AU2020366506A1

AU2020366506A1 - Press tool and method for producing a press tool

Info

Publication number: AU2020366506A1
Application number: AU2020366506A
Authority: AU
Inventors: Thorsten Hagedorn; Berthold Thölen
Original assignee: Hueck Rheinische GmbH
Current assignee: Hueck Rheinische GmbH
Priority date: 2019-10-15
Filing date: 2020-10-12
Publication date: 2022-05-19
Also published as: WO2021074065A1; EP4045307A1; DE102019127655A1; DE102019127655B4

Abstract

The invention relates to a press tool (1) for producing a workpiece. The press tool (1) comprises a pressing surface (2), which has a structure consisting of raised portions (4) and depressions (3), a metal layer (11) provided over all of the surface and a metal layer (12) covering only part of the all-over metal layer (11). The partly-covering metal layer (12) and regions of the all-over metal layer (11) not covered by said partly-covering metal layer (12) form the pressing surface (2). Mineral particles (14) are embedded in the partly-covering metal layer (12) and said partly-covering metal layer (12) is provided on the all-over metal layer (11) in predefined regions (13) that are in particular allocated to the raised portions (4) or predefined raised portions (4) of the pressing surface (2).

Description

Pressing tool and method for producing a pressing tool

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

Pressing tools, for example in the form of pressing plates, endless belts or embossing rollers are, for example, used in the woodworking industry, for example to produce furniture, laminates or panels, i.e. in general workpieces. The workpieces are pressed with the pressing surface of the pressing tool, such that the workpieces obtain surfaces corresponding to the pressing surface.

WO 2009/062488 A2 discloses a pressing plate with a structured pressing surface. The structured pressing surface comprises a structure that has a mountain-like surface with valleys and heights. By use of the pressing surface, a workpiece formed as a material board with a structured surface may be produced. The structured pressing surface comprises a full-surface chromium layer, which is in contact with the material board during pressing. The structured pressing surface is produced by means of deep etching.

WO 2015/036070 Al discloses a pressing tool with a structured pressing surface. Instead of using deep etching, the structured pressing surface is produced by means of metal layers located on top of one another. For this purpose, at least a one-time application of a mask is performed in order to cover partial regions and at least a one time application of a metal layer to the non-covered regions is performed in order to construct the structured pressing surface consisting of protrusions and recesses. These two method steps are repeated until a desired structural depth of the structured pressing surface has been reached. The structured pressing surface may subsequently be provided with a hard chromium layer.

WO 03/016034 Al discloses a further pressing plate with a structured pressing surface. In order to reduce the wear of the pressing plate, the structured pressing surface is provided with a coating consisting of carbon with diamond-like layers and having a surface hardness of more than 1800 HV according to Vickers.

WO 2008/120058 Al discloses a pressing tool, the pressing surface of which is formed by a layer, which consists of a metal matrix with mineral or ceramic particles embedded therein.

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

The object of the invention is achieved by a pressing tool for producing a workpiece, comprising a pressing surface having a structure of protrusions and recesses, a full surface metal layer, and a partial metal layer arranged on the full-surface metal layer, wherein the partial metal layer and regions of the full-surface metal layer free of the partial metal layer form the pressing surface, mineral particles are embedded in the partial metal layer, and the partial metal layer is arranged in predetermined regions on the full-surface metal layer. The full-surface metal layer and the partial metal layer are in particular produced using a galvanic or chemical method. The predetermined regions of the partial metal layer are preferably assigned to the protrusions or predetermined protrusions of the pressing surface.

A further aspect of the invention relates to a method for producing the pressing tool according to the invention, comprising the following method steps:

- applying a mask to the full-surface metal layer, so that predetermined regions of the metal layer, which particularly are assigned to the protrusions or predetermined protrusions of the pressing surface, remain free of the mask, and - applying a further metal layer to the predetermined regions of the full-surface metal layer while adding the mineral particles, in particular by means of a galvanic or chemical method, in order to obtain the partial metal layer with the mineral particles embedded therein arranged on the full-surface metal layer.

The pressing surface may possibly be cleaned to remove residues of the mask.

The pressing tool according to the invention is, for example, an endless belt, an embossing roller or, preferably, a pressing plate and comprises the pressing surface. This comprises a structure of protrusions and recesses, thus being a structured pressing surface. Thereby, the workpiece receives a structured surface corresponding to the structure of the pressing surface.

The workpiece is, for example, a material board. It comprises, for example, a carrier, for example an MDF board or a chipboard, which is pressed e.g. with a resin- or plastic coated and/or resin- or plastic-impregnated carrier, for example in the form of paper by means of the pressing tool. The material board may also be a so-called luxury vinyl tile (LVT).

The pressing surface is formed by the full-surface metal layer and the partial metal layer, which is arranged in the predetermined regions on the full-surface metal layer. The predetermined regions are, in particular, assigned to the protrusions or specific protrusions of the pressing surface, i.e. the partial metal layer is therefore preferably situated essentially only on the protrusions and not in the recesses of the pressing surface.

During the production of the workpiece, the pressing surface is in contact with the workpiece and is therefore exposed to wear. This wear is particularly pronounced in the regions of the protrusions, at least preferably in the regions of specific protrusions, which is why, according to the invention, the mineral particles are embedded in the partial metal layer. Thereby, the wear resistance of the partial metal layer and thus the wear resistance of the pressing surface increases at least in the predetermined regions and thus preferably at least in regions assigned to the protrusions and/or specific protrusions of the pressing surface.

Minerals are, in particular, mostly inorganic, homogeneous, mostly crystalline substances occurring in the earth's crust. The plurality of the minerals known today and recognized as distinct by the International Mineralogical Association are inorganic.

The mineral particles of the partial metal layer in particular have a Mohs hardness of at least 8.

According to an embodiment of the pressing tool according to the invention, the mineral particles have a size in the nanometer or micrometer range. Thus, the mineral particles can be embedded in the metal layer relatively homogeneously, whereby the partial metal layer obtains a relatively homogeneous wear resistance across its entire surface. The size of the individual mineral particles may be different or essentially the same.

The mineral particles preferably have a volume share of at least 50% with regard to the volume of the partial metal layer with mineral particles embedded therein. Due to the size, the volume share, and the type of the minerals of the mineral particles, the desired degree of hardness and/or the wear resistance of the partial metal layer can be adjusted.

In particular, the mineral particles are diamond particles. The diamond particles are in particular industrial diamond particles, i.e. the diamond particles and/or the mineral particles in general can be produced artificially. However, in particular the minerals silicon carbide, boron nitride, boron carbide, aluminum oxide, and titanium oxide may also be used as mineral particles.

The mineral particles are formed, for example as a mineral powder, in particular a diamond powder and preferably as an industrial diamond powder. The pressing tool may be produced particularly dependent on image data assigned to the structure of the structured pressing surface. Preferably, the mask is applied dependent on this image data, which is assigned to the structure of the structure pressing surface.

The pressing surface is, in particular, assigned to a natural material, such as wood or stone. In order to obtain the structure of the pressing surface, it can be provided that a model, for example a piece of wood or a stone is scanned to obtain image data. This image data includes, in particular, information about the structure that the pressing surface is to have.

The image data obtained by scanning can, for example, be edited manually to obtain the image data assigned to the structure of the pressing surface.

The full-surface and the partial metal layers are preferably produced using a galvanic or chemical method. If the partial metal layer is created by means of electroplating while adding the mineral particles, it is in particular a partial metallic dispersion layer, in which the mineral particles are embedded.

In order to produce the partial metal layer with the mineral particles embedded therein in a relatively environmentally friendly manner, the partial metal layer is preferably a chromium-free metal layer. The chromium-free metal layer is in particular a partial nickel layer.

The full-surface metal layer is also preferably chromium-free and in particular a full surface nickel layer.

The full-surface metal layer can be treated prior to the application of the further metal layer and/or partial metal layer. This treatment may comprise a mechanical treatment and/or a galvanic and/or a chemical treatment of the full-surface metal layer and/or the treatment of the full-surface metal layer may be carried out with the aid of a laser. The treatment of the full-surface metal layer may also be a thermal treatment, e.g. tempering of the full-surface metal layer, in order to harden it, for example. If the full surface metal layer is a full-surface nickel layer, the thermal treatment can allow for it to have a hardness of about 1100 Vickers or more.

The partial metal layer may receive additional treatment. This treatment may comprise a mechanical treatment and/or a galvanic and/or a chemical treatment of the partial metal layer and/or the treatment of the partial metal layer may be carried out with the aid of a laser. The treatment of the partial metal layer may also be a thermal treatment, e.g. tempering of the partial metal layer, in order to additionally harden it, for example.

The full-surface metal layer and the partial metal layer each have a degree of gloss. The degrees of gloss of the full-surface metal layer and of the partial metal layer are preferably different from one another, so that the surface of the workpiece produced using the pressing tool also has regions of different degrees of gloss.

In order to additionally harden the pressing surface, further mineral particles may be embedded in the full-surface metal layer.

In particular, the further mineral particles are diamond particles. The further diamond particles are in particular further industrial diamond particles, i.e. the diamond particles and/or the mineral particles in general can be produced artificially.

The mineral particles and the further mineral particles may have the same size, the same volume share with regard to the volume of its metal layer and/or the same type of minerals.

The material of the partial metal layer and the full-surface metal layer may be the same or different.

According to a variant of the pressing tool according to the invention, it comprises a base structure of multiple base metal layers located on top of one another, on which the full-surface metal layer is arranged. Mineral particles may also be embedded in the base metal layers, located on top of one another, of the base structure. Thus, the wear resistance of the entire pressing tool is increased. The base metal layers are preferably chromium-free, in particular base nickel layers.

The mineral particles of the base metal layers may have the same size, the same volume share with regard to the volume of the base metal layers and/or the same type of minerals as the mineral particles of the metal layer.

The material of the base metal layers may be the same as that of the metal layer or may be different therefrom.

During its production, this variant of the pressing tool according to the invention preferably comprises an at least one-time application of a further mask to a base metal layer in order to cover regions, at least a one-time application of a further base metal layer to the regions not covered by the further mask, and a repetition of these steps until the base structure has formed. Subsequently, the full-surface metal layer is arranged on the base structure, possibly while adding the further mineral particles. This kind of producing the base structure may take place without etching, whereby a relatively environmentally friendly production is made possible.

The base structure may be treated before the full-surface metal layer is arranged, for example in order to modify the structure of the base structure. This treatment may comprise a mechanical treatment and/or a galvanic and/or a chemical treatment of the base structure and/or the treatment of the base structure may be carried out with the aid of a laser. The treatment of the base structure may also be a thermal treatment, e.g. tempering in order to harden it, for example.

In particular, it may be provided that each of the base metal layers is thermally treated, for example tempered, before the following base metal layer is applied. Hence, the hardness of the entire base structure can be increased.

The application of the further mask and of the base metal layers particularly takes place dependent on the image data assigned to the structure of the structured pressing surface.

The pressing surface may be changed and/or adapted to specific demands, for example by means of a mechanical or chemical after-treatment.

An exemplary embodiment of the invention is shown in the enclosed schematic figures by way of example. These show:

Fig. 1 a pressing plate with a pressing surface in a perspective representation,

Fig. 2 a cutout from a lateral view of the pressing plate in a sectional representation, and

Fig. 3 an intermediate state of the pressing plate during its production.

Fig. 1 shows, in a perspective representation, a pressing plate 1 with a pressing surface 2 as an example of a pressing tool. Fig. 2 shows a sectional view of a cutout from a lateral view of the pressing plate 1.

The pressing surface 2 comprises a structure of recesses 3 and protrusions 4 and is assigned, for example, to a wood grain.

By the pressing plate 1, a workpiece, e.g. a pressing plate, for example a laminate, can be produced by pressing. After pressing, the workpiece has a surface structured correspondingly to the structure of the pressing surface 2.

In the case of the present exemplary embodiment, the pressing plate 1 comprises a base structure 10, a full-surface metal layer 11 arranged on the base structure 10, and a partial metal layer 12 arranged on the full-surface metal layer 11. The partial metal layer 12 and the regions of the full-surface metal layer 11 that are free of the partial metal layer 12 form the pressing surface 2.

The partial metal layer 12 is arranged in predetermined regions 13 on the full-surface metal layer 11, which regions 13 are assigned to the protrusions 4 or specific protrusions 4, meaning that the partial metal layer 12 is thus located essentially only on protrusions 4 and not in the recesses 3 of the pressing surface 2.

Mineral particles 14 are embedded in the partial metal layer 12. The mineral particles 14 have, in particular, a Mohs hardness of at least 8 and a size in the nanometer or micrometer range. The volume share of the mineral particles 14 is preferably at least 50% with regard to the volume of the partial metal layer 12 with the mineral particles 14 embedded therein.

In the case of the present exemplary embodiment, the mineral particles 14 are diamond particles and the partial metal layer 12 is chromium-free. In particular, the partial metal layer 12 is a partial nickel layer.

In the case of the present exemplary embodiment, the partial metal layer 12 was produced using a chemical or galvanic method, in that a mask 30 shown in Fig. 3 was partially applied to the full-surface metal layer 11, such that the predetermined regions 13 of the full-surface metal layer 11, which are assigned to the protrusions 4, remain free of the mask 30. Subsequently. a further metal layer was applied to the predetermined regions 13 of the full-surface metal layer 11 while adding the mineral particles 14 by means of a galvanic or chemical method, in order to obtain the partial metal layer 12 with the mineral particles 14 embedded therein arranged on the full surface metal layer 11.

The pressing surface 2 may possibly be cleaned to remove residues of the mask 30.

In the case of the present exemplary embodiment, the pressing surface 2 is assigned to a wood surface. In order to obtain the structure of the pressing surface 2, it can be provided that a model, for example a wood surface is scanned to obtain image data. This image data includes, in particular, information about the structure that the pressing surface 2 is to have. The image data obtained by scanning can, for example, be edited manually to obtain image data assigned to the structure of the pressing surface 2.

In the case of the present exemplary embodiment, the application of the mask 30 and of the further metal layer to the predetermined regions 13 that are free of the mask 30 is carried out dependent on the image data assigned to the structure of the pressing surface 2.

In the case of the present exemplary embodiment, further mineral particles 15 are embedded in the full-surface metal layer 11. Preferably, the further mineral particles 15 are diamond particles. The full-surface metal layer 11 is, in particular, a full-surface nickel layer.

The full-surface metal layer 11 can be treated prior to the application of the further metal layer and/or partial metal layer 12. This treatment may comprise a mechanical treatment and/or a galvanic and/or a chemical treatment of the full-surface metal layer 11 and/or the treatment of the full-surface metal layer 11 may be carried out with the aid of a laser. The treatment of the full-surface metal layer 11 may also be a thermal treatment, e.g. tempering of the full-surface metal layer 11.

The partial metal layer 12 may receive additional treatment. This treatment may comprise a mechanical treatment and/or a galvanic and/or a chemical treatment of the partial metal layer 12 and/or the treatment of the partial metal layer 12 may be carried out with the aid of a laser. The treatment of the partial metal layer 12 may also be a thermal treatment, such as tempering of the partial metal layer 12.

The full-surface metal layer 11 and the partial metal layer 12 each have a degree of gloss. In the case of the present exemplary embodiment, the degrees of gloss of the full-surface metal layer 11 and of the partial metal layer 12 are different from one another, so that the surface of the workpiece produced using the pressing plate 1 also has regions of different degrees of gloss.

In the case of the present exemplary embodiment, the pressing plate 1 comprises a base structure 10 of multiple base metal layers 16 located on top of one another, on which the full-surface metal layer 11 is arranged. In the case of the present exemplary embodiment, mineral particles 17 are embedded in the base metal layers 16 located on top of one another, as well.

In the case of the present exemplary embodiment, the base structure 10 was produced using a galvanic or chemical method by applying a further mask to the base metal layer 16 at least once, in order to cover regions, by applying a further base metal layer 16 while adding mineral particles 17 to the regions not covered by the further mask at least once, and repeating these steps until the base structure 10 has formed. Subsequently, the full-surface metal layer 11 was applied to the base structure 10 while adding the further mineral particles 15 by means of a chemical or galvanic method.

The base structure 10 may be treated before the full-surface metal layer 11 is arranged, for example in order to modify the structure of the base structure 10. This treatment may comprise a mechanical treatment and/or a galvanic and/or chemical treatment of the base structure 10 and/or the treatment of the base structure 10 with the aid of a laser carried out by. The treatment of the base structure 10 may also be a thermal treatment, such as tempering. Each of the base metal layers 16 may be thermally treated, for example tempered.

In the case of the present exemplary embodiment, the application of the further mask and of the base metal layers 16 is carried out dependent on the image data assigned to the structure of the pressing surface 2.

In the case of the present exemplary embodiment, the pressing plate 1 comprises a base carrier, in particular a base carrier plate 18, for example of metal, in particular of steel, on which the base structure 10 is arranged.

Claims

CIaims

1. A pressing tool for producing a workpiece, comprising a pressing surface (2) having a structure of protrusions (4) and recesses (3), a full-surface metal layer (11), and a partial metal layer (12) arranged on the full-surface metal layer (11), wherein the partial metal layer (12) and regions of the full-surface metal layer (11) free of the partial metal layer (12) form the pressing surface (2), mineral particles (14) are embedded in the partial metal layer(12), and the partial metal layer(12) is arranged in predetermined regions (13) on the full-surface metal layer (11), which are in particular assigned to the protrusions(4) or predetermined protrusions(4) of the pressing surface (2).

2. The pressing tool according to claim 1, wherein the full-surface metal layer (11) has degree of gloss, and the partial metal layer (12) has a degree of gloss that is different from the degree of gloss of the full-surface metal layer (11).

3. The pressing tool according to claim 1 or 2, wherein further mineral particles (17) are embedded in the full-surface metal layer (11).

4. The pressing tool according to one of claims 1 to 3, comprising a base structure (10) of multiple base metal layers (16) located on top of one another, in which mineral particles (17) are embedded and on which the full-surface metal layer (11) is arranged.

5. The pressing tool according to one of claims 1 to 4, wherein the partial metal layer (12) with the mineral particles (14) embedded therein is a chromium-free partial metal layer, in particular a nickel layer, and/or the partial metal layer (12) is thermally treated in order to increase its hardness, and/or the full-surface metal layer (11) is thermally treated in order to increase its hardness.

6. The pressing tool according to one of claims 1 to 5, wherein the mineral particles (14) have a Mohs hardness of at least 8 and/or are diamond particles and/or have a size in the nanometer or micrometer range and/or have a volume share of at least 50% with regard to the volume of the partial metal layer (11) with mineral particles (14) embedded therein.

7. A method for producing a pressing tool according to one of claims 1 to 6, comprising the following method steps:

- applying a mask (30) to the full-surface metal layer (11), so that predetermined regions (13) of the metal layer (11), which particularly are assigned to the protrusions (4) or predetermined protrusions (4) of the pressing surface (2), remain free of the mask (30), and - applying a further metal layer to the predetermined regions (13) of the full-surface metal layer (11) while adding the mineral particles (14), in particular by means of a galvanic or chemical method, in order to obtain the partial metal layer (12) with the mineral particles (14) embedded therein arranged on the full-surface metal layer (11).

8. The method according to 7, comprising applying the mask (30) and the further metal layer dependent on image data, which is assigned to the structure of the pressing surface (2), and/or thermal treatment of the partial metal layer (12) in order to increase its hardness, and/or thermal treatment of the full-surface metal layer (11) in order to increase its hardness.

9. The method according to claim 7 or 8, in which the pressing a base structure (10) of multiple base metal layers (16) located on top of one another, in which mineral particles (17) are embedded and on which the full-surface metal layer (11) is arranged, comprising the following method steps:

- applying a further mask at least once to a base metal layer (16) in order to cover regions, applying a further base metal layer (16) at least once to the regions not covered by the mask, particularly while adding mineral particles (17), and repeating these steps until the base structure (10) is finished, and - applying the full-surface metal layer (11) to the base structure (10).

10. The method according to 9, comprising applying the further mask and the base metal layers (16) dependent on image data assigned to the structure of the pressing surface (2).