Joinery member and fastener and process and apparatus for placement of the fastener

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. The result, in preferred embodiments having a bore and in preferred embodiments without a bore, is a joinery assembly with a joinery member and an embedded fastener.

1 . A process for forming a pocket joinery assembly comprising the steps of: 
 forming a fastener pocket in a surface of a joinery member proximate to and spaced from an end of the joinery member;    propelling a fastener having a point into the fastener pocket, whereby the fastener impacts and engages a fastener pocket end proximate to the end of the joinery member; and    thereafter driving the fastener to a stable, engaged position wherein the point is intermediate the fastener pocket and the end of the joinery member.    
   
   
       2 . The process of  claim 1 , wherein the point impacts and engages the fastener pocket end.  
   
   
       3 . The process of  claim 1 , wherein the stable, engaged position is immediately adjacent the end of the joinery member.  
   
   
       4 . The process of  claim 1 , wherein propulsion is by applying a surface force to the fastener.  
   
   
       5 . The process of  claim 1 , wherein propulsion is by applying a body force to the fastener.  
   
   
       6 . The process of  claim 1 , wherein propelling a fastener includes propelling along a trajectory, a portion of which trajectory is aligned with an axis of rotation of a fastener-driving head.  
   
   
       7 . The process of  claim 1 , wherein the fastener is a pocket screw.  
   
   
       8 . The process of  claim 1 , wherein the joinery member is comprised of at least one of: a wooden member, a composite member, and a plastic member.  
   
   
       9 . The process of  claim 1 , wherein the pocket is an arcuate pocket increasing in depth in a direction toward the end of the joinery member.  
   
   
       10 . A joinery assembly, comprising: 
 a joinery member having a fastener pocket formed therein proximate an end thereof; and    a fastener located in the fastener pocket and having a point positioned in the joinery member intermediate a fastener pocket end and the end of the joinery member;    wherein the fastener is in direct engaging contact with joinery member material.    
   
   
       11 . The joinery assembly of  claim 10 , wherein the fastener has a shank and the shank is in direct contact with joinery member material and the point is not in direct contact with joinery member material.  
   
   
       12 . The joinery assembly of  claim 10 , wherein the point is in direct contact with the joinery member material.  
   
   
       13 . The joinery assembly of  claim 10 , wherein the point is proximate to the end of the joinery member.  
   
   
       14 . The joinery assembly of  claim 10 , wherein the fastener is a pocket screw.  
   
   
       15 . The process of  claim 10 , wherein the joinery member is comprised of at least one of: a wooden member, a composite member, and a plastic member.  
   
   
       16 . A process for forming a pocket joinery assembly comprising the steps of: 
 restraining a joinery member against movement relative to a supporting surface;    displacing a cutting tool through a predetermined path to form a pocket in the joinery member proximate to an end of the joinery member;    retracting the cutting tool along the predetermined path;    positioning a fastener guide relative to the pocket such that a fastener emerging from the fastener guide impacts an end of the pocket adjacent the end of the joinery member;    propelling the fastener along the fastener guide to impact and engage the end of the pocket;    displacing a fastener-driving head through a linear path to engage the fastener wherein portions of the linear path of the fastener-driving head and the predetermined path of the cutting tool intersect;    driving the fastener to a position intermediate the end of the pocket and the end of the joinery member;    retracting the fastener-driving head and fastener guide; and    releasing the joinery member relative to the supporting surface.    
   
   
       17 . A process for forming a pocket joinery assembly of  claim 16 , wherein the predetermined path is a predetermined arcuate path.  
   
   
       18 . A process for forming a pocket joinery assembly of  claim 16 , wherein a portion of the linear path extends through a portion of the fastener guide  
   
   
       19 . A process for forming a pocket joinery assembly of  claim 16 , wherein the fastener is a pocket screw.  
   
   
       20 . The process for forming a pocket joinery assembly of  claim 16 , wherein the joinery member is comprised of at least one of: a wooden member, a composite member, and a plastic member.  
   
   
       21 . A system for manufacturing pre-fabricated joinery assemblies, comprising: 
 a housing;    a clamp for securing a joinery member against movement relative to a supporting surface;    a router disposed within the housing and coupled to the housing such that a router head has freedom of movement to trace a predetermined path, the predetermined path intersecting a portion of the joinery member to enable formation of a pocket in the joinery member;    a fastener guide disposed within the housing and coupled to the housing such that the fastener guide has freedom of movement to enable a fastener emerging from the fastener guide to impact an end of the pocket;    a fastener driver disposed within the housing and coupled to the housing such that a fastener driver head has freedom of movement to trace a path to engage a fastener head located proximate to the end of the pocket and drive a fastener point to a position intermediate the end of the pocket and a joinery member end; and    propulsion means coupled to the fastener guide for applying a motive force to propel a fastener along the fastener guide.    
   
   
       22 . The system for manufacturing pre-fabricated joinery assemblies of  claim 21 , wherein the fastener guide includes an open channel portion.  
   
   
       23 . The system for manufacturing pre-fabricated joinery assemblies of  claim 21 , wherein the fastener driver head extends through a portion of the fastener guide.  
   
   
       24 . The system for manufacturing pre-fabricated joinery assemblies of  claim 21 , wherein the position intermediate the end of the pocket and a joinery member end is immediately adjacent the joinery member end.  
   
   
       25 . The system for manufacturing pre-fabricated joinery assemblies of  claim 21 , wherein the propulsion means apply a surface force to the fastener.  
   
   
       26 . The system for manufacturing pre-fabricated joinery assemblies of  claim 21 , wherein the propulsion means apply a body force to the fastener.  
   
   
       27 . The system for manufacturing pre-fabricated joinery assemblies of  claim 21 , wherein the predetermined path is a predetermined arcuate path.