Abstract:
The present invention involves a projector mount and micro adjustment capability which allows a projector to be mounted to fixed object (f ex ceiling), rough adjustment to be made with the ceiling mount and then fine adjustments to be made by a micro adjusting mechanism. The micro adjustor provides for a fluid pitch, yaw and roll adjustment without hanging up in place, which might throw off the adjustments. An installation and alignment tool is also provided. A method of adjustment and installation is also disclosed.

Description:
FIELD OF THE INVENTION 
       [0001]    This disclosure relates of the field of projector mounts, particularly ceiling or wall mounted projectors used to project images on a distant surface. 
       BACKGROUND OF THE INVENTION 
       [0002]    For the purposes of projecting a video recording or data, there are advantages to having a projector mounted well above the head height of a standing viewer. Typically in a hotel, conference center or viewing room a mounting bracket at a relatively high locations provides for a projector attached to it to display on a screen without the projected image being interrupted by the passage of a late arrival. However the provision of a high mounting bracket can cause access and alignment problems when a projector is mounted by means of a single bracket. In addition, a proper alignment system should allow for the ready alignment of an attached projector. The system should also provide for ready mounting and dismounting of the projector when the projector is not used for a period of time. This permits the projector to be readily removed from the mounting system, and stored in a secure environment. It also provides for easy off site maintenance. In US published patent application US 20090108150, we (ie common assignee herewith) disclosed a system for mounting and leveling a projector. 
         [0003]    This system provides a convenient way to adjust the position of the projector mount with respect to the fixed object (ceiling, wall, etc), but it does not take into account that sometimes it is necessary to swap out different projectors. This swap can occur because of maintenance (bulb), upgrade, or different projection characteristics are required. 
         [0004]    Furthermore, impact to the mount can through the alignment with the screen off and it would be desirable to be able to readjust the projector aim, without disturbing the basic mount to the fixed structure and without special tools. Wobble must also be avoided. That is the mount must be adjustable to a desired aim, and stay in place despite building movements from HVAC and other forces. Often ceiling projector mounts are difficult to reach, so realignment must be “set and forget” to the greatest extent possible. 
         [0005]    Further aggravating a solution to this problem, is the need for the adjustment to be possible in all planes (x,y,z ie pitch, yaw and roll) in a very compact unit which is completely fluid (non seizing) in response to adjustment yet does not require lubrication or resulting in lubricants dripping on the projector. Such dripping could result in a fire as the projector is extremely hot when in use. 
         [0006]    The fluidity of adjustment, ie smooth non jerky movement, is critical because any force applied to the mount can easily cause other elements of the mount to deform and thus the adjustment must be restarted, possible at the base adjustment of the mount to the fixed element. 
         [0007]    Therefore, there is a need for a precision micro adjustable mount with pitch, yaw and roll micro-adjustment with smooth movement and no wobble. 
       SUMMARY OF THE INVENTION 
       [0008]    To assist the reader in preparing to digest the detailed description and claims below, a short summary has been provided. It is far from complete and only provides a glimpse of the invention concepts. It is not intended to define the scope of the invention. The claims perform that function. 
         [0009]    As mentioned above, there are many more features and embodiments. Reference should be had now to the detailed description and claims which follow. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0010]    An exemplary embodiment of the invention will now be described with reference to the accompanying drawings of a projector mount: 
           [0011]      FIG. 1  is a top perspective view of the mount, mount receiving plate, mounting plate and articulatable legs. 
           [0012]      FIG. 2 . is a top perspective view of the mount aligned to insertion into a mount receiving plate. 
           [0013]      FIG. 3  is a bottom perspective view of the mount and insertion/alignment tool. 
           [0014]      FIG. 4  is a bottom perspective view of the mount. 
           [0015]      FIG. 5  is a top perspective view of the mount, insertion tool and socket wrench. 
           [0016]      FIG. 6  is a bottom perspective view of the insertion alignment tool. 
           [0017]      FIG. 7  is a bottom perspective of the insertion tool used for mounting. 
           [0018]      FIG. 8  is a perspective view of the mount. 
           [0019]      FIG. 9  is a side plan view of  FIG. 9 . 
           [0020]      FIG. 10  is a top plan view of the mount. 
           [0021]      FIG. 11  is a side plan view like  FIG. 9  rotated 90 degrees. 
           [0022]      FIG. 12  is a top plan view of the mount and mount receiving plate and the mounting plate. 
           [0023]      FIG. 13  is a view along line C-C of  FIG. 12 . 
           [0024]      FIG. 14  is a side plan view like  FIG. 11  rotated 90 degrees. 
           [0025]      FIG. 15  is a view along Fig. A-A. 
           [0026]      FIG. 16  is an exploded top perspective view of the mount. 
           [0027]      FIG. 17  is a view like  FIG. 16  rotated 90 degrees. 
           [0028]      FIG. 18  is a view like  FIG. 17  rotated a further 90 degrees. 
           [0029]      FIG. 19  is an exploded bottom perspective view. 
       
    
    
     DETAILED DESCRIPTION 
       [0030]    This disclosure relates to a system and method for micro adjustment of equipment which is mounted to a fixture/fixed surface. The most common type of equipment is a projector, screen or similar device, though this disclosure is not limited to such equipment, but to any item where fine adjustment of its position with respect to a fixed surfaces is desired. Further, the fixed surface may actually be mobile. The term is used as a reference point to some place the equipment is to be mounted, most often it is a wall or ceiling. 
         [0031]      FIG. 1  illustrates a mounting system  10 , having a circular support plate  12 , with a plurality of articulatable legs  14  each having leveling barrels to be affixed to a piece of equipment, such as projector, not shown. The function of theses parts can be seen in US patent publication US 20090108150, which is incorporated herein by reference. 
         [0032]      FIG. 2  shows a close up of the mount unit  20  being slideable received within a optional slide release mount plate  22 . Mount plate  22  has a pair of spaced apart opposing rails  24  which receive like rails  26  on the mount unit  20  to a stop  28 . For safety, a lock fastener  30  is provided as well as a quick release knob  32 . In the preferred embodiment, both must be removed to slide the unit out. 
         [0033]      FIGS. 3-7  relate to various ways to mount unit  20  and a tool therefore. 
         [0034]    The mount unit  20  is often mounted to a threaded pipe  40  ( FIG. 5 ) but may also be mounted to a joist/stud  50  ( FIG. 6 ) or other solid point. 
         [0035]    When mounted to a pipe, the mount unit  20  includes a threaded aperture  42  ( FIG. 1 ), which engages the pipe. The typical way to attach a mount to a pipe is by using wrench to twist the mount unit  20  onto the pipe, but this will either mar or damage the unit. Therefore a multipurpose tool has been created to solve this and joist mounting. 
         [0036]    Tool  60  is a disk is typically circular though any shape is possible. On its peripheral edge are at least one and preferably a plurality of engagement points  62 , usually notches used to engage the mount unit. Also included is a least one tool receiving ports  64  and optionally mounting holes  66 . 
         [0037]    The mounting unit  20  has a set of mating engagement points  72  ( FIG. 4 ) which are sized an spaced apart to receive points  62 . In the preferred embodiment, there is a ring  76  in the inner surface of the mounting unit with projections  72  to mate with recesses  62  (recesses and projections can be swapped). A tool  80  ( FIG. 5 ) is used to turn the mounting unit  20  via the disk  60  onto the pipe. This can be done with no visible damage or distortion of unit  20 . 
         [0038]    In the case where unit  20  is attached to a joist/stud  50 , disk  60  first functions as a marking disk as shown in  FIG. 6  where mounting holes can be marked with the disk before drilling and then the mounting unit  20  itself can be screwed into place. 
         [0039]    Thus it can be seen that the disk  60  functions as a multi-tool for tightening and for mounting. The tool can be characterized as a combination and tightening tool system for affixing a projector mount to a fixed surface where the mound has a collar for a threaded pipe and a central aperture defining a central axis. The inner surface of the disk has a plurality of engagement members spaced around and a like mating set on the aperture. The tool is sized and shaped to be removeably received within the inner surface of the mount and having mating members sized and shaped to received the engagement members. Preferably the tool including a central keyed aperture sized to receive a cranking tool and at least one other aperture therethrough, though it could be cranked by other connections to the disk such as hooks etc. 
         [0040]    A method of attachment and tightening is also disclosed using the steps of including mating engagement members on the mount and a disk, engaging the disk and turning the disk to drive the mount onto a threaded pipe or engaging the disk and fastening the disk to a fixed surfaces thereby capturing the mount between the disk and surface. 
         [0041]    Turning to  FIGS. 8-21 , the operation of the mounting unit and method of micro adjusting will be explained. 
         [0042]      FIGS. 8-15  show the mounting unit in various views and with portions broken away or on section lines. 
         [0043]    Arrow  82 - 86  show the various directions of movement possible by this mount. Arrow  82  showed movement in the X direction (or pitch), arrow  84  shows movement in the Y direction (or Yaw) and arrow  86  shows rotating movement (Roll). 
         [0044]    Each of these movement are accomplished by separate knurled controls  92 ,  94 , and  96  respectively. 
         [0045]    In a broad sense, this is how the micro adjustments work. 
         [0046]    The preferred embodiment has a domed hemispherical base element ( 102   FIG. 16 ), having an inner and outer surfaces and a generally central aperture  102   a . The second hemispherical intermediate element ( 104 ) also has an inner and outer surfaces the inner surface being sized to receive said outer surface of said base element  102  therein, in contact therewith and having a generally central aperture  104   a . There is a third hemispherical top element  106  which has inner and outer surfaces, said inner surface sized to receive said outer surface of said intermediate element  104  in slideable contact therewith and having a generally central aperture  106   a . Then there is a central collar element  109  which has a generally cylindrical portion sized to be received thru said central apertures, and a hemispherical outer surface sized to be received at least partly within and in slideable relation with the inner surface of the base element.  FIG. 13  shows how the various surfaces rest upon each other to allow pitch, yaw and roll independent movement. 
         [0047]    To insure that each element moves in the intended direction, there are guides  110 . The first guides  110  are located between said base  102  and intermediate  104  elements for limiting the movement between said elements along the path defined by the first guides, thereby defining movement in a first orientation—ie pitch. A second set of guides.  112  is located between said intermediate and top elements for limiting the movement between the elements along a path defined by said second guides, thereby defining movement in a second orientation (yaw). A third guides  120  on the collar  108  and  122  on the top element  106 , amongst other guiding elements are located between said top and collar elements for limiting the movement between the elements along a path defined by the second guides, thereby defining movement in a third orientation (roll). 
         [0048]    Further refinements may be a first continuous screw adjustable link  130  between said base and intermediate elements, the link configured to move said base and intermediate elements relative to each other along the path of said first guide. A second continuous screw adjustable link  132 , offset from the first link by 90 degrees, between the intermediate  104  and top elements  106 , the link configured to move said intermediate and top elements relative to each other along the path of said second guide  112  and a third continuous screw adjustable link  134 , offset from at least one of said first or second links by 90 degrees, between said collar  108  and top 106 elements, said links configured to move said collar and top elements relative to each other along the path of the third guide, so that movement of each link controls the positioning of the collar in pitch yaw and roll orientations. 
         [0049]    Of course, the above explanation includes non-essential elements and the full operation will be explained below. 
         [0050]    The basis structure of the preferred embodiment can be seen in  FIGS. 8-21  and in particular  FIGS. 8 and 16 . The central collar unit  108  is the portion which is affixed to a ceiling or other fixed structure. It essentially “floats” within the other shell elements and its positioning guides and adjusters as will be explained below. 
         [0051]    Collar unit  108  has a hemispherical portion  150  which includes a hemispherical flange having a central aperture and a collar stem  152  extending upwardly therefrom also having an aperture and co-axially aligned therewith. To facilitate continuous (ie smooth, not jerky) adjustment, the flange portion at least is coated with non-stick surface material which self lubricates parts which much slide across each other. Therefore, all hemispherical surfaces of the various parts are preferably coated with a non-stick fixed (non liquid) coating. This prevents the parts from “hanging” which would make micro adjustment impossible. (Keep in mind that in a projector, a fraction of a mm movement at the mount, will make centimeters of movement on the projector screen, so precise fluid micro adjustment is critical). 
         [0052]    Around the periphery of collar stem  152  are a pair of opposed recesses  154  (see  FIG. 18 ) and a threaded rack portion  156  and its opposing bearing recess  158  ( FIG. 19 ). These surfaces mate with other components as will be explained herein. 
         [0053]    Straddling collar stem  152  and slideably engaging flange  150  is a hemispherical base element  102  which has an interior surface shaped to slideably engage with flange  150 . The curvature of the inside surface of base  102  and flange  150  are preferably nearly identical so that the maximum number of contacts points exist, thereby reducing the opportunity for wobble and by spreading the force across a larger surface area, the friction at each point. 
         [0054]    The outer surface of base  102  also includes a guide  160  in the form a pair of spaced apart ridges which forms guideways in connection with controlling the movement path of the intermediate unit  104 . Guides  160  are shown as ridges but could be depressions, tracks or any other form of guideway that runs toward the central aperture. 
         [0055]    The base guideway  160  mates with a like guide  170  ( FIG. 19 ) in intermediate element  104 . In this case it is a mating depression but it can be any type so long as it mates and runs longitudinally toward the aperture. It could follow a curved path also, or a path which is straight but not longitudinal if the objective would be to combine two of the three directional controls. Between the intermediate element  104  and top element  106 , guides  161  mate with guide  171  (see  FIG. 20 ). In the preferred embodiment, the guides are in pairs on both sides of the hemisphere (180 degrees apart) and axially aligned with the adjuster for that hemisphere, so that an axis runs thru the adjuster and guide. 
         [0056]    Adjustment of the relative positions of the base and intermediate units is more or less the same in the preferred embodiment. A bolt/nut system is used with L-shaped screws/bolts  130  and  132  being driven by knurled nuts  180 / 182 . the L-shaped screw/bolts are slidingly captured in apertures  186 ,  188  ( FIG. 17 ) and knurled nuts  180 ,  182  are captured in their associated unit by shaft mounts  190 ,  192  which receive the longer portion of the L-shaped screw and capture it as shown in the figures. See  FIG. 15 . Other forms of adjusters can be substituted for the screw/shaft as shown. 
         [0057]    When the knurled nuts are turned, the L-bolt is lengthened or shortened and the base, intermediate and top units move relative to each other but their direction of movement is limited by the guideways which preferably limit their movement to a longitudinal path from the “equator” of the hemisphere to the central axis or “poles”. The two adjusters are located on the sides of their respective hemispheres but rotated 90 degrees from each other. 
         [0058]    The top hemispherical element  106  sits atop the intermediate element  104  and has an inner surface which is likewise coated with an anti-friction coating. Like the other hemispheres, its inner curvature mates with the intermediate element&#39;s outer curvature with substantially the same curvature so as to minimize friction and wobble, increasing bearing surface with maximized contact. 
         [0059]    Rotation of the top element  106  is different from the other elements. It controls the movement of the collar element  108  and consequently the movement of the projector. Top element  106  controls the rotation of the collar element  150  by a rack  156  and pinion gear  200  ( FIG. 18 ) which is attached thru a rod  202  to handles  204 . To maintain the rack and gear in engagement, there is a bearing  206  inserted thru an aperture the unit body opposite (180 degrees) gear  200 . The bearing is a low friction pellet bearing  206  which is biased against the collar  152  by set screw  208  which drives it into the aperture space. Therefore, the collar  152  is suspended between the bearing  206  and the gear  200 . Its rotational freedom is limited by a flange extension  210  ( FIG. 8 ) on the top element  106  which engages a curved slot/recess  212  on the collar  154 . The circumferential extent of the recess determines the maximum amount of roll of the mount. 
         [0060]    All features disclosed in the specification, including the claims, abstracts, and drawings, and all the steps in any method or process disclosed may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. Each feature disclosed in the specification, including the claims, abstract, and drawings, can be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features. 
         [0061]    Any element in a claim that does not explicitly state “means” for performing a specified function or “step” for performing a specified function, should not be interpreted as a “means” or “step” clause as specified in 35 U.S.C. section 112.