Abstract:
The present invention is directed generally to tools that are lightweight, high quality, durable, rigid and strong. For example, various tools used to level items and/or as a straight edge for aligning or drawing lines on items may be designed in an improved or augmented beam style so that they are lightweight, strong, durable and rigid so as to hold their shape under stress or return to their original shape after being stressed. In various exemplary embodiments, the beam style level and/or straight edge may have a first main elongated side to which two elongated perpendicular sides are connected or coupled. At least one or more higher strength elongated sides, for example a second elongate side, may be comprised of a closed or triangular shaped side. For example, the second elongated side may be, for example, a triangular shaped construction.

Description:
This application claims priority to, and is a continuation of, U.S. patent application Ser. No. 14/144,399, filed on Dec. 30, 2013, now to issue on Apr. 26, 2016 as U.S. Pat. No. 9,321,297, U.S. patent application Ser. No. 13/295,457, filed on Nov. 14, 2011, now U.S. Pat. No. 8,615,892, U.S. patent application Ser. No. 12/562,117, filed on Sep. 17, 2009, now U.S. Pat. No. 8,056,249, U.S. patent application Ser. No. 12/168,144, filed on Jul. 6, 2008, now U.S. Pat. No. 7,607,235, U.S. patent application Ser. No. 11/408,176, filed on Apr. 21, 2006, now U.S. Pat. No. 7,409,772, which claims benefit of U.S. Provisional Patent Application No. 60/673,811, filed Apr. 22, 2005. These prior patent applications are hereby incorporated by reference for all purposes. 
    
    
     FIELD OF THE INVENTION 
     The present invention pertains to methods and various apparatus for tools. For example, the invention involves various apparatus and methods for high strength and durability level and/or straight edge tools. 
     BACKGROUND 
     Various levels and straight edge tools have been known in the past for determining whether an item is level and assisting in leveling an item and/or drawing a straight edge in, for example, the building trades. Of the various types of levels, there are generally two types of levels available for use in the building industry; box style and “I” beam style levels. The box style level is, as its name implies, shaped like a rectangular box having four sides formed in an elongated manner with the level indicators or bubble vials encased within the box shape. The I beam style level is, as its name implies, shaped like an I beam having only three main features or “sides” formed in an elongated manner, with a first main side to which the second and third main sides are attached at opposite ends (of the first main side) and are perpendicular with the first main side, so that from a cross section view the level generally has an “I” shape. These same shapes may be commonly used for a straight edge as well as for establishing “level” geometry. 
     These tools may often be used in the building trades. As such, a level and/or straight edge used in the building trades may be subjected to various adverse conditions including, being stepped upon by a worker, being thrown down hard, being dropped from high places, being transported in the bed of a pickup truck, being left out in the weather, etc. Thus, they must exhibit various characteristics, for example, strength, rigidity, durability, consistent and repeatable accuracy. It is also desirable that these products be light in weight, etc. 
     In general, a box level may be stronger and more ridged than an I beam style level, but it is typically heavier in weight than an I beam style. An I beam level and/or straight edge may not be strong or rigid enough and may be too flimsy such that it may be bent or rendered not true or flat by heavy impact or torque. For example, the typical I beam style level and/or straight edge may be twisted about its elongated axis because the design has very little strength in this direction, particularly when it is made of lightweight materials such as aluminum or plastic in thin sections. 
     To be consistently true at determining whether a working surface or item is level or for determining or creating a straight line, a level and/or straight edge must be rigid enough so that a reasonable amount of abuse and heavy impact or excessive torque, that the level or straight edge device receives, does not permanently distort it and rendering it unable to function properly. In the case of I beam style level and/or straight edge made of lightweight materials in thin sections, the product will not be as strong as desired. However it will be lower in weight and cost. In the past, the box level was better for strength and rigidity, but the cost to manufacture and weight were higher than I beam style levels and/or straight edges. 
     Therefore, a level and/or straight edge having improved cost and/or lower weight over the box style with similar, comparable or better durability, strength and rigidity to the box style would be desirable and prove particularly useful in the building trades. 
     SUMMARY 
     The present invention is directed generally to tools that are lightweight, high quality, durable, rigid and strong. For example, various tools used to level items and/or as a straight edge for aligning or drawing lines on items may be designed so that one or more of the sides are designed to be stronger or higher strength than one or more of the other sides, so as to give the device more strength and/or rigidity. In one embodiment, the device may be a level and/or straight edge device having an improved or augmented I beam style so that they are lightweight, strong, durable and rigid so as to hold their shape under stress and after being stressed. The invention is particularly useful for levels and/or straight edge tools used in the building trades, for example, a carpenter level and/or straight edge. 
     In various exemplary embodiments, the I beam style level and/or straight edge may have a first main elongated side to which two elongated perpendicular sides are connected or coupled. However, at least one or more higher strength elongated sides, for example a second elongate side, may be comprised of a closed or box shaped side that is attached to the first main elongated side in, for example, a perpendicular orientation thereto. For example, the second elongated side may be, for example, a box shaped construction. The box shaped side may be larger than the typical side and may be, for example, hollow, contain strengthening walls, or be made of a solid material. The box shape construction may add additional strength and rigidity so that the I beam style level and/or straight edge may retain its true shape even when dropped, stressed and/or twisted about its horizontal axis, independent of it being made from lightweight and/or more flexible materials such as aluminum, magnesium, plastic, wood, etc. In one variation, the I beam style level and/or straight edge may be designed so that the sides are integrally formed and may be formed using, for example, an extrusion process. In another variation, one of the perpendicular sides may be open and the other perpendicular side may be closed. 
     In another exemplary embodiment, the I beam style level and/or straight edge may have one or more perpendicular members or sides that increase the strength and/or rigidity but are made of a different shape. For example, the I beam style level and/or straight edge may have a concave surface on one or more sides of a box type structure. In another variation, the support or strengthening side may be in the shape of a triangle. The triangle may be hollow or include one or more strengthening walls within it. 
     In a still further exemplary embodiment, the I beam style level and/or straight edge may have a typical structure including a first main elongated side to which second perpendicular elongated side and a third perpendicular elongated side are connected. An elongated strengthening member may be attached along the planar surface of one or both of the second perpendicular elongated side and a third perpendicular elongated side. 
     In even further embodiments, the level items and/or straight edge device may have other geometrical shapes that provide improved rigidity without necessarily having strictly an I beam construction. For example, the device may have a cross section that is shaped like a “g” or “P.” Both ends of the structure may be closed. Further, the embodiments may have varying geometry features including non rectangular features, non-uniform wall thicknesses, etc. 
     As should be appreciated, although additional exemplary embodiments and variations of the invention are provided in the Detailed Description section below, neither this Summary nor the Detailed Description section below contain all possible embodiments or variations of the present invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Some of the objects, features and advantages of the present invention will become more readily apparent to those skilled in the art upon reading the following detailed description, in conjunction with the appended drawings, in which: 
         FIG. 1  illustrates a perspective view of a level and/or straight edge, according to at least one exemplary embodiment of the invention; 
         FIG. 2  illustrates a side view of the level and/or straight edge shown in  FIG. 1 , according to at least one exemplary embodiment of the invention; 
         FIG. 3  illustrates a top view of the level and/or straight edge shown in  FIG. 1 , according to at least one exemplary embodiment of the invention; 
         FIG. 4  illustrates a bottom view of the level and/or straight edge shown in  FIG. 1 , according to at least one exemplary embodiment of the invention; 
         FIG. 5  illustrates a cross-section view of the level and/or straight edge shown in  FIG. 1 , according to at least one exemplary embodiment of the invention; 
         FIG. 6  illustrates an inside view of an end cap for the level and/or straight edge shown in  FIG. 1 , according to at least one exemplary embodiment of the invention; 
         FIG. 7  illustrates a cross-section view (or end view without end caps) of the level and/or straight edge, according to at least one other exemplary embodiment of the invention; 
         FIG. 8  illustrates a cross-section view (or end view without end caps) of the level and/or straight edge, according to at least one other exemplary embodiment of the invention; 
         FIG. 9  illustrates a cross-section view (or end view without end caps) of the level and/or straight edge, according to at least one other exemplary embodiment of the invention; 
         FIG. 10  illustrates a cross-section view (or end view without end caps) of the level and/or straight edge, according to at least one other exemplary embodiment of the invention; 
         FIG. 11  illustrates a cross-section view (or end view without end caps) of the level and/or straight edge, according to at least one other exemplary embodiment of the invention; 
         FIG. 12  illustrates a cross-section view (or end view without end caps) of the level and/or straight edge, according to at least one other exemplary embodiment of the invention; and 
         FIGS. 13A-13F  illustrates several cross-section variations (or end view without end caps) which exemplifies some of the range of alternative embodiments of the invention. 
     
    
    
     DETAILED DESCRIPTION 
     The present invention is directed generally to tools that may be lighter in weight, stronger, more rigid and more durable than those presently available. As such, the present invention includes various embodiments showing devices and methods for various tools that may, at least in part, include a side strengthening member. For example, an I beam style level and/or straight edge may have a first main elongated side to which two elongated perpendicular sides are connected or coupled. In various embodiments, at least one or more higher strength structures are used to augment one or more of the perpendicular elongated sides. The invention may be particularly beneficial to building tools such as levels and/or straight edges that need to maintain their original shape, planarity and squared sides orientation (all sides at right angles to one another and the surfaces flat). 
     Referring to  FIGS. 1-5 , an I beam style level and/or straight edge according to at least one exemplary embodiment of the invention is presented.  FIG. 1  shows a perspective view of the I beam style level and/or straight edge  100 . The I beam style level and/or straight edge  100  may be a three level indicator or level vial design having a frame that may include, for example, a top elongated bar  105  formed perpendicular with and connected to a first end of main frame side  108 . The main frame side  108  may also be formed with or connected at a second end (e.g., a bottom end) to, for example, a closed structure such as box structure  110 , and oriented generally perpendicular to the orientation of the main frame side  108 . The main frame side  108  may also house one or more level indicators or vials, for example, the level indicators or level vials  125 ,  130 , and  135 , which may be the mounted in a vertical, horizontal, and 45 degree angle, respectively to the horizontal axis of the I beam style level and/or straight edge  100 . The main frame side  108  may also include various holes or cut outs therein,  140 ,  145 ,  150 ,  155 , that may be used for reducing weight, hanging the I beam style level and/or straight edge  100 , or grasping/handling of the I beam style level and/or straight edge  100 . The I beam style level and/or straight edge  100  may also include end cap  115  and end cap  120  at the far ends of the beam frame. These end caps  115  and  120  may be pressed, screwed, snapped, or glued onto the ends of the beam. 
     The I beam styled structure including the top elongated bar  105 , main frame side  108 , and box structure  110  may be formed integrally together using, for example, an extrusion process that extrudes a continuously integral beam. The extruded beam may then be cut to length. Although any length may be possible, some exemplary lengths may include 1 foot, 2 foot, 4 foot, etc. Alternatively, the I beam style shape may be formed by mounting the three sides together using, for example, brazing or welding. The I beam style structure may be made of a lightweight yet strong material, for example, a metal such as aluminum, magnesium, or any other material that may be extruded and maintain a squared I beam shape. One alternative material may include various types of plastics. Once the solid beam is formed, the holes or cut outs therein,  140 ,  145 ,  150 ,  155 , may be formed by, for example, a punching or cutting operation. Then, the level indicators or level vials  125 ,  130 , and  135  may be attached to the main frame side  108 . Finally, the end caps  115  and  120  may attached onto the ends of the I beam style structure as described previously. 
     Referring now to  FIG. 2 , a side view of the I beam level and/or straight edge  100  according to at least one embodiment is shown. As indicated above, the main frame side  108  may also house one or more level indicators or vials, for example, the level indicators or level vials  125 ,  130 , and  135 . The level indicators or level vials  125 ,  130 , and  135  may include vials of liquid with a gas bubble floating therein and alignment windows  205 ,  215  and  220 . The vials may be mounted within a casing made of, for example, plastic. The plastic casing may have two halves (one on each opposing sides of the main frame  108 ) that may be coupled, mounted or connected to the main frame side  108  using, for example, mounting screws  210 , rivets, or other type of fasteners. Alternatively, they may be adhesively attached thereto. In any case, the level indicators or level vials  125 ,  130 , and  135  may be the mounted in a vertical, horizontal, and 45 degree angle, respectively to the horizontal axis of the I beam style level and/or straight edge  100 . 
     As may be seen more clearly from  FIG. 2 , the top elongated bar  105  may be thin relative to the thickness of box structure  110 . The top elongated bar  105  may be of a thickness typically found on I beam levels and/or straight edges. However, box structure  110  may be thicker, for example 2 to 5 times as thick as top elongated bar  105 , to add additional strength and rigidity so that the I beam style level and/or straight edge  100  will retain its original squared off shape if it is stressed or twisted about the horizontal axis. 
     Referring now to  FIG. 3 , a top view of the I beam style level and/or straight edge  100  according to at least one embodiment is shown. The top elongated bar  105  may include, for example, a flat surface  305  for placing on a working surface to determine if it is level or to be used as a straight edge. The flat surface  305  may include a viewing window  310  for viewing the level indicator or level vial  215  so as to determine if a surface or working piece is level. The flat surface may be smooth or textured. As can be seen, the end caps  115  and  120  may be, for example, rounded or convex in shape. Alternatively, the end caps  115  and  120  may be squared off or eliminated altogether. 
     Referring now to  FIG. 4 , a bottom view of the level and/or straight edge  100  is shown, according to at least one exemplary embodiment of the invention. The closed or box structure  110  has a flat surface  405  for placing on a working surface to determine if the work surface is level and/or flat, or for using as a straight edge. 
     Referring now to  FIG. 5 , a cross-section view of the level and/or straight edge taken across the line  5 - 5  of  FIGS. 1 and 2  is shown, according to at least one exemplary embodiment of the invention. The top elongated bar  105  is formed perpendicular to main frame side or bar  108  and may have short ears  530  and  535  that are parallel with main frame side or bar  108 . The ears  530  and  535  may add rigidity to the structure. Two halves of the level indicator or level vial  130 , side  130 A and side  130 B, are attached to opposite sides of main frame side or bar  108 . End cap  115  closes off the far end of the I beam structure. The closed or box structure  110  may have, for example, four sides that form a rectangle that adds strength and/or rigidity to the typical simple I beam structure. The closed or box structure  110  may be the same width as the top elongated bar  105 . The closed or box structure  110  height may also be greater than the height of top elongated bar  105 . In fact, in various embodiments, the thickness of the top wall of closed or box structure  110  (as well as the other walls) may be the same thickness as the top elongated bar  105  and/or the main frame side or bar  108  so as to keep the weight as light as possible. For example, the thickness may be, for example, in a range of approximately 1/32 to ⅛ of an inch. In any case, the closed or box structure  110  may include one or more internal strengthening walls, for example, walls  505  and  510 , and hollow areas  515 ,  520  and  525 . Using the internal support walls  505  and  510  along with the hollow areas  515 ,  520 , and  525 , in the box structure  110  may increase the strength and rigidity while keeping the device lighter weight. The bottom surface or wall  405  may be flat in this exemplary embodiment and the thickness of all the walls of the closed or box structure  110  may, but need not be approximately the same. 
     Referring now to  FIG. 6 , an inside view of an end cap, for example end cap  115 , for the level and/or straight edge is shown, according to at least one exemplary embodiment of the invention. The end cap  115  may be designed to fit snuggly to the I beam style structure. For example, walls  625  and  630  may be formed of a shape and at a distance apart so as to fit snuggly to the I shape of the elongated bar  105 , main frame side or bar  108 , and top wall of the box structure  110 . Further, three boxes  605 ,  610  and  620  may be formed to fit snuggly within the hollow areas  515 ,  520 , and  525 , of the closed or box structure  110 . The three boxes  605 ,  610  and  620  may themselves be hollow having voids  635 ,  640  and  645 . The end cap  115  may be made of a lightweight and durable material including, for example, plastic, that may be molded and/or cut to shape. In one variation the end caps  115  and  120  may be adhesively attached. In one variation the end caps may be eliminated or replaced with plugs made of plastic or rubber to plug the holes in the closed or box structure. 
     Although not illustrated above, the side surfaces or bottom surface of the closed or box surface may include one or more scales that runs lengthwise for the I beam level and/or straight edge  100 . The scale(s) may be in English and/or Metric gauge and be used for measuring. The scale(s) may be, for example, screen printed or etched into the surface of the sides. Further, the surfaces  305  and  405  may be smooth or textured. The textured surface may be formed on the surface or by a coating, for example, a rubber or plastic coating. Further, although this embodiment shows the closed or box structure used as only one end of the I beam shaped level and/or straight edge  100 , this closed or box structure may be used on both ends of the main frame side or bar  108 , rather than using elongated bar  105 . In either case, using either one or two closed or box shapes will increase the rigidity of the structure and reduce the rotational twisting about the horizontal axis that might deform the squared shape of the I beam shaped level and/or straight edge  100 . Similarly, the elongated bar  105  is shown as an open section that may take on any shape, for example, a C shape. 
     Referring now to  FIG. 7 , the cross-section view (or end view without end caps) of at least one other embodiment for the level and/or straight edge is shown. In this example, a top bar  705  and bottom bar  710  may be formed parallel to one another and perpendicular with a main frame side or bar  708 . The structure may be integrally formed. A closed bar or box structure  715  may be formed separately and may have a hollow area  720 . The closed bar or box structure  715  may be formed separately and may be made of a different or the same materials as the I shaped structure. Although not shown, the hollow area  720  may include one or more support walls similar to those shown in  FIG. 5 . In any case, the box structure  715  may be connected to the bottom bar  710  at surface  725  using any reasonable method, for example, adhesive, welding, brazing, soldering, etc. In some cases, the method of connecting the two separate structures may add more strength and/or rigidity. 
     Referring now to  FIG. 8 , the cross-section view (or end view without end caps) of at least one other embodiment for the level and/or straight edge is shown. In this example, a top bar  805  and bottom closed structure or box  810  may be formed perpendicular to and integral with a main frame side or bar  808 . The closed bar or box structure  810  may have one or more support walls and hollow areas. For example, there may be diagonal support walls  815  and  820 , as well as voids  815  and  825 . This structure may have improved strength and rigidity while being lightweight. 
     Referring now to  FIG. 9 , the cross-section view (or end view without end caps) of at least one other embodiment for the level and/or straight edge is shown. In this example, a top bar  905  and bottom closed structure or box  910  may be formed perpendicular to and integral with a main frame side or bar  908 . The closed bar or box structure  910  may have one or more support walls  910  and hollow areas  925  and  930 . Further, the bottom wall  915  of the closed structure  910  may be formed in a concave manner. This level and/or straight edge design may be particularly advantageous for leveling pipes or other items having a rounded surface. 
     Referring now to  FIG. 10 , the cross-section view (or end view without end caps) of at least one other embodiment for the level and/or straight edge is shown. In this example, a top bar  1005  and bottom closed structure or box  1010  may be formed perpendicular to and integral with a main frame side or bar  1008 . The closed bar or box structure  1010  may be formed in the shape of a triangle having sloped sides, e.g., side  1015 . The closed bar or box structure  1010  may have one or more support walls  1020  and hollow areas  1025 ,  1030  and  1035 . This design enables a strong rigid lightweight structure that has sloped surfaces upon which, for example, a scale may be more easily seen and read. 
     Referring now to  FIG. 11 , the cross-section view (or end view without end caps) of at least one other embodiment for the level and/or straight edge is shown. In this example, a top bar  1105  and bottom structure or box  1110  may be formed perpendicular to and integral with a main frame side or bar  1108 . The bottom bar or box structure  1110  may be a larger solid section that may be stronger and more rigid than other designs. It may also add additional weighting to the bottom side of the level and/or straight edge so that it may be more easily set up on a working surface. Although, the solid bottom bar or box structure  1110  may be heavier. 
     Referring now to  FIG. 12 , the cross-section view (or end view without end caps) of at least one other embodiment for the I shaped level and/or straight edge is shown. In this example, a top bar  1205  and bottom bar  1210  may be formed parallel to one another and perpendicular with a main frame side or bar  1208 . The structure may be integrally formed. In this embodiment, the bottom bar  1210  may also have ears that improve its strength and/or rigidity. A solid bar, plate or box structure  1215  may be formed separately and may be made of a different or the same materials as the I shaped structure. For example, some of the materials may include steel, stainless steel, aluminum, magnesium, plastic, wood, etc. In any case, the bar, plate or box structure  1215  may be connected to the bottom bar  1210  at surface  1220  using any reasonable method, for example, adhesive, welding, brazing, soldering, etc. In some cases, the method of connecting the two separate structures may add more strength and/or rigidity, while still being relatively lightweight. 
     Referring to  FIGS. 13A-13F , those skilled in the art can see, that the premises of this invention is that the full range of embodiments encompasses a structure with at least one closed section for the construction of a level/straight edge.  FIGS. 13A-13F  show various exemplary cross-sections (or end view without end caps) for a level/straight edge, showing a variety of geometry features including non I shaped structures (e.g., b, T, P, g, etc.), non rectangular and irregular shaped features, non-uniform wall thicknesses, and multiple closed structures. In particular,  FIG. 13A  shows a cross-section (or end view without end caps) having a larger closed end comprised of sides  1305 A,  1306 ,  1307  and  1308  and a short open end  1305 B. Note that in this embodiment the configuration is not an I shape, but is rather a “b” shape or upside down P shape.  FIG. 13B  shows a cross-section (or end view without end caps) having an open end comprising side  1310  and a moderately sized closed end comprised of sides  1312 ,  1313 ,  1314 , and a portion of  1311 . In this case it is worth noting that the side  1311  that connects the open end and closed end is not in the center but is on one side of the structure, thus forming an upside down “g” shape or a block “6” shape.  FIG. 13C  shows a cross-section (or end view without end caps) having an open end comprising side  1324  and a closed end comprising sides  1320 ,  1321 ,  1322 , and  1323 . In this example, the open end is formed at an angel, for example 30 degrees (or 45 degrees) from the closed end side  1323 . Further, the side  1320  may be made generally thicker than the other sides and may have a wider portion near side  1324 , which may offer better support and rigidity to side  1324 . 
       FIGS. 13D and 13E  show a cross-section views (or end views without end caps) for the level and/or straight edge having two closed ends.  FIG. 13D  has a first closed end including sides  1336 ,  1337 ,  1338 , and  1339 . Note that side  1339  may be thicker than the other sides for improved strength and may be made at an angle for ease of reading a scale (made longitudinally along the level and/or straight edge.  FIG. 13D  also has a second closed comprising sides  1330 ,  1331 ,  1332 ,  1333 ,  1334 , and a portion of  1335 . This closed end has an irregular geometry. The two closed ends of this embodiment is connected by side  1335 .  FIG. 13E  includes a first closed end comprising sides  1340 ,  1341 ,  1342 , and  1343  and a second closed end comprised of sides  1345 ,  1346 ,  1347 , and  1348 . The second closed end may also include strengthening inner ribs  1349  and  1350 . The two closed ends are connected together by side  1344 , and together form a barbell or l shape with enclosed ends. 
       FIG. 13F  shows a cross-section (or end view without end caps) having an upside down “T” shape with a closed end connected to an open end by an enclosed connecting portion. In this example, the closed end is comprised of sides  1353 ,  1354 ,  1355 , and  1356 . This closed end is connected to the open end  1351  by connection sides  1350  and  1352 . It is also possible that open end  1351  may be elongated so as to form an I shape as in other embodiments. In any case, what can be seen from these examples is that many there are many variations possible for the present invention. 
     Although a particular embodiment(s) of the present invention has been shown and described, it will be understood that it is not intended to limit the invention to the preferred embodiment(s) and it will be obvious to those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the present invention. Thus, the invention is intended to cover alternatives, modifications, and equivalents, which may be included within the spirit and scope of the invention as defined by the claims. 
     All publications, patents, and patent applications cited herein are hereby incorporated by reference in their entirety for all purposes.