Wear-resistant ceramic, cermet or metallic embossing surfaces, methods for producing same, methods of embossing articles by same and novel embossed articles

• US 4,787,837 A
• Filed: 08/07/1986
• Issued: 11/29/1988
• Est. Priority Date: 08/07/1986
• Status: Expired due to Term

• Current Assignee: Praxair S.T. Technology, Inc. (Linde Plc)
• Original Assignee: Union Carbide Corporation (Dow, Inc.)
• Inventors: Bell, Norman D.
• Primary Examiner(s): Hart, Charles
• Application Number:
  US06/894,199
• Time in Patent Office: 845 Days
• Field of Search: 264/284, 264/293, 264/338, 425/385
• US Class Current: 425/385
• CPC Class Codes: B21B 2267/10 Roughness of roll surface
• CPC Class Codes: B21B 27/005 Rolls with a roughened or textured surface; Methods for making same
• CPC Class Codes: B21H 8/005 Embossing sheets or rolls
• CPC Class Codes: B29C 59/002 Component parts, details or accessories; Auxiliary operations
• CPC Class Codes: B29C 59/022 characterised by the disposition or the configuration, e.g. dimensions, of the embossments or the shaping tools therefor
• CPC Class Codes: B30B 15/062 Press plates
• CPC Class Codes: B30B 15/065 Press rams
• CPC Class Codes: B30B 3/005 Roll constructions
• CPC Class Codes: B44B 5/026 Dies B44B5/028 takes precedence

Abstract

Wear- and corrosion-resistant ceramic, cermet or metallic patterned embossing surfaces, e.g., as a coating bonded to an embossing roll, containing an average of 50 to 2,000 peaks per inch covering said patterned embossing surface. Also, methods of producing a patterned, wear-resistant embossing surface by bonding a ceramic, cermet or metallic coating to a patterned embossing surface, e.g., of an embossing roll, providing an average of about 50 to about 2,000 peaks on the external surface of said coating covering said embossing surface. In addition, methods of embossing articles having surfaces embossable by pressure contact to provide an embossed design and matte finish by pressure contacting the embossable surface with a ceramic, cermet or metallic embossing surface having an embossing pattern and an average of about 50 to 2,000 peaks covering said embossing pattern, wherein the embossed surface of said article is covered with an average of 50 to 2,000 indentations providing a matte finish; the range of gloss provided by the matte finishes produced by a number of similar ceramic, cermet or metallic embossing surfaces is much narrower than that provided by matte finishes produced by a number of similar conventional embossing surfaces; and the level of gloss resulting from use of ceramic, cermet or metallic embossing surfaces is much less dependent on line speed and temperatures of the embossing or embossable surfaces than gloss resulting from conventional embossing surfaces. Additionally, novel embossed articles produced by the novel embossing surfaces and processes are characterized by surprising increases in impact strength and scuff-resistance and a decrease in gloss.

Claims

1. A wear-resistant, pressure contact embossing tool having an embossing surface formed with an embossing pattern for providing a matte finish and an embossed design to an article having a surface embossable by pressure contact therewith, said embossing surface having a ceramic, cermet or metallic coating bonded thereto by a thermal spray process, wherein the external surface of said coating generally conforms to said embossing pattern and contains an average of about 50 to 2,000 peaks per inch covering said external surface of said coating, whereby said peaks indent the embossable surface of said article when pressure contacted with the external surface of said coating to provide the embossable surface of said article with a matte finish and said embossing surface provides an embossed design thereto.

2. Embossing tool as claimed in claim 1 wherein said peaks covering the external surface of said coating have a maximum peak height of about 100 to about 5,000 microinches.

3. Embossing tool as claimed in claim 1 wherein said peaks covering the external surface of said coating have a maximum peak height of about 500 to about 3,000 microinches.

4. Embossing tool as claimed in claim 3 wherein said coating has a nominal thickness of about 1.5 to about 30 mils.

5. Embossing tool as claimed in claim 4 wherein said tool is in the shape of an embossing roll having a cylindrical patterned embossing surface.

6. Embossing tool as claimed in claim 4 wherein said tool is in the form of an impression stamp having a flat or shaped patterned embossing surface.

7. Embossing tool as claimed in claim 4 wherein said coating is aluminum oxide applied by a detonation gun.

8. Embossing tool as claimed in claim 4 wherein said coating is aluminum oxide applied by a plasma torch.

9. Embossing tool as claimed in claim 4 wherein said embossing surface is provided with a woodgrain design for imparting a woodgrain design to said article.