Abstract:
A light emitting module and a modular light emitting system with leveling capability. The system relates to light-based (e.g. lower-based) layout tools of the type used in the construction industry. More specifically, the system relates to a modular light emitting system for projection visible patterns, such as dots, lines, cross-lines and other patterns, on one or more distant surfaces for purposes of alignment, construction, verification and the like.

Description:
[0001]     This application claims priority to provisional application Ser. No. 60/486,696, filed Jul. 11, 2003 entitled “MODULAR LASER LAYOUT SYSTEM”, Charles E. HEGER, et al. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     This invention relates to a modular layout system used, for example, to provide plumbing and leveling for projection of a laser beam.  
         [0003]     There are numerous available laser dot and laser line generators used, e.g., in the construction industry. Some laser generators emit a stationary laser beam resulting in a projection of a single fixed dot. Other laser generators emit a wedge of laser light in a plane to project a single fixed line. Still other laser generators project multiple fixed laser dots or lines. Spinning lasers project a laser line 360-degrees around a room by spinning a laser beam about an axis.  
         [0004]     Many such laser generators utilize a self-leveling mechanism to project dots or a line. The self-leveling mechanism typically includes a suspended pendulum with one or more lasers attached to the pendulum and includes a mechanical device for adjusting the laser and pendulum assembly to achieve a desired level of accuracy. Other self-leveling mechanisms use a liquid and liquid sensors to set a laser beam&#39;s orientation. A spinning laser that incorporates a self-leveling mechanism can project a level line along, e.g., the inside perimeter of a room. Such level lines may be helpful for installation of, for example, wainscoting, cabinets, countertops and windows.  
         [0005]     Unfortunately, known laser generators are inflexible in their design and lack ease of adaptability. Although many laser generators included a self-leveling capability, each is fixed in its functionality. For example, a spinning laser might only be capable of projecting a horizontal line (perpendicular to the gravitational pull) and not capable of projecting vertical lines. Another laser generators project orthogonally arranged sequences of dots but are unable to project orthogonal lines.  
         [0006]     Before selecting a laser dot or laser line generator, a purchaser is forced to determine the requirements of the ultimate application and the intended use. Once a laser generator is purchased, the user is forever limited to that particular fixed configuration. When requirements change, the user is forced to select and purchase new equipment.  
       SUMMARY  
       [0007]     A module comprising a housing having a plurality of sides, an aperture defined in a first side of the sides, and a magnetic fastener on at least two of the sides, and a light source such as a laser diode mounted within the housing, whereby the aperture allows light emitted from the light source to pass out from the housing.  
         [0008]     Other embodiments provide a module comprising a housing having two or more reference sides, wherein each reference side defines a corresponding reference plane, and a light source in the housing and emitting light having a predetermined orientation with respect to each of the reference planes.  
         [0009]     Still other embodiments provide a module comprising a light source, a housing including an electrically conductive member, wherein the electrically conductive member is coupled to the light source, and a conductive lead, wherein the conductive lead is electrically coupled to the light source, and wherein the conductive lead extends from the housing.  
         [0010]     Other embodiments provide a module comprising a housing having an external conductive member providing a conductive surface and an external non-conductive member, a conductive lead, and a laser generator within the housing, the laser generator including a first conductor electrically coupling the laser generator to the conductive surface of the housing, and a second conductor electrically coupling the laser generator to the conductive lead.  
         [0011]     Still other embodiments provide a modular system comprising a leveling platform providing a reference surface, wherein the reference surface is made substantially level, and one or more modules detachable from the leveling platform, wherein each of the modules has at least two sides that allow substantially parallel positioning on the reference surface and allow substantially parallel positioning against another module, wherein each of the modules cooperates with the reference surface to provide oriented light.  
         [0012]     Other embodiments provide a modular system including a self-leveling platform having a level reference surface, and one or more laser modules detachable from the self-leveling platform, wherein each of the laser modules has at least one side that provides for substantially level positioning of the laser module on the reference surface, and wherein each of the laser modules cooperates with the reference surface to provide one or more oriented beams of laser light.  
         [0013]     Features and advantages of the present invention will become more fully understood from the following detailed description and accompanying drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]      FIG. 1  illustrates a self-leveling system utilizing modular lasers on a self-leveling platform in accordance with the present invention.  
         [0015]      FIGS. 2A through 2E  show perspective views of various types of laser modules emitting various patterns of light in accordance with the present invention.  
         [0016]      FIGS. 3A and 3B  show opposing perspective views of a modular laser in accordance with the present invention.  
         [0017]      FIGS. 4A through 4F  show one or more laser modules configured to emit various patters of light and having one or more reference sides in accordance with the present invention.  
         [0018]      FIGS. 5A, 5B  and  5 C show a process of magnetic coupling between two modular laser modules in accordance with the present invention.  
     
    
     DETAILED DESCRIPTION  
       [0019]     This detailed description discloses a modular system for, e.g., lasers or other light sources. A leveling system may include one or more laser modules resting on a self-leveling platform. The self-leveling platform adjusts a reference surface to provide a level surface. The self-leveling platform may be placed on a semi-level surface, or alternatively, may be clamped to a pole, truss or building framing. The pole may be further stabilized by a tripod base mount.  
         [0020]     Unlike known laser systems, which often constrain a user to a single laser generation function, the present system&#39;s modular configuration uses one or more laser modules to create a flexible and versatile, multi-function laser generation system. A user no longer needs separate leveling equipment for each type of configuration he or she will need for a given task. With the same set of modular components, many different configurations are possible.  
         [0021]     One or more modules are placed on a platform to project an image having a particular orientation to the platform. A manually adjusted leveling platform or a self-leveling platform may be considered as two circular plates, one suspended above the other and nominally near parallel, with the upper plate having the ability to be mechanically adjusted in a planar sense with respect to the lower plate.  
         [0022]     In some embodiments, a two axis level sensor is attached to the upper plate, such that the pitch and roll of this plate may be sensed in relation to the gravitational plane. The sensor outputs are then processed and the resulting information used to drive suitable actuators, one for pitch and one for roll, such that the upper plate&#39;s surface will achieve a level condition. The degree of angular compliance between the upper and lower plate is a function of design. In some embodiments, a range of ±5 degrees of angular displacement between the plates may be accommodated.  
         [0023]      FIG. 1  illustrates a self-leveling laser projection system utilizing laser modules  300  on a self-leveling platform  100  in accordance with the present invention. (The use of a laser light source is not limiting.) Self-leveling platform  100  placed on a non-level surface  200  automatically provides a level reference surface  101 . An example of a suitable self-leveling platform  100  is disclosed in co-pending application Ser. No. 10/618,403 entitled “DUAL AXIS CAPACITIVE LEVEL SENSOR” filed on Jul. 11, 2003, and which is herein incorporated by reference in its entirety but this is not limiting.  
         [0024]     The laser modules  300  are placed on the reference surface  101  of the self-leveling platform  100 . The laser modules  300  emit a pattern of light  400  to project a desired pattern on a distant surface. Power may be supplied to the laser modules  300  by a power ring  102  on the self-leveling platform  100 . Each module may have a power lead  310  to provide one-half of an electrical connection between the laser module  300  and the power ring  102  of the self-leveling platform  100 .  
         [0025]     The reference surface  101  of the self-leveling platform  100  may be both metallic (at least in part) for providing a second-half of the electrical conduction and ferrous (e.g., steel or iron) allowing magnetic attraction. This reference surface  101  may rotate about two axes, for example, labeled pitch and roll. Each axis may be driven by a motor system, with both motors mechanically coupled between a base of the platform  100  and the reference surface  101 .  
         [0026]     Alternatively, the reference surface  101  may be provided by a manually-leveled platform of the type well known in the field.  
         [0027]     One or more laser modules  300  may rest on top of the reference surface  101 . The laser modules  300  emit light  400  to form useful patterns against a distant surface such as a wall of a room. Each laser module  300  has an internal light source (e.g., laser) or optics for producing a particular pattern. The particular pattern may have a fixed orientation with respect to one or more sides of the laser module  300 . For example, one type modular module  300  may have an internal light source and optics that generate a plane of light  400 . The plane of light when directed towards a distant surface will project a line on the distant surface. The internal light source and optics may be calibrated so that the plane of light  400  emitted from the laser module  300  is parallel to a first face of the laser module  300  and perpendicular to a second face of the laser module  300 . Additional laser modules  300  may be placed on the reference surface  101  and against a face of other laser module  300  to project additional patterns on distant surfaces. Once a task is complete, the laser modules  300  may be removed and reconfigured for the next task.  
         [0028]     Each laser module  300  is designed for projecting a particular pattern of light. Additional laser modules  300  may be combined to project a number of desired patterns. Examples of projected patterns include a single dot, a single line, an orthogonally set of lines forming a cross, a sequence of evenly spaced dots, as well as other specialty configurations. By placing the necessary number and type of modules on a self-leveling platform, a user sets up a system for projecting a desired pattern. For example, a user may use a single-dot laser module  300  to mark a point on a remote wall of the room.  
         [0029]      FIGS. 2A through 2E  show perspective views of various types of laser modules  300  that emitting various patterns of light in accordance with the present invention. Each laser module  300  may be constructed to project a particular pattern from a windowed face  301  of the laser module  300 .  FIG. 2A  shows a laser module  300 - 1  that emits a beam of light  401 . The beam of light  401  projects a spot  501  on a distant surface.  FIG. 2B  shows a laser module  300 - 2  that emits a horizontal plane of light  402 . The horizontal plane of light  402  results in a horizontal line  502  projected on a distant surface.  FIG. 2C  shows a similar laser module  300 - 3 . Between  FIG. 2B  and  FIG. 2C  the laser module  300  has been rotated 90 degrees. The laser module  300 - 3  emits a vertical plane of light  403 . The vertical plane of light  403  results in a vertical line  503  projected on a distant surface.  FIG. 2D  shows a laser module  300 - 4  that emits two orthogonal planes of light  404 . The orthogonal planes of light  404  result in a cross-pattern of perpendicular lines  504  projection on a distant surface.  FIG. 2E  shows a laser module  300 - 5  that emits multiple beams  405  to form a pattern of dots  505  on a distant surface.  
         [0030]     In some embodiments, each laser module  300  has one or more of its faces provided as a reference side. A reference side is manufactured by use of conventional precision machining or fabrication to a desired tolerance such that it may be positioned substantially parallel to the reference surface  101  of the self-leveling platform  100 . A reference side may be substantially parallel, perpendicular, or otherwise oriented with the laser beam&#39;s orientation. Additionally, a reference side allows that face of the module to rest substantially parallel to a reference side of another laser module  300 . If a side of a laser module is positioned against either another laser module  300  or the reference surface  101 , that side should be a reference side.  
         [0031]     In some embodiments, there is provided an internal mechanical adjustment within the laser module  300  for factory (or other) alignment of the emitted laser beam with respect to the one or more reference sides. The adjustment may include spacers, screws, lifts and/or other suitable mechanisms for holding proper alignment of the laser&#39;s orientation during calibration.  
         [0032]     A laser module  300  may include a laser, associated internal circuitry and a six-sided housing (shell). The laser and circuitry are conventionally mounted within the housing. The six-sided housing may have edges of equal dimensions thereby forming a cube or may have edges of unequal dimensions. Additionally, a laser module  300  may contain an internal power source (battery) or an internal receptacle for a power source both of which are conventionally mounted. Alternatively, a laser module  300  may accept electric power from an external source, for example, a source associated with a self-leveling platform  100  such as a power ring  102  and a conductive reference surface  101 .  
         [0033]      FIGS. 3A and 3B  show perspective views of a laser module  300 . Each face  301 - 306  of a module  300  may have a primary purpose. In the embodiment shown, face  301  acts as a windowed face allowing light to pass from the laser module  300 . Faces  302 - 304  act as references sides and may provide a first electrical path to a power source. Faces  305 - 306  may allow for a lead  310  (shown in  FIG. 1 ) to provide a second electrical path to the power source.  
         [0034]     Face  301  of the laser module  300  has an opening or a window  301 A that allows the light from the laser module  300  to pass out from the laser module  300 . The laser beam&#39;s direction may be oriented to be substantially perpendicular to the plane of the windowed face  301 . A windowed face  301  may also have on it magnets  301 B. If module  300  is to be used to generate a downward plumb line, the laser module  300  may be positioned to emit a beam directly downwards in the direction of the Earth&#39;s gravitational pull. Some manual and self-leveling platforms  100  have a vertical pass-through hole  120  (as shown in  FIG. 4A ) that allows light to pass from above the reference surface  101  through and out of the bottom of the self-leveling platform  100 . When a laser module  300  is positioned over the pass-through hole, magnets  301 B may be used to hold the laser module  300  in place.  
         [0035]     Reference sides  302 - 304  may include magnets  307  for promoting adhesion between a reference side and another reference side or the reference surface  101 . Magnets  307  are described in more detail below with reference to  FIGS. 5A, 5B  and  5 C.  
         [0036]      FIGS. 4A through 4F  show one or more laser modules  300  configured to emit various patters of light  400  and having one or more reference sides. Any of the sides of a laser module  300  may be manufactured to be a reference side. A six-sided laser module or laser cube may have one, two, three, four, five or all six of its sides manufactured as reference sides. Tasks that may require one or more reference sides may require sides to be orthogonal or parallel to an access of the emitted laser beam  400  and/or orthogonal or parallel to another reference side. A laser module  300  may be used to perform certain set of tasks depending on which faces of the laser module  300  are manufactured as reference sides.  
         [0037]      FIG. 4A  shows a side view of “plumb bob” application where the windowed face  301  is a reference side  320 . The laser module  300 - 7  has a beam  401  that is orthogonal to its windowed face  301 . The user places a single-dot generating laser module  300 - 7  on the reference surface  101  of a self-leveling platform  100  over a through hole  120 . A single-dot laser module  300 - 7  emits a beam  401  that projects a point or small circular or elliptical disk on a distant surface. The through hole  120  in the self-leveling platform  100  allows beam  401  of light to pass directly through the platform  100  towards the surface of a floor.  
         [0038]      FIG. 4B-1  shows a side view and  FIG. 4B-2  shows a perspective view of the plumb bob application providing a vertical floor-to-ceiling plumb bob line. By stacking two laser modules  300 - 8  and  300 - 9  on one another and directing their respective beams  401  in opposite directions, a single-axis line may be generated. A first laser module  300 - 8  has its windowed face  301  as a first reference side  320 . A second reference side  320  is located on the side opposite of and parallel to the windowed face  301 . A second laser module  300 - 9  has a reference side  320  located on the side opposite of its windowed face  301 . The beams  401  are aligned during factory production to be orthogonal to the reference sides  320 .  
         [0039]     The pair of single-dot laser modules  300 - 8  and  300 - 9  may be stacked one on the other with beams  401  in opposite directions to generate a bright and vertical plumb line. To do so, the user first places the first single-dot generating module  300 - 8  on the reference surface  101  over a through hole  120  of a self-leveling platform  100 . The through hole  120  in the platform  100  allows light to pass directly through the self-leveling platform  100  towards the surface of a floor. Next, the user places the second single-dot laser module  300 - 9  on top of the first laser module  300 - 8 , such that the second laser module projects a beam  401  vertically upward towards the ceiling thereby creating a vertical floor-to-ceiling plumb bob line.  
         [0040]      FIG. 4C  shows a side view of laser module  300 - 10  containing a reference side  320  parallel to the emitted beam  400 . This reference side  320  may be placed on the self-leveling platform  100  to emit a beam that is aligned to the reference surface  101 . If the laser module  300 - 10  emits a linear beam of light, the beam will project a dot on a distant surface at a known height above the references surface  101 . If the laser module  300 - 10  emits a beam forming a horizontal plane of light, the beam will project a line on a distant surface. The projected line will be parallel to the reference surface  101  and perpendicular to the Earth&#39;s gravitational pull.  
         [0041]      FIG. 4D-1  shows a plan view and  FIG. 4D-2  shows a side view of two laser modules configured to form a 90-degree angle parallel to the plane of the reference surface  101 . A first laser module  300 - 11  has a first reference side  320  opposite from the emitting surface and a second reference side  320  orthogonal to the first reference side  320 . A second laser module  300 - 12  has two reference sides  320  orthogonal to each other and parallel to the emitted beam  401 . The pair of laser modules  300 - 11  and  300 - 12 , when reference sides  320  are placed side-by-side and on the reference surface  101 , emit beams  401  that are parallel to the reference surface  101  and combine to form a 90-degree angle.  
         [0042]      FIG. 4E-1  shows a plan view of a configuration using four similar modules  300 - 12  combined to project a 360-degree plane parallel to the reference surface  101 .  FIG. 4E-2  shows a side view of two of the four laser modules  300 - 12 . Each laser module  300 - 12  contains three reference sides  320 , each orthogonal to each other and separate from the windowed face. The four laser modules  300 - 12  may be placed next to one another such that each non-reference side is exposed and each reference side  320  abuts either a reference side  320  of another laser module  300 - 12  or the reference surface  101  of the self-leveling platform  100 . The four laser modules  300 - 12  together emit a 360-degree pattern. A 360-degree pattern may be used to project a level laser beam line on the interior walls of a room, e.g., for construction purposes.  
         [0043]     By using four laser line modules  300 - 12  placed on a reference surface  101  with their beams projecting horizontal planes of light  402  and with the windowed faces of the modules  300 - 12  positioned orthogonally to one another, a complete 360-degree horizontal line may be generated, thereby duplicating the functionality of a spinning laser often used in the field of construction. The resultant line will be advantageously brighter than that of a spinning laser due to the fact that each line from any given module projects outward at about 90-degrees whereas the spinning laser must distribute its optical power over 360-degrees. This is an important consideration when working under a high ambient light condition.  
         [0044]      FIG. 4F  shows a plan view of four laser modules  300 - 13  through  300 - 16  each configured to emit a linear beam of light  401 . The four laser modules  300 - 13  through  300 - 16  may be used, for example, to emit two beams of light along a first axis parallel to the reference surface  101  and to emit two more beams of light along a second axis parallel to the reference surface  101  and perpendicular to the first axis.  
         [0045]     Many other configurations are possible by using various combinations of laser modules  300  having various combinations of reference sides  320  that emit various patterns of light  400 . A single-line laser module  300 - 2  may be used to emit a plane of light  402  to project a horizontal line  502  on a wall. Either two single-line laser modules  300 - 2 ,  300 - 3  (orthogonally positioned side-by-side) or a single-cross laser module  300 - 4  may be used to generate an orthogonal cross  504  on a wall. A dot-sequence laser module  300  may be designed to project dots having a constant angular spacing between adjacent laser beams. Another dot-sequence laser module  300  may project dots having progressively changing angular spacing between adjacent laser beams such that the dots are evenly spaced across a perpendicular plane.  
         [0046]     A laser module  300  may emit any one of a variety of beams  400  to project various patterns  500  such as a dot, line, cross or other specialty configurations. It is well known how to provide such beam shapes from a conventional low powered laser. The user may mix and match different types of modules  300  for a given task. The laser modules  300  are placed on a manual or self-leveling platform  100  capable of holding multiple modules  300 . A laser module  300  may be rotated, pivoted or turned so as to orient its laser beam in an infinite number of directions.  
         [0047]     A laser module  300  with four reference sides  320  may be used in combination with equivalent laser modules  300  to create any of the above-mentioned configurations. Such a versatile laser module  300  may contain four reference sides  320  oriented such that all sides of the module, except two adjacent sides orthogonal to the windowed face, are reference sides. Alternatively, a laser module  300  may contain five or six reference sides  320 . Additional reference sides  320  allows the laser module  300  to have other laser modules  300  stacked on each reference side  320  including under and/or on top of the module  300 .  
         [0048]     A laser module  300  may have a shell that is in one embodiment formed from separate pieces, thereby allowing ample internal space for mounting electrical and electronic components into the laser module  300  during assembly. The laser module  300  may be manufactured with the reference sides  320  formed with a single shell of a conductive material and the remaining non-reference sides formed with a cap made of a non-conductive material. To construct a shell having one or more such substantially flat and orthogonal surfaces, a manufacture may select the number and position of each reference side  320 . The manufacturer may then die-cast an aluminum shell or other material that provides a conducting shell having the selected configuration of reference sides  320 . If the die-casting results in a shell having dimensions outside of required tolerances, additional precision may be gained by conventionally machining each reference side  320 . Any open sides of the shell may be capped with one or more pieces molded from plastic by minimizing the number of reference sides, manufacturing costs of the laser module  300  may be reduced.  
         [0049]     In some embodiments, an aluminum shell contains three reference sides, thereby leaving open three sides for access and eventual capping them with a three-sided plastic piece. In alternative embodiments, an aluminum shell contains four reference sides, thereby leaving open the two sides for access and eventual capping with a two-sided plastic piece. A module containing four references sides may be formed, for example, by injecting molten metal under pressure into a die or mold, as is well known in the art, resulting in a shell forming four sides of a six sided module  300 . A plastic piece may be molded and used to form the final two sides of the laser module shell. To improve precision, the reference sides  320  of a shell may be machined to be substantially flat and orthogonal or parallel to other reference sides.  
         [0050]     In some embodiments, magnets  301 B and  307  are used for attaching and aligning reference sides to other reference sides and to a reference surface  101 . In some embodiments, a laser module  300  has a pair of cylindrical magnets  307  floating in a cavity on each of the reference sides  320 . The pair of magnets presents both a north pole (N) and a south pole (S) at the face of each reference side.  
         [0051]      FIGS. 5A, 5B  and  5 C show, in sequence, a process of magnetic coupling between two modular laser modules  300  in accordance with the present invention.  FIG. 5A  shows a first laser module  300 - 17  repelling a second laser module  300 - 18 . The magnets  307  may be allowed to rotate and roll within this cavity as shown in  FIG. 5B . As a reference side  320  of the second laser module  300 - 18  approaches the first laser module  300 - 17 , the magnets  307  in either or both laser modules will rotate and slide around such that the laser modules will become magnetically attracted and attach to each other as shown in  FIG. 5C . The rotation of the pairs of magnets  307  eliminates the need for any predetermined north-south polarity installment of the magnets.  
         [0052]     A windowed face, which emits a laser beam, may also be machined as a reference side but not necessarily with non-rotating magnet. A windowed face may have four magnets  301 B, permanently embedded near each corner of the face (as shown in  FIG. 3A ). Any of the reference sides  320 , when placed on a ferrous surface, such as the reference surface  101 , will magnetically adhere to the ferrous surface. The shell of a laser module  300  may be metallic to conduct electricity but non-ferrous so that the shell will not interfere with the functionality of the magnets  301 B and  307 .  
         [0053]     A laser module  300  using external power conventionally requires two electrical paths to supply electrical power to the laser. In some embodiments, the metallic module shells acts as one of the two conductive paths. The second path may be provided through a flying lead  310  that may be mechanically and/or magnetically and electrically attached to a manually or self-leveling platform  100 . The lead  310  may connect to a power ring  102  positioned around the self-leveling platform  100  (as shown in  FIG. 1 ). This ring  102  is electrically isolated from the metallic reference surface  101 . One end of the lead  310  may be connected to the laser module  300 . The other end of the lead  310  may be free and may be permanently and electrically attached to a small magnet. This small magnet at the end of the lead  310  may then be placed anywhere along the power ring  102  to complete the required two electrical paths. Additionally, the lead  310  may be positioned to protrude from the laser module  300  in such a fashion that it does not interfere with the ability to place any reference side  320  of a laser module  300  against another reference side  320  or against a reference surface  101  of the platform  100 .  
         [0054]     While the present invention has been described with reference to one or more particular variations, those skilled in the art will recognize that many changes may be made thereto without departing from the spirit and scope of the present invention. Each of these embodiments and obvious variations thereof are contemplated as falling within the spirit and scope of the claimed invention, which is set forth in the following claims.