AU2015261616B2 - Box level - Google Patents

Abstract

A level (100) comprises an elongate hollow frame (120) having an interior defined by first and second sidewalls (180) and top and bottom walls (130, 140) each extending between the sidewalls (180); a central vial (50) within a topnotch (20) which is formed by removal of a topwall section and adjacent sections of each sidewall including notch-defining bottom and side edges; and a frame-reinforcing external brace (60) substantially spanning the distance between the top and bottom walls (130, 140) about the topnotch (20).

Description

BOX LEVEL

Field of the Invention [0001] This invention relates to levels and, more particularly, to structures for accurate vial installation and reinforcement of the level frame.

Background of the Invention [0002] In heavy-duty levels it is important that the frame of the level maintains stability for accurate measurement readings. It is also important that levels, which are used in professional construction on types of jobs when a level may be dropped from a substantial height and be subjected to various stresses, sustain the impact with minimal or no damage.

[0003] Many box levels have a central vial positioned into a notch which is formed by removing a section of a top wall and adjacent portions of each side wall, as seen in FIGURE 1.

[0004] Because material is removed from the center of the frame, a central frame section becomes the weakest portion of the extrusion. Tests have shown that in prior levels 10, the central region 11 of a frame 12 with the cut-out notch portion 20 for the central vial is substantially weak. FIGURE 2 shows that in such prior levels 10 a bottom 21 of the notch 20 is the weakest region. Portions 22 of sidewalls 13 which surround the central-vial notch 20 are also substantially weak regions 22A which extend to weakened areas 22B.

[0005] It is further seen in FIGURE 2 that there is also a substantial weakness in topwall regions 23 adjacent to hand holes from which material is also removed from the level frame 12.

[0006] Levels include plural vials, almost always including a principal center vial which is parallel to a reference surface and used to indicate a horizontal orientation. Such horizontal vial is normally secured to the level frame in a position that permits viewing of the vial from both sides and also from above to ascertain the orientation of substantially horizontal surfaces. The most desirable positioning of such vial is within a topnotch in the body of a level which topnotch is defined by two sidewalls and the topwall of a hollow level body frame. However, such positioning also presents a challenge for accurate securing of the vial to the frame. Such installation involves multiple steps, including calibration for accurate measurements.

Object of the Invention [0007] It is an object of the present invention to substantially overcome or at least ameliorate one or more of the above disadvantages, or to at least provide a useful alternative.

Summary of the Invention [0008] There is disclosed herein a level comprising: an elongate hollow frame having an interior defined by first and second sidewalls and top and bottom walls each extending between the sidewalls; a central vial within a topnotch which is formed by removal of a topwall section and adjacent sections of each sidewall including notch-defining bottom and side edges; a frame-reinforcing external brace substantially spanning the distance between the top and bottom walls about the topnotch and including first and second plate members each against one of the sidewalls about the notch-defining bottom and side edges and each substantially spanning a respective one of the sidewalls, a fastening member extending through the sidewalls and pulling the plate members toward each other to sandwich the sidewalls therebetween, thereby reinforcing a central frame portion weakened by the removal of the topwall section forming the topnotch.

[0009] There is also disclosed herein a method for manufacturing a reinforced level, the steps comprising: providing an elongate hollow frame with an interior defined by two sidewalls and top and bottom walls each between the sidewalls; forming a central-vial receiving topnotch by removing a topwall section and adjacent sections of sidewalls including notch-defining bottom and side edges; providing a frame-reinforcing external brace configured to substantially span the distance between the top and bottom walls about the topnotch and including a pair of plate members each configured to substantially span one of the sidewalls about the notch-defining edges; positioning each plate member against a respective one of the sidewalls about the notch-defining edges; and securing the external brace to the frame with a fastening member extending through the sidewalls and pulling the plate members toward each other to sandwich the sidewalls therebetween, thereby reinforcing a central frame portion weakened by the removal of the top wall section to form the topnotch.

Brief Description of the Drawings [0010] Preferred embodiments of the invention will be described hereinafter, by way of examples only, with reference to the accompanying drawings.

[0011] FIGURE 1 is a fragmentary perspective view of a prior level showing a top-notch material removal.

[0012] FIGURE 2 is a fragmentary perspective view of a prior level frame showing weak regions around material removal for central-vial top notch and hand-hold holes.

[0013] FIGURE 3 is a perspective view of the frame of a level showing inner walls.

[0014] FIGURE 4 is a fragmentary perspective end view of the frame of the level of FIGURE 3 showing material removal for central-vial top notch and hand-hold holes.

[0015] FIGURE 5 is a fragmentary perspective side view of the level frame of FIGURE 3, showing strengthening of the weak regions around material removal.

[0016] FIGURE 6 is a comparison table reflecting test results showing increase in frame strength in the level frame of FIGURE 5.

[0017] FIGURE 7 is a fragmentary perspective view of the level frame showing precisely parallel surfaces for a calibration-free installation of the central vial.

[0018] FIGURE 8 is an exploded fragmentary perspective view showing one version of the calibration-free installation of the central vial to the level frame of FIGURE 7.

[0019] FIGURES 9-12 are exploded fragmentary perspective views of the box level showing different stages of calibration-free installation of the central vial and exterior strengthening of the central region of the level frame.

[0020] FIGURE 13 and 15 are fragmentary perspective views of the central region of the level assembled as shown in FIGURES 9-12.

[0021] FIGURE 14 is a fragmentary perspective view of the central region of the level and showing precise calibration-free installation of the central vial.

[0022] FIGURE 16 is a fragmentary perspective view of the central region of the inventive level of FIGURE 15 in more detail.

[0023] FIGURE 17 is a fragmentary perspective view of the central region of partially-assembled level showing strengthening by the external reinforcement of the central region.

[0024] FIGURE 18 is a comparison table reflecting test results for increase in frame strengthening in the level frame of FIGURE 5 compared to the level frame of FIGURE 17 and to a prior art level.

[0025] FIGURE 19 is a fragmentary perspective view of the end-vial region of the level, and showing calibration-free installation of the end vial.

[0026] FIGURE 20 is a fragmentary perspective view of the end-vial region of the level showing an improved-visibility plumb vial.

[0027] FIGURE 20A is an exploded view of the end-vial structure of the level of FIGURE 20.

[0028] FIGURE 20B is cross-sectional view of the plumb-vial assembly along a horizontal section plane.

[0029] FIGURES 21 and 22 are fragmentary perspective views of the level and illustrating high-visibility plumb vial aspect of the present invention.

[0030] FIGURE 23 is a detailed fragmentary perspective view of the end-vial region of the level showing an improved-visibility plumb vial and an improved end cap.

[0031] FIGURE 24 is an end view of the level, showing a gripping extension of the plumb-vial assembly.

[0032] FIGURE 25 is a fragmentary perspective view showing details of the improved end cap.

[0033] FIGURE 26 is a front perspective view of the level shown in resting position against a vertical surface.

[0034] FIGURE 27 is a side perspective view of the level shown in resting position against a vertical surface.

[0035] FIGURES 28 and 29 are fragmentary perspective views showing an improved hand grip of the level.

[0036] FIGURE 30 is a perspective view of the level.

[0037] FIGURE 31 is a front elevation of the level.

[0038] FIGURE 32 is a cross-section of the level taken along a horizontal plane.

Detailed Description of Preferred Embodiments [0039] FIGURES 3-5, 7-17 and 19-32 illustrate an inventive level 100 which includes an elongate hollow frame 120 with two sidewalls 180, a top wall 130 and a bottom wall 140 which extend between sidewalls 180 and define top and bottom measuring surfaces. A topnotch 20 is formed by removal of a topwall section and adjacent sections of sidewalls including notch-defining bottom and side edges. A central vial 50 is within topnotch 20.

[0040] In inventive box level 100, level frame 120 includes an internal horizontal wall 30. As seen in FIGURES 3 and 4, such internal horizontal wall 30 is substantially parallel to top wall 130 and is spaced from top wall 130 for a distance 31 necessary for installation of a central vial 50. FIGURE 4 shows that this internal horizontal wall 30 is entirely removed in portions of level frame 120 to form hand-holes 150 and in areas 160 for installation of end vials such as plumb vials 40.

[0041] Because of its specific location along bottom 21 of central-vial notch 20, internal horizontal wall 30 significantly strengthens the central region 170 of frame 120 which has been weakened by the material removal.

[0042] FIGURES 3 and 4 further show that frame 120 of inventive box level 100 further includes an internal vertical wall 35. Such vertical internal wall 35 adds rigidity to entire frame 120 and strengthens areas with material removal and where horizontal wall 30 is not present, including around hand holes 150 and plumb-vial holes 160, as seen in FIGURE 4.

[0043] FIGURE 5 shows that in inventive box level 100 the weakness of the central-vial notch region 20 is reduced to much lesser degree, i.e., to green in previously notch-bottom red areas 21, light blue in previously green areas 22A and to no weakness in previously light blue areas 22B. In fact, a table of FIGURE 6, which includes data from finite element analysis of prior-level frame 12 and the improved frame 120 of level 100 of this invention, shows that the improved frame 120 is 180% stronger then prior frame 12 without the internal horizontal and vertical walls 30 and 35.

[0044] As seen in FIGURES 3 and 4, internal horizontal and vertical walls 30 and 35 form a quad-box structure of a superior strength. It should be noted that during manufacturing of the inventive level 100, the thickness of the frame-forming walls has been reduced. Surprisingly, despite such thinning of the walls, the strength of the frame increased. This was partially explained by decrease in the overall weight of the frame 120 which resulted in static improvement and the frame impact performance. In addition to the improved level performance characteristics, such thinning of the walls provides reduction in material used which translates in lower product cost.

[0045] It is also important to note that specific positioning of the internal horizontal wall 30 at bottom 21 of central-vial notch 20 is important for achieving such improved strength.

[0046] Another important aspect of the present invention is that such positioned internal horizontal wall 30 serves for accurate secure installation of the central vial 50. During manufacturing of the level frame 120, top and bottom measuring walls 130 and 140 and an upper surface 32 of internal horizontal wall 30 within central-vial notch 20 all simultaneously undergo a milling by a computer-numerical control machine (CNC). The CNC milling during a single operation ensures that all three surfaces are parallel to each other. Thus, upper surface 32 of internal horizontal wall 30 is parallel to top and bottom measuring walls 130 and 140, as seen in FIGURE 7.

[0047] Such accurately machined upper surface 32 of the internal horizontal wall 30 forms a reference shelf 33 for precise installation of central vial 50 along vertical axis 53. As shown in FIGURES 8-11, vial 50 is placed in a cradle 51 and mechanically mounted to upper surface 32 of reference shelf 33 with mechanical fasteners such as screws 52.

[0048] Because of the accuracy in machining of reference shelf 33, there is no need for manual calibration or adjustment in the positioning of central vial 50 with respect to measuring surfaces 130 and 140. Such advance in the central-vial installation provides great improvement in manufacturing processes by substantially reducing manual labor. In prior levels, each vial was secured to frame 12 by using an epoxy-based locking system. Each such vial was individually calibrated and only then permanently secured to frame 12. A number of problems are associated with such prior method of vial installation. One is that the need for calibration of the vial prior to permanent securement involves manual labor which increases costs for manufacturing and requires special quality-control procedures. Another problem is that over time due to variations in temperature or humidity adhesives tend to change its characteristics which may contribute to changes in positioning of the vial as well as in weakening of the vial attachment to the frame. In inventive level 100, vial 50 is accurately secured to frame 120 without any glue, but only with mechanical fastening against precisely machined reference surface 33 which does not change overtime.

[0049] Such mechanical securement of central vial 50 also involves an external brace 60 which is secured over central region 170 of level frame 120, as seen in FIGURES 9-15. External brace 60 includes two plates 61 each of which spans the entire surface of the respective vertical side wall 180. External brace 60 is preferably made from cast aluminum and is mechanically secured to the frame with screws 62 which extend through apertures 63 in sidewalls 180 and internal vertical wall 35.

[0050] Such external brace 60 completes mechanical fastening of the central vial 50 to frame 120 by an additional fixing of vial 50 in a horizontal plane 54. As best seen in FIGURES 12-16, brace sandwiches a flange 55 of a vial frame 56 such that vial 50 is securely held in front-to-back, up-and-down and left-to-right directions.

[0051] Furthermore, external brace 60 provides an additional reinforcement of central region 170. In fact, the sandwiching of the central region by external brace 60 substantially eliminates the weakness in that area. Indeed, FIGURE 17 illustrates that tests showed that previously weakest (red) areas in bottom 21 of notch 20, as seen in FIGURE 2 showing prior level 10, are just slightly weakened (light blue) in improved level 100 which includes external brace 60. The areas, which in prior level 10 were substantially weak (green) or weakened (light blue), in improved level 100 (seen in FIGURE 17) exhibit similar strength as the strongest areas of frame 120 where no material removal occurred.

[0052] Moreover, the table of FIGURE 18, which includes data from testing of prior level 10 and improved level 100, shows that improved level 100 is 300% stronger then prior level 10.

[0053] The manufacturing of the improved inventive level 100 also includes CNC milling of openings 160 for plumb vials 40. While entirely removing internal horizontal wall 30 in regions 160 of frame 120, such CNC milling forms precise positioning references 36 in internal vertical wall 35 for installation of plumb vials 40, as seen in FIGURES 19 and 20A. This process allows for adhesive-free installation of plumb vials and ensures precise positioning when the vials are secured within frame 120 without any calibration or adjustment required. This is a great improvement over manufacturing of many prior box levels which required calibration and adjustment of plumb vials. This process further eliminates quality and longevity concerns associated with the use of adhesive, as already discussed above. Vials installed within frame 120 according to the inventive method will remain in their precise position for accurate reading over time.

[0054] FIGURES 20, 20A and 20B show that, in inventive box level 100, plumb vials 40 are encased in a plumb-vial structure 41 made of a high-quality and durability Xenoy* alloy which is a blend of semi-crystalline polyester (typically polybutylene terephthalate, PBT, or polyethylene terephthalate, PET) and polycarbonate (PC). The Xenoy* alloy offers great impact resistance even at low temperatures, heat resistance, and outstanding aesthetic characteristics. Xenoy alloys further offer outstanding performance in applications that are exposed to harsh conditions, or that require a high degree of toughness such as applications for professional-construction levels. Furthermore, Xenoy iQ* resins are created with polybutylene terephthalate (PBT)-based polymers derived from 85% post-consumer plastic waste, consuming less energy and yielding less carbon dioxide (C02) in their manufacturing than traditional resins. It is seen that the use of Xenoy* alloys present many advantages over standard acrylics often used in plumb-vial casings.

[0055] In levels of substantial lengths such as forty-eight inches and greater, plumb vials are positioned at substantial distance from user’s eyes. FIGURE 21 shows how in some prior levels plumb-vial mounting structures may block the view for reading of the plumb vial.

[0056] FIGURES 19-23 illustrate another aspect of the present invention which provides improved visibility of plumb vial 40. Such improved visibility is achieved by an inventive configuration of plumb-vial mounting structure 41 includes an elongate inclined ramp 42 sloping from about the side-wall surface at a reduced angle toward a plumb-vial window 43. Plumb-vial structure 41 has a viewing-end region 47A and an opposite-end region 47B, the viewing-end region 47A including elongate ramp 42 sloping along a level-longitudinal axis 101 toward plumb vial 40 with an inclination angle 400 permitting vial viewing from shallow angles 401. Such reduced angle 400 of inclination facilitates user’s viewing of plumb vial 40 from about central region 170 of level 100 or even from farther distance, as seen in FIGURE 30. FIGURE 20B best shows angle 400 being 8.65° and as little as 5°. Vial opening 43 also has an elongate configuration of an inner portion 44 on the side of the level central region 170. Such elongation allows spacing of vial 40 away from ramp 42. As further seen in FIGURES 22 and 30, such spacing in cooperation with elongate inclined ramp 42 compensates for the extended viewing distance and provides improved visibility of vial 40 for the necessary measurement readings.

[0057] The term “shallow,” as referred to the viewing angle 401, means that such angle is closer to the 0° plane (of the major level sidewall surface) than to the 90° plane (perpendicular to the level sidewalls). Angles 401 are preferably slightly above sidewall surfaces such that the vial becomes visible at a little over angle 400 of sloping ramp 42 shown in FIGURES 20B and 32.

[0058] Plumb-vial window 43 includes lenses 48 made of “bullet proof’ Lexan* material. Such lenses provide further durability and impact resistance of improved level 100.

[0059] FIGURES 20A and 20B show that plumb-vial structure 41 includes first and second side portions 411 and 412. Each side portion 411 and 412 is positioned along one of level sidewalls 180. First side portion 411 includes a high-friction region 46 extending from first side portion 411 outwardly beyond an outmost sidewall portion 190, as best seen in FIGURE 24, for gripping a work surface. High-friction region 46 is preferably made of rubber molded over the Xenoy* alloy. Rubber portions 46 extend beyond the outmost vertical side surface 190 of that side of level 100 to allow gripping of a work surface against which level 100 is positioned for measurements.

[0060] FIGURE 23 further shows an improved end cap 70 which is made with an ABS material on the inside and an outside rubber coating over the ABS material. The rubber coating provides an improved shock absorption even if the level 100 is dropped from a substantial height. As seen in FIGURES 23 and 25, outside rubber coating of end cap 70 includes a slightly raised section 71. While raised section 71 does not extend beyond the outmost vertical side surface 190 of that side of level 100, such raised rubber section 71 facilitates gripping of a vertical surface against which level 100 may be leaned against during a break between jobs, as seen in FIGURES 26 and 27.

[0061] As further seen in FIGURE 25, end cap 70 is held to frame 120 with two cast aluminum mounting plates 72 which are mechanically secured to frame 120 with screws 73. Such secure screw attachment also permits end caps 70 to be removed by simple disengagement of screws 73. While the removal of end caps 70 requires use of additional tools such as screw driver, when necessary, this removable end-cap assembly accommodates precise marking of the work surface even along corners. Each end cap 70 also has an enlarged hang hole 74 which allows for quick hanging of level 100 on the job site.

[0062] As with the plumb-vial casing, a hand grip 80 seen in FIGURE 28 is also made from Xenoy iQ* alloy which is a material used in car bumpers and is very strong in all temperatures, chemical resistant and UV stable. As seen in FIGURE 29, hand grips 80 are made with an enlarged hole 81 to accommodate gloved hands and to reduce fatigue.

Claims (9)

1. A level comprising: an elongate hollow frame having an interior defined by first and second sidewalls and top and bottom walls each extending between the sidewalls; a central vial within a topnotch which is formed by removal of a topwall section and adjacent sections of each sidewall including notch-defining bottom and side edges; a frame-reinforcing external brace substantially spanning the distance between the top and bottom walls about the topnotch and including first and second plate members each against one of the sidewalls about the notch-defining bottom and side edges and each substantially spanning a respective one of the sidewalls, a fastening member extending through the sidewalls and pulling the plate members toward each other to sandwich the sidewalls therebetween, thereby reinforcing a central frame portion weakened by the removal of the topwall section forming the topnotch.

2. The level of claim 1 wherein: each sidewall includes top and bottom outmost wall-portions joined with a recessed major wall-portion by top and bottom inclined wall-portions; and the external brace includes top and bottom ends each positioned against a respective one of the inclined wall-portions such that the brace is substantially recessed with respect to the outmost wall-portions.

3. The level of claim 1 wherein the fastening member secures the plate members through the sidewalls with threaded fasteners extending through apertures in the first plate member and engaging aligned threaded channels protruding inwardly from the second plate member.

4. The level of claim 1 wherein the hollow frame is an extrusion including an inner horizontal wall extending between the sidewalls at the notch-defining bottom edges thereby reinforcing the frame weakened by the removal of the topwall section.

5. The level of claim 1 wherein the hollow frame is a one-piece extrusion which includes an integral vertical wall between the top and bottom walls and reinforcing the frame along the frame length, the fastening member extending through the internal vertical wall thereby further reinforcing the weakened central frame portion.

6. A method for manufacturing a reinforced level, the steps comprising: providing an elongate hollow frame with an interior defined by two sidewalls and top and bottom walls each between the sidewalls; forming a central-vial receiving topnotch by removing a topwall section and adjacent sections of sidewalls including notch-defining bottom and side edges; providing a frame-reinforcing external brace configured to substantially span the distance between the top and bottom walls about the topnotch and including a pair of plate members each configured to substantially span one of the sidewalls about the notch-defining edges; positioning each plate member against a respective one of the sidewalls about the notch-defining edges; and securing the external brace to the frame with a fastening member extending through the sidewalls and pulling the plate members toward each other to sandwich the sidewalls therebetween, thereby reinforcing a central frame portion weakened by the removal of the topwall section to form the topnotch.

7. The method of claim 6 wherein the hollow frame is an extrusion with an inner horizontal wall being integral with the sidewalls thereby reinforcing the frame weakened by the removal of the topwall section to form the topnotch.

8. The method of claim 6 wherein the hollow frame is a one-piece extrusion which includes an integral inner vertical wall extending between the top and bottom walls thereby reinforcing the frame along the frame length.

9. The method of claim 8 wherein, in the securing step, the fastening member extends through the internal vertical wall thereby further reinforcing the weakened central frame portion.