Patent ID: 12240187

DETAILED DESCRIPTION

The present invention is generally directed to a spacer-locator for use in spacing and locating two objects. The spacer-locator provides for spacing and locating two objects to be chemically or physically affixed to one another, such as with adhesive, by welding, by soldering, by vacuum, by mechanical fastening and the like.

In one embodiment, the present invention includes a spacer-locator that provides for a controlled thickness of an adhesive to be used in bonding and maintaining the bond between two bonded surfaces.

In another embodiment, the present invention includes a spacer-locator manufactured from the same material as the bonded surfaces.

In yet another embodiment, the present invention includes a spacer-locator including locating pins that provide additional shear strength.

In yet another embodiment, the present invention includes a spacer-locator that prevents rotation between two mating surfaces.

Typical prior art spacers generally provide adhesive thickness tolerance or locational tolerance of adhered surfaces. The prior art does not disclose, teach, or suggest the use of a spacer-locator that provides for controlled spacing to be used in joining and maintaining the joint between two mating surfaces, enhanced positional tolerance for ease of assembly, and enhanced structural rigidity of joint by incorporating locator pins which provide a mechanical advantage against shear stress.

The present invention is directed to a method of joining two or more surfaces and at least one spacer-locator with locator pins that provide location control and a mechanical advantage against shear stress. The method of the present invention includes locating holes in the two or more surfaces. The locating holes are created by drilling or, alternatively, the locating holes are created through a different process, by way of example and not limitation, incorporating the negative space into the design of the two or more surfaces. The method of the present invention further includes placing spacer-locators into the locating holes of one or more of the two or more surfaces. The method of the present invention further includes applying adhesive or other joining agent to one or more of the two or more surfaces. The present invention further includes the aligning of corresponding locating holes on each of the two or more surfaces that are being joined and pressing the surfaces together, thereby joining the surfaces and the at least one spacer's locator pins, aligning the surfaces in relation to one another. Alternatively, locator pins are placed in the corresponding locator holes, the two or more surfaces are aligned and pressed together, and the joining agent is subsequently injected into the gap between the two or more surfaces.

In one embodiment, the invention is a spacer-locator of a predetermined thickness that is capable of withstanding the pressure applied during a joining process, thereby maintaining the separation of the mating surfaces while ensuring controlled thickness of the joining agent between the mating surfaces. The spacer-locator preferably incorporates pins which serve as locators for aligning the mating surfaces and provide additional shear strength to the joint after the joining process has been completed. In an alternative embodiment, the spacer-locator includes a spacer body, to which the locator pins are reversibly or irreversibly attachable.

The surfaces of the spacer-locator are created with different tolerances, depending on the use of the spacer. This reduces manufacturing costs associated with high-tolerance surfaces that are not critical to the bonding application. By way of example and not limitation, the locator pin sizing is manufactured to a tighter tolerance or looser tolerance depending on whether positioning jigs are used during the bonding process of the two surfaces. Additionally, the spacer tab thickness is manufactured to a tighter tolerance or looser tolerance depending on the importance of the adhesive thickness or joint separation. By way of example and not limitation, the tolerance ranges from 1% to 15% of the specified spacer tab thickness.

In a preferred embodiment of the present invention, the locator pins act as a functional replacement to the positioning jigs currently needed to align components during the joining process. The more complex the final assembly, the larger the impact the locator pins have in reducing the manufacturing cost of the finished product. By way of example and not limitation, bonding a step to a platform requires numerous unique jigs to maintain the positional tolerance during the adhering process. An example of bonding a step to a platform includes, but is not limited to, the step attached to an elevated platform used with utility trucks. Implementing tight tolerance for a spacer-locator with locator pins provides the same benefits of the jig without the added expense of storage and maintenance of numerous jig assemblies. This provides for lower manufacturing costs and subsequently higher profits.

In a preferred embodiment of the present invention, the spacer tabs and locator pins are made of the same material as the mating surfaces. This maintains uniform material characteristics throughout the entire assembly, including by way of example and not limitation, conductivity, corrosion resistance, and aesthetic qualities. Suitable materials include, but are not limited to, fiberglass, plastics, metals, resins, epoxy, composite laminate, and/or ceramic.

The spacer-locator is designed to prevent rotation of bonded surfaces. In one embodiment of the present invention, rotation is prevented between joined surfaces by incorporating two spacer-locators of the present invention on the same mating surfaces. In an alternative embodiment of the present invention, rotation is prevented between mating surfaces by incorporating an anti-rotation feature into the spacer tab.

Thus, the spacer-locator provides for controlling the degrees of freedom between two or more surfaces. For juxtaposed planar surfaces that are to be glued together, there are six possible degrees of freedom with respect to one another (six relative degrees of freedom): the x-, y- and z-axes and the theta, phi, and psi angles (FIG.1). The x-axis and y-axis are along the plane of the first mating surfaces and the z-axis traverses the interface of the first mating surfaces. In the case of planar surfaces, the z-axis is perpendicular to the plane of the mating surfaces. The psi angle is in the plane of the first mating surfaces (around the z-axis); the phi angle is around the x-axis, and the theta angle is around y-axis. Adding a locator pin constrains two axes (x- and y-axes) and two rotational degrees of freedom (phi and theta) and therefore reduces the degrees of freedom to two. Adding an anti-rotation component constrains rotation around the z-axis (psi angle), removes another degree of freedom and reduces the degrees of freedom to one. Adding a spacer tab partially constrains a fifth degree of freedom (z-axis) and additionally constrains the phi and psi angles. Thus, a spacer-locator according to the present invention can constrain two objects to two or one degrees of freedom and can partially constrain the last degree of freedom.

Referring now to the drawings in general, the illustrations are for the purpose of describing preferred embodiments of the invention and are not intended to limit the invention thereto.

FIG.2Ais a side view that illustrates a preferred embodiment of the present invention. The spacer-locator100includes a spacer body101, spacer tabs102, and locator pins103. The spacer body101acts as the core of the spacer-locator100, and acts as a mounting surface for the spacer tabs102and the locator pins103. The spacer tabs102lay on a plane and extend outward perpendicularly from the direction of the locator pins103and outwardly from the spacer body101. Alternatively, the spacer body101, spacer tabs102, and locator pins103are formed from one piece of material. Alternatively, the locator pins103attach to the spacer body101through threaded members. Alternatively, the locator pins103attach to the spacer body101with adhesive.

In one embodiment, the spacer body is about 0.030″ thick. Alternatively, the spacer body thickness is between 0.010″ and 0.030″. In another alternative embodiment, the spacer body thickness is between 0.030″ and 0.1″. In one embodiment, the spacer includes a smooth surface where the locator pin is mounted with adhesive. In another embodiment, the spacer body incorporates an internal threading for mechanical fastening of a locator pin.

In another embodiment of the present invention, the spacer tabs have a thickness of about 0.030″. Alternatively, the spacer tab thickness is between 0.010″ and 0.030″. In another alternative embodiment, the spacer tab thickness is between 0.030″ and 0.1″. Alternatively, the spacer tab thickness is determined by the final adhesive thickness requirements between the bonded surfaces.

In one embodiment of the present invention, the spacer-locator, including the spacer tabs and locator pins are created from a single piece of material. By way of example and not limitation, the spacer-locator is formed, milled, molded, stamped, and/or 3-D printed as one piece.

In an alternative embodiment of the present invention, the spacer tabs and locator pins are made of a different material than the mating material based on the joining application. Preferably, the spacer tabs and locator pins are made of a material having a higher shear strength than the mating material and the mating agent. By way of example and not limitation, the shear strength of Methyl Methacrylate is approximately 3 ksi and the shear strength of carbon steel ranges from 36 to 120 ksi.

Alternatively, the spacer-locator is formed from at least two pieces of material. By way of example and not limitation, the spacer body is formed, milled, molded, stamped, and/or 3-D printed separately from the locator pins. Locator pins are then selected and attached to the spacer body depending on the requirements of the bonded assembly. Attachment of the locator pins to the spacer body occurs through mechanical fastening, by way of example and not limitation, through the utilization of threaded members. In one embodiment, the locator pins incorporate a threaded member with an external thread, and the spacer body incorporates a threaded member with internal threads. Alternatively, the spacer body incorporates external threads and the locator pins incorporates internal threads.

In another embodiment, the locator pins are attached with adhesive. Suitable adhesive includes, but is not limited to, laminates, hot adhesives, reactive adhesives, polyester-polyurethane resin, polyols-polyurethane resin, acrylic polymers-polyurethane resin, epoxy, methacrylate, and/or cyanoacrylate. In another embodiment the locator pins are attached through thermal bonding, including but not limited to, plastic welding, electric welding, tungsten arc welding and/or soldering. In another embodiment the locator pins are attached through the use of magnets within the locator pins and the spacer body. This modular design provides flexibility of the spacer-locator characteristics, thereby having the advantage of reduced costs as spacer-locators do not need to be custom-made for every bonding application.

FIG.2Bis a perspective view of the spacer-locator embodiment illustrated inFIG.2A.

FIG.2Cis a top view of the spacer-locator illustrated inFIGS.2Aand B, further showing the centerline of the spacer tabs104. The spacer tabs104are offset randomly or non-randomly. For example, the offset of the centerline of the spacer tabs104is governed by an equation, wherein the equation is, by way of example and not limitation, 360 degrees divided by the number of spacer tabs. An example is shown inFIG.2C, where the centerlines of the three spacer tabs are offset non-randomly by 120 degrees around the vertical.

In another embodiment of the present invention, the locator pins are sized and shaped according to the shear strength required of the assembly. Prior art spacers ultimately weaken the joint by displacing a portion of adhesive and providing no additional strength to the joint. The spacer-locator of the present invention addresses this weakness and improves upon the prior art by not only preventing the loss of strength at the joint by maintaining spacing, but by adding mechanical shear strength at the joint through the use of locator pins. The locator pins work in tandem with the shear strength associated with the joining agent. In certain embodiments of the present invention, the locator pins are shaped to maximize the shear strength of the joint. By way of example and not limitation,FIG.3Ashows one embodiment of the present invention where the locator pins are shaped and sized for their ability to provide shear strength to the joint.

FIG.3Ais a side view that illustrates an embodiment of the present invention. The spacer-locator100includes spacer tabs102, and locator pins103. The spacer tabs102act as the core of the spacer-locator100, and are a mounting surface for the locator pins103. The spacer tabs102lay on a plane and extend outward perpendicularly from the direction of the locator pins103. The spacer tabs102, and locator pins103are formed from one piece of material. Alternatively, the locator pins103attach to the spacer tabs102through threaded members. Alternatively, the locator pins103attach to the spacer tabs102with adhesive.

FIG.3Bis a top view of the spacer-locator embodiment illustrated inFIG.3A.

FIG.3Cis a side view of the spacer-locator embodiment illustrated inFIGS.3Aand B, further showing an example of bonding surfaces105.

FIG.4Ais a side view of the spacer-locator embodiment inFIG.3A, wherein the locator pins103are hexagonal in shape. The hexagonal shape of the locator pins103advantageously prevents two substrates from rotating about the spacer-locator if only 1 spacer-locator is used in bonding the two substrates.

FIG.4Bis a top view of the spacer-locator embodiment inFIG.3B, wherein the locator pins103are hexagonal in shape.

In another embodiment the spacer-locator contains two spacer tabs. In another alternative the spacer-locator contains more than two spacer tabs. In another embodiment the spacer-locator contains between three and eight spacer tabs. Alternatively, the spacer-locator contains one spacer tab.

In a preferred embodiment of the present invention, the spacer's locator pins incorporate anti-rotation features, thereby eliminating the need for the second spacer-locator in an assembly. The incorporated anti-rotation feature provides the benefit of reducing cost, weight, and assembly time.

FIG.5Ais a perspective view of the spacer-locator embodiment inFIG.3A, wherein the locator pins103are triangular in shape and the spacer-locator includes only one spacer tab102. The triangle shape of the locator pins103advantageously prevents two substrates from rotating about the spacer-locator even if only 1 spacer-locator is used in bonding the two substrates. Notably, the spacer-locator illustrated inFIG.5Aprevents rotation between bonded surfaces by incorporating an anti-rotation feature into the locator pin.

FIG.5Bis a top view of the spacer-locator embodiment inFIG.5A.

FIG.5Cis a side view of the spacer-locator embodiment inFIG.5A.

FIG.6Ais a perspective view of the spacer-locator embodiment inFIG.3A, wherein the locator pins103are slotted in shape. The slotted locator pins are advantageously the simplest method to machine. The shape of the slotted spacer-locator also advantageously provides for anti-rotation feature.

FIG.6Bis a top view of the spacer-locator embodiment inFIG.6A.

FIG.6Cis a side view of the spacer-locator embodiment inFIG.6A.

FIG.7Ais a perspective view of the spacer-locator embodiment inFIG.3A, wherein the locator pins103are double-square in shape. The double-square spacer-locator provides increased resistance to rotational motions of the two substrates to which the double-square spacer-locator is bonded. The double-square also provides greater contact area between the locator pin and the substrates than an equally sized slotted spacer-locator, thereby reducing the risk of deforming the substrates and/or spacer.

FIG.7Bis a top view of the spacer-locator embodiment inFIG.7A.

FIG.7Cis a side view of the spacer-locator embodiment inFIG.7A.

The spacer tabs are any shape that is able to maintain a specified spacing between two substrates. The tabs can be planar or non-planar. Example profile shapes for spacer tabs are shown inFIG.8. This same figure also shows example cross-sectional shapes of the locator pins.

Another embodiment of the present invention provides for a multiplicity of locator pins affixed to a multiplicity of spacer tabs.FIG.9Ais a perspective view of a lattice structure spacer-locator according to one embodiment of the present invention. The spacer-locator100is shaped in a lattice structure. The spacer-locator100includes 12 locator pins103and 17 spacer tabs102. The spacer-locator100, including the spacer tabs102, and locator pins103are formed from one piece of material. Alternatively, the locator pins103attach to the spacer tabs102through threaded members. Alternatively, the locator pins103attach to the spacer tabs102with adhesive. Alternatively, the locator pins103attach to the spacer tabs102with thermal bonding. The lattice design of the spacer-locator intentionally sacrifices adhesive contact area in order to maximize shear strength. To maximize shear strength, the lattice structure spacer-locator is preferably made of a material with a higher shear strength than the joining agent utilized. However, in another embodiment, the lattice structure spacer-locator is made out of a material with an approximately equivalent shear strength to the joining agent utilized.

FIG.9Bis a side view of the spacer-locator embodiment illustrated inFIG.9A.

FIG.9Cis a top view of the spacer-locator embodiment illustrated inFIG.9A.

FIG.10Ais a perspective view of the spacer-locator embodiment illustrated inFIG.9A, further illustrating the spacer-locator100in between bonded materials105.

FIG.10Bis a side view of the spacer-locator embodiment illustrated inFIG.10A, further identifying the individual locator pins103.

FIG.11Ais a perspective view of a locator pin according to one embodiment of the present invention. The male locator pin106represents one half of the locator pin assembly, and includes threading108that mates with the female locator pin (illustrated as107inFIGS.12Aand B). Together, the male locator pin106and the female locator pin107attach to one or more spacer tabs, forming a spacer-locator.

FIG.11Bis a perspective view of the locator pin embodiment illustrated inFIG.11A.

FIG.12Ais a perspective view of a locator pin according to one embodiment of the present invention. The female locator pin107represents one half of the locator pin assembly, and includes threading108that mates with the male locator pin (illustrated inFIG.11AandFIG.14A).

FIG.12Bis a perspective view of the locator pin embodiment illustrated in10A.

FIG.13Ais a perspective view of a spacer tab according to one embodiment of the present invention. The spacer tab102incorporates fluid channels109and an opening110in the center of the spacer tab102for fitting locator pins. The spacer tab includes fluid channels in order to provide control over flow of fluids, such as adhesives, etching fluids, solvents, cleaners, primers, sealants, paints, gasses, dyes or other fluids used for the purpose of inspection, thermoset resins and/or thermoplastic resins. In circumstances where adhesive is injected, strategically positioned spacer-locators that direct fluid flow through the use of shaped spacer tabs allows a uniform and efficient adhesive application process.

FIG.13Bis a top view of the spacer tab embodiment illustrated inFIG.13A.

FIG.13Cis a side view of the spacer tab embodiment illustrated inFIG.13A.

FIG.14Ais a perspective view of a spacer-locator embodiment utilizing the male locator pin illustrated inFIGS.11Aand B, the female locator pin illustrated inFIGS.11Aand B, and the spacer tab illustrated inFIGS.13A-C, according to one embodiment of the present invention. The spacer-locator100includes a spacer tab102with fluid channels109, as well as a male locator pin106and a female locator pin107. The male locator pin106extends through an opening110in the center of the spacer tab102and mates with the female locator pin107. Advantageously, the male locator pin and female locator pin are operable to function with a variety of spacer tabs with different thicknesses. The fluid channels109of the spacer tab direct the flow of adhesive and other fluids outward from the center of the spacer tab.

FIG.14Bis a side view of the spacer-locator embodiment illustrated inFIG.14A, further illustrating the threading108that facilitates the mating of the male locator pin106and the female locator pin107.

In another embodiment of the present invention, the spacer-locator is shaped to allow the joining of more than two surfaces, wherein the multiple surfaces are all on the same bonding plane. This embodiment can bond more than two surfaces together while providing inherent anti-rotation benefits.FIG.15Ais a perspective view of a spacer-locator according to one embodiment of the present invention. The spacer-locator100includes 2 locator pins103and a spacer tab102. The spacer tab102, and locator pins103are formed from one piece of material. Alternatively, the locator pins103attach to the spacer tab102through threaded members. Alternatively, the locator pins103attach to the spacer tab102with adhesive.

FIG.15Bis a side view of the spacer-locator embodiment illustrated inFIG.15A.

FIG.15Cis a top view of the spacer-locator embodiment illustrated inFIG.15A.

In another embodiment of the present invention, the spacer-locator is shaped to allow the joining of more than two surfaces, wherein the multiple surfaces are not all on the same plane.

FIG.16Ais a perspective view of another spacer-locator according to one embodiment of the present invention. The spacer-locator100includes spacer tabs102and locator pins103. The spacer-locator100, including the spacer tabs102, and locator pins103are formed from one piece of material. Alternatively, the locator pins103attach to the spacer tabs102through threaded members. Alternatively, the locator pins103attach to the spacer tabs102with adhesive. Alternatively, the locator pins103attach to the spacer tabs102with thermal bonding. Advantageously, the spacer-locator illustrated inFIG.16Ais shaped to provide an additional spacer plane to allow the bonding of at least 3 surfaces.

FIG.16Bis a side view of the spacer-locator embodiment illustrated inFIG.16A.

FIG.16Cis a top view of the spacer-locator embodiment illustrated inFIG.16A.

In an alternative embodiment, the spacer-locator allows the joining of at least 4 surfaces (FIGS.17A-C). In another alternative embodiment, the locator pins are not perpendicular to the mating surface (FIGS.18A-B). This allows for joining objects that cannot be inserted into the space orthogonally to the mating surfaces, or are angled with respect to the mating surfaces and not of sufficient size to accommodate a perpendicular locator pin. These embodiments provide additional functionality in ensuring substantially uniform adhesive thickness between numerous components that are joined together simultaneously.

In an alternative embodiment of the present invention, rotation is prevented between mating surfaces by incorporating an anti-rotation feature into the spacer tabs.FIGS.19A-Cillustrates a spacer-locator for joining 8 surfaces wherein the anti-rotation feature is provided by the spacer tabs. The vertical tabs111, in addition to maintaining the space between the surfaces, also prevent rotation of the surfaces because the orthogonal shape formed by two adjacent spacer-tabs prevents the rotation of the orthogonal objects being bonded.

The present invention also provides for spacer-locators designed and configured to join non-planar surfaces together. An example spacer-locator with non-planar spacer tab112is shown inFIGS.20A-C. Here, a partial-sphere surface spacer-locator is illustrated which is used to join together a concave and a convex surface. Another example includes a partial-cylinder surface spacer-locator (not shown).

In another embodiment, the spacer-locator contains no spacer tabs. The desired separation is maintained by using at least one spacer locator pin with a length that is greater than the combined depth of the positioning holes. The spacer locator pin is thus sized to provide the desired separation between the mating surfaces and the desired mechanical strength against shear stress. In some examples of this embodiment, the spacer locator pin is shaped as a prolate spheroid, cylinder (FIGS.21A&B) or slot (FIGS.22A&B) The slot shape has a cross-section that is an elongated rectangular with rounded corners; this cross-section shape is also called stadium, discorectangle, or obround.

Another embodiment provides for a spacer-locator integrated into one of the objects to be joined (FIGS.23A-C).FIG.23Aillustrates a perspective view of two spacer-locators integrated into an object.FIGS.23Band C are a side view and a top view of the embodiment, respectively. The mating object contains the corresponding locator hole(s). Thus, the present invention provides a system for joining two objects together, wherein the spacer-locator is integral with one of the objects and the other object contains a corresponding locator hole.

As shown inFIGS.23A-C, the spacer tab and the locator pin are located on the same object. Alternatively, they are located on opposing objects, as shown inFIGS.24A-C.

The spacer-locator and/or locator pin are preferably manufactured with a material that has the same or similar intrinsic material properties as the mating surfaces. For example, the spacer-locator material has the same or similar electrical conductivity, thermal expansion, corrosion resistance, and/or aesthetic qualities as the mating surfaces.

The various components of the spacer-locator are attached to one another using any acceptable means or combinations of means. For example, the components are attached to one another by mechanical fastening, by way of example and not limitation, through the utilization of threaded members. In another example, the components are attached using adhesives, that include, but are not limited to, laminates, hot adhesives, reactive adhesives, polyester-polyurethane resin, polyols-polyurethane resin, acrylic polymers-polyurethane resin, epoxy, methacrylate, and/or cyanoacrylate. In yet another example, the components are attached by thermal bonding, including but not limited to, plastic welding, electric welding, tungsten arc welding and/or soldering. In another example, the components are attached through the use of magnets within the locator pins and the spacer body.

FIGS.25A and25Billustrate one embodiment of the present invention, wherein the spacer-locator includes only a spacer-locator pin, wherein the spacer-locator pin is constructed without a separate spacer. In the illustrated embodiment, a spacer-locator pin2401both separates two surfaces and positions the surfaces without the need for separate spacer elements. The spacer-locator pin2401sits within spacer-locator slots2403, wherein a depth of the spacer locator slot2403A is less than half of the length of the spacer-locator pin2401A when the spacer-locator slots are of equal depth. In another embodiment, the spacer-locator slots have differing depths, wherein a depth of the first spacer-locator slot2403A is different than a depth of the second spacer-locator slot2403B, and wherein a sum of the first depth2403A and the second depth2403B is less than the length of the spacer-locator pin2401A in order to provide space between the surfaces. These constructions each provide space between the two surfaces while simultaneously providing positioning. The spacer-locator pin2401and the spacer-locator slots2403restricts movement in at least two dimensions (e.g., x-axis and y-axis) and restricts rotation in at least one or two dimensions (e.g., θ and φ). The spacer-locator pin2401is operable to be constructed with any shape, size, or dimensions as disclosed in reference to previous spacers and locator pins, including polygonal constructions and shapes that prevent rotation in a third dimension (e.g., ψ). In one embodiment, the spacer-locator pin2401is combined with at least one additional spacer locator pin, wherein the at least one additional spacer-locator pin is either connected to the spacer-locator pin2401or operates separately, and wherein the combination prevents rotation in at least one additional dimension (e.g., ψ). Notably, the spacer-locator pin is operable to be constructed from any shape, size, or dimension that both restricts movement and rotation and provides space between the surfaces.FIG.25Billustrates one alternative embodiment, wherein an ellipsoid spacer locator-pin4205prevents movement in two directions (i.e., x-axis and y-axis). Similar to the spacer-locator inFIG.25A, a corresponding dome-shaped spacer-locator slot2407has a depth2407A equal to less than half of the height of the spacer-locator pin2405A when slots on both surfaces have an equal depth (2407A,2407B). In another embodiment, the depth of the first spacer-locator slot2407A and the depth of the second spacer-locator slot2407B are different, and a sum of the depth of the first spacer locator depth2407A and the second spacer locator depth2407B is less than a height of the spacer2405A. In a further embodiment, the ellipsoid spacer-locator pin is combined with at least one additional ellipsoid spacer-locator pin (and/or any other shaped spacer-locator pin) to prevent rotation in at least one direction (e.g., (φ or θ). While the illustrated tolerances between the spacer-locator pins and spacer-locator slots are exaggerated for clarity, lower tolerances are preferably constructed for a tighter fit (e.g., a close running fit or a sliding fit) for attachment of the spacer-locator pin to the spacer-locator slot. In one embodiment, the spacer-locator pin is adhered, attached, or secured in place via physical, mechanical, or chemical means, including by adhesive, welding, magnetism, pins, screws, bolts, nuts, or any other method known in the art of mechanical design or disclosed herein.

FIGS.26A and26Billustrate another embodiment of the spacer-locator pin, wherein the spacer-locator pin is integrally constructed from, attached to, or secured to one surface. In the illustrated embodiment ofFIG.25A, the cylindrical spacer locator pin2501is integral with a first surface2509and sits within the spacer-locator slot2503of a second surface. The extruded portion of the second surface that makes up the spacer-locator pin2501has a height2501A that is greater than the height of the spacer-locator slot2503A. Similarly, in the illustrated embodiment ofFIG.26B, a semiellipsoid spacer-locator pin2505is integral with a first surface2511and sits within the spacer-locator slot2507of a second surface. The extruded portion of the second surface that makes up the spacer-locator pin2505has a height2505A that is greater than the height of the spacer-locator slot2507A. In alternative embodiments, spacer-locator slots ofFIG.25A,25B,26A, or26B either match or do not match a profile of the spacer-locator pin and/or include pins, locks, sliders, snaps, or other retaining mechanisms to improve retention of the spacer-locators. Additionally, in one embodiment, the spacer-locator includes any of the elements disclosed in prior spacer or locator pin embodiments, such as shapes, cross sections, sizes, threading, holes, or other constructions.

FIG.27Aillustrates one embodiment of a spacer-locator with only spacer tabs and no locator pins. In one embodiment, at least one spacer2601is arranged along a surface2603of a door member2605, wherein the spacers control a space between the surface2603and a second surface (seeFIG.27E). In one embodiment, a thickness of the spacer2601determines a distance between the surface2603and a second surface, and two or more spacers on two or more surfaces restrict rotation along one or more axes (e.g., ψ). In one multi-spacer embodiment, each of the spacers are each equal in thickness. In another embodiment, the spacers are different thicknesses. For example, spacers along a first surface are 0.5 inches (12.7 millimeters) thick, and spacers along a second surface are 0.25 inches (6.35 millimeters) thick. In another embodiment, spacers of the illustrated embodiment are matched with retaining elements such as embossed slots, sleeves, holes, or other similar constructions on a second surface, wherein the retaining elements provide positioning, locating, and support to the spacers. The spacers in this embodiment are thicker, wider, or otherwise larger than the retaining elements in order to maintain spacing between a surface on which spacer is constructed and a surface on which the retaining element is constructed. For example, in one embodiment, the retaining element is an embossed slot with a depth of 0.5 inches (12.7 millimeters), and the spacer has a depth of greater than 0.5 inches (12.7 millimeters). In another embodiment, the retaining element is cone shaped sleeve with a base diameter of 1 inch (25.4 millimeters), and the spacer is cone shaped with a base diameter greater than 1 inch (25.4 millimeters), which ensures that the conic retaining element cannot engage past the 1 inch (25.4 millimeter) diameter of the spacer and maintains space between the two surfaces.

FIG.27Billustrates a detail view of a spacer2601, wherein the spacer2601is tapered such that a slope of at least part of the spacer2601is steeper than that of the surface2603to provide thickness and separate the surface2603from a second surface.

FIG.27Cillustrates a top view of a door member2605including spacers according to one embodiment of the present invention. Side spacers2601without locator pins, as illustrated inFIGS.27A and27B, are included as well as vertical spacer pins2607. Vertical spacer pins2607are spacers that provide separation between the door member2605and a second surface in a similar manner to the spacer-locator pins illustrated inFIGS.26A-26B. The vertical spacers2607in the illustrated embodiment extend from a bottom surface of the door member2605. The vertical spacer pins2607are operable to have any shape disclosed herein for spacers and pins, including cylindrical, hemispherical, wedge shaped, or any other suitable constructions, including those with cross sections that are triangular, star, rectangle and/or any other suitable shape.FIG.27Dillustrates a side view of a spacer pin2607according to one embodiment of the present invention.

FIG.27Eillustrates one embodiment of the door member2605inserted into a second door member2609, wherein at least one side spacer2601and at least one vertical spacer pin both provide separation of surfaces on the door member2605from surfaces of the second door member2609. In one embodiment, the second door member2609is only in contact with spacers and spacer pins of the door member2601.

FIG.27Fillustrates a cross section of the door member2605with one embodiment of a vertical spacer2607, wherein the vertical spacer has a rounded shape and is extends from a bottom of the door member2605.

Each of the above disclosed spacers and pins are preferably removably or irremovably joined together or joined to a surface, a sleeve, a hole, and/or any other spacing and positioning element via physical bonding, chemical bonding, mechanical attachment, mechanical interlocking, magnetism, reversible adhesive, irreversible adhesive, welding including plastic welding, infusion, lamination, and/or vacuum attachment. Additionally, in one embodiment, horizontal spacers, vertical spacers, or any other spacers or pins are all attached or integrated with a first surface or a second surface, or not all of a plurality of spacers and pins are attached or integrated with the same surface. For example, in one embodiment, one or more spacers are integral with a first surface, and one or more additional spacers are integral with a second surface. In another embodiment, at least one first spacer tab is integral with a first mating surface of a first object or a first mating surface of a second object, wherein the at least one first spacer tab is in contact with an opposite surface of the first mating surface of the first object or an opposite surface of the first mating surface of the second object, and at least one second spacer tab is integral with a second mating surface of the first object or a second mating surface of the second object, wherein the at least one second spacer tab is in contact with an opposite surface of the second mating surface of the first object or an opposite surface of the second mating surface of the second object;

The above-mentioned examples are provided to serve the purpose of clarifying the aspects of the invention, and it will be apparent to one skilled in the art that they do not serve to limit the scope of the invention. By way of example, the spacer-locator may be different shapes. Also, by way of example, the locator pins may be different shapes and sizes to provide required strength characteristics or accommodate manufacturing processes. By its nature, this invention is highly adjustable, customizable and adaptable. The above-mention examples are just some of the many configurations that the mentioned components can take on. All modifications and improvements have been deleted herein for the sake of conciseness and readability but are properly within the scope of the present invention.