Level with rotating vial and locking assembly

A level including a rotating level vial is provided. The level includes a locking mechanism that utilizes an actuator that engages a brake to lock the rotating vial into the desired position. The locking mechanism may include a spring element that is compressed by the actuator during locking, and the spring element in turn pushes against the brake facilitating control of the normal force that the brake applies to the vial surround of the rotating vial. The rotating level vial may engage the level body such that the rotating level vial is permitted to rotate 360 degrees in both the clockwise and counter clockwise directions.

BACKGROUND OF THE INVENTION

The present invention relates generally to the field of tools. The present invention relates specifically to a tool, such as a level, with a rotating vial and a locking assembly configured to temporarily, reversibly and/or selectably fix the vial in place at a custom angle as selected by a user. Levels are used to determine the levelness of a structure, surface or workpiece. In use the level is placed on or in contact with a surface to be measured, and the user views the location of a bubble within a vial relative to markings that indicate the levelness of the structure, surface or workpiece.

SUMMARY OF THE INVENTION

One embodiment of the disclosure relates to a tool, specifically a level. The level includes a level body defining a base surface configured to engage a workpiece and a rotating level vial located within the level body. The rotating level vial has an interior chamber containing a mineral spirit liquid and a bubble. The level includes a vial support surrounding and supporting the rotating level vial, and the vial support is located within an opening formed in the level body. The vial support is rotatable within the opening such that the rotating level vial may be oriented at a plurality of angular positions relative to the base surface. The level includes a locking system including a threaded channel, a threaded screw engaging the threaded channel and a brake component having a first surface facing the vial support and a second surface facing the threaded screw. The threaded screw is moveable within the threaded channel between a locked position and an unlocked position. In the locked position, the threaded screw engages the brake component such that the first surface of the brake component engages the vial support with a force sufficient to restrain rotation of the vial support and to hold the rotating level vial and vial support in a selected angular position relative to the base surface. In the unlocked position, the vial support and rotating level vial are permitted to rotate within the opening.

Another embodiment of the disclosure relates to a level. The level includes a level body defining a base surface configured to engage a workpiece and a level vial located within the level body. The level includes a vial support surrounding and supporting the level vial, and the vial support is located within an opening formed in the level body. The vial support is rotatable within the opening such that the level vial may be oriented to a plurality of angular positions relative to the base surface. The level includes a locking system. The locking system includes an actuator and a brake component having a first surface facing the vial support and a second surface facing the actuator. The locking system includes a spring element located between the actuator and the brake such that the actuator compresses the spring element when the actuator is moved from an unlocked position to a locked position in which the actuator causes the first surface of the brake component to engage the vial support with a force sufficient to restrain rotation of the vial support.

Another embodiment of the disclosure relates to a leveling device. The leveling device includes a level body defining a base surface configured to engage a workpiece and a level vial located within the level body. The leveling device includes a vial support surrounding and supporting the level vial. The vial support is located within an opening formed in the level body, and the vial support is rotatable within the opening 360 degrees in both the clockwise and counterclockwise directions such that the level vial may be oriented a plurality of angular positions relative to the base surface. The level includes a locking system configured to lock the vial support in a selected angular position.

DETAILED DESCRIPTION

Referring generally to the figures, various embodiments of a level are shown. In general, the levels discussed herein include one or more level vial and a level base. As will be generally understood, the base surface of the level is placed on a workpiece (e.g., a structure, surface, etc.) in order for the user of the level to determine the levelness of the workpiece surface. The level embodiments discussed herein include one or more rotating vials and a locking mechanism used to temporarily, reversibly and/or selectably fix the rotating vial at a custom angle relative to the level base as may be selected by the level user.

Traditionally, levels include one or more vials preset at specific angles relative to the level base, such as 0, 90, and/or 45 degrees. However, these standard, fixed and preset angles may be difficult to use during some types of work where repeated leveling of surfaces at nonstandard angles is common. The rotating vial of the present disclosure allows the user to select the angle of the level vial relative to the level base. Thus, the user can utilize a single level which can be adapted by the user to a task requiring leveling of surfaces located at a non-standard angle (e.g., measure levelness of surfaces at non-standard angles).

However, a challenge with a rotating level vials is how to secure the vial in place at the angle selected by the user. The level embodiments discussed herein include a locking assembly that Applicant has identified as providing superior locking performance (at least compared to some conventional level designs). In particular, the locking assembly discussed herein reversibly locks the rotating vial in place in a manner that reliably holds the vial in the desired rotational position while reducing/eliminating the chance that the rotating vial inadvertently rotates (e.g., rotates in a pocket, in a tool belt, while being carried, while being used, etc.). As discussed below, in various embodiments, the locking mechanism discussed herein securely fixes the rotating vial within the housing of the level until the locking mechanism is disengaged intentionally by the user. In addition, the rotating vial design discussed herein allows the level vial to be rotated 360 degrees in both the clockwise and counterclockwise directions.

Referring toFIG. 1, a level with a rotating vial, such as level20, is shown according to an exemplary embodiment. Level20includes a level body, shown as housing22, and a base surface, shown as level base23. A first vial24is set in housing22such that it is parallel or at 0 degrees relative to level base23. A second vial26is set in housing22such that it is perpendicular to or at 90 degrees relative to level base23.

Level20includes a rotating level vial assembly25and includes a vial support, shown as vial surround30, and a level vial28. Vial surround30is set in housing22such that it may rotate freely within housing22. Vial28is fixed in vial surround30such that it may be rotated along with vial surround30to form a variety of selected angles relative to level base23. As shown, vial28is rigidly fixed in position relative to vial surround30such that rotation of vial surround30cause rotation of vial28. In general, vials24,26and28are hollow vials (e.g., glass or plastic vials) having an internal chamber holding a liquid, such as a mineral spirit, and including a bubble which moves providing the leveling indication.

In one embodiment, vial surround30is rotatable 360 degrees within housing22. In some such embodiments, vial surround30is rotatable continuously such that vial surround30and vial28may be positioned at an angular position selected by the user. In various embodiments, vial surround30and vial28are rotatable in both the clockwise and counter clockwise directions as shown by arrow27. In other embodiments, vial surround30only rotates a limited number of degrees within housing22(e.g., rotatable less than 360 degrees, less 270 degrees, less than or equal to 180 degrees, etc.).

Referring toFIGS. 1 and 2, a locking system or assembly, shown as locking mechanism32, is set in a cavity31of housing22. Locking mechanism32includes an actuator, shown as adjustable fastener34, that applies a variable coupling force on vial surround30to reversibly and selectably fix vial surround30at a desired angle relative to level base23. Fastener34may be disengaged such that low or zero coupling force is applied to vial surround30allowing vial surround30to rotate within housing22. Various embodiments include various combinations of preset and rotatable vials, including embodiments with one or more rotating vial, only a single rotatable vial and no fixed vials and embodiments with multiple rotatable vials having separate locking mechanisms and no fixed vials.

Referring toFIG. 2, an exploded view of an embodiment of locking mechanism32is shown removed from cavity31. Locking mechanism32includes adjustable fastener34, an insert36, a retainer38, and pad40. Insert36is fixed at the entrance of cavity31and configured to receive fastener34. In one embodiment, an adhesive is used to fix insert36within cavity31, and in another embodiment, insert36is friction fit within cavity31. Retainer38and a brake, shown as pad40, are placed within cavity31behind insert36and sized such that they are movable in the longitudinal direction within cavity31.

In this arrangement, pad40has a first or inner surface facing vial surround30and a second or outer surface facing adjustable fastener34. In one embodiment a biasing element or spring element, shown as spring39, is located between retainer38and pad40. In one embodiment, spring39is a coil spring, and in another embodiment spring39is a washer spring. In various embodiments, the locking assembly may include a wide variety of biasing elements, such as a helical coil spring, a leaf spring, v-spring, Belleville spring, various types of elastic materials including rubbers, foams, etc.

Referring now toFIG. 3, a perspective cross-sectional view of an embodiment of the locking mechanism32and vial surround30within level20is shown. In this embodiment, fastener34is a screw having a head41and body or shaft43, and the body has threads35. Insert36has cooperating threads37that engage threads35such that fastener34may be advanced into and out of cavity31by rotating fastener34. In this embodiment, insert36defines a threaded internal channel within which fastener34is received, but in other embodiments, threads37may be formed directly in the material of level body22.

In general, and as will be explained in more detail below, fastener34is moveable within insert36between a locked position and an unlocked position. In general, in the locked position, the inner surface of pad40is moved to engage the outer surface of vial surround30with a force sufficient to restrain rotation of vial surround30and to hold level vial28and vial surround30in a selected angular position relative to the base23. In general, in the unlocked position, vial surround30and level vial28are permitted to rotate within level body22.

The body of fastener34is longer than insert36such that a portion of the body of fastener34extends into cavity31beyond the inner end of insert36when fastener34is partially or fully advanced within cavity31. A depression42is included on the top of retainer38. Depression42is configured to receive the portion of fastener34that extends beyond the end of insert36. In an alternative embodiment, the depression42is omitted, and retainer38is flat across the surface facing fastener34.

As shown inFIG. 3, the inner end of retainer38includes a reduced diameter post44, and the outer end of pad40facing retainer38includes a reduced post46. As shown inFIG. 3, posts44and46extend into the central cavity of spring39, and in this manner posts44help retain spring39in the appropriate position during locking and unlocking of locking mechanism32.

In general, the compression state of spring39corresponds to the advancement of fastener34within cavity31. When fastener34is fully removed from cavity31, spring39is in its uncompressed state, and when fastener34is fully advanced within cavity31spring39is in its fully compressed state (seeFIG. 4). In other embodiments, fastener34need not be fully removed from cavity31to induce the uncompressed static state in spring39. In some embodiments, fastener34is sized such that, upon retraction, no portion of fastener34extends into cavity31beyond the inner end of insert36resulting in the uncompressed state of spring39.

In one embodiment, one face of retainer38is in contact with the opposing face of insert36when spring39is in its uncompressed static state. In one embodiment, pad40includes a face48in contact with a surface50of vial surround30when spring39is in both the uncompressed state and fully compressed state. The constant contact of pad40with surface50provided by spring39ensures a minimum amount of friction between the surface50and pad40regardless of the position of fastener34. In one embodiment, the minimum friction is such that vial surround30will not freely rotate, but can be moved by applying a slight force, such as a gentle twist. Disabling free rotation of vial surround30when the spring39is in its uncompressed static state allows the vial28to remain set but not locked with respect to level base23as the locking mechanism32is engaged.

To allow the vial to be rotated and positioned at the desired angular position by the user, fastener34is advanced out of cavity31, bringing spring39to its uncompressed state, which in turn decreases the normal force applied by pad40onto the outer surface of vial surround30. In one embodiment, when fastener34is fully withdrawn, no portion extends into cavity31beyond the interior end of insert36. In the unlocked state, no normal force or a relatively small normal force is applied to vial surround30by pad40, which allows vial surround30to rotate within level body22to the desired angle. In one embodiment, vial surround30includes an indicator that corresponds to markings on housing22that indicate the current angle of vial28.

To lock vial surround30in place, fastener34is advanced into cavity31. As fastener34advances it contacts depression42of retainer38. The further advancement of fastener34advances retainer38further into cavity31. The advancement of retainer38engages the first end of spring39and begins to compress the spring39. As spring39is compressed, the second end of spring39pushes pad40against surface50with a greater force. This action increases the amount of friction between surface50and face48. This process will continue until fastener34is fully within cavity31and/or the spring39is in its fully compressed state, at which point vial surround30will be fully locked in place such that rotational movement of vial surround30will be prevented or resisted.

In such embodiments, the normal force between surface50and vial surround30is related to the degree to which fastener34is threaded into insert36and to the amount of compression of spring39, and in specific embodiments, the normal force between surface50and vial surround30increases as the degree of spring compression increases and/or as fastener34is threaded further into insert36. Thus, in such arrangements, utilizing a biasing element, such as spring39, as part of locking mechanism32allows locking mechanism32to provide varying levels of normal force onto vial surround from a low or zero amount of normal force to a high amount of normal force when spring39is fully compressed.

Referring toFIG. 4the locking mechanism32is shown in its fully locked or engaged position with the top of pad40contacting the bottom of retainer38. In this embodiment spring39(labeled inFIG. 3) is fully compressed and located between pad40and retainer38and is shown surrounding first and second posts44and46. In alternative embodiments, the biasing element may fill the space between pad40and retainer38thus preventing contact of the top of pad40and bottom of retainer38. In one embodiment, the portion of cavity31is sealed off by use of standard O-rings around the exterior surfaces of pad40and retainer38.

In another embodiment, a first slot is included on the end of retainer38facing pad40that is configured to receive a first end of a biasing element, such as spring39. In addition, a second slot is included on the end of pad40facing retainer38that is configured to receive a second end of the biasing element, such as spring39. In such embodiments, spring39is located between retainer38and pad40within an area defined by the opposing slots of retainer38and pad40.

In various embodiments, Applicant has developed a rotating level and locking mechanism that is positioned relative to level body22and/or base23in a manner that improves use/access to locking mechanism32and that may facilitate assembly of locking mechanism32. In particular, Applicant believes that the arrangement discussed herein provides a locking mechanism having low complexity that also provides a tight hold on vial surround30when in the locked position.

Referring back toFIG. 1, level body22defines a longitudinal axis52, and vial surround30is positioned so that its axis of rotation is substantially perpendicular (e.g., within 1 degree of perpendicular) to longitudinal axis52and substantially parallel (e.g., within 1 degree of parallel) to the plane defined by base surface23. In addition, as can be seen inFIGS. 1 and 2, a longitudinal axis defined by the threaded channel of insert36is substantially parallel (e.g., within 1 degree of parallel) to longitudinal axis52.

Still referring toFIGS. 1 and 2, longitudinal axis52extends from a front end54to a rear end surface56of level body22, and the threaded channel of insert36includes an open end that is accessible through rear end surface56such that fastener34can be received within the threaded channel through rear end surface56. In this arrangement, the rotating vial surround30and vial28are located between end surface56and central vial24.

Referring toFIG. 1, fastener34is sized and positioned relative to level body22to both provide convenient access to and manipulation of fastener34, without providing a protrusion that might otherwise cause snags, break easily, etc. Thus, as shown inFIG. 1, screw head41of fastener34includes a sidewall58and an endwall60. Fastener34is sized such that endwall60is recessed inward in the direction of longitudinal axis52relative to rear end surface56, thus ensuring, fastener34(at least in the locked position) does not extend past or protrude from end surface56. In addition, sidewall58is textured, patterned, embossed, raised, etc. to provide a gripping surface that allows the user to easily spin fastener34during locking and unlocking.

Referring toFIG. 5, a perspective view from below of level20is shown. In various embodiments, base23may include a groove or channel70extending in the direction of longitudinal axis52along base23. In such embodiments, channel70allows level20to engage an elongate, narrow workpiece, such as conduit. In addition, in some embodiments, level20includes one or more magnetic coupling element72located along base23. In such embodiments, the magnetic coupling element(s)72facilitate use of level20with magnetic workpieces, such as metal conduit, by allowing level20to be coupled to the magnetic workpiece via the magnetic attraction provided by magnetic coupling element(s)72.

Referring toFIGS. 6 and 7, a level100is shown according to an exemplary embodiment. In general, level100is substantially the same as level20, except that level100includes a small level body102. In various embodiments, level body102is sized to fit easily in a pocket, hand, drawer, etc., and level body102has a length in the direction of longitudinal axis52that is less than the length of level body22. In such embodiments, level body102defines a small, short base104. In various embodiments, the length of body102and of base104in the direction of longitudinal axis is less than 12 inches, less than 8 inches, less than 6 inches or less than 4 inches.

As shown, level100includes a rotating level vial assembly25and a locking system32. In contrast to level20, rotating level vial assembly25, and in particular vial surround30, is relatively large compared to level body102. In various embodiments, the maximum outer diameter of vial surround30is at least 10% and less than 80% and specifically, at least 25% and less than 75% of the length of body102.

In various embodiments, locking mechanism32may be used with various styles of levels, including block torpedo style level, billet torpedo type level, box levels, I-beam style levels, etc. In various embodiments, level body22may be formed from die cast metal such as aluminum, and in other embodiments, level body22may be formed from an extruded metal material (e.g., extruded aluminum). In some specific embodiments, base surface23is machined to have a flat, flush or planar surface following extrusion, and in some embodiments, this machined surfaced may be anodized.