Abstract:
A line generator includes a housing carrying a light source for emitting a light beam and a mounting surface for removably mounting the generator on a surface. The line generator includes a gravity dial having at least one indicator, wherein when the mounting surface is substantially vertical, the gravity dial will self level under the influence of gravity and the at least one indicator will indicate whether the emitted light beam is in a predetermined orientation selected from one of a vertical line or a horizontal line.

Description:
[0001]    This application is a continuation-in-part application of U.S. Ser. No. 11/516,674 filed Sep. 5, 2006 (Attorney Docket Number 10710/973 (PTG 1526 PUS), the entire contents of which are incorporated herein by reference. 
         [0002]    The present invention relates to a gravity dial level indicator for a line generator and in particular to a laser level line generator. 
     
     BACKGROUND 
       [0003]    Laser levels typically seek to produce a plane of light for a reference for construction projects. Laser levels may save time during initial layout of a construction job compared to other tools such as beam levels, chalk lines, or torpedo levels. Some examples of jobs where laser levels would be useful include laying tile, mounting cabinets, installing counter tops, and building outdoor decks. Commonly, laser levels are provided with bubble or spirit levels to assist in leveling the housing containing the light source so that the emitted beam is oriented in a desired direction. Bubble levels, however, may be difficult to use and see. It is therefore an object of the present invention to provide a laser level that is inexpensive and usable by the general public. 
       SUMMARY 
       [0004]    The present invention provides a gravity dial for a line generator that is removably disposable on a surface. The leveling line generator includes a housing that carries a light source that emits a planar light beam. The housing includes a mounting surface for removably mounting the generator on a surface and a viewable surface opposite the mounting surface and provided with a gravity dial. The gravity dial includes a weighted disc and a stationary ring surrounding the disc. The weighted disc includes at least one indicator and the stationary ring includes at least one indicator. When the mounting surface is substantially vertical, the weighted disc will self level under the influence of gravity and the at least one indicator on the weighted disc will align with at least one indicator provided on the stationary ring to provide an indication that the emitted planar beam is in a predetermined orientation selected from one of a vertical line or a horizontal line. 
         [0005]    Additional features and benefits of the present invention are described, and will be apparent from, the accompanying drawings and the detailed description below. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1  is a perspective view of one embodiment of a laser level incorporating the self-leveling line generator according to the present invention. 
           [0007]      FIG. 2  is a top view of the laser level of  FIG. 1 . 
           [0008]      FIG. 3  is a perspective view of the second housing of  FIG. 1  with a top portion removed to better show features contained within the housing. 
           [0009]      FIG. 4  is a perspective view of the laser level of  FIG. 1  with the top portion removed and with certain features removed to better illustrate the self-leveling line generator. 
           [0010]      FIG. 5  is a cross sectional view of the first housing shown in  FIG. 4  along line  4 - 4 . 
           [0011]      FIG. 6  is a partially exploded view of the first housing shown in  FIG. 4 . 
           [0012]      FIG. 7  is a side perspective and exploded view of the first housing show in  FIG. 4  with certain features not shown to better illustrate the invention. 
           [0013]      FIG. 8  is a rear view of the device shown in  FIG. 7   
           [0014]      FIG. 9  is a front view of another embodiment of a laser level incorporating the self-leveling line generator according to the present invention. 
           [0015]      FIG. 10  is a side view of the laser level of  FIG. 9 . 
           [0016]      FIG. 11  is a cut-away view of the laser level of  FIG. 9  to illustrate certain features of the present invention. 
           [0017]      FIG. 12  is an exploded view of the laser level of  FIG. 9 . 
       
    
    
     DESCRIPTION 
       [0018]    Turning now to  FIG. 1 , one embodiment of a laser level  1  incorporating the self-leveling line generator  10  according to the present invention is shown. In this embodiment, the laser level  1  is capable of being mounted on a surface so that the projected planar beam is in a fixed orientation which is one of a vertical or a horizontal direction. 
         [0019]    In this embodiment, the line generator  10  includes a first housing  20  that is pivotable or rotatable with respect to a second housing  70 . The first housing  20  may be formed from two clam shell like portions with a first portion  22  and a second portion  24  such as a top and bottom portion or a right and left side. Likewise, the second housing  70  may be formed from two clam shell like portions with a first portion  72  and a second portion  74  such as a top and bottom portion or a right and left side. The first housing  20  may be freely rotatable with respect to the second housing  70 . The first housing  20  may pivot with respect to the second housing  70  about an arc from about 1° to greater than about 360°. Alternatively, the first housing  20  may be rotatably limited to about 360° or some other smaller arc, depending on desired preferences. For example, the first housing  20  may be rotatably limited to a 90° position from a reference position. Alternatively, the first housing  20  may be freely pivotable but may have temporary stops such as detents or the like at one more desired positions such as at 90°, 180°, or other positions from a reference position. 
         [0020]    The first housing  20  contains at least one light source  30  that is positionally fixed with respect to the first housing  20 . In addition, as shown in  FIG. 1 , the first housing  20  may include a barrel  26  containing a lens  32 . The barrel  26  may also contain the light source  30 . As will be discussed in more detail below, the lens  32  is rotatable with respect to light source  30 . The laser level  1  contains a power source  34  for providing power to the light source  30 . Desirably, the light source  30  is a laser diode that emits a beam of light that is received by the lens  32  which converts the beam into a planar light beam that is emitted from the line generator  10 . 
         [0021]    The second housing  70  includes a mounting surface  76  for mounting the line generator  10  to a surface. Alternatively and as shown in  FIGS. 9-12 , the bottom portion of the first housing may include a mounting surface  176 . In this alternative, there is no second housing and thus, one is not present. In any event, the mounting surface  76 ,  176  may be configured to cooperate with known mounting structures such as adhesive tape (removable or otherwise), nails, brackets, magnets, etc. In the embodiment shown in  FIG. 1 , the mounting surface  76  includes a mounting seal  78 ,  178  extending from a lower portion of the bottom portion  74 ,  174  to define a suction mounting area. 
         [0022]    The mounting seal  78 ,  178  has sufficient flexibility and resilience so that when the line generator  10  is pressed toward a surface, the mounting seal  78 ,  178  will deform to create a vacuum within a cavity defined by the mounting seal. The mounting seal  78 ,  178  may be a rubber seal that extends from a lower portion of the housing about the cavity. Other elastomeric materials may be used to accomplish the objective of being deformable to provide a seal. 
         [0023]    The line generator  10  may include a vacuum generating mechanism  80  that cooperates with the mounting seal  78 ,  178  to create a vacuum in the suction mounting area. The vacuum generating mechanism  80  may include a motor  82  disposed within the housing. A vacuum pump  84  is operatively connected to the motor  82  and is mounted adjacent the motor  82  in the housing. It is also understood that the motor  82  and the pump  84  may be assembled as a single unit. The inlet of the pump  82  is connected to an aperture  88  on the bottom of the housing to provide a flow of air from the cavity defined by the mounting seal  78 ,  178  and the attachment surface. The pump  84  cooperates with the mounting seal  78 ,  178  to create a vacuum between the attachment surface and housing to mount the line generator  10  in a fixed relationship relative to the attachment surface. 
         [0024]    A power source  34  is provided to provide power for the motor  82 . Desirably, the power source  34  for the motor  82  also provides power for the light source  30 . Desirably, the housing has a user accessible cavity to permit access to a power source  34  such as batteries (which may be rechargeable or not). The motor  82  may be activated by a switch  90 ,  190  located on an outer surface of the housing. In use, the mounting seal  78 ,  178  is pressed to an attachment surface and the motor  82  can be activated by actuating the switch  78 ,  178  allowing the pump to  84  evacuate air from the suction mounting area created between the attachment surface and the mounting seal  78 ,  178  through the aperture  88 . 
         [0025]    A sensor may be provided proximate the mounting seal  78 ,  178  to monitor the vacuum pressure in the suction mounting area. The sensor may activate the pump  84  to remove air from the suction mounting area when the sensor detects a loss of vacuum pressure in the area between the mounting seal  78 ,  178  and the attachment surface. Loss of vacuum pressure in the suction mounting area may be caused by imperfections in the attachment surface, such as gaps or cracks that limit the effectiveness of mounting seal  78 ,  178 . The sensor allows the pump  84  to compensate for the surface flaws to ensure a proper seal between the line generator  10  and the attachment surface. 
         [0026]      FIGS. 6-9  show another embodiment of a laser level  1  incorporating the self-leveling lens aspect of the present invention. In this embodiment, the housing includes two portions that engage each other to form the housing. In this embodiment, there is only a single housing and it is mountable to a surface in the same manner described above with respect to the embodiment shown in  FIGS. 1-5 . It will be understood that this laser level does not have the pivoting feature described above with respect to the laser level of  FIGS. 1-5 . Further details of a suitable housing and vacuum generating mechanism can be found in U.S. Ser. No. 10/919,708 published as US 2006/0037202, the entire contents of which are incorporated herein by reference. 
         [0027]    Turning now to  FIGS. 4 and 5 , one aspect of the self-leveling line generator  10  of the present invention is shown in connection with a first or top housing  20  formed of a first or top portion  22  and a second or bottom portion  24 . The figures show the top portion  22  removed. A chassis  40  is fixed to either or both of the top  22  and bottom  24  portion. The chassis  40  fixedly holds the light source  30  with respect to the housing  20 . In other words, the light source  30  does not move with respect to the housing  20 . Of course, if the housing  20  is moved then the light source  30  moves. In the instance where a second housing  70  is provided and the first housing  20  is rotatable with respect to the second housing  70 , the chassis  40  remains fixed with respect to the first housing  20  but will of course rotate with the first housing  20  as it rotates with respect to the second housing  70 . 
         [0028]    In the particular embodiment illustrated in  FIGS. 1-5 , the first housing  20  may have a generally circular shape with a cylindrical barrel  26  extending outward from the periphery of the housing. Of course, the first housing  20  may have any suitable and desired shape such that the structural components relating to the generation of a planar light beam and the mounting of the line generator can be contained within. The chassis  40  has a first end  42  and a second end  44 . The chassis  40  is fixed to one of the top  22  or bottom  24  portions of the housing  20 , or both. The first end  42  of the chassis fixedly holds the light source  30 . In other words, the light source  30  does not move with respect to the chassis  40 . The light source  30  is desirably a laser light source that includes at least one diode that projects an alignment beam toward the lens  32  to convert the beam into a planar beam of light, which is emitted from the first housing  20  in a fixed orientation. The lens  32  is desirably located in the barrel  26  so that the user is provided with a visible indication of the source of the laser light. The lens  32  is rotatable with respect to the light source  30  so that the projected planar beam of light is in a fixed orientation despite the orientation of the housing  20 . 
         [0029]    The lens  32  may have any suitable shape to convert the laser beam  31  of light into a planar beam  33  of light. For example, the lens  32  may be cylindrical. Depending on the orientation of the lens  32 , the projected beam  33  will have a selected orientation. Two known and desired orientations are horizontal and vertical. Therefore, the lens  32  may be oriented to provide one of a horizontal or vertical line despite the fact that the housing  20  and, in the instance where the lens  32  is in the barrel  26 , the barrel  26  is not oriented exactly horizontally or vertically. For example,  FIG. 5  shows the lens  32  oriented such that the projected planar beam  33  is in horizontal direction when the bottom of the housing  20  is aligned with a horizontal or substantially horizontal surface. 
         [0030]    The first end of the chassis  42  extends into the barrel  26  toward the distal end  28  of the barrel. A lens holder  50  holds the lens  32  in a position so that the light beam  31  emitted from the laser light source  30  contacts the lens  32 , which converts the light beam  31  into a planar beam  33 . The lens holder  50  is rotatable with respect to the light source  30 . As shown in  FIGS. 4 and 5 , the first end  42  of the chassis includes a fixed bearing  60  in which the lens holder  50  is rotatably mounted. The fixed bearing  60  may be monolithic with the chassis  40  or may be separate as shown in  FIGS. 4 and 5 . In one embodiment, the lens holder  50  is attached to a shaft  62 , which is rotatably mounted within the bearing  60  so that the lens  32  will be rotatable with respect to the light source  30 . The shaft  62  is hollow to permit the light beam  31  from the light source  30  to pass through the shaft  62  to contact the lens  32 . The shaft  62  may be formed monolithically with the lens holder  50  or may be separate as shown in  FIGS. 4 and 5 . 
         [0031]    To provide free rotation between the lens holder  50  and the chassis  40 , each of the bearing  60  and the shaft  62  are circular. In addition, to provide the desired self-leveling capability, the lens holder  50  has a pendulous structure. In one aspect, the lens holder  50  has at least a portion that has circular cross section  52  that is complementary to the shape of the bearing  60  to allow the lens holder  50  to freely rotate within the bearing  60 . A forward portion of the lens holder has a pair of opposing flanges  54  in which the lens  32  can be fixedly held. An arm  56  extends from an outer periphery of the circular portion of the lens holder  50  to provide a weighted structure. The arm  56  may also have an additional weight  58  that extends from the distal end of the arm toward the bearing  60  and that is shaped to approximate the shape of the bearing  60 . In other words, the additional weight  58  may have an arc shape. As a result, the lens holder  50  will swing under the influence of gravity and come to rest at a position so that the projected planar beam  33  is in a fixed orientation. 
         [0032]    A laser light source actuation switch  36  extends through the housing. A power source  34  disposed in the housing can power both the motor  82 , if provided, and the laser light source  30 . In one aspect of the present invention, the power source  34  is a rechargeable battery pack, such as a lithium ion or nickel cadmium power cell securely mounted within housing. Alternatively, the power source is a removable alkaline battery or batteries. The laser light source actuation switch  36  may be separate from the motor actuation switch  90 . Alternatively, a single switch may be provided to activate each of the motor  82  and the light source  30 . 
         [0033]    Referring now to  FIGS. 9-12 , another aspect of the present invention is illustrated. In this aspect, a cylindrical bearing  160  is fixed and the lens holder  150  has a first end that is circular  152  and that freely rotates within the bearing  160 . The lens holder  150  has a second end  151  configured to hold a lens  32  that receives the light beam  31  and converts it into a projected planar light beam  33 . The lens holder  150  is also configured to be weighted along a portion of its structure so that the weighted portion will seek the lowest level under the influence of gravity. In other words, the lens holder  150  will act like a pendulum to fix the lens  32  in a desired location to provide a desired fixed orientation of the planar light beam  33 . 
         [0034]    Turning now to  FIGS. 6-8 , the gravity dial of the present invention is shown. The gravity dial has a top surface and a bottom surface with a flange provided at a portion of the periphery of the dial. The flange receives an adjustable weight that can be used to calibrate the dial, as further explained below. The dial is rotatably mounted with respect to the housing. As a result, when the housing is attached to a vertical surface (or a substantially vertical surface), the dial will pivot with respect to the housing because of the influence of gravity on the weight. In other words, when the plane of the top surface of the dial is vertical or substantially vertical, the dial acts as a pendulum and pivots with respect to the housing. 
         [0035]    The bottom surface is provided with one of a shaft or a bearing to cooperate with a respective bearing or shaft provided in the housing. For example, as seen in  FIG. 8 , a shaft is rotatably provided in a bearing that is mounted in the housing to allow the dial to freely rotate. The bearing is positionally fixed with respect to the housing to allow the dial to rotate with respect to the housing. In the embodiment, shown in  FIGS. 6-8 , a chassis is fixed to the housing and the bearing is fixed on the chassis. In the embodiment shown in  FIGS. 9-12 , a chassis is fixed to the housing and a positioning pin extends toward the dial to carry a bearing in a fixed position with respect to the housing. The bottom surface of the dial has a shaft that is rotatably received by the bearing that allows the dial to freely rotate. 
         [0036]    The top surface is provided with at least one visible indicator. The at least one indicator may be provided directly on the top surface. Alternatively, the at least one indicator may be provided on a plate that is attached to the top surface. The at least one indicator may also be provided on both the dial and the plate. The at least one indicator may have any suitable shape and size but is desirably an arrow shaped projection. In addition, alphanumerical characters may be provided on the top surface to aid the user in understanding the orientation of the housing. For example, as seen in  FIG. 2 , the top surface contains four arrow shaped projections as well as the words “horizontal” and “vertical” associated with respective arrows. 
         [0037]    The housing is provided with at least one indicator that cooperates with the at least one indicator provided on the gravity dial to provide an indication to the use that the projected planar beam is in a desired orientation selected from one of horizontal or vertical. Desirably, the at least one indicator on the dial is aligned with at least one indicator on the housing when the housing is in a vertical or horizontal position. For example, as seen in  FIG. 2 , the arrow shaped projections on the gravity dial are aligned with respective indicators on the housing. The alignment of the indicators can be calibrated using the adjustable weight during assembly of the line generator. 
         [0038]    The indicators on the housing can be provided directly on the housing or they may be provided on a stationary ring that surrounds the dial. As seen in  FIG. 6 , a stationary ring has flanges that can be used to fix the ring to the housing. The top of the ring is provided with at least one indicator that cooperates with the at least one indicator provided on the dial. A cap made from, for example, transparent plastic may be provided to protect the dial from dust and foreign objects yet allow the user to view the indicators on the dial. 
         [0039]    The above description is not to be used to limit the claims and one skilled in the art will understand that various alterations and changes can be made without altering the scope of the claimed invention.