent to about ten
percent, by weight, of at least one surfactant selected from the group
consisting of at least one
polyester resin derived from soy, stearic acid, calcium stearate, at least one
abeitic acid ester, at least
one rosin ester, at least one terpene phenolic ester, at least one styrene-
acrylate copolymer, and at
least one acrylate copolymer, from about ten percent to about forty percent,
by weight, of at least
one first stiff binder selected from the group consisting of low-density
polyethylene, linear low-
density polyethylene, and at least one mixture of such low-density
polyethylene and such linear low-
density polyethylene, from about twelve percent to about twenty-two percent,
by weight, of at least
one ethylene vinyl acetate copolymer, about forty percent, by weight, of
chlorinated polyethylene
elastomer; from about eight percent to about thirty percent, by weight, of at
least one elastomeric
binder selected from the group consisting of at least one low-density ethylene-
octene copolymer, at
least one low-density propylene elastomer, and at least one mixture of such at
least one low-density
ethylene-octene copolymer and such at least one low-density propylene
elastomer, and wherein such
at least one magnetizable sheet provides a favorable balance of stiffness and
flexibility for
enhancing the handling of such at least one magnetizable sheet with commercial
printers, cutting
tools, and processing equipment required for the manufacture of such at least
one magnetizable
sheet.
In addition, this invention provides every novel feature, element,
combination, step and/or
method suggested by this patent application.
GLOSSARY
The following physical properties, physical parameters, and measurements are
explained
below as background and are used throughout the detailed description.
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Rigidity: the quality or state of being stiff and low in flexibility. In the
detailed description,
the term rigidity is used interchangeably with the term stiffness.
Stiffness: the quality or state of being rigid or firm or not easily bent. In
the detailed
description, the term stiffness is used interchangeably with the term
rigidity.
Elastic: capable of being easily stretched and resuming former shape.
Fold test: measures the ability of a sample to bend before breakage occurs.
Tensile strength: the force required to pull a sample to the point of
breakage, expressed in
pounds per square inch (psi) in the detailed description.
Tensile elongation: the maximum tensile stress which can be sustained by a
sample before
breaking.
Tensile stress: the stress applied to a sample which leads to sample
expansion.
Yield strength (yield point): the tensile stress applied to a sample which
causes noticeable
and significant deformation in the sample, expressed in pounds per square inch
(psi) in the detailed
description.
Tear strength: the resistance of a sample to tear.
Toughness: the ability of a sample to absorb energy and deform plastically
before fracture.
Break stress: the tensile stress applied to a sample at which breakage occurs.
Shore durometer: instrument or measurement which measures a sample's hardness
or
resistance to permanent indentation.
Shore durometer hardness: the hardness of a sample determined by a shore
durometer
measurement.
Elongation at break: the percentage elongation of a sample before breaking,
expressed as a
percentage of the original length.
Elongation at yield: the percentage elongation of a sample at the moment the
tensile yield
strength of the sample is attained.
Modulus of Rigidity: a measure of the stiffness of a material in a torsion
test. This
characteristic reflects the change of strain as a function of applied shear or
torsion stress. The
modulus of rigidity of a sample can be measured by the ratio of tensile yield
strength to elongation
at yield, expressed in pounds per square inch (psi) in the detailed
description.
Peel Adhesion: the force required to peel a laminated coating adhesively
applied to the
surface of a sample, expressed in ounces per inch (oz/in) in the detailed
description.
Viscosity: a property which describes a fluid's resistance to flow.
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Millage: the thickness of a sample expressed in mils.
Residual induction (Br): the magnetic induction remaining in a saturated
magnetizable
material after the magnetizing field has been removed, expressed in Gauss (G)
in the detailed
description.
Coercive force (11r): the demagnetizing force required to reduce observed
magnetic induction
of a magnetizable material to zero after the magnetizable material has been
brought to saturation,
expressed in Oersteds (Oe) in the detailed description.
Intrinsic Coercive Force (11c): indicates the resistance of a magnetizable
material to
demagnetization. It is equal to the demagnetizing force which reduces the
intrinsic induction
(contribution of the magnetizable material to the total magnetic induction) in
the materal to zero
after the magnet has been brought to saturation, expressed in Oersteds (Oe) in
the detailed
description.
Maximum energy product (BHmax): the magnetic field strength at the point of
maximum
energy product of a magnetizable material, expressed in Mega Gauss Oersteds
(MG0e) in the
detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a perspective view, illustrating a controlled-flexibility
magnetic sheet of
controlled-flexibility magnetic sheet systems, according to the preferred
embodiment of the present
invention.
FIG. 2 shows a sectional view, through the section 2-2 of FIG. 1, according to
the preferred
embodiment of FIG. 1.
FIG. 3 shows a diagrammatic view, depicting preferred components of a
magnetizable layer
of the rigid magnetic sheet, according to the preferred embodiment of FIG. 1.
FIG. 4 shows a data graph, illustrating the increase in modulus of rigidity
and tensile strength
in magnetic sheets prepared with increasing weight percentages of first stiff
binder.
DETAILED DESCRIPTION OF THE BEST MODES
AND PREFERRED EMBODIMENTS OF THE INVENTION
FIG. 1 shows controlled-flexibility magnetic sheet 102 of controlled-
flexibility magnetic
sheet systems 100, according to the preferred embodiment of the present
invention. FIG. 2 shows a
sectional view, through the section 2-2 of FIG. 1, according to the preferred
embodiment of FIG. 1.
Controlled-flexibility magnetic sheet 102 (at least embodying herein at least
one magnetizable sheet
structured and arranged to provide at least one permanent magnetic field upon
magnetization by at
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least one magnetic-field source; and, at least embodying herein magnetizable-
sheet means for
providing at least one permanent magnetic field upon magnetization by at least
one magnetic-field
source) preferably comprises a preferred balance of rigidity and flexibility
providing for improved
handling during manufacture processes (see below). Controlled-flexibility
magnetic sheet 102
preferably comprises at least one magnetizable layer 110, as shown.
Magnetizable layer 110
preferably is comprised of at least one of a set of preferred chemical
formulations which preferably
provide a preferred balance of rigidity and flexibility to controlled-
flexibility magnetic sheet 102
(see further details below).
Controlled-flexibility magnetic sheet 102 preferably may further comprise at
least one
indicia-accepting coating 104 (at least embodying herein at least one indicia-
acceptor structured and
arranged to accept at least one indicia on at least one surface of such at
least one magnetizable
sheet), as shown. Indicia-accepting coating 104 preferably is compatible with
one or more printing
processes, enabling controlled-flexibility magnetic sheet 102 to be directly
printed upon in order to
display desired text and/or images. Indicia-accepting coating 104 preferably
comprises a thin fluid-
applied, sprayed-on, or hot-melt coating (in each case preferably non-
laminated) applied to at least
one surface of magnetizable layer 110, as shown (this arrangement at least
herein embodying
wherein such at least one indicia-acceptor is applied to such at least one
surface of such at least one
magnetizable sheet).
Preferred indicia-accepting coatings 104 contribute minimally to the overall
mechanical
strength and rigidity of the final controlled-flexibility sheets 102. Upon
reading this specification,
those with ordinary skill in the art will now appreciate that, under
appropriate circumstances,
considering such issues as design preference, manufacturer preference, cost,
changing needs, future
technologies, etc., other types of coatings such as, for example, laminated
coatings, adhesively-
applied coatings, non-indicia-accepting coatings, plastic coatings, paper
coatings, etc., may suffice.
Preferred indicia-accepting coating 104 include the following characteristics:
1) preferably produces a substantially white printable surface;
2) preferably are offset printable and have the ability to be coated or
receptive to standard
commercial ink lines (such as, for example, HP Indigo, Kodak Nexpress and
Xerox Igen ink
products).
3) must have an opacity, whiteness & gloss similar to or better than standard
laminated papers
with a minimum opacity range of about 93 percent, a brightness range of
between about 88
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percent and about 91 percent, and a gloss range of between about 70 percent
and about 72
percent;
4) must preferably lay flat when exposed to temperature and humidity extremes;
5) must preferably not discolor (yellow) when exposed to Ultraviolet (UV)
light under typical
indoor applications;
6) must preferably provide a clean when cut with a guillotine-type shear or
steel rule die;
7) must resist scuffing and abrasion;
8) must not delaminate when exposed to normal processing, handling, freight,
and end use
conditions;
9) must work with magnetizable layers 110 having a variety of thicknesses; and
10) must preferably possess a material safety rating essentially equivalent to
conventional
laminated materials (such as, low chemical toxicity low heavy metal content,
etc.)
Preferred water-based coatings suitable for use as indicia-accepting coating
104 include
flexo-graphically applied opaque white water-based inks number PIPW1619 from
Printing Ink
Partners of Middletown, Ohio, preferably applied using two passes with a 100-
line anilox roll (LAB
value equaling about 89).
Preferred UV-cured coatings suitable for use as indicia-accepting coating 104
include flexo-
graphically-applied opaque white ink from Flint Group North America (LAB value
equals about
89).
Applicant also developed a preferred proprietary Ethylene-Vinyl-Acetate-based
(EVA-
based) thermoplastic coating (also referred to herein as applicant's hot-melt
coating) suitable for use
as indicia-accepting coating 104 the preferred composition of this preferred
coating is noted in the
following formula (percentages by weight):
1) About 91.5 percent EscoreneTM Ultra AD 2528 (EVA);
2) about 8 percent Titanium Dioxide; and
3) about 0.5 percent at least one chemical surfactant.
The above components of applicant's hot-melt coating are preferably melt mixed
together
using a material mixer. Then, the compound is preferably placed in a hot melt
tank, melted, and
applied onto magnetizable layer 110 with either a slot-die coater or roll
coater. The chemical
surfactant preferably comprises at least one biologically-derived polyester
resin, preferably at least
one polyester resin derived from soy, preferably at least one polyester resin
derived from soy sold
under the trademark BIOREZTM (57-133-C or other grades) preferably supplied
from Advanced
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Image Resources, LLC located in Alpharetta, Georgia. Upon reading this
specification, those with
ordinary skill in the art will now appreciate that, under appropriate
circumstances, considering such
issues as design preference, manufacturer preference, cost, changing needs,
future technologies, etc.,
other composition arrangements such as, for example, alternate percentages of
materials, multiple
surfactants, etc., may suffice.
Magnetizable layer 110 preferably comprises at least one of a set of preferred
chemical
formulations (see below) which preferably provide a combination of a preferred
degree of stiffness
and a preferred degree of flexibility, leading to improvements in the
processing and manufacture of
controlled-flexibility sheets 102. The above described favorable physical
properties of controlled-
flexibility magnetic sheets 102 have been at least partially attributed to the
presence of at least one
surfactant 125 (see FIG. 3) in magnetizable layer 110 (see additional details
below).
Applicant has noted that previous flexible magnetic sheet systems employing
such indicia-
accepting coatings 104 often exhibit inadequate mechanical stiffness leading
to poor handling during
processing steps such as printing and sheet cutting. Controlled-flexibility
magnetic sheets 102
preferably exhibit a preferred degree of rigidity leading to improved ease of
handling with
commercial printers and other processing equipment, such as cutting tools and
extruding devices
(see further details below). The preferred degree of rigidity of controlled-
flexibility magnetic sheets
102 preferably provides improved register during printing. In addition,
controlled-flexibility
magnetic sheets 102 preferably provide a preferred degree of stiffness
allowing for both improved
ease of cutting and for improved ease of feeding into processing equipment.
Furthermore,
controlled-flexibility magnetic sheets 102 preferably comprise a favorable
degree of flexibility
preferably allowing controlled-flexibility magnetic sheets 102 to be rolled
(see FIG. 1), to be
elongated and/or bended to a preferred degree without breaking, and to be
readily applied to curved
surfaces in use.
FIG. 3 shows a diagrammatic view, depicting preferred components of
magnetizable layer
110 of controlled-flexibility magnetic sheet 102, according to the preferred
embodiment of FIG. 1.
FIG. 3 is shown for illustrative purposes only, and does not reflect relative
concentrations or weight
percentages, sizes, actual chemical structures, or actual interactions between
components of
magnetizable layer 110.
Through experimentation, applicant has discovered a set of preferred chemical
formulations
(depicted diagrammatically in FIG. 3) for magnetizable layer 110 which lend
favorable properties
for subsequent printing and processing steps associated with the manufacture
of controlled-
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flexibility magnetic sheets 102. Magnetizable layer 110 preferably comprises
magnetizable material
115, as shown. Magnetizable material 115 (at least herein embodying wherein
such at least one
magnetizable sheet comprises at least one magnetizable-material structured and
arranged to be
magnetized by such at least one magnetic-field source; and, at least herein
embodying wherein such
magnetizable-sheet means comprises magnetizable-material means for being
magnetized by such at
least one magnetic-field source) preferably is capable of providing a
permanent magnetic field to
controlled-flexibility magnetic sheet 102 upon magnetization by a magnetic
field.
In magnetizable layer 110, magnetizable material 115 preferably is suspended
in at least one
polymeric matrix 122, as shown. Polymeric matrix 122 preferably comprises at
least one polymeric
binder 130, preferably at least one plurality of polymeric binders 130, as
shown. Polymeric binders
130 (at least herein embodying wherein such at least one magnetizable sheet
further comprises at
least one binder structured and arranged to bind such at least one
magnetizable-material in such at
least one magnetizable sheet; and, at least herein embodying wherein such
magnetizable-sheet
means comprises binder means for binding such magnetizable-material means in
such magnetizable-
sheet means) preferably are structured and arranged to bind magnetizable
material 115 into
magnetizable layer 110, as shown. Furthermore, each polymeric binder 130 in
magnetizable layer
110 preferably contributes at least one or more favorable physical properties
to controlled-flexibility
magnetic sheet 102 (see further details below).
Polymeric binders 130 preferably comprise at least one stiff binder 132, as
shown. Stiff
binder 132 preferably comprises at least one polymer with crystalline
properties which provides
increased stiffness to controlled-flexibility magnetic sheets 102. Stiff
binder 132 preferably
comprises at least one first stiff binder 135 and at least one second stiff
binder 137, as shown.
Polymeric binders 130 preferably further comprise at least one flexible binder
140 and at least one
elastomeric binder 145, as shown. Polymeric matrix 122 preferably further
comprises at least one
surfactant 125, as shown. Many of the favorable properties reported for
controlled-flexibility
magnetic sheets 102 have been attributed to the presence of surfactant 125 in
magnetizable layer 110
(see further details below). Upon reading this specification, those with
ordinary skill in the art will
now appreciate that, under appropriate circumstances, considering such issues
as design preference,
manufacturer preference, cost, changing needs, future technologies, etc.,
other types of composition
arrangements such as, for example, non-polymeric binders, multiple
surfactants, etc., may suffice.
Applicant has noted that the discovered chemical formulations lead to better
die cutting and
guillotine cut performance in resulting controlled-flexibility magnetic sheets
102. Applicant has
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further noted extended blade lives for cutting tools due to improved cutting
ease of controlled-
flexibility magnetic sheets 102. Applicant has further noted an extension in
the lifetime of
processing equipment when working with controlled-flexibility magnetic sheets
102 comprising the
preferred chemical formulations. Furthermore, applicant has noted that the
discovered chemical
formulations allow for faster mixing, milling, and extrusion during the
manufacture of controlled-
flexibility magnetic sheets 102. Furthermore, applicant has noted the
discovered chemical
formulations allow for mixing, milling, and extrusion at a lower temperature
and pressure and/or
applied torque during the manufacture of controlled-flexibility magnetic
sheets 102. Applicant has
further noted an overall decrease in energy use for the production of
controlled-flexibility magnetic
sheets 102 due to such improved ease of processing. Applicant has further
noted an improvement in
the overall appearance of controlled-flexibility magnetic sheets 102 (less
streakiness) comprising the
preferred set of chemical formulations. In addition, applicant has noted
better processing of thin
sheets (around twelve mil in thickness) of controlled-flexibility magnetic
sheets 102. Within
formulations providing enhanced rigidity, Applicant has further noted an
overall increase in material
stability during multi-pass printing processes, thus improving print
registration.
In the preferred set of chemical formulations for magnetizable layer 110,
magnetizable
material 115 preferably comprises ferrite powder, preferably strontium ferrite
powder (SrFei2019),
alternately preferably barium ferrite powder (BaFei2019). Ferrite powder
preferably is obtained
from Hoosier Magnetics, Inc. located in Ogdensburg, New York (product number
HM 410)
(http://www.hoosiermagneticsinc.com/index.html). Alternately preferably,
ferrite powder is
obtained in recycled powder form from TDK Corporation (http://www.tdk.com/).
Upon reading this
specification, those with ordinary skill in the art will now appreciate that,
under appropriate
circumstances, considering such issues as design preference, manufacturer
preference, cost,
changing needs, future technologies, etc., other magnetizable materials such
as, magnetic materials
containing nickel, magnetic materials containing cobalt, magnetic materials
containing gadolinium,
other ferromagnetic materials, etc., may suffice. It is noted that higher-
grade strontium ferrite and
barium ferrite constituents are preferred for high-energy applications.
Preferred formulations for magnetizable layer 110 preferably further comprise
from about
one-tenth to about ten percent, by weight, surfactant 125. Upon reading this
specification, those
with ordinary skill in the art will now appreciate that, under appropriate
circumstances, considering
such issues as design preference, manufacturer preference, cost, changing
needs, future
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technologies, etc., other weight percentage arrangements such as, for example,
higher weight
percentages, lower weight percentages, etc., may suffice.
Surfactant 125 (at least herein embodying wherein such at least one
magnetizable sheet
further comprises at least one interfacial-tension-reducer structured and
arranged to reduce the
interfacial tension between such at least one magnetizable-material and such
at least one binder; and,
at least herein embodying wherein such magnetizable-sheet means comprises
interfacial-tension-
reducer means for reducing the interfacial tension between such magnetizable-
material means and
such binder means) preferably comprises at least one polar region 150 and at
least one nonpolar
region 155, as shown. This arrangement preferably assists in producing
surfactant properties.
Nonpolar region 155 preferably comprises at least one hydrophobic chain.
Surfactant 125
preferably comprises at least one biologically-derived polyester resin,
preferably at least one
polyester resin derived from soy, preferably at least one polyester resin
derived from soy sold under
the trademark BIOREZTM 15062 preferably supplied from Advanced Image
Resources, LLC located
in Alpharetta, Georgia (http://www.air-toner.com/). BIOREZTM 15062
(hereinafter BIOREZTm
15062 will be referred to as "BioRez") preferably comprises a liquid-glass
transition (Tg) of 57
celcius and an acid value of 9.
Alternately preferably, surfactant 125 preferably comprises stearic acid.
Alternately
preferably, surfactant 125 comprises calcium stearate. Alternately preferably,
surfactant 125
comprises at least one tackifying resin such as at least one abietic acid
ester, at least one rosin ester,
or at least one terpene phenolic resin. Such at least one rosin ester
preferably comprises rosin esters
sold under the trademark Foralt or PentrexTm. Alternately preferably,
surfactant 125 comprises at
least one styrene-acrylate copolymer such as Pliolite AC-L. Alternately
preferably, surfactant 125
preferably comprises at least one acrylate copolymer resin such as Pliolite
LV72. Upon reading
this specification, those with ordinary skill in the art will now appreciate
that, under appropriate
circumstances, considering such issues as design preference, manufacturer
preference, cost,
changing needs, future technologies, etc., other types of surfactants such as,
for example, surfactant
mixtures, detergents, other fatty acids, other amphiphilic compounds, other
surfactants, etc., may
suffice.
Preferred formulations for magnetizable layer 110 preferably further comprise
from about
ten percent to about forty percent, by weight, first stiff binder 135, as
shown. Upon reading this
specification, those with ordinary skill in the art will now appreciate that,
under appropriate
circumstances, considering such issues as design preference, manufacturer
preference, cost,
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changing needs, future technologies, etc., other weight percentage
arrangements such as, for
example, higher weight percentages, lower weight percentages, etc., may
suffice.
First stiff binder 135 (at least herein embodying wherein such at least one
binder comprises
at least one first stiffener structured and arranged to stiffen such at least
one magnetizable sheet;
and, at least herein embodying wherein such binder means comprises first-
stiffener means for
stiffening such magnetizable-sheet means) preferably provides favorable
stiffening properties to
controlled-flexibility magnetic sheets 102 (see further details below). First
stiff binder 135
preferably comprises at least one polyethylene polymer with crystalline
properties, preferably at
least one low-density polyethylene (LDPE), preferably at least one low-density
polyethylene derived
from post-manufacture plastic bag waste. Alternately preferably, first stiff
binder 135 comprises at
least one linear low-density polyethylene (LLDPE), preferably at least one
linear low-density
polyethylene derived from post-manufacture plastic bag waste. Alternately
preferably, first stiff
binder 135 comprises at least one mixture of at least one low-density
polyethylene and at least one
linear low-density polyethylene, preferably at least one mixture of at least
one low-density
polyethylene and at least one linear low-density polyethylene derived from
post-manufacture plastic
bag waste. Such post-manufacture plastic bag waste preferably comprises
plastic bag waste sold
under the trademark Ziploct (see Table 1 though Table 7). Upon reading this
specification, those
with ordinary skill in the art will now appreciate that, under appropriate
circumstances, considering
such issues as design preference, manufacturer preference, cost, changing
needs, future
technologies, etc., other stiffening agents such as, for example, other
stiffening polymeric binders,
stiffening plastics, rubbers, polymeric resins, polymers derived from other
sources, etc., may suffice.
Preferred formulations for magnetizable layer 110 preferably further comprise
from about
twelve percent to about twenty-two percent, by weight, second stiff binder
137, as shown. Upon
reading this specification, those with ordinary skill in the art will now
appreciate that, under
appropriate circumstances, considering such issues as design preference,
manufacturer preference,
cost, changing needs, future technologies, etc., other weight percentage
arrangements such as, for
example, higher weight percentages, lower weight percentages, etc., may
suffice.
Second stiff binder 137 (at least herein embodying wherein such at least one
binder further
comprises at least one second stiffener structured and arranged to stiffen
such at least one
magnetizable sheet) preferably further contributes favorable stiffening
properties to controlled-
flexibility magnetic sheets 102. Furthermore, second stiff binder 137
preferably comprises polar
groups 160 which preferably assist in the adhesion of polar coatings applied
to the surface of
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controlled-flexibility magnetic sheets 102. Second stiff binder 137 preferably
comprises at least one
polymer with crystalline properties, preferably at least one ethylene vinyl
acetate (EVA) copolymer,
preferably at least one film grade ethylene vinyl acetate (EVA) copolymer.
Such at least one film
grade ethylene vinyl acetate (EVA) copolymer preferably is obtained from
Equistar
(http://www.lyondellbasell.com/Aboutus/WorldWideLocations/) and is sold under
the product name
Ultrathenet UE62400. Upon reading this specification, those with ordinary
skill in the art will now
appreciate that, under appropriate circumstances, considering such issues as
design preference,
manufacturer preference, cost, changing needs, future technologies, etc.,
other stiffening agents such
as, for example, other stiffening polymeric binders, stiffening plastics,
rubbers, polymeric resins,
etc., may suffice.
Preferred formulations for magnetizable layer 110 preferably further comprise
about forty
percent, by weight, of at least one flexible binder 140, as shown. Upon
reading this specification,
those with ordinary skill in the art will now appreciate that, under
appropriate circumstances,
considering such issues as design preference, manufacturer preference, cost,
changing needs, future
technologies, etc., other weight percentage arrangements such as, for example,
higher weight
percentages, lower weight percentages, etc., may suffice.
Flexible binder 140 (at least herein embodying wherein such at least one
binder further
comprises at least one flexible-binder structured and arranged to provide
flexibility to such at least
one magnetizable sheet) preferably contributes flexibility to resulting
magnetic sheets 102. In
addition, flexible binder 140 preferably comprises polar groups 165 which
preferably assist in the
adhesion of polar coatings applied to the surface of controlled-flexibility
magnetic sheets 102.
Flexible binder 140 preferably comprises at least one flexible thermoplastic
polymer, preferably at
least one chlorinated polyethylene elastomer (CPE), preferably at least one
chlorinated polyethylene
elastomer (CPE) comprising a chlorine content of about thirty percent. Such at
least one chlorinated
polyethylene elastomer (CPE) preferably is obtained from Alternative Rubber
and Plastics, Inc.
located in Amherst, New York (http://www.altrubber.com/) (product number CM
301). In preferred
formulations for polymeric matrix 122, chlorinated polyethylene elastomer
preferably is present at
about forty percent, by weight (see Table 1 through Table 7). Upon reading
this specification, those
with ordinary skill in the art will now appreciate that, under appropriate
circumstances, considering
such issues as design preference, manufacturer preference, cost, changing
needs, future
technologies, etc., other arrangements such as, for example, other flexible
polymeric binders,
flexible plastics, rubbers, polymeric resins, flexible thermoplastic resins,
etc., may suffice.
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Preferred compositions of polymeric matrix 122 preferably further comprises
from about
eight percent to about thirty percent, by weight, of at least one elastomeric
binder 145, as shown.
Upon reading this specification, those with ordinary skill in the art will now
appreciate that, under
appropriate circumstances, considering such issues as design preference,
manufacturer preference,
cost, changing needs, future technologies, etc., other weight percentage
arrangements such as, for
example, higher weight percentages, lower weight percentages, etc., may
suffice.
Elastomeric binder 145 (at least herein embodying wherein such at least one
binder further
comprises at least one elastomeric-binder structured and arranged to provide
elastomeric properties
to such at least one magnetizable sheet) preferably contributes favorable
elastomeric properties to
controlled-flexibility magnetic sheets 102. Elasotomeric binder 145 preferably
comprises at least
one low-density elastomeric polymer which assists with the loading of
magnetizable material 115 in
magnetizable layer 110. Such at least one low-density elastomeric polymer
preferably comprises at
least one low-density ethylene-octene copolymer, preferably at least one low-
density ethylene-
octene copolymer sold under the trademark ENGAGETM 8200. Alternately
preferably, such at
least one low-density elastomeric polymer preferably comprises at least one
low-density propylene
elastomer, preferably at least one low-density low-density propylene elastomer
sold under the
trademark VistamaxxTM 6102. Alternately preferably, such at least one low-
density elastomeric
polymer preferably comprises at least one mixture of such at least one low-
density ethylene-octene
copolymer sold under the trademark ENGAGETM 8200 and such at least one low-
density propylene
elastomer sold under the trademark VistamaxxTM 6102. ENGAGETM 8200 preferably
is supplied
from Dow chemical company (http://www.dow.com/) with corporate headquarters
in Midland,
Michigan. VistamaxxTM 6102 preferably is obtained from ExxonMobil Chemical
(http://www.exxonmobilchemical.com/Chem-English/default.aspx) located in
Houston, Texas.
Elastomeric binder 145 preferably comprises a density in the range of about
0.86 g/cm3 to about
0.87 g/cm3. Upon reading this specification, those with ordinary skill in the
art will now appreciate
that, under appropriate circumstances, considering such issues as design
preference, manufacturer
preference, cost, changing needs, future technologies, etc., other
arrangements such as, for example,
other elastomeric binders, elastomeric plastics, rubbers, polymeric resins,
elastomeric resins, etc.,
may suffice.
Tables 1 through Tables 7 outline seven examples of chemical formulations for
magnetic
sheets having enhanced rigidity. Tables 1 through Tables 3 present control
formulations (prepared
without surfactant 125). Tables 4 through Tables 7 illustrate examples for
preferred chemical
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formulations for controlled-flexibility magnetic sheets 102 (prepared with
surfactant 125), according
to the preferred embodiment of the present invention.
Table 1: Example 1
Formula MF(S) 1053 R1 (control formulation)
Material Grade Weight (lbs)1
Weight %
CPE Jamplast CPE 130A 15.24
39.08
EVA MI=2,2 VA=18%,2 4.93
12.64
Escorene Ultra LD
7282
ENGAGE 8200 3.59 9.20
Vistamaxx V6102 10.31 26.44
LDPE/LLDPE Ziplockt bag scrap 4.93
12.64
BioRez 13062 0.00 0.00
Total 39.00
100.00
'Formula MF(S) 1053 R1 further contains 300 lbs 410 ferrite powder (Hoosier
grade) and 55 lbs
recycled ferrite powder (TDK grade).2MI = equivalent melt index; VA = vinyl
acetate content.
Table 2: Example 2
Formula BDR027 (control formulation)
Material Grade Weight (lbs)1
Weight %
CPE Jamplast CPE 130A 15.05
39.08
EVA MI=2,2 VA=18%,2 4.87
12.64
Escorene Ultra LD
7282
ENGAGE 8200 3.54 9.20
Vistamaxx V6102 7.35 19.08
LDPE/LLDPE Ziplockt bag scrap 7.70
20.00
BioRez 13062 0.00 0.00
Total 38.50
100.00
'Formula BDR027 further contains 300 lbs ferrite powder (Hoosier grade) and 55
lbs recycled
ferrite powder (TDK grade). 2MI = equivalent melt index; VA = vinyl acetate
content.
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Table 3: Example 3
Formula BDR029 (control formulation)
Material Grade Weight (lbs)1
Weight %
CPE Jamplast CPE 130A 15.24 39.08
EVA MI=2,2 VA=18%,2 4.93 12.64
Escorene Ultra LD 728
ENGAGE 8200 3.23 8.28
Vistamaxx V6102 0.00 0.00
LDPE/LLDPE Ziplock bag scrap 15.60 40.00
BioRez 13062 0.00 0.00
Total 39.00
100.00
'Formula BDR029 further contains 250 lbs 410 ferrite powder (Hoosier grade)
and 110 lbs recycled
ferrite powder (TDK grade). 2MI = equivalent melt index; VA = vinyl acetate
content.
Table 4: Example 4
Formula BDR030 (formulation for controlled-flexibility magnetic sheet 102)
Material Grade Weight (lbs)1
Weight %
CPE Jamplast CPE 130A 14.85 38.08
EVA MI=2,2 VA=18%,2 4.80 12.32
Escorene Ultra LD 728
ENGAGE 8200 3.50 8.96
Vistamaxx V6102 7.25 18.59
LDPE/LLDPE Ziplock bag scrap 7.60 19.49
BioRez 13062 1.00 2.56
Total 39.00
100.00
'Formula BDR030 further contains 250 lbs 410 ferrite powder (Hoosier grade)
and 110 lbs recycled
ferrite powder (TDK grade). 2MI = equivalent melt index; VA = vinyl acetate
content.
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Table 5: Example 5
Formula BDR031 (formulation for controlled-flexibility magnetic sheet 102)
Material Grade Weight (lbs)1
Weight %
CPE Jamplast CPE 130A 14.85 38.57
EVA MI=2,2 VA=18%,2 4.80 12.48
Escorene Ultra LD 728
ENGAGE 8200 3.15 8.17
Vistamaxx V6102 0.00 0.00
LDPE/LLDPE Ziplock bag scrap 15.20 39.48
BioRez 13062 0.50 1.30
Total 38.50
100.00
'Formula BDR031 further contains 300 lbs 410 ferrite powder (Hoosier grade)
and 55 lbs recycled
ferrite powder (TDK grade). 2MI = equivalent melt index; VA = vinyl acetate
content.
Table 6: Example 6
Formula BDR032 (formulation for controlled-flexibility magnetic sheet 102)
Material Grade Weight (lbs)1
Weight %
CPE Jamplast CPE 130A 14.65 38.06
EVA MI=2,2 VA=18%,2 4.74 12.31
Escorene Ultra LD 728
ENGAGE 8200 3.11 8.07
Vistamaxx V6102 0.00 0.00
LDPE/LLDPE Ziplock bag scrap 15.00 38.96
BioRez 13062 1.00 2.60
Total 38.50
100.00
'Formula BDR032 further contains 300 lbs 410 ferrite powder (Hoosier grade)
and 55 lbs recycled
ferrite powder (TDK grade). 2MI = equivalent melt index; VA = vinyl acetate
content.
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Table 7: Example 7
Formula BDR033 (formulation for controlled-flexibility magnetic sheet 102)
Material Grade Weight (lbs)1
Weight %
CPE Jamplast CPE 130A 15.03 38.06
EVA MI =2,2 VA=18%,2 4.86 12.31
Escorene Ultra LD 728
ENGAGE 8200 3.19 8.07
Vistamaxx V6102 0.00 0.00
LDPE/LLDPE Ziplock bag scrap 15.39 38.96
BioRez 13062 1.03 2.60
Total 39.50
100.00
'Formula BDR033 further contains 150 lbs 410 ferrite powder (Hoosier grade)
and 220 lbs recycled
ferrite powder (TDK grade). 2MI = equivalent melt index; VA = vinyl acetate
content.
In the above examples, CPE is chlorinated polyethylene and preferably
comprises flexible
binder 140. EVA is ethylene vinyl acetate and preferably comprises second
stiff binder 137.
ENGAGE comprises an ethylene-octene copolymer which preferably functions as
elastomeric
binder 145. Vistamaxx comprises a propylene elastomer which preferably
functions as elastomeric
binder 145. LDPE/LLDPE is a mixture of low-density polyethylene (LDPE) and
linear low-density
polyethylene (LLDPE) derived from ZiplocTM bag scrap and preferably functions
as first stiff binder
135. BioRez is a polyester resin derived from soy oil and preferably functions
as surfactant 125.
In specific reference to Formula MF(S) 1053 R1 (Table 1, control formulation
prepared
without surfactant 125), the formulation comprises about 39%, by weight,
chlorinated polyethylene
(CPE); about 13%, by weight, ethylene vinyl acetate (EVA); about 9%, by
weight, ENGAGE; about
26%, by weight Vistamaxx; and about 13%, by weight of low-density polyethylene
(LDPE) and
linear low-density polyethylene (LLDPE), as shown.
In specific reference to Formula BDR027 (Table 2, control formulation prepared
without
surfactant 125), the formulation comprises about 39%, by weight, chlorinated
polyethylene (CPE);
about 13%, by weight, ethylene vinyl acetate (EVA); about 9%, by weight,
ENGAGE; about 19%,
by weight, Vistamaxx; and about 20%, by weight, low-density polyethylene
(LDPE) and linear low-
density polyethylene (LLDPE), as shown.
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In specific reference to Formula BDR029 (Table 3, control formulation prepared
without
surfactant 125), the formulation comprises about 39%, by weight, chlorinated
polyethylene (CPE);
about 13%, by weight, ethylene vinyl acetate (EVA); about 8%, by weight,
ENGAGE; and about
40%, by weight, low-density polyethylene (LDPE) and linear low-density
polyethylene (LLDPE), as
shown.
In specific reference to Formula BDR030 for controlled-flexibility magnetic
sheet 102
(Table 4), the preferred formulation comprises about 38%, by weight,
chlorinated polyethylene
(CPE); about 12%, by weight, ethylene vinyl acetate (EVA); about 9%, by
weight, ENGAGE; about
19%, by weight, Vistamaxx; about 19%, by weight, low-density polyethylene
(LDPE) and linear
low-density polyethylene (LLDPE); and about 2.6%, by weight, BioRez
surfactant, as shown.
In specific reference to Formula BDR031 for controlled-flexibility magnetic
sheet 102
(Table 5), the preferred formulation comprises about 39% chlorinated
polyethylene (CPE); about
12%, by weight, ethylene vinyl acetate (EVA); about 8%, by weight, ENGAGE;
about 39%, by
weight, low-density polyethylene (LDPE) and linear low-density polyethylene
(LLDPE); and about
1.3%, by weight, BioRez surfactant, as shown.
In specific reference to Formula BDR032 for controlled-flexibility magnetic
sheet 102
(Table 6), the formulation comprises about 38%, by weight, chlorinated
polyethylene (CPE); about
12%, by weight, ethylene vinyl acetate (EVA); about 8%, by weight, ENGAGE;
about 39%, by
weight, low-density polyethylene (LDPE) and linear low-density polyethylene
(LLDPE); and about
2.6%, by weight, BioRez surfactant, as shown.
In specific reference to Formula BDR033 for controlled-flexibility magnetic
sheet 102
(Table 7), the formulation comprises about 38%, by weight, chlorinated
polyethylene (CPE); about
12%, by weight, ethylene vinyl acetate (EVA); about 8%, by weight, ENGAGE;
about 39%, by
weight, low-density polyethylene (LDPE) and linear low-density polyethylene
(LLDPE); and about
2.6%, by weight, BioRez surfactant, as shown.
Table 8 lists the physical properties of magnetic sheets (control magnetic
sheets) prepared
according to the formulations listed in Table 1 through Table 3. Table 9 lists
the physical properties
of controlled-flexibility magnetic sheets 102 prepared according to the
preferred formulations
provided in Table 4 through Table 7. Table 10 shows the peel adhesion results
(see glossary) for
magnetic sheets (control magnetic sheets) and controlled-flexibility magnetic
sheets 102 prepared
according to the formulations provided in Table 1 through Table 7.
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Table 8: Physical Properties for Magnetic Sheets (Control Sheets)
Formula MF(S) 1053 R1 MF(S) 1053 R1 BDR027
BDR029
Ferrite Powder Lot(s) HSr3 lot 1581,
Hsr3 lot 1589, bag H5r3 lot 1581
(amount) bag 9 (300 lbs) 1 (300 lbs)
bag 9 (250 lbs)
TDK4 (amount) Run 315 bag 10 (55 lbs)
Run 315 bag 10
(55 lbs)
(110 lbs)
Formula/Binder MF(S) 1053 R1 Premix 2(38.5 lbs)
BDR029 (39
(amount) (39 lbs) lbs)
Mixer Blow Out 205 200 205
Temperature
(Fahrenheit)
Mixer Dump 205 260 205
Temperature
(Fahrenheit)
Calender TCUl Top 175; Bottom Top 195; Bottom Top
175;
Settings (Farenheit) 205 225
Bottom 205
Initial
Tensile Strength (psi) 891 822 1088 1644
Elongation at Break 15.1 30.4 12.3 16.9
(%)
Yield Strength (psi) 998 912 1114 1679
Elongation at Yield 9.4 9.9 8.3 12.4
(%)
Modulus of Rigidity 106 134 135
(psi)
24 hr dwell
Tensile Strength (psi) 938 835 917 1436
Elongation at Break 13.7 20.3 9.5 15.8
(%)
Yield Strength (psi) 1058 938 1060 1548
Elongation at Yield 8.7 9.2 7.2 5.5
(%)
Modulus of Rigidity 122 148 284
(psi)
Millage 0.011 0.014 0.011 0.015
Br (G) 1593 1613 1580 1586
H, (Oe) 1091 1061 1051 1052
H,, (Oe) 1791 1671 1720 1761
BHmax (MG0e) 0.49 0.50 0.43 0.48
Relative Density 3.55 3.51 3.54 3.59
(g/cm3)
Shore Durometer 56 60 60 71
Hardness
(Shore A)
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Block (2.00 lbs/ 2 in.) 1.04 0.607
0.100
Flexibility with fold
CD&MD (initial)
Flexibility with fold CD: OK, MD: CD: very slight CD:
OK, MD:
CD&MD (24 hr pinholes pinhole, MD:
cracks
dwell) pinholes and
slight cracking
Flexibility 3/4" Rod CD and MD: OK passes CD/MD CD and MD: OK CD: OK, MD:
CD & MD5 (24 hr cracks (96hr
dwell)
dwell)
1TCU = temperature control units. 2Binders are pre-mixed before adding ferrite
powder. 3Ferrite
powder obtained from Hoosier Magnetics, Inc. territe powder obtained from TDK
Corporation.
5Flexibility test in which the magnetic sheet is bent around a one-quarter
inch diameter cylindrical
rod.
Table 9: Physical Properties for Rigid Magnetic Sheets
Formula BDR030 BDR031 BDR032
BDR033
Ferrite Powder Lot(s) Hsr2 lot 1581 (300 lbs)
(amount) bag 9 (250 lbs)
TDK3 and amount Run 315 bag 10 (55 lbs)
(110 lbs)
Formula/Binder (amount) BDR030 (39 BDR031 (38.5
lbs) lbs)
Mixer Blow Out 205
Temperature (Fahrenheit)
Mixer Dump Temperature 255
(Fahrenheit)
Calender TCU1 Settings Top 175;
(Farenheit) Bottom 205
Initial
Tensile Strength (psi) 1178 13 1090 1289
Elongation and Break (%) 34.3 3.3 16.7 20.5
Yield Strength (psi) 1185 1138 1378
Elongation at Yield (%) 33.7 9.4 14.7
Modulus of Rigidity (psi) 35.2
24 hr dwell (72 hr dwell) (24 hr dwell) (24 hr dwell)
Tensile Strength (psi) 1194 1509 1055 1451
Elongation at Break (%) 25.3 19.1 11.2 26.4
Yield Strength (psi) 1208 1565 1178 1467
Elongation at Yield (%) 8.5 16.0 7.0 26.0
Modulus of Rigidity (psi) 143 107
Millage 0.013 0.015 0.0100
0.014
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Block (2.00 lbs/ 2 in.) 0.628 0.497 0.705 0.416
Br 1500 (G) 1582 1607 1615 1455
II, (Oe) 1047 1048 1058 888.8
lic, (Oe) 1743 1668 1694 1452
BHmax (MG0e) 0.47 0.49 0.49 0.37
Relative Density (g/cm3) 3.58 3.58 3.57 3.57
Shore Durometer Hardness 65 71 61
66
(Shore A)
Flexibility with fold
CD&MD (initial)
Flexibility with fold CD: OK, MD: CD: OK, MD:
CD&MD (24 hr dwell) pinholes cracks (64 hr
dwell)
Flexibility 3/4" Rod CD and MD: CD and MD: Passes CD/MD Passes CD/MD
CD&MD4 (24 hr dwell) OK OK (64 hr and
168 hr dwell)
1TCU = temperature control units. 2Ferrite powder obtained from Hoosier
Magnetics, Inc. 3Ferrite
powder obtained from TDK Corporation. 4Flexibility test in which a magnetic
sheet is bent around
a one-quarter inch diameter cylindrical rod.
Table 10: Peel Adhesion Results for Rigid Magnetic Sheets
Formula Weight Dwell time Peel Adhesion'
95% Confidence
Percent (oz/in)
BioRez
BDR0302 2.6 15 min 21.7 0.2 Same
BDR0272 0.0 15 min 21.4 1.3
BDR0302 2.6 15 min 21.7 0.2 Same
MF(S) 1053 R12 0.0 15 min 20.6 1.0
BDR0302 2.6 96 hr 28.6 1.1 Same
BDR0272 0.0 96 hr 27.6 2.7
BDR0302 2.6 96 hr 28.6 1.1 Same
MF(S) 1053 R12 0.0 96 hr 27.7 1.1
BDR0313 1.3 72 hr 34.6 1.9
Different(24%)
MF(S) 1053 R13 0.0 72 hr 27.9 0.5
BDR0322 2.6 34.3 0.6
Different(2.4%)
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MF(S) 1053 R12 0.0 33.5 0.4
BDR0332 2.6 32.7 1.4 Same
MF(S) 1053 R12 0.0 33.5 0.4
BDR0322 2.6 34.3 0.6
Different(4.9%)
BDR0332 2.6 32.7 1.4
Oven BDR0322'4 2.6 20.8 1.2 Same
Oven MF(S) 1053 0.0 20.3 0.2
R12'4
Oven BDR033 2'4 2.3 24.1 1.6 Different(19%)
Oven MF(S) 1053 0.0 20.3 0.2
R12'4
Oven BDR0322'4 2.6 20.8 1.2 Different(16%)
Oven BDR0332 2.6 24.1 1.6
'See glossary. 2Samples were hand laminated. 3Samples were laminated in
production. 40ven
temperature = 150 degrees Celsius.
Applicant has noted that surfactant 125 allows for a higher loading of
magnetizable material
115 in magnetizable layer 110 (this arrangement at least herein embodying
wherein such at least one
interfacial-tension-reducer comprises at least one magnetizable-material-
loading-capacity-enhancer
structured and arranged to enhance the capacity for loading such at least one
magnetizable-material
in such at least one magnetizable sheet). More particularly, applicant has
noted higher loadings of
strontium ferrite in magnetizable layer 110 in the presence of surfactant 125.
Such higher loadings
of strontium ferrite in the presence of surfactant 125 is indicated by the
increased flexibility of
controlled-flexibility magnetic sheets 102 prepared in the presence of
surfactant 125. In particular,
increased flexibility of controlled-flexibility magnetic sheets 102 is
indicated by higher elongations
of controlled-flexibility magnetic sheets 102 prepared in the presence of
surfactant 125. Applicant
has noted that magnetic sheet flexibility is correlated with the amount of
ferrite powder loaded into
magnetic sheets. Within formulations providing enhanced rigidity, Applicant
has further noted an
overall increase in material stability during multi-pass printing processes,
thus improving print
registration.
Applicant has further noted improved dispersion of magnetizable material 125
in
magnetizable layer 110 in the presence of surfactant 125 (this arrangement at
least herein
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embodying wherein such at least one interfacial-tension-reducer further
comprises at least one
disperser structured and arranged to disperse such at least one magnetizable-
material in such at least
one magnetizable sheet). Applicant proposes surfactant 125 mediates the
interaction between
magnetizable material 115, which is relatively polar, and polymeric binders
130, which comprise
nonpolar properties. Surfactant 125 preferably mediates the interaction
between relatively polar
magnetizable material 115 and relatively nonpolar polymeric binders 130 by
virtue of its dual polar
nature, as best shown in FIG. 3. Surfactant 125 preferably may form at least
one micelle structure
170 around magnetizable material 115, effectively creating a hydrophobic
(nonpolar) layer on its
surface, as shown. This arrangement preferably reduces the interfacial tension
between polar
magnetizable material 115 and nonpolar polymeric binders 130 present in
polymeric matrix 122, as
shown, leading to enhanced loading of magnetizable material 115 in
magnetizable layer 110. In
addition, this arrangement could also enhance the dispersion (decrease
clustering) of magnetizable
material 115 in magnetizable layer 110.
Applicant has further noted increased magnetic pull strengths in controlled-
flexibility
magnetic sheets 102 prepared with surfactant 125. Such increased magnetic pull
strengths in
controlled-flexibility magnetic sheets 102 prepared with surfactant 125
results from the ability to
load more magnetizable material 115 in magnetizable layer 110.
Applicant has further noted enhanced loading of stiff binders 132 in
magnetizable layer 110
in the presence of surfactant 125 (this arrangement at least herein embodying
wherein such at least
one interfacial-tension-reducer further comprises at least one binder-capacity-
loading-enhancer
structured and arranged to enhance the capacity for loading of such at least
one binder in such at
least one magnetizable sheet). Such enhanced loading of stiff binders 132 is
indicated by the
performance of controlled-flexibility magnetic sheets 102 in the flexibility
test in which controlled-
flexibility magnetic sheets 102 are bent around a one-quarter inch diameter
cylindrical rod (see
Table 8 and Table 9). For example, controlled-flexibility magnetic sheets 102
prepared using
formula BDR031, formula BDR032, and formula BDR033 (see Table 5 through Table
7) containing
BioRez surfactant all pass the flexibility test, whereas a magnetic sheet
prepared using control
formula BDR029 (see Table 3) does not (see Table 8 and Table 9). Applicant has
noted that the
performance of magnetic sheets in the flexibility test is correlated with the
degree of loading of stiff
binder 132.
Applicant has proposed that the loading of stiff binders 132 is enhanced by
virtue of reduced
interfacial tension between stiff binders 132 and magnetizable material 115 in
the presence of
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surfactant 125, according to the mechanism described above and illustrated in
FIG. 3. The increased
capacity to load stiff binders 132 in magnetizable layer 110 preferably allows
for the production of
controlled-flexibility magnetic sheets 102 with increased stiffness.
Applicant has further noted that controlled-flexibility magnetic sheets 102
prepared with
surfactant 125 maintain an adequate degree of flexibility, as measured by the
fold test (measures
ability to bend before breakage occurs) and by tensile elongation measurements
(see glossary).
Applicant has also noted an increase elongation in controlled-flexibility
magnetic sheet 102 in the
presence of surfactant 125, as measured by percent elongation at break
elongation at yield (see
glossary). Applicant has further noted that the incorporation of surfactant
125 leads to an increase
in the toughness (ability to absorb energy and deform plastically) and tear
strength (resistance to
tear) in controlled-flexibility magnetic sheets 102 (see glossary).
The increase in toughness of controlled-flexibility magnetic sheets 102
prepared with
surfactant 125 is indicated by higher elongations while maintaining equal or
higher tensile strengths,
when comparing magnetic sheets of approximately the same thickness. As one
illustrative example,
the values for elongation at break and tensile strength for a control magnetic
sheet prepared using
formula BDR029 were 15.8% and 1436 psi, respectively, at 24 hr dwell time (see
Table 8), whereas
the values for elongation at break and tensile strength for a controlled-
flexibility magnetic sheet 102
prepared using formula BDR031 containing 1.3% BioRez surfactant were 19.1% and
1509 psi,
respectively, at 24 hr dwell time (see Table 9). With the exception of BioRez,
the weight
percentages of all other components in formula BDR029 and formula BDR031 are
approximately
equivalent (within 1% variation) (see Table 3 and Table 5), supporting that
the higher elongation
results from the presence of BioRez surfactant in formula BDR031. A second
illustrative example
of improved tear strength associated with the presence of the surfactant is
provided in Table 11.
Applicant has further noted an increase in yield strength (see glossary) in
controlled-flexibility
magnetic sheets 102 prepared with surfactant 125.
In addition, applicant has noted an increase in breakstress (measure of the
amount of stress
required to cause breakage) in controlled-flexibility magnetic sheets 102
prepared with surfactant
125. The increase in breakstress in controlled-flexibility magnetic sheets 102
prepared with
surfactant 125 is indicated by the increase in tensile strength at break for
controlled-flexibility
magnetic sheet 102 prepared using formula BDR030 containing about 2.6% BioRez
surfactant,
compared with a control magnetic sheet prepared using formula BDR027. With the
exception of
BioRez, the weight percentages of all other components in formula BDR027 and
BDR030 are
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approximately equivalent (within 1% variation) (see Table 2 and Table 4),
supporting that the
increase in tensile strength at break results from the presence of BioRez
surfactant in formula
BDR030. Similarly, an increase in tensile strength at break was also observed
for controlled-
flexibility magnetic sheet 102 prepared using formula BDR031 containing 1.3%
BioRez, compared
with a control magnetic sheet prepared using formula BDR029.
In addition, applicant has noted an increase in hardness in controlled-
flexibility magnetic
sheets 102 prepared with surfactant 125. Applicant has noted that the increase
in hardness of
controlled-flexibility magnetic sheets 102 prepared with surfactant 125
relates to the enhanced
capability to load stiff binders 132.
The increase in toughness, tear strength, yield strength, breakstress, and
hardness in
controlled-flexibility magnetic sheets 102 prepared with surfactant 125 may be
due to intrinsic
stiffening properties of surfactant 125, the interaction of surfactant 125
with polymeric binders 130,
and/or the ability of surfactant 125 to enhance the loading of stiff binders
132.
Applicant has further noted that surfactant 125 decreases the viscosity of
formulations for
controlled-flexibility magnetic sheets 102 at the melting temperature of the
magnetic sheet melting,
due to the flow properties of BioRez surfactant compared with stiff binders
132.
Applicant has further noted that the incorporation of surfactant 125 in
controlled-flexibility
magnetic sheets 102 increases the adhesion of polar coatings laminated on the
surface of
magnetizable layer 110 (see Table 10) (this arrangement at least herein
embodying wherein such at
least one interfacial-tension-reducer further comprises at least one adhesion-
promoter structured and
arranged to promote the adhesion of such at least one indicia-acceptor to such
at least one surface of
such at least one magnetizable sheet). As an example, the peel adhesion (see
glossary for definition)
measured for a laminated coating increased from about 28 ounces per inch
(oz/in) for a control
magnetic sheet prepared using formula MF(S) 1053 R1 (see Table 1) to about 35
ounces per inch
(oz/in) for a controlled-flexibility magnetic sheet 102 prepared using formula
BDR031 containing
1.3%, by weight, BioRez surfactant (see Table 5 and Table 10). Applicant
proposes that surfactant
125 enhances the adhesion of coatings by participating in favorable polar
interactions with such
coatings.
Applicant has noted an increase in stiffness in controlled-flexibility
magnetic sheets 102
formed with first stiff binder 135 (see FIG. 4). Applicant has further noted
an increase in tensile
strength (maximum amount of tensile stress which can be applied without
breaking) in controlled-
flexibility magnetic sheets 102 prepared with stiff binder 135 (see FIG. 4).
Applicant has proposed
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that the increase in stiffness and tensile strength results, at least in part,
from the crystalline
properties of the preferred stiff binders 135 low-density polyethylene and
linear low-density
polyethylene, which promotes their self-association in a regular, rigid
packing order in solid
materials, as depicted in FIG. 3.
FIG. 4 shows a data graph, illustrating the increase in modulus of rigidity
and tensile strength
in magnetic sheets prepared with increasing weight percentages of first stiff
binder 135. As shown
in FIG. 4, the values for modulus of rigidity, which reflects the stiffness of
a sample (see glossary),
and the values for tensile strength (see glossary) both increase with
increasing weight percent of first
stiff binder 135 in three magnetic sheets prepared using formula MF(S) 1053 R1
(comprising about
12%, by weight, stiff binder 135 as low-density polyethylene and linear low-
density polyethylene),
formula BDR027 (comprising about 20%, by weight, stiff binder 135 as low-
density polyethylene
and linear low-density polyethylene), and formula BDR029 (about 40%, by
weight, stiff binder 135
low-density polyethylene and linear low-density polyethylene).
Example 8 of table 11 outlines a preferred chemical formulation for a magnetic
sheet having
enhanced tear strength. Applicant noted an association between enhanced tear
strength and the
improved elongation and toughness of controlled-flexibility magnetic sheets
102 containing
surfactant 125 in combination with the below-noted component loadings. Table
12 provides a listing
of physical properties of the resulting tear resistant magnetic sheet formula
of Table 11.
Table 11: Example 8
Formula 1080 (formulation for tear-resistant controlled-flexibility magnetic
sheet 102)
Material Grade Weight (lbs)1
Weight %
CPE Alternative Rubber 17.00 39.56
CPE CM 301
EVA MI =2, VA=18%, 5.30 12.33
Escorene Ultra LD 728
ENGAGE 8200 4.60 10.74
Vistamaxx V6102 11.15 0.00
LDPE/LLDPE Ziplockt bag scrap 3.95 9.16
BioRez 13062 1.00 2.33
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Total 43.00 100.00
'Formula 1080 further contains 200 lbs 410 Strontium Ferrite Powder (Hoosier
sheet grade), 100 lbs
410 Strontium Ferrite (Hoosier extrusion grade), and 55 lbs of TDK.
Table 12: Physical Properties of Tear Resistant Magnetic Sheet ¨ Formula 1080
Formula 1080
24 hr dwell
Tensile Strength (PSI) 804
Elongation at Break (%) 33.9
Yield Strength (PSI) 906
Elongation at Yield (%) 9.9
Modulus of Rigidity (PSI) 92
Millage 0.0105
Preferred formulations of magnetizable layer 110 preferably are prepared by
mixing
magnetizable material 115, preferably in powdered form, with polymeric binders
130 and surfactant
125. Mixing is preferably performed at 290 degrees Fahrenheit (F).
Magnetizable layer 110,
polymeric binders 130, and surfactant 125 preferably are mixed in any order.
The resultant
composition preferably is shaped into a sheet by an extrusion process or a
calendering method.
Magnetizable layer 110 preferably is extruded (or shaped by a calendering
method) to a final
thickness A (see FIG. 1) in the range of between about ten mil (about one-
quarter of a millimeter) to
about twenty mil (about half of a millimeter). Upon reading this
specification, those with ordinary
skill in the art will now appreciate that, under appropriate circumstances,
considering such issues as
design preference, manufacturer preference, cost, changing needs, future
technologies, etc., other
types of magnetic sheet thicknesses such as, for example, thinner magnetic
sheets, thicker magnetic
sheets, etc., may suffice.
Following extrusion (or shaping by a calendering method), indicia-accepting
coating 104
preferably may be sprayed-on or fluid-applied to at least one surface of
magnetizable layer 110, as
shown in FIG. 1. Alternately preferably, an alternative indicia-accepting
coating may be applied by
lamination to at least one surface of magnetizable layer 110. The resulting
controlled-flexibility
magnetic sheet 102 preferably may be subsequently processed by guillotine
cutting and/or printing
on indicia-accepting coating 104 by inserting into a commercial printer.
Magnetizable layer 110
preferably is magnetized by placement in a magnetic field, either before or
after application of
indicia-accepting coating 104, and either before or after any cutting or
printing processes.
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Although applicant has described applicant's preferred embodiments of this
invention, it will
be understood that the broadest scope of this invention includes modifications
such as diverse
shapes, sizes, and materials. Such scope is limited only by the below claims
as read in connection
with the above specification. Further, many other advantages of applicant's
invention will be
apparent to those skilled in the art from the above descriptions and the below
claims.
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