US20170037629A1

US20170037629A1 - Magnetically attached building composite

Info

Publication number: US20170037629A1
Application number: US15/211,499
Authority: US
Inventors: Sudhanshu Srivastava; Venkatkrishna Raghavendran; Daniel T. McBride; I Tim Scott; LeAnne O. Flack; Jacob J. Smrekar; Kevin Weir
Original assignee: Milliken and Co
Current assignee: Milliken and Co
Priority date: 2015-08-05
Filing date: 2016-07-15
Publication date: 2017-02-09
Also published as: WO2017023668A1

Abstract

A magnetically attached building composite containing at least a first building component and a second building component. The first building component has an upper surface and a lower surface, where the lower surface of the first building component comprises magnetizable or magnetically responsive materials. The second building component has an upper surface and a lower surface, where the upper surface of the second building component is adjacent the lower surface of the first building component, and wherein the upper and lower surfaces of the second building component comprise magnetizable or magnetically responsive materials. At least one of the lower surface of the first building component and the upper surface of the second building component comprise magnetizable materials.

Description

RELATED APPLICATIONS

This application claims priority to co-pending U.S. provisional patent application 62/201,143 filed on Aug. 5, 2015, which is herein incorporated by reference in its entirety.

FIELD OF THE INVENTION

The present invention generally relates to attaching various building components together with the use of magnets.

BACKGROUND

Buildings (both commercial and residential) contain a large number of components that are attached together such as weather barrier systems, insulation, and roofing materials. Currently, these components are typically attached to the building (and other components) by glues, screws, nails and/or staples. These attachment methods are labor intensive, sometimes release VOC (volatile organic compounds), and are not able to be easily removed and reapplied. Thus, there is a need for an attachment means to more easily attach building components to the building structure and other building components.

BRIEF SUMMARY

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates one embodiment of a magnetically attached building composite containing two building components.

FIG. 2 illustrates one embodiment of a magnetically attached building composite containing three building components.

FIG. 3 illustrates one embodiment of a magnetically attached building composite containing four building components.

FIG. 4 illustrates one embodiment of a magnetically attached building composite being a house wrap system.

FIG. 5 illustrates one embodiment of a magnetically attached building composite being a roofing system.

DETAILED DESCRIPTION

Building components may be attached to building and other building components through the use of magnets. This may reduce or eliminate the need for other fixing methods such as adhesive, screws, nails, and staples. The magnetic fastenings will help facilitate installation, reduce labor and decrease the penetrations from nails/staples and other fasteners into the building structure. For example installing roof waterproofing membranes or applying thermal barriers such as insulation boards and batts, will be much easier for laborers to position and install, minimizing the labor, time and materials required to nail, staple and adhere them. Site quality and safety can be enhanced. A further advantage of using magnetic fastening over adhesives is to reduce the release of VOCs. The new way of fastening may allow to create a whole spectrum of design possibilities to the building and infrastructure markets. Building systems are easier to inspect, maintain and replace, with less landfill due to inefficient removal of damaged components and products at the end of their useful life.
Some examples of possible uses of magnetically attached building components include magnetic roof decking (concrete, metal, wood other), flashings for parapets and through-deck intrusions, roof tiles, structural and non-structural building sheathing material, weather barrier systems such as house wraps, window and door tapes and flashings, thermal management systems (such as insulation such as foam boards, rockwool and glass fiber rolls & batts, and reflective thermal barriers, water management for roofs, facades, basements, park decks, bridges and other infrastructure systems, external cladding and siding materials (metal, wood, plastic, gypsum, glass and the like), rigid and flexible solar panel attachments, and roofing membranes (such as TPO, PVC, and EPDM).
Referring now to FIG. 1, there is shown one embodiment of a magnetically attached building composite 10 containing a first building component 100 and a second building component 200. The building components (including the first building component 100, second building component, and additional building components (third, fourth, fifth, etc) may be any suitable building component. The building components may be structural components meaning that they are able to sustain their own weight and typically the weight of other components (such as plywood, I-beams, rafters, and decking) or may be non-structural components such as membranes, films, and fabric layers.
The first building component 100 has a first side 100 a and a second side 100 b. In the case of the first building component being the outermost component in the magnetically attached building composite 10, then the second side 100 b of the first building component forms the outer surface of the magnetically attached building composite 10.
The second building component 200 has a first side 200 a and a second side 200 b. In the case of the second building component being the outermost component in the magnetically attached building composite 10, then the first side 200 a of the second building component forms the outer surface of the magnetically attached building composite 10. In the embodiment of FIG. 1 where there are two building components (100, 200), the second side 100 b of the first building component and the first side 200 a of the second building component form the outer surfaces of the magnetically attached building composite 10.
The building components 100, 200 are oriented such that the first side 100 a of the first building component and the second side 200 b of the second building component are adjacent and facing each other. In some embodiments there may be an additional layer or component between the building components 100, 200. In another embodiment, there are no elements between the building components 100 and 200 are their surfaces (100 a, 200 b) are in physical and intimate contact.
Referring now to FIG. 2, there is shown another embodiment of the magnetically attached building composite 10 having three building components. The first building component 100 has a first side 100 a and a second side 100 b. The second building component 200 has a first side 200 a and a second side 200 b. The third building component 300 has a first side 300 a and a second side 300 b.
In this embodiment, the second surface 100 b of the first building component 100 and the first surface 200 a of the second building component 200 form the outermost surfaces of the composite 10. The third building component 300 is sandwiched between the first building component 100 and the second building component 200.
The building components 100, 200, 300 are oriented such that the first side 100 a of the first building component and the second side 300 b of the third building component are adjacent and facing each other and the first side 300 a of the third building component and the second side 200 b of the second building component are adjacent and facing each other. In some embodiments there may be an additional layer or component between the building components 100, 200, 300. In another embodiment, there are no elements between the building components 100, 200, 300 are their adjacent surfaces are in physical and intimate contact.
Referring now to FIG. 3, there is shown another embodiment of the magnetically attached building composite 10 having four building components. The first building component 100 has a first side 100 a and a second side 100 b. The second building component 200 has a first side 200 a and a second side 200 b. The third building component 300 has a first side 300 a and a second side 300 b. The fourth building component 400 has a first side 400 a and a second side 400 b.
In this embodiment, the second surface 100 b of the first building component 100 and the first surface 200 a of the second building component 200 form the outermost surfaces of the composite 10. The third building component 300 and fourth building component are sandwiched between the first building component 100 and the second building component 200.
The building components 100, 200, 300, 400 are oriented such that the first side 100 a of the first building component and the second side 300 b of the third building component are adjacent and facing each other, the first side 300 a of the third building component and the second side 400 b of the fourth building component are adjacent and facing each other, and the first side 400 a of the fourth building component and the second side 200 b of the second building component are adjacent and facing each other. In some embodiments there may be an additional layer or component between the building components 100, 200, 300, 400. In another embodiment, there are no elements between the building components 100, 200, 300 are their adjacent surfaces are in physical and intimate contact. In other embodiments there may be more than 4 building components stacked together so form the composite 10.
Within each pair of adjacent surfaces within the composite 10, at least one of the surfaces must be magnetizable. In one embodiment, one of the surfaces is magnetizable and the other is magnetically respective. In another embodiment, both of the surfaces are magnetizable. The methods and materials to form the magnetizable and the other is magnetically respective are the same as discussed previously in regards to FIG. 1.
In this application magnetizable is defined to mean the particles present in the coating are permanently magnetized or can be magnetized permanently using external magnets or electromagnets. Once the particles are magnetized, they will keep their magnetic response permanently. The magnetizable behavior for generating permanent magnetism falls broadly under ferromagnets and ferrimagnets. Barium ferrites, strontium ferrites, neodymium and other rare earth metal based alloys are some of the examples that can be applied in the coatings.
In this application magnetically responsive is defined to mean the particles present in the coating are only magnetically responsive in the presence of external magnets. Once the magnetic field is removed from the vicinity, the particles will become non-magnetic. The magnetically responsive behavior or responsive magnetic behavior falls broadly under paramagnets or superparamagnets (particle size less than 50 nm). Iron oxide, steel, iron, nickel, aluminum or their alloys that are not included in ferromagnets are some of the examples that can be applied in the coatings.
The surface of the components may be magnetically responsive or magnetizable in any suitable manner. In one embodiment, surface is made to be magnetically responsive or magnetizable by applying a magnetically responsive or magnetizable coating on the surface. In another embodiment, surface is made to be magnetically responsive or magnetizable by materials within the component (preferably located near or close to the surface of the component).
Barium ferrites, strontium ferrites, neodymium and other rare earth metal based alloys can be mixed with the appropriate binder to be coated on the substrate. There are 2 ways the surface can be permanently magnetized after the curing or during the curing.
Process 1: After the coating method, the magnetizable particles loaded in the film are cured with the appropriate binder and composition. Then the permanent magnets can be rolled over the surface coated with the film 1 to 10 times as required by the inline manufacturing. Depending upon the pole size, strength and domains on the permanent magnet or electromagnet can magnetize the magnetizable coating to a value between 10 and 5000 gauss or a value close to the maximum gauss value of the magnetizing medium. Once the film is magnetized, it will remain permanently magnetized.
Process 2: During the cure, the magnetizable particles are mixed with the appropriate binder and applied via coating technique on the substrate to be magnetized. Once the coating is complete, the particles are magnetized in the presence of external magnets during the curing process. The coating will be put in a magnetic field to align the magnetic poles and hold the dipoles in place in the presence of the magnetic field until the binder is cured.
The surface(s) of the components (100, 200, 300, 400, etc) may be made to be magnetic in any suitable method. In one embodiment, the magnetic material is applied to a surface as a coating. In another embodiment, the magnetic material is applied as a separate film that is adhered to the surface of the component. In another embodiment, the magnetic material is integral (meaning that it is formed as part of the component and not added after the component is formed). Some preferred coating methods include knife coating, padding, painting, spraying, roll-on-roll, troweling, extrusion, foam coating, pattern coating, printing, and lamination. The magnetic particles may also be extruded with the component.
In one embodiment, the magnetic material is applied as an approximately uniform coating having approximately the same thickness, magnetic strength, and/or composition across the surface of the component. In another embodiment, the magnetic material can vary across the surface(s) of the components. The magnetic material may be in a gradient or pattern. These patterns may help with alignment of one component relative to its adjacent components.
Any type of magnetizable particles can be used, including but are limited to: BaFe₃O₄, SrFe₃O₄, NdFeB, AlNiCo, CoSm and other rare earth metal based alloys. Any type of magnetically responsive particles can be used, including but are limited to: Fe₂O₃, Fe₃O₄, steel, iron particles etc (Para or Superpara). In one embodiment, the particle size of the magnetic particles is between 10 nm to 50 nm (super paramagnets) or 100 nm and larger (paramagnets or Ferro magnets). Magnetic behavior is shown at any loading of the above materials, the response increases as the loading increases. A range 25% to 95% by weight is preferred for most practical usages.
The magnetic particles may be any suitable binder system, including but not limited to urethanes, acrylates, silicones, thermosets (rubber and others), thermoplastics and other textile binders. In some embodiments not requiring flexibility, inorganic binders like cement and geopolymers can also be used.
In one embodiment shown in FIG. 4, there is shown a magnetically attached building composite 10 being a house with house wrap composite 2000. In this embodiment, the substructure of the house (typically a plywood) would be the first building component 100 and the house wrap (typically a fabric) would be the second building component 200. In this embodiment, the outer facing surface of the first building component 100 (100 a using previous terminology) would be magnetizable and the inner facing surface of second building component 200 (200 b using previous terminology) would be magnetically respective. Preferably, these magnetic surfaces would be achieved thorough coatings or adhering a magnetic film/layer to the surface of the components 100, 200.
In one embodiment shown in FIG. 5, there is shown a magnetically attached building composite 10 being a roofing system 3000. In this embodiment, the substructure of the house (typically a plywood) would be the first building component 100, an insulation layer 300 would be the third building component, and the roofing tiles would be the second building component 200. In this embodiment, preferably the outer facing surface of the first building component 100 (100 a using previous terminology) would be magnetizable and the inner facing surface of second building component 200 (200 b using previous terminology) would be magnetically respective. Preferably, these magnetic surfaces would be achieved thorough coatings or adhering a magnetic film/layer to the surface of the components 100, 200.
In one embodiment, the magnetically attached building composite may be used in a weather barrier or water drainage system. Weather barrier and water drainage systems protect structures from wind-driven rain, manage and control moisture through the building or envelope and drain excess water away from the structure. Such weather barrier systems include roofing underlayments; roofing felt paper, polymeric or synthetic roofing fabrics, self-adhering ice and water shield tapes, façade protection systems such as housewraps and self-adhered synthetic tapes window and door flashing tapes. Water drainage systems include basement drainage products, such as and mechanically fixed or loose fitting dimpled polymeric membranes, drainage mats or grooved, sometimes fleece-lined rigid-foam boards.
Weather barrier systems are typically supplied in 3-10′ rolls or 6-12′ tape forms. Housewraps are typically polymeric (eg. polyethylene or polypropylene) spun, non-woven, or perforated and coated woven-tape textile structures, or felt impregnated building paper. They are designed to prevent rot and mold inside walls by controlling moisture through the structure and improving thermal efficiency through air flow control.
Housewraps and felt building paper are typically installed by 2 contractors. Starting in the bottom corner, the housewrap is rolled out horizontally in relatively short lengths and fixed with plastic-capped staples or nails, typically between 12-18 inch spacing's, horizontally and vertically and a minimum of 9″ from headers and openings. 6-12″ vertical and horizontal overlaps are also fixed preferably with 1″ plastic-capped staples and the taped with 2-3″ pressure sensitive contractors adhesive tape. Window and door openings are cut out using a sharp knife, trimmed, stapled and finally taped into the intrusions to provide protection and drainage of sills and jambs.
The application of magnetic coatings may allow for a single contractor to place and position the fabric easily against a substrate (particularly in high wind scenarios).
Fixings and intrusions can be significantly reduced or eliminated. Improper use of mechanical fixings can cause creases and folds (sometimes termed “fishmouth”) which can act as drainage paths for water towards the interior of the structure. Using magnetic coatings, creases are more easily smoothed out with hand pressure. Furthermore, the fabric may be more easily removed and repositioned to ensure straightness and square, not easily done if mechanically fixed or with peel and stick pressure sensitive adhesives. Magnetic coatings may eliminate or reduce the practice of leaning on ladders with heavy staple guns to attach fixings, which is a safety hazard. The reduction, even elimination of mechanical fixings removes undesirable penetrations into the air and water barrier system, improving barrier performance and energy efficiency. A secondary job of taping the overlap joints may even be eliminated.
Roofing underlayments are made of similar materials to housewrap products or modified thermoplastic copolymers. They are typically designed for residential roofs with a pitch >2:12 to 4:12 and used and fixed in a similar way to housewraps, stapled, nailed or self-adhered. The fabric is staples at 4-8″ OC depending on wind speeds. The typically 48″ wide rolls are installed horizontally in “shingle style” fashion with 4″ course overlaps and 6″ end laps beginning along the eave edge. End laps are offset in successive courses by 6 feet. For roof valleys, a polymer-backed self-adhered tape often 6-12″ wide is adhered over the roofing underlayment for additional sealing and protection.
In all these cases, the use installation recommendations with regards to the number, distances and type of staples or nails used is sometimes abused. Often too many are used, adding to the number of undesirable penetrations into the protective water barrier layer that can contribute to roof leaks. Sometimes insufficient fixings are used, leading to ripping away of the fabric or felt paper in high wind situations.
With magnetic coatings, fixings and intrusions can be significantly reduced or eliminated. Roofing underlayment is easier to position and apply, particularly in high wind scenarios. Some manufacturers are marketing primers to promote adhesion between self-adhered weather barriers and substrates, mainly for cold weather applications. These need a clean dry deck, are difficult to apply in cold weather <45 degrees F., difficult to reposition and may blister in the heat. Magnetic coatings eliminates these challenges.
In another embodiment, the magnetically attached building composite may be used in window and door tapes. Window and door tapes typically are a self-adhering “peel and stick” roll-goods, generally 4-12″ wide. A typical tape construction is a plastic facer; often polyethylene, polypropylene and metalized films, coated with an asphalt, butyl, acrylic, polyurethane or other pressure-sensitive adhesive and covered with a polymeric or paper release lining. To install the product, the tape is cut 12 inches longer than width of sill rough opening. The self-adhering tape is applied to the lower horizontal sill or door jamb is by aligning the edge with the inside edge of sill. Taped are adhered to the rough opening across sill and up jambs a minimum of 6 inches. In some cases, the edges may be mechanically fastened at the corners. 6-12″ inch wide strips the self-adhering tape are then applied to the window and door jambs. A spray-apply primer may be applied to the top 6 inches of jambs and exposed sheathing. The self-adhering tape is now attached at opening head using same installation procedures used at sill, overlapping the jamb flashing a minimum of 2 inches. After positioning the weather barrier head flap across head flashing, construction tape or a 4-inch wide section of self-adhering tape is applied over the 45-degree seams to complete the air barrier.
Magnetic coatings may help to speed this flashing process. Peeling of backing paper is eliminated. The need for special primers to adhere to the substrate is eliminated. The tape may be applied in all weather and temperatures. Creases (“fishmouth”) during installation is reduced or eliminated. Repositioning is facilitated.
In another embodiment, the magnetically attached building composite may be used in a basement water drainage system. Basement and foundation water drainage products protect the thin, water proofing membrane from damage, protects basement insulation from damage and minimizes insulation water absorption over time, critical in maintaining its insulation properties. These thick, robust plastic sheets, often made from Polyethylene, polypropylene or other plastics and sometimes dimpled, grooved or textured in order to drain external ground water away from the structure and keep earth, rocks and water pressure away from the structure. They typically come in roll or sheet form, often 3-13′ wide. The water drainage system is typically set to a height 3-6″ above the grade and is fixed using 1-2″ plastic capped nails applied in a zig-zag fashion at 6″ OC to 16″ OC, depending on the construction, through the water proofing membrane and into the structure. When protecting an external insulation layer, longer nails are used. Sealing tars, rows of drainage plugs, capping materials and moldings are often used to complete the water draining system at joints and overlaps. These plastic drainage systems can also be applied to the interior of the basement, particularly to fix basement leaks in existing basements, to drain water away from the basement interior.
Magnetic coatings may increase speed of installation. The layer can be easily positioned and can be re-positioned. Mechanical fixings are reduced or eliminated, reducing undesirable penetrations and cost. Creases (“fishmouth”) are reduced or eliminated. Capping materials and moldings are easily applied with minimal or no mechanical fixings.
Another basement and foundation drainage system uses rigid boards, often insulation boards. Typically, these are foam boards because they are water resistant, but fiberglass polyester fiber and other fibrous insulation boards are used. These rigid insulation boards are sometimes grooved to allow water to drain down its surface and away from the structure. They are typically fixed using suitable adhesives or plastic capped nails, through the thin water proofing membrane and into the structure. Sometimes they are temporary fixed and require the soils to keep them permanently in place. J or Z flashing strips are often applied to the top edge to prevent debris and soils from getting behind the board.
Magnetic coatings on the components may allow for a simple, quick and efficient application of insulated or non-insulated drainage boards. Positioning and repositioning is easy and the boards will stay in place in high wind situations without the application of adhesives and/or undesirable mechanical fixings.
The magnetically attached building composite may also be used for internal basement walls which are often insulated to condition the space for living purposes, increase energy efficiency and to prevent pipes freezing.
Typically, wood framing is attached to the structure and filled with rolled batt insulation such as fiberglass R11, R13, R19 and R30 Insulation Kraft Faced Batts 16 or 23 in.×48 or 93″). Typically, 1-3″ rigid foam insulation boards can also be fitted into the framing structure. Gypsum board is screwed to the wood framing to cover the insulation and leave an interior surface finish for painting. Another time-saving method of Insulating basement walls with rigid foam board is to bond the board securely to the substrate such as a concrete or masonry block wall, using a structural adhesive. Another method for fixing rigid insulation board requires no adhesive because the insulation boards have slots in the long edges designed to receive 1″×3″ (2.5 cm×7.6 cm) wood furring strips. Or, a 2″×3″ (5 cm×7.6 cm) furring strip can be used to provide an air space behind drywall for installation of electrical wiring.
Magnetic coatings may simplify the insulation process and reduce costs. Positioning and repositioning of the boards is easy and boards can be quickly remove for inspection, maintenance and upgrades. The ability to coat multiple surfaces allows for the foam to be fixed to the substrate and exterior gypsum board to be fixed to the foam with fewer or no mechanical fixings. The elimination of adhesives means no curing time and no additional VOC's.
In another embodiment, the magnetically attached building composite may be used in a roofing shingle system. Shingles are typically made from wood, stone, fiberglass, metal, plastic and in the US, often paper and glass fiber-reinforced asphalt. Asphalt shingles are supplied in 10×10 ft. squares, on pallets. Each shingle strip is a tab, typically 3 shingles across. The tabs are laid in courses usually with each shingle offset from its neighbors. The first course is the starter course and the last being a ridge course or ridge slates for a slate roof. The ridge is often being covered with a ridge cap, board, piece, or roll sometimes with a special ridge vent material. Typically, 4 nails are used per shingle and 6 nails on the prevailing windward sides of the roof, as wind resistance nailing. Some local codes require the 6 nails on all sides. Typical fasteners include zinc coated steel or aluminum nails, 10-12 gauge barbed or smooth shank, ⅜′- 7/16″ heads, driven straight and flush through the shingle, underlayment and roofing deck.
Roof valleys are extra sensitive to wind, water flow and ice/snow build up and are typically applied during the shingle installation process using either a woven, open valley or closed-cut valley methods, depending on shingle type and thickness. Typically, valley shingles lie over a self-adhered, polymeric or felt paper roofing underlayment.
Magnetic coatings between the components of a roofing shingle system may increase the speed of applying roofing shingles. The coatings allows positioning and repositioning of tiles and anchors the tiles at the overlap. Undesirable mechanical fixings are reduced or eliminated, reducing water ingress, saving time, costs and minimizing installation errors
In another embodiment, the magnetically attached building composite may be used in a low slope roofing system. Low slope roofing systems, (typically having slopes of less than 2:12) such as flat roofs, car park decks etc, have little slope for water drainage and pose special problems due to pooling water. 1 meter wide membranes and/or self-adhering base sheets, are fixed to the low slope deck are finished with a tough, weather resilient cap sheet.
Self-adhering products must be installed on a clean, dry deck, in temperatures above 45 degrees F. Self-adhering sheets have a backer sheet. To install the membrane, the sheet is folded back on itself to expose the backing release liner. The release liner is split and the exposed liner is peeled away exposing the adhesive. The adhesive layer is pressed firmly onto the deck or mechanically-fixed base layer (if there is one). The remaining section is now rolled back and the remaining adhesive layer pressed firmly to the substrate. Finally, the whole area is rolled to apply pressure and expel any remaining air pockets that could cause blisters.
Mechanically fixed base sheets are polymeric-coated textiles. The base sheet is nailed, using metal or plastic-capped nails, into the deck, or adhered to the deck. The cap sheet is applied starting from the bottom of the roof slope and then shingled across the roof, overlapping 6″ and ensuring that joints do not overlap with the base sheet. Metal or plastic drip edges are adhered and then mechanically fixed to finish the roofing system at the roof terminations. Typically, the leading edge of fasteners are 1-2″ from the edge and 9″ OC. The next row of fasteners are typically 14″ from the leading edge and 18″ OC. The third row of fasteners are 26″ from the leading edge and 18″ OC. Second and third row fasteners are staggered to minimize wind uplift. Finally, a self-adhering cap sheet can be installed using similar methods to the previous self-adhering membrane, ensuring a good bond between the salvage edge and the adjacent membrane strip and taking care to add additional sealants, such as SBS adhesives, at top edge and T-joints, to prevent water ingress and blisters.
At parapets, flashings are nailed at the top and counter flashed. Magnetic coatings may simplify the process of installing roofing membranes in low-slope roofing applications by having magnetic surfaces between the different components. Positioning and repositioning of large membrane sheets is easy and minimizes the potential for air or moisture entrapment and associated blisters. Post inspection and maintenance is simplified. Undesirable mechanical fixings which cause intrusions for potential water damage, are minimized or eliminated. Associated costs are reduced and installation quality is improved. The need to have a clean, dry deck for installing self-adhered roofing is eliminate. Magnetic coating products can be installed in all weathers and temperatures. Multi-layer magnetic coating more easily facilitates the application of various layers on top of each other. Finishes such as parapet flashings are easy to overlap and fix to existing magnetic layers.
In another embodiment, the magnetically attached building composite may be used in a siding and wall cladding system. Siding and wall cladding is the exterior material applied to the walls of a house or other building meant to shed water, protect the walls from the effects of weather, insulate, and is a key in the aesthetics of the structure. Siding may be made of wood, metal, plastic (vinyl), masonry, or composite materials. Siding may be formed of horizontal or vertical boards, shingles, or sheet materials. It may be attached directly to the building structure (wood or metal studs), or to an intermediate layer of structural sheathing material, typically wood (fiber boards, plywood, oriented strand board). Fiber Cement board is typically installed over plywood, OSB, or comparable sheathing. Sidings materials can be installed over braced wood or steel studs in accordance with local building codes.
Siding materials typically cover an intermediate air and moisture barrier such as housewrap or building felt paper. Fiber cement siding panels must be nailed into structural framing or structural; sheathing. Typical fixings include nails or screws. Fixings are commonly applied using a pneumatic nail gun designed for siding applications is it is faster than hand nailing. Collated and uncollated screw guns are also used to apply fixings. Nails must penetrate a minimum of 1¼″ into the structural framing. The siding and the trim is caulked. Fixings should be a minimum of ⅜″ from the board edges and corners.
Subsequent courses are overlapped and butt end/joints are staggered to avoid noticeable patterns. Shapes siding, such as shingle siding, is installed in similar ways to lap siding, but care is required to ensure a random look and correct distance between subsequent layers.
Magnetic coatings may speed the installation by reducing or eliminating fixings and thereby improve the quality of siding installation. Boards can be easily positioned and repositioned and removed for inspection. Mechanical fixing can cause stress points that can lead to cracking and undesirable waves in the façade, which is eliminated with magnetic coatings. The ability to magnetically coat multiple layers allows fixing of overlapping layers.
In another embodiment, the magnetically attached building composite may be used in a vinyl siding or shakes system. Vinyl siding and shakes are typically provided in sections 10′ to 16′8″ and 32″-4′, widths typically 4′-18″ and various thicknesses depending on the supplier, eg. 0.044-0.125″. They typically project ¾″ and 1¼″ for insulated variants. Some variants have built-in insulation to add thermal efficiency to the home and impact resistance to the façade. All fasteners must be able to penetrate a minimum of ¾″ (19 mm) into framing or furring and typically the fasteners are nails or screws. If staples are being used instead of nails or screws, they are typically not be less than 16-gauge and semi-flattened to an elliptical cross-section. They must penetrate not less than ¾″ (19 mm) into framing or furring and be wide enough in the crown to allow free movement of the siding (approximately 1/32″ [0.8 mm] away from the nailing hem.
Typically, the first course (row of panels) are placed in the starter strip and securely locked along the entire length of the siding panel before fastening. Panels are fastened in the center of the nailing slots, allowing ¼″ (6.4 mm) gap between the siding and all corner posts and channels for expansion. Panels typically overlap by one half the length of the notch at the end of the panel, or approximately 1″. Siding section end-laps are staggered so that no two courses (rows of panels) are aligned vertically, unless separated by at least three courses.
Magnetic coatings simplify the application and installation quality of vinyl and other plastic siding. Positioning and repositioning of the siding is facilitated whilst post-inspection and maintenance of the building envelope is easier. The requirement for fixings is reduced or eliminated. The ability to magnetically coat multiple layers allows fixing of overlapping layers
In another embodiment, the magnetically attached building composite may be used in an insulated siding system. Upgrading the insulation on an external wall is a cost-effective means of improving energy efficiency in buildings.
For exterior wall insulation and re-siding, plastic cap nails with minimum ½″ (1.3 cm) diameter washers are used to fasten insulation boards tightly to the wall. The nails penetrate the studs by 1″ (2.5 cm), either directly or through old siding. Nails can be spaced 6″ (15 cm) along the perimeter of the board and 12″×16″ (30 cm×41 cm) in the field. The rigid insulation boards are butted tightly at the edges and installed in a staggered pattern.
Magnetic coating allows quick and easy installation of rigid insulation boards, particularly in windy conditions. Positioning and repositioning of the boards is simplified and allows easy inspection and maintenance. The requirement for mechanical fixings is reduced or eliminated. The need for structural adhesives is eliminated.
In another embodiment, the magnetically attached building composite may be used in an attic insulation system. Attic insulation in walls and cathedral ceilings, can turn a hot roof space into a conditioned space and even an extra living space. This can significantly improve a home's energy efficiency.
Typically, batt insulation is placed between the rafters without compacting the batts or blocking the air channel. Often, 1-2″ thick rigid foam Insulation is adhered, or mechanically fixed using screws or plastic capped nails. To the rafters in order to cover the entire inside rafter surface. Gypsum board (drywall) is applied to cover the insulation and rafters to deliver a clean finish, using 3″ (7.6 cm) drywall screws to penetrate the insulation boards and 1″ (2.5 cm) into the rafters.
Magnetic coatings allow the fast installation of rigid insulation and gypsum boards with minimum or no fasteners. Adhesive materials used to bond the materials to the substrate are eliminated along with associated VOC's and long curing times. Boards can be positioned and re-positioned more easily and simple removed for inspection and maintenance.
In another embodiment, the magnetically attached building composite may be used in an insulated crawl space system. Insulating crawl spaces improves a buildings energy efficiency, conditions the space, minimizing moisture and related rot, mold and mildew issues, and prevents freezing of water pipes.
The entire underside of the floor and sometimes, the internal basement walls areas, are covered typically with 2″ (5 cm) thick rigid insulation boards. The boards are staggered and fixed perpendicular to the joists with mechanical fixings (screws or plastic-capped nails) or with adhesives. ½″ (1.3 cm) layer of drywall over the insulation boards may be installed for fire protection. A dirt base may be covered with a 6 mil polyethylene sheets to prevent moisture from entering the space.
Using magnetic coatings, the rigid foam boards and heavy gypsum boards are easily positioned, repositioned and removed for easy inspection and maintenance. The requirement to apply mechanical fixings with heavy mechanical tools is eliminated. The process of applying adhesives is eliminated along with associated cure times and production of VOC's in and enclosed space.
In another embodiment, the magnetically attached building composite is a single ply roofing system. This embodiment would correspond to 3 or 4 components (FIGS. 2 and 3). The first component 100 would be the structural deck—(also called the roof deck) which can be any suitable material such as steel, wood, concrete, or gypsum board. The purpose of the roof deck is to provide a consistent level support for the other roofing materials, provide vertical support to the other layers of the roof, and/or to be a horizontal diaphragm to transfer horizontal shear loads. The next layer (component 300) would be insulation. The insulation layer can be any suitable insulation including polyiso foam, polystyrene, fiberboard, gypsum, and polyiso coverboards, wood fiber board, perlite board, cellular glass or a combination of the above. The purpose of insulation is to provide a thermal barrier (increase R-value/thermal efficiency). The next component (component 200 if in a three layer system or component 400 if in a four layer system) is a membrane which can be made of any suitable membrane material such as polyester fabric reinforced EPDM, TPO, or PVC membranes or nonreinforced EDPM, TPO, or PVC. The membrane is typically welded or seamed together to form a solid unit. The purpose of the membrane is to provide an impenetrable layer to withstand long term outdoor conditions including waterproofing, improve energy efficiency through reflectivity, chemical resistance, hail resistance, UV resistance, and wind uplift resistance. The roofing system may optionally contain accessories such as venting, skylights, etc. Plastic accessories with preattached membrane flaps can be used to protect the opening and allow the membrane system to remain impenetrable. The membrane layer may be the outermost layer or an additional fleece backed membrane may form the outermost layer. This additional membrane can be made of polyester fabric reinforced EPDM, TPO, or PVC membranes or nonreinforced EDPM, TPO, or PVC. A polyester or polypropylene fleece can be bonded to the membrane to allow a new membrane to be placed over an existing membrane in a reroofing application.
There are three main ways typically used to combine the above elements into a roofing system. A first is to be mechanically fastened where a combination of fasteners, plates, and screws are used to join the structural deck, insulation, membrane, and accessories together. This system is easy to maintain and is light weight. However is not typically suitable for areas with high winds. The second method is to fully adhere the system. In this method, an adhesive is used to join the membrane to insulation layer. Also adhesives or fasteners and plates are used to join the insulation to the structural deck. This system provides the highest wind uplift resistance and horizontal shear resistance but typically has VOC's in the compound and takes more time and labor to apply. The third method is to ballast the system. In this method, a layer of gravel, river stone, pavers, or vegetation is placed on top of the membrane to weigh it down and hold it in place. The insulation can be joined to the structural deck loosely (by the weight of the ballast) or by adhesives, fasteners, or plates. This method provides an economical choice as labor and time are significantly reduced to join the various elements however the loose stone is not suitable for areas prone to high winds.
The primary purpose of joining the various elements of a roof system is to improve wind uplift and horizontal shear resistance. Typically the fully adhered systems using adhesives are used in areas prone to storms and/or earthquakes as the adhesives provide the best adhering properties and resistance. The main negative to using adhesives is the extra labor and time it takes to apply the adhesive to each surface and wait for it to “set”. Also most adhesives have high VOC content.
Another method for joining a roof system could be to use magnetic elements in place of the adhesives, screws, plates, and fasteners. This magnetized fully adhered system would provide a greener option as it would reduce the VOC's and off gassing common with adhesives, reduce installation labor by eliminating the adhesive application or mechanical fastening step, would be easier to remove, replace, and reposition, prevent damage/penetrations inherent in the mechanically fastened system, reduce installation time by eliminating the need for adhesives to “set”, and could be installed in a wider range of temperatures and weather conditions.

EXAMPLES

Example 1

The first example of a magnetically attached building composite was formed using 3 layers. The layers were as follows (in order) a wood board base (layer 1), a barrier foam layer (Layer 2) and a TPO (Thermoplastic polyolefin) (Layer 3). The magnetic responsive coating was made using Fe₃O₄bought from Atlantic Equipment Engineers particles 100 mesh in size mixed with acrylate binder (AC-115 in aqueous solution) in a 70:30 (Fe₃O₄:AC-115) ratio by weight. Once the Fe₃O₄particles were added to the binder, the mixture was mixed vigorously for 15 min to make it homogeneously mixed. The magnetically responsive coating was then coated on layer 1 and Layer 3 only on one side, leaving the other side uncoated. The coatings were cured at 250° F. for 10 min. A permanently magnetic layer (˜250 Gauss) purchased from Arnold Magnetics was glued on both the sides of the foam (Layer 2). All the layers were assembled by putting layer 1 as the base facing magnetically responsive coating on top to the bottom of the permanently magnetic layer 2. For layer 2 permanently magnetic top was put facing the magnetic responsive coating on the bottom layer of TPO.

Example 2

The second example of a magnetically attached building composite was formed using 3 layers. The layers were as follows (in order) a wood board as base (layer 1), a barrier foam layer (Layer 2) and a PVC (Vinyl Film) (Layer 3). The magnetic responsive coating was made using Fe₃O₄bought from Atlantic Equipment Engineers particles 100 mesh in size mixed with acrylate binder (AC-115 in aqueous solution) in a 70:30 (Fe₃O₄:AC-115) ratio by weight. Once the Fe₃O₄particles were added to the binder, the mixture was mixed vigorously for 15 min to make it homogeneously mixed. The magnetically responsive coating was then coated on layer 1 and Layer 3 only on one side, leaving the other side uncoated. The coatings were cured at 250° F. for 10 min. A permanently magnetic layer (˜250 Gauss) purchased from Arnold Magnetics was glued on both the sides of the foam (Layer 2). All the layers were assembled by putting layer 1 as the base facing magnetically responsive coating on top to the bottom of the permanently magnetic layer 2. For layer 2 permanently magnetic top was put facing the magnetic responsive coating on the bottom layer of PVC.

Example 3

To show the concept of sidings and overlaying different surfaces a wood board (layer 1) was coated with magnetically responsive coating and then cured as mentioned in Example 1. Permanently magnetic layer was put on both the sides of the foam as layer 2 to attach it on the wood base. Magnetically responsive coating was then put on the vinyl based sidings and laminates to assemble it on the foam surface or overlaid on each other by covering only half of the surface.

Example 4

To show the concept of parapet and flexibility of the magnetically responsive coatings A wood board (layer 1) was coated with magnetically responsive coating and then cured as mentioned in Example 1. A additional wood piece was coated with a permanently magnetic layer. A permanently magnetic layer was put on both the sides of the foam as layer 2 to attach it on the wood base facing magnetically responsive coating. A magnetically responsive coating was then made on PVC as layer 3. Layer 3 was attached on the wood board via permanently magnetic layer and then took it over the attached foam surface on the wood. The flexibility of the magnetic coating on Layer 3 was enough to attach layer 1 and layer 2 at two different heights at the same time, without any cracking issues.
For each of the examples 1-3, it was found that the 3 layer system attached with magnetic force was enough to hold together all the layers in a flat orientation, at 90 degree orientation, and also in inverted orientation”.
All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.

Claims

What is claimed is:

1. A magnetically attached building composite comprising:

a first building component having an upper surface and a lower surface, wherein the lower surface of the first building component comprises magnetizable or magnetically responsive materials;

a second building component having an upper surface and a lower surface, wherein the upper surface of the second building component is adjacent the lower surface of the first building component, wherein the upper and lower surfaces of the second building component comprise magnetizable or magnetically responsive materials;

a third building component having an upper surface and a lower surface, wherein the upper surface of the third building component is adjacent the lower surface of the second building component, wherein the upper surface of the third building component comprises magnetizable or magnetically responsive materials;

wherein at least one of the lower surface of the first building component and the upper surface of the second building component comprise magnetizable materials and wherein at least one of the lower surface of the second building component and the upper surface of the third building component comprise magnetizable materials.

2. The magnetically attached building composite of claim 1, wherein the first building component comprises plywood.

3. The magnetically attached building composite of claim 1, wherein the third building component comprises an insulation layer.

4. The magnetically attached building composite of claim 1, wherein the second building component comprises a roofing tile.

5. The magnetically attached building composite of claim 1, wherein the first building component is a structural component.

6. The magnetically attached building composite of claim 1, wherein the second and third building components are non-structural components.

7. The magnetically attached building composite of claim 1, wherein the magnetizable materials are ferromagnets or ferrimagnets.

8. The magnetically attached building composite of claim 1, wherein the magnetizable materials comprise a material selected from the group consisting of barium ferrites, strontium ferrites and neodymium.

9. The magnetically attached building composite of claim 1, wherein the magnetically responsive materials comprise a material selected from the group consisting of iron oxide, steel, iron, nickel, and aluminum.

10. A magnetically attached building composite comprising:

wherein at least one of the lower surface of the first building component and the upper surface of the second building component comprise magnetizable materials.

11. The magnetically attached building composite of claim 10, wherein the first building component comprises plywood.

12. The magnetically attached building composite of claim 10, wherein the second building component comprises a fabric.

13. The magnetically attached building composite of claim 10, wherein the second building component comprises a metal flashing.

14. The magnetically attached building composite of claim 10, wherein the second building component comprises paper.

15. The magnetically attached building composite of claim 10, wherein the second building component comprises a tape.

16. The magnetically attached building composite of claim 10, wherein the first building component is a structural component.

17. The magnetically attached building composite of claim 10, wherein the second building component is a non-structural component.

18. The magnetically attached building composite of claim 10, wherein the magnetizable materials are ferromagnets or ferrimagnets.

19. The magnetically attached building composite of claim 10, wherein the magnetizable materials comprise a material selected from the group consisting of barium ferrites, strontium ferrites and neodymium.

20. The magnetically attached building composite of claim 10, wherein the magnetically responsive materials comprise a material selected from the group consisting of iron oxide, steel, iron, nickel, and aluminum.