Press tool and manufacturing method of press plate

Abstract

To provide a press tool having a press surface, and to provide a manufacturing method of the press tool.SOLUTION: The invention relates to a press tool for manufacturing a workpiece, which includes a press surface (2). The press tool includes: a base structure (10); and at least two ceramic layers (11, 12) which are disposed overlapping with each other on a surface (31) to form the press surface (2). One of the ceramic layers is a full ceramic layer (12) having a certain gloss level. The other ceramic layer is a partial ceramic layer (11) having another gross level different from the gloss level of the full ceramic layer (12).SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a press tool having a press surface and a method for manufacturing a press tool. [Background technology]

[0002] Press tools in the form of press plates, endless belts, embossing rollers, etc. are used in particular in the woodworking industry for the production of, for example, furniture, laminates, panels, etc., i.e., workpieces in general. The workpieces are pressed against the press surface of the press tool, which provides the workpiece with a surface corresponding to the press surface.

[0003] Patent Document 1 discloses a method for processing a press surface with an embossed structure. A first chrome layer is applied over the entire surface, and at least one additional chrome layer is applied in a predetermined area. The two chrome layers have different gloss levels. This press surface allows the production of workpieces formed as blanks with surfaces with structures of different gloss levels. The production of this press tool is relatively harmful to the environment due to the use of chrome layers.

[0004] Patent Document 2 discloses a method for producing a flat press surface for producing decorative laminates from resin-impregnated paper. For this purpose, the flat press surface is given a desired finish, 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 a mixture of these substances to a Vickers hardness of at least 2000 HV using a surface magnetron sputtering coating device, by moving the flat surface and the sputtering head of the surface magnetron sputtering coating device relative to each other at a scanning speed sufficient to generate a thermal gradient of 27.78°C or less in the flat press surface. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] International Publication No. 2009 / 062488(A2) [Patent Document 2] U.S. Patent No. 6,190,514(B1) Summary of the Invention [Problem to be solved by the invention]

[0006] SUMMARY OF THE INVENTION It is an object of the present invention to provide a press tool having a press surface with different gloss levels in specific areas, which is relatively environmentally friendly to manufacture. [Means for solving the problem]

[0007] The above problem is solved by a press tool for manufacturing a workpiece, which has a press surface, a base structure, and at least two ceramic layers arranged on top of each other to form the press surface, one of which is a full ceramic layer having a certain glossiness, and the other of which is a partial ceramic layer having another glossiness different from the glossiness of the full ceramic layer.

[0008] The press tool according to the invention is, for example, an endless belt or an embossing roller. Preferably, the press tool according to the invention is a press plate.

[0009] The pressing surface can be, for example, smooth, but can also be designed as a structured pressing surface, in particular the pressing surface can have a structure consisting of ridges and depressions, and the base structure can have a surface that is structured corresponding to the structure of the pressing surface.

[0010] Another aspect of the present invention is a method for manufacturing a press tool according to the present invention, comprising the steps of: providing a base structure; applying one ceramic layer to a surface of a base structure; and applying a ceramic layer to the ceramic layer applied to the structured surface, the ceramic layers having different gloss levels.

[0011] The press tool according to the invention therefore comprises, in a variant, a base structure with a correspondingly structured surface, which may be formed as a structured press surface. The base structure may comprise a number of partial metal layers arranged one on top of the other and forming the surface of the base structure, as is known, for example, from DE 199 02 04 11 52 A1, cited above as an example.

[0012] However, in order to obtain a relatively hard pressing surface, according to the present invention, this surface is coated with a ceramic layer rather than a chromium layer. The ceramic can likewise be designed to be relatively hard, for example, having a Vickers hardness of at least 2000 HV. Suitable ceramic materials for the ceramic layer are, for example, hafnium diboride, molybdenum diboride, tantalum diboride, titanium diboride, tungsten diboride, vanadium diboride, zirconium diboride, or mixtures of these ceramic materials. The application or coating of a ceramic layer is significantly more environmentally friendly than the application or coating of a chromium layer.

[0013] Furthermore, the press tool according to the present invention includes at least two ceramic layers arranged on top of each other, preferably exactly two ceramic layers arranged on top of each other. One ceramic layer is a partial ceramic layer, and the other ceramic layer is a full ceramic layer. According to the present invention, the glossiness of the full ceramic layer differs from that of the partial ceramic layer, so that the press surface has different glossiness in different areas, and thus the surface of the workpiece produced by the press plate also has different glossiness corresponding to each area. As a result, the quality of the workpiece produced by pressing with the press surface can be improved. The workpiece can be, for example, a material board, particularly a laminate or panel.

[0014] In particular, it is also possible to relatively easily remove a worn or damaged ceramic layer from the base structure in order to apply a new ceramic layer to the base structure, thereby allowing for relatively cost-effective repair of worn or damaged press tools.

[0015] The application of the ceramic layer can be carried out, for example, using a surface magnetron sputtering coating device.

[0016] The thickness of both ceramic layers is preferably in the range of 1 μm to 2 μm.

[0017] To achieve different gloss levels for the full ceramic layer and the partial ceramic layer, the thickness of the full ceramic layer is preferably different from the thickness of the partial ceramic layer. That is, the gloss level of each ceramic layer can be adjusted by their thickness. In this case, both ceramic layers preferably consist of the same ceramic material, which can have a positive effect on the manufacturing costs of the press tool according to the present invention. When manufacturing a press plate, the required thickness of the ceramic layer can be achieved, for example, by appropriately controlling a surface magnetron sputtering coating device.

[0018] The glossiness of the two ceramic layers can also be adjusted by using different ceramic materials for the partial and full ceramic layers. Therefore, in a variant of the press plate according to the invention, the ceramic materials of the two ceramic layers can be different in order to obtain different glossinesses for the full ceramic layer and the partial ceramic layer. In this case, in particular, the thickness of the full ceramic layer is equal to the thickness of the partial ceramic layer.

[0019] Preferably, the partial ceramic layer is arranged between the full ceramic layer and the surface of the base structure. Applying a partial mask to the surface of the base structure; applying a ceramic layer to the masked surface in areas not covered by the mask; removing the mask so that the partial ceramic layer is disposed on the structured surface; It can be produced by applying a complete ceramic layer to a partial ceramic layer.

[0020] However, partial ceramic layers can also be produced, for example, by suitable control of a surface magnetron sputtering coating device.

[0021] This modification of the press tool allows for a relatively smooth press surface to be produced relatively easily, since a full ceramic layer is applied over the partial ceramic layer. However, the full ceramic layer must be such that it does not completely cover the glossiness of the underlying partial ceramic layer. In particular, the full ceramic layer is thinner than the partial ceramic layer. That is, the thickness of the full ceramic layer is less than the thickness of the partial ceramic layer.

[0022] However, the press tool according to the invention can also be designed so that a full ceramic layer is arranged between the partial ceramic layer and the structured surface of the base structure, i.e. so that the partial ceramic layer is applied onto the full ceramic layer. A ceramic layer is applied to the entire surface of the base structure, A partial mask is applied to the entire ceramic layer, applying a ceramic layer to the masked full ceramic layer in the areas not covered by the mask; The mask can be removed to leave a partial ceramic layer disposed on the full ceramic layer.

[0023] However, partial ceramic layers can also be produced, for example, by suitable control of a surface magnetron sputtering coating device.

[0024] To obtain a predetermined gloss level for each ceramic layer, the gloss level of the partial and full ceramic layers can also be achieved by post-treatment of the corresponding applied ceramic layers, which can include, for example, polishing or laser treatment of the corresponding ceramic layers.

[0025] According to an embodiment of the press tool according to the invention, the surface of the base structure can have different gloss levels in different areas, in particular different gloss levels between the full ceramic layer and the partial ceramic layer. The adjustment of different gloss levels on the surface of the base structure can be achieved, for example, by using a laser or, in the case of a base structure consisting of several layers arranged on top of one another, as is known from WO 2009 / 062488 A2.

[0026] Embodiments of the present invention are illustrated by way of example in the accompanying schematic drawings. [Brief explanation of the drawings]

[0027] [Figure 1] FIG. 1 is a perspective view of a press plate having a press surface. [Figure 2] FIG. 2 is a side cross-sectional view of the press plate portion. [Figure 3A-3C] 3A-3C show intermediate stages of the press plate during manufacture. DETAILED DESCRIPTION OF THE INVENTION

[0028] Figure 1 shows a perspective view of a press tool, in this case designed as a press plate, which comprises a press surface 2. Figure 2 shows a side cross-sectional view of a portion of the press plate.

[0029] The press surface 2 may be formed smooth, but in this embodiment, it includes a structure consisting of raised portions 4 and recessed portions 3 .

[0030] The structure of the pressing surface 2 is adapted in particular to natural materials, in this case wood.

[0031] The press plate 1 allows workpieces, for example material boards, for example laminates, to be produced by pressing. After pressing, the workpiece has a structured surface corresponding to the structure of the press surface 2.

[0032] The press plate 1 comprises a base structure 10 with a structured surface 31 corresponding to the structure of the press surface 2, in this example shown in FIG. 3A.

[0033] The press plate 1 comprises, in this embodiment, a partial ceramic layer 11 arranged on the structured surface 31 of the base structure 10 and a full ceramic layer 12 arranged on this partial ceramic layer 11 and forming the press surface 2.

[0034] In this embodiment, the base structure 10 is made of metal.

[0035] The press plate 1 comprises in this example a base support, in particular a base support plate 14, for example made of metal, on which the base structure 10 is arranged.

[0036] In this embodiment, the base structure 10 includes a plurality of metal layers 15 positioned one above the other, the metal layers 15 preferably being made of nickel, at least some of which are partially engineered.

[0037] To produce the base structure 10, a mask (not shown in detail) is applied to the metal layer 15 at least once to cover areas, for example in accordance with image data corresponding to the structure of the structured pressing surface 2, and then another metal layer 15 is applied to the areas not covered by this mask, repeating this process until the base structure 10 is produced. The base structure 10 is produced in particular in accordance with the structure of the pressing surface 2, i.e. in accordance with image data corresponding to the protrusions 4 and depressions 5, for which purpose the mask and the metal layer 15 are applied successively in accordance with these image data, for example by electroplating or chemical methods.

[0038] Next, in this embodiment, a mask 32 shown in FIG. 3B is applied to the structured surface 31 of the base structure 10 to partially cover the structured surface 31 of the base structure 10 .

[0039] In this embodiment, a ceramic layer is then applied to the regions of the structured surface 31 of the base structure 10 that are not covered by the mask 32 using a surface magnetron sputtering coating device 33. The mask 32 is then removed, leaving only the regions of the structured surface 31 of the base structure 10 that are not covered by the mask 32 covered with the ceramic layer, resulting in a partial ceramic layer 11. See Figure 3c. By appropriately controlling the surface magnetron sputtering coating device 33, the partial ceramic layer 11 can be given a predetermined thickness, thereby achieving a predetermined glossiness.

[0040] Next, in this embodiment, a full ceramic layer 12 is applied onto the partial ceramic layer 11 using a surface magnetron sputtering coating device 33. In order to adjust the glossiness of the full ceramic layer 12, the full ceramic layer 12 is controlled by the surface magnetron sputtering coating device 33 to obtain a predetermined thickness.

[0041] In this embodiment, both ceramic layers 11, 12 are made of the same ceramic material, such as hafnium diboride, molybdenum diboride, tantalum diboride, titanium diboride, tungsten diboride, vanadium diboride, zirconium diboride, or a mixture of these ceramic materials.

[0042] Since the ceramic layers 11 and 12 have different gloss levels, in this embodiment the thicknesses of the two ceramic layers are different, in particular the full ceramic layer 12 is thinner than the partial ceramic layer 11, and in particular both ceramic layers 11 and 12 are made of the same ceramic material.

[0043] The thickness of both ceramic layers 11 and 12 is preferably in the range of 1 μm to 2 μm.

[0044] The ceramic layer preferably has a Vickers hardness of at least 2000 HV.

[0045] To adjust the different gloss levels of the ceramic layers 11, 12, they may also have different ceramic materials.

[0046] To adjust the glossiness of the ceramic layers 11 and 12, post-treatment such as polishing or laser treatment may be performed.

[0047] It is also possible to first apply the full ceramic layer 12 to the structured surface 31 of the base structure 10 and then apply the partial ceramic layer 11 thereon.

[0048] By properly controlling the surface magnetron sputtering coating device 33, it is also possible to produce a partial ceramic layer 11.

Claims

1. A press tool for manufacturing a workpiece, comprising: a press surface (2); a base structure (10) having a surface (31); At least two ceramic layers (11, 12) arranged on top of each other on the surface (31) and forming the pressing surface (2), one of the ceramic layers being a full ceramic layer (12) having a certain glossiness, and the other ceramic layer being a partial ceramic layer (11) having another glossiness different from the glossiness of the full ceramic layer (12); A press tool comprising:

2. The press surface (2) has a structure consisting of raised portions (4) and recessed portions (3), 2. The press tool according to claim 1, wherein the base structure (10) has a structured surface (31) corresponding to the structure of the press surface (2), in particular the base structure (12) comprises a plurality of partial metal layers (15) arranged one on top of another and forming the structured surface (31) of the base structure (10).

3. The thickness of the full ceramic layer (12) is different from the thickness of the partial ceramic layer (11) in order to obtain different gloss levels of the full ceramic layer (12) and the partial ceramic layer (11).

3. A press tool according to claim 1 or 2, in particular, wherein the two ceramic layers (11, 12) consist of the same ceramic material.

4. The ceramic materials of both ceramic layers (11, 12) are different in order to obtain different gloss levels of the full ceramic layer (12) and the partial ceramic layer (11), 3. A press tool according to claim 1 or 2, in particular, wherein the thickness of the full ceramic layer (12) is equal to the thickness of the partial ceramic layer (11).

5. 5. The press tool according to claim 1, wherein the partial ceramic layer (11) is arranged between the full ceramic layer (12) and a structured surface (31) of the base structure (10) or on the full ceramic layer (12).

6. 6. The press tool according to any one of claims 1 to 5, wherein the thickness of the at least two ceramic layers (11, 12) is in the range of 1 μm to 2 μm, and / or the ceramic material of the at least two ceramic layers (11, 12) is hafnium diboride, molybdenum diboride, tantalum diboride, titanium diboride, tungsten diboride, vanadium diboride, zirconium diboride, or a mixture of these ceramic materials.

7. 7. The press tool according to claim 1, wherein the structured surface (31) of the base structure (10) has different gloss levels in different areas, in particular these gloss levels being different from the gloss levels of the full ceramic layer (12) and the partial ceramic layer (11).

8. A method for manufacturing a press tool according to any one of claims 1 to 7, providing the base structure (10); applying one of the at least two ceramic layers (11, 12) to the structured surface (31) of the base structure (10); applying one of the at least two ceramic layers (11, 12) onto the ceramic layer applied to the structured surface (10), The method for manufacturing a press tool, wherein the at least two ceramic layers (11, 12) have different gloss levels.

9. applying a partial mask to the surface (31) of the base structure (10); applying a ceramic layer to the partially masked structured surface (31) in the areas not covered by the partially masked surface; removing the partial mask so that the partial ceramic layer (11) is disposed on the structured surface (31); and applying the full ceramic layer (12) onto the partial ceramic layer (11).

10. applying the full ceramic layer (12) to the surface (31) of the base structure (10); applying a partial mask to the full ceramic layer (12); applying a ceramic layer onto the partial masked full ceramic layer (12) in areas not covered by the partial mask; removing the partial mask so that the partial ceramic layer (11) is disposed on the full ceramic layer (12); The method of claim 8, comprising:

11. A method for manufacturing a press tool according to any one of claims 8 to 10, comprising a step of post-treating the corresponding applied ceramic layer in order to obtain a predetermined gloss level of the corresponding ceramic layer.

12. applying the at least two ceramic layers (11, 12) by a surface magnetron sputtering coating device (33); The method for manufacturing a press tool according to any one of claims 8 to 11, in particular, manufacturing the partial ceramic layer (11) by appropriately controlling the surface magnetron sputtering coating device (33).

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