Asymmetrical Corner Joint for One-Pass Self-Aligning Routing
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Solution Overview
Problem
Conventional corner joint techniques, such as miter and miter lock joints, require multiple passes and complex setups, making them inefficient for creating asymmetrical joints with consistent finishes and self-alignment.
Innovation Solution
An asymmetrical corner joint design where both joint ends are created with one pass using a router-driven cutting tool, featuring a slant plane and beveled plane with self-aligning features, and a corresponding tool set with a bevel/shoulder bit and canting mechanism for precise angle adjustments, allowing for efficient formation of joints with various angles and depths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional miter or miter lock joints are used, then corner joints can be formed, but multiple passes and complex setups are required, reducing efficiency
Solution Approach 1:
The joint creation process is divided into two distinct joint ends (first joint end with slant plane, second joint end with beveled and shoulder planes) that can be formed simultaneously in one pass, eliminating the need for multiple sequential operations required by conventional miter and miter lock joints
Solution Approach 2:
The routing operation performs multiple functions simultaneously: creating the slant plane on the first joint end, creating both the beveled plane and shoulder plane on the second joint end, and establishing self-aligning features all in a single pass, replacing multiple specialized operations
2Ease of operation
If symmetrical V-grooves are used for corner joints, then material can be folded to form corners, but the edge grain is exposed and alignment is not improved
Solution Approach 1:
The joint design transitions from symmetrical V-grooves to an asymmetrical configuration where the first joint end has a slant plane and the second joint end has distinct beveled and shoulder planes, creating self-aligning features that improve alignment while maintaining a clean appearance without exposing edge grain
Solution Approach 2:
Different surface characteristics are applied to different parts of the joint: the slant plane on the first joint end and the combination of beveled plane and shoulder plane on the second joint end, with the shoulder plane specifically designed to provide a flat bearing surface for alignment while keeping the edge grain concealed
3Loss of substance
If conventional corner joints are made, then joints can be formed, but material waste increases and consistent finishes are difficult to achieve
Solution Approach 1:
The routing operation with the bevel/shoulder bit preemptively creates both the slant plane and the beveled plane with shoulder plane in one pass, properly shaping both joint ends before assembly, which reduces material waste by eliminating the need for additional trimming or adjustment operations
Solution Approach 2:
The invention changes the geometric parameters of the joint ends by introducing specific angle relationships between the slant plane and the beveled plane, and between the shoulder plane and the planar band, enabling self-alignment that ensures consistent finishes without requiring additional precision trimming
Data Source
AI summary
An asymmetrical corner joint in a material having a planar surface, in which one side of the joint is shaped to be a slanted plane and the other side of the joint is shaped to be a beveled plane and a shoulder plane, such that when the joint is formed the slanted plane and beveled plane abut and the shoulder plane abuts a portion of the planar surface adjacent the slanted plane. A tool set for use with a router for shaping the two sides of the asymmetrical corner joint in one pass, the tool set including a bit with an angle cutting portion and a shoulder cutting portion, and a canting base for use with the router for tilting the angle of rotation of the bit such that the angle cutting portion cuts both sides of the cut and the shoulder cutting portion only cuts one side.