Abstract:
A light generating system including a base comprising a bottom surface comprising a nonmechanical attachment structure and a light generating device rotatably mounted to the base about an axis.

Description:
This application claims priority under 35 U.S.C. § 119(e) to the filing date of U.S. Provisional Application Ser. No. 60/291,135, filed May 15, 2001, this application is also a continuation-in-part application of U.S. Pat. application Ser. No. 10/819,543, filed Apr. 7, 2004, now abandoned which claims priority under 35 U.S.C. § 119(e) to the filing date of U.S. Provisional Application Ser. No. 60/291,135, filed May 15, 2001, and which is both a continuation-in-part application of U.S. Pat. application Ser. No. 10/141,392, filed May 7, 2002, now U.S. Pat. No. 6,735,879, and a continuation application of U.S. Pat. application Ser. No. 10/612,035, filed Jul. 1, 2003, now U.S. Pat. No. 7,278,218, which is a continuation application of U.S. Pat. application Ser. No. 10/465,534, filed Jun. 18, 2003 now abandoned; and U.S. Provisional Application Ser. No. 60/599,413, filed Aug. 6, 2004; the entire contents of each of which is incorporated herein by reference. 

   BACKGROUND OF THE INVENTION 
   The technical field of the application is that of alignment devices, and in particular an alignment device and an attachment that allows the alignment device to be releasably attached from a surface on which alignment is desired. 
   DISCUSSION OF RELATED ART 
   Alignment of surfaces is a perennial problem in a variety of fields, ranging from construction to interior decorating. Alignment is necessary for walls that should be perpendicular to a floor, or otherwise plumb. Masonry and brick-laying practitioners are well aware of the importance of plumbed and aligned surfaces and chalk lines. A home interior decorated with pictures and other wall ornamentation makes a much better appearance when the ornamentation is aligned, especially with respect to vertical or horizontal alignment. Many mechanical and electrical alignment devices are available, and some laser devices are available. Some of these products are cumbersome; others are not suitable for certain uses. Chalk lines, for instance, are sometimes undesirable for use in finished, interior areas. 
   One aspect of alignment-product performance and in particular of laser-alignment products that could be improved is the ability to rotationally adjust the laser line. 
   Another disadvantage of laser-alignment products is that do not use allow the laser generating device to be attached to a variety of surfaces, including vertical walls, while allowing for flexibility in changing the rotational orientation of the laser line. 
   BRIEF SUMMARY OF THE INVENTION 
   One aspect of the present invention regards a light generating system including a base comprising a bottom surface comprising a nonmechanical attachment structure and a light generating device rotatably mounted to the base about an axis. 
   A second aspect of the present invention regards A light generating system including a base having a reference marking, a plurality of graduations and a stationary bottom portion, wherein the plurality of graduations move relative to the reference marking and the stationary bottom portion. A light generating device is rotatably mounted to the base about an axis, wherein the reference marking rotatably moves with the light generating device about the axis. 
   Each of the above aspects of the present invention provides the advantage of improving the ability to rotationally adjust the laser line. 
   In addition, the first aspect of the present invention provides the advantage of allowing the laser generating device to be attached to a variety of surfaces, including vertical walls, while allowing for flexibility in changing the rotational orientation of the laser line. 
   The following drawings form part of the present specification and are included to further demonstrate certain aspects of the present invention. The invention may be better understood by reference to one or more of these drawings in combination with the detailed description of specific embodiments presented herein. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a left perspective view of an embodiment of a light generating system in accordance with the present invention; 
       FIG. 2  is an exploded view of the light generating system of  FIG. 1 ; 
       FIG. 3  is a partially exploded view of an embodiment of a light generating device to be used with the light generating system of  FIG. 1  in accordance with the present invention; 
       FIG. 4  is an exploded view of an embodiment of a light support to be used with the light generating system of  FIG. 1  in accordance with the present invention; 
       FIG. 5  is a partially exploded view of the light generating system of  FIG. 1 ; 
       FIG. 6  is a left perspective view of the light generating system of  FIG. 1  wherein the graduations on the index ring are shown; 
       FIG. 7  is a bottom view of the light generating system of  FIG. 1 ; and 
       FIGS. 8A ,  8 B and  8 C depict the light generating system of  FIG. 1  projecting a laser beam in a narrow beam or fan and aligning objects on a wall. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   The present invention is better understood by reference to the figures and description below. In particular,  FIG. 1  shows a light generating system  100  that includes a light general device  102  and a base  104 . As shown in  FIGS. 2-4 , the light generating device  102  includes a housing  106  made of a left housing shell  108  and a right housing shell  110 . The shells  108  and  110  are made of a durable material, such as plastic, and are attached to one another via a snap fit and screws (not shown). 
   Prior to attachment of the shells  108  and  110  to one another, several components are positioned within the interior of the housing  106 . For example, a laser chassis  112  made of zinc is attached to the right housing shell  110  via a screw that is inserted through opening of the laser chassis  112  and threadedly engages a threaded opening formed in the right housing shell  110 . Of course, as an alternative the left housing shell  108  and the right housing shell  110  can be adapted so that the laser chassis  112  is attached to the left housing shell  108  instead of the right housing shell  100 . Such attachment would be similar to that described above with respect to the attachment of the right housing shell  110 . In addition, the left housing shell  108  and the right housing shell  110  can be adapted so that the laser chassis  112  is attached to both via a screw attachment similar to that described previously with respect to the right housing shell  110 . 
   As shown in  FIGS. 3 and 4 , the laser chassis  112  supports two bubble vials  118 ,  120  that are arranged at right angles to one another. The bubble vials  118 ,  120  are attached to the laser chassis  112  by a mechanical attachment, such as a snap fit, or via an adhesive. Of course other attachments are possible. Besides the bubble vials  118 ,  120 , a laser holder  122  is attached to the laser chassis  112  via a screw  124  that is inserted through opening  125  of the laser chassis  112  and engages a threaded opening (not shown) located at the bottom of the laser holder  122 . The laser holder  122  defines a central cylindrical chamber into which a laser module  126  is inserted so that its exit window  128  is pointed toward an end  130  of the laser holder  122 . The laser module  126  preferably contains a 635 nm light emitting laser diode. The end  130  includes an exit opening (not shown) and a frame to support a lens  132  inserted therein. The lens  132  is preferably similar to the lens described in U.S. Pat. No. 6,735,879, the entire contents of which are incorporated herein by reference. The lens  132  receives laser light emitted by the laser diode and that passes through the exit opening of the laser module  126 . The effect of the lens  132  is to shape the laser light passing through it into a planar, fan-shaped “comet beam” or fan shape. The intensity of the light and the shape of the beam may be asymmetric, in which one side of the “comet” may be larger and brighter than the other side. Thus, the embodiment shown in  FIG. 8B  and  FIG. 8C , the intensity of the laser light will be greater at outer edge  212  than at the inner edge  214  where the fan-shaped beam intersects the wall  194  while the beam is used to align object  208 , such as a picture frame.  FIG. 8C  schematically depicts the comet effect or asymmetry of the planar fan, the Intensity of light being greater in the portion of the beam that is further away from the wall or plane of interest. 
   The fan shaped beam is then routed so that the less bright side of the fan-shaped beam is nearest the wall of interest, and the brighter side is away from the wall. In this orientation, the fan shaped beam of light will propagate a long distance from its origin, and the laser light will be usable a long distance away from the laser line generating device. 
   The laser light generated by the laser line generator preferably exits from the top, curved corner of the lens. When the beam or fan of light exits the lens, it forms a thin plane in the length-wise direction of the device. Because the light is now a plane, rather than a pinpoint, it is able to project over and beyond obstacles, allowing a user to align several objects without having to move them. 
   As shown in  FIG. 3 , the housing  106  contains a pair of batteries  134  that are confined between corresponding positive and negative terminals  136 ,  138  in a well known manner. The current from the batteries  134  is directed to the laser module  126 , via a wire (not shown). The current is controlled by a switch  140  in a well known manner by moving the switch  140  from an “on” position to an “off” position. The switch  140  is attached to the rear portion of the housing  106 . 
   As shown in  FIG. 3 , a tilt nut  142  is positioned at the bottom interior portion of the housing  106  so that its threaded opening  144  is exposed via the bottom centrally located rectangular opening (not shown in  FIG. 3 ) defined by the housing  106 . The tilt nut  142  is larger in area than the rectangular opening and is able to slide along the bottom interior surface  148  of the housing  106 . 
   Once the housing  106  is assembled, a laser housing cover  150  is attached to the central top portion of the housing  106  as shown in  FIG. 2 . Similarly, a battery door  152  is removably attached to a rear portion of the housing  106  so as to enclose the batteries  134  within the housing  106 . The assembled light generating device  102  is then positioned upon base  104 . 
   The base  104  includes three components: 1) a top ring  154 , 2) an index ring  156  and 3) a bottom support  158 . As shown in  FIG. 2 , the bottom support  158  has a circular-like shape with flanges  160 ,  162  positioned opposite one another. The flanges  160 ,  162  each include an opening to receive a corresponding pin  164  as shown in  FIG. 1 . As shown in  FIG. 2 , the flanges  160 ,  162  are integrally attached to a bottom annular-like portion  166  that defines a top annular shelf  168  upon which lies the index ring  156 . The index ring  156  is unattached to the bottom support  158  so that the index ring  156  can be rotated freely upon the shelf  168 . As shown in  FIG. 6 , the index ring  156  includes equally spaced graduations or markings  170  formed on its exterior side wall  172 . There are preferably 72 graduations  170  formed on the wall  172  so that the index ring  156  acts as a protractor by defining angular positions every 5 degrees, from zero degrees to 360 degrees. Note that numerical indicia, such as the sequence 0, 45, 90, 135, 180, 225, 270, 315, 360 or the sequence 0, 45, 90, 45, 0, 45, 90, 45 ( FIG. 6 ) can be placed on the index ring  156  so as to denote the angular positions represented by one or more of the graduations. Note that other numbers of graduations are possible, such as 360 wherein the separation between adjoining graduations represents one degree of rotation. 
   The top ring  154  couples the light generating device  102  to the base  104 . In particular, the top ring  154  includes a plurality of downwardly extending flanges  174  that are inserted within a vertical channel  176  formed in the bottom support  158 . The top ring  154  defines a top annular-like surface  177  that is slanted downward and inward toward the center of the base  104 . The top surface  177  also includes a vertical index marker  178  that is inserted into an index slot (not shown) formed in the housing  106  of the light generating device so that the top ring  154  engages with and rotates with the housing  106 . Note that additional protrusions  180  can be formed on the top surface  177  so that they engage corresponding slots formed in the bottom surface of the laser housing  106 . The index marker  178  points in the same lateral direction that the laser beam leaves the housing  106 . 
   When assembled, the left housing shell  108  and the right housing shell  110  define a concave bottom surface  182  that lies upon a concave-like receptor surface  184  of the base  104  that includes a plurality of concave ribs  186  that are spaced apart from one another and extend radially from a center portion of the concave-like receptor surface  184 . The outer portion  185  of the bottom surface  182  also lies upon the top annular-like surface  176 . The bottom surface  182  preferably has a radius of curvature that substantially matches the radius of curvature of the receptor surface  184  and the top annular-like surface  176 . Once the bottom surface  182  is supported on the base  104 , it is slidingly attached thereto by having a screw pass  187  through the center hole  186  of the base  104  (see  FIG. 5 ), the bottom rectangular opening (not shown) of the housing  106  and threadingly engage with the threaded opening  144  formed in the tilt nut  142 . With this attachment, the housing  106  is rotatable and pivotable with respect to the base  104  so as to create a full 360° swiveling and orienting capability. The amount of swivel with respect to a plane that that is intersected at right angles by an axis A defined by the hole  186  is approximately ±4°. Note that the receptor surface  184  may be solid instead of being ribbed. 
   As shown in  FIG. 7 , one or more adhesive strips  188  are adhesively mountable in a recess  189  formed in the bottom surface  190  of the base  104 , and portions thereof of release tab  192  for strip  188  may protrude from the side of the attachment. For additional support, pins  164  can be inserted into the openings of the flanges  160 ,  162  so that their tips penetrate the support surface as shown in  FIG. 1 . 
   In an alternative embodiment, the adhesive strip  188  can be attached to a moving plate that can be pressed to be activated. 
   A method of practicing the invention includes providing a surface, such as a wall, wherein orientation with a line is desired, and also providing the laser generator. A user mounts the light generating system  100  by attaching the bottom surface  190  of the base  104  onto the wall and orients the laser generator in one or more planes. Attachment is accomplished by removing a first release liner  191  from one side of a strip  188  so that an adhesive  193  is exposed. The exposed adhesive  193  is then placed so that it adhesively engages the surface on which objects are to be aligned, such as wall  194  of  FIGS. 8A-8C . If removable pressure-sensitive adhesives are used, the swivel base may be removed without damaging the surface on which the objects were aligned. While many such adhesives may be used, “Command Strips,” from the 3M Company, Minneapolis, Minn., are preferred. These adhesives are actually two adhesives interlocked in the center. These adhesives may be purchased, separable and aligned, for single use in adhering the base  104  to a wall or other surface. A pack of six strips may be adhered to the bottom surface of the base  104 . Note that if the base  104  is attached to a vertical-like structure, there is sufficient friction present in the light generating system  100  that prevents the light generating device  102  from freely rotating relative to the base  104 . Note that a similar adhesive attachment scheme is disclosed in U.S. Pat. application Ser. No. 10/819,543 ,the entire contents of which are incorporated herein by reference. 
   After the base  104  is attached to the surface, a reference level, such as bubble level  118 , is then used to orient and true the light generating device  102  in one place, for instance, the vertical plane, using the swiveling light generating device  102  as described above. The second bubble level  120  may be used if the user wishes to orient the laser generating device  102  in a horizontal plane. When the user is satisfied that the light generating devise  102  has established a reference either being level, plumb or lined up with some external feature of the surface, the user turns on the laser generating device  102  via moving switch to the “on” position. As described in U.S. Pat. No. 6,735,879 , the entire contents of which are incorporated herein by reference, the output of the laser generating device  102  is a fan-shaped beam  200 . The fan-shaped beam  200  propagates along the surface of the wall in the direction of propagation. Because the plane of the beam runs perpendicular to the wall  194  along the length of the beam, the line of intersection between the beam and the wall forms a visible line of alignment. It is also noteworthy that the axis of alignment, such as the alignment of pictures on a wall, is substantially parallel to the direction of propagation of the laser light. With the instant laser line marking device, a user projects a fan-shaped beam in a propagation direction  202  that is substantially parallel, rather than perpendicular, to the surface on which alignment is desired, the fan-shaped dimension of the beam being perpendicular to the wall. With a fan-shaped beam, the laser light is able to project over and beyond obstacles, such as moldings placed in a doorway, picture frames in the way of those being aligned on one horizontal line, or other obstacles, such as a wavy or stuccoed surface on an interior wall. 
   In the particular example shown in  FIGS. 8A-B , the fan-shaped beam  200  is able to align a first picture frame  204  on wall  194 . The beam  200  is able to overcome obstacles such as door moldings  206  with its fan shape and extend above the molding with sufficient clarity to align another object, such as picture frame  208 . While the direction of propagation  202  is in the direction from the light generating system  100  to the objects on which alignment is desired, such as picture frames  204 ,  208 , the width of the fan is perpendicular to the wall  194 . The fan-shaped beam  200  intersects the wall  194  and the light is visible on the wall at the intersection  210  of the fan-shaped beam  200  with the wall  194 . 
   Once the beam is generated it establishes a reference position or direction. From this reference position, the angular position of the beam can be altered in a precise manner. For example, the graduation on the index ring corresponding to the reference position is first recorded and the light generating device  102  and marker  178  are rotated, while index ring  156  remains stationary, until the beam travels a desired angular position relative to the graduation corresponding to the reference position. For example, if the reference position corresponds to the 20° graduation and it is desired to move the beam 40° from the reference position, the light generating device  102  is rotated so that the marker  178  is aligned with either the 60° or the 340° graduation, depending on the desired direction of the beam. 
   In an alternative aligning procedure, once the beam is generated and establishes a reference position or direction in the manner described above, the index ring  156  is rotated until a reference graduation, such as the 0° graduation, is aligned with the beam and the marker  178 . In the case of the 0° graduation being the reference graduation, if it is desired to move the beam α degrees from the reference position, the light generating device  102  is rotated until the marker  178  is aligned with either the α degree graduation or the (360°-α°) graduation, depending on the desired direction of the beam. When the 0° graduation is the reference graduation there obviously is less need for calculating the graduation to which the light generating device  102  is rotated. 
   When the user has completed the alignment task, the user pulls on the release tabs  192 , releasing the adhesive  193  from wall  194  or other surface. The adhesive strip that was used may then be removed from bottom surface  190  of the base  104 . The user may then go on to other alignment tasks as desired. 
   While this invention has been shown and described in connection with the preferred embodiments, it is apparent that certain changes and modifications, in addition to those mentioned above, may be made from the basic features of this invention. While the laser line generator may be most convenient to use when mounted to a wall, it may also be mounted on a table, floor, or other flat surface, and used to project a line without being mounted on a wall. Many other variations of the invention may also be used without departing from the principles outlined above. For example, multiple laser beams could be generated orthogonally to one another. Accordingly, it is the intention of the applicant to protect all variations and modifications within the valid scope of the present invention. It is intended that the invention be defined by the following claims, including all equivalents.