Abstract:
A decorative magnetic cover is provided. The cover includes a plurality of octagonal and triangular openings, allowing the cover to securely attach to a rounded item without kinking or otherwise unsightly attachment. The cover includes a magnetic sheet having a magnetic face and nonmagnetic face, and a decorative element attached to the nonmagnetic face. The cover is manufactured by scoring the nonmagnetic face of the magnetic sheet and applying the decorative element to the nonmagnetic face. The resulting magnetic element is the cut to form the octagonal and triangular openings.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Patent Application No. 62/055,927, entitled “Circumferential Magnetic Device Covers and Methods of Manufacture”, filed on Sep. 26, 2014, the contents of which are herein incorporated by reference. 
    
    
     FIELD OF INVENTION 
     This invention relates to magnetic device covers and methods of manufacturing the same. More specifically, the present invention provides a circular magnetic device cover having tapered edges adapted to cover the device without gaps or bulges in the cover. 
     BACKGROUND OF THE INVENTION 
     Magnetic sheets are formed by adding a magnetic alloy powder, such as iron-silicon alloys (Fe—Si—Al and the like), ceramic magnet powder, magnetic powder, nickel, cobalt, lodestone alnico, ferrite strontium-ferrite powder, or neodymium (NdFeB) powder, to some binder, such as an epoxy resin, acrylic resin, or rubber, and curing the composition to form into a sheet by hot pressing. The magnetic sheets are commonly used for depression of noise, RFID, and ornamental purposes. Ornamental magnetic covers are used to decorate ferromagnetic items, such as car body panels, bumpers, refrigerator doors. In ornamental use, the magnetic sheets can be screen printed, painted, or otherwise coated with a decorative element. For example, Vela (U.S. Appl. 2001/0008702) discloses flexible magnetic materials. However, the ornamental covers could not be flexed, due to cracking or splitting of the cover. The magnetic sheets are also used in forming thermochromic strips to detect gas contents within a container, as seen in Parker (U.S. Pat. No. 5,323,652). 
     However, many uses of ornamental covers on many items are frustrated by the shape of the item, and thus a poor fit of the ornamental cover onto the item. In most cases, the ornamental cover is a strip or flat element, requiring the item to have a flat surface to accommodate the cover. For example, propane tanks have a tubular body, with tapers on the upper and lower edges of the tubular body. As such, ornamental covers either cannot extend to the tapered edges, or have unpleasant overlaps of the cover. 
     SUMMARY OF THE INVENTION 
     The present invention addresses the shortcomings of the art by providing ornamentally cut magnetic sheets to form fit over propane tanks and similarly shaped items. 
     Geometric patterns of openings on the edges of the magnetic sheets permit the ornamental covers to tightly adhere to the tubular body and tapered edges of the tank. The geometric patterns are formed by scoring the non-magnetic faces of the magnetic sheets to allow flexibility of flat sheets, along with shaped cuts to take on the form of a semi spherical, tapered surface of a propane tank without kinking or overlap in the magnetic sheets, as is commonly the case with such magnetic covers. Optional shapes for the geometric patterns include hexagons, octagons, diamonds, squares, triangles, and star shapes. 
     As such, a magnetic cover is disclosed comprising a magnetic sheet having an upper longitudinal edge and a lower longitudinal edge, wherein the magnetic sheet comprises a magnetic face and a non-magnetic face. Examples of materials that are useful in forming the magnetic face include ceramic magnet powder, magnetic powder, strontium-ferrite powder, neodymium (NdFeB) powder, or a combination thereof bonded with synthetic rubber, elastic thermoplastic carrier, or binder and a curing agent. Specific variations and methods of making such films may be found in Aramaki, et al. (U.S. Appl. 2011/0033732). Alternatively, the magnetic face may be formed by bonding rare earth metals, as described in Furuya, et al. (U.S. Pat. No. 5,393,445), by magnetic polymers, as described by Minnick (U.S. Pat. No. 5,919,848), or by use of magnetic ink. Non-limiting examples of magnetic ink formulations include Murphy (U.S. Pat. No. 4,293,627), and Gaudioso (U.S. Pat. No. 4,288,516). 
     A decorative element is attached to the non-magnetic face. In some variations, the decorative element is a sheet made of vinyl, polyvinyl chloride, or polyvinyl fluoride. In more specific variations, the sheet a self-adhesive. The decorative element is alternatively a print sensitive film (not shown) that can be laminated to the magnetic sheet. In embodiments using a film or sheet, a decorative design is added using printing, silk screening or other application of the desired decorative design. The decorative element is optionally an adhesive-backed sheet containing U.V. screening or digital ink printing of some decorative design. Where decorative element is an adhesive vinyl sheet, the vinyl sheet is optionally first printed, and subsequently mounted to the non-magnetic face of each sheet specifically place in designated positions over corresponding scores. In other variations, the decorative element is applied to the magnetic sheet in a continuous process by paint or silk screening, such as by squeegees. Alternatively, a preprinted sheet or film can be laminated to the magnetic sheet in a continuous process by pressure roller or rollers, as is known to those skilled in the art. 
     A series of interlocking octagonal and triangular openings are disposed on the upper longitudinal edge, the lower longitudinal edge, or both, and define at least one taper section of the magnetic cover. In specific variations, both the upper longitudinal edge and the lower longitudinal edge contain the interlocking octagonal and triangular openings, defining a plurality of taper sections disposed above and below a tubular section. Optionally, one or more tabs are disposed on a first transverse edge of the magnetic sheet, in the tubular section of the cover, with a complementary depression correspondingly disposed on a second transverse edge. In specific embodiments, the cover includes 1 tab and 1 complementary depression, 2 tabs and 2 complementary depressions, 3 tabs and 3 complementary depressions, or 4 tabs and 4 complementary depressions. 
     A method is also provided for the manufacturing of the magnetic cover described above. A magnetic sheet is provided, where the sheet has an upper longitudinal edge and a lower longitudinal edge, wherein the magnetic sheet comprises a magnetic face and a non-magnetic face. The magnetic face is formed from materials, as described above. The non-magnetic face of the magnetic sheet is scored with a plurality of interlocking octagonal and triangular scores on the upper longitudinal edge, the lower longitudinal edge, or on the upper longitudinal edge and the lower longitudinal edge of the magnetic sheet to form at least one taper section. A tubular section is disposed adjacent to the at least one taper section. A decorative element is applied to the non-magnetic face, where the decorative element is described above. 
     A series of interlocking octagonal and triangular openings on the magnetic element are cut into the upper longitudinal edge, the lower longitudinal edge, or both, wherein the plurality of interlocking octagonal and triangular openings correspond to the plurality of interlocking octagonal and triangular scores on the edges of the magnetic sheet. The interlocking octagonal and triangular scores are formed by die-cutting, laser cutting or router cutting. In specific variations, one or more tabs are disposed on a first transverse edge of the magnetic sheet, on the tubular section, with a corresponding, complementary depression on a second transverse edge. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a fuller understanding of the invention, reference should be made to the following detailed description, taken in connection with the accompanying drawings, in which: 
         FIG. 1  is an illustration of the magnetic sheet showing the scoring on the top edge of the nonmagnetic face. 
         FIG. 2  is an illustration of the magnetic face of the magnetic sheet showing the geometric openings formed on the sheet with the top edge perforated. Scoring of the non-magnetic sheet was shown in black and triangular and octagonal cuts shown in gray. 
         FIG. 3  is an illustration of an embodiment of the decorative element formed from a decorative sheet, such as a vinyl sheet. 
         FIG. 4  is an illustration of the magnetic sheet with the top edge perforated, being applied to a propane tank. 
         FIG. 5  is an illustration of the magnetic sheet showing the scoring on the top and bottom edges of the nonmagnetic face. 
         FIG. 6  is an illustration of the magnetic sheet having an upper and lower tapered section with geometric openings. 
         FIG. 7  is an illustration of the magnetic sheet with the top and bottom edges perforated, being applied to a propane tank. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     As used herein, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “an opening” includes both one and two or more openings and the like. 
     As used herein, “about” means approximately or nearly and in the context of a numerical value or range set forth means±15% of the numerical. 
     As used herein, “magnetic” means a material that possesses magnetic field inherently or is of a ferro-magnetic composition and therefore capable of being induced to emit magnetic fields. 
     As used herein, “interlocking” refers to a connection between a tab and its complementary depression so that separation or movement between the tab and depression is constrained. “Complementary” means the elements are sized and shaped to allow at least one element from one complementary half to engage at least one element from the opposing complementary half. 
     As used herein, “upper”, “above”, “lower” and “bottom” are referenced based on the image depicted in  FIG. 4 . “Upper” or “above” means any portion of the cover directed to the top of  FIG. 6 . For example, reference number  23   b  is the “upper” taper section in  FIG. 6  and is “above” tubular section  23   a . “Lower” or “bottom” is directed toward the bottom of  FIG. 4 . For example reference number  23   c  is the “lower” taper section. 
     Example 1 
     Magnetic sheet  5  is formed of a ceramic magnetic powder, magnetic powder, strontium-ferrite powder, neodymium (NdFeB) powder, or a combination of materials, embedded in a synthetic rubber, elastic thermoplastic carrier. Magnetic sheet  5  therefore has a magnetic face  14  of the magnetic material formed into a film, and a non-magnetic face  13  of polymer or rubber. First transverse edge  11  is either straight, as seen in  FIG. 1 , or contoured with at least one tab  24 , as seen in  FIG. 2 . In embodiments utilizing the tab, a complementary depression  25  is disposed on second transverse edge  12 , as seen in  FIG. 2 . Magnetic sheet  5  may be manufactured with tabs and depressions, cut to form the at least one tab and depression prior to further processing of the longitudinal edge as discussed below, or cut to form the at least one tab and depression after the processing of the longitudinal edge. 
     Octagonal and triangular openings scores  15  were made on upper longitudinal edge  9  of non-magnetic face  13  of magnetic sheet  5  utilizing specific geometrically scoring by die-cutting, laser cutting or router cutting, seen in  FIG. 1 . Octagonal and triangular openings scores  15  aligned in a pattern that allows (in combination with final through cut along the outer edge) the edges of magnetic sheet  5  to form around the spherical edges of a propane tank thus eliminating all kinking that would normally occur from forming a flat sheet over a rounded surface. 
     After octagonal and triangular openings scores  15  were introduced to non-magnetic face  13 , decorative element  20  was added to non-magnetic face  13 , as seen in  FIG. 2 . Decorative element  20  is optionally decorative sheet  21 , made of elastomeric material containing a decoration adhered to side  20   a  of the decorative element  20  using techniques such as silk screening, painting or other techniques known to those skilled in the art, as seen in  FIG. 3 . Alternatively, a vinyl sheet or alternative print sensitive film (not shown) is pre-printed with a decoration, and the pre-printed sheet is laminated to magnetic sheet  5 , thereby applying the desired decorative design to non-magnetic face  13 . 
     After mounting decorative element  20 , octagonal and triangular cuts  16  were made into both the non-magnetic face  13  and magnetic face  14  of magnetic sheet  5  via steel rule die-cutter, laser cutter or router, rendering voids in magnetic sheet  5  that form octagonal and triangular openings  18 , thereby forming magnetic cover  22 , seen in  FIG. 2 . The voids, octagonal and triangular openings  18  define upper taper section  23   b  from tubular section  23   a , and allow magnetic sheet  5  to form fit around tubular body  31  and upper taper  32  of propane tank  30 , seen in  FIG. 4 . 
     Example 2 
     Magnetic sheet  5 , as described in Example 1, was scored with a plurality of octagonal and triangular upper segment scores  15   a  on upper longitudinal edge  9  and lower segment scores  15   b  on lower longitudinal edge  10  made on the edges of the magnetic sheets of the non-magnetic side only. Scores were made utilizing specific geometrically scoring by die-cutting, laser cutting or router cutting the nonmagnetic face of each sheet of magnetic material, seen in  FIG. 5 . 
     After upper segment scores  15   a  and lower segment scores  15   b  were introduced to non-magnetic face  13 , decorative element  20 , as described in Example 1, was added to non-magnetic face  13 . After mounting decorative element  20 , magnetic sheet  5  has upper octagonal and triangular cuts  16   a  made into both the non-magnetic face  13  and magnetic face  14  of upper longitudinal edge  9  and lower octagonal and triangular cuts  16   b  made into both faces of lower longitudinal edge  10  via steel rule die-cutter, laser cutter or router, as seen in  FIG. 6 . Upper octagonal and triangular cuts  16   a  define upper taper section  23   b , lower octagonal and triangular cuts  16   b  define lower taper section  23   c , and tubular section  23   a  the uncut section between upper taper section  23   b  and lower taper section  23   c . The resulting voids in each sheet form octagonal and triangular openings  18 , which allow magnetic sheet  5  to form fit around tubular body  31  and upper taper  32  and lower taper  33  of propane tank  30 , seen in  FIG. 7 , and prevent kinking that would normally occur from forming a flat sheet over a rounded surface. 
     Example 3 
     Magnetic cover  22 , formed from sheet  5  and decorative element  20  disposed on the nonmagnetic face, as disclosed above in Example 1, is aligned with propane tank  30 . However, the cover of the present invention can be used with other items, as would be readily apparent to one of skill in the art in light of the disclosure 
     Magnetic cover  22  is affixed to propane tank  30  by aligning upper taper section  23   b  with upper taper  32  of the propane tank, seen in  FIG. 4 . Upon aligning upper taper  32  and upper taper section  23   b , a user magnetically attaches either the right or left edge of tubular section  23   a  to tubular body  31  of propane tank  30 , seen in  FIG. 4 . Tubular section  23   a  of magnetic cover  22  is wrapped around tubular body  31  of propane tank  30  and magnetically fixed to the propane tank. The user then magnetically attaches upper taper section  23   b  to upper taper  32  of the propane tank. Octagonal and triangular openings  15  provide sufficient space to allow the magnetic sections of upper taper section and lower taper section  23   c  to contact the propane tank without overlap of the magnetic sections. 
     Where at least one tab  24  is used, as discussed in Example 1, the user attached either first transverse edge  11  or second transverse edge  12  to the propane tank and wrapped magnetic cover  22  around tubular body  31  of propane tank  30 , ensuring tab  24  engaged the corresponding depression  25  in tubular section  23   a . Upper taper section  23   b  was then attached to the propane tank, as discussed above. 
     Example 4 
     Magnetic cover  22 , formed as disclosed above in Example 2, is aligned with propane tank  30 , or other items, as would be readily apparent to one of skill in the art in light of the disclosure. Magnetic cover  22  is affixed to propane tank  30  by aligning upper taper section  23   b , followed by aligning lower taper section  23   c  with lower taper  33  of the propane tank. A user magnetically attaches either the right or left edge of into tubular section  23   a  to tubular body  31  of propane tank  30 , seen in  FIG. 7 . Tubular section  23   a  of magnetic cover  22  is wrapped around tubular body  31  of propane tank  30  and magnetically fixed to the propane tank. The user then magnetically attaches upper taper section  23   b  to upper taper  32  of the propane tank, and lower taper section  23   c  to lower taper  33 . Octagonal and triangular openings  15  provide sufficient space to allow the magnetic sections of upper taper section  23   b  and lower taper section  23   c  to contact the propane tank without overlap of the magnetic sections. Where one or more tabs  24  are used, as discussed in Example 2, the user attached either first transverse edge  11  or second transverse edge  12  to the propane tank and wrapped magnetic cover  22  around tubular body  31  of propane tank  30 , ensuring tab  24  engaged the corresponding depression  25  in tubular section  23   a . Upper taper section  23   b  and lower taper section  23   c  were then attached to the propane tank, as discussed above In the preceding specification, all documents, acts, or information disclosed does not constitute an admission that the document, act, or information of any combination thereof was publicly available, known to the public, part of the general knowledge in the art, or was known to be relevant to solve any problem at the time of priority. 
     The disclosures of all publications cited above are expressly incorporated herein by reference, each in its entirety, to the same extent as if each were incorporated by reference individually. 
     While there has been described and illustrated specific embodiments of a magnetic decorative cover and method of manufacturing the same, it will be apparent to those skilled in the art that variations and modifications are possible without deviating from the broad spirit and principle of the present invention. It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.