Electrolysis: processes – compositions used therein – and methods – Electroforming or composition therefor – Mold – mask – or masterform
Patent
1990-05-16
1993-02-02
Niebling, John
Electrolysis: processes, compositions used therein, and methods
Electroforming or composition therefor
Mold, mask, or masterform
205 67, 205 76, C25D 110, B23P 1524
Patent
active
051835517
DESCRIPTION:
BRIEF SUMMARY
The invention relates to a method for making an endless metal band having a pattern, or three-dimensional surface impressions for use in the continuous production of pressed laminated sheets or boards.
Pressed laminated sheets, such as plastic-coated hard fiber boards, fiberglass boards or the like used in the manufacture of furniture or room interiors have a variety of design patterns impressed in their outer surface. Such designs include e.g. intricate patterning, corrugations, knubs as well as wood grain textures. The pattern is impressed into the board surfaces with presses. In a known press disclosed in EP-B1-31 613 the laminated boards are continuously form-pressed between two endless bands. The unfinished board is pressed between two endless bands which move in opposite directions of rotation. One of the endless bands has a pattern impressed into its surface which faces the laminated board. Such a band comprises an endless stainless steel carrier band that is coated with a thin metal layer into which the pattern has been etched. However, manufacturing such an endless band by welding its ends together, smoothing the weld seams and coating the surface with a layer of non-ferric metal into which the pattern is etched is very costly. Endless bands of this type may have a length of up to 30 m.
To generate such a pattern it is conventional to first grind and polish the metal layer and then apply to it a masking compound. The compound may be applied in accordance with a variety of suitable methods. These include applying the compound with rolls, or pressure cylinders (filter rolls, offset rolls) which carry the desired pattern. Alternatively, photographic reproduction processes can be employed in which the metal is coated with a photosensitive material and then exposed light through a superimposed negative of the desired pattern. Unexposed portions of the photographic layer which correspond to the desired pattern remain after development of the photosensitive layer. This procedure can be repeated one or more times with identical or differing masks to obtain impressions of varying depths on the endless band. Given their limited durability and the not infrequent damage to the bands, it is necessary to produce or refurbish several endless bands having the same pattern. When producing a plurality of identical endless bands it has heretofore been necessary to employ the above described method for each of them. Such a multi-step operation, however, is tedious and very expensive.
It is therefore an object of the present invention to develop an economically more efficient method for producing one or more endless bands having identical surface patterns. The object is achieved with the present invention in that a cast in the form of an endless, resilient plastic band is made from the surface pattern of a first endless band. A thin metal layer is galvanically applied to the patterned surface of the plastic band to produce a working duplicate in the form of an endless galvanic metal band. In a final step the plastic band is separated from the galvanic metal band.
The present invention makes it possible to produce from a conventionally manufactured metal band having the desired surface pattern a multiplicity of endless duplicates which have the identical surface patterns. The conventionally manufactured original band serves as a master band or die from which the working duplicates for the continuous production of laminated boards are produced. Such a duplicating process for large bands is simpler, more efficient and substantially more economical than the conventional etching process. The working duplicates require no stainless steel carrier band, thus eliminating the need for the costly manufacture of endless bands by welding its ends together and then smoothing the weld. By contrast the galvanic band of the present invention is rigid enough to withstand the mechanical stresses imposed on it by the press; moreover a cast for a flexible, continuous plastic band is simple and inexpensive to manufacture. A plastic cast re
REFERENCES:
patent: 3532587 (1970-10-01), Ungar et al.
patent: 4478769 (1984-10-01), Pricone et al.
patent: 4537810 (1985-08-01), Held
Leader William T.
Niebling John
Standex International GmbH
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