Pressing tool and method for manufacturing a pressing tool

Description

[0001] The invention relates to a pressing tool and a method for producing a pressing tool. The pressing tool comprises a structured pressing surface.

[0002] Press tools, such as press plates, endless belts, or embossing rollers, are used in the woodworking industry, for example, to produce workpieces such as furniture, laminates, or panels. The workpieces are pressed with the pressing surface of the press tool, resulting in surfaces that match the pressing surface.

[0003] WO 2015 / 036070 A1 discloses a pressing tool with a structured pressing surface produced by superimposed metal layers. This involves applying a mask at least once to cover partial areas, and applying a metal layer at least once to the uncovered areas to create the structured pressing surface consisting of elevations and depressions. These two process steps are repeated until the desired structural depth of the structured pressing surface is achieved. The structured pressing surface can then be coated with a hard chrome layer.

[0004] WO 2008 / 120058 A1 discloses a pressing tool whose pressing surface is formed by a layer consisting of a metal matrix with mineral or ceramic particles embedded therein.

[0005] CH711268 B1 discloses a method for coating a gripping surface of a gripping tool. In this method, several diamond grains with a uniform first grain diameter are provisionally and uniformly fixed in such a way that the tips of the diamond grains can be aligned. The diamond grains are attached to a gripping surface by applying nickel-containing metal.

[0006] WO2014202041 A1 discloses a method for producing a surface structure of a pressing tool for pressing material plates, plastic films, release films, PVC surfaces, LVT (luxury vinyl tiles), check cards, passports, credit cards or plastic cards.

[0007] EP 2 497 650 A1 discloses a pressing tool according to the preamble of claim 11.

[0008] DE 20 2015 005608 U1 discloses a finishing of a metallic pressed sheet or endless belt surface.

[0009] The object of the invention is to provide an improved pressing tool with a structured pressing surface.

[0010] The object of the invention is achieved by a method having the features of claim 1 and a pressing tool having the features of claim 11.

[0011] The pressing tool according to the invention is produced in particular using the method according to the invention.

[0012] If necessary, the pressing surface can be cleaned to remove residues from the masks.

[0013] The pressing tool according to the invention is, for example, an endless belt, an embossing roller, or preferably a pressing plate, and comprises the pressing surface. This comprises the structure of the elevations and depressions, thus forming a structured pressing surface. This gives the workpiece produced with the pressing tool a structured surface corresponding to the structure of the pressing surface.

[0014] The workpiece is, for example, a material board. This comprises a carrier, such as an MDF board or particle board, which is pressed onto a resin- or plastic-impregnated substrate, such as paper, using the pressing tool. The material board can also be a so-called luxury vinyl tile (LVT).

[0015] The pressing tool according to the invention comprises several metal layers superimposed in layers, i.e. in particular several metal layers lying on top of one another.

[0016] The metal layers are preferably chromium-free, such as nickel layers. This increases the environmental compatibility of the manufacturing process.

[0017] According to the method according to the invention, the pressing tool is manufactured by repeatedly applying a mask to cover certain areas and then coating the areas not covered by the mask with a metal layer. This is repeated until the pressing surface with its structure is created. This results in a layered structure of the pressing tool, structured by the metal layers, which are particularly partial metal layers, and thus the pressing surface with its structure of elevations and depressions. The pressing surface is thus not formed by an additional hard chrome layer, the production of which is relatively harmful to the environment.

[0018] During workpiece production, the pressing surface is in contact with the workpiece and is therefore subject to wear. To increase the wear resistance of the metal layers and thus the wear resistance of the pressing surface despite omitting the full-surface hard chrome coating, mineral particles are embedded in the individual metal layers. This makes it possible to avoid coating the pressing surface of the pressing tool with a full-surface hard layer, for example, of hard chrome, which, for example, reduces the cost of manufacturing the pressing tool.

[0019] In order to increase the wear resistance of the pressing surface, the mineral particles are embedded in the metal layers of the pressing tool or the metal layers are applied layer by layer with the addition of the metal layers.

[0020] Thus, the process according to the invention eliminates the need for a full-surface coating of the press surface with a hard layer, e.g., of hard chrome, or the need for a full-surface application of a hard layer, e.g., of hard chrome, to the press surface. Eliminating the hard chrome layer also increases the environmental compatibility of the press tool's production.

[0021] Preferably, the metal layers can be tempered, which, in the case of nickel layers as metal layers, can result in a hardness of at least 1100 HV. This hardness is even greater than the hardness of the hard chrome layer of conventional pressing tools.

[0022] The production by applying the metal layers layer by layer is preferably carried out using a galvanic or chemical process, in particular without etching. This makes the production of the pressed sheet relatively environmentally friendly.

[0023] If the metal layers are applied using a galvanic process with the addition of mineral particles, then the metal layers with embedded mineral particles are dispersion layers.

[0024] Minerals are mostly inorganic, homogeneous, and mostly crystallized substances found primarily in the Earth's crust. The majority of minerals known today and recognized as independent minerals by the International Mineralogical Association are inorganic.

[0025] In particular, the mineral particles of the metal layers have a Mohs hardness of at least 8.

[0026] The mineral particles are preferably in the nanometer or micrometer range. This allows the mineral particles to be embedded relatively homogeneously into the metal layers, giving the press tool relatively homogeneous wear resistance across its entire pressing surface. The size of the individual mineral particles can be different or essentially the same.

[0027] The mineral particles preferably have a volume fraction of at least 50% relative to the volume of the corresponding metal layer with embedded mineral particles. The desired degree of hardness or wear resistance of the metal layers can be adjusted based on the size, volume fraction, and type of minerals in the mineral particles.

[0028] The mineral particles are, in particular, diamond particles. The diamond particles are, in particular, industrial diamond particles, meaning that diamond particles, or mineral particles in general, can be artificially produced. However, the minerals silicon carbide, boron nitride, boron carbide, aluminum oxide, and titanium oxide, in particular, can also be used as mineral particles.

[0029] The mineral particles are formed, for example, as mineral powder, in particular as diamond powder and preferably as industrial diamond powder.

[0030] According to a preferred embodiment of the method according to the invention, the pressing surface is treated after step c). This treatment may comprise a mechanical treatment and / or a galvanic and / or chemical treatment of the pressing surface, and / or the treatment may be carried out with a laser. The treatment of the pressing surface may also be a thermal treatment, e.g., tempering.

[0031] The press tool comprises several metal layers applied one above the other with the mineral particles embedded within them. Since the metal layers were only applied to the areas not covered by the corresponding masks, these metal layers are partial metal layers, not full-surface metal layers.

[0032] The pressing surface of the pressing tool has different gloss levels in certain areas, which are in particular predetermined gloss levels. This means that the pressing surface has areas with different gloss levels, in particular areas with predetermined different gloss levels.

[0033] According to the invention, the metal of at least two metal layers differs in order to obtain areas with different gloss levels. This allows for the realization of areas with different gloss levels in a relatively simple manner.

[0034] To achieve the different gloss levels, it may also be necessary to treat the resulting composite metal layer before applying the final or uppermost metal layer. This treatment may include mechanical treatment and / or galvanic and / or chemical treatment of the pressed surface, and / or the treatment may be carried out with a laser.

[0035] The application of the masks can preferably be carried out depending on image data associated with the structure of the press surface.

[0036] The pressing tool can be manufactured, in particular, depending on image data associated with the structure of the structured pressing surface. Preferably, the masks are applied depending on these image data associated with the structure of the structured pressing surface.

[0037] The pressing surface is, in particular, associated with a natural material, such as wood or stone. To obtain the structure of the pressing surface, it may be provided that a template, e.g., a piece of wood or stone, is scanned to obtain image data. This image data includes, in particular, information about the structure the pressing surface is intended to have.

[0038] The image data obtained by scanning can, for example, be manually processed to obtain the image data associated with the structure of the press surface.

[0039] The masks are applied using a print head, for example. If the pressing tool is a press plate, then the masks are preferably applied using such a print head, which is arranged above the pressing surface to be produced and which is moved in a plane parallel to the pressing surface during the application of the masks. Since the layer composite of the currently applied metal layers becomes higher, it is preferably provided that the print head is moved in a direction perpendicular to the pressing surface so that the distance between the currently applied mask and the print head is kept constant. Due to the constant distance, the currently applied mask can be applied more effectively with the print head.

[0040] Embodiments of the invention are illustrated by way of example in the accompanying schematic figures. They show: Fig. 1 shows a press plate with a pressing surface in a perspective view, Fig. 2 shows a section of a side view of the press plate in a sectional view, Fig. 3 shows an intermediate stage of the press plate during its production, Fig. 4 shows a device for applying masks.

[0041] The Fig. 1 shows a perspective view of a press plate 1 with a pressing surface 2 as an example of a pressing tool. Fig. 2 shows a sectioned view of a side view of the press plate 1 and the Fig. 3 shows an intermediate stage of the press sheet 1 during its production.

[0042] The pressing surface 2 comprises a structure of depressions 3 and elevations 4 and is assigned, for example, to a wood grain.

[0043] In the present embodiment, the pressing surface 2 is rectangular and has a transverse extension 7 and a longitudinal extension 8. Furthermore, the structure of the structured pressing surface 2 extends along a preferred direction 6, which in the present embodiment runs along the longitudinal extension 8.

[0044] Using the press plate 1, a workpiece, e.g., a material plate, such as a laminate, can be produced by pressing. After pressing, the workpiece has a surface structured according to the structure of the press surface 2.

[0045] In the present embodiment, the press plate 1 comprises a steel base support 21 and several metal layers 22 arranged one above the other or superimposed in layers, each of which has mineral particles 23 embedded therein and which are arranged on the base support 21. The metal layers 22 are, in particular, nickel layers. The metal layers 22 with the mineral particles 23 embedded therein form the press surface 2.

[0046] The mineral particles 23 in particular have a Mohs hardness of at least 8 and a size in the nanometer or micrometer range. The volume fraction of the mineral particles 23 is preferably at least 50% based on the volume of the metal layer 22 with the mineral particles 23 embedded therein.

[0047] In the case of the present embodiment, the mineral particles 23 are industrial diamond particles.

[0048] In the case of the present embodiment, the metal layers 22 were produced by a chemical or galvanic process.

[0049] The press sheet 1 was manufactured without etching by applying a mask 24 to cover areas, applying a metal layer 22 to the areas 25 not covered by the mask 24 with the addition of the mineral particles 23, and repeating this until the press surface 2 with the structure of the elevations 4 and depressions 3 was created by repeatedly applying masks 24 and metal layers 22 layer by layer with the addition of mineral particles 23.

[0050] The Fig. 3 shows in particular a section of a side view in a sectional representation of an intermediate stage of the press plate 1 during its production. Fig. 3 In particular, it shows a layered composite comprising several metal layers 22 arranged one above the other or superimposed in layers, with mineral particles 23 embedded therein, to which a mask 24 is applied to cover certain areas. In the subsequent step, another metal layer 22 is applied to this layered composite with the addition of mineral particles 23. This is repeated, as already described, until the pressing surface 2 with the structure of the elevations 4 and depressions 3 is created. The metal layers 22 with the mineral particles 23 embedded therein are partial metal layers.

[0051] The Fig. 4shows a plan view of an example of a device 41 for applying the masks 24 to the layered composite. In the present embodiment, this device comprises a support table 42 having a support surface 44 made of several individual flat surfaces 43. To produce the press plate 1, the base support 21 is first placed on the support surface 42 such that the side on which the press surface 2 is to be constructed faces away from the support surface 44.

[0052] The support surface 44 is in particular rectangular and has a dimension adapted to the dimensions of the press plate 1.

[0053] In the case of the present embodiment, the device 41 comprises an electronic control device 45 which controls the operation of the device 41.

[0054] In the case of the present embodiment, suction openings are formed in the flat surfaces 43, which suction openings pull the press plate 1 or the base support 21 onto the flat surfaces 43 by means of a vacuum pump of the device 41 (not shown) controlled by the electronic control device 45, whereby the press plate 1 or its base support is fixed on the support surface 44.

[0055] The device 41 is designed such that the press plate 1 fixed on the support surface 44 or its base support 21 is arranged between the support surface 44 and the print head 49.

[0056] Thus, it is possible, controlled by the electronic control device 45, to move the print head 49 to the desired position relative to the base support 21. In particular, it is provided that the print head 49 is moved in the direction perpendicular to the pressing surface 2 by means of the electric drive 52 such that the distance between the currently applied mask 24 and the print head 49 is kept constant.

[0057] In the present embodiment, the pressing surface 2 is associated with a wooden surface. To obtain the structure of the pressing surface 2, it can be provided that a template, e.g., a wooden surface, is scanned to obtain image data. This image data includes, in particular, information about the structure that the pressing surface 2 is to have. The image data obtained by scanning can, for example, be manually processed to obtain image data 5 associated with the structure of the pressing surface 2.

[0058] In the case of the present embodiment, the application of the masks 24 and the metal layers 22 takes place depending on the image data 5 assigned to the structure of the pressing surface 2.

[0059] In the present embodiment, the image data 5 associated with the structure of the press surface 2 are stored in the electronic control device 45. The electronic control device 45 is particularly configured to control the electric drive 50, the further electric drive 51, and the print head 49 depending on the image data 5.

[0060] In the case of the present embodiment, the pressing surface 2 is cleaned if necessary, for example to remove residues of the masks 24.

[0061] The pressing surface 2, in particular, has regions with different, preferably predetermined gloss levels. To achieve this, it can be provided that the metal of at least two metal layers 22 differs. It can also be provided that the composite layer of metal layers 22 is treated before the application of the last or uppermost metal layer. This treatment can include a mechanical treatment, e.g., polishing or matting, and / or a galvanic and / or chemical treatment of the pressing surface 2, and / or the treatment can be carried out with a laser.

[0062] The pressing surface 2 can further be treated. This treatment can include a mechanical treatment, e.g., polishing, and / or a galvanic and / or chemical treatment of the pressing surface 2, and / or the treatment can be carried out with a laser. The treatment of the pressing surface 2 can also be a thermal treatment, e.g., tempering of the pressing surface 2. This can give the pressing surface 2 a hardness of, e.g., at least 1100 HV, particularly in the case of nickel layers.

Claims

1. A method for producing a pressing tool provided for producing a workpiece, which pressing tool has a pressing surface (2) having a structure of protrusions (4) and recesses (3), comprising the following method steps: a) applying a mask (24) for covering regions, b) applying a metal layer (22) to the regions (25) not covered by the mask (24) with the addition of mineral particles (23), and c) repeating steps a) and b) until the pressing surface (2) with the structure of the protrusions (4) and recesses (3) is formed by repeated, layered application of masks (24) and metal layers (22) with the addition of mineral particles (23), wherein the pressing surface (2) has regions of different degrees of gloss, and wherein the metal of at least two metal layers (22) is different, in order to obtain the regions of different degrees of gloss.

2. The method according to claim 1, comprising applying the mask (24) dependent on image data (5) assigned to the structure of the pressing surface (2).

3. The method according to claim 1 or 2, comprising treating the pressing surface (2) after step c).

4. The method according to one of claims 1 to 3, comprising treating the pressing surface (2) after step c) by means of polishing or matting of the pressing surface (2), and / or by means of a chemical or galvanic method and / or by means of a laser.

5. The method according to one of claims 1 to 4, wherein the regions of different degrees of gloss are regions of predetermined different degrees of gloss.

6. The method according to claim 5, in which the multilayer composite of metal layers (22) obtained by then is treated prior to the application of the top metal layer.

7. The method according to one of claims 1 to 6, comprising tempering of the pressing surface (2) after step c), so that in particular the pressing surface (2) obtains a hardness of at least 1100 HV.

8. The method according to one of claims 1 to 7, wherein the metal layers (22) are chromium-free metal layers, in particular nickel layers, and / or the method is a non-etching method, and / or the metal layers are applied by means of a chemical or galvanic method.

9. The method according to one of claims 1 to 8, wherein the mineral particles (23) have a Mohs hardness of at least 8 and / or are diamond particles and / or have a size in the nanometer or micrometer range and / or have a volume share of at least 50% with regard to the volume of the relevant metal layer (22) with mineral particles (23) embedded therein.

10. The method according to one of claims 1 to 9, in which the pressing tool is a pressing plate (1), comprising: applying the masks (24) using a print head (49), which is arranged above the pressing surface (2) to be produced and which is moved during the application of the masks (24) in a plane parallel to the pressing surface (2), and moving the print head (49) in a direction orthogonal to the pressing surface (2), such that the distance between the currently applied mask (24) and the print head (49) is kept constant.

11. A pressing tool which is provided for producing a workpiece and was produced in particular by means of the method according to one of claims 1 to 10, comprising a pressing surface (2) having a structure of protrusions (4) and recesses (3) and multiple metal layers (22) superimposed in layers, which metal layers (22) form the pressing surface (2), wherein the pressing surface (2) has regions of different degrees of gloss, and wherein the metal of at least two metal layers (22) is different, in order to obtain the regions of different degrees of gloss, characterized in that mineral particles (23) are embedded in each one of the metal layers (22).