CN117062714A

CN117062714A - Press die and method for manufacturing pressed board

Info

Publication number: CN117062714A
Application number: CN202280022834.5A
Authority: CN
Inventors: A·考克; T·哈格多恩; B·特伦
Original assignee: Hueck Rheinische GmbH
Current assignee: Hueck Rheinische GmbH
Priority date: 2021-11-04
Filing date: 2022-10-25
Publication date: 2023-11-14

Abstract

The application relates to a pressing tool for producing workpieces, comprising a pressing surface (2). The pressing die comprises a basic structure (10) and at least two ceramic layers (11, 12) arranged on a surface (31) and forming a pressing surface (2), wherein a first ceramic layer (11) has a first gloss level and a second ceramic layer (12) has a second gloss level different from the first gloss level of the first ceramic layer (11).

Description

Press die and method for manufacturing pressed board

Technical Field

The present application relates to a pressing die having a pressing surface and a method for manufacturing a pressing die.

Background

Pressing dies, for example in the form of pressed boards, continuous belts or embossing rollers, are used in particular in the wood working industry, for example for the manufacture of furniture, material sheets (such as laminates or panels), i.e. workpieces in general. The workpiece is pressed by the pressing surface of the pressing die so that the workpiece obtains a surface corresponding to the pressing surface.

Material panels, such as wood panels, are required for the furniture industry and interior finishing, such as laminate flooring. The material sheet has a core made of MDF (medium density fiberboard) or HDF (high density fiberboard) to which at least one side is applied a different material coating layer, such as a (optical) decorative layer and a protective layer (cover layer).

In order to avoid warping in the manufactured material sheet, such material sheets typically have the same number of material layers on both sides; in order to interconnect the individual layers of the material sheets (core, material coating, etc.), they are pressed together in a press using special pressing dies, in particular pressing plates or continuous strips. The surface of the material sheet is embossed here too. Hot pressing is generally used here to thermally join the coating of different materials composed of thermosetting resins, for example melamine resins, to the core surface by melting the plastic material.

The decorative layer here determines the pattern and color design of the material sheet; while the desired surface structure may be achieved by using a matched press die. For example, wood or tile decorations may be printed on the decoration layer (decoration paper), or a decoration layer with patterns and color designs designed according to the corresponding usage destination artistic land may be used. In this case, a cover layer pressed on the upper side or the lower side may also be used.

In order to improve a realistic reproduction, in particular in the case of material sheets with wood, tile or natural stone decorations, the pressing mold has a surface structure portion which is formed in conformity with the decorative layer and forms a negative image of the desired surface structure. Thus, the pressing die has a three-dimensional profile (depth structure) which simulates, for example, the wood grain of a wood surface, so as to give the decorative layer of the material sheet an appearance of such a wood surface.

In order to achieve a consistent embossing of a material sheet or laminate, i.e. the required matching accuracy of the decorative layer and the structure of the pressing surface of the laminate, a high quality standard is required for the production of the pressing mould. In particular, the press plate or the continuous belt is used in this case as an upper and lower die in a short-cycle press covered by the press plate and preferably the press pad, or in a double-belt press in which the material plate is embossed and heated simultaneously, so that the thermosetting resin of the decorative and/or cover layer of the material plate is first melted, a surface structure corresponding to the structure of the pressing surface of the press die is introduced into the material cover layer located on the outside, and the structured material cover layer is connected with the core of the material plate by subsequent curing.

WO 2009/062488A2 discloses a method for machining a structured pressing surface of an embossing die. The surface has a first chromium layer overall, on which at least one further chromium layer is arranged in a predetermined region. The two chromium layers differ in gloss. By pressing the surfaces, it is possible to produce workpieces constructed as material sheets having structured surfaces with different gloss levels. The manufacture of the compression mold is relatively environmentally hazardous due to the use of a chromium layer and multiple masking and cleaning steps.

US 6,190,514 B1 discloses a method for manufacturing a flat pressing surface in order to manufacture a decorative laminate from paper impregnated with resin. To this end, the desired finished surface is produced on a flat pressing surface, impurities are removed from the flat surface, and the flat surface is coated with hafnium diboride, molybdenum diboride, tantalum diboride, titanium diboride, tungsten diboride, vanadium diboride, zirconium diboride or a mixture of these substances in a face magnetron sputter coating system to a vickers hardness of at least 2000HV by movement of the sputtering heads of the flat surface and the face magnetron sputter coating system relative to each other at a scan speed sufficient to produce a thermal gradient of 27.78 ℃ or less in the flat pressing surface.

Disclosure of Invention

The object of the present application is to provide a pressing tool whose pressing surfaces have locally different gloss levels, the production of which is relatively environmentally friendly.

Furthermore, a method for manufacturing a pressing die will be shown, which guarantees easier reproducibility at lower costs.

Furthermore, a pressing tool for producing workpieces, in particular material sheets, is to be provided, whose surface structures comprise different structures, for example coarse and fine structures, having arbitrary detail and quality measures.

Further objects of the application come from the disclosure of the application.

The object of the application is achieved by a pressing tool for producing workpieces, having a pressing surface, a basic structure and at least two ceramic layers which are arranged on top of one another on the surface and form the pressing surface, one of the ceramic layers being a full-face ceramic layer having a gloss level and the other being a partial ceramic layer having another gloss level than the gloss level of the full-face ceramic layer.

The pressing die according to the application is, for example, a continuous belt or an embossing roll. Preferably, the pressing die according to the present application is a pressing plate.

The pressing surface is smooth, for example, but may also be designed as a structured pressing surface. In particular, the pressing surface can thus have a structure consisting of projections and depressions, and the basic structure has a structured surface corresponding to the structure of the pressing surface, or the pressing surface differs in its three-dimensional shape due to the additional coating of the layer, in particular of the ceramic layer.

Another aspect of the application is a method for producing a pressing die according to the application, having the following method steps:

-providing a support structure for the basic structure;

-applying at least two basic structure layers onto a support structure to establish a basic structure;

-manufacturing a structured surface on a support structure;

-applying a first ceramic layer onto a surface of the basic structure; and

-applying a second ceramic layer onto the structured surface and/or onto the coated first ceramic layer.

The pressing tool according to the application can therefore have a basic structure which, according to one variant, has a structured surface corresponding to a pressing surface which is configured as a structured pressing surface if necessary. The basic structure comprises, for example, a plurality of partial metal layers arranged one above the other and forming the surface of the basic structure, as is known from WO 2009/062488A2 mentioned in the introduction.

However, in order to obtain a relatively hard pressed surface, according to the application the surface may not be provided with a chromium layer, but with a ceramic layer. The ceramic can also 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 mixtures of these ceramic materials. The coating or coating of the ceramic layer is significantly more environmentally friendly than the coating or coating of the chromium layer.

Furthermore, the pressing tool according to the application may comprise at least two ceramic layers arranged one above the other, preferably exactly two ceramic layers arranged one above the other. One of the ceramic layers is a partial ceramic layer and the other may be a full ceramic layer. Since the gloss of the overall ceramic layer according to the application may be different from that of a part of the ceramic layer, the pressed surface has different gloss in different areas, so that the surface of a workpiece manufactured from the pressed plate may also have a locally corresponding different gloss. The quality of the workpiece produced by pressing with the pressing surface can thereby be improved. The workpiece is for example a sheet of material, in particular a laminate or a panel.

In particular, it is also possible to remove worn or damaged ceramic layers relatively easily from the basic structure in order to provide the basic structure with new ceramic layers. This results in a relatively cost-effective repair of worn or damaged pressing molds.

The application of the ceramic layer may be performed, for example, by an in-plane magnetron sputtering coating system.

The thickness of the two ceramic layers is preferably in the range between 1 μm and 2 μm.

In order to obtain different gloss levels of the monolithic ceramic layer and the partial ceramic layer, it is preferred that the thickness of the monolithic ceramic layer is different from the thickness of the partial ceramic layer. It is thus possible to set the gloss of the respective ceramic layer in terms of its thickness. In this case, the two ceramic layers are preferably composed of the same ceramic material, which can have a positive effect on the production costs of the pressing tool according to the application. The necessary thickness of the ceramic layer can be achieved, for example, by appropriate control of the opposing magnetron sputtering coating system when manufacturing the pressboard.

The gloss of the two ceramic layers can also be adjusted by using different ceramic materials for part of the ceramic layers and the full ceramic layer. Thus, according to a variant of the pressboard of the application, the ceramic materials of the two ceramic layers may be different in order to obtain different gloss levels of the overall ceramic layer and of the partial ceramic layer. In this case, the thickness of the overall ceramic layer is equal to the thickness of the partial ceramic layer in particular.

Preferably, a portion of the ceramic layer is disposed between the monolithic ceramic layer and the surface of the base structure. This embodiment of the pressboard according to the application can be manufactured, for example, by the following method:

-applying a partial mask onto the surface of the basic structure;

-applying a ceramic layer on the surface provided with the mask in the areas not covered by the mask;

-removing the mask such that a portion of the ceramic layer is arranged on the structured surface; and is also provided with

-applying a full ceramic layer onto a portion of the ceramic layer.

However, parts of the ceramic layer may also be manufactured, for example, by suitably controlling the surface magnetron sputtering coating system.

Since the full ceramic layer is coated on a part of the ceramic layer according to this variant of the pressing die, a relatively smooth pressing surface can be produced in a relatively simple manner. In this case, however, the overall ceramic layer must be made such that it does not completely mask the gloss of the portion of the ceramic layer that is located below it. In particular, in this case, the overall ceramic layer is thinner than a portion of the ceramic layer, i.e., the thickness of the overall ceramic layer is less than the thickness of the portion of the ceramic layer.

However, the pressing tool according to the application can also be designed such that the monolithic ceramic layer is arranged between a part of the ceramic layer and the structured surface of the basic structure, i.e. a part of the ceramic layer is applied on the monolithic ceramic layer. This embodiment of the pressing die according to the application can be manufactured, for example, by:

-applying a full-face ceramic layer onto the surface of the basic structure;

-applying a partial mask onto the global ceramic layer;

-applying a ceramic layer on the blanket ceramic layer provided with the mask in the areas not covered by the mask;

-removing the mask such that a portion of the ceramic layer is arranged on the global ceramic layer.

The gloss of the partial ceramic layer and the full ceramic layer can also be achieved by post-treating the ceramic layer that has been correspondingly coated to obtain a predetermined gloss of the corresponding ceramic layer. The post-treatment may for example comprise polishing or laser treatment of the corresponding ceramic layer.

According to one embodiment of the pressing tool according to the application, the surface of the basic structure may have different gloss levels in different areas, which in particular differ from the gloss levels of the full ceramic layer and the partial ceramic layer. The adjustment of the different gloss levels of the surfaces of the basic structure can be achieved, for example, by means of a laser or is known from WO 2009/062488A2 in the case of a basic structure made up of a plurality of layers arranged one above the other.

According to the application, the press mould can be used for manufacturing workpieces, in particular material sheets for the furniture industry or for laminate floor panels. The pressing die has a pressing surface that is in direct contact with and faces the material sheet to be pressed when the material sheet is pressed in the press.

The pressing die includes a basic structure having a surface. The surface may be shaped flat or three-dimensional. The surface may preferably be formed of a metallic surface, such as chromium, copper, stainless steel, nickel, tin or a metal alloy. A ceramic layer is disposed on the surface, the ceramic layer forming a pressing surface. The first ceramic layer has a first gloss and the second ceramic layer has a second gloss. The gloss can be determined by the material properties of the pressed surface, the layer structure of the surface structure of one or both ceramic layers or the underlying surface of the basic structure. The first gloss level of the first ceramic layer is different from the second gloss level. It is thus possible to create a surface that is particularly resistant, but which can still be designed such that it closely mimics a natural appearance, in particular a wood appearance.

Preferably, the pressing die is a pressing plate for manufacturing a material plate. Material sheets are used in the furniture industry or laminate floor panels. In this case, it is advantageous if the pressboard can be used in existing furniture pressing systems and in the flooring industry.

In another embodiment, the basic structure of the pressing die may be a support structure made of metal, in particular stainless steel. The metal support structure ensures that the pressing pressure is evenly distributed over the material sheet to be pressed and is wear-resistant.

It may be preferred that the pressing surface has a structure of projections and depressions and that the basic structure has a structured surface arranged on a support structure, wherein at least two basic structure layers, in particular of metal, which constitute the structured surface of the basic structure, are arranged at least partially on top of each other on the support structure. These basic structural layers may be flat or applied in three dimensions by additive manufacturing methods. Additive manufacturing methods may be, for example, inkjet printing, three-dimensional printing, sintering, lithography, painting, printing with UV curable inks or acrylates. In this case, it is particularly advantageous to use less expensive materials and faster and less precise coating methods for the intermediate layer of the basic structure layer. This allows for a cost-effective production with a high surface quality of the pressing surface.

Furthermore, it may be expedient if the first or the second ceramic layer is also applied only partially to the structured surface of the basic structure and thus forms a relief layer structure of the structured surface. This allows further fine structuring of the relief layer structure, while having a higher resistance of the ceramic layer and/or achieving special optical effects.

However, it can also be provided that the first ceramic layer and the second ceramic layer are also applied, for example, only partially on the structured surface of the basic structure. This allows further fine structuring of the relief layer structure, while having a higher resistance to the ceramic layer and/or achieving special optical effects, such as different gloss or matt in the areas of partial application.

In an embodiment, the second ceramic layer may be arranged at least partially on the first ceramic layer. Thus, regions having different surface characteristics and different structures can be created. This may also assist in the formation of the relief layer structure.

Preferably, the first ceramic layer or the second ceramic layer can be processed by means of a laser at least in the laser processing region. The gloss, matt, structure can be changed by laser processing or incisions can be made in the layer above it on the pressing surface.

In the second ceramic layer, a recess may be provided, which extends as seen in the basic structural direction up to the first ceramic layer. Thus creating at least two areas of different appearance or different structure when the pressing surface is viewed.

Preferably, the void may be a cut created by a subsequent process of the applied second ceramic layer. Possible processing steps here may be milling, laser irradiation, masking, color masking with UV curing, and removal with lye or acid or etching or cleavage. Here, for example, sodium hydroxide solution containing hydrogen peroxide can be used for the removal. These incisions allow application over the entire surface and allow the layers underneath to be visible or visually effective.

Furthermore, it may be expedient for the subsequent processing to be laser processing. Advantageously, laser processing allows for very precise and fine processing, even in terms of the depth of the layer.

In another possible embodiment of the application, one of the metal layers arranged on the pressing side of the basic structure may be a nickel layer or a nickel-containing metal layer. Above the pressing side a first and/or a second ceramic layer may be arranged. A metal layer, a nickel layer or a nickel-containing metal layer may be additionally arranged between the first and the second ceramic layer. These metal layers allow the application of layers that function further as connection layers.

In another possible embodiment, the structured surface of the base structure is fabricated in a three-dimensional relief layer structure at least in part using an additive manufacturing process. Additive manufacturing methods may be, for example, inkjet printing, three-dimensional printing, sintering, lithography, painting, printing with UV curable inks or acrylates. Such a production method allows for small batches and for the realization of the individual structural requirements of the furniture industry.

Instead, the structured surface of the basic structure may be manufactured in three dimensions at least in part using electrochemical, mechanical or laser machining methods. In this case, for example, masking and etching methods or electrochemical chromium plating methods known from the prior art can be used. The tested method can be used here together with the improvement according to the application on a pressing tool and thus increase the versatility of application.

The second ceramic layer can optionally cover the structured surface of the basic structure (10) in an overall manner and has a thickness of preferably 0.001mm to 2mm, wherein the first ceramic layer has a different thickness, but also preferably a thickness in the range of 0001mm to 2 mm. The difference in layer thickness leads to a structural change of the first and second ceramic layers and thus to different gloss values, wherein in particular both ceramic layers may consist of the same ceramic material. Different layer thicknesses can be used to achieve the optical effect.

Instead of this, the ceramic materials of the two ceramic layers may also be different in order to obtain different gloss levels of the first ceramic layer and the second ceramic layer, wherein in particular the thickness of the second ceramic layer may be equal to the thickness of the first ceramic layer. The use of different ceramic layers further increases the optical and combination possibilities for achieving a realistic imitation of natural materials.

For example, the following materials may be used as the ceramic material of the ceramic layer: hafnium diboride, molybdenum diboride, tantalum diboride, titanium diboride, tungsten diboride, vanadium diboride, zirconium diboride or mixtures of these ceramic materials. The advantage of these materials is their resistance and hardness, which results in improved pressing characteristics of the pressing die.

Embodiments of the pressing die according to the application can be manufactured, for example, by:

-providing a support structure for the basic structure;

-manufacturing a structured surface on a support structure;

-applying a first ceramic layer onto a surface of the basic structure; and

It is thus possible to create a surface that is particularly resistant, but which can still be designed such that it closely mimics a natural appearance, in particular a wood appearance.

In a further advantageous development, the method may comprise the steps of:

-applying a partial mask onto the structured surface of the basic structure;

-applying a first ceramic layer on the structured surface provided with the mask;

-removing the mask such that the first ceramic layer is only partially arranged on the structured surface;

-applying the second ceramic layer globally to the partially coated first ceramic layer and to the structured surface of the basic structure.

The advantage here is that the individual areas on the pressing tool can have different optical properties, such as gloss, and that the production is still simple and the masking method is tested.

In an alternative embodiment, the method may comprise the steps of:

-applying a first ceramic layer globally to the structured surface of the basic structure;

-applying a partial mask onto the first ceramic layer;

-coating a second ceramic layer on the first ceramic layer provided with the mask.

The advantage here is that the individual regions on the press tool can have different optical properties, such as gloss, and also contribute to the overall relief structure of the press tool.

Alternatively, the mask can be removed here, so that the first ceramic layer is only partially arranged on the structured surface.

In another alternative method embodiment, a metal layer, a chromium layer, a nickel layer, or a nickel-containing metal layer may be applied as a mask.

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

The method according to the application can be supplemented by a post-treatment step, wherein the respective coated ceramic layer or mask is treated to obtain a predetermined gloss of the respective ceramic layer or mask.

In one embodiment, the application of the ceramic layer may be achieved by means of an in-plane magnetron sputtering coating system, wherein the partial fabrication of the ceramic layer is achieved by suitably controlling the in-plane magnetron sputtering coating system. This ensures a coherent coating of the ceramic layer and a precisely controllable or adjustable layer thickness.

The method according to the application can be developed such that the following steps are additionally carried out:

-transporting the pressboard on a transport system;

-opening a first gate to the process chamber;

-transporting the pressboard into a process chamber of a surface magnetron sputtering coating system;

-closing the first gate;

-applying a vacuum in the process chamber by means of a vacuum pump;

-coating one or more ceramic layers with a magnetron;

-opening a first gate to the process chamber;

transporting the pressboard away from the process chamber of the surface magnetron sputtering coating system by means of a first gate.

By this advantageous development, a cost-effective production of the pressing tool can be achieved.

The method according to the application may comprise the additional steps of:

the transport press plate is passed through a vacuum pre-chamber with a pre-chamber gate, which is located upstream of the process chamber as seen in the transport direction, wherein the vacuum pre-chamber is brought by a vacuum pump to a pressure level between atmospheric pressure and the process pressure during the application of the ceramic layer in the process chamber, which is in particular below 10 ^-5 Millibars, preferably 10 ^-8 And millibars.

An energy-efficient coating is ensured by this advantageous process improvement.

The method according to the application may alternatively comprise the additional step of:

the transport press plate is passed through a vacuum pre-chamber with a pre-chamber gate, which is located upstream of the process chamber as seen in the transport direction, wherein the vacuum pre-chamber is brought by a vacuum pump to a pressure level between atmospheric pressure and the process pressure during the application of the ceramic layer in the process chamber, which is in particular below 10 ^-5 Millibars, preferably 10 ^-8 A millibar;

the transport press plate is passed through a vacuum back chamber with a back chamber gate, which is located downstream of the process chamber as seen in the transport direction, wherein the vacuum back chamber is brought to a pressure level between atmospheric pressure and the process pressure by a vacuum pump. It is therefore advantageous to be able to achieve an optimized process with a low energy generation vacuum.

Another aspect of the application is the use of a press mould according to the application for manufacturing material panels, in particular for the furniture industry or for laminating material panels. Advantageously, with the press mould according to the application a large number of material sheets, in particular for the furniture industry or for laminate floor panels, can be manufactured in a low-wear manner.

Drawings

Embodiments of the application are illustrated in the accompanying schematic drawings. In the drawings:

FIG. 1 shows a perspective view of a pressboard having a pressing surface;

FIG. 2 shows a cross-sectional view of a portion of a side view of a pressboard;

fig. 3 shows the pressboard in an intermediate stage during its manufacture;

FIG. 4 shows a cross-sectional view of a portion of a side view of an alternative embodiment of a pressboard;

FIG. 5 shows a cross-sectional view of a portion of a side view of another alternative embodiment of a pressboard;

FIG. 6 shows a cross-sectional view of a portion of a side view of a pressboard with a laminate during a pressing process in a closed press;

FIG. 7 shows a cross-sectional view of a side view of a surface magnetron sputtering coating system.

Detailed Description

Fig. 1 shows a perspective view of a pressing die configured as a pressing plate 1 in the case of the present embodiment. The pressboard 1 comprises a pressing surface 2. The pressing side 3 is the side of the press plate 1 that faces the laminate during the pressing process in the press.

Fig. 2 shows a cross-sectional view of a part of a side view of the pressboard 1.

The pressing surface 2 can be designed smooth, but in the case of the present embodiment has a structure consisting of projections 4 and depressions 3.

The structure of the pressing surface 2 is in particular assigned to natural material, which in the case of the present embodiment is wood.

The pressing surface 2 is arranged on a plurality of basic structure layers 15 of the basic structure 10. In addition to the basic structure layer 15, the basic structure 10 comprises a support structure.

The first ceramic layer 11 is in this embodiment partially arranged on the basic structure 10 and the second ceramic layer 12 completely covers the surface 31 of the basic structure 10 and the first ceramic layer 11.

With the pressboard 1, a workpiece, for example a material sheet, such as a laminate, can be manufactured by pressing. After pressing, the workpiece has a structured surface corresponding to the structure of the pressing surface 2.

In the case of the present embodiment, the pressboard 1 comprises the basic structure 10 shown in fig. 3A, which has a structured surface 31 assigned to the structure of the pressing surface 2.

In the case of the present embodiment, the pressboard 1 comprises a partial ceramic layer 11 arranged on the structured surface 31 of the basic structure 10 and a comprehensive ceramic layer 12 arranged on the partial ceramic layer 11 constituting the pressing surface 2.

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

In the case of the present embodiment, the pressboard 1 comprises a basic carrier, in particular a support structure 14, for example composed of metal, on which the basic structure 10 is arranged.

In the case of the present embodiment, the basic structure 10 comprises a plurality of basic structure layers 15 arranged one above the other. The basic structure layer 15 is preferably made of nickel and is at least partially designed and forms a relief layer structure 16 together with the ceramic layers 11, 12.

The basic structure 10 may be manufactured, for example, by: a mask, not shown in detail, is applied to the basic structural layer 15 at least once to cover the areas according to the image data of the structure assigned to the structured pressing surface 2, and then a further basic structural layer 15 is applied to the areas not covered by the mask. This operation is repeated until the basic structure 10 is produced. The basic structure 10 is produced in particular from the structure of the pressing surface 2, i.e. from the image data associated with the projections 4 and the depressions 5, in that the mask and the basic structure layer 15 are applied in succession, for example by electroplating or chemical means, from the image data.

Then, in the case of the present embodiment, a mask 32 shown in fig. 3B is applied onto the structured surface 31 of the basic structure 10, which partially covers the structured surface 31 of the basic structure 10.

Subsequently, in the case of the present embodiment, a ceramic layer is applied to the areas of the structured surface 31 of the basic structure 10 which are not covered by the mask 32 by means of the in-plane magnetron sputtering coating system 33. Subsequently, the mask 32 is removed such that only the areas of the structured surface 31 of the basic structure 10 not covered by the mask 32 are covered by the ceramic layer, thereby yielding a portion of the ceramic layer 11, see fig. 3C. By properly controlling the surface magnetron sputtering coating system 33, a predetermined thickness of a portion of the ceramic layer 11 is obtained, thereby making it a predetermined glossiness.

Then, in the case of the present embodiment, the global ceramic layer 12 is applied onto a part of the ceramic layer 11 by means of the surface magnetron sputtering coating system 33. In order to set the gloss of the global ceramic layer 12, it is given a predetermined thickness under control of the surface magnetron sputtering coating system 33.

In the case of the present embodiment, the two ceramic layers 11, 12 are made of, for example, the same ceramic material, hafnium diboride, molybdenum diboride, tantalum diboride, titanium diboride, tungsten diboride, vanadium diboride, zirconium diboride or a mixture of these ceramic materials.

In order to give the ceramic layers 11, 12 different gloss, in the case of the present embodiment, the thickness of the two ceramic layers is different. In particular, the overall ceramic layer 12 is thinner than a portion of the ceramic layer 11. In particular, the two ceramic layers 11, 12 consist of the same ceramic material.

The thickness of the two ceramic layers 11, 12 is preferably in the range between 1 μm and 2 μm.

The ceramic layer preferably has a vickers hardness of at least 2000 HV.

In order to set the different gloss levels of the ceramic layers 11, 12, they can also have different ceramic materials.

In order to set the gloss of the ceramic layers 11, 12, they may also be subjected to post-treatments, for example polishing or laser treatments.

It is also possible to first provide the structured surface 31 of the basic structure 10 with a full ceramic layer 12 and to apply a partial ceramic layer 11 thereon.

It is also possible to manufacture part of the ceramic layer 11 by suitably controlling the surface magnetron sputtering coating system 33.

Fig. 4 shows a cross-sectional view of a portion of a side view of an alternative embodiment of a pressboard. The first ceramic layer 11 and the second ceramic layer 12 are each only partially applied on the structured surface 31 of the basic structure 10. As with the other embodiments, the base structure layer 15 may be made of metal, in particular nickel, but also of other materials such as plastics or ceramics. The basic structural layer 15 may be applied using known additive or subtractive manufacturing methods.

In a further advantageous development of the present embodiment, the second ceramic layer 12 may be arranged at least partially on the first ceramic layer 11.

Furthermore, the first ceramic layer 11 or the second ceramic layer 12 can be processed by means of a laser at least in the laser processing region 17. The laser processing can be used in particular to influence the gloss, reflection properties, matt or structural properties of the ceramic layer and thus positively transfer these structural properties to the laminate to be produced.

In a further embodiment according to fig. 4, the second ceramic layer 12 can entirely cover the structured surface 31 of the basic structure 10 and has a second thickness 19, wherein the first ceramic layer 11 has a first thickness 18. The first thickness 18 and the second thickness 19 may have different layer thicknesses in order to obtain different gloss values of the first and the second ceramic layer 11, 12, wherein in particular the two ceramic layers 11, 12 may consist of the same ceramic material.

In all embodiments of the application, the ceramic material of the ceramic layers 11, 12 may for example consist of hafnium diboride, molybdenum diboride, tantalum diboride, titanium diboride, tungsten diboride, vanadium diboride, zirconium diboride or mixtures of these ceramic materials.

In another embodiment according to fig. 4, the ceramic materials of the two ceramic layers 11, 12 may be different in order to obtain different gloss levels of the first ceramic layer 11 and the second ceramic layer 12, wherein in particular the thickness 19 of the second ceramic layer 12 is equal to the thickness 18 of the first ceramic layer 11.

The thickness of the two ceramic layers 11, 12 is preferably in the range between 1 μm and 2 mm.

In the covering region 13, two ceramic layers may be arranged at least partially on top of each other.

Fig. 5 shows a cross-section of a part of a side view of a pressed board of another alternative embodiment, wherein two ceramic layers 11, 12 are arranged at least partially on top of each other. The second ceramic layer 12 arranged on the pressing side 7 of the pressing tool has at least one recess 5 which makes the first ceramic layer appear on the surface or opens a cutout 6 for this purpose, which is equivalent to a window. Here, the fabrication may be performed using the mask 32 at the time of applying the ceramic layer 12 and then removing the mask 32, or by removing a portion of the second ceramic layer 12 by a chemical method using, for example, a sodium hydroxide solution containing hydrogen peroxide.

Furthermore, the basic structure is based on the embodiments of fig. 2 and 3 or 4.

Fig. 6 shows a cross-sectional view of a portion of a side view of a pressboard with a laminate during a pressing process in a closed press. In particular the press die of the press plate 1 is placed on the press pad 9 in a press 20, for example a short-cycle press. During the shown pressing process with the closing part of the press 20, the laminate 8, in particular a material sheet for the furniture industry or floor panels, melts under the effect of temperature and pressure, and the pressing surface 2 shows a positive shape in the laminate 8 in its negative shape of the depressions 3 and the protrusions 4.

Fig. 7 shows a cross-sectional view of a side view of an in-plane magnetron sputtering coating system 33.

In the present embodiment, an in-plane magnetron sputtering coating system 33 having a multi-chamber system is shown. However, instead of this, a single chamber system with only one process chamber 24 and no additional chambers is possible.

The pressing die, in particular the pressboard 1, is fed into the vacuum prechamber 25 by means of the transport system 21 when the prechamber gate 26 is open. The pre-chamber gate 26 is closed and the vacuum pump 30 reduces the pressure in the vacuum pre-chamber 25, e.g. below 10 ^-2 Pressure of mbar, preferably at 10 ^-5 Pressure in millibars. At the same time, the gate 22 is closed and a process pressure is present in the process chamber. The gate 22 is then opened and pressure is adapted between the process chamber 24 and the pre-vacuum chamber 25. Thereby saving energy and achieving beat time compared to a single chamber system. The pressing die is transported to the processing chamber 24. The gates 22 and 23 are closed and vacuum is applied in the process chamber by vacuum pump 29. The process pressure is here less than 10 ^-5 Mbar, preferably 10 ^-8 And millibars. After the processing is completed, the pressing dieThe tool is transported to the vacuum back chamber through the open sluice 23. Before the back chamber gate is opened, there is a pressure level comparable to the vacuum front chamber. The vacuum front chamber and the vacuum rear chamber may be connected together by a vacuum pipe having a valve so that vacuum is exchanged between the vacuum front chamber and the vacuum rear chamber at the time of the tact change in the continuous operation of the surface magnetron sputtering coating system 33, thereby saving energy for the operation of the vacuum pump 30. Other PVD coating systems, PVD sputtering devices, magnetron sputtering devices, or the like may be used in place of the surface magnetron sputtering coating system for all embodiments of the application.

List of reference numerals

1. Pressed board

2. Pressing surface

3. Recess in the bottom of the container

4. Protrusions

5. Void portion

6. Incision

7. Pressing side

8. Material plate

9. Pressing pad

10. Basic structure

11. Ceramic layer

12. Ceramic layer

13. Coverage area

14. Supporting structure

15. Basic structural layer

16. Relief layer structure

17. Laser machining region

18 Thickness (of first ceramic layer)

19 Thickness (of second layer ceramic)

20. Press machine

21. Transport system

22. Gate valve

23. Gate valve

24. Processing chamber

25. Vacuum pre-chamber

26. Pre-chamber gate

27. Vacuum back chamber

28. Rear chamber gate

29. Vacuum pump

30. Vacuum pump

31 Surface (of basic structure 10)

32. Mask for mask

33. Surface magnetic control sputtering coating system

34. Metal layer

35. Functional layer

36. Magnetron with a magnetron body having a plurality of magnetron electrodes

Claims

1. A press die for manufacturing a workpiece includes

A pressing surface (2),

a basic structure (10) having a surface (31), and

at least two ceramic layers (11, 12) arranged on the surface (31) and constituting the pressing surface (2), wherein the first ceramic layer (11) has a first gloss and the second ceramic layer (12) has a second gloss different from the first gloss of the first ceramic layer (11).

2. A press mould according to claim 1, wherein the press mould is a press plate (1) for manufacturing a material plate (8).

3. Press die according to claim 1 or 2, wherein the basic structure (10) of the press die has a support structure (14) made of metal, in particular stainless steel.

4. A pressing tool according to one of claims 1 to 3, wherein the pressing surface (2) has a structure of projections (4) and depressions (3), and the basic structure (10) has a structured surface (31) provided on a support structure (14), at least two basic structure layers (15), in particular made of metal, which are arranged at least partially on top of one another, are provided on the support structure (14), which basic structure layers constitute the structured surface (31) of the basic structure (10).

5. Press mould according to one of claims 1 to 4, wherein the first or second ceramic layer (11, 12) is applied only partially on the structured surface (31) of the basic structure (10) and thereby constitutes the relief layer structure (16) of the structured surface (31).

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

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

8. Pressing die according to one of claims 1 to 7, wherein the first ceramic layer (11) or the second ceramic layer (12) is processed by laser at least in a laser processing region (17).

9. Pressing die according to claim 7, wherein a void (5) is provided in the second ceramic layer (12), which void extends as seen in the direction of the basic structure (10) up to the first ceramic layer (11).

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

11. A pressing die according to claim 10, wherein the subsequent processing is laser processing.

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

13. The pressing die according to one of claims 1 to 12, wherein the structured surface (31) of the basic structure (10) is manufactured in a three-dimensional relief layer structure (16) at least partly by an additive manufacturing method.

14. Press die according to one of claims 1 to 12, wherein the structured surface (31) of the basic structure (10) is manufactured at least partly in three-dimensional shape by means of electrochemical, mechanical or laser machining methods.

15. Pressing die according to one of claims 1 to 14, wherein the second ceramic layer (12) completely covers the structured surface (31) of the basic structure (10) and has a second thickness (19), the first ceramic layer (11) having a first thickness (18), the first thickness (18) and the second thickness (19) having different layer thicknesses, in order to obtain different gloss values of the first and second ceramic layers (11, 12), in particular the two ceramic layers (11, 12) being composed of the same ceramic material.

16. Pressing die according to one of claims 1 to 14, wherein the ceramic materials of the two 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), in particular the thickness (19) of the second ceramic layer (12) being equal to the thickness (18) of the first ceramic layer (11).

17. Pressing die according to one of claims 1 to 16, wherein the ceramic material of the ceramic layer (11, 12) is hafnium diboride, molybdenum diboride, tantalum diboride, titanium diboride, tungsten diboride, vanadium diboride, zirconium diboride or a mixture of these ceramic materials.

18. Method for manufacturing a pressing die according to one of claims 1 to 17, comprising the following method steps:

-providing a support structure (14) for the basic structure (10);

-applying at least two basic structure layers (15) onto a support structure (14) to establish a basic structure (10);

-manufacturing a structured surface (31) on a support structure (14);

-applying a first ceramic layer (11) onto a surface (31) of the basic structure (10); and

-applying a second ceramic layer (12) onto the structured surface (10) and/or onto the coated first ceramic layer (11).

19. The method of claim 18, comprising

-applying a partial mask (32) onto the structured surface (31) of the basic structure (10);

-applying a first ceramic layer (11) onto a structured surface (31) provided with a mask;

-removing the mask (32) such that the first ceramic layer (11) is only partially arranged on the structured surface (31); and is also provided with

-applying the second ceramic layer (12) over the entire surface of the partially applied first ceramic layer (11) and the structured surface (31) of the basic structure (10).

20. The method of claim 18, comprising

-applying the first ceramic layer (11) globally to the structured surface (31) of the basic structure (10);

-applying a portion of a mask (32) onto the first ceramic layer (11);

-coating a second ceramic layer on the first ceramic layer (11) provided with the mask.

21. A method according to claim 20, comprising removing the mask (32) such that the first ceramic layer (11) is only partially arranged on the structured surface (31).

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

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

24. The method according to one of claims 18 to 24, comprising post-treating the respective coated ceramic layer (11, 12) or mask (32) to obtain a predetermined gloss of the respective ceramic layer (11, 12) or mask (32).

25. The method according to one of claims 18 to 24, comprising coating the ceramic layer (11, 12) by means of a surface magnetron sputtering coating system (33), wherein the ceramic layer (11, 12) is partly manufactured by means of a suitable control of the surface magnetron sputtering coating system (33).

26. The method of claim 25, comprising

-transporting the pressboard (1) on a transport system (21);

-opening a first gate (22) to the process chamber (24);

-transporting the pressboard (1) into a process chamber (24) of a surface magnetron sputtering coating system (33);

-closing the first gate (22);

-applying a vacuum in the process chamber (24) by means of a vacuum pump (29);

-coating one or more ceramic layers (11, 12) by means of a magnetron (36);

-opening a first gate (22) to the process chamber (24);

-transporting the pressboard (1) away from the process chamber (24) of the surface magnetron sputtering coating system (33) by means of a first gate (22).

27. The method of claim 26, comprising the additional step of

-transporting the pressboard (1) through a vacuum pre-chamber (25) with a pre-chamber gate (26), which vacuum pre-chamber is located upstream of the process chamber (24) as seen in the transport direction, wherein the vacuum pre-chamber (25) is brought by means of a vacuum pump (30) to a pressure level between atmospheric pressure and a process pressure during the coating of the ceramic layer (11, 12) in the process chamber (25), which process pressure is in particular below 10 ^-5 Millibars, preferably 10 ^-8 And millibars.

28. The method of claim 26, comprising the additional step of

-transporting the pressboard (1) through a vacuum pre-chamber (25) with a pre-chamber gate (26), which vacuum pre-chamber is located upstream of the process chamber (24) as seen in the transport direction, wherein the vacuum pre-chamber (25) is brought by means of a vacuum pump (30) to a pressure level between atmospheric pressure and a process pressure during the coating of the ceramic layer (11, 12) in the process chamber (25), which process pressure is in particular below 10 ^-5 Millibars, preferably 10 ^-8 A millibar;

-transporting the pressboard (1) through a vacuum back chamber (27) with a back chamber gate (28), which vacuum back chamber is located downstream of the process chamber (24) as seen in the transport direction, wherein the vacuum back chamber (27) is placed at a pressure level between atmospheric pressure and process pressure by means of a vacuum pump (30).

29. Use of a press die according to one of claims 1 to 17 for manufacturing a sheet of material according to the application.