Method for manufacturing press tools and press plates

Abstract

The present invention relates to a press tool for manufacturing workpieces, comprising a press surface (2), the press tool comprising a base structure (10) and at least two ceramic layers (11, 12) forming the press surface (2) arranged on a surface (31), a first ceramic layer (11) of the plurality of ceramic layers (11, 12) having a first glossiness and a second ceramic layer (12) having a second glossiness different from the first glossiness of the first ceramic layer (11).

Description

[Technical Field]

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

[0002] Pressing tools, such as press plates, endless belts, and embossing rollers, are used particularly in the woodworking industry to manufacture materials such as furniture, laminates, or panels—in other words, workpieces in general. The workpiece is pressed against the pressing surface of the pressing tool, giving the workpiece a surface corresponding to the pressing surface.

[0003] Material boards, such as wood-based material boards, are required for the furniture industry and interior finishing, such as laminate flooring. Material boards have a core made of MDF (medium-density fiberboard) or HDF (high-density fiberboard), and various material layers, such as a (visual) decorative layer or a protective layer (overlay layer), are formed on at least one side of the core.

[0004] To prevent warping of the manufactured material boards, such boards typically have the same number of material layers on both sides. To bond the individual layers of the material board (core material, material layers, etc.) together, they are pressed against each other using a press machine with special pressing tools, particularly a press plate or endless belt. Surface marking of the material board is also performed during this process. Typically, a hot press is used to fuse the plastic material with heat, bonding various material layers of thermosetting resins, such as melamine resin, to the surface of the core material.

[0005] In this case, the decorative layer determines the pattern and color of the material board. On the other hand, the desired surface structure can be achieved by using appropriate pressing tools. For example, wood or tile decorations can be printed on the decorative layer (decorative paper), or decorative layers with artistically designed patterns and colors can be used according to their respective purposes. Overlay layers printed on the top or bottom surface can also be used.

[0006] To improve the accuracy of the reproduction, the pressing tool is designed to perfectly match the decorative layer, especially in the case of material boards with wood, tile, or natural stone decorations, and features a surface structure that forms a negative image of the desired surface structure. Thus, the pressing tool can, for example, have a 3D profile (depth structure) that mimics the veins of a wood surface, thereby giving the decorative layer of the material board the appearance of such a wood surface.

[0007] Achieving the precise matching required for the structure of the pressed surface of the material board or laminate, i.e., the matching of the decorative layer and the laminate, requires high quality standards in the manufacture of the press tool. In particular, the press plate or endless belt is used as the upper and lower die in a short-cycle press machine covered with a press plate and preferably a press pad, or in the case of an endless belt, in a double-belt press, to simultaneously stamp and heat the material board. As a result, the thermosetting resin of the decorative layer and / or overlay layer of the material board is first melted, introducing a surface structure corresponding to the structure of the press tool's pressed surface into the outer material layer, and subsequent curing bonds the structured material layer to the core material of the material board.

[0008] Patent Document 1 discloses a method for processing an embossed, structured press surface. A first chromium layer is applied to the entire surface, and at least one other chromium layer is placed in a predetermined area on this surface. The gloss levels of the two chromium layers are different. The press surface can be used to manufacture workpieces formed as material boards with surfaces having different gloss levels. The manufacture of this press tool is relatively harmful to the environment due to the use of chromium layers and multiple masking and cleaning steps.

[0009] Patent Document 2 discloses a method for manufacturing a flat press surface for producing decorative laminates from resin-impregnated paper. For this purpose, a flat press surface is given a desired finish, impurities are removed from the flat surface, and this flat surface is coated with hafnium diboride, molybdenum diboride, tantalum diboride, titanium diboride, tungsten diboride, vanadium diboride, zirconium diboride, or a mixture thereof to a Vickers hardness of at least 2000 HV using a surface magnetron sputtering coating apparatus, for which the flat surface and the sputtering head of the surface magnetron sputtering coating apparatus are moved relative to each other at a scanning speed sufficient to create a thermal gradient of 27.78°C or less within the flat press surface. [Prior art documents] [Patent Documents]

[0010] [Patent Document 1] International Publication No. 2009 / 062488(A2) [Patent Document 2] U.S. Patent No. 6190514(B1) [Overview of the project] [Problems that the invention aims to solve]

[0011] The object of the present invention is to provide a press tool having a press surface with different gloss levels in specific areas, manufactured in a relatively environmentally friendly manner. Furthermore, this paper presents a method for manufacturing press tools that guarantees easier reproducibility at a lower cost.

[0012] Furthermore, the present invention provides press tools for manufacturing material boards, in particular, which have workpieces and surface structures with different structures, such as coarse and fine structures, and with any degree of detail and quality.

[0013] Other issues of the present invention will become apparent from the disclosures of this application. [Means for solving the problem]

[0014] 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 the surface overlapping each other to form the press surface, one of which is a full ceramic layer having a certain glossiness, and the other ceramic layer is a partial ceramic layer having a different glossiness than that of the full ceramic layer.

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

[0016] The press surface can be, for example, smooth, but it can also be designed as a structured press surface. In particular, the press surface can have a structure consisting of raised and recessed parts, and the base structure can have a structured surface corresponding to the structure of the press surface, or the press surface can deviate from its three-dimensional shape by further coating layers, especially ceramic layers.

[0017] Another aspect of the present invention is a method for manufacturing a press tool according to the present invention, Steps include preparing a support structure for the base structure, The steps include applying at least two base structural layers to the support structure to form the base structure, A step of creating a structured surface on a support structure, The steps include applying a first ceramic layer to the surface of the base structure, The process includes the step of applying a second ceramic layer onto a structured surface and / or a first ceramic layer that has been coated.

[0018] Accordingly, the pressing tool according to the present invention may, according to a variant, comprise a base structure having a structured surface corresponding to a pressing surface that is optionally formed as a structured pressing surface. The base structure comprises a plurality of partial metal layers arranged superimposed on one another to form the surface of the base structure, as is known, for example, from Patent Document 1 cited as an example at the beginning.

[0019] However, in order to obtain a relatively hard pressing surface, according to the present invention, this surface is provided not with a chromium layer but with a ceramic layer. Ceramics can likewise be designed to be relatively hard, and can for example have 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 a mixture of these ceramic materials. Applying or coating the ceramic layer is significantly more environmentally friendly compared to applying or coating a chromium layer.

[0020] Furthermore, the pressing tool according to the present invention may comprise at least two ceramic layers arranged superimposed on one another, preferably exactly two ceramic layers arranged superimposed on one another. One ceramic layer may be a partial ceramic layer and the other ceramic layer may be a full-face ceramic layer. According to the present invention, the glossiness of the full-face ceramic layer can be different from the glossiness of the partial ceramic layer, so that the pressing surface has different glossiness in different regions, whereby the surface of a workpiece produced by the pressing plate can likewise have different glossiness corresponding to the respective regions. As a result, the quality of the workpiece produced by pressing with the pressing surface can be improved. The workpiece is, for example, a material board, in particular a laminate or a panel.

[0021] In particular, in order to apply a new ceramic layer to the base structure, it is also possible to remove a worn or damaged ceramic layer from the base structure relatively easily. Therefore, a worn or damaged pressing tool can be repaired relatively cost-effectively.

[0022] The ceramic layer can be applied, for example, by using a surface magnetron sputtering coating apparatus.

[0023] The thickness of both ceramic layers is preferably in the range of 1 μm to 2 μm.

[0024] In order to obtain different glossiness between the full-surface ceramic layer and the partial ceramic layer, the thickness of the full-surface ceramic layer is preferably different from the thickness of the partial ceramic layer. That is, it is possible to adjust the glossiness of each ceramic layer through their thicknesses. In this case, both ceramic layers are preferably made of the same ceramic material, which can have a favorable influence on the manufacturing cost 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 apparatus.

[0025] The glossiness of both ceramic layers can also be adjusted by using different ceramic materials for the partial ceramic layer and the full-surface ceramic layer. Therefore, according to a variant of the press plate according to the present invention, in order to obtain different glossiness between the full-surface ceramic layer and the partial ceramic layer, the ceramic materials of both ceramic layers can be different. 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 present invention is, for example, applying a partial mask on the surface of a base structure, applying a ceramic layer to regions not covered by the mask on the masked surface, removing the mask such that the partial ceramic layer is arranged on the structured surface, can be manufactured by applying a complete ceramic layer onto the partial ceramic layer.

[0027] However, partial ceramic layers can also be manufactured, for example, by properly controlling a surface magnetron sputtering coating apparatus.

[0028] According to this modified press tool, a full ceramic layer is applied over a partial ceramic layer, making it relatively easy to produce a relatively smooth press surface. However, in this case, the full ceramic layer must not completely cover the glossiness of the underlying partial ceramic layer. In particular, in this case, 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.

[0029] However, the press tool according to the present invention may also be designed such that the full ceramic layer is positioned between the partial ceramic layer and the structured surface of the base structure, i.e., the partial ceramic layer is coated on the full ceramic layer. An embodiment of this press tool according to the present invention is, for example, A ceramic layer is applied to the entire surface of the base structure. Apply a partial mask to the entire ceramic layer, On a full-surface ceramic layer that has been masked, a ceramic layer is applied to the areas not covered by the mask. It can be manufactured by removing the mask so that a partial ceramic layer is placed on top of a full ceramic layer.

[0030] However, partial ceramic layers can also be manufactured, for example, by appropriately controlling a surface magnetron sputtering coating apparatus.

[0031] To obtain a predetermined gloss level for each ceramic layer, the gloss levels of the partial and full ceramic layers can also be achieved by post-treatment of the correspondingly applied ceramic layers. Post-treatment may include, for example, polishing or laser treatment of the corresponding ceramic layers.

[0032] According to embodiments of the press tool of the present invention, the surface of the base structure can have different gloss levels in different regions, and these gloss levels differ in particular from those of the full ceramic layer and the partial ceramic layer. Adjusting the different gloss levels of the surface of the base structure can be done, for example, using a laser, or, in the case of a base structure consisting of multiple layers arranged in overlapping positions, as is known from International Publication No. 2009 / 062488(A2) (Patent Document 1).

[0033] According to the present invention, a press tool can be used to manufacture workpieces, particularly material boards or laminate flooring panels for the furniture industry. The press tool has a pressing surface that is in direct contact with and faces the material board being pressed when the material board is pressed in a press machine.

[0034] The press tool has a support structure with a surface. This surface may be formed in a planar or three-dimensional manner. The surface can preferably be made of a metal such as chromium, copper, stainless steel, nickel, tin, or a metal alloy. On this surface, a ceramic layer is placed to form the press surface. The first ceramic layer has a first gloss, and the second ceramic layer has a second gloss. In this case, the gloss can be determined by the material properties of the press surface, the layer structure, the surface structure of one or both ceramic layers, or the surface of the base structure located beneath them. The first gloss of the first ceramic layer is different from the second gloss. This makes it possible to create a particularly durable surface, and yet the surface can be designed to realistically mimic the appearance of real objects, especially wood.

[0035] Preferably, the press tool is a press plate for manufacturing material boards. These material boards are used in the furniture industry and for laminate flooring panels. The advantage of using a press plate is that it can be used with existing press equipment in the furniture and flooring industries.

[0036] In another embodiment, the basic structure of the press tool may have a support structure made of metal, particularly stainless steel. The metal support structure ensures that the pressing pressure is evenly distributed on the material board being pressed and is wear-resistant.

[0037] Preferably, the press surface has a structure consisting of raised and recessed portions, and the base structure may have a structured surface provided on a support structure, wherein at least two particularly metallic base structure layers are provided on the support structure, at least partially overlapping each other, to create the structured surface of the base structure. These base structure layers can be applied planarly or in a three-dimensional form by additive manufacturing. Additive manufacturing methods can be, for example, inkjet printing, 3D printing, sintering, lithography, lacquer coating, UV-curing ink, or acrylate printing. Particularly advantageous here is the use of less expensive materials and faster, less precise application methods for the intermediate layers of the base structure layers. This enables the production of a more cost-effective press surface with high surface quality.

[0038] Furthermore, it may be useful to partially apply the first or second ceramic layer to the structured surface of the base structure to form a relief layer structure on the structured surface. This allows for even finer structuring of the relief layer structure, while simultaneously increasing the durability of the ceramic layer and / or achieving special visual effects.

[0039] Furthermore, the first and second ceramic layers can be applied only partially to the structured surface of the base structure. This allows for a more finely structured relief layer, while simultaneously increasing the durability of the ceramic layers and / or achieving special visual effects, such as different levels of gloss or matte finish in the partially applied areas.

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

[0041] Preferably, the first or second ceramic layer can be processed using a laser in at least the laser processing area. Laser processing can cause changes in glossiness, mattiness, and structure, or cuts in the layer located on the press surface.

[0042] An opening can be provided within the second ceramic layer that extends to the first ceramic layer when viewed in the direction of the base structure. As a result, when the pressed surface is observed, at least two regions with different appearances or different structures are created.

[0043] Preferably, the openings can be notches created by subsequent processing of the coated second ceramic layer. Possible processing steps include milling, laser irradiation, masking, masking with UV-curing paint, removal or etching with alkali or acid, or cracking. For example, a sodium hydroxide solution containing hydrogen peroxide can be used for removal. These notches allow for coating the entire surface, making the underlying layer visible or creating a visual effect.

[0044] Furthermore, if the subsequent processing is laser processing, it can be useful. The advantage in this case is that laser processing allows for very precise and fine processing even in deep layers.

[0045] In another possible embodiment of the present invention, at least one of the metal layers positioned on the press side of the base structure may be a nickel layer or a nickel-containing metal layer. A first ceramic layer and / or a second ceramic layer may be positioned on the press side. An additional metal layer, nickel layer, or nickel-containing metal layer may be positioned between the first ceramic layer and the second ceramic layer. These metal layers allow for the introduction of another layer that functions as a binding layer.

[0046] In another possible embodiment, the structured surface of the base structure is manufactured by additive manufacturing with at least partially a three-dimensional relief layer structure. Additive manufacturing methods can include, for example, inkjet printing, 3D printing, sintering, lithography, lacquering, UV-curing inks, or acrylate printing. Such manufacturing methods enable small-batch production and meet the individual structural requirements of the furniture industry.

[0047] As an alternative to the above, the structured surface of the base structure can be manufactured into at least partially three-dimensional shapes using electrochemical, mechanical, or laser processing methods. In this case, for example, masking and etching processes known in the prior art, or electrochemical chromium plating processes can be used. Herein, the demonstrated methods can be used with press tools along with improvements according to the present invention, thereby increasing the versatility of applications.

[0048] The second ceramic layer can optionally completely cover the structured surface of the base structure (10) and preferably has a thickness of 0.001 mm to 2 mm, while the first ceramic layer preferably has a different thickness, preferably in the range of 0.001 mm to 2 mm. As a result of the different layer thicknesses, the structures of the first and second ceramic layers will be different, and consequently, their gloss levels will also be different, and in particular, both ceramic layers can be made of the same ceramic material. Different layer thicknesses can be used to achieve visual effects.

[0049] As an alternative to the above, the ceramic materials of the first and second ceramic layers can also be different in order to obtain different gloss levels for the first and second ceramic layers, and in particular, the thickness of the second ceramic layer may be equal to the thickness of the first ceramic layer. By using different ceramic layers, the visual and combination possibilities for realistically imitating natural materials are further enhanced.

[0050] For example, the following materials can be used as the ceramic material for the ceramic layer: hafnium diboride, molybdenum diboride, tantalum diboride, titanium diboride, tungsten diboride, vanadium diboride, zirconium diboride, or mixtures of these ceramic materials. The advantages of these materials are their durability and hardness, which leads to improved pressing properties of the press tool.

[0051] Embodiments of the press tool according to the present invention include, for example, Prepare a support structure for the base structure, To form the base structure, at least two base structure layers are applied to the support structure. A structured surface is created on the support structure, A first ceramic layer is applied to the surface of the base structure. It can be manufactured by coating a second ceramic layer onto a structured surface and / or a coated first ceramic layer.

[0052] By doing so, a particularly durable surface can be formed, and yet the surface can be shaped to realistically mimic the appearance of the real thing, especially the appearance of wood.

[0053] In another advantageous developmental form, this method The steps include applying a partial mask to the structured surface of the base structure, The steps include applying a first ceramic layer to a masked, structured surface, The steps include removing the mask so that the first ceramic layer is only partially positioned on the structured surface, The process includes the steps of partially coating a first ceramic layer and then completely coating a second ceramic layer onto the structured surface of a base structure.

[0054] The advantage in this case is that individual areas on the press tool can have different visual characteristics, such as glossiness, yet the manufacturing process is simple, and the masking method has proven effective.

[0055] In an alternative embodiment, this method is The steps include: applying a first ceramic layer to the entire structured surface of the base structure; The steps include applying a partial mask to the first ceramic layer, The method includes the step of applying a second ceramic layer onto a first ceramic layer that has been masked.

[0056] An advantage in this case is that individual areas on the press tool can have different visual characteristics, such as glossiness, which also contributes to the overall relief structure of the press tool.

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

[0058] In another optional embodiment of the method, a metal layer, a chromium layer, a nickel layer, or a nickel-containing metal layer may be applied as a mask.

[0059] In this case, advantageously, the mask can remain on the press tool as a functional layer.

[0060] The method according to the present invention can be complemented by a post-treatment step, which involves treating the respective coated ceramic layers or masks to impart a predetermined gloss to the corresponding ceramic layers or masks.

[0061] In one embodiment, the ceramic layer can be coated using a surface magnetron sputtering coating apparatus, and the ceramic layer can be partially manufactured by appropriately controlling the surface magnetron sputtering coating apparatus. This ensures a consistent coating of the ceramic layer with precisely controlled or adjustable layer thickness.

[0062] The method according to the present invention can be further developed to include the following additional steps. Steps include transporting the press plate on a conveying device, Steps to open the first lock leading to the processing chamber, The step of transporting the press plate into the processing chamber of the surface magnetron sputtering coating apparatus, Step to close the first lock, A step of creating a vacuum inside the processing chamber using a vacuum pump. A step of applying one or more ceramic layers using a magnetron, Steps to open the first lock leading to the processing chamber, A step of removing the press plate from the processing chamber of the surface magnetron sputtering coating apparatus through the first lock.

[0063] This advantageous developmental model makes it possible to manufacture press tools in a cost-effective manner.

[0064] The method according to the present invention includes the following additional steps, namely, The press plate is transported through a vacuum pre-chamber equipped with a pre-chamber lock, which is located upstream of the processing chamber in the transport direction. The vacuum pre-chamber is brought to a pressure level between atmospheric pressure and the processing pressure when the ceramic layer is applied in the processing chamber by a vacuum pump, and this processing pressure is particularly 10 -5 mbar or less, preferably 10 -8 It can include steps that are mbar.

[0065] This advantageous process improvement enables the creation of energy-efficient coatings.

[0066] Alternatively, the method according to the present invention involves an additional step, namely, The press plate is transported through a vacuum pre-chamber equipped with a pre-chamber lock, which is located upstream of the processing chamber in the transport direction. The vacuum pre-chamber is brought to a pressure level between atmospheric pressure and the processing pressure when the ceramic layer is applied in the processing chamber by a vacuum pump, and this processing pressure is particularly 10 -5 mbar or less, preferably 10 -8 Steps that are mbar, The process may include transporting the press plate through a vacuum post chamber equipped with a post chamber lock, the vacuum post chamber being located downstream of the processing chamber in the transport direction, and the vacuum post chamber being brought to a pressure level between atmospheric pressure and processing pressure by a vacuum pump. Advantageously, this optimized processing is made possible using a small amount of energy for vacuum generation.

[0067] Another aspect of the present invention is the use of the press tool according to the present invention to manufacture material boards, particularly material boards for the furniture industry or laminate flooring panels. Advantageously, the press tool according to the present invention can be used to mass-produce low-wear material boards, particularly material boards for the furniture industry or laminate flooring panels.

[0068] Examples of the present invention are illustrated in the attached schematic diagram. [Brief explanation of the drawing]

[0069] [Figure 1] Figure 1 is a perspective view of a press plate with a pressing surface. [Figure 2] Figure 2 is a side cross-sectional view of the press plate portion. [Figure 3A-3C] Figure 3A-3C shows an intermediate stage of a press plate during manufacturing. [Figure 4] Figure 4 is a side cross-sectional view of the press plate portion of the alternative embodiment. [Figure 5] Figure 5 is a side cross-sectional view of the press plate portion of another alternative embodiment. [Figure 6] Figure 6 is a side cross-sectional view of the press plate and laminate during the pressing process in a closed press machine. [Figure 7] Figure 7 is a side cross-sectional view of a surface magnetron sputtering coating apparatus. [Modes for carrying out the invention]

[0070] Figure 1 is a perspective view of a press tool designed as press plate 1 in this embodiment. Press plate 1 includes a press surface 2. The press side 3 is the side of press plate 1 that faces the laminate during the pressing process in the press machine.

[0071] Figure 2 is a side cross-sectional view of the press plate portion.

[0072] The press surface 2 may be formed smoothly, but in this embodiment, it includes a structure consisting of a raised portion 4 and a recessed portion 3.

[0073] The structure of the pressing surface 2 is particularly suited to natural materials, in this embodiment, wood.

[0074] The press surface 2 is positioned on multiple base structural layers 15 of the base structure 10. In addition to the base structural layers 15, the base structure 10 also includes a support structure.

[0075] In this embodiment, the first ceramic layer 11 is partially placed on the base structure 10, and the second ceramic layer 12 completely covers the surface 31 of the base structure 10 and the first ceramic layer 11.

[0076] The press plate 1 allows for the manufacture of workpieces, such as material boards or laminates, by press working. After press working, the workpiece has a structured surface corresponding to the structure of the press surface 2.

[0077] In this embodiment, the press plate 1 includes a base structure 10 having a surface 31 structured to correspond to the structure of the press surface 2, as shown in Figure 3A.

[0078] In this embodiment, the press plate 1 includes a partial ceramic layer 11 placed on the structured surface 31 of the base structure 10, and a full ceramic layer 12 placed on the partial ceramic layer 11 to form the press surface 2.

[0079] In this embodiment, the base structure 10 is made of metal.

[0080] In this embodiment, the press plate 1 includes a base support, particularly a metal support structure 14, on which the base structure 10 is placed.

[0081] In this embodiment, the base structure 10 includes a plurality of base structural layers 15 that are positioned overlapping each other. The base structural layers 15 are preferably made of nickel and are at least partially designed to form a relief layer structure 16 together with the ceramic layers 11 and 12.

[0082] To fabricate the base structure 10, for example, according to image data corresponding to the structure of the structured press surface 2, a mask (not shown in detail) is applied to the base structure layer 15 at least once to cover an area, and then another base structure layer 15 is applied to the area not covered by this mask. This is repeated until the base structure 10 is completed. The base structure 10 is fabricated in particular according to the structure of the press surface 2, that is, according to image data corresponding to the raised portion 4 and the recessed portion 5, and for this purpose, the mask and base structure layer 15 are applied sequentially according to this image data, for example by electroplating or chemical method.

[0083] Next, in this embodiment, the mask 32 shown in Figure 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.

[0084] Next, in this embodiment, a surface magnetron sputtering coating apparatus 33 is used to apply a ceramic layer to the area of ​​the structured surface 31 of the base structure 10 that is not covered by the mask 32. Subsequently, when the mask 32 is removed, only the area of ​​the structured surface 31 of the base structure 10 that is not covered by the mask 32 is covered with the ceramic layer, resulting in a partial ceramic layer 11. See Figure 3C. By appropriately controlling the surface magnetron sputtering coating apparatus 33, the partial ceramic layer 11 is given a predetermined thickness, thereby obtaining a predetermined gloss level.

[0085] Next, in this embodiment, a full-surface ceramic layer 12 is applied to the partial ceramic layer 11 using a surface magnetron sputtering coating apparatus 33. To adjust the glossiness of the full-surface ceramic layer 12, the full-surface ceramic layer 12 is controlled by the surface magnetron sputtering coating apparatus 33 to obtain a predetermined thickness.

[0086] In this embodiment, both ceramic layers 11 and 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 thereof.

[0087] In this embodiment, the thicknesses of the two ceramic layers differ because the ceramic layers 11 and 12 have different degrees of gloss. In particular, the full ceramic layer 12 is thinner than the partial ceramic layer 11, and both ceramic layers 11 and 12 are made of the same ceramic material.

[0088] The thickness of both ceramic layers 11 and 12 is preferably in the range of 1 μm to 2 μm.

[0089] The ceramic layer preferably has a Vickers hardness of at least 2000 HV.

[0090] To adjust the different gloss levels of the ceramic layers 11 and 12, they can also be made of different ceramic materials.

[0091] Post-treatments such as polishing or laser processing can be applied to adjust the glossiness of the ceramic layers 11 and 12.

[0092] It is also possible to first apply a full ceramic layer 12 to the structured surface 31 of the base structure 10, and then apply a partial ceramic layer 11 on top of that.

[0093] By appropriately controlling the surface magnetron sputtering coating apparatus 33, it is also possible to fabricate a partial ceramic layer 11.

[0094] Figure 4 shows a side cross-sectional view of a press plate in an alternative embodiment. The first ceramic layer 11 and the second ceramic layer 12 are each partially applied to the structured surface 31 of the base structure 10. The base structure layer 15 can be made of a metal, particularly nickel, as in other embodiments, but it can also be made of other materials, such as plastic or ceramic. The base structure layer 15 can be manufactured using known additive or subtractive manufacturing methods.

[0095] In another advantageous development of this embodiment, the second ceramic layer 12 can be at least partially placed on the first ceramic layer 11.

[0096] The first ceramic layer 11 or the second ceramic layer 12 may also be processed using a laser in at least the laser processing area 17. Laser processing can be used to positively transfer these structural properties to the laminate produced, particularly affecting the glossiness, reflectivity, matteness, or structure of the ceramic layer.

[0097] In another embodiment shown in Figure 4, the second ceramic layer 12 can completely cover the structured surface 31 of the base structure 10 and has a second thickness 19, while the first ceramic layer 11 has a first thickness 18. In this case, the first thickness 18 and the second thickness 19 can have different layer thicknesses in order to obtain different gloss levels for the first ceramic layer 11 and the second ceramic layer 12, and in particular, both ceramic layers 11 and 12 can be made of the same ceramic material.

[0098] The ceramic material of the ceramic layers 11 and 12 in all embodiments of the present invention may consist of, for example, hafnium diboride, molybdenum diboride, tantalum diboride, titanium diboride, tungsten diboride, vanadium diboride, zirconium diboride, or mixtures thereof.

[0099] In another embodiment shown in Figure 4, the ceramic materials of the two ceramic layers 11 and 12 may be different in order to obtain different gloss levels for the first ceramic layer 11 and the second ceramic layer 12, and in particular the thickness 19 of the second ceramic layer 12 is equal to the thickness 18 of the first ceramic layer 11.

[0100] The thickness of both ceramic layers 11 and 12 is preferably in the range of 1 μm to 2 mm.

[0101] In the overlapping region 13, both ceramic layers can be arranged to overlap each other at least partially.

[0102] Figure 5 shows a side cross-sectional view of a press plate portion of another alternative embodiment, in which both ceramic layers 11 and 12 are arranged to overlap each other at least partially. The second ceramic layer 12, located on the press side 7 of the press tool, has at least one opening 5 where the first ceramic layer is exposed on the surface or opens a notch 6 like a window facing the surface. It can be manufactured by using a mask 32 when coating the ceramic layer 12 and then removing the mask 32, or by a chemical method, for example, by using a sodium hydroxide solution to remove a portion of the second ceramic layer 12.

[0103] In other respects, the base structure is based on the embodiments shown in Figures 2 and 3 or 4.

[0104] Figure 6 shows a side cross-sectional view of a press plate and laminate during a pressing process in a closed press machine. In a press machine 20, for example, a short-cycle press machine, a pressing tool, in particular a press plate 1, is placed on a press pad 9. During the illustrated pressing process with the press machine 20 closed, the laminate 8, in particular a material board for the furniture industry or flooring panels, is melted under the action of temperature and pressure, and the negative shape of the press surface 2, with recesses 3 and raised areas 4, is reproduced as a positive shape in the laminate 8.

[0105] Figure 7 shows a side cross-sectional view of the surface magnetron sputtering coating apparatus 33.

[0106] In this embodiment, a surface magnetron sputtering coating apparatus 33 having a multi-chamber system is shown. However, as an alternative, a single-chamber system having only one processing chamber 24 and no other chambers is also possible.

[0107] The press tool, particularly the press plate 1, is introduced into the vacuum pre-chamber 25 by the conveying device 21 when the pre-chamber lock 26 is opened. When the pre-chamber lock 26 is closed, the vacuum pump 30 raises the pressure inside the vacuum pre-chamber 25 to, for example, 10 -2 mbar or less, preferably 10 -5 The pressure is reduced to mbar. During this time, lock 22 is closed, and the machining chamber is at machining pressure. Then lock 22 opens, and the pressure between the machining chamber 24 and the vacuum pre-chamber 25 is harmonized. This saves energy and allows for longer cycle times compared to a single-chamber system. The press tool is transported into the machining chamber 24. Locks 22 and 23 close, and the machining chamber is evacuated by the vacuum pump 29. The machining pressure is 10 -3 Pa(10 -5mbar or less, preferably 10 -6 Pa (10 -8 mbar). After completion of the processing step, the pressing tool is conveyed into the vacuum chamber through the opened lock 23. Said chamber is at a pressure level equivalent to that of the vacuum pre-chamber before the post-chamber lock is opened. The vacuum pre-chamber and the vacuum post-chamber can be connected to each other via a valved vacuum line, whereby vacuum can be exchanged between the vacuum pre-chamber and the vacuum post-chamber when the cycle is changed in the continuous operation of the surface magnetron sputtering coating apparatus 33, so as to save energy for the operation of the vacuum pump 30. For all embodiments of the present invention, instead of the surface magnetron sputtering coating apparatus, it is also possible to use other PVD coating apparatuses, PVD sputtering apparatuses, magnetron sputtering apparatuses or similar apparatuses. Description of Reference Numerals

[0108] 1 Press plate 2 Pressing surface 3 Recessed portion 4 Raised portion 5 Opening 6 Notch 7 Press side 8 Material board 9 Press pad 10 Base structure 11 Ceramic layer 12 Ceramic layer 13 Overlapping region 14 Support structure 15 Base structure layer 16 Relief layer structure 17 Laser processing region 18 Thickness (first ceramic layer) 19 Thickness (second ceramic layer) 20 Press machine 21 Conveying device 22 Lock 23 Lock 24 Processing chamber 25 Vacuum pre-chamber 26 Pre-chamber lock 27 Vacuum Post Chamber 28 Post-Chamber Lock 29 Vacuum pump 30 Vacuum pumps 31 Surface (of base structure 10) 32 masks 33 Surface magnetron sputtering coating apparatus 34 Metal layer 3. 5 Functional Layers 36 Magnetron

Claims

1. A press tool for manufacturing panels, Press surface (2), A base structure (10) having a surface (31), At least two ceramic layers (11, 12) are arranged on the surface (31) and form the press surface (2), wherein the first ceramic layer (11) has a first glossiness, and the second ceramic layer (12) has a second glossiness that is different from the first glossiness of the first ceramic layer (11), The second ceramic layer (12) completely covers the structured surface (31) of the base structure (10) and has a second thickness (19). The first ceramic layer (11) has a first thickness (18), The first thickness (18) and the second thickness (19) have different layer thicknesses to obtain different gloss levels for the first ceramic layer (11) and the second ceramic layer (12), and in particular, both ceramic layers (11, 12) are made of the same ceramic material. A press tool used to manufacture panels.

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

3. The press tool according to claim 1 or 2, wherein the base structure (10) of the press tool has a support structure (14) made of metal, particularly stainless steel.

4. The press surface (2) has a structure of raised portions (4) and recessed portions (3), and the base structure (10) has a structured surface (31) provided on the support structure (14). A press tool according to claim 1 or 2, wherein at least two, particularly metallic, base structural layers (15) are provided on the support structure (14), and the base structural layers (15) are arranged to overlap each other at least partially to form the structured surface (31) of the base structure (10).

5. The press tool according to claim 1 or 2, wherein the first ceramic layer (11) or the second ceramic layer (12) is applied only partially to the structured surface (31) of the base structure (10) to form a relief layer structure (16) of the structured surface (31).

6. The press tool according to claim 1 or 2, wherein the first ceramic layer (11) and the second ceramic layer (12) are each partially applied to the structured surface (31) of the base structure (10).

7. The press tool according to claim 1 or 2, wherein the second ceramic layer (12) is at least partially disposed on the first ceramic layer (11).

8. The press tool according to claim 1 or 2, wherein the first ceramic layer (11) or the second ceramic layer (12) is processed using a laser in at least the laser processing area (17).

9. The press tool according to claim 7, wherein an opening (5) is provided in the second ceramic layer (12) that reaches the first ceramic layer (11) when viewed in the direction of the base structure (10).

10. The press tool according to claim 9, wherein the opening (5) is a notch (6) created by subsequent processing of the coated second ceramic layer (12).

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

12. The press tool according to claim 1 or 2, wherein at least one of the metal layers (15) disposed on the press side (7) of the base structure (10) is a nickel layer or a nickel-containing metal layer.

13. The press tool according to claim 1 or 2, wherein the structured surface (31) of the base structure (10) is manufactured by an additive manufacturing method in which at least partially a three-dimensional relief layer structure (16).

14. The press tool according to claim 1 or 2, wherein the structured surface (31) of the base structure (10) is manufactured in at least partially three-dimensional shape by an electrochemical process, a mechanical process or a laser processing process.

15. The ceramic materials of both ceramic layers (11, 12) are different in order to obtain different gloss levels of the first ceramic layer (11) and the second ceramic layer (12), and in particular, the thickness (19) of the second ceramic layer (12) is equal to the thickness (18) of the first ceramic layer (11), as described in claim 1 or 2.

16. The press tool according to claim 1 or 2, wherein 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 thereof.

17. A method for manufacturing a press tool according to claim 1 or 2, comprising the following method steps, namely: The steps include preparing a support structure (14) for the base structure (10), The steps include applying at least two base structural layers (15) to the support structure (14) in order to constitute the base structure (10), The steps include creating a structured surface (31) on the support structure (14), The steps include applying the first ceramic layer (11) to the structured surface (31) of the base structure (10), The step includes applying the second ceramic layer (12) onto the structured surface (31) and / or the applied first ceramic layer (11), The first ceramic layer (11) has a first glossiness, and the second ceramic layer (12) has a second glossiness that is different from the first glossiness of the first ceramic layer (11). The second ceramic layer (12) completely covers the structured surface (31) of the base structure (10) and has a second thickness (19). The first ceramic layer (11) has a first thickness (18), The first thickness (18) and the second thickness (19) have different layer thicknesses to obtain different gloss levels for the first ceramic layer (11) and the second ceramic layer (12), and in particular, both ceramic layers (11, 12) are made of the same ceramic material. A method for manufacturing press tools.

18. The steps include applying a partial mask (32) to the structured surface (31) of the base structure (10), The steps include applying the first ceramic layer (11) to the structured surface (31) on which the partial mask has been applied, The steps include removing the partial mask (32) so that the first ceramic layer (11) is only partially placed on the structured surface (31), A method for manufacturing a press tool according to claim 17, comprising the step of applying the second ceramic layer (12) to the structured surface (31) of the base structure (10) and partially applied the first ceramic layer (11).

19. The steps include: applying the first ceramic layer (11) to the entire structured surface (31) of the base structure (10); The steps include applying a partial mask (32) to the first ceramic layer (11), A method for manufacturing a press tool according to claim 17, comprising the step of applying the second ceramic layer onto the first ceramic layer (11) on which the partial mask (32) has been applied.

20. A method for manufacturing a press tool according to claim 19, comprising the step of removing the partial mask (32) so that the first ceramic layer (11) is only partially positioned on the structured surface (31).

21. A method for manufacturing a press tool according to claim 18, wherein a metal layer (34), a chromium layer, a nickel layer, or a nickel-containing metal layer is applied as the partial mask (32).

22. The method for manufacturing a press tool according to claim 21, wherein the partial mask (32) remains on the press tool as a functional layer (35).

23. A method for manufacturing a press tool according to claim 17, comprising the step of post-treating the corresponding coated ceramic layers (11, 12) or partial mask (32) to obtain a predetermined gloss of the corresponding ceramic layers (11, 12) or mask (32).

24. The step includes applying the at least two ceramic layers (11, 12) using a surface magnetron sputtering coating apparatus (33), The method for manufacturing a press tool according to claim 17, wherein the partial manufacturing of the at least two ceramic layers (11, 12) is carried out by appropriately controlling the surface magnetron sputtering coating apparatus (33).

25. The steps include transporting the press plate (1) on the transport device (21), The steps include opening the first lock (22) following the processing chamber (24), The steps include: transporting the press plate (1) into the processing chamber (24) of the surface magnetron sputtering coating apparatus (33); The steps include closing the first lock (22), The steps include: creating a vacuum inside the processing chamber (24) using a vacuum pump (29); The steps include applying one or more ceramic layers (11, 12) using a magnetron (36), The steps include opening the first lock (22) following the processing chamber (24), A method for manufacturing a press tool according to claim 24, comprising the step of removing the press plate (1) from the processing chamber (24) of the surface magnetron sputtering coating apparatus (33) through the first lock (22).

26. The process includes an additional step of transporting the press plate (1) through a vacuum pre-chamber (25) equipped with a pre-chamber lock (26), The vacuum pre-chamber (25) is located upstream of the processing chamber (24) when viewed in the transport direction. The method for manufacturing a press tool according to claim 25, wherein the vacuum pre-chamber (25) is brought to a pressure level between atmospheric pressure and the processing pressure when applying the ceramic layers (11, 12) in the processing chamber (24) by a vacuum pump (30), and this processing pressure is particularly 10⁻³ Pa or less, preferably 10⁶ Pa.

27. Additional steps, namely, The press plate (1) is transported through a vacuum pre-chamber (25) equipped with a pre-chamber lock (26), and this vacuum pre-chamber (25) is located upstream of the processing chamber (24) when viewed in the transport direction. The vacuum pre-chamber (25) is brought to a pressure level between atmospheric pressure and the processing pressure when applying the ceramic layers (11, 12) in the processing chamber (25) by a vacuum pump (30), wherein this processing pressure is particularly 10⁻³ Pa or less, preferably 10⁻⁶ Pa. The press plate (1) is transported through a vacuum post chamber (27) equipped with a post chamber lock (28), and this vacuum post chamber (27) is located downstream of the processing chamber (24) when viewed in the transport direction. The method for manufacturing a press tool according to claim 25, comprising the step of bringing the vacuum post chamber (27) to a pressure level between atmospheric pressure and processing pressure by a vacuum pump (30).

28. Use of the press tool according to claim 1 or 2 for the manufacture of a material board.

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