Adhesive mount for a leveling device and a leveling device

A mount for removably mounting a device to a reference surface is provided. The mount includes a thermoplastic hot melt adhesive, and a tab that extends from the adhesive. The adhesive is configured to adhere to the surface and the device when the device is mounted to the surface. The adhesive is also configured to be removed from the surface without damaging the surface by moving the tab in a direction substantially parallel to the surface.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an adhesive mount. The present invention further relates to a leveling device. The present invention further relates to the combination of a leveling device and an adhesive mount for removably adhering the leveling device to a surface.

2. Description of Related Art

Mounting structures that are used to mount items to surfaces, such as walls, are widely used. For example, nails may be used to fasten a picture hanger to a wall in a semi-permanent manner. When hanging such pictures, leveling devices may be used to ensure the picture is level and/or lined up correctly with other features in a room. The leveling devices themselves may need to be temporarily attached to the wall so that the user may attend to the picture frame with two hands. Pins and other devices that may damage the wall have been used, as well as various suction-type devices. Adhesive devices have also been used to attach leveling devices to walls. However, such known adhesive devices have various shortcomings as well.

Wall mounted leveling devices have also been provided with various mechanisms that provide for desired positioning of the device on the wall, and additional mechanisms for enabling adjustment of a laser beam emitted from the leveling device after it has been wall mounted. Such known mechanisms have various shortcomings, and the present invention overcomes these shortcomings and provides further advantages as well.

BRIEF SUMMARY OF THE INVENTION

In an embodiment, a mount for removably mounting a device to a reference surface is provided. The mount includes a thermoplastic hot melt adhesive, and a tab that extends from the adhesive. The adhesive is configured to adhere to the surface and the device when the device is mounted to the surface, and to be removed from the surface without damaging the surface by moving the tab in a direction substantially parallel to the surface.

In an embodiment, a device is provided. The device includes a housing for supporting at least one light source arranged to form a line of light on a reference surface, a leveling device for positioning the light source so that the line of light projects on the reference surface in a desired orientation, and a mount for removably mounting the housing to a reference surface. The mount includes a thermoplastic hot melt adhesive and a tab attached to the adhesive. The adhesive is configured to adhere to the surface and the housing when the housing is mounted to the surface, and to be removed from the surface without damaging the surface by moving the tab in a direction substantially parallel to the surface.

In an embodiment, a method of manufacturing a mount is provided. The method includes dispensing a predetermined amount of molten thermoplastic adhesive on a release liner, attaching a tab to the adhesive while the adhesive is at a temperature above its softening point, and cooling the adhesive to a temperature below its softening point.

In an embodiment, a method of manufacturing a mount is provided. The method includes dispensing a first predetermined amount of molten thermoplastic adhesive on a release liner, attaching a pull tab to a portion of the first adhesive, dispensing a second predetermined amount of molten thermoplastic adhesive on a second release liner, and placing the second adhesive on the first adhesive and the pull tab.

In an embodiment, a device is provided. The device includes a housing, a vial carried by the housing, a light source carried by the housing, and a base movably connected to the housing. The base and the housing have cooperating structures so as to allow movement of the housing and the base relative to each other along an arc.

In an embodiment, a device is provided. The device includes a housing, a light source carried by the housing and arranged to form a line of light on a reference surface, an adhesive for removably mounting the housing to a reference surface, and a plurality of spacers configured to be movable between an extended position away from the housing and a retracted position at least partially within the housing. The plurality of spacers are configured to create a space between the reference surface and the adhesive when in the extended position relative to the housing and to allow the adhesive to contact the reference surface when in the retracted position relative to the housing.

In an embodiment, a method for mounting a device to a reference surface is provided. The device includes a housing for supporting at least one level, and a base movably connected to the housing. The method includes attaching at least one mount to the base, extending at least one spacer from the housing and past the base and the at least one mount, placing the at least one spacer against the reference surface, and applying a force to the housing so as to move the at least one spacer into the housing.

In an embodiment, a method for mounting a device to a wall is provided. The device includes a base for mounting on the wall, and a housing movably connected to the base. The housing supports at least one bubble vial and at least one light source for generating a beam of light on the wall on which the base is to be mounted. The method includes attaching the base to the wall, and moving the housing relative to the base along an arcuate path to adjust the beam of light in accordance with the bubble vial.

In an embodiment, a method for mounting a device to a reference surface is provided. The device includes a light source for generating a beam of light, and an adhesive for mounting the device to the reference surface. The method includes maintaining at least one spacer in an extended condition from the device as the device is moved relative to the reference surface, and forcing the device toward the reference surface so as to cause the spacer to retract and the adhesive to engage the reference surface, thereby adhering the device to the reference surface.

Other aspects, features, and advantages of the present invention will become apparent from the following detailed description, the accompanying drawings, and the appended claims.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1Ashows a mount10according to an embodiment of the present invention. The mount10includes a pressure sensitive thermoplastic adhesive12with a pull tab14disposed therein. The mount10has a first surface16, and a second surface18that is preferably substantially parallel to the first surface16, thereby defining a thickness T of the mount10therebetween. The first and second surfaces16,18each have sufficient adhesive properties so as to allow the mount10to adhere to a product P at the first surface16, and to a reference surface RS at the second surface18, as discussed in further detail below.

The adhesive12is preferably a hot melt adhesive that is heated to a temperature that is above its softening point (typically in the range of about 60° C.-150° C.), which may be represented by its glass transition temperature, and dispensed in a predetermined amount onto a release liner20. If the hot melt adhesive exhibits a melting point, it is preferable heated to a temperature that is above its melting point. As shown inFIG. 4, a plurality of mounts10may be dispensed on the liner20with perforations22being provided in the liner20in between the mounts10so that the mounts10may optionally be separated from each other at a later time.

Examples of manufacturing processes for dispensing hot melt adhesives that can be used in the present invention are disclosed in U.S. Pat. Nos. 5,935,670, 6,319,442, and 6,640,864, all of which are incorporated herein by reference in their entireties. In such manufacturing processes, a predetermined amount of adhesive is dispensed onto a liner.

In one embodiment of the present invention, the pull tab14is inserted into the adhesive12while the adhesive12is in the molten state, i.e. above its softening and/or melting point. This can be achieved by inserting (piercing) the pull tab14into the middle of a recently dispensed, molten mass of adhesive. The adhesive12is also preferably shaped into a disc while it is still in the molten state. The adhesive12may be shaped into the disc by applying a second liner20to the first surface16of the adhesive12, and applying pressure so as to form the disc. In other embodiments, the adhesive12may be shaped into other shapes, such as a square, rectangle, triangle, etc. Alternatively, a single release liner may be used such that once the adhesive12has been dispensed onto the release liner20, the release liner20may be rolled so that the adhesive discs12are on an interior of the roll. This allows for the top surface16of the adhesive discs12to come into contact with the back of the release liner20. The pressure created as the roll is created allows the adhesive discs12to be flattened. Once the adhesive12has cooled to a temperature below its softening point (i.e., its glass transition temperature), the mount10is ready to be used. The illustrated embodiment is not intended to be limiting in any way.

In another embodiment, illustrated inFIGS. 3A and 3B, the pull tab14includes a hinge15in a center portion thereof, and one end of the pull tab14is attached to the first (top) surface16of the adhesive12and the other end of the pull tab14is attached to the second (bottom) surface18of the adhesive12. In this embodiment, the pull tab14is attached to the adhesive12while the adhesive12is still at a temperature above its softening point. Alternatively, the pull tab14may be attached to the adhesive12after the adhesive12has cooled to a temperature below its softening point.

In embodiments, the predetermined volume of adhesive is between about 0.15 cm3and about 3.0 cm3. The predetermined amount may be between 0.5 and 1.5 cm3, and in one particular embodiment may be about 1.0 cm3. In embodiments, the adhesive12of the mount10has a thickness T of about 2 mm to about 4 mm and a diameter D of about 10 mm to about 30 mm. The adhesive12may have a thickness T of between about 2.5-3.5 mm, and a diameter D of about 15-30 mm. In one particular embodiment, the adhesive12may have a diameter of about 24 mm and a thickness of about 3.0 mm. These ranges and values are not intended to be limiting in any way, but are instead intended to provide examples of the dimensions of the adhesive.

In an embodiment, the pull tab14is formed from polyvinylchloride (PVC). In other embodiments, the pull tab14may be formed from polyester, such as biaxially oriented polyethylene terephthalate (PET). The pull tab14may also be formed from a fibrous material, such as TYVEK®, which is a registered trademark of E. I. du Pont de Nemours and Company of Wilmington, Del. Preferably, the pull tab14is formed from a substantially rigid, non-stretchable material that deforms a very small (essentially zero) amount when force is applied to the pull tab. This allows the energy being applied to the pull tab14(shown as a force F inFIG. 3) to transfer to the adhesive12and deform the adhesive12, as shown inFIG. 2, so that the adhesive12will release from the reference surface RS without damaging the reference surface RS. The pull tab14may have a length in the range of about 25-75 mm, a width in the range of about 7-15 mm, and a thickness in the range of about 0.1-0.2 mm. These ranges are not intended to be limiting in any way, but are instead intended to provide examples of the dimensions of the pull tab.

When the mount10is ready to be used, one of the liners20may be removed from the adhesive12so as to expose one side of the adhesive12. The exposed side of the adhesive12may then be pressed against a product P to be mounted on a surface. In the illustrated embodiment, shown inFIGS. 5 and 6, the product P includes leveling device, such as a laser level LL, and the surface is a reference surface RS. It should be appreciated, however, that the mount10can be used to adhere other products to any appropriate surface. The laser level LL is discussed in greater detail below. The user may then remove the other liner20that is still attached to the adhesive12, and press the adhesive12against the reference surface RS via the laser level LL, thereby firmly attaching the laser level LL to the reference surface RS. The mount10is attached to the laser level LL such that the pull tab14may be readily accessible (e.g., has sufficient length), even after the laser level LL has been mounted to the surface.

When the user has finished using the laser level LL, the mount10may be removed from the reference surface RS by pulling the tab14in a direction that is substantially parallel to the reference surface RS so as to create the force F, described above, in that direction, as shown inFIG. 3.

FIGS. 7-10illustrate another embodiment of a manufacturing process to manufacture a plurality of mounts10, and the manner of positioning the pull tabs14relative to the adhesive during the manufacture process. In this embodiment, a plurality of adhesives12are formed in the shape of discs between a pair of release liners20. As shown inFIG. 7, one of the release liners20is removed so as to expose the top surface16of the adhesives12. Then, as shown inFIG. 8, one pull tab14is attached to the top surface16of each adhesive12such that the majority of the pull tab14extends away from the adhesive12. Next, one of the release liners20is removed from a second plurality of adhesives12, just like the ones shown inFIG. 7. The top surface16of each of the second plurality of adhesives12is positioned over the top surface16of one of the first plurality of adhesives12, with the pull tab14in the middle, as shown inFIG. 9. This leaves the assembled plurality of mounts10in the condition shown inFIG. 10. Of course, the release liners may include perforations between the mounts10so that single mounts may be easily separated with the release liners20still attached to the mount10. In addition, the liners20may be cut with scissors or some other type of blade in locations between the mounts10so that individual mounts10may be used. When one of the mounts10needs to be used, one of the release liners20may be pulled back so as to expose a single mount10. The mount10may be applied to the product P and pressed in place and then the opposite release liner20may be removed from the mount10. The product P is now ready to be attached to the reference surface RS.

In the illustrated embodiment ofFIGS. 5 and 6, the laser level LL includes a housing100, a light source110carried by the housing100, and a power source120disposed within the housing100. In one embodiment, the light source110is a laser or a laser diode. The power source120, such as a battery, is electrically connected to the laser110to power the same. The laser110may be a laser diode. The laser level LL may also include a cylinder lens or other lens or mirror and/or optic system that converts the line beam generated by the laser10into a plane of light that, when projected onto a surface (such as the wall surface) forms a line of light on that surface. Such optic systems may also optionally be a prism lens, or a motor that rotates the laser110or a mirror or lens to generate a line on the desired surface (such as the wall surface on which the laser level LL is mounted). As shown inFIG. 5, the laser level LL also includes at least one bubble (spirit) vial130to provide a manual indication of the horizontalness (level) or verticalness (plumb) of the laser10itself. Bubble vials are generally well-known, so the details of the bubble vials130depicted in the figures will not be described herein. The vials130may be used to position the laser level LL before the mount10is pressed against the reference surface RS. This way, the line that is generated by the laser110provides a level or plumb reference line for the user. The laser level LL may also include an adjustor (not shown) that may be used to adjust the position of the laser110between the horizontal and vertical positions. For example, the adjustor may be an indexing mechanism that allows the laser110to be rotated by a known angle so that a line may be generated at a known angle relative to horizontal and/or vertical. The illustrated embodiment of the laser level LL is not intended to be limiting in any way, but is merely shown as an example of a leveling device that may be used with the mount10described above.

Another laser level LL, that can be used with the mount10is disclosed in United States Patent Application Publication No. 2005/0078303, which is hereby incorporated by reference in its entirety. In at least one embodiment of the laser level of the present invention, the laser level LL includes within the housing a stud finder circuit capable of detecting a stud located behind a wall surface (wall board). An example of one type of stud finder is disclosed in United States Patent Application Publication No. 2005/0078303, which is incorporated herein by reference in its entirety.

Another embodiment of a leveling device in the form of a laser level LL′ is shown inFIGS. 11-14. In this embodiment, the laser level LL′ includes a housing200, and a light source210and power source220that are carried by the housing200. In the illustrated embodiment, the light source210is a laser. Such lasers210are known and are described by, for example, U.S. Pat. No. 6,935,034, which is hereby incorporated by reference. The laser210may cooperate with a cylinder lens or other optical system as described above for generating a plane of light that is configured to intercept the reference surface RS when the laser level LL′ is placed on the reference surface RS. In an embodiment, the laser210cooperates with a line lens of the type described in U.S. Pat. No. 6,914,930, which is hereby incorporated by reference.

In an embodiment, the laser210and any associated lens or optical system may be oriented so as to provide a beam of light that that includes a major axis that is parallel to the reference surface RS and a minor axis that is perpendicular to the reference surface RS. With the beam of light oriented with its major axis parallel to the reference surface RS, a line may be generated on the reference surface RS that is thicker and more visible than a line that is generated with a beam of light that is oriented with its major axis perpendicular to the reference surface.

The power source220may be a battery that is capable of powering the laser210. In the illustrated embodiment, the power source220is a pair of batteries. Power between the power source220and the light source210may be controlled with a power switch243. The power switch243may be moved between an ON position and an OFF position.

A plurality of bubble vials230are supported by the housing200. In one embodiment, at least two vials are used and are disposed on the housing200so as to be perpendicular to each other and such that one of them has its longitudinal axis disposed generally parallel to the plane of light that is emitted from the housing200(while the other vial has its longitudinal axis perpendicular to the plane of light). This allows the laser210to generate a line on the reference surface that is either horizontal (level) or vertical (plumb), which are the two most commonly used orientations. The laser level LL′ may be oriented in any position to generate a line on the reference surface at any angle.

As shown inFIG. 12, the housing200is movably connected to a base240. Specifically, the housing200has an arc-shaped slot202that is configured to receive an arc-shaped protrusion242that is located on the base240. Of course, the slot may be located on the base and the protrusion may be located on the housing. In addition, other interacting shapes and configurations may be used. The shapes can have dissimilar configurations (for example a straight pin or pins that ride in a curved slot). The illustrated embodiment is not intended to be limiting in any way.

The arc-shaped slot202and protrusion242are shaped such that they have a large radius of curvature. In one embodiment, their centers of curvature are located at a point that is offset (displaced) from the base240and housing200of the laser level LL′. The large radius of curvature arc allows for a relatively fine adjustment of the laser beam position that is less sensitive to movement of the housing200relative to the base240, as compared to a pivotal movement of a housing about an axis of rotation. Specifically, because the arc-shaped slot has a large radius of curvature, e.g. in the range of about 2.5-7.5 cm, the housing200may be moved relatively liberally along the arc to affect a relatively small change in the angular positioning of the laser line on the wall surface. This allows for easy manual adjustment, while viewing the bubble vial, to ensure that the line of light projected on the wall surface is either plumb or level. This is a more affective (more precise) mechanism for positioning the laser light in comparison with pivotal movements used in the prior art. In the illustrated embodiment, the slot202and protrusion242are designed to allow a total adjustment of 20° (e.g. +/−10° from center of the arc). Of course, the slot and protrusion may be designed to allow an adjustment that is greater than or less than 20°. In an embodiment, some frictional resistance is provided so that when the housing200is moved relative to the base240, the position is held by frictional engagement between the base240and the housing200. The illustrated embodiment is not intended to be limiting in any way.

While in one embodiment the arc configuration of the protrusion and slot may form part of a circle, it is contemplated that any curved configuration is contemplated by the term “arc” herein.

In an embodiment, the laser210is carried by a pendulum that is supported by the housing200so that the laser210may be self-leveling. Such a pendulum is known from U.S. Pat. No. 6,914,930, which is hereby incorporated by reference in its entirety, and is therefore not described in further detail. In such an embodiment, no bubble vial need be used. In addition, a single housing may be used rather than a base and housing movable relative to the base.

In one embodiment, the base240is configured to receive one to three of the mounts10that are described above. The pull tab14portions of the mounts10are not shown inFIGS. 11,13, and14. As shown inFIG. 12, the pull tabs14extend away from the laser level LL′ a sufficient distance so that once the laser level LL′ is mounted to the reference surface RS, the pull tabs14may be used to remove the laser level LL′ from the reference surface RS, as described above.

As shown, the base240is molded to define three areas244with peripheral walls246that extend away from the housing200. The areas244are each sized to each receive one of the mounts10. In the illustrated embodiment, two mounts10are used, and the adhesive12of each mount10is shaped as an oval. In other embodiments, the adhesive12may be shaped as a circular disc, a square, a triangle, or other shape, and the areas244on the base240that receive the mounts10may be of a corresponding shape. The illustrated embodiment is not intended to be limiting in any way.

The laser level LL′ also includes a plurality of retractable spacers250that are received by the housing200. The spacers250are spring loaded and biased so that they extend outwardly from the housing200in a biased extended position, as will be discussed in greater detail below. As shown inFIG. 13, when the spacers250are in the extended position, they extend past the base240and the mounts10(when the mounts are attached to the base). The spacers250are configured to come into contact with the reference surface, without damaging the reference surface, and create a space254between the reference surface and the mounts10. The spacers250allow the user to place the laser level LL′ on the reference surface RS and position the laser level LL′ to the desired location and general orientation before actually mounting the laser level LL′ to the reference surface RS by engaging the adhesive with the reference surface (e.g., vertical wall). In other words, when the mounts10are adhered on one side thereof to the areas244in the base240, the spacers250maintain the opposite side of the mounts10in spaced relation from the reference surface so that the base can be oriented as desired by sliding the spacers250on the reference surface until the desired position and orientation of the base is achieved, for example, by viewing one or more of the vials230. When the desired position is attained, the user pushes the housing and/or base towards the reference surface.

The spacers250are configured to retract toward and at least partially into the housing200to a retracted position when the housing200is forced towards the reference surface against the bias of the internal springs, as discussed in greater detail below. When the housing200or base240is pressed toward the reference surface RS, the spacers250will retract toward and at least partially into the housing200against the bias of the springs and lock in the retracted position by an internal locking mechanism so that the internal spring does not apply a force to the mounted laser level LL′ and thereby tend to push the base240away from the reference surface. When the spacers250are in the retracted position, the mounts10come into contact with the reference surface RS so that the laser level LL′ is mounted to the reference surface via the mounts10.

FIGS. 15-17illustrate an embodiment of a spacer assembly260that comprises the plurality of spacers250in greater detail. In the illustrated embodiment, the spacer assembly260includes a pair of spacer members262that each carry a pair of reference surface engaging spacers250. Because each side of the spacer assembly260is essentially the same, only one side will be discussed in further detail.

A spring264is provided between the housing200and the spacer member262to bias the spacer member262, as well as the spacers250, toward the reference surface RS when the laser level LL′ engages the reference surface RS. The spacer member262includes an opening266that is configured to receive a distal end268of a locking member270when the spacer member262is in a retracted and locked position relative to the housing200, as shown inFIG. 16. The locking member270is biased outward by a spring272and toward the spacer member262. The distal end268of the locking member270includes a sloped surface274that is configured to engage a corresponding sloped surface276defined by an upper portion of the spacer member262. When the spacer member262is in the extended position, a force that is provided to the spacers250in a direction toward the housing200will cause the spacer member262to move against the bias of the spring264. Such movement causes the sloped surface276on the upper portion of the spacer member262to slide along the sloped surface274of the distal end268of the locking member270, thereby causing the locking member270to move against the bias of the spring272. When the spacer member262moves to a position that aligns opening266with the distal end268of the locking member270, the bias of the spring272causes the locking member270to move into the opening266, thereby locking the spacer member262in the retracted position relative to the housing200, as shown inFIG. 16.

A proximal end portion278of the locking member270includes a sloped surface280the is configured to engage a sloped surface282provided by a releasing button284. An opposite end286of the releasing button284is configured to be received by the user's finger or thumb. The releasing button284is biased to a non-engaging position by a spring288that is positioned between the housing200and the releasing button284. When the locking member270is biased in its locked position, i.e. the distal end268is engaged with the spacer member262in the opening266, and the releasing button284is biased in its upward position, the spacers250remain in the retracted position relative to the housing200.

When the user would like to move the spacers250to the extended position (seeFIG. 17), the user presses the releasing button284against the bias of the spring288. This causes the sloped surface282to engage and ride along the sloped surface280provided by the proximal end portion278of the locking member270, which causes the locking member270to move against the bias of the spring272. When the locking member270has moved a distance that allows the distal end268to pull out of the opening266, the bias of the spring264causes the spacer member262to move to the extended position relative to the housing200. The illustrated embodiment tended to be limiting in any way.

Returning toFIG. 11, once the laser level LL′ is firmly mounted to the reference surface, the vials230may be used to more finely adjust the orientation of the housing200relative to the base240so that the beam of light generated by the laser210is either horizontal or vertical, depending on which vial230is being used. As discussed above, the arc shaped slot202and protrusion242provide for an adjustment. In one embodiment, the arc shaped slot202defines an arc that provides about 20° of movement (i.e., ±10° from the center of the arc). Of course, if the user would rather use the laser210to generate a line between two existing points on the reference surface, the levels230do not have to be used at all.

It should be appreciated that, in one embodiment, the spacer assembly260can be used with a laser level that has a single housing that integrates what is disclosed above as the base and the housing. For example, in a contemplated embodiment, a pendulum for mounting the light source (laser diode) can be used instead of the bubble vial for leveling the laser line projected on the wall surface.

To remove the laser level LL′ from the reference surface, the pull tab14of each mount10may be pulled in a direction that is substantially parallel to the reference surface so as to deform the adhesive12and allow the cohesive bonds between the adhesive12and the reference surface to break, thereby releasing the mounts10from the reference surface, as described above. If the mounts10are still attached to the base240, they may be peeled off of the base, or the pull tabs14may be pulled again so that the mounts10release from the base240.

After (or concurrently with) removal of the laser level LL′ from the reference surface, the spacers250can be moved again to the extended position. This can be achieved by pushing the releasing button284, which releases the spacers250from being locked by the locking mechanism in the retracted position, so that the internal spring264moves the spacers250to the extended position.

The foregoing illustrated embodiments have been provided to illustrate the structural and functional principles of the present invention and are not intended to be limiting. To the contrary, the present invention is intended to encompass all modifications, alterations and substitutions within the spirit and scope of the appended claims.