Abstract: A method for making a consolidated wood product comprising coating wood components with a B-stageable, phenol-formaldehyde resole resin; heating the coated wood components to about 80 to 140° C. for a time sufficient to advance the resin to a B-stage; forming a mat or stack of the wood components coated with the B-stage resin; exposing the mat or stack of coated wood components to a saturated or superheated steam atmosphere in a hot press; and compressing the layup to form the consolidated wood product. The phenol-formaldehyde resole resin used in the method has a number average molecular weight of between about 200 and 600, has a F:P mole ratio of about 1.3:1 to 2.0:1, and has been modified with 0 to about 5.5 wt % of caustic based on resin solids.

Abstract: A consolidated man-made board, such as hardboard, is "post-press" embossed with a contoured embossing plate at a pressure of at least about 1000 psi, at a temperature in the range of about 400.degree.-550.degree. F. and for a period of time sufficient to permanently re-shape the surface of the consolidated board.

Abstract: A consolidated man-made board, such as hardboard, is wetted on one surface with a chemical, such as ammonium hydroxide, and thereafter embossed with a contoured embossing plate at a pressure of at least about 1000 p.s.i., at a temperature in the range of about 400.degree.-550.degree. F. and for a period of time sufficient to permanently reshape the surface of the consolidated board. The use of chemical wetting agents including ammonium hydroxide, mineral acids including hydrochloric, sulfuric, nitric and phosphoric acids, oxalic acid, and metheneamine is disclosed.

Abstract: A consolidated man-made board, such as hardboard, is wetted on one surface and thereafter embossed with a contoured embossing plate at a pressure of at least about 1000 p.s.i., at a temperature in the range of about 400.degree.-550.degree. F. and for a period of time sufficient to permanently re-shape the surface of the consolidated board.