Abstract:
A method of constructing an interlocking corner joint by combining fixed or variable sized interlocking fingers from at least two sides, full or partial feed though dowel pegs or other geometrically shaped pegs, finishing nails, pins or screws and glue or epoxy at the interface of the interlocking fingers and pegs and pins. The resulting interlocking corner joint is much stronger than a standard dovetail joint or box finger joint due to the increased surface area created by the holes, pegs and pins. Due to the interlocking fingers, holes, pegs and pins, the interlocking corner joint will not pull apart in any one dimension x,y,z in the event that the glue joint fails.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention pertains generally to furniture manufacturing and specifically but is not limited to the making of drawer box joints.  
       BACKGROUND OF THE INVENTION  
       [0002]     Drawer box joints are generally made several ways from wood of varying species or composite woods and vary from manufacturer to manufacturer. Drawer box joints generally are made from finger box joints, dovetail joints, lap joints, tongue and groove joints and other similar joints.  
         [0003]     Drawer box joints are typically fastened together with some type of wood glue or epoxy and where the glue or epoxy is applied directly at the interface between the pieces of wood that overlap. In some cases mechanical plates are applied in addition to the glue joints. This added mechanical fastener provides additional strength to the joint and makes the joint less susceptible to mechanical stress over time. Drawer box joints with mechanical plates are much more expensive than drawers box joints without mechanical plates.  
         [0004]     Most drawer box joints without mechanical plates are susceptible to failure in at least one or more of three possible x,y,z dimensions due to mechanical stress over time. The strength of the joint depends on the type of glue or epoxy used and the type of joint chosen. The strongest drawer box joint, a dovetail joint, may pull apart in one of the three x,y,z dimensions upon failure of the glue joint under stress. Finger box joints or tongue and groove joints may pull apart in two of the three possible x,y,z dimensions upon failure of the glue joint under stress. The weakest drawer box joint may be the lap joint or overlap joint and may pull apart in three of the possible x,y,z dimensions upon failure of the glue joint under stress.  
         [0005]     It would therefore be advantageous to create or manufacture a drawer box joint that was not susceptible to stress or failure in any of the three possible x,y,z dimensions over time, and create a joint that dramatically increases the glued joint surface area and did not require expensive mechanical plates for additional support.  
       SUMMARY OF THE INVENTION  
       [0006]     The present invention overcomes the disadvantages and limitations of previous solutions by providing a system and method for designing and manufacturing drawer box joints with improved strength and reliability under mechanical stress over time by dramatically increasing the glued surface area of the overlapping pieces of the drawer box joint, and fastening the pieces through multiple steps that prevent the movement of the joint in any of the three x,y,z dimensions in the event of a glue joint failure without the use of additional expensive mechanical plates.  
         [0007]     One embodiment of the present invention may include a finger box joint, a round hole drilled through the top corner of the joint, a dowel peg placed into the hole in the interlocking fingers, a set of finishing nails driven into one or more sides of the interlocking fingers in the corner joint such that the finishing nails are driven into and through the dowel peg and into the opposing corner piece.  
         [0008]     Another embodiment of the present invention may include a dove tail joint, a square or rectangular hole drilled through the top corner of the joint, a square or rectangular peg placed into the hole in the interlocking fingers, one or more screws turned into one or more sides of the interlocking fingers in the corner joint such that the screws are turned into and through the square or rectangular peg and into the opposing corner piece.  
         [0009]     The advantages of the present invention are that it has an increased gluing surface area resulting in a much higher strength joint and results in a joint that will not fail in any one dimension of the x,y,z plane. Additional metal plates are not needed to achieve the final joint strength. In some cases the resulting joint will not have to be clamped during the cure time of the glue due to its construction. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]      FIG. 1  is an illustration of prior art for a box finger joint.  
         [0011]      FIG. 2  is an illustration of an embodiment of a finger box joint which utilizes a dowel peg and finishing nails.  
         [0012]      FIG. 3  is an illustration of an embodiment of a left side cross section of a finger box joint in  FIG. 2  which utilizes a dowel peg and finishing nails.  
         [0013]      FIG. 4  is an illustration of an embodiment of a right side cross section of a finger box joint in  FIG. 2  which utilizes a dowel peg and finishing nails.  
         [0014]      FIG. 5  is an illustration of an alternative embodiment of a finger box joint which utilizes a square or rectangular peg and finishing nails on both sides of the joint.  
         [0015]      FIG. 6  is an illustration of an alternative embodiment of a finger box joint which utilizes variable sized interlocking fingers, partial feed through dowel pegs and finishing nails on both sides of the joint.  
         [0016]      FIG. 7  is an illustration of an embodiment of a left side cross section of a finger box joint in  FIG. 6  which utilizes variable sized interlocking fingers, partial feed through dowel pegs and finishing nails on both sides of the joint.  
         [0017]      FIG. 8  is an illustration of the various types of pegs that may be placed in the corner and through the interlocking fingers of the finger box joint.  
         [0018]      FIG. 9  is an illustration of an alternative embodiment of a two piece “T” shaped interlocking corner joint which utilizes a dowel peg and finishing nails.  
         [0019]      FIG. 10  is an illustration of an alternative embodiment of a three piece “T” shaped interlocking corner joint which utilizes a dowel peg and finishing nails. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0020]     The specific embodiments of the invention are described in this section. The embodiments that follow below were selected to illustrate the various features of the invention, but should not be construed to limit the invention to the embodiments illustrated and described, as the invention is susceptible to various modifications and alternate forms. In general, the embodiments were selected to bring to light the inventive feature, aspects and components of the invention. The invention is intended to cover all variations, modifications and equivalents falling within the scope and nature of the invention as described by the claims.  
         [0021]     The invention may be embodied as individual methods, containers, boxes, drawers or part of tables, cabinets, night stands, dressers or any type of furniture or fixture that contains a corner joint. The angle of the corner joint may be 90 degrees but is not limited to any angle including the range from 0 to 180 degrees or from 0 to −180 degrees. The corner joint may be composed of two or more interlocking pieces. In the case of two interlocking pieces, an “L” or a “T” shaped corner joint may be formed. In the case of three interlocking pieces, a “T”, “Y” or an “X” shaped corner joint may be formed. In the case of 4 interlocking pieces, an “X” shaped corner joint may be formed. The number of interlocking pieces and angle between each interlocking piece is not limited, nor is the number of geometric shapes that can be formed at the interlocking corner joint. The illustrations shown in the  FIGS. 1 through 8  shows various embodiments of a two piece “L” shaped interlocking corner joint.  FIG. 9  shows an alternative embodiment of a two piece “T” shaped interlocking corner joint.  FIG. 10  shows an alternative embodiment of a three piece “T” shaped interlocking corner joint. Anyone skilled in the art may be able to extend the inventive concepts illustrated in  FIGS. 1 through 10  to create the additional geometric shapes mentioned above or any additional geometric shape from any number of interlocking pieces. The invention may be comprised of stone, stone composite, metal, molded or formed metal, plastic, glass, wood, glue, epoxy resin, fiber glass, polymer resin, plexiglass or any formed, welded, shaped or cut material.  
         [0022]      FIG. 1  illustrates prior art of a box finger joint  100 . The left side  101  of the box finger joint  100  is created by cutting or forming the alternating left side interlocking fingers  104 . In a similar manner, the right side  102  of the box finger joint  100  is created by cutting or forming the alternating right side interlocking fingers  103 . Subsequently the left side  101  and right side  102  are joined together and the interface between the right side interlocking fingers  103  and left side interlocking fingers  104 , are typically glued and clamped in a clamping device until dry.  
         [0023]      FIG. 2  illustrates an embodiment  200  of the present invention showing stronger box finger joint with dowel peg and finishing nails. The left side  201  of the box finger joint  200  is created by cutting or forming the alternating left side interlocking fingers  204 . In a similar manner, the right side  202  of the box finger joint  200  is created by cutting or forming the alternating right side interlocking fingers  203 . Subsequently the left side  201  and right side  202  are joined together and the interface between the right side interlocking fingers  203  and left side interlocking fingers  204 , and are typically clamped in a clamping device. While still in the clamping device, a round hole is drilled at the top corner of  200 . The pieces can now be removed from the clamping device. Glue is placed in the drilled hole and at the interface of the right and left side interlocking fingers  203  and  204  respectively. The pieces are clamped in a clamping device and subsequently a dowel peg  206  is placed in the hole. After insertion of the dowel peg  206 , finishing nails  205  are driven into the right side interlocking fingers  203  and through the dowel peg  206  and into the left side  201 . The clamping device may be left in place until the glue has cured. Alternatively the clamping device may be removed after the box finger joint with dowel peg and finishing nails  200  is completed but prior to the glue cure time. The order in which the interlocking fingers  203  and  204 , the hole for the dowel peg  206  are formed, as well as the order of the glue application and clamping may be varied.  
         [0024]      FIG. 3  is an illustration of an embodiment  300  of a left side cross section of the corner of the box finger joint with dowel peg and finishing nails  200  in  FIG. 2 . The left side  301  is aligned so that the left side interlocking fingers  304  are perpendicular to the right side interlocking fingers  303 . The hole is drilled at the corner of  300  through the left and right side interlocking fingers  304  and  303  respectively. The location of the dowel peg  306  inserted into the hole and through  303  and  304  is shown. The finishing nails  305  may be driven into the right side interlocking fingers  303  and through the dowel peg  306  and into the left side  301 .  
         [0025]      FIG. 4  is an illustration of an embodiment  400  of a right side cross section of the corner of the box finger joint with dowel peg and finishing nails  200  in  FIG. 2 . The right side  402  is aligned so that the right side interlocking fingers  403  are perpendicular to the left side interlocking fingers  404 . The hole is drilled at the corner of  400  through the right and left side interlocking fingers  403  and  404  respectively. The location of the dowel peg  406  inserted into the hole and through  403  and  404  is shown. The finishing nails  405  may be driven into the right side interlocking fingers  403  and through the dowel peg  406  and into the left side.  
         [0026]      FIG. 5  illustrates an alternative embodiment  500  of the present invention showing stronger box finger joint with square peg and finishing nails. The left side  501  of the box finger joint  500  is created by cutting or forming the alternating left side interlocking fingers  504 . In a similar manner, the right side  502  of the box finger joint  500  is created by cutting or forming the alternating right side interlocking fingers  503 . Subsequently the left side  501  and right side  502  are joined together and the interface between the right side interlocking fingers  503  and left side interlocking fingers  504 , and are typically clamped in a clamping device. While still in the clamping device, a square or rectangular mortise hole is drilled at the top corner of  500 . The pieces can now be removed from the clamping device. Glue is placed in the drilled or mortised hole and at the interface of the right and left side interlocking fingers  503  and  504  respectively. The pieces are clamped in a clamping device and subsequently a square or rectangular peg  506  is placed in the hole. After insertion of the square or rectangular peg  506 , finishing nails  505  are driven into the right and left side interlocking fingers  503  and  504  respectively and through the square or rectangular peg  506  and into the left and right sides  501  and  502  respectively. The clamping device may be left in place until the glue has cured. Alternatively the clamping device may be removed after the box finger joint with square peg and finishing nails  505  is completed but prior to the glue cure time. The order in which the interlocking fingers  503  and  504 , the hole for the square or rectangular peg  506  are formed, as well as the order of the glue application and clamping may be varied.  
         [0027]      FIG. 6  illustrates an alternative embodiment  600  of the present invention showing stronger box finger joint with partial feed through dowel pegs and finishing nails. The left side  601  of the box finger joint  600  is created by cutting or forming the alternating left side interlocking fingers  604 . In a similar manner, the right side  602  of the box finger joint  600  is created by cutting or forming the alternating variable sized right side interlocking fingers  603 . Subsequently the left side  601  and right side  602  are joined together and the interface between the right side variable sized interlocking fingers  603  and left side interlocking fingers  604  is typically glued and clamped in a clamping device. While still in the clamping device, a hole is drilled at the top corner of  600 . The hole at the top corner of  600  typically may not go all the way through  600  but may stop almost half way through  600 . Glue is placed in the drilled top hole and subsequently a top side partial feed through dowel peg  606  is placed in the hole. In a similar manner, a hole is drilled at the bottom corner of  600 . The hole at the bottom of the corner of  600  typically may not go all the way through  600  but may stop almost half way through  600 . Glue is placed in the drilled bottom hole and subsequently a bottom side partial feed through dowel peg  607  is placed in the hole. After insertion of the top and bottom partial feed through pegs  606  and  607  respectively, finishing nails  605  are driven into the right and left side interlocking fingers  603  and  604  respectively and through the top partial feed through peg  606  and bottom partial feed through peg  607  and into the left and right sides  601  and  602  respectively. The clamping device may be left in place until the glue has cured. Alternatively the clamping device may be removed after the box finger joint with partial feed through dowel pegs  606  and  607  and finishing nails  605  is completed but prior to the glue cure time. The order in which the interlocking fingers  603  and  604 , the holes for the partial feed through pegs  606  and  607  are formed, as well as the order of the glue application and clamping may be varied.  
         [0028]      FIG. 7  is an illustration of an embodiment  700  of a left side cross section of the corner of the box finger joint with partial feed through dowel pegs and finishing nails  600  in  FIG. 6 . The left side  701  is aligned so that the left side interlocking fingers  704  are perpendicular to the variable sized right side interlocking fingers  703 . The hole is drilled at the corner of  700  through the left and variable sized right side interlocking fingers  704  and  703  respectively. The location of the top side partial feed through dowel peg  706  and bottom side partial feed through dowel peg  707  inserted into the top and bottom side holes respectively and through the right side variable sized interlocking fingers  703  and left side interlocking fingers  704  is shown. The finishing nails  705  may be driven into the right side variable sized interlocking fingers  703  and left side interlocking fingers  704  and through the partial feed through dowel pegs  706  and  707  and into the left side  701  and into the opposing side piece.  
         [0029]     Alternatively the round top side and bottom side partial feed through dowel pegs  706  and  707  respectively may be replaced by but is not limited to square pegs, rectangular pegs, epoxy resin, fastening nails, staples, screws or any other type of tapered or stepped shaped peg. The appropriate top and bottom sized holes need to be first drilled to fit the screw or geometric shape of the peg chosen. In addition, the finishing nails  705  may be omitted or replaced by but is not limited to screws or other type of hole and smaller peg. Also the finishing nails  705  may only go partially through the top side and bottom side partial feed through dowel pegs  706  and  707  respectively. The right side variable sized interlocking fingers  703  and left side interlocking fingers  704  may be replaced by but is not limited to dovetail joints or any other type of full or partial interlocking finger joint. A right side cross section of  600  in  FIG. 6  is not shown but should be obvious to the reader based on the previous discussion of  FIG. 2 ,  FIG. 3  and  FIG. 4 .  
         [0030]      FIG. 8  illustrates an embodiment  800  of the present invention showing various sized and shaped pegs that may be used in place of  706  and  707  in  FIG. 7 . The size and shape of the pegs may take the form but are not limited to the pegs  801 ,  802 ,  803  and  804  shown.  801  is an exemplary illustration of a round dowel peg.  802  is an alternative exemplary illustration of a square or rectangular peg.  803  is an alternative exemplary illustration of a variable step round peg.  804  is an alternative exemplary illustration of a tapered round peg.  
         [0031]      FIG. 9  illustrates an alternative embodiment  900  of the present invention showing a stronger two piece “T” shaped box finger joint with dowel peg and finishing nails. The front side  901  of the box finger joint  900  is created by cutting or forming the alternating front side interlocking fingers  904 . In a similar manner, the back side  902  of the box finger joint  900  is created by cutting or forming the alternating back side interlocking fingers  903 . Subsequently the front side  901  and back side  902  are joined together and the interface between the back side interlocking fingers  903  and front side interlocking fingers  904 , and are typically clamped in a clamping device. While still in the clamping device, a round hole is drilled at the top corner of  900 . The pieces can now be removed from the clamping device. Glue is placed in the drilled hole and at the interface of the back and front side interlocking fingers  903  and  904  respectively. The pieces are clamped in a clamping device and subsequently a dowel peg  906  is placed in the hole. After insertion of the dowel peg  906 , finishing nails  905  are driven into the front side interlocking fingers  904  and through the dowel peg  906  and into the back side  902 . The clamping device may be left in place until the glue has cured. Alternatively the clamping device may be removed after the two piece “T” shaped box finger joint with dowel peg and finishing nails  900  is completed but prior to the glue cure time. The order in which the interlocking fingers  903  and  904 , the hole for the dowel peg  906  are formed, as well as the order of the glue application and clamping may be varied.  
         [0032]     Alternatively, the back side interlocking fingers  903  may only come partially through the front side  901 . In addition, the front side interlocking fingers  904  may not be cut all the way through to the front side  901 . This is what is known as a blind interlocking box finger joint since the back side interlocking fingers cannot be seen from the front face of the front side  901 .  
         [0033]     Other alternative embodiments may combine a tongue and groove joint with the interlocking finger box joint. A channel or dado is first cut through the back face of the front side  901  where it intersects with the back side  902 . Subsequently the front side interlocking fingers  904  may then be formed in the front side  901 . The back side interlocking fingers  903  may then be formed. The depth of the back side interlocking fingers  903  may be cut equal to the thickness of the front side  901  minus the depth of the channel or dado cut into the back face of the front side  901 . The front side  901  and the back side  902  may then be combined with the back side  902  partially embedded into the dado or channel in the front side  901 .  
         [0034]      FIG. 10  illustrates an alternative embodiment  1000  of the present invention showing a stronger three piece “T” shaped box finger joint with dowel peg and finishing nails. The left side  1001  of the box finger joint  1000  is created by cutting or forming the alternating left side interlocking fingers  1004 . The right side  1008  of the box finger joint  1000  is created by cutting or forming the alternating right side interlocking fingers  1007 . In a similar manner, the back side  1002  of the box finger joint  1000  is created by cutting or forming the alternating back side interlocking fingers  1003 . Subsequently the left side  1001 , right side  1008  and back side  1002  are joined together and the interface between the back side interlocking fingers  1003 , left side interlocking fingers  1004  and right side interlocking fingers  1007 , are typically clamped in a clamping device. While still in the clamping device, a round hole is drilled at the top corner of  1000 . The pieces can now be removed from the clamping device. Glue is placed in the drilled hole and at the interface of the left, right and back side interlocking fingers  1004 ,  1007 , and  1003  respectively. The pieces are clamped in a clamping device and subsequently a dowel peg  1006  is placed in the hole. After insertion of the dowel peg  1006 , finishing nails  1005  are driven into the left and right side interlocking fingers  1004  and  1007  and through the dowel peg  1006  and into the back side  1002 . The clamping device may be left in place until the glue has cured. Alternatively the clamping device may be removed after the three piece “T” shaped box finger joint with dowel peg and finishing nails  1000  is completed but prior to the glue cure time. The order in which the interlocking fingers  1003 ,  1004  and  1007 , the hole for the dowel peg  1006  are formed, as well as the order of the glue application and clamping may be varied.