WO2020016880A1

WO2020016880A1 - Extruded aluminum spirit levels and method of manufacturing therefor

Info

Publication number: WO2020016880A1
Application number: PCT/IL2019/050728
Authority: WO
Inventors: Rafi BEN JOSEF; Yossi Palatshe
Original assignee: Kapro Industries Ltd
Priority date: 2018-07-19
Filing date: 2019-07-01
Publication date: 2020-01-23
Also published as: IL260681A

Abstract

A spirit level including a setting surface and a horizontal bubble vial wherein the spirit level is constituted by an extruded aluminum slice cut by an extrusion cutter from aluminum extruded through an extrusion die in a direction of extrusion, the extruded aluminum slice having an opposite parallel pair of cut surfaces perpendicular to the direction of extrusion and a uniform thickness peripheral surface between the opposite parallel pair of cut surfaces, the peripheral surface defining the spirit level's length and height in a front elevation view of the spirit level for setting a generally horizontal work surface relative to the horizontal and the spirit level's depth in the direction of extrusion.

Description

Extruded Aluminum Spirit Levels and Method of

Manufacturing Therefor

Field of the Invention

This present invention relates to spirit levels and method of manufacturing therefor.

Background of the Invention

Spirit levels have a spirit level body with a setting surface for setting on a work surface to be set. Spirit levels include a horizontal bubble vial for setting a generally horizontal work surface relative to the horizontal. Spirit levels are available in a wide range of lengths in a front elevation view of a spirit level for setting a generally horizontal work surface for different leveling purposes. The shortest spirit levels are so-called mini-levels are about 5 cm long. The longest spirit levels are so-called screed levels are about 100 cm long or even longer. Depending on their length, spirit levels can include one or more vertical bubble vials for setting a generally upright work surface relative to the vertical, one or more handgrips for assisting handling, and additional bubble vials for setting an inclined surface, for example, at 45° to the horizontal. Spirit levels often include one or more magnets for hand free use on magnetic surfaces.

Aluminum extrusion is a commonly employed manufacturing method for manufacturing spirit levels of all lengths ranging from the shortest spirit levels to the longest spirit levels. Extruded aluminum spirit levels are manufactured by extruding aluminum through an extrusion die in a direction of extrusion and thereafter cutting extrudate strips at predetermined lengths in the direction of extrusion. Extruded aluminum spirit levels can be classified into one of two types by their cross section profile, namely, box profile or I-beam profile. After extrusion, extrudates are punched or stamped to form dual open-sided recesses in a peripheral surface and/or dual open-sided cavities for subsequent mounting of bubble vials, handgrips, and the like. Thereafter, extrudates are painted and an opposite pair of end caps are mounted onto an opposite parallel pair of cut surfaces for both safety and aesthetic purposes.

Exemplary extruded aluminum spirit levels available from the Applicant include:

Catalog No. 246 Handy Level with a box profile and a horizontal bubble vial only https://kapro.com/product/246-handy-level-10cm/

Catalog No. 105 Topgrade with a box profile with horizontal vials calibrated at 0%, 1% and 2% percentages /105-i op grad e/

Catalog No. 176 Maxpro Professional I-beam level with an I-beam profile and handgrip https://kapro.com/product/176-maxpro-magnetic/

There is a need for extruded aluminum spirit levels which are simpler and less expensive to manufacture than present commercially available extruded aluminum spirit levels. Summary of the Invention

The present invention is directed towards extruded aluminum spirit levels and method of manufacturing therefor. The extruded aluminum spirit levels of the present invention differ from commercially available extruded aluminum spirit levels in terms of the geometries of the extrusion dies from which they are manufactured. In accordance with present extrusion manufacturing, a spirit level’s length is set by a length of an extrudate strip cut by an extrusion cutter along a direction of extrusion. In contradistinction to present extrusion manufacturing, in accordance with the present invention, a spirit level’s length is set by an extrusion die’s width, namely, transverse to a direction of extrusion therethrough. Accordingly, in a front elevation view of an extruded aluminum spirit level in accordance with the present invention for setting a generally horizontal work surface to the horizontal, a spirit level’s three dimensions, length, height and depth are defined as follows: its length and height are defined by its uniform thickness peripheral surface between its opposite pair of parallel cut surfaces and its depth is defined between its opposite pair of parallel cut surfaces in the direction of extrusion.

Extruded aluminum spirit levels of the present invention are formed from extrusion dies having different die geometries as follows: Simple die geometries having peripheral recesses only such that a resulting extrudate slice has a uniform thickness solid spirit level body between an opposite parallel pair of cut surfaces with a corresponding number of dual open-sided recesses in its peripheral surface. More complicated die geometries having at least one cavity such that a resulting extrudate slice has a uniform thickness spirit level body between an opposite parallel pair of cut surfaces with a corresponding number of dual open-sided cavities. The difference between a dual open-sided recess and a dual open-sided cavity is that in a front elevation view of a spirit level for setting a generally horizontal work surface relative to the horizontal, a dual open-sided recess defines an open shape and a dual open-sided cavity bounds a closed shape. And still more complicated die geometries resulting in extrudate slices having a combination of dual open-sided recesses and dual open-sided cavities. Such dual open-sided recesses and dual open-sided cavities are employed for mounting of bubble vials, handgrips, magnets, and the like, therein. In accordance with the present invention, an extruded aluminum spirit level body is manufactured with integrally formed recesses and/or cavities during extrusion thereby precluding presently required punching and/or stamping.

Further manufacturing steps in accordance with the present invention include inter alia mounting bubble vials, handgrips, magnets, and the like, into integrally formed dual open-sided recesses and/or cavities, painting, and the like. Advantageously, the method of manufacturing extruded aluminum spirit levels of the present invention precludes the hitherto required need for an opposite pair of end caps. Bubble vial holders are preferably employed for mounting bubble vials in dual open-sided recesses and/or cavities. Bubble vial holders can be intended for snap fit, gluing, and the like, in dual open-sided recesses and/or cavities. Extruded aluminum spirit levels of the present invention can be manufactured in the same wide range of lengths similar to present commercially available extruded aluminum spirit levels and with the same optional features in terms of multiple bubble vials, handgrips, magnets, and the like.

Brief Description of the Drawings

In order to understand the invention and to see how it can be carried out in practice, preferred embodiments will now be described, by way of non-limiting examples only, with reference to the accompanying drawings in which similar parts are likewise numbered, and in which:

Fig. 1 is a schematic drawing showing cutting a conventional extruded aluminum box profile extrudate strip;

Fig. 2 is a transverse cross section of the Figure 1 extruded aluminum box profile extrudate strip along line 2-2 in Figure 1;

Fig. 3 is a schematic drawing showing cutting a conventional extruded aluminum I-beam profile extrudate strip;

Fig. 4 is a transverse cross section of the Figure 3 extruded aluminum I- beam profile extrudate strip along line 4-4 in Figure 3;

Fig. 5 is a front perspective view of a commercially available box profile mini-level;

Fig. 6 is a transverse cross section of the Figure 5 mini-level along line 6-6 in Figure 5 ;

Fig. 7 is a front perspective view of a commercially available I-beam profile spirit level;

Fig. 8 is a transverse cross section of the Figure 7 spirit level along line 8-8 in Figure 7 ;

Fig. 9 is a schematic drawing showing cutting a solid body extrudate slice in accordance with the present invention; Fig. 10 is a schematic drawing showing cutting an extrudate slice bounding a dual open-sided cavity in accordance with the present invention;

Fig. 11 is a front perspective view of a mini-level in accordance with the present invention;

Fig. 12 is a front perspective view of a toolbox level in accordance with the present invention;

Fig. 13 is a front perspective view of an alternative toolbox level in accordance with the present invention;

Fig. 14 is a front perspective view of a spirit level with a handgrip in accordance with the present invention;

Fig. 15 is a front perspective view of a solid body spirit level in accordance with the present invention;

Fig. 16 is a front perspective view of an alternative solid body spirit level in accordance with the present invention;

Fig. 17 is a front perspective view of another alternative solid body spirit level in accordance with the present invention;

Fig. 18 is a front perspective view of another spirit level in accordance with the present invention; and

Fig. 19 is a front perspective view of another spirit level in accordance with the present invention.

Detailed Description of the Drawings

Figure 1 and Figure 2 show a box profile extrudate 10 pushed through an extrusion die in a direction of extrusion indicated by arrow A and thereafter cut by an extrusion cutter (not shown) to form a box profile extrudate strip 11 in accordance with present commonly employed aluminum extrusion manufacturing method. The box profile extrudate strip 11 includes an opposite parallel pair of cut surfaces 12 perpendicular to the direction of extrusion A and a rectangular uniform thickness peripheral surface 13 extending lengthwise between the opposite parallel pair of cut surfaces 12. The extrudate strip 11 is cut along the direction of extrusion A to determine a length L of a spirit length in accordance with its intended application. The peripheral surface 13 determines the height H and depth D of a spirit level. Typical range of height H is from about 2.5 cm to 5 cm depending on an intended application of a spirit level. Typical range of depth D is from about 15 mm to 30 mm depending on an intended application of a spirit level.

Figure 3 and Figure 4 show an I-beam profile extrudate 20 pushed through an extrusion die in a direction of extrusion indicated by arrow A and thereafter cut by an extrusion cutter (not shown) to form an I-beam profile extrudate strip 21 in accordance with present commonly employed aluminum extrusion manufacturing method. The I-beam profile extrudate strip 21 includes an opposite parallel pair of cut surfaces 22 perpendicular to the direction of extrusion A and an I-beam web 23 extending lengthwise between the opposite parallel pair of cut surfaces 22. The extrudate strip 21 is cut along the direction of extrusion A to determine a length L of a spirit length in accordance with its intended application. The I-beam web 23 determines the height H and depth D of a spirit level. Typical range of height H is from about 2.5 cm to 5 cm depending on an intended application of a spirit level. Typical range of depth D is from about 15 mm to 30 mm depending on an intended application of a spirit level.

Figure 5 and Figure 6 show a commercially available box profile mini-level 30 having a horizontal bubble vial 31 only and an opposite pair of end caps 32. The mini-level 30 has a 9 cm length L, a 5 cm height H and a 2 cm depth D in a front elevation view of a spirit level for setting a generally horizontal work surface relative to the horizontal.

Figure 7 and Figure 8 show a commercially available I-beam profile spirit level 40 having a horizontal bubble vial 41, a vertical bubble vial 42, a 45° inclined bubble vial 43, a handgrip 44 and an opposite pair of end caps 46. The spirit level 40 has a 80 cm length L, a 5 cm height H and a 3 cm depth D in a front elevation view of a spirit level for setting a generally horizontal work surface relative to the horizontal.

Figure 9 shows a solid body extrudate 50 formed from extruded material pushed through an extrusion die in a direction of extrusion indicated by arrow A. The solid body extrudate 50 is cut by an extrusion cutter (not shown) into extrudate slices 51. Each extrudate slice 51 includes an opposite parallel pair of cut surfaces 52 perpendicular to the direction of extrusion A and a uniform thickness peripheral surface 53 between the opposite parallel pair of cut surfaces 52. The peripheral surface 53 bounds a uniform thickness solid body in the direction of extrusion A between the opposite parallel pair of cut surfaces 52. The width of an extrusion die transverse to the direction of extrusion A therethrough determines a spirit level’s length L. The extrusion die’s height determines a spirit level’s height H. The distance between the opposite parallel pair of cut surfaces 52 as determined by the length of extruded aluminum passed through an extrusion cutter in the direction of extrusion A between cutting operations determines a spirit level’s depth D.

Figure 10 shows the extrudate slice 51 bounds a single dual open-sided cavity 54 between the opposite parallel pair of cut surfaces 52.

Figure 11 shows a mini-level 60 similar to the mini-level 30 in terms of application but differing therefrom in terms of its method of manufacture. The mini-level 60 has a 10 cm length L, a 5 cm height H and a 3 cm depth D in a front elevation view for setting a generally horizontal work surface along a X axis in a horizontal X-Y plane. The mini-level 60 includes an extruded aluminum mini level body 61 manufactured from an extruded aluminum slice. The extruded aluminum mini-level body 61 includes an opposite parallel pair of cut surfaces 62 and a uniform thickness peripheral surface 63 extending therebetween. The peripheral surface 63 includes a setting surface 64A for setting on a work surface and an uppermost major horizontal surface 64B opposite the setting surface 64A such that the setting surface 64A and the uppermost major horizontal surface 64B constitute an opposite pair of major horizontal surfaces 64. The peripheral surface 63 includes an opposite pair of minor upright end surfaces 66A and 66B extending between the setting surface 64A and the uppermost major horizontal surface 64B. The opposite pair of major horizontal surfaces 64 and the opposite pair of minor upright end surfaces 66 bound a dual open-sided dual cavity 67 between the opposite parallel pair of cut surfaces 62. The uppermost major horizontal surface 64B is formed with a dual-open sided central horizontal bubble vial recess 68 for receiving a bubble vial holder 69 having a horizontal bubble vial 71. The extruded aluminum mini-level body 61 includes an upright strut 72 between the setting surface 64A and the dual open-sided central horizontal bubble vial recess 68 for supporting same.

Figure 12 shows a toolbox level 80A so named because it has a 16 cm to 25 cm length L, a 5 cm height H and a 2 cm depth D in a front elevation view for setting a generally horizontal work surface along a X axis in a horizontal X-Y plane. The toolbox level 80A includes an extruded aluminum toolbox level body 81 manufactured from an extruded aluminum slice. The extruded aluminum toolbox level body 81 includes an opposite parallel pair of cut surfaces 82 and a uniform thickness peripheral surface 83 extending therebetween. The peripheral surface 83 includes a setting surface 84A for setting on a work surface and an uppermost major horizontal surface 84B opposite the setting surface 84A such that the setting surface 84A and the uppermost major horizontal surface 84B constitute an opposite pair of major horizontal surfaces 84. The peripheral surface 83 includes an opposite pair of minor upright end surfaces 86A and 86B extending between the setting surface 84 A and the uppermost major horizontal surface 84B. The opposite pair of major horizontal surfaces 84 and the opposite pair of minor upright end surfaces 86 bound a dual open-sided multiple cavity 87 between the opposite parallel pair of cut surfaces 82. The uppermost major horizontal surface 84B is formed with a dual open-sided central horizontal bubble vial recess 88 for receiving a bubble vial holder 89 having a horizontal bubble vial 91. The extruded aluminum toolbox level body 81 includes an upright stmt 92 between the setting surface 84A and the central horizontal bubble vial recess 88 for supporting same.

The toolbox level body 81 includes a dual open-sided vertical bubble vial cavity 93 and a dual open- sided inclined bubble vial cavity 94 between the setting surface 84A and the uppermost major horizontal surface 84B and between the opposite pair of minor upright end surfaces 86A and 68B. The dual open-sided vertical bubble vial cavity 93 is bound between two upright struts 96. The inclined bubble vial cavity 94 is bound between two inclined struts 97. The upright struts 96 and the inclined struts 97 are formed during extmsion of the toolbox level body 81 and therefore extend between the opposite parallel pair of cut surfaces 82. The dual open-sided vertical bubble vial cavity 93 receives a bubble vial holder 98 with a vertical bubble vial 99 therein. The dual open-sided inclined bubble vial cavity 94 receives a bubble vial holder 101 with an inclined bubble vial 102 therein. Suitable inclinations include 30°, 45°, and the like.

Figure 13 shows an alternative toolbox level 80B similar to toolbox level

80A and differing therefrom in terms of its vertical bubble vial 99 and its inclined bubble vial 102. The toolbox level 80B has a 16 cm to 25 cm length L, a 5 cm height H and a 2 cm depth D in a front elevation view for setting a generally horizontal work surface. The latter 80B includes a setting surface 84 A, an uppermost major horizontal surface 84B, an upright left end surface 86 A and an inclined right end surface 86B. The setting surface 84A and the uppermost major horizontal surface 84B both extend beyond the upright left end surface 86B to form a dual open-sided vertical bubble vial recess 103. The setting surface 84A and the uppermost major horizontal surface 84B both extend beyond the upright right end surface 86B to form a dual open-sided inclined bubble vial recess 104.

Figure 14 shows a spirit level 110 similar to the spirit level 40 in terms of application but differing therefrom in terms of its method of manufacture. The spirit level 110 has a length L, a 5 cm height H and a 3 cm depth D in a front elevation view for setting a generally horizontal work surface along a X axis in a horizontal X-Y plane. The spirit level 110 includes a dual open-sided horizontal bubble vial recess 111 for mounting a horizontal bubble vial 112 therein, a dual open-sided vertical bubble vial cavity 113 for mounting a vertical bubble vial 114 therein, a dual open-sided inclined bubble vial cavity 116 for mounting a 45° inclined bubble vial 117 therein, and a dual open-sided handgrip cavityl l8 for mounting a handgrip 119 therein. The broken lines indicate the spirit level 110 can be manufactured in different lengths similar to box profile spirit levels starting from, say, 30 cm through to screed level lengths.

Figure 15 to Figure 17 show three spirit levels 120, 130 and 140 manufactured from extrudate slices 121, 131, and 141. The spirit levels 120, 130 and 140 have corresponding setting surfaces 122, 132 and 142 and corresponding horizontal bubble vials 123, 133 and 143 for setting a horizontal work surface. The spirit levels 120, 130 and 140 have different shaped major uppermost surfaces 124, 134 and 144 opposite their respective setting surfaces 122, 132 and 142. The major uppermost surfaces 124, 134 and 144 can include inter alia inclined sections, partial circular sections, partial elliptical sections, and the like. The spirit levels 120, 130 and 140 have corresponding dual open-sided horizontal bubble vial recesses 126, 136 and 146 for mounting the horizontal bubble vials 123, 133 and 143 therein.

Figure 18 shows a spirit level 150 having a 15 cm length L, a 15 cm height

H and a 3 cm depth D in a front elevation view for setting a horizontal work surface. The spirit level 150 has a horizontal bubble vial 151, a vertical bubble vial 152, and a 45° inclined bubble vial 153. The spirit level 150 is formed with dual open-sided recesses 154 for snugly receiving magnets.

Figure 19 shows a spirit level 160 for use as a surface level for simultaneously setting a horizontal work surface along a X-axis and a Y-axis perpendicular to the X axis in a horizontal X-Y plane. The spirit level 160 has a 25 cm length L, a 15 cm height H and a 15 cm depth D in a front elevation view for setting a horizontal work surface. The spirit level 160 has a horizontal bubble vial 161 for setting the work surface along the X-axis and a horizontal bubble vial 162 for setting the work surface along the Y-axis.

While particular embodiments of the present invention are illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention.

Claims

1. A spirit level for setting a generally horizontal work surface relative to the horizontal, the spirit level comprising:

a spirit level body having a setting surface for setting on the generally horizontal work surface,

a horizontal bubble vial mounted in said spirit level body parallel to said setting surface for setting the generally horizontal work surface relative to the horizontal,

said spirit level body being constituted by an extruded aluminum slice cut by an extrusion cutter from aluminum extruded through an extrusion die in a direction of extrusion,

said extruded aluminum slice having an opposite parallel pair of cut surfaces perpendicular to said direction of extrusion and a uniform thickness peripheral surface between said opposite parallel pair of cut surfaces,

said peripheral surface defining the spirit level’s length and height in a front elevation view of the spirit level for setting the generally horizontal work surface and the spirit level’s depth in said direction of extrusion.

2. The level according to claim 1 wherein said peripheral surface includes a dual open-sided horizontal bubble vial recess between said opposite parallel pair of cut surfaces for receiving said horizontal bubble vial.

3. The level according to claim 2 wherein said peripheral surface includes a dual open-sided bubble vial recess between said opposite parallel pair of cut surfaces for receiving an additional bubble vial inclined with respect to said horizontal bubble vial.

4. The level according to any one of claims 1 to 3 wherein said peripheral surface bounds at least one dual open-sided cavity between said opposite parallel pair of cut surfaces.

5. The level according to any one of claims 1 to 4 wherein said spirit level body includes a first horizontal bubble vial for setting the horizontal work surface with respect to a X axis in a horizontal X-Y plane and a second horizontal bubble vial for setting the horizontal work surface with respect to a Y axis perpendicular to said X axis in said horizontal X-Y plane.

6. The level according to any one of claims 1 to 5 wherein a spirit level has the following external dimensions in said front elevation view: at least 5 cm length, from 15 mm to 15 cm height and from 10 mm to 15 cm depth.

7. A method of manufacturing a spirit level comprising the steps of:

(a) extruding aluminum through an extrusion die along a direction of extrusion;

(b) cutting an extruded aluminum slice from the extruded aluminum,

the extruded aluminum slice constituting a spirit level body having an opposite parallel pair of cut surfaces perpendicular to the direction of extrusion and a uniform thickness peripheral surface between the opposite parallel pair of cut surfaces,

the peripheral surface including a setting surface for setting on a work surface

the peripheral surface defining the spirit level’s length and height in a front elevation view of the spirit level for setting a generally horizontal work surface relative to the horizontal and the spirit level’s depth in the direction of extrusion; and (c) mounting a horizontal bubble vial in the spirit level body parallel to the setting surface for setting a generally horizontal work surface relative to the horizontal.

8. The method according to claim 7 wherein the peripheral surface includes a dual open- sided horizontal bubble vial recess between the opposite parallel pair of cut surfaces for receiving the horizontal bubble vial.

9. The method according to claim 8 wherein the peripheral surface includes a dual open-sided bubble vial recess between the opposite parallel pair of cut surfaces for receiving an additional bubble vial inclined with respect to the horizontal bubble vial.

10. The method according to any one of claims 7 to 9 wherein the peripheral surface bounds at least one dual open-sided cavity between the opposite parallel pair of cut surfaces.

11. The method according to any one of claims 7 to 10 wherein the spirit level body includes a first horizontal bubble vial for setting the horizontal work surface with respect to a X axis in a horizontal X-Y plane and a second horizontal bubble vial for setting the horizontal work surface with respect to a Y axis perpendicular to said X axis in the horizontal X-Y plane.

12. The method according to any one of claims 7 to 11 wherein a spirit level has the following external dimensions in said front elevation view: at least 5 cm length, from 15 mm to 15 cm height and from 10 mm to 15 cm depth.