LASER LEVEL ASSEMBLY

A laser level assembly includes a mounting bracket and a laser level on the mounting bracket. The mounting bracket includes a base part and a back cap. The laser level includes a laser generator, the laser level projects at least one of a horizontal line, a vertical line or a laser spot. The laser level also includes a battery pack receptacle configured to selectively receive a removable battery pack, a wireless transmitter, a circuit board in the mounting bracket, and a secondary power device on the circuit board. The removable battery pack is configured to power the at least one laser generator. The secondary power device is configured to selectively power the wireless transmitter.

FIELD OF THE INVENTION

The present invention relates to construction tools such as a construction laser level.

BACKGROUND

There are various existing laser levels. It is desired to provide a laser level assembly with a unique construction.

SUMMARY

According to one aspect, the present disclosure describes a laser level assembly, comprising: a mount; a rotational base; a laser level on the rotational base; wherein the laser level and the rotational base are rotatable about a first axis relative to the mount; and wherein the laser level is rotatable about a second axis relative to the mount and the rotational base; wherein rotation of the laser level about the second axis is driven by a motor.

The laser level assembly may further comprise a battery powering the motor.

The laser level assembly may further comprise a controller configured to control operation of the motor.

The laser level assembly may further comprise a wireless transceiver configured to receive wireless control signals.

According to another aspect, there is a laser level assembly, comprising a mount; a rotational base; a laser level on the rotational base; wherein the laser level and the rotational base are rotatable about a first axis relative to the mount; and wherein the laser level is rotatable about a second axis relative to the mount and the rotational base; wherein rotation of the laser level about the first axis is driven by a first motor; and wherein rotation of the laser level about the second axis is driven by a second motor.

The first motor may be disposed in the mount.

The second motor may be disposed in the rotational base.

The laser level assembly may further comprise a removable battery pack powering the first motor and the second motor.

The laser level assembly may further comprise a controller configured to control operation of the motor.

The laser level assembly may further comprise a wireless transceiver configured to receive wireless control signals.

According to another aspect, there is an exemplary embodiment of a laser level assembly, comprising: a mount comprising a mounting portion and a base portion transverse to the mounting portion, wherein the mounting portion is configured to be secured to a surface; a rotational base on the base portion of the mount; a laser level on the rotational base; wherein the laser level comprises a first vertical beam; a second vertical beam and a first horizontal beam; wherein the laser level is rotatable about a first axis; wherein the laser level is rotatable about a second axis; wherein the second axis is at a cross point of the first vertical beam and the second vertical beam; wherein rotation of the laser level about the first axis is driven by a first motor; and wherein rotation of the laser level about the second axis is driven by a second motor.

The first motor may be disposed in the mount.

The second motor may be disposed in the rotational base.

The laser level assembly may further comprise a removable battery pack powering the first motor and the second motor.

The laser level assembly may further comprise a controller configured to control operation of the motor.

The laser level assembly may further comprise a wireless transceiver configured to receive wireless control signals.

The mounting portion of the mount may include magnets.

According to another aspect, there is an exemplary embodiment of laser level assembly including: a mounting bracket; a laser level; and a motor; wherein the mounting bracket includes a mounting portion and a base portion transverse to the mounting portion; wherein the laser level is disposed on the base portion; and wherein the base portion is configured for vertical translation relative to the mounting portion; and wherein the motor drives the vertical translation of the base portion.

The motor may be mounted in the mounting bracket.

The laser level assembly may further comprise a rack and a pinion engaged with the rack.

The motor may drive rotation of the pinion.

The rack may be on the mounting portion of the mounting bracket.

The mounting bracket may further comprise a bottom portion.

The bottom portion may be parallel to the base portion.

The bottom portion may include a screw thread mount.

The rack may extend in a vertical direction along the mounting portion.

The rack may extend along a central portion of the mounting portion.

The rack may extend along a side of the mounting portion.

According to another aspect, there is an exemplary embodiment of a laser level assembly including a mounting bracket comprising a mounting portion and a base portion transverse to the mounting portion; a laser level; and a first motor configured to drive vertical translation of the laser level relative to the mounting portion of the mounting bracket; and a second motor configured to drive rotational motion of the laser level about a vertical axis.

The first motor may be disposed in the mounting bracket.

The second motor may be disposed in the mounting bracket.

The laser level assembly may further include a rack and a pinion.

According to another aspect, there is an exemplary embodiment of a laser level assembly including: a mounting bracket comprising a mounting portion and a base portion transverse to the mounting portion; a laser level on the mounting bracket; and a ceiling wall mount. The mounting bracket is connected to the ceiling wall mount at the mounting portion. The mounting bracket includes a motor and a pinion driven by the motor. The ceiling wall mount includes a rack engaged with the pinion. Rotation of the motor causes the mounting bracket to translate in a vertical direction relative to the ceiling wall mount.

The ceiling wall mount may include a metal plate.

The mounting portion may include magnets, and attraction between the magnets and the metal plate connect the mounting bracket to the ceiling wall mount.

The rack may extend along an edge of the metal plate.

The rack may extend along opposite edges of the metal plate.

The mounting bracket may further include a rotational motor which selectively drives rotational motion of the laser level about a vertical axis.

According to an aspect of an example embodiment, a laser level assembly includes: a mounting bracket comprising an attachment bracket and a movable bracket; a laser level mounted on the movable bracket, the laser level configured to project at least one of a horizontal line, a vertical line or a laser spot; a motor in the movable bracket, wherein the motor is configured to drive movement of the movable bracket relative to the attachment bracket; and a clutch operatively associated with the motor.

The laser level assembly may further include a pinion driven by the motor.

The clutch may be operatively between the motor and the pinion.

The attachment bracket may include a rack.

The pinion may be engaged with the rack.

The attachment bracket may further include a door that is movable between an open position and a closed position. When the door is in the closed position, the door blocks the pinion from disengagement from the rack. Wherein when the door is in the open position, the door does not block the pinion from disengagement from the rack.

The movable bracket may include a biasing member that biases the movable bracket away from the attachment bracket to facilitate movement of the movable bracket relative to the attachment bracket.

The door may be at a top end of the attachment bracket.

The attachment bracket may include magnets.

The movable bracket may include a battery receptacle configured to receive a battery pack.

According to an aspect of an example embodiment, a laser level assembly includes: an attachment bracket; a movable bracket attached to the attachment bracket and configured to translate relative to the attachment bracket; a laser level mounted on the movable bracket, the laser level configured to project at least one of a horizontal line, a vertical line or a laser spot; a motor in the movable bracket, wherein the motor is configured to drive translation of the movable bracket relative to the attachment bracket; further comprising a clutch operatively associated with the motor.

The laser level assembly may further include a pinion driven by the motor.

The clutch may be operatively between the motor and the pinion.

The attachment bracket may further include a rack.

The clutch may include a first clutch part with first teeth and a second clutch part with second teeth. The first teeth and second teeth may be selectively engaged.

The pinion may be integral with the second clutch part.

The attachment bracket may include a rack.

According to an aspect of an example embodiment, a laser level assembly includes: a mounting bracket comprising an attachment bracket and a movable bracket; a laser level mounted on the movable bracket, the laser level configured to project at least one of a horizontal line, a vertical line or a laser spot; a motor in the movable bracket, wherein the motor is configured to drive movement of the movable bracket relative to the attachment bracket; and a pinion driven by the motor. The attachment bracket may include a rack. The pinion may be engaged with the rack. The attachment bracket may include a door that is movable between an open position and a closed position. When the door is in the closed position, the door blocks the pinion from disengagement from the rack. When the door is in the open position, the door does not block the pinion from disengagement from the rack.

The movable bracket may include a biasing member that biases the movable bracket away from the attachment bracket to facilitate movement of the movable bracket relative to the attachment bracket.

According to an aspect of an example embodiment, a laser level assembly includes: a mounting bracket comprising an attachment bracket and a movable bracket; a laser level mounted on the movable bracket, the laser level configured to project at least one of a horizontal line, a vertical line or a laser spot; a first motor in the movable bracket, wherein the first motor is configured to drive movement of the movable bracket relative to the attachment bracket. The movable bracket may include a base part configured to support the laser level and a battery cap part attached to the base part.

The laser level assembly may further include a first sealing member between the base part and the battery cap part.

The battery cap part may be configured to receive a battery pack.

The battery cap part may be configured to hold a battery pack receptacle.

The battery pack receptacle includes at least one electrical connector configured to connect to the battery pack.

The laser level assembly may further include a second motor between the battery cap part and the base part.

The movable mounting bracket may further include a back cap.

The laser level assembly may further include a second sealing member between the back cap and the base part.

The first motor may be housed between the back cap and the base part.

The back cap may be configured to engage the attachment bracket.

The battery cap part may include a frame and a cover plate.

According to an aspect of an example embodiment, a laser level assembly includes: a mounting bracket comprising an attachment bracket and a movable bracket; a laser level mounted on the movable bracket, the laser level configured to project at least one of a horizontal line, a vertical line or a laser spot; a first motor in the movable bracket, wherein the first motor is configured to drive movement of the movable bracket relative to the attachment bracket. The movable bracket may include a base part configured to support the laser level and a back cap part attached to the base part. The laser level assembly may also include a sealing member between the back cap part and the base part.

The laser level assembly may further include a battery cap part attached to the base part and configured to receive a battery pack.

The battery cap part may be configured to hold a battery pack receptacle.

The battery pack receptacle may include at least one electrical connector configured to connect to the battery pack.

The laser level assembly may further include a second motor between the battery cap part and the base part.

The first motor may be housed between the back cap and the base part.

The back cap may be configured to engage the attachment bracket.

According to an aspect of an example embodiment, a laser level includes: a pendulum; a laser generator on the pendulum, the laser generator configured to project at laser beam; a pendulum lock configured to selectively lock the pendulum; a pendulum lock switch configured to move between a pendulum lock position and a pendulum unlocked position; and a power button configured to control operation of the laser generator. When the pendulum lock switch is in a locked position and the power button is turned on, the laser generator turns on.

When the pendulum lock switch is in a locked position and the power button is turned off, the laser generator turns off.

When the pendulum lock switch is in the unlocked position and the power button is turned from an on condition to an off condition, the laser level is not turned off.

According to an aspect of an example embodiment, a laser level assembly includes a mounting bracket; a laser level on the mounting bracket, the laser level comprising a laser generator, the laser level configured to project at least one of a horizontal line, a vertical line or a laser spot; wherein the mounting bracket comprises a battery pack receptacle configured to selectively receive a removable battery pack; at least one of a wireless transmitter and a controller; a secondary power device; wherein the removable battery pack is configured to power the at least one laser generator; wherein the secondary power device is configured to power at least one of a wireless transmitter and the controller.

The secondary power device may be in the mounting bracket.

The secondary power device may supply power at a first voltage; the removable battery pack may supply power at a second voltage; and the first voltage may be lower than the second voltage.

The secondary power device may include an internal battery.

The secondary power device may include a coin cell.

According to an aspect of an example embodiment, a laser level assembly includes: a mounting bracket, the mounting bracket comprising a base part and a back cap; a laser level on the mounting bracket, the laser level comprising a laser generator, the laser level configured to project at least one of a horizontal line, a vertical line or a laser spot; a battery pack receptacle configured to selectively receive a removable battery pack; a wireless transmitter; a circuit board in the mounting bracket; a secondary power device on the circuit board; wherein the removable battery pack is configured to power the at least one laser generator; wherein the secondary power device is configured to selectively power the wireless transmitter.

The secondary power device may be in the mounting bracket.

The secondary power device may be in the mounting bracket between the base part and the back cap.

The base part and the back cap may be fixed together via fasteners.

The laser level assembly may include a sealing member between the base part and the back cap.

The secondary power device may supply power at a first voltage, the removable battery pack may supply power at a second voltage; and the first voltage is lower than the second voltage.

The laser level assembly may include a controller on the circuit board.

The secondary power device may include a coin cell.

The secondary power device may be integral with the laser level assembly and replaceable via service center.

According to an aspect of an example embodiment, a laser level assembly includes: a laser level, the laser level comprising a laser generator, the laser level configured to project at least one horizontal line and at least one vertical line; a battery pack receptacle configured to selectively receive a removable battery pack, the removable battery pack configured to power the laser generator; a wireless transmitter; a secondary power device, the secondary power device configured to power the wireless transmitter; wherein the secondary power device is in a water-resistant housing.

The water-resistant housing may include a first housing part, a second housing part and a sealing member between the first housing part and the second housing part.

The first housing part may be fixed to the second housing part via at least one fastener.

The secondary power device may supply power at a first voltage; the removable battery pack may supply power at a second voltage; and the first voltage may be lower than the second voltage.

The laser level assembly may include a circuit board in the water-resistant housing.

The secondary power device may be on the circuit board.

The secondary power device may be integral with the laser level assembly and replaceable via service center.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

The drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the invention. In addition, it should be appreciated that structural features shown or described in any one embodiment herein can be used in other embodiments as well. As used in the specification and in the claims, the singular form of “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise.

All closed-ended (e.g., between A and B) and open-ended (greater than C) ranges of values disclosed herein explicitly include all ranges that fall within or nest within such ranges. For example, a disclosed range of 1-10 is understood as also disclosing, among other ranged, 2-10, 1-9, 3-9, etc.

As used herein, the terminology “at least one of A, B and C” and “at least one of A, B or C” each mean any one of A, B or C or any combination of A, B and C. For example, at least one of A, B and C may include only A, only B, only C, A and B, A and C, B and C, or A, B and C.

FIG.1illustrates a perspective view of a non-limiting, exemplary embodiment of a laser level assembly10of the present application. The laser level assembly10ofFIG.1includes a 3×360 laser level100. The laser level100produces two vertical laser beams and one horizontal laser beam. As shown inFIG.1, the laser level100includes three laser projectors101,102and103. The three laser projectors project three perpendicular laser beams.

FIGS.12and13illustrate a laser module assembly160which produces the laser lines111,112and113that project out of the three laser projectors101,102and103, respectively. The laser module assembly160is housed in the housing110of the laser level100. The laser module assembly160includes three laser modules170. The three laser modules170are carried on a pendulum assembly175. Each laser module includes a laser generator such as a laser diode and a reflector such as a cone reflector. The laser diode produces a laser beam which is reflected off the surface of the reflective cone to project laser lines111,112, and113at the three laser projectors101,102and103. The laser generator may include a diode pumped solid state laser (DPSSL).

The pendulum assembly175rotates about a relatively small angle so that the laser modules170project beams in the horizontal and vertical planes when placed on a surface that is not entirely horizontally flat. For example, if the laser level10is placed on a surface that is sloped five degrees (5 degrees) with respect to horizontal, the pendulum assembly175will tilt under the influence of gravity so that the laser modules170are aligned to produce a laser line111in a horizontal plane and laser lines112and113in vertical planes. Additionally, in some embodiments the laser level100includes a locking device to lock the pendulum assembly175. In those instances the pendulum assembly110will be locked in a particular position rather than allowed to rotate under the influence of gravity and it may produce laser lines offset from the vertical and horizontal.

The laser lines111,112,113project out from the laser level100onto walls, floors ceilings or other surfaces. As there are three beams which project in a circular pattern, the laser level100may be referred to as a 3×360 laser level. When the laser level assembly10is attached to a vertical wall at the mounting portion203, the laser level100produces two vertical laser lines and one horizontal laser line. Similarly, when the laser level assembly is placed on a flat horizontal surface, the laser level100produces two vertical laser lines and one horizontal laser line. In some instances, the laser level100may be considered to be located at a front of the laser level assembly10and the mounting portion203at the back of the laser level assembly10.

FIGS.1-3illustrate various views of the laser level assembly10.FIG.1is a perspective view of the laser level assembly10andFIGS.2and3are top views of the laser level assembly10. The laser level assembly10includes the laser level100. The laser level100is situated on a rotational base300. The laser level100and the rotational base300are mounted on a bracket200. The bracket200has a mounting portion203, a base portion204, and a bottom of the mount205at the bottom of the base portion204. The mounting portion203may include magnets so that the bracket200can be secured to a metal part such as metal beam, metal stud, metal cabinet or other structure. In other embodiments, the mounting portion203may have another securing mechanism instead of or in addition to magnets, such as a clamp, tie, strap or other securing structure.

In operation, the laser level100and rotational base300may move together about a central axis of the laser level100relative to the mount200. The central axis “A” of the laser level100is a vertical axis through the projector101. In this case, all three projectors101,102and103rotate about the central axis. Since the projector101projects a horizontal line111, rotation about a vertical axis does not affect the location of the line111. That is, a horizontal line111remains horizontal. The vertical lines112and113rotate about the central vertical axis A. Both vertical lines as well as a cross point151at which the vertical lines112and113intersect rotate about the vertical axis Z.

The laser level100may also be rotated relative to the rotational base300. In that instance, the rotational base300remains stationary relative to the mount200. The laser level100rotates relative to the rotational base about the cross-point151. In this instance, the vertical lines112and113move as they rotate about the cross-point151. However, a position of the cross-point151remains the same since the vertical lines112and113rotate about the cross point. As with rotation about central axis A, when the laser level100rotates about the cross-point151, the projector101continues to project a horizontal line111in a horizontal plane regardless of the rotational position.

Rotation of the laser level100about the cross-point151is shown inFIGS.2and3. As shown inFIG.2, the laser level100can rotate about cross-point151in the rotational direction “B”. As shown by arrow B, the laser level100may rotate in either a clockwise or counterclockwise direction.FIGS.2and3are top view of the laser level assembly10.FIG.2illustrates the laser level100in a starting position. In this position, the laser level100is aligned with the rotational base300and the mount200. For example, the vertical line111is parallel to side surfaces of the mount200. In the starting position, vertical line112is parallel to a mounting surface on which the mounting portion203is secured if the mounting surface is a flat vertical surface such as a wall.

FIG.3illustrates the laser level100rotated about the cross-point151relative to the starting position shown inFIG.2. As shown inFIG.3, the laser level100is rotated relative to the rotational base300. The orientation of the vertical laser lines112and113also change. For example, when the mounting portion203is secured to a flat vertical mounting surface, laser line112is no longer parallel to sides of the mount200and vertical line112is no longer parallel to the mounting surface, but instead are at angles with respect to such surfaces. As also shown, the laser level100is angled with respect to the rotational base300. While the position of the projector101has moved inFIG.3relative toFIG.2, the projector101continues to project a horizontal line111in the same horizontal plane whether in the rotational position ofFIG.2orFIG.3.

FIGS.4and5illustrate a lower housing section400of the laser level100.FIG.4is a bottom view of the lower housing section400. The surfaces shown inFIG.4face downwardly towards the rotational base300.FIG.5is a top view of the lower housing section400, as would be seen looking down at the lower housing from an inside of a housing the laser level100.

As shown inFIG.4. The lower housing section400has a first guide way410, a second guide way420and an arc gear connection slot430. The arc gear connection slot430includes a pair of connection through holes431. The connection through holes431each accommodate a fastener or connector and may be threaded. The lower housing section also includes a hole440through which cables may pass. The cables may be wires and may carry electric power or information/data. The loser housing section400also includes screw thread holes401at each corner. The thread holes401allow the lower housing section400to be screwed onto the remainder of the housing for the laser level100. In other embodiments, the lower housing section400may be attached in other ways, may be integrally formed with other parts of the laser level100housing or various other clam-shell arrangements or attachments may be implemented.

FIG.6is a top perspective view of the rotational base300. As shown, the rotational base300includes a first guideway boss310. The first guideway boss310engages and sits in the first guide way410and can move within the first guide way410illustrated inFIG.4. The rotational base300also includes a second guideway boss320. The second guideway boss310engages and sits in the second guide way420illustrated inFIG.4and can move within the second guide way420. The rotational base further includes an arc gear330that is movable within an arc gear slot335. The arc gear330is attached to the lower housing section400at the arc gear connection slot430. The arc gear330may be secured to the slot430via connection through holes331on the arc gear330and connection through holes431in the arc connection slot430. For example, fasteners may be inserted through the holes to securely fasten the arc gear330to the arc gear connection slot430. These may be threaded fasteners, rivets or other connectors. The arc gear330may be secured to the arc gear connection slot430by other means.

The complementary structures of the lower housing400and the rotational base300allow for relative movement of the lower housing400, and thus the laser level100generally, with respect to the rotational base300. In particular, if the arc gear330moves in the arc gear slot335, the lower housing400moves along with the arc gear330owing to the connection of the arc gear330with the lower housing400. The bosses310and330slide along the respective guide ways410and420. In this way, the arc gear330can be moved and cause the laser level100to rotate relative to both the rotational base300and the mount200. When the arc gear330is moved within the slot335and the mount200is secured in place, the laser level100rotates such as between the positions shown inFIGS.2and3.

As shown inFIG.6, the rotational base300also includes a cable transfer slot340. The cable transfer slot340provides room for cables. Cables may carry electrical power or information/data. The cable transfer slot340may vary in size, shape, length or other dimensions and may include one or more through holes.FIG.6also illustrates the cross point151. The arc gear330rotates in an arc about the axis151. As shown, the axis151is outside of the footprint of the rotational base300.

FIGS.7and8illustrate the top section315of the rotational base300.FIGS.7and8are each perspective bottom view of the top section. The top section315of the rotational base300may be integrally formed with the rest of the rotational base300or may be attached through screws or other fasteners or fastening or attachment structures.FIG.7illustrates the top section315of the rotational base300with the arc gear330in the slot335. As shown, the arc gear330includes a plurality of gear teeth331and several bosses332. As shown, there is also a recess368for receiving a spur gear. As discussed below, a spur gear rotates and teeth of the spur gear interact with the gear teeth331in order to move the arc gear330.

FIG.8illustrates the top section315with a biasing spring370. The arc gear330is not illustrated inFIG.8for purposes of explanation. In an embodiment, the biasing spring370presses the arc gear330towards the spur gear to facilitate engagement between the gears. In some embodiments, other biasing members may be used instead of a spring370or engagement may be facilitated solely by the alignment by the respective tracks and recesses.

FIG.9is a perspective bottom view of the rotational base300. As shown, the rotational base300has a mounting cylinder380with a central cable transfer hole390. The rotational base300also has a central rotation guide way375. The mounting cylinder380engages with the mount200and is aligned about the central axis A. The central rotation guide way375is similarly aligned about the central axis A. The cable transfer hole390allows cables to travel from the mount to the rotational base300. Cables may also travel through or from the rotational base300to the laser level100.

The mount200has a guide way boss that engages the central rotation guide way375. The mount200includes a gear, belt, friction, direct drive that transfers rotational motion to the rotational base300so that the rotational base300rotates about the mounting cylinder380about central axis A, as described above. The laser level100moves along with the rotational base300when the rotational base300rotates about the central axis A. The central rotation guide way375may limit rotation of the rotational base300.

In an exemplary embodiment, the mount200includes a motor. The motor includes an output that is engaged with the mounting cylinder380. The motor output may be engaged with the mounting cylinder380through a threaded connection. A user can control the motor housed in the mount200and as the motor turns, the motor output rotates the rotational base300and so the laser level100about the central axis A. In some embodiments, there may be a transmission between the motor and the mounting cylinder380. In other embodiments it may be a direct drive connection. In still other embodiments, a manual input may be used instead of or in addition to a motor.

FIGS.10and11are perspective internal views of the rotational base300. As shown, the rotational base includes a motor50. The motor50may be a micro motor. Additionally, there may be a quadrature encoder. The motor50drives a worm gear51. The worm gear51drives a worm wheel52. The worm wheel52is on a shaft53with a spur gear54so that when the worm wheel52rotates, the spur gear54likewise rotates. The spur gear54engages the arc gear330. Accordingly, when the motor50is actuated, the arc gear330is moved to cause actuation of the laser level110about cross point151, as described above. The motor50may rotate in a forward or reverse direction to move the arc gear330back and forth. In some embodiments, a transmission may be operably connected to the motor50. In some embodiments a clutch may be operably connected to the motor50.

FIG.14illustrates a schematic diagram. A battery250is connected to controller260, motor50and wireless transceiver270. The controller260may include a microprocessor. The wireless transceiver270may receive wireless control signals from a user. The wireless control signals may be from a dedicated remote controller or from a computing device such as a tablet, computer or smartphone. The controller260may operate the motors50and60in accordance with the wireless control signals. In other embodiments, inputs for the control signals may be made from a wired connection or user input on the laser level assembly10. In some embodiments, control signals may be provided wirelessly or from on-board user input on the laser level assembly10. Motor60may be likewise connected to the battery250and controller260. Motor60may be the motor disposed in the mount200for rotation about central axis A. Motor60may be similarly controlled by the controller260in accordance with user inputs. Wireless signals may be, for example, Wi-Fi signals, infrared signals, radio frequency (RF) signals or may use a Bluetooth protocol.

The battery250may be an internal battery or a removable power tool battery pack such as is generally known in the power tool construction space and may be compatible with other tools, such as drills, saws, sanders and impact drivers and power such tools. For example, the battery pack250may be of the type shown and described by U.S. Pat. Nos. 8,092,932; 7,719,234; or U.S. Pat. No. 6,729,413. U.S. Pat. Nos. 8,092,932; 7,719,234; and 6,729,413 are hereby incorporated by reference in their entireties. If the battery250is a removable battery pack, it may be slidingly engaged on the laser level100or a portion of the mount200. If disposed on the mount200, the removable battery pack may be disposed on the bottom of the mount200, between the mounting portion203and the laser level100and base300, or at another location. Cables such as wires may transfer electrical power from the battery pack250to the various components of the laser level assembly100, including to any laser diodes, controllers, motors, or other electrical components. Electrical connections may be made by other means. The battery pack250may include lithium-ion battery cells, though embodiments are not limited thereto.

In some embodiments, there may be more than one battery pack or battery that may provide power to one or more electrical components. For example, in some embodiments, there may be an internal battery for powering laser diodes and a removable battery pack for powering motors. Other embodiments may have the reverse in which an internal battery pack powers the motors and a removable battery pack powers the laser diodes. In other embodiments, there may be multiple internal batteries for powering various components. In some embodiments, a removable battery pack may power both the laser diodes and the motors and a separate battery, such as an internal battery, may power one or more of a controller or a wireless transceiver.

Internal batteries may be located in any suitable component such as the mount200, base300or the laser level100. Similarly, the controller260and wireless transceiver270may be disposed in any suitable location or component, and electrical connections made as necessary throughout the laser level assembly10.

In some embodiments, the laser level100may be a different type of laser level other than a 3×360 laser level. For example, the laser level may be a cross line laser level. The laser level may project a variety of beams or dots.

FIGS.15-29illustrate exemplary embodiments of laser level assemblies that incorporate vertical movement. The vertical movement allows the height of a laser level beam to be adjusted by a user. For example, a horizontal line projected by a laser level may be moved up or down to create a horizontal line higher or lower on a wall. Various features of the exemplary embodiments ofFIG.15-29may be combined or integrated with previously described embodiments. Also, like the previously described exemplary embodiments, the laser level is described with respect to a 3×360 laser level that projects one horizontal and two vertical beams. However, other laser levels with various lines and dots, including cross-lines, and plumb dots, may be utilized.

A first exemplary embodiment of a vertically translating laser level assembly11is shown inFIGS.15-23.FIG.15illustrates a side view of the laser level assembly11.FIG.16is a side view of the laser level assembly11, with the ceiling wall mount240separated from the mounting bracket220.FIG.17is a perspective view of the laser level assembly11with the ceiling wall mount240.FIG.18is a perspective view of the laser level assembly11without the ceiling wall mount240.FIG.19is a perspective cut-away view of the laser level assembly ofFIG.18.FIG.20is a side cut-away view of the laser level assembly.FIG.21is a bottom cut-away view of the laser level assembly11through a portion of the bottom of the mounting bracket220.FIG.22is an exploded view of parts of the laser level assembly11.FIG.23is a close-up view of a rotational driving feature of the laser level assembly11.

As shown inFIGS.15, the laser level system11includes a laser level121. The laser level121is generally similar to the laser level100ofFIG.1. In general, parts of laser level121should be assumed to be the same as laser level100unless otherwise shown or described. In the exemplary embodiment ofFIG.15, the laser level121has a different bottom section400than the laser level100ofFIG.1. It is specifically contemplated that the laser level assembly11of the embodiment ofFIG.15may include the base portion400and rotational base300of the embodiment ofFIG.1so as to facilitate rotation about two different axes, as described above. In that instance, the laser level would be able to travel vertically and rotate about both a central axis and a cross-point axis. The laser level121may be removably attached to the base221.

As shown inFIGS.15and16, the laser level121includes a variety of buttons122for user input and control. The buttons122may allow the user to turn on and off the various lasers that project out of projectors101,102,103. The buttons122may also allow a user to operate rotational or vertical motor control. As discussed above, there may be wireless controls instead of or in addition to such on board buttons122serving as user controls. Any function of the laser level121or the laser level system11may be controlled by one or more of wireless control, on-board controls or wired control. As discussed above, a remote control device for controlling functions wirelessly may include one or more of a dedicated remote control or a computing device such as a smartphone or tablet, though embodiments are not limited thereto. The remote control device may include a user input such as a touchscreen, a keyboard or buttons. The remote control device may include a controller including, for example, a microprocessor. The remote control device may include a display configured to display information about the laser. For example, the remote control device may display whether one or more lasers is activated. The remote control device may display the type of laser. The remote control device may display a state of a battery charge. The remote control device may display a speed of rotation or vertical translation. The remote control device may display a state of rotation or vertical translation. The remote control device may display rotational or vertical position.

As shown inFIGS.15and16, the laser level system11further includes a vertical mounting bracket220and a ceiling wall mount240. The ceiling wall mount240may include a clamp242for clamping onto a structure such as a pipe, beam or other structure. Additionally, the ceiling wall mount240may have a threaded screw hole241for mounting to a tripod or other structure.

The vertical mounting bracket220includes a base portion221, a mounting portion222, a bottom portion223and a movable mount portion224. The laser level121and a removable power tool battery pack250are mounted on the base portion221. The mounting portion includes a number of magnets227. The magnets227allow the vertical mounting bracket220to be mounted to a surface or the ceiling wall mount240, which includes a metal plate surface243. The bottom portion223may have a screw thread hole229as shown inFIGS.19and20so that the vertical mounting bracket220may be mounted to a tripod or other structure.

The removable power tool battery pack250may be of various voltages, capacity or sizes. For example, the base portion221may receive any of a variety of power tool battery packs in a power tool battery pack system or a sub-set of power tool battery packs of a power tool battery pack system. For example, the distance between base portion221and bottom portion223may be made large enough to receive all of the battery packs of a particular power tool battery pack system or any of a select number of battery packs of a power tool battery pack system. In some instances, the amount of vertical translation may be affected by the size of the battery pack250. For example, a large battery pack250may limit movement of the base portion221towards the bottom portion223because the battery pack250contacts the bottom portion223. In this instance, a clutch may help to prevent further movement downward.

In some embodiments, a sensor may sense when a positional limit is reached and prevent further movement of the laser level121. For example, one or more sensors may sense when a position a positional limitation has been reached. For example, a sensor including a contact switch may be included on the bottom portion223and when the battery pack250contacts the contact switch, the controller260may prevent further movement or downward movement of the base portion. In some embodiments, the sensor may include a light sensor. In some embodiments, a sensor may include a Hall sensor.

FIG.17illustrates the vertical mounting bracket220mounted to the ceiling wall mount240via magnetic attraction.

Operation of the laser level assembly11will be described with respect toFIGS.19to23.FIG.22illustrates an exploded view of the laser level121and vertical mounting bracket220.FIG.22illustrates a motor150and pinion151driven by the motor150.FIG.22also illustrates a motor160and gear161driven by motor160. Although shown separately for illustrative purposes inFIG.22, motor150, pinion151, second motor160and gear161are housed in the mounting bracket220, and particularly, the base portion221of the mounting bracket220, as seen in cut-awayFIGS.19,20and21. One or both of the motors150and160may include a clutch. The clutch may be an internal or an external clutch. A clutch may otherwise be attached to the motor or configured to work with the motor.

As also shown inFIG.22, the mounting bracket220also includes a rack226in the mounting portion222. The pinion151is engaged with the rack222. Accordingly, when the motor150is activated, the pinion151rotates and causes the base221and movable section224of the mount220to move relative to the mounting portion222. When the motor150and pinion151are rotated in a first direction, the base221moves upwardly and when the motor150and pinion151are rotated in a second direction, the base221moves downwardly. The movable mount portion224interacts with the mounting portion222to provide smooth sliding support. The mount portion224may include a variety of slots, grooves and projections and the mounting portion222may include corresponding slots, grooves or projections to facilitate relative sliding. For example, the movable portion224may include a pair of projections and the mounting portion222may include corresponding slots which receive the pair of projections.

The rack222and pinion151are also seen in the cut-away views ofFIGS.19and20. InFIGS.19and20, the pinion is at a bottom of the rack and the battery pack250is resting near a bottom portion223of the mount.

In the exemplary embodiment ofFIGS.15-23, the pinion151rotates about an axis perpendicular to a work surface on which the mounting portion222is mounted. As discussed above, the mounting portion222may also be mounted on a metal plate243of the ceiling bracket240. In that case, the pinion151rotates about an axis perpendicular to the surface of the metal plate243. The axis about which the pinion151rotates is also perpendicular to the central axis A and parallel to an insertion direction of the battery pack250.

In other embodiments, the pinion151and rack222may be in different planes. For example, as shown inFIGS.30and31, the rack222may be on one or both sides of the metal plate243. Additionally, the pinion151may rotate about an axis parallel to a rear surface of the mounting portion222.

Motor160is a configured to rotate the laser level121. As shown inFIG.23, motor160drives gear161. Gear161meshes with gear162so that when the motor160rotates, gear162rotates. Gear162is secured to a cylindrical mount163of the laser level121. Accordingly, the motor161drives rotation of the laser level121. The motor161may rotate clockwise or counterclockwise to rotate the laser level121in opposite direction.

Motors150and160may be controlled by controller260, as previously described. Additionally, the assembly121may receive remote wireless signals through a wireless transceiver270. Electrical connection may be made through the various components to convey electrical power and/or control information through wires or other structures. Battery pack250may power the motors150,160any laser generators or other components. As discussed above, additional batteries may be used in some instances to power various components.

FIGS.24-31illustrate various different modifications to provide for different configurations. Operation of the vertical translation feature and the laser level generally is the same as in previous embodiments.

FIGS.28and29illustrate other configurations for a laser level assembly1010and1011with mounting brackets1220and2220. InFIGS.28and29, the battery pack251is mounted to a modified bottom portion1223and2223of the respective mounting brackets1220and2220rather than to the mounting portion221. The battery pack251may be mounted to a bottom of the modified bottom portion1223so that the battery pack251is generally below the bottom portion1223, as shown inFIG.28, or to a top of the modified bottom portion1223so that the battery pack251is generally above the bottom portion1223, as shown inFIG.29. In any event, the controller260and transceiver270may be housed in any available location of the mount220and connections made through conventional means. As shown, the exemplary embodiments ofFIGS.28and29include magnets227. The magnets227allow the mounting brackets1220and2200to be mounted to a metal work surface or to a ceiling mount such as ceiling mount240with a metal plate243.

FIGS.24,25,26,30and31illustrate another exemplary embodiment. the previously described exemplary embodiments, a motor causes one portion of the mounting bracket moved relative to another portion of the mounting bracket. In the exemplary embodiment ofFIGS.24,25,26,30and31, a motor moves the mounting bracket4220relative to a ceiling mount240. In this instance, motor150drives a pinion151. The pinion151is located in a position to engage a rack located on the ceiling mount2240. As shown, the rack226is on either side of a metal plate. Accordingly, the mounting bracket4220may be secured to the metal plate243of the ceiling mount240. This brings the motor driven pinion151into engagement with a rack222on the ceiling mount240. When the motor150drives the pinion151, the mounting bracket4220is moved up and down relative to the ceiling mount240. A sensor may be used to determine a location of the mounting bracket4220. For example, a magnetic sensor may be included on the ceiling mount240and a magnet for providing a signal to the magnetic sensor may be included on the mounting bracket4220. The sensor may be used to help control the vertical movement of the mount240and may be used to provide information about a vertical location to a user. For example, the sensor may be used to sense when a top or bottom position is reached and the controller260may then prevent further movement. As shown in, for example,FIGS.24,26and31, physical projections may also limit upward and downward movement of the mounting bracket4220.

In this embodiment, the mounting bracket4220is somewhat simplified because it does not require parts that are vertically movable with respect to one another. Instead, the mounting bracket4220is a simple L-shaped bracket with an added motor150and pinion151. This embodiment uses a larger battery pack251which serves the same function as the battery pack250. Either battery pack250or251may be used in this and other embodiments and the mount221may accept battery packs of a variety of sizes, types or voltages. As shown in, for example,FIGS.24and25, the battery pack251may be mounted to the mounting portion221and there may be empty space below the battery pack251. The mount4220may include a plurality of magnets227. The magnets227may have a rectangular shape. As shown, the magnets227may be mounted on a portion transverse to the mounting portion221.

The modified mount4220includes a pinion151that rotates about an axis parallel to a rear surface of the mounting portion.

FIG.27is another exemplary embodiment. The exemplary embodiment ofFIG.27is the same as the exemplary embodiments ofFIGS.24,25,26,30and31, except that the tripod mount241of the ceiling bracket240is in a different location below the battery pack251and base portion221of a mount.

FIGS.32-47illustrate another exemplary embodiment of a laser level assembly3010. The laser level assembly3010has components, elements, parts and functions similar to other exemplary embodiments unless otherwise shown or described. Additionally, components, elements, parts and functions of the exemplary embodiments may be substituted or combined as applicable.

As shown inFIG.32, the laser level assembly3010includes a laser level1121. The laser level1121has the same basic operation as previous exemplary embodiments of laser levels, such as laser levels100and121. Laser level1121of the exemplary embodiment is a 3×360 laser level includes laser module160and projects three laser lines111,112and113. In other exemplary embodiments, the laser level1121may be another type of laser level and may project other lines and dots/spots. For example, the laser level1121may be a cross-line laser level and project a single horizontal laser line and a single vertical laser line. The laser level1121may be a cross and spot laser that projects crossing laser lines and at least one laser spot. The laser level1121may be a spot laser level that projects a number of spots, such as vertically upward and downward projecting spots, a forward projecting spot and left and right side projecting spots.

With reference toFIGS.32and39, the laser level assembly3010further includes a bracket assembly2220. The bracket includes an attachment mounting bracket2230and vertical movement or movable mounting bracket2320. The attachment mounting bracket2230includes a mounting portion2222and a base portion2223. The mounting portion2222is generally transverse to the base portion2223. The mounting portion2223is configured to be mounted to a structure. In the example embodiment, the mounting portion2223includes a plurality of magnets for mounting the mounting portion2223to an object. The mounting portion may alternatively or additionally include other mounting features, such as a clamp or strap.

The vertical movement mounting bracket2320is attached to the mounting bracket2230and translatable relative to the mounting bracket2230. The movable bracket2320includes a base portion2321and an interface portion2322. The interface portion2322is generally transverse to the base portion2321. The laser level1121is rotatably connected to the base portion2321of the movable bracket2320. In some embodiments, the laser level1121may be removably coupled to the movable bracket2320. In such an example embodiment various different types of laser levels may be selectively attached to the base portion2321of the movable bracket2320. For example, a 3×360 laser level may be removed and a cross-line, cross and spot or spot laser level may be attached to the movable bracket2320in its place. Thus, a user may use the same bracket assembly2220for a variety of different laser levels.

As shown in, for example,FIG.32, the movable bracket2320may include a control panel2100. The control panel2100may include a variety of buttons for controlling the laser level1121and laser level assembly3010. For example, the control panel may include a power button for turning the laser level assembly3010on an off. The control panel2100may also include buttons to control operation of the laser lines or spots. For example, each of the laser lines111,112,113may be controlled separately or together. That is, for example, one button may turn on and off all of laser lines111,112, and113. Also, separate buttons may separately turn on and off laser lines111,112,113so that any combination of laser lines111,112, and113may be on at a particular time. Additionally, the control panel2100may include buttons for controlling motion of the laser level assembly3010. For example buttons may be included for controlling up and down movement of the movable bracket2320relative to the mounting bracket2230. Control panel2100may also include buttons for controlling rotation of the laser level1121relative to the movable bracket2320. Control panel2100may be used to control speed and direction of movement. Control panel2100may also be used to control intensity of the laser lines111,112,113. As shown inFIG.33, in the example embodiment there may also be a remote control2000. The laser level assembly3010may additionally or alternatively be controlled by remote control2000. That is, all of the functions described above with respect to the control panel2100may be implemented additionally or alternatively on the remote control2000. For example, the remote control2000may be used to turn on and off each of the laser lines111,112,113and the intensity of the laser lines111,112,113. The remote control2000may communicate with the laser level assembly3010wirelessly through one or more of a radio frequency (RF), infrared signal, WiFi, or a Bluetooth protocol, for example. The remote control2000may have a separate power source such as alkaline batteries.

FIGS.34-36illustrate rotation of the laser level1121relative to the mounting bracket2220.FIG.35illustrates the laser level1121in a central position. In this central position, laser projector projects a laser line beam112generally parallel to a rear surface of the mounting bracket2220and laser line projector103projects a laser line beam113generally perpendicular to a rear surface of the mounting bracket2220. Accordingly, if the mounting bracket2220is mounted to a flat vertical wall, laser line beam112will be projected generally parallel to the wall and laser line beam113will be projected generally perpendicular to the wall.

FIG.34illustrates laser level1121rotated to the left (counter-clockwise) andFIG.36illustrates laser level1121rotated to the right (clockwise). As shown, the bracket2220may include a stop1123. The stop may limit rotational movement of the laser level1121. As shown, inFIGS.34and36, a portion of the laser level1121may hit the stop1123and limit further movement. Rotational movement may also be limited by a controller such that the controller limits rotational movement to a certain range. The range of rotational movement of the laser level1121may be, for example, in a range of 5 to 90 degrees; 10 to 90 degrees 10 to 85 degrees; 15 to 60 degrees; 15 to 80 degrees, or 20 to 75 degrees.

As shown inFIGS.37and38, the movable mount2320is translatable relative to the mounting bracket2230. Since the battery pack250is removably attached to the movable mount2320and the laser level1121is mounted to a base of the movable mount2320, the laser level1121and the battery pack250also translate along with the mounting bracket2320. In particular, the movable mount2320is movable in a vertical direction up and down.

FIG.40is a cross-sectional view of the laser level assembly3010andFIG.41is a close-up cross-sectional view of a portion of the laser level assembly3010including a rack2062and pinion2061.

As shown inFIGS.40and41, a motor2060is housed it the movable mount2320. The motor2060may be a stepper motor. The motor may have a clutch2070. A pinion2061is attached to an output of the motor2060and driven by the motor2060. The pinion2061has gear teeth engaged with rack2062. Accordingly, as the motor2060rotates in a first direction the pinion2061rotates in a first direction and moves the movable mount2320upwardly. When the pinion rotates2061in a second direction, opposite the first direction, the movable mount2320moves downwardly. Accordingly, operation of the motor2060causes upward and downward movement of the mount2320and so the laser level1121on the mount2320. As discussed above, the motor2060may be controlled by the user through one or both of the control panel2100or the remote control2000.

FIGS.42to45illustrate components for facilitating rotational movement of the laser level1121relative to the movable mount2320and, in particular, relative to the base2321of the movable mount2320. As shown, a stepping motor2050is mounted in the base2321of the movable mount2320. The stepping motor2050drives a worm which may also be referred to as a worm screw. The worm screw2051drives a worm wheel2052, which may also be referred to as a worm gear2052. A spring2053biases the worm screw2051toward the worm wheel2052to facilitate contact between the teeth of the worm wheel2052and the worm screw2051. The laser level1121is operatively connected to the worm wheel2052so that as the worm wheel2052rotates, the laser level1121rotates along with the worm wheel2052. For example, a shaft2054may be fixedly connected to the worm wheel2052and the laser level so that the shaft2054rotates with the worm wheel2052and the laser level1121rotates along with the shaft2054. In this manner, rotation of the second stepping motor2050causes rotation of the laser level1121, as shown inFIGS.34-36. As shown, a rotational axis and longitudinal axis of the worm screw2051is disposed at an angle. That is, in an example embodiment, the rotational axis and longitudinal axis of the worm screw2051are not parallel or perpendicular to a rear surface of the mounting bracket2220that is attached to a wall.

FIG.46illustrates the attachment mounting bracket2230. As shown, the attachment mounting bracket2230may include a screw thread2235for mounting to a tripod or other mount. The attachment mounting bracket2230may also include a key hole2236for hanging on a screw or a nail. As also shown inFIG.47, a rear surface of the attachment mount2230may include a plurality of magnets227.

As shown inFIG.46, there is a door2400at the top end of the rack2062. The door2400selectively blocks the pinion2061from further upward movement.FIGS.48and49illustrate close-up view of the door2400. The door2400is in a closed position inFIG.48and an open position inFIG.49. When the door2400is in the closed position as shown inFIG.48, when the door prevents the pinion2061from moving further upward and so the movable bracket2320is connected to the attachment bracket2230. That is, in the example embodiment, when the door2400is in the closed position ofFIG.48, the movable bracket2320and the attachment bracket2230remain connected.

In contrast, in the example embodiment, when the door2400is moved to the open position shown inFIG.49, upward movement of the pinion2061is not prevented. Accordingly, the pinion2061can be moved upwardly out of engagement with the rack2062and the rack area and the movable bracket2320can be removed from the attachment bracket2230. Accordingly, the movable bracket2320and laser level1121may used without the attachment bracket2230. Additionally, a different movable bracket2320and laser level1121may be then engaged with the attachment bracket2230. For example, a different type of laser level may be used with the attachment bracket, such as a line and spot laser.

As shown inFIGS.48and49, the door2400is biased towards the closed position ofFIG.48by a spring2401. Additionally, the attachment bracket2230includes a groove2405. The door2400may have a protrusion that engages the groove2405. The groove2405and protrusion may provide support and guidance for rotation of the door2400between the open and closed positions.

FIG.50illustrates the door2400in the open position and the pinion2601in a position adjacent to the open door2400.

FIG.51is a perspective illustrative view of the motor2060and pinion2061engaged with one side of a rack2062. A portion of the attachment bracket2230is removed for illustrative purposes. In the exemplary embodiment, the rack2062may include gear teeth on a single side along a single vertically extending axis. In other example embodiments, the rack may include gear teeth on opposite sides. That is, two sets of teeth extending along vertical lines and opposite to one another. InFIG.51, the door2400is shown in the open position.

FIG.52is a cross-sectional view illustrating engagement of teeth of the pinion2061and the rack2062as well as the clutch2070.FIG.53is another cross-sectional view illustrating engagement of teeth of the pinion2061and the rack2062.

FIG.54illustrates a perspective view of the motor2060and pinion2061.

FIG.55is an exploded view of the motor2060and clutch2070. The clutch2070disengages if torque on the pinion2061exceeds a particular amount, such as exceeding 150 millinewtonmeter (mN·m); 200 mN·m, 300 mN·m or 400 mN·m. The clutch may also protect the laser level1121in case of a sudden drop. The motors2050and2060may be stepper motors.

As shown inFIG.55, there is a motor output shaft2081that is selectively driven in a rotational motion. A motor assembly back cap2082is adjacent to the motor2060, main sleeve2083is adjacent to the motor assembly back cap2082. Belville springs2084maintain engagement of teeth2086of a first clutch part2085and teeth2089of a second clutch part2088. A rubber boot2887provides protection and insulation from dust, debris or liquid. Second clutch part2088includes clutch part teeth2089and spur gear teeth and serves as pinion2061. A sleeve bearing2097supports the motor shaft2081on a base bracket. As will be appreciated, the spring2084biases first clutch part2085towards second clutch part2088. When the first clutch part2085and the second clutch part2088are engaged, the teeth2086and2089are engaged and rotational power from the motor2060is transferred to the pinion2061such that the pinion2061rotates along with rotation of the motor2060. When sufficient torque is applied, the biasing force of the spring2084is overcome, teeth2086and2089disengage, and torque is no longer transferred between the motor2060and the pinion2061. The clutch2070may be integrated into the motor2060or clutch parts may be adjacent to the motor. In either event, the clutch2070may be operatively between the motor2060and the pinion2061. In some embodiments, motor2050may include a clutch2070.

FIGS.56and57illustrate the rear surface of the movable bracket2320. As shown inFIGS.56and57, there are a pair of springs3101. The springs3101bias the movable bracket2320away from the attachment bracket2230so as to reduce friction and facilitate smooth vertical motion. Additionally, the rear surface of the movable bracket2320includes a vertical guideway3102that engages corresponding vertical guideways3202on the attachment bracket2230. As also shown inFIG.57, a bracket3103helps to secure the pinion2061.

FIGS.58-65illustrate parts of an exemplary embodiment of the laser level assembly3010.FIG.58illustrates an exploded view of the movable mounting bracket2320. The movable mounting bracket2320includes a base part4001, a back cap4002and a battery cap4003.

FIG.59illustrates a perspective exploded view of the battery cap4003. The battery cap4003includes a frame4004and a cover plate4005. The frame4004and the cover plate4005may be made of different materials. The frame4004may include plastic. The cover plate4005may include metal. A sealing member4007may be disposed between the frame4004and the cover plate4005. The frame4004and the cover plate4005may be attached together by fasteners such as screws. The sealing member4007may include at least one of plastic, rubber or silicon. The sealing member4007may be compressible and form a seal to prevent dirt, dust, debris or liquids from entering in a space between the frame4004and the cover plate4005. The sealing member4007may form a closed loop. Fastening the frame4004together with the cover plate4005may compress the sealing member4007. With reference toFIG.58, the base part4001may have a sealing member4008the same as or similar to the sealing member4007. The base part4001may have a housing that includes plastic. The sealing member4008may prevent dirt, dust, debris or liquids from entering between the base part4001and the back cap4002. The base part4001and the back cap4002may be fastened together such as by screws and the sealing member4008may be compressed when the base part4001and the back cap4002are fastened together. As shown inFIG.60, the base part4001may also include a sealing member4009between the base part4001and the battery cap4003. The sealing member4009may be the same as or similar to the sealing members4007and4008. The base part4001and the battery cap4003may be fastened together such as by screws and the sealing member4009may be compressed when the base part4001and the battery cap are fastened together. The base part4001, back cap4002and battery cap4003cooperate to form an internal space that is protected from ingress of dirt, dust, debris and liquids. The base part4001, back cap4002and battery cap4003construction result in an IP54or better rated design.

Locations of the sealing members4007,4008and4009may be changed and there may be additional sealing members. For example, in the example embodiment, the sealing member4008between the base part4001and the back cap4002is on the base part4001. In other example embodiments, the sealing member4007between the base part4001and the back cap4002may be on the back cap4002or there may be a sealing member on both the base part4001and the back cap4002. Similarly, the sealing members4008and4009may be moved to the other of the pair of parts that they are between or there may be a sealing member on each of the two mating parts.

FIG.60is a bottom view with the battery cap4003removed. As shown, parts such as the stepper motor2050, worm2051and worm wheel2052are housed in the base part4001and enclosed by the battery cap4003. One or more of a circuit board and a controller, temperature sensor, accelerometer, current sensor, voltage sensors, over and under voltage protection electronics; over and under current protection electronics, a wireless transceiver, data ports, LED lights, motor, LED or laser generator/laser diode driver electronics or other electronics may be further housed in the space between the base part4001and the battery cap4003. The accelerometer may detect movement of the laser level assembly3010, for example if the laser level assembly3010or a particular part thereof has experienced a free-fall, such as by being dropped.

The battery cap4003includes a pair of parallel rails4211for receiving battery pack250or other battery packs or larger or smaller sizes, voltages or capacities. As shown inFIG.61, the frame4004holds a battery pack interface4011. The battery pack interface4011may include one or more electrical connectors. The electrical connectors may include a positive receiving terminal, a negative receiving terminal and an ID receiving terminal. Wires or other electrical connectors may be engaged with the battery pack interface4011in order to transfer electrical power and/or data to and from the battery pack250through the electrical connectors of the battery pack interface4011.

FIG.62illustrates the rear of the base part4001. As shown, a circuit board4014is housed in this rear/vertical portion of the base part4001. A variety of wire connectors are on the circuit board4014and wires or other electric connectors may connect the various electronic components throughout the laser level assembly3010. Additionally, one or more of a controller, temperature sensor, accelerometer, current sensor, voltage sensors, over and under voltage protection electronics; over and under current protection electronics, a wireless transceiver, data ports, LED lights, motor, LED or laser generator/laser diode driver electronics or other electronics may be on the circuit board4014. As shown inFIG.62, an internal battery6000in the form of a coin cell is on the circuit board4014. The internal battery6000may selectively power one or more components, including a wireless transmitter or receiver, controller or other components, including the components on the circuit board4014.

In an embodiment, the internal battery6000may be used in conjunction with the removable battery pack250as shown in the schematic ofFIG.74. As shown inFIG.74, the removable battery pack250may serve as main power. When the removable battery pack250is present and available, the removable battery pack powers full power main circuitry6010. The full power main circuitry6010provides for all or most of the operation of the laser level assembly3010. For example, the full power main circuitry6010may include power for any laser generators in the laser modules170and any power for motors2050and2060. The full power main circuitry6010may also include power for controllers, wireless transmitters and receivers (transceiver), and a user interface. When the full power main circuitry6010is used and powered by the battery pack250, the battery backup6000may not be utilized. Micro-circuit feedback6030may determine whether the main power250is available or the battery backup6000should be utilized.

When the battery pack250is unavailable, due to, for example, not being connected or an undervoltage being detected (i.e., the battery pack250does not have sufficient charge), the switchover circuitry6001may change over to using the battery backup6000. The battery backup6000may power a low power subcircuit6020that powers less functionality than the full power main circuitry6010. For example, the lower power subcircuit6020may power only a wireless function by powering one or more of wireless transmission, wireless reception, and a controller. In an embodiment, the battery backup6000and the low power sub-circuit6020may be configured so that they do not power the or more motors2050,2060and may be configured such that they do not power one or more laser generators of the laser modules170. Configured not to power may include configured not to power at a functional capacity.

The secondary power device6000may supply power at a lower voltage than the removable battery pack250. For example, the removable battery pack250may supply power at a nominal voltage of at least 10 volts (V); or at least 17V. The secondary power device6000may supply power at a nominal voltage of less than 15 V, less than 10V or less than 8V. In an example embodiment, the removable battery pack250may provide a nominal voltage or about 18V and the secondary power device may provide a nominal voltage of about 5V.

In an example embodiment, the laser level assembly3010may be able to wirelessly communicate via one way or two-way communication with one or both of remote2000and a remote computing device such as a smartphone, tablet, laptop or desktop computer. In the example embodiment, the remote2000may be a dedicated remote control2000. The remote computing device may be used for one or more of asset tracking, monitoring of the tool, monitoring of the battery pack250(such as displaying a state of charge of the battery pack250or a health of the battery pack250), programming or changing a programming of the laser level assembly3010. For example, the remote computing device may be a computing device as described in U.S. Patent Application Publication No. 2014/0107853 and the laser level assembly3010and other example embodiments of laser level assemblies may communicate with the remote computing device as described in U.S. Patent Application Publication No. 2014/0107853. U.S. Patent Application Publication No. 2014/0107853 is herein incorporated by reference in its entirety. In an example embodiment, a single wireless transmitter on the circuit board4014may communicate with both the dedicated remote control2000and the remote computing device. In another example embodiment there may be a first wireless transmitter and receiver on the circuit board for communicating with the dedicated remote control and a second wireless transmitter and receiver on the circuit board for communicating with the remote computing device.

FIG.63is a view of the back cap4002facing the base part4001and of the motor2060mounted thereon. As shown, the back cap4002may include a sealing member4015between the back cap4002and the base part4001similar to other sealing members. The sealing member4015may be in a groove that is less than 5 mm, less than 4 mm or less than 3 mm and one or both of the back cap4002and base part4001may include a groove for accepting part of the sealing member4015. The sealing member4015may be compressible and prevent dust, debris, dirt or liquids from passing into the movable mounting bracket2320and contribute to the IP54or better rating of the exemplary embodiment discussed above. As shown inFIGS.62and63, wires4700may extend from the motor2060. An electrical connector in the form of plug4701may be at the end of wires4700and may connect to the circuit board4014.

FIG.64is a perspective view of the back cap4002facing the base part with the motor2060mounted thereon. As shown inFIG.64, there is a groove4016for receiving the sealing member4015. The sealing member4015is not shown inFIG.64. As further shown inFIG.64, the motor2060may be fastened onto the back cap4002by fasteners such as screws. In the example embodiment, there are a pair of screw holes417on opposite sides of the motor2060. As shown inFIG.63a pair of screws418are used to fasten the motor2060to the back cap4002via the screw holes417. In other embodiments there may be more or fewer through holes and fasteners.

FIG.65illustrates the motor2060and clutch2070in a partially exploded view. A sealing member4017is provided on a rear face of the motor assembly back cap2082. A sealing member4018is provided on a front face of the motor assembly back cap2082, as shown inFIGS.54and55.

FIG.66illustrates a pendulum lock switch5000in a pendulum unlocked position andFIG.67illustrates the pendulum lock switch5000in a pendulum locked position. The pendulum lock switch5000can be slid between the forward/unlocked position shown inFIG.66and the rearward/locked position ofFIG.67.FIG.71illustrates an exemplary embodiment of a user interface7000for control panel2100. As shown inFIG.71, the user interface7000includes a number of buttons including a power button7001; laser line buttons7002,7003and7004for individually activating and deactivating laser lines111,112and113; laser brightness button7005configured to increase or decrease brightness of the laser lines111,112and113; clockwise rotation button7008, counterclockwise rotation button7009, upward vertical movement button7006and downward vertical movement button7007for operating rotational and vertical operation of the laser level assembly3010. The user interface7000also includes a plurality of indicators7010,7011and7012. In the example embodiment, indicator7010indicates a state of charge of the battery2050, indicator7011indicates whether if the laser level assembly3010is paired with remote2000, and indicator7012indicates if the laser level has experienced a free-fall condition, such as may be detected by an accelerometer and determined by a fall happening for a specific period of time or more.

FIG.68is a chart illustrating operation of the laser level depending upon the position of the pendulum lock switch5000and the power button7001. The first column entitled “Pendulum Lock Position” indicates the position of the pendulum lock switch5000. The second column entitled “Power Button” indicates the status of the power button7001. The third column entitled “Result” indicates a resultant function. As shown inFIG.68, when the pendulum lock switch5000is in the locked position, the power button7001turns the laser level on and off. That is, the lines111,112,113of the laser level3010that are on are turned off and/or on. However, the user must put the pendulum in the locked position by moving the pendulum lock switch5000to the lock position in order to turn off the laser level3010. For example, in the example embodiment, if the pendulum lock switch5000is in the unlocked position, the laser level3010is on such that at least one laser line111,112,113is project, and the power button7001is actuated, the laser level3010does not turn off. In the example embodiment, no action may be taken. In other example embodiments, action may be taken such as turning off one or more laser lines111,112,113, but leaving other laser lines on. In other example embodiments, one or more laser lines111,112,113may blink.

FIGS.69and70schematically illustrate operation of a pendulum lock8000. The pendulum lock8000may include a first arm8001and a second arm8002. The pendulum lock8000may be biased towards the closed position shown inFIG.69in which the arms8001and8002close around the pendulum8050to lock the pendulum from movement.FIG.70illustrates the pendulum lock8000in the open position in which the arms8001and8002are moved away from the pendulum8050by the switch5000so that the pendulum8050may swing. In the example embodiments ofFIGS.69and70horizontal and vertical laser line generators8051,8052are disposed on the pendulum8050to produce horizontal and vertical laser lines.FIGS.69and70are explanatory illustrations of an example embodiment. The pendulum lock8000may similarly be applied to the laser module assembly160producing three laser lines111,112,113or other pendulums with various laser generators providing laser lines and spots. Additionally, the operation described by the table ofFIG.68may be applied to the pendulum lock and switch shown inFIGS.69and70and to other embodiments of a pendulum lock and switch.

FIG.72illustrates remote control2000with user interface2900.FIG.73illustrates an exploded view of remote control2000. As shown inFIG.72., the remote control includes a user interface2900. In various embodiments, the user interface2900may include the same features as user interface7000, fewer features or additional features. The laser level assembly3010may be controlled via the user interface7000or via the user interface2900. In some embodiments, operation via user interface7000may be selectively locked out so that only the remote control2000commands operate the laser level assembly3010at a given time or operation via user interface2900may be selectively locked out so that only commands via user interface7000operate the laser level assembly3010at a given time.

As shown inFIG.72, user interface2900includes buttons2901,2902and2903for selectively operating laser lines111,112and113; button2904for adjusting the brightness of laser lines111,112and113; button2905for clockwise rotation of laser level1121, button2906for counter-clockwise rotation of laser level1121, button2907for upward vertical movement of the movable bracket2320and the laser level1121on the movable bracket2320and button2908for downward vertical movement of the movable bracket2320and the laser level1121on the movable bracket2320. Display icon2909indicates whether the remote control2000is wirelessly paired with the laser level assembly3010. Indicator2910is an LED light that flashes when one or more of the buttons on the remote control2000is actuated.

FIG.73illustrates an exploded view of the remote control2000. As shown inFIG.73, the remote control includes a front cover2951, a rear cover2952and a battery door2953. A printed circuit board2954is housed in the remote control2000in the internal space defined by the front cover2951and rear cover2952. A variety of electronic components may be on the printed circuit board2954including, for example, a controller a wireless transceiver, sensors such as an accelerometer, temperature sensor, light sensor, current sensor, a memory and wire plugs or harnesses. The remote control also includes a flexible printed circuit2955with buttons on the front cover2051for facilitating the user interface2900. The flexible circuit board2955may be electrically connected to the circuit board2954. In the example embodiment, the remote control2000is powered by removable batteries such as alkaline batteries. In other embodiments, the remote control2000may be powered by integral batteries. In some embodiments the batteries may be rechargeable batteries.

Removal and replacement of the internal battery6000will be described with reference toFIGS.56,62,63,75and76. As shown inFIG.63, the back cap4002includes a plurality of screw holes8001. As shown inFIG.76, the base part4001also includes a plurality of corresponding screw holes8002. As shown inFIG.56, a plurality of fasteners8003in the form of screws may be inserted into the screw holes8001of the back cap4002. The screws8003engage with screw holes8001and8002to hold the back cap4002to the base part4001as shown inFIG.75. In an example embodiment, the screws may be Phillips head screws; hex screws or hexalobular internal head screws. In an example embodiment, the screws7003may be tamper resistant screws such as tamper resistant hex screws, tamper resistant hexalobular internal head screws or one-way screws. In an example embodiment the fasteners may be another type of fasteners, such as rivets.

In order to remove and replace the internal battery6000, the fasteners8003are removed. Once the fasteners8003are removed, the back cap4002may be removed, providing access to the circuit board4014and the internal battery6000on the circuit board4014as shown inFIG.76. The internal battery6000may then be removed and replaced by a new internal battery6000. Then the back cap4002is placed back into alignment with the base part4001. Fasteners8003are then inserted through holes8001and8002to reattach the back cap4002to the base part4001. The back cap4002may be reattached to the base part4001with the sealing member4015therebetween to provide water and/or dust resistance.

In an example embodiment, new replacement fasteners8003may be used in place of the original fasteners8003. In an example embodiment, one or more parts may be damaged and replaced in order to facilitate replacement of the internal battery6000. For example, in an example embodiment the fasteners may be drilled out to remove them and new fasteners may be utilized. For example, replacement of the internal battery6000may require damaging and replacing one or more connector for the internal battery6000.

In an example embodiment, the internal battery6000is configured to be removed and replaced by a service center. That is, the laser level assembly3010may be configured such that a user of the laser level assembly3010may send or bring the laser level assembly3010to a service center for replacement of the internal battery6000. The service center may be a center for repairing tools and may include specialized technicians and equipment. In other embodiments, the laser level assembly3010may allow user replacement of the internal battery6000.

In some embodiments, a speed of operation of the motors2050and2060may be changed. For example, either or both of the motors2050and2060may be operated in a slow, medium or high speed.

In some embodiments, brightness of the laser lines111,112, and113may be changed a specific increments such as a low, medium and high brightness. The low brightness setting may be the lowest intensity output and may be used when there is low ambient light or the laser lines111,112,113are projected onto objects a relatively short distance away.

In some embodiments, the laser level assembly3010may include asset tracking to identify location, operation, power status, ownership or other characteristics as part of a power tool system tracking operation. The remote control2000may operate at a range of at least 50 meters, at least 60 meters, at least 70 meters, at least 80 meters or at least 90 meters.

The laser level assembly3010may log data and the logged data may be retrievable wirelessly or with a wire. The logged data may include usage time, temperature, movement, performance, battery life or other data.

The battery pack250, motors2050,2060or other electronics may be monitored for temperature, voltage, current or other parameter and be shut down if the measured values are determined to be too high or too low.

The battery pack250, motors2050,2060, wireless transceivers and laser generators may all be controlled by the same controller, each by individual controllers or other combinations of controllers. For example, the battery pack250, may be controlled by a first controller and the motors2050,2060controlled by a separate controller.

The motors2050,2060may include a backlash compensation algorithm to compensate for backlash and provide smooth, precise and reliable operation.

Although described by way of exemplary embodiments, it is understood that the words which have been used herein are words of description, rather than words of limitation. Although the description provided above provides detail for the purpose of illustration based on what is currently considered to be the most practical and preferred embodiments, it is to be understood that such detail is solely for that purpose and that the disclosure is not limited to the expressly disclosed embodiments, but, on the contrary, is intended to cover modifications and equivalent arrangements that are within the spirit and scope of the appended claims

It is to be understood that the present disclosure contemplates that, to the extent possible, one or more features of any embodiment can be combined or exchanged with one or more features of any other embodiment.