Patent Publication Number: US-7908753-B2

Title: Hands-free level

Description:
RELATED APPLICATION 
     This application is a continuation of U.S. application Ser. No. 12/208,171, filed Sep. 10, 2008 now U.S. Pat. No. 7,797,847, the contents of which are incorporated herein. 
    
    
     FIELD OF THE INVENTION 
     This invention relates to levels and, more particularly, to levels and devices for holding levels against structural members for hands-free gauging of structural-member orientation. 
     BACKGROUND OF THE INVENTION 
     In the construction industry, levels are used to ensure that structural members are installed in their exact intended orientations. Some examples of such structural members are vertical and horizontal studs which have to be positioned as close to their respective plumb and level orientations as possible. In some cases, levels are also used to orient studs or other structural members at specific angles. In such situations two people are often involved in the process of stud installation, because one person holds the level against the structural member while the other person adjusts structural-member orientation and secures it in the proper orientation. 
     Very often a person who works alone needs to gauge a structural member such as a stud for its vertical orientation. This task becomes difficult because the holding on the level and the fastening of the stud typically have to be done simultaneously. Even if a sole worker were able to gauge the stud with one hand while fastening the stud with the other, such task would require an extra physical strain which increases the risk of injury and makes the operation much slower than desired and may still result in inaccurate orientation of the stud. 
     There have been various devices that have offered certain support for levels against structural members, but such devices have problems or disadvantages rendering them of little use in most situations. 
     One example of such devices is described in U.S. Pat. No. 3,296,708 to Moody. The Moody device, however, is designed for use with walls which have either a plurality of holes therethrough or an apertured mesh such that the Moody device can engage the holes or the mesh apertures to secure the level against the wall. The Moody device would not secure a level to a stud. Furthermore, the Moody device is not usable for securing a level in orientations other than vertical such as holding the level to the bottom of a generally horizontally oriented structural member. 
     Another example of such devices is described in U.S. Pat. No. 5,088,205 to Egbert. The Egbert device requires special manipulation with an adjustable gripping element. Such gripping element, depending on its orientation with respect to an arm, is either freely slidable along the arm or is held in place thereon. The Egbert device requires precise positioning of the gripping element to secure a level against a stud or other object. The level, however, can become easily disengaged from the stud if the gripping element is not in its correct position or if such position changes due to adjustment movements of the level or the stud. Such disengagement would result in unfortunate falling of the level which may become damaged or completely broken. 
     Yet another example of a device intended for holding a level against a structural member is described in U.S. Pat. No. 5,815,937 to Glorioso, Jr. The Glorioso device would not be operable in the intended manner described in the Glorioso patent. More specifically, despite its rather complicated construction the Glorioso device, as shown, would not hold the level against a structural component, at least because spring  146 , by virtue of its manner of mounting, would fail to draw the arm against the object to be gauged. 
     In summary, there is a need for an improved level which is held securely against a stud or other structural member and which overcomes all of the aforementioned problems. 
     OBJECTS OF THE INVENTION 
     It is an object of the invention to provide an improved level which is held securely against a stud or other structural member and which overcomes some of the problems and shortcomings of the prior art, including those referred to above. 
     Another object of this invention is to provide a level allowing easy hands-free operation, such that a person working alone can install studs and similar structural elements quickly and without any need for a helper. 
     Another object of the invention is to provide a level which is easily secured against a stud. 
     Another object of the invention is to provide a level which is reliably held against the stud with minimal chances for accidental disengagement. 
     Yet another object of the invention is to provide a level which can be held against structural members of various sizes and configurations. 
     How these and other objects are accomplished will become apparent from the following descriptions and the drawings. 
     SUMMARY OF THE INVENTION 
     This invention, which will be described in detail below, is an improvement in levels for gauging stud orientation, or the orientation of a wide variety of structural members. While there is much reference in this document to studs, such as the common wooden studs used in building framing, the term “stud” is not to be taken as a limiting term when it comes to the usefulness of the invention. Use with wooden structural members, metal structural elements, or structural elements of other materials is contemplated. 
     The inventive level, which may be a box level, I-beam level or other level, is of the type including an elongate frame with two side-faces and at least one main reference surface which extends therealong and has a mainwidth. A level indicator is secured to the frame. The inventive level is of the type further including a support arm to facilitate holding of the reference surface against a stud. 
     In the inventive level, a support arm has a proximal end and extends to a free distal end to which an end member is secured. The proximal end is pivotably secured to the frame about a pivot axis intersecting the side-faces such that the distal end and end member are movable between a storage position along one of the side-faces and a use position beyond the reference surface and stud. A coil spring is preferably about the pivot axis to bias the distal end and end member to the storage position. The end member extends from the distal end crosswise with respect to the mainwidth and terminates in a stud-engaging portion extending in a direction intersecting the plane of the reference surface. When the reference surface is against a stud surface the stud-engaging portion engages the opposite side of the stud for hands-free holding of the level thereagainst. 
     In some preferred embodiments, the stud-engaging portion of the end member is a pointed end for piercing engagement with the stud. The pointed end allows for secure holding of the level which is stable enough that the level may be positioned below a stud and remain securely against the stud despite impacts such as caused by hammering. 
     The pointed end preferably extends at an acute angle with respect to the direction of the support arm such that, when engaged with a substantially vertical stud at a position above the pivot axis, gravity facilitates the hands-free holding. The end member also preferably includes a cross-portion extending from the distal end of the arm crosswise with respect to the mainwidth to the stud-engaging portion. It is preferred that the stud-engaging portion be substantially perpendicular to the cross-portion. 
     In some alternative embodiments, the stud-engaging portion may extend directly from the distal end diagonally in a direction which is both crosswise the mainwidth and intersecting the reference-surface plane. 
     In some embodiments, the end member is preferably a friction member for frictional engagement with the stud. Such embodiments are usable for gauging finished objects, such as furniture, doors or windows. Such frictional engagement is also useful for various structural elements which are not easily pierced as in case of metal structural members. 
     The side-face along which the support arm is in its storage position is preferably recessed such that the support arm and end member are recessed in the storage position. 
     In some preferred embodiments, the arm has an adjustable arm-length such that the stud-engaging portion is engageable along the middle third of the length of the level frame despite being used with studs of different sizes (1×2&#39;s, 2×4&#39;s, 2×6&#39;s, 2×8&#39;s, etc.). In other words, the arm is adjustable such that contact of the stud-engaging portion with the stud may be achieved at a contact position such that a perpendicular line from the reference surface to the contact position will extend from the reference surface at a position in the middle third of the frame length, and preferably as close as possible to the mid-point of the frame length. The use of the adjustable arm-length allows for setting the arm-length to accommodate the stud size (based on the distance from the reference surface to the surface of the stud engaged by the stud-engaging portion). 
     The arm-length is preferably adjustable to a plurality of specific positions each of which corresponds to a specific stud size. The arm preferably includes arm-length markings indicating the corresponding stud size. 
     In the preferred embodiments of the type with the arm having an adjustable arm-length, the support arm preferably includes at least two interconnected length-sections. Such support arm further preferably includes at least one locking projection on one of the length-sections and a plurality of apertures spaced along the other one of the length-sections to receive the locking projection therethrough for setting a selected specific arm-length. The locking projection is preferably outwardly biased such that it extends through the aperture for secure connection. One example of such biasing is a spring-loaded nub that allows for depressing the nub into the aperture to adjust the arm-length. The nub securely extends through the aperture to firmly maintain the desired arm-length. 
     In some embodiments, the support arm is a single piece. The end member may also be a single piece. Such support arm and end member preferably form a single piece. 
     In certain preferred embodiments, the coil spring which biases the support arm toward its storage position has first and second spring-ends. The first spring-end is held in fixed position with respect to the frame. The proximal end of the support arm preferably includes a coil-spring-engaging portion which engages the second spring-end. 
     In some preferred embodiments, including those described in the paragraph above, the proximal end of the support arm is preferably further axially biased toward the side-face of the storage position and is axially depressible to the support-arm pivot use position. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of one embodiment of a level of this invention with a support arm in its pivoting use position. 
         FIG. 2  is an exploded perspective view of the level of  FIG. 1 . 
         FIG. 2A  is a perspective view of a blank of the single-piece support arm of  FIG. 1  prior to shaping into the support-arm configuration. 
         FIG. 3  is a perspective view of the level of  FIG. 1  with the support arm in its storage position. 
         FIG. 4  is a perspective view of another embodiment of the level of this invention which is similar to the level of  FIG. 1  except that it has a different end member. 
         FIG. 4A  is a end-elevation view of the level of  FIG. 4 . 
         FIG. 5  is a perspective view of a level of the present invention which has an adjustable arm-length, the level being shown against a vertical stud. 
         FIG. 6  is a perspective view of the level as in  FIG. 5  shown against a horizontal stud. 
         FIG. 7  is a perspective fragmentary view of the level of  FIG. 5  better showing the support arm. 
         FIG. 8  is an exploded perspective view of the level of  FIG. 5 . 
         FIG. 9  is an enlarged fragmentary perspective view of  FIG. 8 . 
         FIGS. 10 and 10A  are yet other fragmentary exploded perspective views of the arm-mounting arrangement to the frame, shown from different angles. 
         FIG. 11  is an enlarged fragmentary exploded perspective view of the stud-engaging end member of the level of  FIG. 5 . 
         FIG. 12  is a fragmentary perspective view as in  FIG. 11  but from a different angle to show aspects of the end member. 
         FIG. 13  is another exploded fragmentary perspective view illustrating the interconnection of the arm length-sections and the end member of the level of  FIG. 5 . 
         FIG. 14  is a perspective view of the level of  FIG. 5  with the support arm in its storage position. 
         FIG. 15  is a perspective view of the other side-face of the level of  FIG. 14 . 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     The drawings show an improved level  10  for gauging orientation of a stud  1 . Improved level  10  is of a type that includes an elongate frame  11  with two side-faces  12  and at least one main reference surface  13  which extends along side-faces and has a mainwidth  14 . A level indicator  15  is secured to frame  11 . Inventive level  10  further includes a support arm  20  to facilitate holding of reference surface  13  against stud  1 . 
     In level  10 , as shown in  FIGS. 1-7 , support arm  20  has a proximal end  21  and extends to a free distal end  22  to which an end member  30  is secured. As best seen in  FIG. 2 , proximal end  21  is pivotably secured to frame  11  about a pivot axis  5  intersecting side-faces  12  such that distal end  22  and end member  30  are movable between a storage position (illustrated in  FIGS. 3 and 14 ) along one of side-faces  12  and a use position beyond reference surface  13  and stud  1 , as illustrated in  FIGS. 1 ,  5  and  6 . End member  30  extends from distal end  22  crosswise with respect to mainwidth  14  and terminates in a stud-engaging portion  31  extending in a direction intersecting the plane  13 A of reference surface  13 .  FIGS. 6 and 7  illustrate that, when reference surface  13  is against a stud surface  2 , stud-engaging portion  31  engages the opposite side  3  of stud  1  for hands-free holding of level  10  against stud  1 . 
     As best seen in  FIGS. 1 and 11 , stud-engaging portion  31  of end member  30  may be a pointed end  32  for piercing engagement with the stud. Pointed end  32  allows for such secure holding of level  10  to stud  1  that level  10  may be positioned below stud  1  and that level  10  remains securely held against stud  1  even when stud  1  is affected by various impacts such as a hammer shock.  FIG. 6  illustrates level  102  held against a bottom surface of horizontally-positioned stud  1 . Pointed end  32  preferably extends at an acute angle  33  with respect to the direction of support arm  20  such that, when engaged with a substantially vertical stud  1  at a position above pivot axis  5 , as shown in  FIG. 5 , gravity facilitates the hands-free holding. End member  30  also includes a cross-portion  34  which extends from distal end  22  of arm  20  crosswise with respect to mainwidth  14  to stud-engaging portion  31 .  FIGS. 2 ,  4  and  7  show stud-engaging portion  31  being substantially perpendicular to cross-portion  34 . 
       FIGS. 8 ,  11  and  12  show an embodiment with end member  30 A which has a friction member  35  for frictional engagement with stud  1 .  FIGS. 11 and 12  best illustrate friction member  35  in form of cross-member  34 A which is coated with a friction material such as rubber or any other suitable substance. When use of friction member  35  is desired to hold level  10  against an object, pointed end  32  can be rotated or removed to open friction member  35  for engagement with such object. 
       FIGS. 3 and 14  show side-face  121 , along which support arm  20  in its storage position, being recessed such that support arm  20  and end member  30  are recessed in their storage position. As further seen in  FIGS. 3 and 14 , frame  11  defines an aperture  16  which receives end member  30  for storage. 
       FIGS. 5-14  show support arm  20 A which has an adjustable arm-length  25  such that stud-engaging portion  31  is engageable with studs of different sizes along the middle third  18  of the frame length  17 . Adjustable arm-length  25  allows for setting an appropriate arm-length based on a stud size. The stud size defines a dimension between stud surface  2  and opposite side  3 . 
     Arm-length  25  is adjustable to a plurality of specific positions each of which corresponds to a specific stud size. As best seen in  FIGS. 7 and 11 , arm  20 A includes arm-length markings  26  indicating the corresponding stud size. 
       FIGS. 8 and 13  best illustrate that support arm  20 A includes two interconnected length-sections  27 . Support arm  20 A further includes a locking projection  28  on one of length-sections  27  and apertures  29  spaced along the other one of length-sections  27  to receive locking projection  28  therethrough for setting a selected specific arm-length  25 . Locking projection  28  is biased to extend through the aperture for secure connection. As best seen in  FIG. 13 , locking projection  28  is mounted on a detent member  24  secured to the corresponding length-section  27 . Detent member  24  is made of a spring material which biases locking projection  28  for engagement into aperture  29 . Such detent member  24  is depressible to free locking projection  28  from aperture  29  for movement along arm-length  25  to engage another aperture  29  for adjusting arm-length  25  to the selected length. 
       FIGS. 1-3  show level  10  with support arm  20  being a single piece. In level  10 , end member  30  is also a single piece. And, both support arm  20  and end member  30  together form a single piece; i.e., support arm  20  and end member  30  are together formed of one elongate piece of metal  7  ( FIG. 2A ). Support arm  20  shown in  FIG. 2  has a substantially flat elongate structure defining arm-side surfaces  23  which are substantially parallel to side face  12  of frame  11 . In support arm  20 , distal end  22 A is twisted about 90° to change orientation of piece of metal  7  by about 90° to continue as cross-portion  34  which extends substantially perpendicular to side-face  12  and crosswise mainwidth  14  to stud-engaging portion  31 . Stud-engaging portion  31  extends substantially parallel to side-face  12  in the direction intersecting reference-surface plane  13 A. 
       FIGS. 4 and 4A  show level  101  with support arm  20  being a single piece. End member  30 A is assembled of separate pointed end  32 A and cross-portion  34 A secured to distal end  22  of arm  20 . Cross-portion  34 A in level  101  is friction member  35 .  FIGS. 11-13  best show that cross-portion  34 A friction member  35  has a bore hole  351  with a bore-hole opening  352  facing pointed end  32 A. Pointed end  32 A has an aperture  311  which corresponds to bore hole  351 . A screw  36  extends through aperture  311  into bore hole  351  to secure pointed end  32 A to friction member  35 . When desired to use friction member  35  for engaging an object need to be gauged, pointed end  32 A can be taken off by simply removing screw  36 . 
       FIGS. 5-8  show yet another embodiment of level  102  which has support arm  20 A made of two interconnected length-sections  27 . One length-section  271  extends from proximal end  21  to terminate with locking projection  28 . Locking projection  28  is on detent member  24  secured to length-section  271  for connection with length-section  272  which extends to distal end  22 A.  FIGS. 11-13  best illustrate that length-section  272  has a channel  272 A formed by two curved sidewalls  2728  extending from and along sides of a bottom wall  272 C and shaped for secure slidable engagement of length-section  271 . Length-sections  271  and  272  are fixed at the selected arm-length  25  by locking projection  28  extending through one of apertures  29  which are made through bottom wall  271 C and are spaced therealong. 
     Level  102  has end member  30 A with cross-portion  34 A being friction member  35  secured to distal end  22 A of length-section  272 . Friction member  35  has an arm-mounting end-portion  353  which is configured to snugly slide into channel  272 A for securement of cross-portion  34 A to distal end  22 A of arm  20 A. 
       FIGS. 2 ,  8 - 10  and  15  illustrate a mounting arrangement of proximal end  21  to frame  11 . A coil spring  40  is about pivot axis  5  to bias distal end  22  and end member  30  to the storage position. Coil spring  40  has first and second straight spring-ends  401  and  402 . Level further includes a cover  41  which has a spring-retaining member  411  for holding first straight spring-end  401  in fixed position with respect to frame  11  (see  FIG. 10 ). Support arm  20  has a coil-spring-engaging portion  211  which extends from proximal end  21  crosswise with respect to mainwidth  14 . Spring-engaging portion  211  includes a substantially cylindrical axial portion  211 A which terminates with a transverse annular portion  211 B. Cylindrical portion  211 A has a plurality of slots  211 C therealong for biasing engagement of second straight spring-end  402 . Cover  41  defines an axial aperture  410  sized to receive spring-engaging portion  211  therethrough for the engagement with coil spring  40 . Cover  41  further includes a limiting collar  413  positioned around axial aperture  410  to limit range of pivot of support arm  20 . Cover  41  is secured to frame  11  by screws  4  extending through side-faces  12  into screw-receiving portions  414  in cover  41 . 
     Level  10  also includes a base member  43  which includes a sleeve portion  431  extending between a closed base-end  432  ( FIG. 15 ) and an outward flange  433 . Frame  11  has a sleeve-receiving aperture  111  through side-faces  12 . Outward flange  433  is mounted against side-face  121  of the support-arm storage position and has mounting holes  433 A which receive screws  6  extending through side-faces 12  to secure base member  43  to frame  11 . 
     Proximal end  21  of support arm  20  is axially biased toward side-face  121  of the support-arm storage position and is axially depressible to a support-arm pivot use position. Level  10  further includes an axial coil spring  44  about a shoulder screw  45  which is positioned inside cylindrical axial portion  211 A of spring-engaging portion  211 . A first coil-end  441  of the spring  44  is against transverse annular portion  211 B and a second coil-end  442  is against a screw head  451 . Cylindrical axial portion  211 A is in turn positioned through axial aperture  410  in cover  41  inside sleeve portion  431  of base member  43  such that a threaded end  452  of shoulder screw  45  is screwed into closed base-end  432 . Therefore, to move support arm  20  into its use position, proximal end  21  is pulled away from frame  11  such that axial spring  44  is depressed to bias proximal end  21  of support arm  20  toward side-face  121  of the storage position. 
     While the principles of the invention have been shown and described in connection with specific embodiments, it is to be understood that such embodiments are by way of example and are not limiting.