Method of forming an embossing caul

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. In this manner, a relief of the textured design of the wood panel is transferred to the caul as it is further cured. The plastic caul may then be separated from the wood panel of the mold and fully cured by use or baking, or both. The configuration of the wood panel assumed in relief by the plastic cauls is thus permanently maintained and the caul may be used for embossing overlaid wood panels with the textured grain pattern of the panel used in making the mold.