Patent Publication Number: US-2010122466-A1

Title: Alignment apparatus

Description:
FIELD OF THE INVENTION 
     The present invention relates to an alignment apparatus and, more particularly, to an alignment apparatus for more efficient installation of raceways and surface mount wire covers. 
     BACKGROUND OF THE INVENTION 
     The installation of raceways and other apparatus that require straight-line installation on wall surfaces is a labor-intensive process. Typically, the installer determines an appropriate location for the raceway, attaches a raceway-mounting bracket to a wall, and measures the distance from the bracket to the floor. To ensure level installation of the raceway in both horizontal and vertical dimensions relative to the bracket, the installer next measures the same distance from the floor or wall in multiple locations prior to mounting another raceway-mounting bracket and, finally, mounting the raceway. 
     This method of installation is disadvantageous for several reasons. As noted above, the process is labor-intensive, which ultimately increases construction costs. Furthermore, this method of installation does not guarantee a perfectly level raceway because floors are not uniformly level. Thus, even measuring in multiple locations will not guarantee a precisely horizontal line. Likewise, if installation of a vertical raceway is desired, the installer would typically take measurements from a wall corner or door frame, which naturally includes variations in size and shape from one end to another and in-between. 
     Therefore, there exists a need for an improved device and method for installing raceways and other wall- and floor-mounted apparatus requiring level installation. 
     SUMMARY OF THE INVENTION 
     According to the present invention, an alignment apparatus comprises an adapter base having a support for rotatably mounting a laser level device thereon and at least one bracket receptacle adapted to attach to an end of a raceway-mounting bracket or other type of bracket. 
     Also according to the present invention, another embodiment includes the adapter base having more than one type of bracket receptacle to accommodate different types of brackets. 
     The foregoing and other advantages of the present invention become more apparent in light of the present invention described in the following detailed description of the exemplary embodiments thereof, as illustrated in the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an alignment apparatus having a laser level device mounted to an adapter base, according to the present invention; 
         FIG. 2  is a perspective view of the alignment apparatus of  FIG. 1  generating a beam line; 
         FIG. 3  is a bottom view of the adapter base of  FIG. 1 ; 
         FIG. 4  is a bottom view of the adapter base of  FIG. 1  engaging a first bracket; 
         FIG. 5  is a cross sectional view of the adapter base of  FIG. 3  taken along line  5 - 5 ; 
         FIG. 6  is a cross sectional view of the adapter base of  FIG. 3  taken along line  6 - 6 ; 
         FIG. 7  is a bottom view of the adapter base of the alignment apparatus of  FIG. 1  engaging a second bracket; 
         FIG. 8  is a bottom view of the adapter base of  FIG. 1 , including a cover plate; 
         FIG. 9  is a perspective view of the alignment apparatus of  FIG. 1  before engaging the first bracket; 
         FIG. 10  is a perspective view of the alignment apparatus of  FIG. 1  engaging the first bracket showing an activated laser mechanism generating the beam line; 
         FIG. 11  is a perspective view of the alignment apparatus of  FIG. 1  before engaging the second bracket; 
         FIG. 12  is a perspective view of the alignment apparatus of  FIG. 1  engaging the second bracket showing an activated laser mechanism generating the beam line; 
         FIG. 13  is a top perspective, exploded view of the alignment apparatus according to another embodiment of the invention; and 
         FIG. 14  is a bottom perspective, exploded view of the alignment apparatus of  FIG. 13 . 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     Referring to  FIG. 1 , an alignment apparatus  10  for mounting on a wall  12  includes an adapter base  14  and a laser level device  16  rotatably mounted thereon. The laser level device  16  is a standard type laser level having a leveling mechanism  20  and a laser mechanism  22  generating a beam line  24 , as seen in  FIG. 2 . Leveling mechanism  20  includes two level indicators  26  set 90 degrees apart to indicate leveling in the horizontal or vertical direction. One type of such laser level device that can be used is manufactured and sold by Strait-Line, a division of Irwin Industrial Tools Company of Ohio, USA under the name of “Strait-Line.” However, any other leveling device may be used. 
     Referring to  FIGS. 1 and 3 , the adapter base  14  includes a base body  30  having an upper surface  32 , a lower surface  34 , and a sidewall  36  spanning between the upper surface  32  and the lower surface  34  and extending around a perimeter of the base body  30 . The base body  30  also includes a support  40  extending downward from the upper surface  32 , to which the laser level device  16  is mounted. Optionally, a plurality of stiffeners  42  may extend across the base body  30  for providing structural rigidity thereto. 
     Referring to  FIGS. 3 ,  4 , and  5 , the adapter base  14  may include a bracket receptacle  44 , the configuration of which is adapted to mate with and support a bracket end  50  of a bracket  52 . The bracket receptacle  44  includes two ribs  54  and a central flange  56  extending radially outward from stiffeners  42 . The ribs  54  and central flange  56  cooperate to define a shape of the bracket receptacle  44  to mate with a geometry of the bracket end  50 . The ribs  54  may include friction-generating elements  60  to generate friction against the wall  12  and additional features, such as grooves  62 , which allow engagement between the bracket receptacle  44  and the bracket end  50 . The bracket receptacle  44  also includes a cutout  64  of the sidewall  36 . Cutout  64  extends along a perimeter of the base body  30  and is dimensioned to accommodate a width and height of the bracket end  50 . Optionally, the bracket receptacle  44  may also include a magnet  66  disposed in a boss  68 , which strengthens the attachment of the bracket receptacle  44  to the bracket end  50 . However, it will be appreciated that the magnet  66  could be secured to the bracket receptacle  44  by any known means such as glue or bonding. 
     Referring to  FIGS. 3 ,  6 , and  7 , the present invention may also include a second bracket receptacle  144 , the configuration of which is adapted to mate with and support a second bracket end  150  of a second bracket  152 . The bracket receptacle  144  includes a plurality of ribs  154 , which cooperate to define a geometry that is complementary to a geometry of the bracket end  150 , shown in  FIG. 7 . The ribs  154  may include friction-generating elements  160  to generate friction against the wall  12 . The bracket receptacle  144  also includes a cutout  164  of the sidewall  36 . Cutout  164  extends along a perimeter of the base body  30  and is dimensioned to accommodate a width and height of the bracket end  150 . Optionally, the bracket receptacle  144  may also include a magnet  166  disposed in a boss  168 , which further secures attachment of the bracket receptacle  144  to the bracket end  150 . However, it will be appreciated that the magnet  166  could be secure to the bracket receptacle  144  by any known means such as glue or bonding. Optionally, as shown in  FIG. 8 , the bracket receptacle  144  may also include a cover plate  170  attached to the adapter base  14  by a fastener  172  to allow more secure engagement between the bracket receptacle  144  and the bracket end  150 . 
     Referring to  FIGS. 13 and 14 , in another embodiment of the invention, wherein the like numerals represent the like elements, an alignment apparatus  210  includes wings  276  extending from the adapter base  214  and a locking mechanism  278 . The wings  276  include an edge  280  and a wings bottom surface  282  that is substantially flat and flush with the lower surface  234  of the adapter base  214 . The locking mechanism  278  includes adapter base protrusions  286 , best seen in  FIG. 13 , and level indents  288 , best seen in  FIG. 14 . The protrusions  286  and indents  288  mate to lock the alignment apparatus  210  in a locking position such that the laser level device  216  is locked with respect to the adapter base  214  in a position so that one of the level indicators  226  of the laser level device  216  is level with respect to the edge  280 . Although the adapter base protrusions  286  are shown as being substantially parallel to the edge  280 , the position of the protrusions  286  and indents  288  is not limited to the embodiment shown. Rather, the locking mechanism  278  may be any type of mechanism as long as its mating condition locks the laser level device  216  in a position parallel with respect to the edge  280 . Additionally, the adapter base  214  includes a bracket receptacle  244  and a second bracket receptacle  344  disposed substantially 90° offset from each other so as to not to interfere with the locking mechanism  278 . 
     In operation, the operator pre-assembles the alignment apparatus  10  by mounting the laser level device  16  upon the support  40  of the adapter base  14 . Once the bracket  52  is mounted onto the wall  12  at any desired location, as shown in  FIG. 9 , the bracket receptacle  44  is aligned with the bracket end  50 . As the alignment apparatus  10  is brought into contact with the bracket  52 , as shown in  FIG. 10 , the grooves  62  of the bracket receptacle  44  receive the edges of the bracket end  50  as the bracket receptacle  44  mates with and attaches to the bracket end  50 . The ribs  54  and central notch  56  of the bracket receptacle  44  ensure that the alignment apparatus  10  attaches to the bracket  52  securely and without play for proper alignment. To increase cohesion between the bracket receptacle  44  and the bracket end  50 , the magnet  66  attracts the bracket end  50 . The friction generating elements  60  ensure that the alignment apparatus  10  does not slip against the wall  12 . 
     When the alignment apparatus is to be used with bracket  152 , bracket  152  is mounted to the wall  12  and the alignment apparatus  10  is brought into engagement with the bracket  152  by inserting the bracket end  150  between the cover plate  170  and the adapter base  14 , as shown in  FIG. 12 . The magnet  166  attracts the bracket end  150  to increase cohesion between the bracket receptacle  144  and the bracket end  150 . 
     Once the alignment apparatus  10  is attached to either bracket  52  or  152 , as shown in  FIGS. 10 and 12 , the laser level device  16  is rotated relative to the adapter base  14  until the level indicator  26  of the leveling mechanism  20  indicates that the alignment apparatus  10  is level in a horizontal direction. Once the desired leveling is achieved, the laser mechanism  22  is activated to generate the beam line  24 , which indicates a straight line on the wall  12 , as shown in  FIGS. 10 and 12 . The beam line  24  is used to mark a level location for the subsequent mounting of a second bracket of like type. The pair of brackets may ultimately support a raceway or any other type of device requiring level installation, such as a shelf. If vertical alignment with bracket  52  or  152  is desired, the laser level device  16  can be rotated 90° with respect to the base so that the leveling and mounting in the vertical direction can be also performed without disengaging the adapter base  14  from the bracket  52 . 
     The locking mechanism  278  and the edge  280  cooperate to allow the alignment apparatus  210  to function as a level. The laser level device  216  is rotated until the adapter base protrusions  286  and level indents  288  mate into a locking position. Once in the locking position, the edge  280  can be lined up to any item to insure that it is plumb. Thus, an installer of the raceway, can lock the alignment apparatus  210  and insure that the electrical box, for example, is mounted properly on the wall. Upon completion of using the alignment apparatus  210  as a level, the laser level device  216  is rotated with respect to the adapter base  214  so that the alignment apparatus  210  can be used for installation of raceways or other items. In the embodiments shown in  FIGS. 13 and 14 , the bracket receptacles  244 ,  344  are disposed 90° apart to avoid interference with the locking mechanism  278 . Thus, once the alignment apparatus  210  is moved from the locking position, and rotated 180° therefrom, it is not restrained and can be easily rotated to allow fine-tuning for leveling with respect to the bracket (not shown in this FIG.). 
     One advantage of the present invention is that the alignment apparatus  10  simplifies and significantly improves the installation process of raceways. In particular, the alignment apparatus  10  of the present invention allows installation of raceways without the need for measuring and marking the wall in multiple locations. 
     Another advantage of the present invention is that the alignment apparatus  10  allows for superior accuracy and reliability in the installation of raceway systems. For example, relying on a floor for a baseline measurement for drawing a line parallel to the floor at a pre-determined distance therefrom is not accurate due to imperfections and dips in flooring. 
     Yet another advantage of the present invention is that the alignment apparatus  10  allows for alignment and positioning of raceways in two dimensions relative to the brackets. The laser level device  16  can be rotated and adjusted to generate beam lines in both horizontal and vertical directions with minimal effort from the operator because the laser level device  16  includes level indicators  26  for both the horizontal and vertical directions and is rotatably mounted on the adapter base  14 . 
     A further advantage of the present invention is that the alignment apparatus  10  allows for installation of not only raceway systems or apparatus, but also installation of any system or apparatus requiring a horizontal or vertical line, such as shelving systems or even large wall hangings. More specifically, the configuration of structural features such as ribs, notches, grooves, and cutouts of the bracket receptacles can be adjusted to accommodate brackets for any type of industry. 
     An advantage of the locking mechanism  278  and the edge  280  is that it allows the alignment apparatus  210  to function as a regular leveling mechanism. Moreover, the wings  276  add further stability to the alignment apparatus  210 . 
     Although this invention has been shown and described with respect to the detailed embodiments thereof, it will be understood by those skilled in the art that various changes in form and detail thereof may be made without departing from the spirit and the scope of the invention. For example, although the Figures show the adapter base  14  having two bracket receptacles, one, three, four or another number of receptacles can be formed in the adapter base  14 . Moreover, while bracket receptacle  44  and  144  have been defined by certain structural features such as ribs, notches, grooves and cutouts, it will be appreciated that any structural elements may be employed in the base body  30  to form a bracket receptacle having a shape complementary to the geometrical elements of any bracket. In particular, while bracket receptacles  44  and  144  are adapted to mate with brackets  52  and  152 , respectively, which are commonly used in the raceway industry, it will be appreciated that the bracket receptacles of the present invention can be modified to accommodate brackets used for mounting shelving units or home electronics equipment, or for any other application. Furthermore, the alignment apparatus  10  can be used with a plurality of adapter bases. For example, the laser level device  16  can be detached and be placed onto various adapter bases with each of the adapter bases having multiple bracket receptacles adapted to engage with multiple types of brackets. Thus, the interchangeable adapter bases would allow use of the alignment apparatus  10  in various industries. Although the edge  280  is shown to be extending from the adapter base  214  in  FIGS. 13 and 14 , the edge  280  can be formed integrally with the base  214 . For example, the base  214  can have a square or rectangular shape, thus, incorporating the edge  280  therein.