Patent Publication Number: US-9850676-B2

Title: Level adjustment tool, system and method for free standing poles and structural columns

Description:
This United States Continuation Application claims priority to U.S. Utility patent application Ser. No. 12/025,245 (US Patent Publication 2008/0184633) entitled “Level Adjustment System and Method for Free Standing Poles and Structural Columns” that was filed on Feb. 4, 2008 and claims priority to U.S. Provisional Application Ser. No. 60/900,002 filed on Feb. 17, 2007, both of which are commonly-owned and incorporated by reference in their entirety. 
    
    
     FIELD OF THE SUBJECT MATTER 
     The subject matter disclosed herein is related to leveling vertically standing poles and columns, and more particularly to a system, apparatus/tool and method of utilizing that tool that utilizes nuts vertically adjustable on bolts to level or to provide a level support for such poles and columns. 
     BACKGROUND 
     In the prior art, poles are generally leveled by installing four bolts in a concrete base spaced from each other as are the mounting holes in the base of the pole. Nuts with washers over them are then installed on each of the bolts. The nuts on pairs of bolts are then successively vertically adjusted so they are level with each other with a Torpedo level which is placed between two nuts. This type of leveling operation is repeated with different pairs of nuts until all are indicated to be in a level state. The base of the pole is then mounted on the bolts and additional leveling is done. This is a rather tedious and time consuming operation and is readily subject to errors. 
     U.S. Pat. No. 4,194,237 issued on Conklin discloses bolts that are designed to make the pole “break-a-way”. This is very important, because there is nothing in Conklin that would lead one of ordinary skill in the art to consider a non-break-a-way pole and leveling a pole that is not designed to break away. In the Conklin reference, the bolts that are originally installed in the foundation base do not fit through the apertures in the light pole base. In Conklin, the bolts that are originally installed in the foundation base are coupled to a “break-a-way” coupling providing a gap between the foundation base bolts and the pole base coupling, so that when a car hits the pole—the pole breaks off and falls away from the car. The foundation bolts do not fit through the apertures in the vertical structure base. 
     Therefore, there is a need for a level system that is simple to use, removable and able to level a pole on a support base. 
     SUMMARY OF THE SUBJECT MATTER 
     A contemplated system has four threaded bolts, which are installed in a concrete block with their threaded portions protruding upwardly above the surface of the block. The bolts are positioned in a circular configuration spaced equally from each other around the block. A nut is installed on each of the bolts and a washer may be installed over each bolt between the nut and the bolt. A plate which serves as a removable tool is fabricated of a rigid material which may be of aluminum and is thick enough to resist bending. The tool plate has a central aperture and four slots equally spaced from each other which run from the central aperture towards the periphery of the plate. Each of the bolts is fitted into a separate one of said slots with the edges of each slot being supported either directly on the bolt or on a washer fitted on the bolt. A leveling gage is mounted on the plate. The nuts are adjusted in position on each of the bolts to bring the plate into a level position as indicated by the gage. The tool plate is then removed for use on another installation with the four bolts providing an accurately level support for the pole. 
     A removable tool for leveling a vertical structure in a vertically level orientation is also disclosed, the tool including a flat substantially non-bendable material, wherein the tool has a central hole formed in the center thereof that does not extend to or open out to the periphery of the tool, and four slots extending radially away from the hole and spaced from each other evenly about the tool. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a top plan view of a contemplated embodiment with the tool removed. 
         FIG. 2  is side perspective view of a contemplated embodiment with the tool removed. 
         FIG. 3  is a side perspective view of a contemplated embodiment with the tool installed in position. 
         FIG. 4  is a top plan view of a contemplated embodiment with the tool installed in position. 
         FIG. 5  is a side perspective view showing a contemplated embodiment with a pole installed thereon. 
         FIG. 6  is a top plan view of an arch which may be employed to support the level; 
         FIG. 7  is a side perspective view of the arch shown in  FIG. 6 ; and 
         FIG. 8  is a side elevational view of the leveler and its tensioner. 
         FIG. 9  is another side perspective view showing the contemplated embodiment of  FIG. 5 ; 
     
    
    
     DETAILED DESCRIPTION 
     The device and method of the embodiments disclosed herein has many advantages over this prior art approach. First, the accuracy of the achieved level is greatly improved over the prior art approach which involves the use of a torpedo level to level from one bolt to the next. The use of the flat plate of the tool in contemplated embodiments alone or with a circular level mounted on it allows a complete and accurate leveling in a simple operation, thereby minimizing the possibility of any error between the support points. In addition, the use of the tool disclosed herein allows an “all point” contact, rather than in-line leveling of a bolt circle. This all point contact embodiment has never been achieved by conventional tools or methods. 
     Further, by pre-leveling the bottom nut prior to pole installation, there is no need to leave a large gap for future adjustment. Recessing the bolts into the concrete allows the pole base direct contact with the concrete base with no resulting gap; or the nuts can be leveled closer to the concrete base, resulting in a smaller gap. By either minimizing the adjustment gap or eliminating it entirely, a much stronger and more structurally sound installation of the pole is obtained. The need for expansion material (dry pack) is also reduced or eliminated. In addition, the poles are automatically pre-plumb with no additional adjustment needed after installation. 
     Specifically, a removable tool for leveling a vertical structure in a vertically level orientation is disclosed where the tool comprises a flat substantially non-bendable material, wherein the tool has a central hole formed in the center thereof that does not extend to or open out to the periphery of the tool, and four slots extending radially away from the hole and spaced from each other evenly about the tool. 
     Referring to  FIGS. 1-4 , a contemplated embodiment is illustrated. Concrete base  11  is preferably circular in configuration and rests on the ground where the pole for a light or other purpose is to be installed. Embedded in the concrete are four bolts  12   a - 12   d  with the threaded portions above the surface of the concrete. The bolts are arranged in a circular configuration, equidistant from each other. A nut  17  is threadably attached to each bolt  12   a - 12   d  in a position spaced upwardly from the surface of the concrete base. 
     The bolts may have a lower nut  13  embedded in the concrete to which they are threadably attached, as shown in  FIG. 3 . On top of each of the nuts  17   a - 17   d  is a washer  14   a - 14   d . It is to be noted that while the washers are helpful, they are not essential to make for an operative device. In the center of the concrete base, are a pair of conduits  15  and  16  which run through the base and can be used to carry electrical lines for lights or other devices which may be mounted on the pole. 
     Referring now to  FIGS. 3 and 4 , the tool  24  used to level the device is illustrated. This contemplated tool is fabricated of a rigid material which may be a sheet of aluminum of about one inch in thickness. The tool has a central aperture  21  which may be round, substantially circular, oval, square or rectangular and through which the conduits  15  and  16  for electrical lines may pass. However, it should be understood that while conduits for electrical lines can be utilized, the tool is not meant to be a permanent installation, but is instead designed to be removable, so the actual electrical lines will not be installed until the tool is removed—if their installation results in a design that doesn&#39;t allow easy removal of the tool. 
     Four slots  30   a - 30   d  are formed in the tool. These slots are equally spaced and run from the central aperture  21  to the periphery of the tool. Fitted in each of the slots is one of bolts  12   a - 12   d . The edges of the slots abut against the washers  14   a - 14   d  which are directly beneath them. A substantially rectangular slot  33  is formed in the tool to facilitate its handling. 
     A level  32  is provided, this level being commercially available. A level which may be used is identified as follows: (inventor please give us model and manufacturer). The nuts  17   a - 17   d  are each manually adjusted on bolts  12   a - 12   d  respectively until accurate leveling of the tool is indicated by level  32 . The desired leveling for the pole base is now provided and the tool can be removed for future use. 
     Referring to  FIG. 5 , the support of a pole  40  on the leveled support is illustrated. The bolts  12   a - 12   d  are fitted through apertures  40   a  formed in the base plate  10   b  of the pole with the base plate  40   b  resting on the washers and bolts leveled with the leveling tool. 
     Referring now to  FIGS. 6 and 7 , an alternate structure for balancing the tool  20  is shown. In this instance, the tool  20  is exactly as previously described in conjunction with its balancing except that the leveler  32  is placed on an arch  41  above the tool plate. This provides some simulation of height. It is necessary, however that the top portion of the arch be precisely parallel to the surface of the base tool. 
     Referring now to  FIG. 8 , a stabilizing device for supporting leveler  32  firmly in position is illustrated. The leveler is attached to support plate  34  by means of bolts  36  which threadably engage the plate and are adjusted to bring the level to a level position. Wavy washer  37  abuts against arch  41  and the leveler  32  to tension the leveler firmly in position. 
     Additional embodiments include a method for providing a level support in a vertical position for a pole comprising the steps of: installing four bolts in a concrete block with the top end of the bolts protruding from the top surface of the block, wherein the bolts are positioned in a circular configuration spaced around the surface of said block; installing a nut on each of the bolts; installing a flat plate of rigid material forming a tool having a central aperture and four slots formed therein, wherein the slots are about equally spaced from each other and extending from the central aperture towards the periphery of the plate; and wherein the flat plate is installed with each bolt fitted into one of the slots and the edges of the bolts abutting against the edges of the slots; installing a leveling gage on the plate; adjusting each of the nuts on its associated bolt to level the plate as indicated by the leveling gage; and removing the flat plate tool for future use, the four nuts having been adjusted to support the pole in a level position. 
     In other embodiments, a method for mounting a support for a vertical structure in a vertically level orientation is contemplated comprising: providing a solid support base; installing four bolts in said base, wherein the bolts are arranged away from each other in a substantially circular configuration; threadably engaging a nut onto each of said bolts; fabricating a tool of a flat substantially non-bendable material, wherein the tool has a central hole formed in the center thereof that does not extend to or open out to the periphery of the tool, and four slots extending radially away from the hole and spaced from each other evenly about the tool; fitting each of the bolts into a separate one of the slots in the tool with the nuts on the bolts supporting the tool; and supporting a leveling instrument on the tool; whereby each of the nuts is vertically adjusted to bring the tool to a level position, the tool then being removed with the nuts providing a vertically level support for the vertical structure and wherein the vertical structure comprises apertures and is in direct contact with the nuts, wherein the bolts are fitted through the apertures and wherein the tool is removable. 
     It is important to distinguish the current embodiments over those in the prior art, since the methods, systems and tools disclosed herein could be viewed as a simple solution. The central hole that is disclosed herein is different from Conklin&#39;s level, as disclosed in the Background section, which is designed to slide on to the base without needing to detach the electrical wiring. Therefore, it has an opening on the side of the level to allow it to slide on. As a matter of fact, the center hole disclosed herein does not extend to or open out to the periphery of the tool, which is very different from Conklin. The design of the sliding opening of Conklin is specifically designed to slide on to a pole assembly without the need to disconnect any electrical wiring—and therefore, the center aperture must extend out to and open out to the periphery of the tool—it is mandatory. 
     The method and tool disclosed herein are also distinct in view of the Korfanta reference (U.S. Pat. No. 4,194,237). Korfanta shows a base that can be used to hold a smaller pole. So, the small pole is inserted into the top portion of the device and is bolted into the device. Then, a second set of bolts attaches the device to the ground. In the current application, the bolts go into the leveling device, through the leveling device and to the solid support base or the concrete block support member. The Korfanta device does not inspire one of ordinary skill in the art to modify the device in Conklin to arrive at the current leveling device, for example, because one wouldn&#39;t view Korfanta as a device that is applicable to a leveling design, as it is purely meant to retrofit a smaller diameter pole into a hold made for a larger pole. In addition, the device in Korfanta is not removable, unlike the tool recited in the current claims. 
     Thus, specific embodiments, methods of level adjustment systems, tools and methods for leveling free standing poles and structural columns have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the disclosure herein. Moreover, in interpreting the specification and claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. While the subject matter herein has been described and illustrated in detail, this is to be taken by way of illustration and example only and not by way of limitation, the spirit and scope of the contemplated embodiments of the subject matter being determined by the following claims.