Abstract: A plastic caul for embossing wood panels with grain patterns comprises a laminate of sheets of epoxy prepreg made of such heat insensitive non-cellulosic webs such as fiberglass or woven graphite impregnated with partially cured epoxy resin. The caul may also include a metal core or backing sheet. The embossing face of the caul contains a relief design, usually transferred from a natural wood grain pattern.To form the caul, a mold is first prepared. The mold may comprise a textured wood panel, the grain surface of which has been sealed with a material such as urethane varnish or a water reducible imine catalyzed acrylic varnish with a urethane additive. The sealed textured face is then coated with a release agent. This treatment prevents the panel and future caul from sticking together. Sheets of the epoxy prepreg are then layered between the treated surface of the panel and a backing sheet and compressed under heat and pressure until substantially cured.

Abstract: A press caul suitable for embossing wood panels to produce textured wood surface designs is described. This caul is made by casting liquid, epoxy resin filled with aluminum powder against a panel surface bearing a textured design and applying sufficient heat to cure at least partially. The product caul may then be separated for use.If the desired degree of curing is not reached in the molding step, the caul may be baked. This ensures the permanency of the applied relief. In a further optional embodiment, the resin may contain a plurality of sheets of embedded fiberglass fabric to provide reinforcement.