Toe Notch Plate Router Attachment for Cabinet Face Frame Joinery

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Solution Overview

Problem

Conventional methods for attaching a face frame to a cabinet involve nailing through the face into the body, resulting in noticeable holes that require filling and sanding, which is time-consuming and costly, and provides a weaker attachment as nails pass through dense lumber into less dense plywood.

Innovation Solution

A toe notch plate system that attaches to a standard router, maintaining a predetermined angle and distance from the work piece, creating an angled groove for brad nails to secure the face frame, offering a stronger and more aesthetic attachment by toe nailing into denser lumber from less dense plywood.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If nails are driven through the face frame into the cabinet body, then the face frame can be attached to the cabinet, but noticeable holes are created that require putty and sanding

Engineering Contradiction:

Improveattachment processVSAvoidhole filling and sanding time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

Instead of nailing through the face frame into the cabinet body, the invention inverts the approach by creating an angled groove that allows nails to be driven from the cabinet body into the face frame at an angle, eliminating the need for hole filling and sanding on the visible face frame surface

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The invention performs preliminary action by creating an angled groove in the cabinet body before attaching the face frame. This groove is specifically shaped to receive and guide the nail, ensuring proper angle and position before the actual nailing operation occurs

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If nails are driven through the face frame into the cabinet body, then the face frame can be attached to the cabinet, but the attachment strength is reduced because nails pass through dense lumber into less dense plywood

Engineering Contradiction:

Improveattachment processVSAvoidattachment strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The invention inverts the nailing direction so that nails are driven from the cabinet body into the face frame rather than through the face frame. This ensures that the nail shaft engages with the dense lumber of the face frame, maximizing holding strength while the angled groove in the plywood cabinet body provides adequate support

Inventive Principle:

Principle #13The other way round (Inversion)

3Shape

If putty and sanding are used to cover nail holes, then the appearance can be improved, but costs increase due to additional materials and labor

Engineering Contradiction:

Improvesurface appearanceVSAvoidputty and sandpaper costs

Core Design Contradiction:

ShapeVSLoss of substance

Solution Approach 1:

By inverting the nailing approach and using an angled groove system, the invention eliminates the creation of visible holes on the face frame surface. This removes the need for putty and sanding materials entirely, saving both material costs and the labor associated with their application

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS10556362B2Toe notch plate

Publication Date: 2020.02.11 CLARK BRUCE DAMON

AI summary

A toe notch plate is described that attaches to a router and maintains the router at a predefined angle from a work piece. The toe notch plants further maintains a router bit at a consistent and predetermined distance from an edge of the work piece. When the router is moved along the edge of the work piece, the toe notch plate causes a groove to be formed in the work piece, where the groove has a structure suitable for use of a nail gun or a staple gun, and an entry point for nails or staples. This allows the work piece with the groove to be toe nailed to another piece of wood.