Abstract:
A magnetic tool-holder, comprising a flexible outer web defining an enclosed area and enclosing an array of solid, rigid magnets. The magnets are regularly interspersed in direction of polarization, so that the nearest neighbors of a magnet having a north pole facing in a first direction all have a north pole facing in a second direction, opposite to the first direction.

Description:
BACKGROUND 
     The present invention is in the field of magnetic tool holders. In the prior art, U.S. Pat. No. 4,826,059, issued to Bosch et al. shows a tool belt having an array of rectangular magnets for holding tools and parts in an easily accessible manner on the front of the belt. This patent mentions attaching the tool-holder to a “magnetically responsive objects or surfaces.” Because of the longitudinal extent of the magnets, however, the belt would not conform along that extent unless the magnets were flexible. Flexible magnets tend to be less powerful than rigid magnets. 
     Also, published application no. 2004/0173484 discloses a magnetic tool-holder in which a loose array of magnets is sewn into individual pockets. Such a loose array will not tend to provide a powerful enough magnetic force to hold larger tools and to stay on a metal car surface when loaded down with an array of heavy tools and parts. Also, although this application discloses arranging the magnets with random polarization, such random polarization would tend not to produce the maximum magnetic force. 
     SUMMARY 
     The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tools and methods which are meant to be exemplary and illustrative, not limiting in scope. In various embodiments, one or more of the above-described problems have been reduced or eliminated, while other embodiments are directed to other improvements. 
     In a first separate aspect, the invention may take the form of a magnetic tool-holder, having a flexible outer web defining an enclosed area and enclosing an array of elliptical, solid, rigid magnets. The magnets cover over 30% of the enclosed area. 
     In a second separate aspect, the invention may take the form of a method of making a magnetic tool-holder, starting with a web of flexible material placed on a web of magnetically responsive material and then placing the magnets on the web of flexible material, whereby the engagement of the magnets and the web of magnetically responsive material holds the magnets in place, despite magnetic forces between the magnets. Then, the magnets are enclosed in the flexible material. 
     In a third separate aspect, the invention may take the form of a magnetic tool-holder, comprising a flexible outer web defining an enclosed area and enclosing an array of solid, rigid magnets. The magnets are regularly interspersed in direction of polarization, so that the nearest neighbors of a magnet having a north pole facing in a first direction all have a north pole facing in a second direction, opposite to the first direction. 
     In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the drawings and by study of the following detailed descriptions. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Exemplary embodiments are illustrated in referenced drawings. It is intended that the embodiments and figures disclosed herein are to be considered illustrative rather than restrictive. 
         FIG. 1  shows the first step in a production process of a magnetic tool holder, according to the present invention. 
         FIG. 2  shows the first step in an alternative production process of a magnetic tool holder, according to the present invention. 
         FIG. 3  shows a further step of the production process of  FIG. 1 . 
         FIG. 4  shows a further step of the production process of  FIG. 2   
         FIG. 5  shows a partially completed magnetic tool holder, according to the present invention. 
         FIG. 6  shows a completed magnetic tool holder, according to the present invention. 
         FIG. 7  shows a completed magnetic holder affixed to a metal car surface. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to  FIG. 1 , in one preferred embodiment a method of producing a magnetic tool holder begins with a template  10 , set atop a piece of web material, such as a flexible sheet  12  having an adhesive surface  13  ( FIG. 5 ), set in turn on a sheet  14  of magnetically responsive material, such as steel. Template  10  defines a regular series of large through-holes  16 , and smaller through-holes  18  that are interspersed diagonally. Turning to  FIG. 3 , a person may now use a tool to place large magnets  22  and smaller magnets  24  ( FIG. 5 ) in each of the through-holes  16  and  18 , respectively, so that they rest on adhesive surface  13 . Referring to  FIGS. 2 and 4 , in an alternative preferred method, a thinner template  10 ′ is used, and the magnets  22  may be placed in a stack and for each hole  16 , a single magnet  22  is placed inside and then separated from the stack by shearing the stack  26  away from the magnet  22 , as shown. The same process may be performed with respect to magnets  24  and holes  18 . 
     Referring to  FIG. 5 , when template  10  or  10 ′ is removed, the strength of the magnetic attraction between magnets  22  and  24  and magnetically responsive sheet  14  keeps the magnets from being drawn together, which would disturb the positioning. As shown, in a preferred embodiment the small magnets  24  are all oriented with their polarities 180 degrees from the polarities of the large magnets  22 . In an alternative preferred embodiment large magnets are interspersed in polarity, so that across a row a first large magnet  22  would have its plus pole on top (in the dimensions of  FIG. 5 ) and the next large magnet  22  would have its minus pole on top. The small magnets  24  could be similarly interspersed. In another preferred embodiment the magnets are all the same size, but arranged so that their polarities are regularly interspersed. Although the drawings show these operations being performed by hand, they could be automated and performed by a machine, without falling outside of the scope of the invention. 
     Finally  FIG. 6  shows the finished product  28  made by providing another sheet  14  also having an adhesive surface and placing it so that the adhesive surface contacts magnets  22  and  24  and also mutually adhering both sheets  14  together. In one preferred embodiment sheets  14  and  14 ′ are all part of a larger sheet which is folded over about magnets  22  and  24 . Finally, sheets  14  and  14 ′ are sewn together at their margins, with some backing material  30  added to buttress the seam. In a further preferred embodiment, grommets, loops, or other features to more easily permit the tool holder  28  to be hung on a hook, are provided. Moreover, pockets and/or other convenience or safety features could be added to tool holder  28 , without departing from the scope of the invention. 
     In use, as shown for one embodiment in  FIG. 7 , the device  28 ′ provides a powerful magnetic force that can hold even quite heavy pieces in place. With respect to the device  28 , the close spacing of magnets  22  and  24  made possible in part by the differing sizes, helps to create a powerful magnetic force, which is also made possible by the regularly interspersed polarity of the magnets  22  and  24 , which greatly increases the magnetic force when magnetically attached to a magnetically responsive material, as opposed to all the magnets having the same polarity, or the magnets having random polarization. 
     In one preferred embodiment, magnets  22  and  24  are hard ferrite magnets. Not only is this type of magnet relatively inexpensive, but it also has high coercivity and remanence, desirable qualities in the present application, where they may be used for years, without losing significant magnetic force. In a preferred embodiment, large magnets  22  are 1″×⅕″ (one inch by one-fifth inch), and the small magnets  24  are ¾″×⅕″ (three-quarters inch by one-fifth inch). In a preferred embodiment the circular edges of magnets  22  and  24  are rounded. 
     While a number of exemplary aspects and embodiments have been discussed above, those possessed of skill in the art will recognize that certain modifications, permutations, additions and sub-combinations thereof exist. It is therefore intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions and sub-combinations as are within their true spirit and scope.