Abstract: A pocket-cutting device routs staggered pockets in elongated joinery member. The pocket-cutting device includes a base having a worktop, a clamp assembly for clamping the joinery member to the worktop, a router assembly for routing the pockets in the joinery member, a drill assembly for drilling bores in the joinery member, and a guide mounted in the worktop dimensioned and configured to position the joinery member in first and second positions relative to the router assembly for routing first and second pockets and first and second bores in the joinery member at staggered positions. A method of using the staggered pockets is also disclosed.

Abstract: An adjustable pocket-cutting device includes a worktop supporting a workpiece, an actuation lever assembly including an actuation lever pivoting about an actuation lever pivot and configured to support a router having a router bit such that the router bit sweeps through a slot in the worktop and into a workpiece as the actuation lever pivots from a retracted position to a deployed position, and a stop assembly for adjustably limiting pivotal movement of the actuation lever to the deployed position. The stop assembly includes a stop lever adjustably mounted relative to the worktop and a stop member extending from the stop lever across or through the actuation lever, wherein the stop member abuts against an abutment surface of the actuation lever to adjustably limit the movement of the actuation lever to the deployed position.

Abstract: An adjustable pocket-cutting device includes a body, a router, an actuation lever assembly, and a stop lever assembly. The actuation lever assembly includes an actuation lever pivotally mounted on the housing at an actuation lever pivot, a router mount, and pivots from a retracted position to a deployed position. The stop lever assembly adjustably limits the sweep of the router bit into the work clamped to the worktop and includes a stop lever adjustably mounted to the housing, a stop pin extending through a clearance opening in the housing and across a thickness of the actuation lever such that it abuts against an abutment surface of the actuation lever to limit the sweep of the router bit as the router assembly pivots to the deployed position. A method of using the adjustable pocket-cutting device is also disclosed.

Abstract: A solar panel rack may comprise a vertical support, a transverse support, brackets attaching hollow beams to the transverse support, and brackets configured to attach solar panels or solar panel assemblies to the hollow beams. Internal splices may couple collinearly arranged hollow beams in the solar panel rack. Some or all of these components may be formed from folded sheet metal blanks comprising bend lines predefined by bend-inducing features formed in the blanks. Preformed slots, holes, or other openings in the sheet metal blanks may predefine the relative positions of various components in the solar panel rack and predefine the positions of solar panels or solar panel assemblies to be supported by the solar panel rack. Individual components of the solar panel rack may be useful in other structures and applications apart from solar panel racks.

Abstract: A solar panel rack may comprise one or more sheet metal brackets configured to attach solar panels to the solar panel rack. The sheet metal brackets may include clinching tabs configured to be clinched to features on the solar panels to attach the solar panels to the solar panel rack. The sheet metal brackets may further include protrusions configured to facilitate electrical contact between the brackets and the solar panels when the clinching tabs are clinched to features on the solar panels. The sheet metal brackets may additionally or alternatively include positioning tabs configured to contact features on the solar panels to position the solar panels in desired locations on the solar panel rack.

Abstract: A solar panel rack may comprise one or more sheet metal brackets configured to attach solar panels to the solar panel rack. The sheet metal brackets may include clinching tabs configured to be clinched to features on the solar panels to attach the solar panels to the solar panel rack. The sheet metal brackets may further include protrusions configured to facilitate electrical contact between the brackets and the solar panels when the clinching tabs are clinched to features on the solar panels. The sheet metal brackets may additionally or alternatively include positioning tabs configured to contact features on the solar panels to position the solar panels in desired locations on the solar panel rack.

Abstract: A solar panel rack may comprise a vertical support, a transverse support, brackets attaching hollow beams to the transverse support, and brackets configured to attach solar panels or solar panel assemblies to the hollow beams. Internal splices may couple collinearly arranged hollow beams in the solar panel rack. Some or all of these components may be formed from folded sheet metal blanks comprising bend lines predefined by bend-inducing features formed in the blanks Preformed slots, holes, or other openings in the sheet metal blanks may predefine the relative positions of various components in the solar panel rack and predefine the positions of solar panels or solar panel assemblies to be supported by the solar panel rack. Individual components of the solar panel rack may be useful in other structures and applications apart from solar panel racks.

Abstract: A solar panel rack may comprise one or more sheet metal brackets configured to attach solar panels to the solar panel rack. The sheet metal brackets may include clinching tabs configured to be clinched to features on the solar panels to attach the solar panels to the solar panel rack. The sheet metal brackets may further include protrusions configured to facilitate electrical contact between the brackets and the solar panels when the clinching tabs are clinched to features on the solar panels. The sheet metal brackets may additionally or alternatively include positioning tabs configured to contact features on the solar panels to position the solar panels in desired locations on the solar panel rack.

Abstract: A solar panel rack may comprise a vertical support, a transverse support, brackets attaching hollow beams to the transverse support, and brackets configured to attach solar panels or solar panel assemblies to the hollow beams. Internal splices may couple collinearly arranged hollow beams in the solar panel rack. Some or all of these components may be formed from folded sheet metal blanks comprising bend lines predefined by bend-inducing features formed in the blanks. Preformed slots, holes, or other openings in the sheet metal blanks may predefine the relative positions of various components in the solar panel rack and predefine the positions of solar panels or solar panel assemblies to be supported by the solar panel rack. Individual components of the solar panel rack may be useful in other structures and applications apart from solar panel racks.

Abstract: A solar panel rack may comprise a vertical support, a transverse support, brackets attaching hollow beams to the transverse support, and brackets configured to attach solar panels or solar panel assemblies to the hollow beams. Internal splices may couple collinearly arranged hollow beams in the solar panel rack. Some or all of these components may be formed from folded sheet metal blanks comprising bend lines predefined by bend-inducing features formed in the blanks. Preformed slots, holes, or other openings in the sheet metal blanks may predefine the relative positions of various components in the solar panel rack and predefine the positions of solar panels or solar panel assemblies to be supported by the solar panel rack. Individual components of the solar panel rack may be useful in other structures and applications apart from solar panel racks.

Abstract: A solar panel rack may comprise a vertical support, a transverse support, brackets attaching hollow beams to the transverse support, and brackets configured to attach solar panels or solar panel assemblies to the hollow beams. Internal splices may couple collinearly arranged hollow beams in the solar panel rack. Some or all of these components may be formed from folded sheet metal blanks comprising bend lines predefined by bend-inducing features formed in the blanks. Preformed slots, holes, or other openings in the sheet metal blanks may predefine the relative positions of various components in the solar panel rack and predefine the positions of solar panels or solar panel assemblies to be supported by the solar panel rack. Individual components of the solar panel rack may be useful in other structures and applications apart from solar panel racks.

Abstract: A solar panel rack may comprise one or more sheet metal brackets configured to attach solar panels to the solar panel rack. The sheet metal brackets may include clinching tabs configured to be clinched to features on the solar panels to attach the solar panels to the solar panel rack. The sheet metal brackets may further include protrusions configured to facilitate electrical contact between the brackets and the solar panels when the clinching tabs are clinched to features on the solar panels. The sheet metal brackets may additionally or alternatively include positioning tabs configured to contact features on the solar panels to position the solar panels in desired locations on the solar panel rack.

Abstract: A bearing cage for use with a plurality of rolling elements in a bearing assembly includes a plurality of bridge elements arranged to separate the rolling elements from each other and to retain the rolling elements in alignment in the bearing assembly. Each of the bridge elements is formed of sheet material bent to define a partially hollow component. The cage further includes at least one rim element connecting the plurality of bridge elements.

Abstract: A bearing cage for use with a plurality of rolling elements in a bearing assembly includes a plurality of bridge elements arranged to separate the rolling elements from each other and to retain the rolling elements in alignment in the bearing assembly. Each of the bridge elements is formed of sheet material bent to define a partially hollow component. The cage further includes at least one rim element connecting the plurality of bridge elements.

Abstract: A solar panel rack may comprise a vertical support, a transverse support, brackets attaching hollow beams to the transverse support, and brackets configured to attach solar panels or solar panel assemblies to the hollow beams. Internal splices may couple collinearly arranged hollow beams in the solar panel rack. Some or all of these components may be formed from folded sheet metal blanks comprising bend lines predefined by bend-inducing features formed in the blanks. Preformed slots, holes, or other openings in the sheet metal blanks may predefine the relative positions of various components in the solar panel rack and predefine the positions of solar panels or solar panel assemblies to be supported by the solar panel rack. Individual components of the solar panel rack may be useful in other structures and applications apart from solar panel racks.

Abstract: A load-bearing three-dimensional structure including a skeletal structure formed by a sheet of material having a plurality of bend lines, each bend line including a plurality of folding displacements, wherein the sheet of material is bent along the bend lines into a box-section; and a reinforcing member configured for substantially surrounding a portion of the skeletal structure when bent into a box-section to reinforce the structural integrity of the skeletal structure. A method of manufacturing the three-dimensional structure is also disclosed.

Abstract: A two-dimensional sheet material is provided that is suitable for bending along a bend line to form a three-dimensional object. The sheet material is provided with a plurality of displacements in a thickness direction of the sheet material on one side of the bend line. A portion of the displacements shear adjacent the bend line and define an edge and an opposed face. The edge and opposed face configured to produce edge-to-face engagement of the sheet material during bending. Alternatively, sheet material is provided with a plurality of displacements in a thickness direction of the sheet material on one or both sides of the bend line, and with a plurality of corresponding and cooperating protrusions to improve structural integrity and/or to improve electromagnetic and radio frequency shielding. The sheet material may also be provided with a self-latching structure. A method of preparing and using these sheet materials is also described.

Abstract: Precision-folded, high strength, fatigue-resistant structures and a sheet therefore are disclosed. To form the structures, methods for precision bending of a sheet of material along a bend line and a sheet of material formed with bending strap-defining structures, such as slits or grooves, are disclosed. Methods include steps of designing and then separately forming longitudinally extending slits or grooves through the sheet of material in axially spaced relation to produce precise bending of the sheet when bent along the bend line. The bending straps have a configuration and orientation which increases their strength and fatigue resistance, and most preferably slits or arcs are used which causes edges to be engaged and supported on faces of the sheet material on opposite sides of the slits or arcs. The edge-to-face contact produces bending along a virtual fulcrum position in superimposed relation to the bend line.

Abstract: A sheet of material formed for bending along a bend line comprises a plurality of slits positioned proximate and along the bend line. The slits each have opposite end portions which diverge away from the bend line. The slits are configured and positioned to produce bending of the sheet of material along the bend line. The diverging slit end portions reduce stress in the sheet of material during bending.

Abstract: A method of preparing a sheet of material for bending along a bend line comprising the step of forming of at least one displacement in the thickness direction of the sheet of material with a portion of the periphery of the displacement closest to the bend line providing an edge and opposed face configured in position to produce edge-to-face engagement of the sheet on opposite sides of the periphery during bending. The forming step is preferably accomplished using one of a stamping process, a punching process, a roll-forming process and an embossing process. A sheet of material suitable for bending using the process also is disclosed, as are the use of coatings, shin guards and displacing the area of the sheet between bending inducing slits.