Abstract:
Apparatus and methods are provided which are particularly useful in determining the location for producing aligned holes or hangers in consecutive support members such as joists from which pipe, conduit, wire, duct, and the like, will be supported, with the minimum amount of measuring or errors in measurements. The present invention includes an instrument that houses a small diameter light beam projector, e.g., a laser light beam projector, that is provided with the ability to adjust the direction of beam projection from the instrument relative to its housing. The instrument is adapted to fit through a pre-bored hole or a hanging support so as to direct the laser light beam into the desired direction to locate additional bored holes or hangers. The projected beam position is checked and if there is error, the projector is adjusted within the instrument housing to properly place the beam center at the desired location with respect to second joist. In the case of a through hole, the second hole is drilled and the beam passes through the second hole to the third joist. The beam now accurately identifies the location for the third hole to be drilled and the procedure continues through the joists to the desired termination of the conduit.

Description:
RELATED APPLICATIONS 
   This application claims the benefit of U.S. Provisional Application Ser. No. 60/237,502, filed Oct. 4, 2000. 

   FIELD OF THE INVENTION 
   This invention pertains to apparatus and methods to aid in the production or placement of aligned holes or supports through or along multiple support beams or joists in a building structure to enable placement of straight rigid conduit for use, e.g., as water lines, stringing of electrical wire and the like. 
   BACKGROUND OF INVENTION 
   In a building structure, water, electricity and venting need to be available at different locations in the building. Wire conveying conduit, water pipes and vent ducts are typically provided in the walls and flooring of the building structures. Such spaces also are occupied by support members such as beams or joists and it is frequently necessary to direct such conduit, pipes and the like either through the joists or hung from below the joists as the pipes are extended, e.g., from one side of the building to the other. 
   In order to properly place the conduit and the like, the builder commonly provides a series of aligned through holes within the joists or aligned hangers below the joists. Misalignment of the through holes or hangers results in considerable re-measuring and rework. The builder typically locates a first hole or hanger in a joist, for example, by measuring from a common reference, such as the floor and adjoining wall. The builder continues this measuring process with subsequent joists along the desired path. Measurement of each hole or hanger is a time and labor intensive operation. Misalignment of even a single hole or hanger will prevent the proper placement of the conduit. In joists, a misaligned through hole may require that the through hole be reworked, possibly requiring the repair or replacement of the joist. 
   There is a need for apparatus and methods to replace the labor intensive and costly production of aligned holes and hangers in spaced-apart structures that is less complex and labor intensive, while reducing the potential for misalignment. 
   SUMMARY OF INVENTION 
   The present invention includes an instrument that houses a small diameter light beam projector, e.g., a laser light beam projector, that is provided with the ability to adjust the direction of beam projection from the instrument relative to its housing. The instrument is adapted to fit through a pre-bored hole in a support joist and to be securely clamped to the joist so as to direct the laser light beam onto an adjacent support joist. The projection of the light beam onto the adjacent joist is intended to identify the center of the hole to be bored in the adjacent or second joist. The projected beam position is checked and if there is error, the projector is adjusted within the instrument housing to properly place the beam center at the desired hole center for the second joist. The second hole is drilled and the beam passes through the second hole to the third joist. The beam now accurately identifies the location for the third hole to be drilled and the procedure continues through the joists to the desired termination of the conduit. 
   Clamping of the instrument to the first joist is important, as is the ability to adjust the beam projection. Cross hairs may be provided on the projector lens to pinpoint the beam center. Because there are different hole sizes, the instrument is either adapted to adjust to the different hole sizes or adjusting sleeves are provided to adapt projector to the hole. These and other variations as well as the invention itself will become more readily apparent upon reference to the following detailed description that follows. 

   
     BRIEF DESCRIPTION OF DRAWINGS 
       FIGS. 1A and 1B  are partial cross-sectional side exploded and assembled views, respectively, of a location projector in accordance with an embodiment of the invention. 
       FIGS. 2A and 2B  are partial cross-sectional side exploded and assembled views, respectively, of a location projector in accordance with an embodiment of the invention. 
       FIGS. 3A and 3B  are cross-sectional side and end views, respectively, of a location projector hole adapter, in accordance with an embodiment of the invention. 
       FIG. 3C  is a partial cross-sectional side view of a location projector with hole adapter, in accordance with an embodiment of the invention. 
       FIGS. 4A and 4B  are partial cross-sectional side exploded and assembled views, respectively, of a location projector in accordance with an embodiment of the invention. 
       FIGS. 5A and 5B  are partial cross-sectional side exploded and assembled views, respectively, of a location projector in accordance with an embodiment of the invention. 
       FIG. 6  is a side view of an embodiment of a location projector being used in accordance with an embodiment of a method of the present invention. 
   

   DESCRIPTION 
   In the following detailed description, reference is made to the accompanying drawings which form a part hereof wherein like numerals designate like parts throughout, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention. Therefore, the following detailed description is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims and their equivalents. 
   The following embodiments and figures refer to a laser used as an illuminating source. The scope of the invention is not to be limited to lasers. The scope of the invention includes, but is not limited to, any illuminating source or apparatus suitable for the intended purpose. 
     FIG. 1A  is a partial cross-sectional exploded side view of a location projector  100  in accordance with an embodiment of the present invention.  FIG. 1B  is a partial cross-sectional assembled side view of the location projector  100  in accordance with the method of using the embodiment of FIG.  1 A. The location projector  100  comprises a first portion  110  and a second portion  120  adapted to be coupled together through a first through bore  152  in a first support member  150  and, as coupled, to be securely clamped to the first support member  150 . 
   The first portion  110  comprises a cylindrical first end  111  having external helical threads  112 . The first end  111  is adapted to be inserted into the first through bore  152  from a first side  154  of the first support member  150 . The length of the first end  111  is adapted to be longer than the length of the first through bore  152  such that when inserted into the first through bore  152 , at least a portion  113  of the first end  111  extends beyond an opposite side  156  of the support member  150 . The first portion  110  further comprises a second end  116 . The second end  116  has a first enlarged portion  117  adapted to prevent the second end  116  from entering the first through bore  152 . The first enlarged portion  117  comprises a flat first contact surface  118 . 
   The second portion  120  comprises a second portion through bore  122 , wherein at least a portion of which comprises internal helical threads  124 . The internal threads  124  are adapted to accept the external threads  112  of the first end  111 . The second portion  120  further comprises a second enlarged portion  126  adapted to prevent the second portion  120  from entering the first through bore  152 . The second enlarged portion  126  comprises a flat second contact surface  127 . 
   The first portion  110  further comprises a laser projector  140 . The laser projector  140  produces a light beam  142  that exits the first end  111  of the first portion  110  in substantially coaxial alignment with the first end  111 . 
   Referring again to  FIG. 1B , the first support member  150 , such as a joist or a beam, among others, is measured to locate and produce the first through bore  152  using conventional methods. The location projector  100  is coupled to the first support member  150  through the first through bore  152  in such a way as to project the light beam  142  along the desired path to locate positions on adjacent support members to produce subsequent through bores. 
   The first end  111  is inserted into the first through bore  152  from the first side  154  of the first support member  150 , with the flat first contact surface  118  abutting the first side  154 . From the opposite side  156  of the first support member  150 , the second portion  120  is threaded onto the portion  113  of the first end  111  that extends beyond the first through bore  152 . The second portion  120  is advanced such that the flat second contact surface  127  of the second enlarged portion  126  abuts the opposite side  156  of the first support member  150 . In cooperation with the first contact surface  118 , the second contact surface  127  applies clamping engagement with the first support member  150 . This clamping engagement of the first and second contact surfaces  118 ,  127  against the first and opposite sides  154 , 156 , respectively, of the first support member  150 , firmly couples the location projector  100  to the first support member  150 . Thus, the light beam  142  of the laser projector  140  is substantially perpendicular to the support member first and opposite sides  154 , 156  and substantially coaxial with the first through bore  152 . This position of the light beam  142  may be used as a reference for subsequent light beam positioning. 
   The laser projector  140  projects a light beam  142  through the second portion through bore  122  of the second portion  120  to illuminate a location on a second support member  158  which is adjacent to the first support member  150 . The impingement point  153  of the light beam  142  onto the second support member  158  can therefore be marked for producing a through bore on the second support member  158 . The impingement point  153  may then be measured in relation to the second support member  158  to ensure that the impingement point  153  is correctly placed. 
   The position of the light beam  142  is adapted to be adjustable. The adjustment may be made using a variety of apparatus. In an embodiment of a location projector  100  with a position apparatus (not shown), the position of the location projector  100  relative to the first through bore  152  is adjusted using a vernier. A vernier is defined here as an auxiliary device used with a main device to obtain fine adjustment. In another embodiment (not shown), the positioning apparatus includes optics that is used to focus and adjust the position of the light beam  142 . One skilled in the use of lasers will recognize numerous method of adjusting the position of a light beam with respect to a device in which it is mounted. 
   The adjustment of the light beam  142  may be used to compensate for placement errors of the location projector  100  within the first through bore  152 . Further, the adjustment may also be used to adjust the beam off the axis of the first through bore  152  to a desired angle. An off-axis angle may be useful for, for example, but not limited to, defining locations for subsequent placement of a gravity-fed drainage pipe. Such a drainage pipe may require, for example, a downwardly sloping mounting such that a downwardly sloping alignment of through bores would be desired. 
   In another embodiment in accordance with the present invention, the location projector  100  her comprises a horizontal bubble-level  114 . The bubble-level  114  is in alignment with the axis of the light beam  142 . The bubble-level  114  provides a visual indication of the horizontal condition of the light beam  142 . In another embodiment, or in addition to the aforementioned embodiments, the location projector  100  further comprises a bulls-eye bubble indicator  115 . The bulls-eye bubble indicator  115  provides a visual indication of the vertical condition of the light beam  142 . It is within the scope of the invention that the location of the bubble-level  114  and the bulls-eye bubble indicator  115  may be placed on either the first or second portion  110 , 120  in a location suitable for the intended purpose. 
   Once the impingement point  153  of the light beam  142  on the second support member  158  is correctly placed and marked, the mark is used to produce a second through bore  152  in the second support member  158  which will be aligned with the first through bore  152 . 
   After the second through bore  155  is made in the second support member  158 , the light beam  142  will project through the second through bore  152  to illuminate an impingement location  153  on a subsequent support member  159  into which an aligned through bore may be produced. Measurement of the impingement location of the light beam  142  is not needed beyond the second support member  158  in order to accurately produce through bores which are aligned with the first through bore  152 . This method is sequentially repeated until the desired number of aligned through bores is made. 
   It is anticipated that for some applications, the diameter of the first end  111  will be substantially smaller than the diameter of the first through hole  152 . In such cases, the location projector  100  may be susceptible to shifting within the first through bore  152 . Shifting can be caused by, for example, construction shock and vibration, as well as holding the location projector  100  centered within the through hole  152  when clamped. Therefore, the invention includes embodiments for apparatus and methods for compensating for this mismatch. 
     FIG. 2A  is a partial cross-sectional exploded side view of a location projector  102  in accordance with an embodiment of the present invention.  FIG. 2B  is a partial cross-sectional assembled side view of the location projector  102  in accordance with the method of using the embodiment of FIG.  2 A. The location projector  102  comprises essentially the same elements as the embodiment of  FIGS. 1A and 1B  with the addition of a sleeve  130 . The sleeve  130  is sized to adapt the diameter of the first end  111  to the diameter of the first through bore  152  such that the location projector  102  is substantially centered and restricted from shifting within the first through bore  152 . That is, the interior diameter of the sleeve  130  is substantially the same as the diameter of the first end  111 , and the exterior diameter of the sleeve  130  is substantially the same as the diameter of the first through bore  152 . 
   During assembly, the sleeve  130  is slipped over the first end  111  such that an end of the sleeve  130  abuts the first contact surface  118  of the first portion  110 . The sleeve  130  has a length substantially equal to the depth of the first through bore  152 . Once the first end  111  and the sleeve  130  are inserted into the first through bore  152 , the second portion  120  is advanced onto the first end  111  in substantially the same method as previously discussed. The sleeve  130  will be contained within the first through bore  152  and will not interfere with the clamping engagement of the first and second contact surfaces  118 , 127  and the first support member  150 . 
   In another embodiment of the invention, not shown, the sleeve  130  is adapted to be compressible. The sleeve  130  has a length greater than the depth of the first through bore  152 . In an embodiment of the method, the sleeve  130  is advanced over the first end  111  with an end abutting the first contact surface  118 . The first end  111  and the sleeve  130  are inserted into the first through bore  152 . The second portion  120  is threaded onto the first end  111  and advanced such that the second contact surface  126  abuts the sleeve  130 . 
   Upon further advancement of the second portion  120 , the sleeve  130  is confined between the first and second contact surfaces  118 ,  127  causing the sleeve  130  to compress lengthwise and expand and/or increase in diameter. The sleeve  130  is adapted to radially expand against at least a portion of the inside surface of the first through bore  152 . The sleeve  130  bears against the inside of the first through bore  152  and against the first end  111  securing and centering the location projector  102  inside the first through bore  152 . Further tightening of the second portion  120  causes the first and second contact surfaces  118 ,  127  to abut and apply clamping pressure to the first and opposite sides  154 , 156  of the first support member  150  in substantially the same way as the previous embodiment. 
     FIGS. 3A and 3B  are cross-sectional side and end views, respectively, of a through bore adapter  170 , in accordance with an embodiment of the invention.  FIG. 3C  is a partial cross-sectional side view of the location projector  104  comprising the through bore adapter  170  in accordance with the method of using the embodiment of  FIGS. 3A and 3B . The through bore adapter  170  comprises a flange  174  and a cylindrical portion  172 . The cylindrical portion  172  has an outside diameter substantially the same as the inside diameter of a first through bore  252  in a first support member  250  into which it is placed. The through bore adapter  170  includes an adapter through bore  176 . The adapter through bore  176  is substantially the same as the diameter of the first end  111 . 
   The cylindrical portion  172  of the through bore adapter  170  has a length adapted to span at least a portion of the depth of the first through bore  252 . The flange  174  of the through bore adapter  170  is adapted to rest adjacent a first side  254  of the first support member  250 . 
   The first portion  110  and the second portion  120  is substantially the same as in previous embodiments. 
   In an embodiment of the method of the present invention, the cylindrical portion  172  of the through bore adapter  170  is inserted into the first through bore  252  in the first support member  250  with the flange  174  abutting the first side  254 . The first end  111  is inserted into the adapter bore  176  with the first contact surface  118  abutting the flange  174 . The second portion  120  is advanced onto the first portion  111  in substantially the same method as previously discussed. 
   The first and second contact surfaces  118 ,  127  applies clamping engagement with the flange  174  of the through bore adapter  170  and the opposite side  256 , respectively, firmly securing the location projector  104  to the first support member  250 . By this method, the location projector  104  is substantially centered within the through bore  252  and is removably coupled to the first support member  250 . 
   Through bore adapters of various diameters and lengths are within the scope of the present invention to adapt the location projector  104  to many different through bore sizes and support member widths. Additionally, it is within the scope of the invention that the through bore adapter  170  can be used in combination with the sleeve  130  such as shown in the embodiment of  FIG. 2A , if needed. 
   In the previous embodiments, the laser projector  140  is contained within the first portion  110  of the location projector  100 ,  102 ,  104 , with the light beam  142  exiting the first end  111 . In other embodiments within the scope of the invention (not shown), the laser projector  140  is located on the second portion  120 . Further, in other embodiments, the laser projector is a removable component of the location projector. 
     FIG. 4A  is a partial cross-sectional exploded side view of a location projector  106  in accordance with an embodiment of the present invention.  FIG. 4B  is a partial cross-sectional side view of the location projector  106  in accordance with the method of using the embodiment of FIG.  4 A. The location projector  106  is similar to the embodiment of  FIGS. 1A and 1B  but that the laser projector  170  is a removable component of the location projector  106 . The location projector  106  comprises a first portion  160  and a second portion  120 . The second portion  120  is essentially the same as the previous embodiments and used in essentially the same way as the previous embodiments. 
   The first portion  160  comprises a cylindrical first end  161  having helical external threads  162 . The first end  161  is adapted to be inserted into the first through bore  152  from the first side  154  of the first support member  150 . At least a portion  163  of the first end  161  extends beyond the opposite side  156  of the first support member  150 . The first portion  160  further comprises a second end  166  having a first enlarged portion  167  adapted to prevent the second end  166  from entering the first through bore  152 . The first enlarged portion  167  comprises a flat first contact surface  168 . The first portion  160  further comprises a first portion through bore  169  between the first end  161  and the second end  166 . The first portion  160  and the second portion  120  are adapted such that the first portion through bore  169  and the second portion through bore  122  are in substantially coaxial alignment with each other when assembled. 
   The first and second portions  160 ,  120  are assembled onto the support member  150  in much the same way as the embodiment of FIG.  1 B. The second end  166  of the first portion  160  is adapted to couple with a laser projector  170 . The laser projector  170  is coupled to the second end  166  such that the light beam  172  projects down the first portion through bore  169  and passes through the second portion through bore  122 . 
     FIG. 5A  is a partial cross-sectional side exploded view of a location projector  108  in accordance with another embodiment of the invention. The location projector  108  comprises a first portion  210  and a second portion  220 . The first portion  210  comprises a first end  211 , a second end  216  and a bore  269  between the first and second end  211 ,  216 . The first end  211  comprises external helical threads  212 . Proximal the first end  211  is a shoulder  217 . In one embodiment of the invention, the shoulder  217  is tapered. 
   The second portion  220  comprises a helical threaded through bore  224  adapted to accept the first end  211  of the first portion  210 . The second portion  220  further comprises a sleeve-bearing end  227  that, in one embodiment, is tapered. The location projector  108  further comprises a cylindrical sleeve  230  that is adapted to be compressible. The sleeve  230  is substantially the same as sleeve  130  shown in the embodiment of  FIGS. 2A and 2B . 
     FIG. 5B  is a partial cross-sectional side view of the location projector  108  in accordance with an embodiment of the method of using the present invention of  FIG. 5A. A  first through bore  152  is measured and produced in a first support member  150  using conventional methods. The sleeve  230  is sized to adapt the diameter of the first end  211  and the diameter of the first through bore  152  such that the location projector  108  will be substantially centered and restricted from shifting within the first through bore  152 . That is, the interior diameter of the sleeve  230  is substantially the same as the diameter of the first end  211 , and the exterior diameter of the sleeve  230  is substantially the same as the diameter of the first through bore  152 . 
   The sleeve  230  is adapted to be compressible. The sleeve  230  has a length greater than the depth of the first through bore  152 . The sleeve  230  is advanced over the first end  211  with an end abutting the shoulder  217 . The first end  211  and the sleeve  230  are inserted into the first through bore  152 . The second portion  220  is threaded onto the first end  211  and advanced such that the sleeve-bearing end  227  abuts the sleeve  230 . 
   Upon further advancement of the second portion  220 , the sleeve  230  is confined between the sleeve-bearing end  227  and the shoulder  217  causing the sleeve  230  to compress lengthwise and expand and/or increase in diameter. The sleeve  230  is adapted to radially expand against at least a portion of the inside surface of the first through bore  152 . The sleeve  230  bears against the inside of the first through bore  152  and against the first end  211  securing and centering the location projector  108  inside the first through bore  152 . 
   An illuminating source, such as a laser projector  240 , is coupled to the second end  216  of the first portion  210  in substantially the same method shown in FIG.  4 B. The location projector  108  is thereafter used in substantially the same way as previously described in previous embodiments. 
   In the previous embodiments, the location projector is used to locate positions on joists and the like to produce aligned through holes. In other applications, it is desired to attach conduit and the like from either below the support members or vertically along a support member. The location projector of the present invention can be used to locate positions on one or more support members from which to attach hangers and the like to support conduit, plumbing, and other like materials used in building construction. 
     FIG. 6  is a side view of an embodiment of a location projector  109  in accordance with an embodiment of the method of the present invention. The location projector  109  is used to locate positions along a series of support members from which to attach hangers. The hangers, for example, J-hooks, are aligned in order to properly support the construction material. The embodiment of  FIG. 6  illustrates an application wherein it is desired to support the construction material, such as a drainage pipe, in a downwardly sloping configuration. 
   In an embodiment of the method, a first hanger  352  is attached to a first support member  360 , the location of which having been previously measured using conventional methods. The location projector  109  is securely coupled to the first hanger  352  using one of the methods described above or by other methods suitable for the intended purpose. The location projector  109  is used to project a light beam  142  which is used to locate the desired position of subsequent hangers  353 - 356  from subsequent support members  361 - 364 , respectively. 
   As described in previous embodiments, the light beam  142  may be adjusted in a desired elevation suitable for a particular purpose. In an embodiment of a method in accordance with the present invention, the light beam  142  is adjusted in a horizontal orientation to locate hanger positions that will result in a horizontal run for conduit or the like. In another embodiment of the method, the light beam  142  is adjusted in a direction away from horizontal, to assist in locating hangers for applications requiring a sloping run, such as drainage plumbing. 
   The desired location of the hangers  353 - 356  may be determined in a number of ways. In an embodiment in accordance with a method of the invention, smoke is used to illuminate the light beam  142  to locate the desired hanger location with respect to the light beam  142  and the support members. In another embodiment of the method, the light beam  142  may be used to illuminate an opaque surface, such as a paper card, one&#39;s hand, or the hanger itself, to determine the desired hanger location upon each support member. Once the hanger location is determined, the hanger may be secured to the support member. 
   Although specific embodiments have been illustrated and described herein for purposes of description of the preferred embodiment, it will be appreciated by those of ordinary skill in the art that a wide variety of alternate and/or equivalent implementations calculated to achieve the same purposes may be substituted for the specific embodiment shown and described without departing from the scope of the present invention. Those with skill in the construction arts will readily appreciate that the present invention may be implemented in a very wide variety of embodiments. This application is intended to cover any adaptations or variations of the embodiments discussed herein. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof.