Abstract: A pocket-cutting/screw-insertion system is configured for cutting screw pockets in a work piece and inserting screws therein. The system includes a clamp assembly, a router assembly, a drill assembly, and a delivery/insertion assembly including a screw delivery tube for delivering a screw, a stop block for arresting forward motion of the screw, an insertion rod for pushing the screw into the screw pocket and screw bore, and a screw channel for supporting the screw as it is inserted into the screw pocket and screw bore, wherein the stop block is positioned above the insertion rod and the screw channel such the screw first falls from the stop block onto the insertion rod once the stop block arrests forward motion of the screw and then falls from the insertion rod onto the screw channel. A method of using the system is also disclosed.

Abstract: A pocket-cutting/screw-insertion system is configured for cutting screw pockets in a work piece and inserting screws therein. The system includes a clamp assembly, a router assembly, a drill assembly, and a delivery/insertion assembly including a screw delivery tube for delivering a screw, a stop block for arresting forward motion of the screw, an insertion rod for pushing the screw into the screw pocket and screw bore, and a screw channel for supporting the screw as it is inserted into the screw pocket and screw bore, wherein the stop block is positioned above the insertion rod and the screw channel such the screw first falls from the stop block onto the insertion rod once the stop block arrests forward motion of the screw and then falls from the insertion rod onto the screw channel. A method of using the system is also disclosed.

Abstract: A apparatus for forming a three-dimensional (3D) object from a sheet material preferably includes a sheet material, a shaping die defining a cavity adapted to receive at least a portion of the sheet material, a portion of the cavity having a shape corresponding to a desired surface of the 3D object, and a forming member positioned relative to the sheet material opposite the cavity and having a rigid edge having a shape corresponding to a desired small-radii event of the 3D object. When force is applied to the sheet material and to the forming member, the sheet material is forced against the portion of the cavity to form the desired surface, and the rigid edge is forced against the sheet material to form the desired small-radii event. A method of using the apparatus for spline bending of sheet material is also disclosed.

Abstract: A sheet of material (21, 61, 81) formed for control bending along a bend line (23, 63) while maintaining a continuous web of material (26) across the bend line (23, 63). The sheet has at least one groove (22, 62, 82) formed therein with a central groove portion (24, 64, 84) extending in the direction of and positioned proximate to a desired bend line (23, 63). The groove is formed with a continuous web of material (26) at a bottom of the groove (22, 62, 82) and has a configuration defining at least one bending strap (27, 67) extending across the bending line (23, 63) at the end of the groove with a centerline (28) of the bending strap (27, 67) oriented obliquely across the bend line (23, 63) so that a balancing of the forces during bending of the web along the central portion (24, 64, 84) of the grooves and bending of the oblique bending strap occur and control the location of bending of the sheet.

Abstract: A method and apparatus for imparting compound folds on sheet materials includes a tool base for receiving and supporting the sheet material, a locator for positioning the sheet material relative to the work base, and a bend actuator mounted on the tool base. The bend actuator has an actuator member movable between an initial retracted position and a deployed extended position for applying a force against an unsecured portion of sheet material to effect bending of the sheet material about the first fold line as the actuator member moves from the initial retracted position and contacts the unsecured portion. The bend actuator also has a contact member positioned to abut against an outer portion of the unsecured portion as the actuator member continues to bend the sheet material about the first fold line, wherein the contact member effects bending of the sheet material along the second fold lines as the actuator member continues moving toward the deployed extended position.

Abstract: A process of forming bend-controlling structures, such as slits, grooves or displacements (22), in a sheet of material (21, 121, 221, 321, 421, 521, 621, 721). The bend-controlling structures (22) have central portions (26) extending substantially parallel to a desired bend line (23) on the sheet and end portions (27) which diverge away from the bend line (23). In one embodiment the process includes the step of forming the bending straps (24) between pairs of slit end portions (27) at a desired spaced apart distances along the bend line (23) with the straps (24) having a desired configuration, and the step of forming central portions (26) which connect the end portions (27) to complete the slits (22) using a separate die set. A plurality of end portion dies (51/54) can be used to produce end portions (27) of various shapes and straps (24) of various widths, and a single set of central portion forming dies (71/74) are used to connect the end portions (27).

Abstract: A plane-to-plane joint is configured for securing planar segments of one or more sheet materials together without the need for additional fasteners. The plane-to-plane joint includes a first planar segment having an upper planar surface, a second planar segment having a lower planar surface, a joinder structure monolithically formed on the first planar segment, the joinder structure including a transition zone located below the upper planar surface and a registration zone extending upwardly from the transition zone and out-of-plane from the planar segment, and an aperture in the second planar segment for receiving the joinder structure. The aperture is dimensioned and configured to cooperate with the registration zone of the joinder structure to register the relative position of the first and second planar segments when the lower planar surface abuts against the upper surface. A method of making and using the plane-to-plane joint is also disclosed.

Abstract: A sheet of material, suitable for bending along a bend line to a predetermined angle, includes one planar segment on one side of the bend line, another planar segment on another side of the bend line, one displacement extending in the thickness direction of the sheet of material from the one planar segment, and another displacement extending in the thickness direction of the sheet of material from the another planar segment. The displacements are dimensioned and configured such that they engage one another during bending and limit the angular displacement of the one side relative to the another side. As such, the displacements self-key the resulting corner at the predetermined angle and provide structural integrity to the corner.

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 three-dimensional structure formed with precision fold technology includes a first sheet section having a first edge formed with a first joinder structure proximate the first edge, a second sheet section having a second edge formed with a second joinder structure proximate the second edge for interlocking engagement with said first joinder structure, and a plurality of folding structures formed in the sheet of material along a plurality of desired fold lines which divide the sheet of material into said first and second sheet sections, the folding structures being formed to produce sufficiently precise folding of the sheet of material along the fold lines to position the first and second edges together such that said first and second joinder structures interengage with one another and retain the sheet of material in a folded condition.

Abstract: A sheet of material formed for folding into a three-dimensional structure. The sheet has edges formed with joinder structures, such as dovetails, and a plurality of folding structures, such as slits, grooves or displacements, that control folding of the sheet in a manner causing the joinder structures to be folded into interlocking interengagement. The folding structures are configured for very precise folding of the sheet so that the folding structures will be in precise registered juxtaposition. Additionally, the sheet of material includes a retention structure, such as a retention fold or a retention deformation, which will prevent unfolding of the sheet. A method for fastener-free joining of sheet edges together also is disclosed, as are the resulting three-dimensional structures.

Abstract: A method of preparing a sheet of material for bending along a bend line includes the step of forming at least one displacement in the thickness direction of the sheet of material, the displacement including a flat zone substantially parallel to the sheet of material with a portion of the periphery of the flat zone extending along and adjacent to the bend line, and including an angled transition zone interconnecting the flat zone with a remainder of the sheet of material. 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 card guide for mounting printed circuit boards, electronic pathway or component carrying cards, or the like, to an electronic equipment housing having a wall with a pair of openings formed to receive mounting feet provided on the card guide. The card guide body includes a card-receiving guideway on an inwardly facing side of the body and a card mounting structure on the outwardly facing side of the body. The card mounting structure preferably includes L-shaped posts or feet having longitudinally extending portions which enable the card guide to be inserted through an opening in a housing wall to a position in which the L-shaped feet interlock with the housing wall adjacent to the openings. Most preferably the card guide body is resiliently flexible and can be bowed to allow insertion into pairs of mounting openings and will spring back once inserted to secure the card guide to the housing wall.

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 heat dissipation structure suitable for use in electrical and electronic equipment enclosed in housings which equipment is fan cooled. The structure includes a partition array inside the housing formed to preferentially cool relatively high heat-generating electronic components mounted to a PCB board or the like. The structure advantageously includes partitions which narrow to a throat that accelerates the airflow past the heat-generating components for maximum heat transfer. A method of dissipating heat from the high heat-generating electronic components in an electronic device also is disclosed.

Abstract: A sheet of material formed for bending along a bend line including a sheet of material (30) includes a plurality of dividing slits (37) and a plurality of strap slits (39) formed therethrough. The dividing slits extending substantially along a desired bend line (35) and divide the sheet of material into first and second planar regions (32, 33). The strap slits intersect the desired bend line and adjacent pairs of strap slits form a bending strap therebetween. The bending strap has a longitudinal strap axis intersecting the desired bend line. The sheet of material may be formed of composite materials. A method of forming and using the sheet of material is also disclosed.

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 bending tool system is provided for forming a three-dimensional structure from a two-dimensional sheet material which includes a predetermined fold line. The system includes a tool base for receiving and supporting the sheet material in a work plane, a clamp for engaging against the sheet material to secure a portion of the sheet material relative to the tool base, a locator for positioning the sheet material relative to the tool base such that the clamp extends through the clamping aperture, and a bending arm located adjacent the clamp, the bending arm movable from an initial position located below the work plane to an upper position in order to apply an upward force against an unsecured portion of the sheet metal to effect bending of the sheet material about the fold line. A method of using the tool system for bending sheet materials is also described.

Abstract: A sheet of material (111) having a plurality of bend-inducing structures (113) configured and positioned to produce bending along a bend line (115). The bend-inducing structures (113) have arcuate return portions (122) extending from opposite ends (121) back along the bend-inducing structures (113) toward the other return portion (122) and each return portion (122) has a length dimension and a radius of curvature reducing stress concentrations. Preferably, the length dimension of the arcuate return portion (122) is in excess of twice the thickness. The lateral distance, LD, to which the bend-inducing structures (113) is formed in the sheet away from the bend line (115) is preferably minimized by small radius arcs (125) which connect the return portions (122) to the remainder of the bend-inducing structures (113).

Abstract: A ready-to-use pocket joinery assembly is manufactured by first forming a fastener pocket in a surface of a joinery member near to and spaced from an end of the joinery member. Subsequently, one propels a fastener having a tip or point into the fastener pocket to impact and engage a fastener pocket end, which is opposite the end of the joinery member. In preferred embodiments having a bore, a fastener point does not impact the fastener pocket end. Rather, a shank portion of the fastener impacts a fastener pocket end around the bore. In preferred embodiments without a bore, a fastener point does impact the fastener pocket end because there is no bore opening. Finally, to a greater or lesser extent across a range of embodiments, one drives the fastener to a stable, engaged position wherein the fastener point or tip is intermediate between the fastener pocket and the end of the joinery member.