Press tool and method for producing a press plate

Description

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

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

[0003] Material boards, such as wood-based panels, are used in the furniture industry and for interior design, such as laminate flooring. These boards have a core made of MDF (medium-density fiberboard) or HDF (high-density fiberboard), onto which various materials are applied on at least one side, such as a decorative (optical) layer and a protective layer (overlay layer).

[0004] To prevent warping in the manufactured material boards, such material boards are usually provided with the same number of material layers on both sides. To bond the individual layers of the material boards (core, material layers, etc.), they are pressed together in a press using special pressing tools, particularly press plates or endless belts. This also involves surface embossing of the material boards. Hot presses are typically used to bond the various material layers made of thermosetting resins, such as melamine resin, to the surface of the core under the influence of heat by fusing the plastic materials.

[0005] The decorative layers determine the pattern and color design of the material panel; however, a desired surface structure can be achieved using suitable pressing tools. For example, a wood or tile pattern can be printed on the decorative layer (decorative paper), or decorative layers with patterns and color designs can be used that are artistically designed according to the respective intended use. Overlay layers printed on the top or bottom side can also be used.

[0006] To improve a true-to-life reproduction, especially for material boards with wood, tile, or natural stone decor, the pressing tools are provided with a surface texture that conforms to the decorative layer and creates a negative image of the desired surface texture. Therefore, the pressing tools feature a 3D profile (depth texture) that, for example, mimics the grain of a wooden surface, giving the decorative layer of the material board the appearance of such a wooden surface.

[0007] To achieve conformal embossing of the material sheets or laminates—that is, the required precision fit of the decorative layer(s) and the structure of the laminate's pressing surface—a high quality standard is required for the production of the pressing tools. In particular, the pressing plates or endless belts are used as upper and lower tools in short-cycle presses equipped with pressing plates and preferably pressing pads, or in double-belt presses with endless belts. Embossing and heating of the material sheets occur simultaneously. The thermoset resins of the decorative and / or overlay layers of the material sheets are first melted, the surface structure corresponding to the structure of the pressing surface of the pressing tools is introduced into the outer material layers, and the structured material layers are bonded to the core of the material sheet by subsequent curing.

[0008] WO 2009 / 062488 A2 discloses a method for machining a structured pressing surface of a stamping tool. The surface is fully coated with a first chrome layer, on which at least one additional chrome layer is applied in predetermined areas. The gloss levels of the two chrome layers differ. Using the pressing surface, a workpiece designed as a material plate can be produced with a structured surface that exhibits different gloss levels. Due to the use of the chrome layers and multiple masking and cleaning steps, the production of this pressing tool is relatively environmentally harmful.

[0009] US 6,190,514 B1 discloses a method for producing a flat press surface for producing a decorative laminate from resin-impregnated paper. To this end, a desired finish is created on a flat press surface, impurities are removed from the flat surface, and the flat surface is coated with hafnium diboride, molybdenum diboride, tantalum diboride, titanium diboride, tungsten diboride, vanadium diboride, zirconium diboride, or mixtures of these materials in a surface magnetron sputter coating system to a Vickers hardness of at least 2000 HV by moving the flat surface and a sputtering head of the surface magnetron sputter coating system relative to each other at a scanning speed sufficient to create a thermal gradient of 27.78°C or less in the flat press surface.

[0010] From EP 1063 085 A1 a pressing tool according to the preamble of the appended claim 1 is known.

[0011] The object of the invention is to provide a pressing tool with a pressing surface with different gloss levels in certain areas, the production of which is relatively environmentally friendly.

[0012] Furthermore, a method for manufacturing a pressing tool is to be demonstrated that ensures easier reproducibility at lower costs. Furthermore, a pressing tool for producing a workpiece, in particular a material plate, is to be created whose surface structure has different structures, for example, coarse and fine structures, with any desired degree of detail and quality.

[0013] Further objects of the invention will become apparent from the disclosure of this application.

[0014] The object of the invention is achieved by a pressing tool for producing a workpiece, comprising a pressing surface, a basic structure, and at least two ceramic layers arranged one above the other on the surface, which form the pressing surface, of which one of the ceramic layers is a full-surface ceramic layer with one degree of gloss and the other is a partial ceramic layer with a further degree of gloss that differs from the degree of gloss of the full-surface ceramic layer.

[0015] The pressing tool according to the invention is, for example, an endless belt or an embossing roller. Preferably, the pressing tool according to the invention is a press plate.

[0016] The pressing surface can be smooth, for example, but can also be designed as a structured pressing surface. In particular, the pressing surface can have a structure of elevations and depressions, and the base structure can have a structured surface corresponding to the structure of the pressing surface, or the pressing surface can deviate in its 3D form through the application of additional layers, particularly ceramic layers.

[0017] A further aspect of the invention is a method for producing the pressing tool according to the invention, comprising the following method steps: Providing a support structure for a base structure, applying at least two base structure layers to the support structure to build up the base structure, producing a structured surface on the support structure, applying a first ceramic layer to the surface of the base structure, and applying a second ceramic layer to the structured surface and / or to the applied first ceramic layer.

[0018] The pressing tool according to the invention can therefore have the basic structure, which, according to one variant, has a structured surface corresponding to the pressing surface, which may be designed as a structured pressing surface. The basic structure comprises, for example, several partial metal layers arranged one above the other, which form the surface of the basic structure, as is known, for example, from WO 2009 / 062488 A2 cited in the introduction.

[0019] However, to achieve a relatively hard pressing surface, according to the invention, this surface can be coated not with a chromium layer, but with ceramic layers. Ceramic can also be relatively hard and can, for example, have a Vickers hardness of at least 2000 HV. Suitable ceramic materials for the ceramic layers include hafnium diboride, molybdenum diboride, tantalum diboride, titanium diboride, tungsten diboride, vanadium diboride, zirconium diboride, or mixtures of these ceramic materials. Applying or coating the ceramic layers is significantly more environmentally friendly than applying or coating the chromium layer.

[0020] Furthermore, the pressing tool according to the invention can comprise at least two ceramic layers arranged one above the other, preferably exactly two ceramic layers arranged one above the other. One of the ceramic layers is a partial and the other can be a full-surface ceramic layer. Because, according to the invention, the gloss levels of the full-surface and the partial ceramic layer can differ, the pressing surface has different gloss levels in different regions, as a result of which the surface of the workpiece produced with the pressing plate can also have correspondingly different gloss levels in certain regions. This can improve the quality of the workpieces produced by pressing with the pressing surface. Workpieces include, for example, material plates, in particular laminates or panels.

[0021] In particular, it is also possible to relatively easily remove a worn or damaged ceramic layer from the base structure and recoat the base structure with new ceramic layers. This results in a relatively cost-effective repair of a worn or damaged press tool.

[0022] The ceramic layers can be applied using a surface magnetron sputtering coating system, for example.

[0023] The thicknesses of the two ceramic layers are preferably in the range between 1µm and 2µm.

[0024] To achieve the different gloss levels of the full-surface and partial ceramic layers, the thickness of the full-surface ceramic layer preferably differs from the thickness of the partial ceramic layer. This is because it is possible to adjust the gloss level of the corresponding ceramic layer via its thickness. In this case, the two ceramic layers preferably consist of the same ceramic material, which can have a positive effect on the manufacturing costs of the pressing tool according to the invention. The required thickness of the ceramic layers can be achieved during the production of the press sheet, for example, by appropriately controlling the surface magnetron sputtering coating system.

[0025] The gloss level of the two ceramic layers can also be adjusted by using different ceramic materials for the partial and full-surface ceramic layers. According to a variant of the press plate according to the invention, the ceramic materials of the two ceramic layers can therefore differ in order to achieve the different gloss levels of the full-surface and partial ceramic layers. In this case, in particular, the thickness of the full-surface ceramic layer is equal to the thickness of the partial ceramic layer.

[0026] Preferably, the partial ceramic layer is arranged between the full-surface ceramic layer and the surface of the base structure. This embodiment of the press plate according to the invention can be produced, for example, by Applying a partial mask to the surface of the basic structure, applying a ceramic layer to the surface provided with the mask in areas not covered by the mask, removing the mask so that the partial ceramic layer is arranged on the structured surface, and applying the full-surface ceramic layer to the partial ceramic layer.

[0027] However, the partial ceramic layer can also be produced, for example, by appropriately controlling the surface magnetron sputtering coating system.

[0028] Since, according to this variant of the pressing tool, the full-surface ceramic layer is applied to the partial ceramic layer, a relatively smooth pressing surface can be produced relatively easily. In this case, however, the full-surface ceramic layer must be designed in such a way that it does not completely cover the gloss level of the underlying partial ceramic layer. In particular, in this case, the full-surface ceramic layer is thinner than the partial ceramic layer, i.e., the thickness of the full-surface ceramic layer is smaller than the thickness of the partial ceramic layer.

[0029] However, the pressing tool according to the invention can also be designed such that the full-surface ceramic layer is arranged between the partial ceramic layer and the structured surface of the base structure, ie that the partial ceramic layer is applied to the full-surface ceramic layer. This embodiment of the pressing tool according to the invention can be produced, for example, by Applying the full-surface ceramic layer to the surface of the base structure, applying a partial mask to the full-surface ceramic layer, applying a ceramic layer to the full-surface ceramic layer provided with the mask in areas not covered by the mask, removing the mask so that the partial ceramic layer is arranged on the full-surface ceramic layer.

[0030] However, the partial ceramic layer can also be produced, for example, by appropriately controlling the surface magnetron sputtering coating system.

[0031] The gloss levels of the partial and full-surface ceramic layers can also be adjusted by post-treating the applied ceramic layer to achieve a specified gloss level. Post-treatment can include, for example, polishing or laser treatment of the respective ceramic layer.

[0032] According to one embodiment of the pressing tool according to the invention, the surface of the base structure can have different gloss levels in different areas, which differ in particular from the gloss levels of the full-surface and the partial ceramic layer. The different gloss levels of the surface of the base structure can be adjusted, for example, using a laser or, in the case of a base structure consisting of several layers arranged one above the other, as is known from WO 2009 / 062488 A2.

[0033] According to the invention, the pressing tool can be used to produce a workpiece, in particular material boards for the furniture industry or for laminate flooring panels. The pressing tool has a pressing surface that is in direct contact with the material board to be pressed and faces it during the pressing of the material board in a press.

[0034] The pressing tool has a basic structure with a surface. This surface can be flat or 3-dimensional. The surface can preferably be formed from a metallic surface, such as chromium, copper, stainless steel, nickel, tin or metallic alloys. Ceramic layers are arranged on this surface and form the pressing surface. A first ceramic layer has a first gloss level and a second ceramic layer a second gloss level. The gloss level can be determined by the material properties of the pressing surface, the layer structure, the surface structure of one or both ceramic layers or the underlying surface of the basic structure. The first gloss level of the first ceramic layer differs from the second gloss level.This makes it possible to create a particularly resistant surface, which can nevertheless be designed in such a way that it realistically replicates a natural look, in particular a wood look.

[0035] The press tool is preferably a press plate for the production of composite panels. Composite panels are used in the furniture industry or for laminate flooring panels. The advantage of using a press plate is that it can be used in existing press systems in the furniture and flooring industries.

[0036] In a further embodiment, the base structure of the pressing tool can comprise a support structure made of metal, particularly stainless steel. A metallic support structure ensures an even distribution of the pressing pressure across the material plate to be pressed and is wear-resistant.

[0037] Preferably, the pressing surface may have a structure of elevations and depressions, and the base structure may have a structured surface provided on the supporting structure, wherein at least two basic structural layers, in particular made of metal, are provided on the supporting structure, which are arranged at least partially one above the other and form the structured surface of the basic structure. These basic structural layers can be applied flatly or in 3D using an additive manufacturing process. Additive manufacturing processes can be, for example, inkjet printing, 3D printing, sintering, lithography, painting, printing with UV-curing ink or acrylate. It is particularly advantageous that cheaper materials and faster and less precise application methods can be used for intermediate layers of the basic structural layer. This enables more cost-effective production with high surface quality on the pressing surface.

[0038] Furthermore, it may be advantageous if the first or second ceramic layer can be applied only partially to the structured surface of the base structure, thus forming a relief layer structure of the structured surface. This allows for further fine structuring of the relief layer structure while simultaneously increasing the resistance of the ceramic layers and / or achieving special optical effects.

[0039] Furthermore, it can be provided that the first ceramic layer and the second ceramic layer can each be applied only partially to the structured surface of the base structure. This allows for further fine structuring of the relief layer structure while simultaneously increasing the resistance of the ceramic layers and / or achieving special optical effects, such as different degrees of gloss or mattness in the partially applied areas.

[0040] In a further development, the second ceramic layer can be arranged at least partially on the first ceramic layer. This can create regions with different surface properties and different structures. This can also contribute to the formation of a relief layer structure.

[0041] Preferably, the first ceramic layer or the second ceramic layer can be laser-processed at least in one laser processing area. Laser processing can be used to alter the degree of gloss, mattness, structure, or create a cutout in an overlying layer on the pressing surface.

[0042] A recess can be provided in the second ceramic layer, which, viewed in the direction of the base structure, extends to the first ceramic layer. When viewed from the press surface, this results in at least two areas that appear different or have different structures.

[0043] Preferably, the recess can be a cutout created by subsequent processing of the applied second ceramic layer. Possible processing steps include milling, laser irradiation, masking, masking with UV-curing ink, and removal, etching, or cracking using alkali or acid. For example, a sodium hydroxide solution containing hydrogen peroxide can be used for removal. These cutouts allow for application over the entire surface and make underlying layers visible or visually effective.

[0044] Furthermore, it may be advantageous for the subsequent processing to be laser processing. The advantage here is that laser processing allows for very precise and fine processing, even at the depth of the layers.

[0045] In a further possible embodiment of the invention, one of the metal layers arranged on the press side of the base structure can be a nickel layer or a nickel-containing metal layer. The first and / or second ceramic layers can be arranged above it on the press side. A metal layer, a nickel layer, or a nickel-containing metal layer can additionally be arranged between the first and second ceramic layers. These metal layers enable the attachment of further layers to function as a connecting layer.

[0046] In another possible embodiment, the structured surface of the base structure is at least partially produced in a 3-dimensional relief layer structure using an additive manufacturing process. Additive manufacturing processes can include, for example, inkjet printing, 3D printing, sintering, lithography, varnishing, printing with UV-curing ink, or acrylic. Such manufacturing processes enable small batch sizes and the realization of customized structural requirements in the furniture industry.

[0047] Alternatively, the structured surface of the base structure can be produced at least partially in 3D form using an electrochemical, mechanical, or laser processing method. For example, masking and etching processes known from the prior art, or electrochemical chromium plating processes, can be used. Proven processes can be used in conjunction with the improvements according to the invention on the press tool, thus increasing the versatility of use.

[0048] The second ceramic layer can optionally fully cover the structured surface of the base structure (10) and have a thickness of preferably 0.001 mm to 2 mm, wherein the first ceramic layer has a different thickness, but preferably also preferably in the range of 0.001 mm to 2 mm. The differences in layer thickness lead to a changed structure and thus to different gloss levels of the first and second ceramic layers, wherein, in particular, the two ceramic layers can consist of the same ceramic material. The different layer thicknesses can be used to achieve optical effects.

[0049] Alternatively, the ceramic material of the two ceramic layers can also be different to achieve the different gloss levels of the first and second ceramic layers, whereby, in particular, the thickness of the second ceramic layer can be the same as the thickness of the first ceramic layer. The use of different ceramic layers further increases the optical and combinatorial possibilities for achieving a lifelike imitation of natural materials.

[0050] The following materials can be used as ceramic materials for the ceramic layers: hafnium diboride, molybdenum diboride, tantalum diboride, titanium diboride, tungsten diboride, vanadium diboride, zirconium diboride, or mixtures of these ceramic materials. The advantage of these materials is their durability and hardness, which leads to improved pressing properties of the pressing tool.

[0051] An embodiment of the pressing tool according to the invention is produced by Providing a support structure for a base structure, applying at least two base structure layers to the support structure to build up the base structure, producing a structured surface on the support structure, applying a first ceramic layer to the surface of the base structure, and applying a second ceramic layer to the structured surface and / or to the applied first ceramic layer.

[0052] This makes it possible to create a particularly resistant surface, which can nevertheless be designed in such a way that it realistically replicates a natural look, in particular a wood look.

[0053] In a further advantageous development, the procedure can include the following steps: Applying a partial mask to the structured surface of the basic structure, applying a first ceramic layer to the structured surface provided with the mask, removing the mask so that the first ceramic layer is only partially arranged on the structured surface, and applying the second ceramic layer over the entire surface of the partially applied first ceramic layer and the structured surface of the basic structure.

[0054] The advantage here is that individual areas on the pressing tool can have different optical properties, such as gloss levels, while production is still simple and masking processes are tried and tested.

[0055] In an alternative embodiment, the method may comprise the following steps: Full-surface application of the first ceramic layer to the structured surface of the base structure. Application of a partial mask to the first ceramic layer. Application of the second ceramic layer to the first ceramic layer provided with the mask.

[0056] The advantage here is that individual areas on the pressing tool can have different optical properties, such as gloss levels, and also contribute to the overall relief structure of the pressing tool.

[0057] Optionally, the mask can be removed so that the first ceramic layer is only partially arranged on the structured surface.

[0058] In a further optional process, a metal layer, a chromium layer, a nickel layer or a nickel-containing metal layer can be applied as a mask.

[0059] The mask can advantageously remain on the pressing tool as a functional layer.

[0060] The method according to the invention can be supplemented by the step of a post-treatment in which the corresponding applied ceramic layer or mask is treated in such a way as to obtain a predetermined degree of gloss of the corresponding ceramic layer or mask.

[0061] In one embodiment, the ceramic layers can be applied using a surface magnetron sputter coating system, with the partial production of the ceramic layer being achieved by appropriately controlling the surface magnetron sputter coating system. This ensures a coherent application of the ceramic layers with a precisely controllable or adjustable layer thickness.

[0062] The method according to the invention can be developed in such a way that the following steps are additionally carried out: Transport of the pressed sheet on a transport system Opening a first lock to the processing area Transport of the pressed sheet into the processing area of the surface magnetron sputtering coating system Closing the first lock Creating a vacuum in the processing area using a vacuum pump Applying one or more ceramic layers using a magnetron Opening the first lock to the processing area Transport of the pressed sheet through the first lock out of the processing area of the surface magnetron sputtering coating system.

[0063] This advantageous further development enables cost-effective production of the pressing tool.

[0064] The method according to the invention may comprise the following additional steps: Transport of the press sheet through a vacuum pre-chamber with a pre-chamber lock, which vacuum pre-chamber is arranged upstream of the processing chamber in the transport direction, wherein the vacuum pre-chamber is brought by means of a vacuum pump to a pressure level which lies between atmospheric pressure and a processing pressure during the application of a ceramic layer in the processing chamber, wherein this processing pressure is in particular below 10^-5 mbar, preferably at 10^-8 mbar.

[0065] This advantageous process improvement ensures energy-efficient coating.

[0066] The method according to the invention may alternatively comprise the additional steps: Transport of the press sheet through a vacuum pre-chamber with a pre-chamber lock, which vacuum pre-chamber is arranged upstream of the processing chamber in the transport direction, wherein the vacuum pre-chamber is brought by means of a vacuum pump to a pressure level which lies between atmospheric pressure and a processing pressure during the application of a ceramic layer in the processing chamber, wherein this processing pressure is in particular below 10^-5 mbar, preferably 10^-8 mbar. Transport of the press sheet through a vacuum post-chamber with a post-chamber lock, which vacuum post-chamber is arranged downstream of the processing chamber in the transport direction, wherein the vacuum post-chamber is brought by means of a vacuum pump to a pressure level which lies between atmospheric pressure and the processing pressure. Advantageously, this enables optimized processing using small amounts of energy to generate the vacuum.

[0067] A further aspect of the invention is the use of a pressing tool according to the invention for producing material boards, in particular material boards for the furniture industry or for laminate flooring panels. Advantageously, the pressing tool according to the invention can be used to produce large quantities of material boards, in particular material boards for the furniture industry or for laminate flooring panels, with minimal wear.

[0068] 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 intermediate stages of the press plate during its production, Fig. 4 shows a section of a side view of the press plate in a sectional view of an alternative embodiment, Fig. 5 shows a section of a side view of the press plate in a sectional view of a further alternative embodiment, Fig. 6 shows a section of a side view of the press plate with a laminate during a pressing process in a closed press in a sectional view, Fig. 7 shows a side view of a surface magnetron sputtering coating system in a sectional view.

[0069] The Fig. 1shows a perspective view of a pressing tool which, in the case of the present exemplary embodiment, is designed as a pressing plate 1. The pressing plate 1 comprises a pressing surface 2. The pressing side 3 is the side of the pressing plate 1 which faces the laminate during a pressing process in a press.

[0070] The Fig. 2 shows a section of a side view of the press plate 1 in a sectional view.

[0071] The pressing surface 2 can be smooth, but in the case of the present embodiment comprises a structure of the elevations 4 and depressions 3.

[0072] The structure of the pressing surface 2 is in particular associated with a natural material, in the case of the present embodiment wood.

[0073] The pressing surface 2 is arranged on several basic structural layers 15 of the basic structure 10. In addition to the basic structural layers 15, the basic structure 10 also includes the supporting structure.

[0074] In this embodiment, the first ceramic layer 11 is arranged partially on the base structure 10 and the second ceramic layer 12 covers the surface 31 of the base structure 10 and the first ceramic layer 11 over its entire area.

[0075] 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 structured surface corresponding to the structure of the press surface 2.

[0076] In the case of the present embodiment, the press plate 1 comprises a Fig. 3A shown basic structure 10 with a structured surface 31 assigned to the structure of the pressing surface 2.

[0077] In the case of the present exemplary embodiment, the press plate 1 comprises a partial ceramic layer 11 arranged on the structured surface 31 of the base structure 10 and a full-surface ceramic layer 12 arranged on the partial ceramic layer 11, which forms the press surface 2.

[0078] In the case of the present embodiment, the basic structure 10 is made of metal.

[0079] In the case of the present embodiment, the press plate 1 comprises a base support, in particular a support structure 14, e.g. made of metal, on which the base structure 10 is arranged.

[0080] In the case of the present embodiment, the basic structure 10 comprises several basic structure layers 15 lying one above the other. The basic structure layers 15 are preferably made of nickel and are at least partially formed and, together with the ceramic layers 11, 12, form the relief layer structure 16.

[0081] The basic structure 10 can be produced, for example, by applying a mask (not shown in detail) at least once to a basic structure layer 15 in accordance with the image data associated with the structure of the structured pressing surface 2 in order to cover areas, and then applying a further basic structure layer 15 to the areas not covered by this mask. This is repeated until the basic structure 10 has been created. The basic structure 10 is produced, in particular, in accordance with the structure of the pressing surface 2, i.e. in accordance with the image data associated with the elevations 4 and depressions 5, by applying the masks and the basic structure layers 15 one after the other, for example by means of a galvanic or chemical process, in accordance with this image data.

[0082] In the case of the present embodiment, a layer of material in the Fig. 3Bshown mask 32 is applied, which partially covers the structured surface 31 of the basic structure 10.

[0083] Subsequently, in the case of the present embodiment, a ceramic layer is applied to the areas of the structured surface 31 of the base structure 10 not covered by the mask 32 using a surface magnetron sputtering coating system 33. The mask 32 is then removed, so that only the areas of the structured surface 31 of the base structure 10 not covered by the mask 32 are covered with the ceramic layer, thereby forming the partial ceramic layer 11, see Fig. 3c By appropriately controlling the surface magnetron sputter coating system 33, the partial ceramic layer 11 is given a predetermined thickness, thereby obtaining a predetermined degree of gloss.

[0084] Subsequently, in the case of the present embodiment, the full-surface ceramic layer 12 is applied to the partial ceramic layer 11 by means of the surface magnetron sputter coating system 33. To adjust the gloss level of the full-surface ceramic layer 12, it is given a predetermined thickness, controlled by the surface magnetron sputter coating system 33.

[0085] In the case of the present embodiment, the two ceramic layers 11, 12 are made of the same ceramic material, e.g. hafnium diboride, molybdenum diboride, tantalum diboride, titanium diboride, tungsten diboride, vanadium diboride, zirconium diboride or mixtures of these ceramic materials.

[0086] In order for the ceramic layers 11, 12 to have different gloss levels, the thicknesses of the two ceramic layers differ in the present embodiment. In particular, the full-surface ceramic layer 12 is thinner than the partial ceramic layer 11. In particular, the two ceramic layers 11, 12 consist of the same ceramic material.

[0087] The thicknesses of the two ceramic layers 11, 12 are preferably in the range between 1µm and 2µm.

[0088] The ceramic layers preferably have a Vickers hardness of at least 2000 HV.

[0089] In order to achieve different gloss levels of the ceramic layers 11, 12, these can also comprise different ceramic materials.

[0090] In order to adjust the gloss levels of the ceramic layers 11, 12, they can also be subjected to a post-treatment, e.g. polishing or laser treatment.

[0091] It is also possible to first provide the structured surface 31 of the basic structure 10 with the full-surface ceramic layer 12 and to apply the partial ceramic layer 11 thereto.

[0092] It is also possible to produce the partial ceramic layer 11 by appropriately controlling the surface magnetron sputter coating system 33 Fig. 4 shows a section of a side view of the press plate in a sectional representation of an alternative embodiment. The first ceramic layer 11 and the second ceramic layer 12 are each only partially applied to the structured surface 31 of the base structure 10. As in the other exemplary embodiments, the base structure layers 15 can be metallic, in particular made of nickel, but also of other materials such as plastic or ceramic. The base structure layers 15 can be applied using known additive or subtractive manufacturing processes.

[0093] In a further advantageous development of this embodiment, the second ceramic layer 12 can be arranged at least partially on the first ceramic layer 11.

[0094] The first ceramic layer 11 or the second ceramic layer 12 can also be processed by means of a laser, at least in a laser processing area 17. Processing by a laser can serve, in particular, to influence the degree of gloss, the reflection properties, the mattness, or the structure of the ceramic layer and thus to transfer these structural properties as a positive to the laminate to be produced.

[0095] In a further embodiment according to Figure 4The second ceramic layer 12 can completely cover the structured surface 31 of the base structure 10 and have a second thickness 19, wherein the first ceramic layer 11 has a first thickness 18. The first thickness 18 and the second thickness 19 can have different layer thicknesses in order to achieve the different gloss levels of the first and second ceramic layers 11, 12, wherein, in particular, the two ceramic layers 11, 12 can consist of the same ceramic material.

[0096] The ceramic material of the ceramic layers 11, 12 in all embodiments of this invention can consist, for example, of hafnium diboride, molybdenum diboride, tantalum diboride, titanium diboride, tungsten diboride, vanadium diboride, zirconium diboride or mixtures of these ceramic materials.

[0097] In a further embodiment according to Figure 4. The ceramic material of the two ceramic layers 11, 12 may differ in order to obtain different degrees of gloss of the first ceramic layer 11 and the second ceramic layer 12, wherein in particular the thickness 19 of the second ceramic layer 12 is equal to the thickness 18 of the first ceramic layer 11.

[0098] The thicknesses of the two ceramic layers 11, 12 are preferably in the range between 1µm and 2mm.

[0099] In overlapping areas 13, the two ceramic layers can be arranged at least partially on top of each other.

[0100] Fig. 5shows a section of a side view of the press plate in a sectional representation of a further alternative embodiment, in which the two ceramic layers 11, 12 are arranged at least partially one above the other. The second ceramic layer 12 arranged on the pressing side 7 of the pressing tool has at least one recess 5 which allows the first ceramic layer to emerge to the surface, or opens a cutout 6 like a window thereto. Production can take place using masks 32 during the application of the ceramic layer 12 and subsequent removal of the mask 32, or by removing part of the second ceramic layer 12 using a chemical process, for example using sodium hydroxide solution containing hydrogen peroxide.

[0101] Furthermore, the basic structure is based on the implementation examples of the Figures 2 and 3 or 4 .

[0102] Fig. 6shows a section of a side view of the press plate with a laminate during a pressing process in a closed press in a sectional view. The pressing tool, in particular a press plate 1, is placed on a press pad 9 in a press 20, for example, a short-cycle press. During the illustrated pressing process with closed parts of the press 20, a laminate 8, in particular a material plate for the furniture industry or floor panels, is fused under the influence of temperature and pressure, and the negative form of the pressing surface 2 with its depressions 3 and elevations 4 is reproduced as a positive in the laminate 8.

[0103] Fig. 7 shows a side view of a surface magnetron sputtering coating system 33 in a sectional view.

[0104] In this embodiment, a surface magnetron sputter coating system 33 is shown which has a multi-chamber system.

[0105] Alternatively, a single-chamber system with only one processing chamber 24 without additional chambers is also possible.

[0106] A pressing tool, in particular a press sheet 1, is introduced into a vacuum pre-chamber 25 by means of a transport system 21 with the pre-chamber lock 26 open. The pre-chamber lock 26 is closed, and the vacuum pump 30 reduces the pressure in the vacuum pre-chamber 25. For example, to a pressure of less than 10^-2 mbar, preferably 10^-5 mbar. During this time, the lock 22 is closed, and a processing pressure prevails in the processing chamber. Subsequently, the lock 22 is opened, and the pressure adjusts between the processing chamber 24 and the vacuum pre-chamber 25. This allows energy to be saved and cycle time to be gained compared to a single-chamber system. The pressing tool is conveyed into the processing chamber 24. The locks 22 and 23 are closed, and a vacuum is applied in the processing chamber by the vacuum pump 29. The processing pressure is less than 10^-5 mbar, preferably 10^-8 mbar.After completion of the machining process, the pressing tool is conveyed through the opened lock 23 into the vacuum post-chamber. There, a pressure level comparable to that of the vacuum pre-chamber prevails before the post-chamber lock is opened. The vacuum pre-chamber and the vacuum post-chamber can be connected to each other via vacuum lines with valves in order to exchange vacuum between the vacuum pre-chamber and the vacuum post-chamber during a cycle change in continuous operation of the surface magnetron sputter coating system 33, thus saving energy for the operation of the vacuum pumps 30. For all embodiments of the invention, it is possible to use other PVD coating systems, PVD sputtering systems, magnetron sputtering systems, or similar systems instead of a surface magnetron sputtering coating system. Reference symbol list

[0107] 1Press plate 2Press surface 3Recesses 4Protrusions 5Recess 6Cutout 7Press side 8Material plate 9Press pad 10Base structure 11Ceramic layer 12Ceramic layer 13Coverage area 14Support structure 15Base structure layer 16Relief layer structure 17Laser processing area 18Thickness (of the first ceramic layer) 19Thickness (of the second ceramic layer) 20Press 21Transport system 22Lock 23Lock 24Processing chamber 25Vacuum pre-chamber 26Pre-chamber lock 27Vacuum post-chamber 28Post-chamber lock 29Vacuum pump 30Vacuum pump 31Surface (of the base structure 10) 32Mask 33Area magnetron sputtering coating system 34Metal layer 35Functional layer 36Magnetron

Claims

1. A pressing tool for producing a workpiece, comprising a pressing surface (2), a base structure (10), which comprises a surface (31), and at least two ceramic layers (11, 12) which are arranged on the surface (31) and form the pressing surface (2), characterized in that a first ceramic layer (11) has a first degree of gloss and a second ceramic layer (12) has a second degree of gloss, which differs from the first degree of gloss of the first ceramic layer (11).

2. The pressing tool according to claim 1, wherein the pressing tool is a press plate (1) for producing a material board (8).

3. The pressing tool according to claim 1 or 2, wherein the base structure (10) of the pressing tool comprises a support structure (14) made of metal, in particular stainless steel.

4. The pressing tool according to one of claims 1 to 3, wherein the pressing surface (2) has a structure of protrusions (4) and recesses (3), and the base structure (10) has a structured surface (31) provided on the support structure (14), wherein at least two base structure layers (15), in particular made of metal, are provided on the support structure (14), which are arranged at least partially one above the other and form the structured surface (31) of the base structure (10).

5. The pressing tool according to one of claims 1 to 4, wherein the first or the second ceramic layer (11, 12) are applied only partially to the structured surface (31) of the base structure (10) and thus form a relief layer structure (16) of the structured surface (31).

6. The pressing tool according to one of claims 1 to 4, wherein the first ceramic layer (11) and the second ceramic layer (12) are each applied only partially on the structured surface (31) of the base structure (10).

7. The pressing tool according to one of claims 1 to 6, wherein the second ceramic layer (12) is arranged at least partially on the first ceramic layer (11).

8. The pressing tool according to one of claims 1 to 7, wherein the first ceramic layer (11) or the second ceramic layer (12) is processed by means of a laser at least in a laser processing area (17).

9. The pressing tool according to claim 7, wherein a clearance (5) is provided in the second ceramic layer (12), which, viewed in the direction of the base structure (10), extends to the first ceramic layer (11).

10. The pressing tool according to claim 9, wherein the clearance (5) is a cutout (6) produced by subsequent processing of the applied second ceramic layer (12).

11. The pressing tool according to claim 10, wherein the subsequent processing is a laser processing.

12. The pressing tool according to one of claims 1 to 11, wherein at least one of the metal layers (15) arranged on the pressing side (7) of the base structure (10), is a nickel layer or nickel-containing metal layer.

13. The pressing tool according to one of claims 1 to 12, wherein the structured surface (31) of the base structure (10) is at least partially produced in a 3-dimensional relief layer structure (16) using an additive manufacturing process.

14. The pressing tool according to one of claims 1 to 12, wherein the structured surface (31) of the base structure (10) is produced at least partially in a 3-dimensional form using an electrochemical, mechanical or laser processing process.

15. The pressing tool according to one of claims 1 to 14, wherein the second ceramic layer (12) covers the structured surface (31) of the base structure (10) over the entire surface and has a second thickness (19), wherein the first ceramic layer (11) has a first thickness (18), wherein the first thickness (18) and the second thickness (19) have different layer thicknesses in order to obtain the different degrees of gloss of the first and the second ceramic layers (11, 12), wherein in particular the two ceramic layers (11, 12) consist of the same ceramic material.

16. The pressing tool according to one of claims 1 to 14, wherein the ceramic material of the two ceramic layers (11, 12) differs to obtain different degrees of gloss of the first ceramic layer (11) and the second ceramic layer (12), wherein in particular the thickness (19) of the second ceramic layer (12) is equal to the thickness (18) of the first ceramic layer (11).

17. The pressing tool according to one of claims 1 to 16, wherein the ceramic material of the ceramic layers (11, 12) is hafnium diboride, molybdenum diboride, tantalum diboride, titanium diboride, tungsten diboride, vanadium diboride, zirconium diboride or mixtures of these ceramic materials.

18. A method for producing a pressing tool according to one of claims 1 to 17, comprising the following method steps: - providing a support structure (14) for a base structure (10), - applying at least two base structure layers (15) onto the support structure (14) to build the base structure (10) - producing a structured surface (31) on the support structure (14) - applying a first ceramic layer (11) onto the surface (31) of the base structure (10), and - applying a second ceramic layer (12) onto the structured surface (10) and / or onto the applied first ceramic layer (11).

19. The method according to claim 18, comprising - applying a partial mask (32) onto the structured surface (31) of the base structure (10), - applying a first ceramic layer (11) onto the structured surface (31) provided with the mask, - removing the mask (32) so that the first ceramic layer (11) is only partially arranged on the structured surface (31), and - full-surface application of the second ceramic layer (12) onto the partially applied first ceramic layer (11) and the structured surface (31) of the base structure (10).

20. The method according to claim 18, comprising - full-surface application of the first ceramic layer (11) onto the structured surface (31) of the base structure (10), - applying a partial mask (32) onto the first ceramic layer (11), - applying the second ceramic layer onto the first ceramic layer (11) provided with the mask.

21. The method according to claim 20, comprising removal of the mask (32) so that the first ceramic layer (11) is only partially arranged on the structured surface (31).

22. The method according to one of claims 19 to 21, wherein a metal layer (34), a chromium layer, a nickel layer or nickel-containing metal layer is applied as the mask (32).

23. The method according to claim 22, wherein the mask (32) remains on the pressing tool as a functional layer (35).

24. The method according to one of claims 18 to 24, comprising subsequent treatment of the corresponding applied ceramic layer (11, 12) or mask (32) in order to obtain a predetermined degree of gloss of the corresponding ceramic layer (11, 12) or mask (32).

25. The method according to one of claims 18 to 24, comprising application of the ceramic layers (11, 12) by means of a surface magnetron sputter coating system (33), wherein the partial production of the ceramic layer (11, 12) is performed by suitably controlling the surface magnetron sputter coating system (33).

26. The method according to claim 25, comprising - transport of the press plate (1) on a transport system (21) - opening of a first lock (22) to the processing chamber (24) - transport of the press plate (1) into the processing chamber (24) of the surface magnetron sputter coating system (33) - closing of the first lock (22) - application of a vacuum in the processing chamber (24) by means of a vacuum pump (29) - application of one or more ceramic layers (11, 12) by means of a magnetron (36) - opening of the first lock (22) to the processing chamber (24) - transport of the press plate (1) through the first lock (22) out of the processing chamber (24) of the surface magnetron sputter coating system (33).

27. The method according to claim 26 comprising the additional steps - transport of the press plate (1) through a vacuum prechamber (25) with a prechamber lock (26), which vacuum prechamber is upstream of the processing chamber (24) as seen in the transport direction, wherein the vacuum prechamber (25) is brought by means of a vacuum pump (30) to a pressure level which is between atmospheric pressure and a processing pressure during the application of a ceramic layer (11, 12) in the processing chamber (25), wherein this processing pressure is in particular below 10^-5 mbar, preferably at 10^-8 mbar.

28. The method according to claim 26 comprising the additional steps - transport of the press plate (1) through a vacuum prechamber (25) with a prechamber lock (26), which vacuum prechamber is upstream of the processing chamber (24) as seen in the transport direction, wherein the vacuum prechamber (25) is brought by means of a vacuum pump (30) to a pressure level which is between atmospheric pressure and a processing pressure, during the application of a ceramic layer (11, 12) in the processing chamber (25), wherein this processing pressure is in particular below 10^-5 mbar, preferably at 10^-8 mbar. - transport of the press plate (1) through a vacuum postchamber (27) with a postchamber lock (28), which vacuum postchamber is located downstream of the processing chamber (24) as seen in the transport direction, wherein the vacuum postchamber (27) is brought by means of a vacuum pump (30) to a pressure level which is between the atmospheric pressure and the processing pressure.

29. A use of a pressing tool according to the invention according to one of claims 1 to 17 for producing material boards.