Abstract: A process for designing and manufacturing precision-folded, high strength, fatigue-resistant structures and a sheet therefore. The techniques include methods for precision bending of a sheet of material (41, 241, 341, 441, 541) along a bend line (45, 245, 345, 445,543) and a sheet of material formed with bending strap-defining structures, such as slits or grooves (43, 243, 343, 443, 542), are disclosed. Methods include steps of designing and then separately forming longitudinally extending slits or grooves (43, 243, 343, 443, 542) through the sheet of material in axially spaced relation to produce precise bending of the sheet (41, 241, 341, 441,541) when bent along the bend line (45, 245, 345, 445, 543). 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 (257, 457) to be engaged and supported on faces (255, 455) of the sheet material on opposite sides of the slits or arcs.

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.

Abstract: A process for designing and manufacturing precision-folded, high strength, fatigue-resistant structures and a sheet therefore. The techniques include methods for precision bending of a sheet of material (41, 241, 341, 441, 541) along a bend line (45, 245, 345, 445,543) and a sheet of material formed with bending strap-defining structures, such as slits or grooves (43, 243, 343, 443, 542), are disclosed. Methods include steps of designing and then separately forming longitudinally extending slits or grooves (43, 243, 343, 443, 542) through the sheet of material in axially spaced relation to produce precise bending of the sheet (41, 241, 341, 441, 541) when bent along the bend line (45, 245, 345, 445, 543). 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 (257, 457) to be engaged and supported on faces (255, 455) of the sheet material on opposite sides of the slits or arcs.

Abstract: A method for precision bending of a sheet of material (41, 241, 341, 441) along a bend line (45, 245, 345, 445) and the resulting sheet are disclosed. A method includes a step of forming longitudinally extending slits (43, 243, 343, 443) through the sheet of material in axially spaced relation to produce precise bending of the sheet (41, 241, 341, 441) along the bend line (45, 245, 345, 445) with edges (257, 457) engaged and supported on faces (255, 455) of the sheet material on opposite sides of the slits. The edge-to-face contact produces bending along a virtual fulcrum position in superimposed relation to the bend line (45, 245, 345, 445). Several slit embodiments (43, 243, 343, 443) suitable for producing edge-to-face engagement support and precise bending are disclosed, as is the use of the slit sheets to enhance various fabrication techniques.

Abstract: A device (41) for positioning a joinery fastener (74) in a joinery member (33) for later use in forming a joinery assembly. The fastener positioning device (41) includes a feed magazine (82) formed for feeding joinery fasteners (74) to a gripping apparatus (83). The gripping apparatus (83) is positioned to receive the fasteners (74) and is further adapted to releasably grip individual fasteners (74) at a position (103) below the fastener head (86) to hold the fasteners (74) in a known and controlled, indexed relation to the gripping apparatus (83). The gripping apparatus is movable between a fastener gripping position to a fastener placement position while the pointed end (88) of the fastener (74) remains in indexed relation, and a placement arm (92) is formed to urge the fastener (74) from the gripping apparatus (83) and into interference fit with the joinery member (33).

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.

Abstract: A device (41) for positioning a joinery fastener (74) in a joinery member (33) for later use in forming a joinery assembly. The fastener positioning device (41) includes a feed magazine (82) formed for feeding joinery fasteners (74) to a gripping apparatus (83). The gripping apparatus (83) is positioned to receive the fasteners (74) and is further adapted to releasably grip individual fasteners (74) at a position (103) below the fastener head (86) to hold the fasteners (74) in a known and controlled, indexed relation to the gripping apparatus (83). The gripping apparatus is movable between a fastener gripping position to a fastener placement position while the pointed end (88) of the fastener (74) remains in indexed relation, and a placement arm (92) is formed to urge the fastener (74) from the gripping apparatus (83) and into interference fit with the joinery member (33).

Abstract: A process for designing and manufacturing precision-folded, high strength, fatigue-resistant structures and a sheet therefore. The techniques include methods for precision bending of a sheet of material (41, 241, 341, 441, 541) along a bend line (45, 245, 345, 445,543) and a sheet of material formed with bending strap-defining structures, such as slits or grooves (43, 243, 343, 443, 542), are disclosed. Methods include steps of designing and then separately forming longitudinally extending slits or grooves (43, 243, 343, 443, 542) through the sheet of material in axially spaced relation to produce precise bending of the sheet (41, 241, 341, 441,541) when bent along the bend line (45, 245, 345, 445, 543). 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 (257, 457) to be engaged and supported on faces (255, 455) of the sheet material on opposite sides of the slits or arcs.

Abstract: A method for precision bending of a sheet of material (41, 241, 341, 441) along a bend line (45, 245, 345, 445) and the resulting sheet are disclosed. A method includes a step of forming longitudinally extending slits (43, 243, 343, 443) through the sheet of material in axially spaced relation to produce precise bending of the sheet (41, 241, 341, 441) along the bend line (45, 245, 345, 445) with edges (257, 457) engaged and supported on faces (255, 455) of the sheet material on opposite sides of the slits. The edge-to-face contact produces bending along a virtual fulcrum position in superimposed relation to the bend line (45, 245, 345, 445). Several slit embodiments (43, 243, 343, 443) suitable for producing edge-to-face engagement support and precise bending are disclosed, as is the use of the slit sheets to enhance various fabrication techniques.

Abstract: A device (41) for positioning a joinery fastener (74) in a joinery member (33) for later use in forming a joinery assembly. The fastener positioning device (41) includes a feed magazine (82) formed for feeding joinery fasteners (74) to a gripping apparatus (83). The gripping apparatus (83) is positioned to receive the fasteners (74) and is further adapted to releasably grip individual fasteners (74) at a position (103) below the fastener head (86) to hold the fasteners (74) in a known and controlled, indexed relation to the gripping apparatus (83). The gripping apparatus is movable between a fastener gripping position to a fastener placement position while the pointed end (88) of the fastener (74) remains in indexed relation, and a placement arm (92) is formed to urge the fastener (74) from the gripping apparatus (83) and into interference fit with the joinery member (33).

Abstract: A method for precision bending of a sheet of material (31,41,61,91,231) along a bend line (35,45,62-66,96,235) and the resulting sheet are disclosed. A method includes a step of forming and longitudinally extending slits (33,43,68,92,233) through the sheet of material in axially spaced relation to define bending webs (37,47,71,72,106,237), forming stress reducing structures such as enlarged openings (39,49,69,73) or transversely extending slits (239) at each of adjacent ends of pairs of slits in order to reduce crack propagation across the bending webs. In another aspect, the elongated slits (43,68,92,233) are formed with pairs of longitudinally extending slit segments (51,52;74,76;98,99;127) proximate to and on opposite sides of and substantially parallel to the desired bend line. Longitudinally extending slit segments further are connected by at least one intermediate transversely extending slit segment (53,77,101,128). Sheets of slit material suitable for bending also are disclosed.

Abstract: An edge banding apparatus (21) for adhesively securing banding material (28) to an edge of a board (27). The apparatus (21) includes a board support structure (22) formed to support a board (26) in a near vertical orientation with the edge (27) to be banded in a downwardly facing orientation. An adhesive applying assembly (23) is positioned relative to the board support structure (22) and is formed to apply adhesive (54) to the downwardly facing edge (27) during relative motion between the board (26) and the adhesive applying assembly (23). The apparatus (21) includes a banding material applying assembly (24) positioned downstream of the adhesive applying assembly (23) and formed to apply a banding material (28) to the edge after the adhesive (54) is applied and a cutoff assembly (25) which cuts off the banding material (28) as the banded board (26) passes the cutoff device (25).

Abstract: A saw and router assembly (70) preferably including a hand-held rotary saw (50) and a router device (76) having a router bit (52) mounted immediately forward of rotary saw (50) and in alignment with the plane of the saw blade. In one embodiment, separate motors (72, 76) are provided to drive the rotating saw blade (50) and the router bit (52), and in another embodiment a single motor (102) is operatively coupled to drive both the saw blade (50) and the router bit (52). A method of substantially splinter-free cutting of workpieces (14) also is disclosed.

Abstract: A multiple spindle drilling apparatus (10) having an eccentric drive link (11), and a primary drive mechanism (12) coupled to the drive link (11) in an eccentric off-set manner. This eccentric off-set causes eccentric circular motion of the drive link (11) about a predetermined radius (R). A frame member (15) is included, as well as a plurality of in-line spindle units (16) rotatably mounted to the frame member (15) for rotation about corresponding spindle axis (17) thereof. An off-set coupling (21) is rotatably mounted between the drive link (11) and respective crank members (20) mounted to corresponding spindle drive shafts (22) to drive the spindle about the spindle axis (17). The coupling (21) is eccentrically off-set from the spindle axis by a radial distance substantially equivalent to the predetermined radius, and further in-phase with the eccentric off-set of the drive link (11).

Abstract: A spade drill bit device including an elongated shaft formed for rotation about a longitudinal axis thereof, and a flattened blade portion at one end of said shaft. The blade portion has generally planar and parallel opposing faces, and defines opposing side edges, and an end cutting edge therebetween. The cutting edge includes a pair of opposing side spurs each having spur tip portions positioned at the lateral extremities of the cutting edge and terminates at the corresponding side edge. A cutting edge triangular-shaped center tip is included axially aligned with the longitudinal axis, and having a distal end extending beyond the side spurs. The center tip is defined by downward edge portions extending away from the distal end. The cutting edge further includes respective converging edge portions extending between and connecting each side spur to the center tip.

Abstract: An apparatus (30) and method for forming an obliquely oriented counterbore (17) in a surface (15) of a workpiece (13) and a fastener receiving passage (19) proximate an edge (32) of the workpiece (13). The apparatus (30) includes a support frame (33), and a router assembly (34). The router assembly (34) is mounted for arcuate movement between a stored position, out of contact with the workpiece (13), and a routing position where a router bit (36) contacts the workpiece (13) to cut a tapering recess (1.7). A drill assembly (39) is movably mounted to the frame (33) for linear movement between a recessed position, out of contact with the workpiece (13), and a drilling position. In the drilling position, a drill bit (41) engages the workpiece (13) in a direction generally opposing the router bit (36) to drill the passage (19).

Abstract: A hand tool useful in forming a pocket mortise in the surface of a workpiece proximate an edge of the workpiece. The hand tool includes a clamping assembly for releasably clamping the tool to the workpiece, and a router carried by the clamp assembly and mounted for manual displacement toward the workpiece edge at an incline to progressively cut deeper into the workpiece and form an inclined pocket mortise. The hand tool also preferably carries a drill bit guide on the clamp assembly which is formed to receive and guide a drill bit from a hand drill for drilling a bore from the workpiece edge to the mortise. A method of forming a pocket mortise including the steps of clamping the clamp assembly with a movable router to a workpiece, routing the pocket mortise and then drilling a hole to the pocket mortise from the edge of the workpiece by a hand drill also is described.

Abstract: A joint for ready-to assemble furniture including a mortise in a first of two workpieces, an insert for the mortise and a fastener, such as a screw for securely joining the workpieces. The fastener receiving insert has a curved front wall corresponding to a curved load-bearing face of the mortise. An insert bore penetrates the insert for receiving the fastener, and a cover cap on the insert covers the insert member and the mortise from view when two workpieces are joined. The second workpiece has a pre-drilled bore which receives the threaded end of the fastener. The fastener is screwed into threaded engagement with the pre-drilled bore in the second workpiece to securely joint the two workpieces. A plurality of embodiments of the joint and a method of joining the workpieces also are disclosed.

Abstract: A method and apparatus for forming a counterbore and a bore in a workpiece for toe fastening of the piece to a second member is disclosed. The apparatus includes a router mounted with its cutting bit transverse to the workpiece so that the bit may be progressively urged into the workpiece surface to produce a shallow counterbore. Additionally, a drillbit is mounted so that it can be urged from the edge of the workpiece in an opposite direction toward the counterbore to produce a fastener receiving bore which communicates with the counterbore. The router and drill are mounted on a common carriage, and in one embodiment the carriage is pivoted, while in another it is slid, in opposite directions to produce the counterbore and bore. A method of forming the bore and counterbore is also disclosed.