WO1998041817A1

WO1998041817A1 - Leveling device

Info

Publication number: WO1998041817A1
Application number: PCT/US1998/004097
Authority: WO
Inventors: Kenneth W. Maxwell
Original assignee: Maxwell Kenneth W
Priority date: 1997-03-18
Filing date: 1998-03-03
Publication date: 1998-09-24
Also published as: AU6444798A

Abstract

A leveling device (10) is disclosed which comprises a housing (12), a laser oscillator (80) and first and second level indicators (16, 18). The laser oscillator (80) projects a laser beam along an axis of the device (10) for alignment of remote surfaces. The first and second level indicators (16, 18) provide an indication of the orthogonality of a structure in two distinct orthogonal planes. One of the first and second level indicators (16, 18) can be movably mounted to the housing (12) between a first retracted position and a second extended position whereby in the extended position the second level indicator (18) is orthogonal to the first level indicator (16). The device (10) can also be mounted via a bracket (112) to a conduit (108) end and the laser oscillator (80) can be energized to direct a laser beam toward an extension of the conduit (108) end remote from the device (10).

Description

LEVELING DEVICE

Related Cases:

This application claims priority from U.S. Patent Application Serial No. 80/819,765, filed March 18, 1997.

BACKGROUND OF THE INVENTION

Field of the Invention

This invention relates to a leveling device, and more specifically, to a leveling device adapted to be adjusted in two orthogonal planes and adapted to be aligned by a laser. Description of the Related Art

It has long been known to use a leveling device when constructing architectural structures. Typically, a bubble level is used to determine whether a first object is orthogonally aligned with a second object. A conventional bubble level comprises an elongated member, often with graduated markings for measurement thereon, having a horizontal and a vertical bubble chambers mounted therein. The bubble chambers typically comprise a sealed housing having a volume of semi- viscous liquid contained therein which, in turn, contains a volume of air defining a bubble. The bubble floats within the housing and indicates a level position when the bubble is disposed between a pair of markings on the housing.

Conventional bubble levels contain a large propensity for error because they require that a user read the location of a bubble as it floats between the markings. Further, conventional bubble levels are only useful in determining orthogonality with respect to a horizontal or a vertical surface. If a user desires to determine an angular reading other than 0 or 90 degrees, additional tools are needed. Further, if a pair of surfaces are remotely located with respect to one another, additional tools and time are needed to determine whether the surfaces are orthogonal, parallel or otherwise aligned. Several attempts have been made to devise a tool which overcome the shortcomings of conventional leveling devices. For example, U.S. Patent No. 4,852,265 to Rando, issued August 1, 1989, discloses a leveling device indicator having a horizontal or vertical laser for marking remote areas in alignment with the device. U.S. Patent No. 3,911,588 to Rando, issued October 14, 1975, discloses an optical marker having a gimbal-mounted light projector for projecting a horizontal or a vertical beam of light. Other such devices are disclosed in U.S. Patent Nos. 3,505,739 to Abrams, 4,106,207 to Boyett et al., and 5,012,585 to DiMaggio.

These devices are insufficient to solve to above-identified problems because they fail to provide a portable device which allows alignment of a pair of objects in more than one orthogonal plane and which allows alignment of remote surfaces at angles other than 0 or 90 degrees.

SUMMARY OF THE INVENTION The invention overcomes the limitations of the prior art by providing a leveling device which can provide an indication of orthogonality in two distinct planes. In addition, the device also includes a laser alignment assembly which allows alignment of a pair of remote surfaces or a determination of an extension of a surface such as a conduit end.

In one aspect of the invention, a leveling device according to the invention comprises a housing, a first level indicator mounted to the housing, and a second level indicator mounted to the housing and movable between a first position and a second position. In the first position, the device preferably occupies less space for easy transportation. In the second position, the second level indicator is generally orthogonal to the first level indicator. The housing preferably has at least one planar surface thereon whereby the housing can easily rest on a planar surface. The device preferably further comprises a laser oscillator mounted to the housing to direct a laser beam along a first axis. The housing preferably has a forward surface and a second axis whereby the forward surface of the housing mounts the laser oscillator in a position to preferably direct the laser beam outwardly from the forward surface thereof. The first axis preferably is generally parallel to the second axis. The housing preferably has a rearward surface which includes an outwardly-extending protrusion having a tip thereon and a third axis. The third axis preferably is generally parallel to the first axis. In another aspect of the invention, a device is provided for locating an extension of an existing conduit having a first axis and an end. The device comprises a body, a laser oscillator preferably mounted to the body in a position to direct a laser beam along a second axis, and a bracket for mounting the body to the conduit end wherein the second axis is generally aligned with the first axis. When the device is mounted to the end of the conduit by the bracket and the laser oscillator is energized, the laser beam emitted therefrom will identify a location for the extension of the conduit.

The body preferably has at least one planar surface thereon whereby the body can easily rest on a planar surface. The bracket preferably includes at least one flange adapted to receive a rim of a conduit. The device preferably further comprises a fastener which engages both the conduit and the bracket to retain the bracket against the conduit. The bracket preferably comprises a member adapted to engage a rim of a conduit. The bracket preferably further includes an aperture and the body preferably includes a protrusion whereby when the protrusion is inserted in the aperture the body is mounted to the bracket. The device preferably further comprises first and second level indicators mounted to the body. Either the first or second level indicator is preferably mounted to the body and movable between a first position adjacent the body and a second position extended from the body. The second level indicator is preferably adapted to be positioned orthogonal to the first level indicator.

BRIEF DESCRIPTION OF THE DRAWINGS The invention will now be described with reference to the drawings wherein:

FIG. 1 is a perspective view of the leveling device according to the invention; FIG. 2 is a cross-sectional view of a portion of the leveling device of FIG. 1, taken along lines 2-2;

FIG. 3 is a cross-sectional view of the leveling device taken along lines 3-3 of FIG. 1; FIG. 3 A is a perspective view of a door assembly of the leveling device according to the invention with the remaining components of the leveling device removed for clarity;

FIG. 4 is a rear elevational view of the leveling device taken along lines 4-4 of FIG. 1; FIG. 5 is a perspective view of the leveling device of FIG. 1 and the bracket of FIG. 5, shown in use to align pipes;

FIG. 6 is a perspective view of an attachment bracket to be used with the leveling device shown in FIG. 1 ;

FIG. 7 is an enlarged perspective view of the region marked 7 of FIG. 5; and

FIG. 8 is an exploded perspective view of the leveling device of FIG. 1 mounted to a self-leveling attachment stand.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to the drawings and to FIGS. 1-4 in particular, a leveling device is shown generally at 10 comprising a housing 12, a laser alignment assembly 14 and first and second levels 16 and 18, respectively. The first and second levels 16 and 18, respectively, provide an indication of the orthogonality of a structure in two distinct orthogonal planes.

The housing 12 comprises a longitudinal rectangular body 20 preferably formed from a rigid plastic material or any other suitable material such as wood, metal, and the like. The rectangular body 20 is defined by front and rear faces 22 and 24, top and bottom faces 26 and 28, and first and second side walls 30 and 32, respectively. The front face 22 is a substantially vertical face having a circular aperture 34 concentrically aligned with the vertical and horizontal midpoints of the front face 22. The rear face 24 is of the same shape as, and parallel to, the front face 22 and is provided with a cylindrical stud 36 having a conical tip 38 extending rearwardly from the rear face 24 in concentric alignment with the horizontal and vertical midpoints of the rear face 24. The stud 36 is also in concentric alignment with the center of the aperture 34 on the front face 22. The rear face 24 also includes a pair of threaded studs 40 and 42 oppositely disposed and in spaced vertical relationship from the stud 36. The threaded studs 40 and 42 can receive wing nuts 44 and 46, respectively.

The top face 26 includes an aperture 48 located near the forward end of the top face 26 and adjacent a medial longitudinal axis of the top face 26. The bottom face 28 is of the same longitudinal rectangular configuration as the top face 26. The first and second side walls 30 and 32 include wells 50 and 52 adapted to receive the first and second levels 16 and 18, respectively. Each well 50 and 52 is preferably a substantially square recess which is located near the longitudinal midpoint of the side wall 30 or 32 and is of a sufficient depth to receive the first or second level 16 or 18 so that the outward face thereof is flush with the side wall 30 or 32. The side wall 30 further includes a cover plate 54.

The cover plate 54 is defined by a vertical face 56 having an inwardly- extending front vertical wall 58 and top and bottom inwardly-extending horizontal walls 60 and 62. The cover plate 54 is located along the forward end of the first side wall 30 of the housing 12 and is adapted to enclose a laser alignment assembly recess 64 in the forward end of the rectangular body 20. The laser alignment assembly recess 64 comprises a laser recess 66, and switch recess 68 and a battery recess 70. The laser recess 66 comprises a semi-cylindrical indentation which initiates at the aperture 34 of the front face 22 an extends rearwardly therefrom. The laser recess 66 can be formed to receive any particular laser element, the particular shape of which is not critical to this invention. The switch recess 68 starts at the aperture 48 on the top face 26 and extends downwardly therefrom. The battery recess 70 starts adjacent the rearwardmost and lowest point of the laser recess 66 and switch recess 68, respectively, and comprises a rearwardly-extending rectangular recess provided with conventional battery contacts 72 mounted therein. The cover plate 54 can be mounted to the forward end of the rectangular body 20 by a plurality of threaded fasteners 74 countersunk within apertures 76 in the cover plate 54 and received within threaded apertures 78 in the rectangular body 20 as shown in FIG. 2. Alternatively, the cover plate 54 and the forward end of the rectangular body 20 can be provided with a mating rail and groove, respectively, so that the cover plate 54 can be slidably inserted within the groove on the rectangular body 20 and locked therein.

As shown in FIG. 2, the laser alignment assembly 14 comprises a laser emitter 80, a switch 82 and a power supply 84. The laser emitter 80, switch 82 and power supply 84 are operably electrically connected so that the actuation of the switch 82 provides or interrupts the flow of electricity from the power supply 84 to the laser emitter 80. The laser emitter 80 is preferably any suitable visible laser emitting element. An example of such a laser emitter is a laser pointing mechanism having a 660-680nm wavelength laser providing 5 milliwatts of output power available from ALPEC TEAM, Inc., P.O. Box 1162, Danville, California, 94526. The laser emitter 80 preferably emits a small visible point of light onto a surface toward which it is directed. The switch 82 is preferably a conventional toggle-type switch having a button 86 mounted upon a spring-biased base 88. Alternatively, the switch 82 can also comprise a pressure-type button assembly or a slidable or pivotable on-off flip switch assembly. The switch 82 is best comprised from a switch assembly which allows the user to depress or flip the switch once to activate or de-activate the laser alignment assembly 14 for hands-free operation. The power supply 84 comprises any type of conventional power cell such as the batteries shown in FIG. 2.

The first and second levels 16 and 18 each preferably comprise an angle finding device which has a substantially flat plate 90 provided with a dial 92 having graduated indicia and a pivotable needle (not shown) which provides an indication of the particular angle at which the plate 90 is positioned relative to a vertical or horizontal axis. An example of such a angle finding device is the ANGLE FINDER available from Dasco Pro. Alternatively, the first and second level 16 and 18 each can comprise a conventional bubble-type spirit level well known in the prior art. The first level 16 is fixedly mounted to a pivotable assembly 94. The pivotable assembly 94 comprises a substantially flat plate 96 having a pair of triangular flanges 98 and 100 extending upwardly from opposite edges therefrom. The triangular flanges 98 and 100 include outwardly extending protrusions 102 and 104 located adjacent a rearward portion of the triangular flanges 98 and 100, respectively, as shown in greater detail in FIG. 3A.

In assembly, the laser alignment assembly 14 is installed within the laser alignment assembly recess 64 in the rectangular body 20 by fixedly mounting the laser emitter 80 within the laser recess 66 so that a beam-emitting end of the laser emitter 80 is aligned with the aperture 34 in the front face 22 so that it may emit light outwardly therefrom without obstruction. The switch 82 is mounted to the rectangular body 20 within the switch recess 68 so that the button 86 of the switch 82 is accessible through the aperture 48 in the top face 26 of the rectangular body 20. The batteries 84 are conventionally installed within the battery recess 70 such that the batteries operably connect to the battery contacts 72 mounted therein. The laser emitter 80, switch 82 and batteries 84 are operably electrically connected to each other so that actuation of the switch 82 supplies or interrupts power from the batteries 84 to the laser emitter 80. The cover plate 54 is then installed over the laser alignment assembly recess 64 to enclose the laser alignment assembly 14 therein. The cover plate 54 is removable to provide access to the batteries 84 for periodical replacement. The first level 16 is fixedly mounted to the plate 96 of the pivotable assembly 94 between the triangular flanges 98 and 100. The protrusions 102 and 104 on the triangular flanges 98 and 100, respectively, pivotally mount to corresponding apertures (not shown) within the aperture 50 in the first side wall 30. The first level 16 is thus pivotable to and between a first retracted position within the well 50 and a second extended position wherein it extends substantially parallel to the top face 26 of the rectangular body 20 as shown in the phantom outline in FIG. 3. The second level 18 is fixedly mounted within the well 52 in the second side wall 32 so that the second level 18 is parallel to and flush with the second side wall 32. In operation, the leveling device 10 can be placed upon a surface of a structure (not shown) so that the bottom face 28 of the rectangular body 20 rests thereon. The first level 16 is then pivoted to the extended position shown in FIG. 3 so that the leveling device 10 can provide angular alignment readings in a horizontal plane by the first level 16 and in a vertical plane by the second level 18. If desired, the switch 82 can be actuated which activates the laser emitter 80 and emits a beam of laser light through the aperture 34 in the front face 22 of the rectangular body 20. This beam of laser light can provide a reference point on a remote structure which can denote where the surface on which the leveling device 10 would intersect the remote structure.

The leveling device 10 can also be used as a "plumb bob" device for a particular surface. The laser emitter 80 is actuated and pointed at a particular location on a surface (not shown). The device 10 can then be repositioned until the first and second levels 16 and 18 provide predetermined angle readings as to the plumb condition of the surface. The device 10 therefore eliminates the need for hanging a string with a weighted portion on the end thereof and reading the angle of the string with respect to a vertical plane.

Often, it is desirable to actually determine where the center of a first conduit would intersect a second remotely-located conduit in electrical or plumbing applications. As shown in FIG. 6, a first pipe 106 is shown having an angle connector 108 installed in one end. Often, a worker must determine where a pipe installed in the opposite end of the angle connector 108 would intersect a second remotely-located pipe 110 if the angle connector 108 were to be extended to reach the second pipe 110. This may be accomplished by mounting the leveling device 10 to an attachment bracket 112 which, in turn, is mounted to an end of the angled connector 108 so that the front face 22 of the leveling device 10 points towards the second pipe 110.

As shown in FIG. 6, the attachment bracket 112 comprises a longitudinally-extending rectangular plate 114 having first and second mounting flanges 116 and 118 located at each end of the plate 114. The plate 114 further includes a circular aperture 120 concentrically aligned with the horizontal and vertical midpoints of the plate 114 and having a diameter equal to or slightly larger than the stud 36 on the leveling device 10. The plate 114 is also provided with a pair of apertures 122 and 124 in spaced relationship to the aperture 120 corresponding in diameter and location to the threaded studs 40 and 42 which extend from the rear face 24 of the leveling device 10. The first and second mounting flanges 116 and 118 each comprise inner and outer plates 126 and 128, respectively, and a clamp 130. The inner and outer plates 126 and 128 are mounted to or integrally formed with the underside of the plate 114. The outer plate 128 extends downwardly from a longitudinal edge of the plate 114 and the inner plate 126 extends downwardly from a point spaced inwardly from and parallel to the outer plate 128. The inner plate 126 and the outer plate 128 define a channel 138 therebetween. The outer plate further includes a threaded aperture 132 which extends through the outer plate 128 and parallel to a longitudinal axis of the plate 114. The clamp 130 comprises a threaded shaft 134 having a laterally-extending head 136 which may be easily gripped by a user. The attachment bracket 112 can be manufactured in several lengths to correspond with the diameters of several different pipes, or alternatively, can be made with a telescoping portion such that the attachment bracket can be expanded or retracted to fit a variety of pipes.

As shown in FIG. 5 and in greater detail in FIG. 7, the leveling device 10 is mounted to the attachment bracket 112 which, in turn, is mounted to the end of a pipe 106 or connector 108 to align the pipe relative to a vertical or horizontal axis and to provide a reference point where the pipe or connector, if extended, would intersect a second remotely-located pipe such as that shown at 110 in FIG. 5. The wing nuts 44 and 46 are first removed from the threaded studs 40 and 42 on the rear face 24 of the leveling device 10. An attachment bracket 112 can then be selected or adjusted to ensure that the longitudinal length between the channels 138 of the first and second mounting flanges 116 and 118, respectively, corresponds to the diameter of the pipe 106 or connector 108 onto which the leveling device 10 is to be mounted. The leveling device 10 is positioned relative to the attachment bracket 112 so that the stud 36 is received within the aperture 120 and the threaded studs 40 and 42 are received within the apertures 122 and 124, respectively. The wing nuts 44 and 46 can then be threaded onto the studs 40 and 42 and firmly tightened to further mount the leveling device 10 to the attachment bracket 112. The first and second mounting flanges 116 and 118 of the attachment bracket 112 are then mounted to opposite tangential edges of a pipe 106 or connector 108 by inserting the opposite tangential edges of the tubular member within the channels 138 in the first and second mounting flanges 116 and 118. The clamps 130 are then rotated to urge the threaded shaft 134 within the threaded aperture 132 and against the pipe 106 or connector 108 to retain the attachment bracket 112 thereto as shown in FIG. 7. When the mounting is complete, the switch 82 can be actuated to emit a stream of laser light through the aperture 34 in the front face 22 of the leveling device 10 which provides a point of light on the second remotely-located pipe 110 which denotes the location where the center of the pipe 106 or connector 108 would intersect the second remotely-located pipe 110 if extended to that point. Thus, the leveling device 110 assists a worker laying conduit to precisely determine where two pipes would intersect, and thus, the location where a connecting joint or tap-in should be located.

It is often desirable to fixedly mount the leveling device 10 in a vertical alignment. For example, an application may require that a reference point on a ceiling be determined from a point on a floor. As shown in FIG. 8, the leveling device 10 is gimballed to a stand 152 by an attachment bracket 150 so that the front face 22 of the leveling device 10 will tend to point vertically upwardly in order to locate, for example, a connection point on a ceiling.

The attachment bracket 150 comprises a U-shaped flange 154 and a rod 156. The U-shaped flange 154 is defined by a pair of arcuate arms 158 and 160, each having an aperture 162 and 164, respectively, located adjacent an outer end thereof, the apertures 162 and 164 can include an annular bearing 166. The arms 158 and 160 of U-shaped flange 154 intersect at a bight portion 168 thereof. One end of the rod 156 is mounted to the bight portion 168 and extends outwardly therefrom having a longitudinal axis 170 located within the same plane as an axis between the centers of the apertures 162 and 164 of the U-shaped flange 154. An opposite end of the rod 156 includes an axially-extending stud 172. The stud 172 can be a threaded or keyed and adapted to be received within a corresponding aperture in the stand 152.

The stand 152 comprises a U-shaped base 174 and an upwardly- extending arm 176. The U-shaped base 174 is defined by a pair of arcuate arms 178 and 180 which intersect at a bight portion 182 thereof. The bight portion 182 of the stand 152 includes an upper surface from which the arm 176 extends upwardly and includes a threaded or keyed recess 184 at an upper end 186 thereof.

In assembly, the attachment bracket 150 is mounted to the stand 152 by engaging the stud 172 of the rod 156 within the recess 184 of the arm 176. When completed, the attachment bracket 150 is retained parallel to a ground surface on which the U-shaped base 174 of the stand 172 rests.

In operation, the leveling device 10 is mounted to the U-shaped flange 154 of the attachment bracket 150 by engaging a pair of thumb screws 188 and 190 into a pair of apertures 192 located on the first and second sidewalls 30 and 32 adjacent the front face 22 on the leveling device 10. The mounting of the thumb screws 188 and 190 into the apertures 192 permit the leveling device 10 to rotate about the thumb screws 188 and 190 which are journaled within the bearings 166 in the apertures 162 and 164 on the attachment bracket 150. The weight of the leveling device 10 causes the leveling device 10 to hang in a vertical position which can be verified by noting the reading on the first and second levels 16 and 18, respectively. The laser alignment assembly 14 can then be activated to provide a reference point on a remote surface above the front face 22 of the leveling device 10.

While particular embodiments of the invention have been shown, it will be understood, of course, that the invention is not limited thereto since modifications may be made by those skilled in the art, particularly in light of the foregoing teachings. Reasonable variation and modification are possible within the scope of the foregoing disclosure of the invention without departing from the spirit of the invention.

Claims

CLAIMSThe embodiments for which an exclusive property or privilege is claimed are defined as follows:

1. A leveling device 10 comprising: a housing 12; a first level indicator 16 mounted to the housing 12; and a second level indicator 18 mounted to the housing 12 and movable between a first position and a second position; whereby in the first position the device 10 occupies less space for easy transportation and in the second position the second level indicator 18 is generally orthogonal to the first level indicator 16.

2. The device 10 of claim 1 wherein the housing 12 has at least one planar surface thereon whereby the housing 12 can easily rest on a planar surface.

3. The device 10 of claim 2 and further comprising a laser oscillator 80 mounted to the housing 12 to direct a laser beam along a first axis.

4. The device 10 of claim 3 wherein: the housing 12 has a forward surface 22 and a second axis; and the forward surface 22 of the housing 12 mounts the laser oscillator 80 in a position to direct the laser beam outwardly from the forward surface

22 thereof.

5. The device 10 of claim 4 wherein the first axis is generally parallel to the second axis.

6. The device 10 of claim 5 wherein: the housing 12 has a rearward surface 24; and the rearward surface 24 of the housing 12 includes an outwardly-extending protrusion 36 having a tip 38 thereon and a third axis.

7. The device 10 of claim 6 wherein the third axis is generally parallel to the first axis.

8. The device of claim 1 and further comprising a laser oscillator 80 mounted to the housing 12 to direct a laser beam along an axis.

9. The device 10 of claim 1 wherein: the housing 12 has a forward portion 22 and a longitudinal axis; and the forward portion 22 of the housing 12 mounts a laser oscillator 80 in a position to direct a laser beam outwardly from the forward portion 22 thereof.

10. The device 10 of claim 1 wherein the housing 12 has a rearward portion 24 including an outwardly-extending protrusion 36 having a tip 38 thereon.

11. The device 10 of claim 10 wherein the protrusion 36 has a first axis and the housing 12 has a second axis and the first axis is generally parallel to the second axis.

12. A device 10 for locating an extension of an existing conduit 108 having a first axis and an end comprising: a body 20; a laser oscillator 80 mounted to the body 20 in a position to direct a laser beam along a second axis; and a bracket 112 for mounting the body 20 to the conduit end wherein the second axis is generally aligned with the first axis; whereby when the device 10 is mounted to the end of the conduit 108 by the bracket 112 and the laser oscillator 80 is energized, the laser beam emitted therefrom will identify a location for the extension of the conduit 108.

13. The device of claim 12 wherein the body 20 has at least one planar surface thereon whereby the body 20 can easily rest on a planar surface.

14. The device of claim 12 wherein the bracket 112 includes at least one flange 116, 118 adapted to receive a rim of the conduit 108.

15. The device of claim 14 and further comprising a fastener 130 which engages both the conduit 108 and the bracket 112 to retain the bracket 112 against the conduit 108.

16. The device of claim 12 wherein the bracket 112 comprises a member adapted to engage a rim of a conduit 108.

17. The device of claim 16 wherein the bracket 112 further includes an aperture 120 and the body 20 includes a protrusion 36 whereby when the protrusion 36 is inserted in the aperture 120 the body 20 is mounted to the bracket 112.

18. The device of claim 12 and further comprising first and second level indicators 16, 18 mounted to the body 20.

19. The device of claim 18 wherein one of the first and second level indicators 16, 18 is movably mounted to the body 20 between a first position adjacent the body and a second position extended from the body 20.

20. The device of claim 18 wherein the second level indicator 18 is adapted to be positioned orthogonal to the first level indicator 16.