Patent Application
20170304975
Toe Notch Plate relates to wood joinery. It provides a means to attach a face frame to a cabinet carcass in such a manner so that there are no blemishes or nail heads on the front or exposed side of the face frame.
In this method a “pocket hole” is created in the side panel with a pocket hole machine or a pocket hole jig and the face frame is attached with a screw going from the pocket hole into the back of the face frame
In this method a “biscuit slot is cut into the back of the face frame and the front edge of the side panel, glue is applied to both, a biscuit is inserted into each hole and then the face frame is clamped to the side panel. The clamp needs to remain until the glue has setup.
In this method glue is applied to the contact surfaces and then placed together and clamped. The clamp needs to remain until the glue has set up.
4) Nailing Through Face Frame into Side Panel
In this method the face frame is held in place against the cabinet carcass and nailed through the face frame into the cabinet carcass.
With the conventional or current method of attaching a face frame to a cabinet, it is customary to nail through the face of the cabinet into the body (or carcass) of the cabinet. This attachment method leaves holes in the face frame that have to then be covered with putty and then sanded. The filled holes are typically quite noticeable, especially in woods with little or no grain.
The Toe Notch method provides a means to fasten the face frame to the carcass from behind the face frame. This method saves time by not having to patch the nail holes or wait for the putty to dry and then sanding, and saves money for the putty and sandpaper. Beyond saving time, this allows for a more secure fastening system.
The Toe Notch Plate attaches to a standard router and maintains the router at approximately a 75 degree angle from the work piece. It also maintains the router bit a consistent distance from the edge of the work piece. This plate is made to be used with varying thickness of side panels, typically they will be either ¾′ or ½′ thick. When the router is moved along the edge of the work piece it will create an angled groove such that the nose of a nail gun can rest in the groove. This will provide stability, consistency and an entry point for the brad nails to enter into the work piece at a low angle allowing the piece to be toe nailed to another piece of wood which typically will be perpendicular to it.
This Toe Notch method of attaching a face frame to a cabinet is a stronger way than nailing through the face into the side panel. In the traditional method of attaching a face frame to the cabinet the nail goes through the dense lumber into the less dense plywood. There is nothing holding the nail into the less dense plywood. In the Toe Notch method the nail goes through the less dense plywood into the more dense lumber. To pull apart the Toe Notch attached face frame, the nail head has to be pulled through the plywood.
The Toe Notch method provides a finished product that is stronger and more aesthetic than conventional nailing methods, and less cumbersome and time consuming than other methods.
FIG. A: This is the top view of the Toenail Plate. Number 1 is one router base mounting hole. Number 2 is the router bit clearance hole. Number 3 is the router base mounting hole for 0.75″ thick material. Number 4 is the router base mounting hole for 0.5″ thick material. Number 5 is the edge guide.
FIG. B: This is the end view of the Toenail Plate. Number 6 shows the router mounting surface. Number 7 shows the edge guide. Number 8 shows the work piece contact area.
FIG. C: This is a 3-D view of the Toenail Plate.
FIG. D: This is a 3-D view of the Toenail Plate with the router bit in the router bit hole. It also shows how the plate sits on the work piece.
FIG. E: This is the side view of FIG. D. Number 9 shows the work piece. Number 10 shows the Toenail Plate. Number 11 shows the router bit.
FIG. F: This shows the router bit. A standard 0.75″ dado bit can be used.
FIG. G: This is the end view of the Toenail Plate.
FIG. H: This is the side view of the work piece. Number 12 shows the angled groove that is cut by the router when the Toenail Plate is used.
FIG. I: This is a 3-D view of the work piece attached to the face frame with nails. Number 13 shows the nails attaching the two pieces.
FIG. J: This is a side view of the work piece attached to the face frame. Number 14 shows the work piece, which for cabinet making will be the sides, top or bottom of the cabinet carcass. Number 15 shows the nail attaching the two. Number 16 shows the face frame. Number 17 shows where the head of the nail gun rest and where the nail enters into the work piece.
The Toe Notch Plate is made of a single piece of sheet metal (could be any rigid material) with 3 bends (FIG. B), three mounting holes (FIG. A, #1, 3 & 4) and one large clearance hole (FIG. A, #2) for the router bit (FIG. E, #11) to pass through. One of the bends creates an edge guide (FIG. B, #7) and the other two bends work together to create the work piece contact area (FIG. B, #8).
The Toe Notch Plate will typically be mounted to a standard router such as a Porter Cable Router. But it could be fastened to any type of motor. To do this the factory sub base must be first removed by removing the 3 mounting screws that hold the sub base onto the router base. Once these screws are removed, take off the sub base and set it aside. It will not be needed while using the Toe Notch Plate. With the router base facing up, place the Toe Notch Plate on the router base with the router mounting surface (FIG. B, #6) down so that it contacts the router base. Using the screws that were removed from the router sub base, insert a screw through screw clearance hole #1 in FIG. A. If working with 0.75″ material insert a screw through hole #3 in FIG. A. If working with 0.5″ material insert a screw through hole #4 FIG. A. Ensure all screws are tightened.
A 0.75″ router bit must be installed in the router as per the router manufacturer's procedures. When working with 0.75″ material, set the router bit so that it extrudes approximately 0.3125″ past the Toe Notch Plate. When working with 0.5″ material, set the router bit so that it extrudes approximately 0.25″ past the Toe Notch Plate.
Once the Toe Notch Plate is attached to the router, place a work piece securely on a worktable. With the router on, place the edge guide (FIG. B, #7) against the edge of the work piece and the work piece contact area (FIG. B, #8) on the top of the work piece (FIG. D). Traverse the router (with the Toe Notch Plate attached) along the desired length of the work piece to create the toe notch (FIG. H, #13)
Once you have the toe notch in the work piece, place the face frame adjacent to the work piece (FIG. J). Then place the nose of the brad or nail gun against the nail entry ridge (FIG. J, #18) and press the trigger inserting a nail (FIG. J, #16) through the work piece into the face frame
The Toe Notch Plate is made out of sheet metal, but is could also be made out of any hard material such as plastic or wood. It is used it for attaching a face frame to a cabinet box, but it also could be used in other applications that need an angled groove.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 62275197 | Jan 2016 | US |
| Child | 15396906 | US |
