US20040187327A1 - Laser line generation device with attachment base - Google Patents

Abstract

A line generating device comprising a housing with a support structure that substantially extends along a first plane, a light source mounted within the housing, and a lens that receives light and projects the light in the shape of a fan, wherein the fan lies substantially within a second plane that intersects the first plane at an angle. The device also includes at least one reference level on an outside of the housing.

Description

CLAIM TO PRIORITY
• This application claims priority under 35 U.S.C. § 119(e) to the filing date of U.S.[0001]Provisional Application 60/291,135, filed May 15, 2001; this application is also a continuation-in-part of U.S. pat. appl. Ser. No. 10/141,392, filed on May 7, 2002, pending; this application is a continuation of U.S. pat. appl. Ser. No. 10/612,035, filed Jul. 1, 2003, which is a continuation of U.S. pat. appl. Ser. No. 10/456,534, filed Jun. 18, 2003; all of which are hereby incorporated by reference in their entirety.
BACKGROUND
• The technical field of the application is that of alignment devices, and in particular an alignment device and an attachment that allows the alignment device to be releasably attached from a surface on which alignment is desired.[0002]
• Alignment of surfaces is a perennial problem in a variety of fields, ranging from construction to interior decorating. Alignment is necessary for walls that should be perpendicular to a floor, or otherwise plumb. Masonry and brick-laying practitioners are well aware of the importance of plumbed and aligned surfaces and chalk lines. A home interior decorated with pictures and other wall ornamentation makes a much better appearance when the ornamentation is aligned, especially with respect to vertical or horizontal alignment. Many mechanical and electrical alignment devices are available, and some laser devices are available. Some of these products are cumbersome, others are not suitable for certain uses. Chalk lines, for instance, are sometimes undesirable for use in finished, interior areas.[0003]
• One aspect of alignment-product performance, and in particular of laser-alignment products, that could be improved is the width, brightness and straightness of the laser light. A visible, straight laser line is acceptable, but may be limited in its brightness over a distance, and may also tend to defocus and become dimmer as a user works away from the source of the laser. Rotating lasers are used to project lines on walls perpendicular to the direction of propagation of the laser. Thus, such devices may have limited utility or may not work in confined spaces requiring a longer alignment tool.[0004]
• Moreover, a conventional laser is not well-equipped for projecting a flat or planar beam of light. The essence of laser light is that it is coherent or substantially monochromatic, that is, of a single wavelength or a narrow wavelength band. Thus, when a beam of laser light is refracted through a prism, the prism output is not a spreading of the beam as with ordinary “white” light, but rather a coherent, focused beam, very similar to the input. The laser beam is thin and is usefully only visible when projected onto a surface.[0005]
• Another aspect that could be improved is the inability of laser devices to work around obstructions. That is, if a wall-hanging, such as a picture frame, interrupts the laser beam, it may be blocked from further projection. Therefore, it is necessary to mark locations or heights, one by one, rather than working with the actual objects, in order to align them. Obstructions may include moldings placed in a doorway, picture frames in the way of those being aligned on one horizontal line, the operator of the device, other obstacles, or even textured or stuccoed surfaces on interior walls.[0006]
• There are devices that direct a laser beam parallel to but away from a surface requiring alignment. A marker device or detector component is then used to sight the beam and mark corresponding locations on the wall adjacent the beam. Use of such a device requires multiple components and at least two people, one to align the laser and another to mark the wall. Moreover, the wall itself requires marking with this method.[0007]
• A conventional laser beam projector is thus not able to project a laser line on the wall on which it is mounted, nor can it go around obstructions. A laser alignment beam mounting on the wall where alignment is needed would allow a person seeking alignment, whether a carpenter, a painter, or an interior decorator, to accomplish his or her task in a quicker and easier fashion. The ability to work around obstacles would save much time and effort. Such laser alignment devices must be aligned themselves, and are typically equipped with a tripod and a sophisticated leveling device so that they read true for horizontal and vertical plumbs. While leveling is necessary, such sophistication as a tripod adds to the expense and bulkiness of the leveling device. What is desired is a convenient, easy-to-level laser device useful for aligning objects. It would be even more desirable if the alignment device could be easily mounted on a vertical or horizontal surface, and oriented in the desired direction. Better alignment devices are thus required to overcome these deficiencies in the prior art.[0008]
BRIEF SUMMARY
• One aspect of the invention is a line generating device. The device includes a housing including a support structure that substantially extends along a first plane, a light source mounted within the housing, a lens that receives light and projects the light in the shape of a fan, wherein the fan substantially lies within a second plane that intersects the first plane at an angle. The device also includes a reference level on an outside of the housing, and an adhesive for mounting to the support structure for mounting the device to a surface.[0009]
• Another aspect of the invention is a line generating device. The line generating device includes a housing, a support structure attached to the housing, the support structure comprising an external adhesive for supporting the device on a surface, a light source mounted within the housing, a lens receiving light from the light source, and an aperture on an outside of the housing for emitting light.[0010]
• Another aspect of the invention is a light generating device. The device includes a housing including a support structure that substantially extends along a first plane, a laser light source mounted within the housing, a lens that receives light and projects the light substantially within a second plane that intersects the first plane at an angle, a reference level on an exterior of the housing, and an adhesive attached to the support structure for mounting the device to a surface, wherein the support structure includes an inner portion and an outer portion that rotate and swivel with respect to one another.[0011]
• Another aspect of the invention is a method of aligning an object with a light beam. The method includes positioning a light generator adjacent to a surface, adhesively mounting the light generator to the surface, generating light from the light generator along a direction of propagation so that a line is formed along the surface, and placing an object so that a portion of the object is aligned by the light. The line is interruptible in that should an impediment be positioned on the line, the line will be present on either side of the impediment, wherein the step of generating includes actuating a switch from a first position to a second position and causing light to be generated, and placing an object that so a portion of the object is aligned by the light.[0012]
• Another aspect of the invention is a kit for a light generating device with a base. The kit includes a container defining a volume of space, a base positioned within the volume of space. The base includes an attachment structure. The kit also includes a light generating device positioned within the volume of space so as to be unattached to the base, wherein the attachment structure can be used to mount the light generating device to an external surface.[0013]
• Another aspect of the invention includes a kit for a leveling device with a base. The kit includes a container defining a volume of space, and a base positioned within the volume of space. The base includes an attachment structure for mounting the light generating device to an external surface. The kit also includes a leveling device positioned within the volume of space so as to be unattached to the base.[0014]
• Each of the above aspects of the present invention provides an improved structure and/or method for mounting or positioning either a leveling device or a light generating device on a surface. The following drawings form part of the present specification and are included to further demonstrate certain aspects of the present invention. The invention may be better understood by reference to one or more of these drawings in combination with the detailed description of specific embodiments presented herein.[0015]
BRIEF DESCRIPTION OF THE DRAWINGS
• FIG. 1 is an isometric view of an outside of an embodiment of a laser line generator according to the present invention.[0016]
• FIG. 2 is an alternate view of the generator of FIG. 1.[0017]
• FIG. 3 is a cutaway isometric view showing the inside of the generator of FIG. 1.[0018]
• FIG. 4 is a view depicting the bottom of the generator of FIG. 1.[0019]
• FIG. 5 is another view depicting the bottom of the generator of FIG. 1.[0020]
• FIG. 6 depicts an embodiment of optics to be used with the laser light generator of FIG. 1.[0021]
• FIG. 7 depicts a side view of the workings of a second embodiment of laser light generator optics to be used with the laser line generator of FIG. 1.[0022]
• FIG. 8 depicts a top view of the workings of the laser light generator optics of FIG. 7.[0023]
• FIGS. 9A, 9B, and[0024]9C depict a laser line generating device projecting the laser light in a narrow beam or fan and aligning objects on a wall.
• FIG. 10 depicts an exploded view of a swivel base for the laser line generating device.[0025]
• FIGS. 11[0026]aand11bdepict top and bottom views of the top portion of the embodiment of FIG. 10.
• FIGS. 12[0027]aand12bdepict top and bottom views of the bottom portion of the embodiment of FIG. 10.
• FIG. 13 depicts an assembled laser line generator with swivel base.[0028]
• FIGS. 14A, 14B, and[0029]15 depict other techniques used to assemble a light generator to a swivel base.
DETAILED DESCRIPTION OF THE DRAWINGS AND THE PRESENTLY PREFERRED EMBODIMENTS
• The present invention is better understood by reference to the figures and description below. FIG. 1 presents a view of a leveling device, such as laser alignment device and[0030]generator10. The generator comes in ahousing12, which may be made of plastic or other suitable material such as metal. It possesses ahandgrip area14 for handling, the area preferably made of an elastomeric substance for easier gripping. The generator has afirst leveling indicator16, a spirit level or “bubble” for orientation leveling device is selected from the group consisting of a pendulum, a cantilevered tilt mechanism, an electronic leveler, and a shaft held between journals or leveling in one plane, such as horizontal or vertical. It also has asecond leveling indicator18, for orientation or leveling in a second plane perpendicular to the first plane. The housing also contains aprotective door20 with a linked switch for turning on the laser light source when opening the door for access to the laser beam. The generator also may have one or more slidingpin actuators22 suitable for use by a finger or a thumb and mechanically connected for extending or retracting one ormore pins26 from thegenerator bottom28. Without a swivel base attached to bottom28, each pin desirably penetrates into a surface, such as a drywall or lumber surface, to suspend and hold the laser generator on the surface while it is in use. FIG. 1 depicts thedoor20 in an open position and aprojection lens24. The door oraperture20 provides an exit for the light generated within the housing, and in the open position, does not substantially block the exit of light from the housing.
• As shown in FIG. 1, a[0031]preferred projection lens24 includes arounded corner25 on itsfront face27. The effect of the lens is to shape the laser light passing through it into a planar, fan-shaped “comet beam” or fan shape. The intensity of the light and the shape of the beam may be asymmetric, in which one side of the “comet” may be larger and brighter than the other side. The fan shaped beam is then routed so that the less bright side of the fan-shaped beam is nearest the wall of interest, and the brighter side is away from the wall. In this orientation, the fan-shaped beam of light will propagate a long distance from its origin, and the laser light will be usable a long distance away from the laser line generating device.
• The laser light generated by the laser line generator preferably exits from the top, curved corner of the lens. The radius of the corner is desirably from about 0.030 inches (0.75 mm) to about 0.060 (1.50 mm) inches, and preferably about 0.047 inches (1.2 mm). The height of the rounded corner of the lens is desirably one or two inches above the bottom surface of the laser line generating device. When the beam or fan of light exits the lens, it forms a thin plane in the length-wise direction of the device, and the beam forms a plane from the top, curved corner of the lens downward, to the wall or other surface on which alignment is sought. Because the light is now a plane, rather than a pinpoint, it is able to project over and beyond obstacles, allowing a user to align several objects without having to move them.[0032]
• In the embodiments shown, the laser light projects generally in the direction of the alignment surface, a generally flat, planar bottom support surface. The direction of propagation is the direction the light travels, generally parallel to the wall or surface on which the laser line generating device is mounted. The fan-shaped aspect of the beam is perpendicular to the wall, and is preferably no higher than the height of the[0033]lens24 above the wall. The laser light generating device and its lens are mounted on the wall viapins26 or with the swivel base, which is discussed below. The fanshape of the beam extends from a height of the lens above the wall to the wall surface itself, in a very thin plane, about {fraction (1/32)} of an inch thick. The plane of the fan-shaped beam is also perpendicular to the flat bottom surface of the laser line generating device.
• FIG. 2 depicts the same device with the[0034]door20 closed, and with a linked internal switch (not shown) open, and the laser thus off. The figure depicts thegenerator10,housing12, grippingsurface14 andlevels16,18 withpin actuator22 raised so that the pin remains inside the housing and the laser generator is not suspended on a wall or other surface. The door oraperture20 may also be a switch for the power supply of the laser line generating device. In the position shown in FIG. 2, with the door closed, the switch is preferably in a closed position and there is no power supplied from the power supply to the light source. In this position, the door acts as a lens cover and substantially blocks the exit of the beam from the device.
• FIG. 3 depicts a cutaway view of the interior of the laser generator, showing a supporting[0035]structure34,40, forlevels16,18, and also showing an area for a power source orbattery32, alaser diode42, alens24, and acircuit board36. FIG. 4 more clearly depicts a view from the bottom orflat face30 of thegenerator10. The bottom surface desirably has adoor52 for access to a battery or power source for the generator. Also shown areholes54 for theretractable pins26 used to secure the generator to a wall or a surface. Anotch56 may also be useful for aligning or orienting the generator on a surface. FIG. 5 depicts the bottom of the laser generator with the pins retracted, with a better view ofholes54.
• While one or more pins may be used to hold the generator onto a wall, other devices may be used as retainers. These devices include, but are not limited to, a string or a wire, a fastener, tape, putty-type substances or other adhesives. While the laser line generator may be most convenient to use when pinned to a wall, it may also be mounted on a table, floor, or other flat surface, and used to project a line without being mounted on a wall.[0036]
• A method of practicing the invention includes providing a surface, such as a wall wherein orientation with a line is desired, and also providing the laser generator. In the case where pins[0037]26 are not used, a user mounts thelaser generator10 via its flat surface and a swivel base (see FIGS. 10-12) onto the wall and orients the laser generator in one or more planes. A reference level, such asbubble level18, is then used to orient and true thelaser generator10 in one plane, for instance, the vertical plane, using the swiveling swivel base described below. Thesecond bubble level16 may be used if the user wishes to orient thelaser generator10 in a horizontal plane. When the user is satisfied with the orientation, the user turns on thegenerator10, projecting a laser beam from the vertical or horizontal plane of the device. In one embodiment, the generator is turned on by opening the lens door or aperture.
• A desirable feature of the invention is that the output of the generator is not merely a linear beam of light, but rather a fan-shaped beam. The fan-shaped beam propagates along the surface of the wall in the direction of propagation. Because the plane of the beam runs perpendicular to the wall along the length of the beam, the line of intersection between the beam and the wall forms a visible line of alignment. With a fan-shaped beam, the laser light is able to project over and beyond obstacles, such as moldings placed in a doorway, picture frames in the way of those being aligned on one horizontal line, or other obstacles, such as a wavy or stuccoed surface on an interior wall. With a conventional laser generator, these obstacles must be removed or the laser itself must be repositioned to avoid each obstacle. Of course, moving and relocating the laser alignment tool destroys the continuity of the line of alignment. Moreover, a conventional laser is not well-equipped for shaping the laser beam into a fan. The essence of laser light is that it is coherent, that is, of a single wavelength or a narrow wavelength band. Thus, when laser light is refracted through a prism, the prism output is not a spreading of the beam as with ordinary “white” light, but rather a coherent, focused beam, very similar to the input. The present invention overcomes this obstacle by sending a sharp, focused pinpoint of light through a specifically constructed lens to create a flat planar, fan-shaped beam of light.[0038]
• It is also noteworthy that the axis of alignment, such as the alignment of pictures on a wall, is substantially parallel to the direction of propagation of the laser light. By contrast, a conventional and less useful method is to project a laser light perpendicular to a wall or other surface in which alignment is desired, and perpendicular to the direction of propagation. With the instant laser line marking device, a user projects a fan-shaped beam in a propagation direction that is substantially parallel, rather than perpendicular, to the surface on which alignment is desired, the fan-shaped dimension of the beam being perpendicular to the wall.[0039]
• As seen in FIG. 9[0040]a, the laser line generating device propagates light in the length-wise direction of the laserline generating device10. The direction of propagation, shown byarrow84, is substantially parallel to the wall, with the fan-shaped aspect of the beam being perpendicular to the wall. In one example, if a narrow fan projects from a line marking device according to the present invention, the beam is “substantially parallel” if it is substantially parallel for at least several lengths of the line marking device in the direction of propagation of the laser. It is substantially parallel because even a “narrow” fan spreads rapidly and the beam is no longer strictly parallel. The device and the beam are easily distinguished, however, from a beam that has a direction of propagation perpendicular to the wall, such as shown in U.S. Pat. No. 5,208,438.
• The laser light exits the lens or prism in an elongated fan in a direction of propagation. The direction of propagation, as discussed above, is substantially parallel to the surface on which alignment is desired. The width of the fan, however, is perpendicular to the surface, and the intersection of the beam with the surface generates the visible line of alignment that the user seeks. It is this width that allows the fan to project over and beyond obstacles. That is, even though an obstacle may partially obscure the fan-shaped beam of light, at least part of the fan-shaped beam extends above and beyond the obstacle, and a user may continue to align objects on which alignment is desired.[0041]
• FIG. 6 depicts an embodiment of the invention, in which a[0042]laser diode60 emits coherent laser light, such as, coherent laser light at 635 nm wavelength. The light is collimated into an ovate shape bycollimation optics62, for instance at least one collimating lens, by techniques well known to those skilled in optic arts. The ovate beam then enters aprojection lens64 from the right side in FIG. 6, desirably at an angle in which total internal reflection will occur, that is, all the incident light will be reflected rather than refracted from the back face of the lens. It has been found that this phenomenon is reinforced further if theback surface66 of the lens is mirrored. The phenomenon is also reinforced if a corner of the lens or prism is radiused as mentioned above. When the light emerges from the radiusedcorner65 of theprojection lens64 in FIG. 6, it is in the shape of a narrow beam or fan, rather than a single point or beam of light, and is able to extend around and beyond obstacles for the convenience of a user. In one embodiment of the invention, the angle A between the mirror surface of the collimating lens and the incident light from the laser diode source is from about 60 to about 65 degrees, preferably about 63 degrees, for maximum reflection of light through the lens, rather than refraction at angles that detract from the performance of the generator. In this depiction, the light68 is planar within the plane of the paper, when it leaves the lens. In one embodiment of the invention, the laser diode, the collimation lens, and the projection lens are contained within a single element, such as a laser diode with included collimating optics.
• In one embodiment shown in FIG. 6, an[0043]aspherical projection lens64 is made from optic grade glass, in the form of an equilateral triangle with the back face mirrored. Desirably, the lens is about 0.45 inches on a side, with onecorner65 radiused to about 0.030 to about 0.060 inches and the other corners rounded to a radius of 0.005 to 0.015 inches. With this geometry, the lens or prism is able to focus an ovate beam into a planar fan-shaped beam useful for aligning objects.
• FIG. 7 depicts a side view of another embodiment of the invention, in which a[0044]laser light source70, such as a laser diode, emits laser light, which is collimated into an ovate shape by collimatingoptics72 and then sent to anaspherical projection lens74 with onecorner75 radiused as mentioned above for projection of a narrow fan oflight76. In one embodiment, the axes of the ovate-shaped beam sent to the lens are about {fraction (3/16)} inches by about {fraction (1/16)} inch. The planar, fan-shapedbeam76 emerging fromprojection lens74 is than about {fraction (1/32)} inch thick. Note that thetop corner75 on the face of the lens in FIG. 7 is radiused from about 0.030 to about 0.060 inches, and preferably about 0.047 inches. FIG. 8 depicts the same embodiment in a top view, in which the rounding may not be observable. The source oflaser light70 generates visible laser light and thecollimating optics72 shape the light into a narrow beam. From the top view, the beam of light is very thin and is about the width of theprojection lens74, 0.4 inches wide. From the side view, the projected light is a thin beam; from the top view, the projected light is a thin fan.
• One embodiment of the invention features a lens, such as the lenses depicted in FIGS. 7 and 8, that is about 0.4 inches (10 mm) square, and about 0.1 inches thick (2.5 mm) in the direction of propagation, that is able to focus the incoming laser light beam and reflect it into a planar fan shape. The lenses are aspherical, cylindrical lenses. The lens may be made from one of several optical-grade clear, highly transparent materials, including BK7 glass having an index of refraction of about 1.5168 and a Vd of 64.17. In another embodiment, acrylic resin having an index of refraction of 1.4917 and a Vd of about 55.31 is useful. It has been found that the lens works better if the exit face has only one corner radiused about 0.047 inches, with the other faces being radiused for normal manufacturing custom, to about 0.005 to about 0.015 inches. More details on the performance of these lenses are discussed in copending application U.S. pat. appl. Ser. No. 10/141,392, entitled Laser Line Generating Device, assigned to the assignee of the present application and which is hereby incorporated by reference in its entirety.[0045]
• FIG. 9A demonstrates the use of an embodiment of a[0046]laser generator10 according to the present invention, in which a fan-shapedbeam76 is able to align afirst picture frame78 onwall77. The generator is convenient to use because it projects a laser beam on the wall adjacent the generator. The beam is able to overcome obstacles such asdoor moldings80 with its fan shape and extend above the molding with sufficient clarity to align another object, such aspicture frame82. It is able to overcome these obstacles because the corner from which the light exits is one or two inches removed or offset from the wall, allowing a fan or beam of light to form. The direction ofpropagation84 generally is in the direction from the generator to the objects on which alignment is desired, such as picture frames. At the same time, the width of the fan is perpendicular to thewall77 on which the paintings are hung or on which, more generally, alignment is desired. The fan-shapedbeam76 intersects thewall77 and the light is visible on the wall at theintersection79 of the fan-shapedbeam76 with thewall77. In one embodiment, the housing of the laser line generator is a support face that substantially extends along a first planar surface, such aswall77, and the fan shapedbeam76 substantially lies within a second planar surface, such as the plane oflight76. The second planar surface may intersect the first planar surface at an angle. The angle may preferably be 90°, or a right angle between the fan-shaped beam and the surface on which objects are to be aligned.
• The “comet” effect means that the intensity of the planar fan is less nearer the wall and greater away from the wall, so that the beam is able to usefully travel further, and enable a user to align objects at greater distances. Thus, in FIGS. 9B and 9C, the intensity of the laser light will be greater at[0047]outer edge87 than at theinner edge85 where the fan-shaped beam intersects thewall77 while the beam is used to alignobject82, such as a picture frame. There is no practical limitation to the distance the fan-shaped beam can travel. Laser diodes of 5-15 mW can be successfully used to project beams 30-50 feet long along painted wall-board surfaces.
• The[0048]laser line generator10 described previously with respect to FIGS. 1-9C can be utilized with an adhesive base or attachment, an embodiment of which is depicted in FIGS. 10-13. FIG. 10 shows an exploded view of theattachment100.Attachment100 includes an inner ortop portion102, an outer orbottom portion104 and a joiningportion105. The joining portion may include a largeplastic retainer106, abolt107,washer108, and anut125. Top andbottom portions102,104 may be molded from any convenient plastic, andnut125 may be molded intobottom portion104. The attachment is assembled with a fastener, such asbolt107 threaded intonut125.Retainer106 fits into arecess112 on the top surface oftop portion102.Retainer106 may be flat on its top and convex on itsbottom surface106ato match the contours of theconcave recess112. Adhesive strips109 are mountable to thebottom surface126 ofbottom portion104, and portions thereof or releasetabs127 forstrips109 may protrude from the side of the attachment. Additional washers, such as lock washers, may also be used with the fastener and retainer.Top portion102 also mounts alatch116 for retaining the laser line generator on the swivel base. The top portion may also mount one or more level indicators, such as the bubble levels described above, for one or more axes of the top portion, such as on the long and short sides oftop portion102. With these levels, a user may place the base on a wall and use the bubble levels to orient first the swivel base and then the laser line generator to a true plumb alignment.
• In addition to manual level indicators, as described above, the swivel base may also include other automatic levelers. These devices may include automatic pendulum-type levelers, in which an internal or external pendulum, along with gravity, orients and levels the swivel base, and thus the laser line generator. Other automatic levelers could include electronic levelers, a shaft held between journals, cantilevered tilt mechanisms, and so forth. Details on some of these levelers are disclosed in U.S. Pat. Nos. 4,031,629, 4,751,782, 5,075,977, and 5,992,029, among others.[0049]
• FIGS. 11[0050]aand11bare more detailed views of the top and bottom oftop portion102 of the attachment.Top portion102 includes aflat surface111, arecess112, and anorifice113.Flat surface111 may be adapted so that the bottom surface of thelaser line generator10 of FIGS. 1-9C, contacts flush with the flat surface betweensidewalls115, which, along withlatch116, retain the laser line generator securely in the swivel base. In the preferred embodiment, the surface is slightly recessed. The end oftop portion102opposite latch116 has anotherrecess118, for receiving a portion of laserline generator bottom28.
• [0051]Recess112 is curved to match the bottom,interface surface114 oftop portion102.Interface surface114 allowstop portion102 to swivel or rotate relative tobottom portion104 for a full 360° swiveling and orienting capability. Theunderside interface surface114, which includes a convex shape, may be solid or may be ribbed as shown for lighter weight and ease of use of both the swivel base and the mounted laser line generating device.
• A user inserts the bottom[0052]30 of laserline generating device10 of FIGS. 1-9C intorecess118 onflat surface111, while urginglatch116 forward, in the direction of arrow A. After the bottom30 of the laserline generating device10 is inserted and is resting onflat surface111,latch116 is released.Latch116 then moves in the direction of arrow B, and helps to retain the laser line generator in position ontop portion102.Latch116 may be a snap-fit design that can snap into place without the need to urge the latch forward, with abottom surface116aflat to match bottom30 oflaser line generator10.Top portion102 may also have anotch117 to assist in marking purposes. When removing thedevice10 fromtop portion102,latch116 may be urged forward to release the device fromtop portion102.
• In another alternative embodiment of the connection structure, the connection structure of FIGS. 10-13 is interchanged so that the bottom surface of the[0053]laser line generator10 includes side walls and recesses similar toside walls115 and recesses118 of FIGS. 10-13. The bottom surface of the laser line generator also includes a latch similar to latch116. The base and laser line generator are attached to one another by inserting the top portion of the attachment into the recessed area of the bottom surface of the generator and then applying the latch in a manner described previously for embodiments of FIGS. 10-13.
• FIGS. 12A and 12B provide top and bottom views of[0054]bottom portion104 ofadhesive base attachment100.Bottom portion104 has atop surface122 and aninterface surface124 that is curved to match thebottom interface surface114 oftop portion102.Top interface surface124 is concave to match convexbottom interface surface114. This surface may also be ribbed as shown for lighter weight, or may be made from solid material. The remainder oftop surface122 may be solid or may be ribbed, includingrib123 aligned fornut125 which is molded intobottom portion104.Bottom surface126 ofbottom portion104 is preferably flat for mountingadhesive strips109, including adhesive128,release liners129 and releasetabs127. Flatbottom surface126 andadhesive strips109 form an adhesive interface surface for the laser line generator with swivel base.
• [0055]Adhesive128 is preferably a removable pressure-sensitive adhesive for mounting theattachment100 to a wall. The special adhesive used allows for easy removal from a wall on one side and for easy removal fromsurface126 on the other side of the adhesive. Pressure-sensitive adhesives, such asadhesive128, are self-adhering with a slight amount of pressure, rather than adhesives requiring heat or water activation. Pressure-sensitive adhesives may be made from rubber-based or acrylic stocks, and may be manufactured in several ways. For instance, a central carrier or foam core may have pressure-sensitive adhesive applied by a hot melt process, a solvent-evaporation process, or an emulsion process. A release liner may be applied to one or both sides of the adhesive. Strong double-sided tape may be used as well.
• In the preferred embodiment, a first release liner (not shown) is removed from one side of the adhesive so that the adhesive may be secured to[0056]bottom surface126.Release liner129 on the other side is then removed and the swivel base and laser line generator are then adhered to a surface on which objects are to be aligned, such aswall77 of FIGS. 9A-9B. If removable pressure-sensitive adhesives are used, the swivel base may be removed without damaging the surface on which the objects were aligned. While many such adhesives may be used, “Command Strips,” from the 3M Company, Minneapolis, Minn., are preferred. These adhesives are actually two adhesives interlocked in the center. These adhesives may be purchased, separable and aligned, for single use in adhering the swivel base, and the laser line generating device, to a wall or other surface. A pack of six strips may be adhered to the bottom surface of the swivel base in a group as shown, for example, in FIG. 12B. Asingle release liner129 from one of the strips is then removed and theswivel base100 is removably affixed to a wall on which alignment of objects is desired. When the alignment operation is completed, theouter release tab127 is then pulled to release the adhesive strip from the wall and the used adhesive is discarded.
• In use, the[0057]laser line generator10 and the base100 can be packaged as separate from one another within a volume of space defined by a container, wherein the container, generator and base define a kit. In one embodiment, the swivel base may also contain level indicators, such as spirit or bubble levels. Once the generator and base are removed from the container, thelaser line generator10 is assembled or placed ontotop portion102 of the swivel base101, with at least oneadhesive strip109 in place onbottom portion104, as depicted in FIG. 13. Swivel base101 is virtually identical to previously-describedswivel base100, but swivel base101 also includes spirit levels103 oriented on two planes oftop surface102 of swivel base101. Using the ability of the base to swivel and rotate, the user tilts the laser line generator in the desired direction and then uses thebubble levels16,18 to levellaser line generator10. The combination oflaser line generator10 andswivel base100 is used in the same manner as that described with reference to FIGS. 9A-9C, with fan-shapedbeam76 propagating in the direction from thelaser line generator10 toobjects78,82 to be aligned, the width of fan-shapedbeam76 being perpendicular towall77. When the user has completed the alignment task, the user pulls on therelease tab127, releasing the adhesive fromwall77 or other surface. The adhesive strip that was used may then be removed frombottom surface126 ofbottom portion104 and discarded. The user may then go on to other alignment tasks as desired.
• In other embodiments of the connection structure, either the[0058]base30 of thegenerator10 or thetop portion102 may be provided with a magnet that mates magnetically with either another magnet material or ferrous material on the opposing surface. This can retain thelaser generator10 to the swivel base without the use of a latching structure. Hook and loop fasteners, such as Velcro®, may also be used to attach the laser generator to the swivel base. Magnetic attraction may also be used with a magnet on one of the top portion or generator, and a metal plate, such as steel or iron, on the other. Other ways may also be used, such as a tab-and-slot arrangement, with a slot or groove on the bottom portion and a matching tab or other feature on the top portion. All these are ways to join the top portion of the swivel base to the light generator.
• Some of these other ways are depicted in FIGS. 14A, 14B, and[0059]15. For instance, in FIG. 14A, theswivel base top102 may mount aferrous plate141 on its front face, while the light generator bottom30 mounts amagnet142 on its bottom30 nearbattery door52 to attract and hold the ferrous plate and the stud finder.Ferrous plate141 may lie atop therecess112 andorifice113 which may still be utilized to mount top102 of the swivel base to the bottom portion of the swivel base (see FIG. 10). In another method, shown in FIG. 14B, theswivel base bottom102 mounts ahook portion143 of a hook-and-loop fastener, such as Velcro®, while the light generator bottom30 mounts theloop portion144 as part of the battery door, to holdlight generator10 totop portion102 of the swivel base. As is well known, hook and loop fasteners are typically adhered to devices by an adhesive that very firmly bonds the fastener to the device. This adhesive attachment is an inherent part of the hook and loop fasteners herein described. FIG. 15 depicts another way to mount thelight generator150 onto theswivel base top151, by providing atab152 on the bottom surface oflight generator150, and by providing amatching slot153 in thetop surface151 of the swivel base, so the light generator may be slid into the swivel base. A catch or retainer may also be used to insure retention of the light generator when the assembly is held vertically.
• While this invention has been shown and described in connection with the preferred embodiments, it is apparent that certain changes and modifications, in addition to those mentioned above, may be made from the basic features of this invention. While the laser line generator may be most convenient to use when mounted to a wall, it may also be mounted on a table, floor, or other flat surface, and used to project a line without being mounted on a wall. While the swivel base may be used with the described laser line generator, the swivel base may also be used with other leveling devices, laser generators, or with other non-laser light or line generators. Many other variations of the invention may also be used without departing from the principles outlined above. Accordingly, it is the intention of the applicant to protect all variations and modifications within the valid scope of the present invention. It is intended that the invention be defined by the following claims, including all equivalents.[0060]

Claims (54)

What is claimed is:

1. A line generating device, comprising:

a housing comprising a support structure that substantially extends along a first plane;

a light source mounted within the housing;

a lens that receives light and projects the light in the shape of a fan, wherein the fan substantially lies within a second plane that intersects the first plane at an angle;

a reference level on an outside of the housing; and.

an adhesive for mounting to the support structure for mounting the device to a surface.

2. The device ofclaim 1, wherein the adhesive is selected from the group consisting of an adhesive, adhesive tape, adhesive putty, a pressure-sensitive adhesive, and an adhesive strip.

3. The device ofclaim 1, wherein the support face further comprises at least one of a notch and a bore.

4. The device ofclaim 1, further comprising a switch on an exterior of the housing.

5. The device ofclaim 1, further comprising a second reference level that is at a right angle to said reference level.

6. The device ofclaim 1, wherein the support structure further comprises a recess on a bottom of the device.

7. The device ofclaim 1, wherein the adhesive protrudes from a bottom surface of the device.

8. The device ofclaim 1, wherein the adhesive further comprises a liner.

9. The device ofclaim 1, wherein the adhesive is a removable pressure sensitive adhesive comprising an inner portion attached to the support structure and an outer portion releasably attached to the inner portion.

10. The device ofclaim 1, further comprising at least one pin for mounting the device to a surface through a bore in the bottom of the device.

11. The device ofclaim 1, wherein the housing pivots about an axis perpendicular to the first plane.

12. The device ofclaim 11, wherein the housing pivots about an axis perpendicular to the second plane.

13. The device ofclaim 1, wherein the housing pivots about an axis perpendicular to a third plane that intersects the first plane at a second angle.

14. The device ofclaim 1, wherein the housing pivots about an axis perpendicular to the second plane.

15. A line generating device, comprising:

a housing;

a support structure attached to the housing, the support structure comprising an external adhesive for supporting the device on a surface;

a light source mounted within the housing;

a lens receiving light from the light source; and

an aperture on an outside of the housing for emitting light.

16. The device ofclaim 15, further comprising two reference levels mounted at right angles on the housing, wherein an exterior of the housing comprises a hand grip area and a switch.

17. The device ofclaim 15, wherein the support structure is integral with the housing.

18. The device ofclaim 15, wherein the light source comprises a laser light source.

19. The device ofclaim 15, wherein the light source comprises a laser light source with a wavelength of about 635 nm.

20. The device ofclaim 15, wherein the light source generates light in the shape of a fan.

21. The device ofclaim 15, wherein a bottom surface of the housing of the line generating device further comprises at least one of a notch and a bore.

22. The device ofclaim 15, wherein the housing further comprises side surfaces that are substantially planar and perpendicular to the support structure.

23. The device ofclaim 15, wherein the support structure substantially extends along a first plane and the device generates a fan-shaped beam of light that substantially lies within a second plane that intersects the first plane at an angle.

24. The device ofclaim 15, further comprising at least one pin for mounting the device to a surface through a bore in the support structure.

25. The device ofclaim 23, wherein the housing pivots about an axis perpendicular to the first plane.

26. The device ofclaim 25, wherein the housing pivots about an axis perpendicular to the second plane.

27. The device ofclaim 23, wherein the housing pivots about an axis perpendicular to the second plane.

28. The device ofclaim 23, wherein the housing pivots about an axis perpendicular to a third plane that intersects the first plane at a second angle.

29. A light generating device, comprising:

a housing comprising a support structure that substantially extends along a first plane;

a laser light source mounted within the housing;

a lens that receives light and projects the light substantially within a second plane that intersects the first plane at an angle;

a reference level on an exterior of the housing; and

an adhesive attached to the support structure for mounting the device to a surface, wherein the support structure comprises an inner portion and an outer portion that rotate and swivel with respect to one another.

30. The device ofclaim 29, wherein the inner and outer portions have matching curved surfaces.

31. The device ofclaim 29, further comprising a second reference level.

32. The device ofclaim 29, wherein the support structure further comprises a recess for mounting the adhesive.

33. The device ofclaim 29, wherein the support structure includes a bore or a notch.

34. The device ofclaim 29, wherein the lens is cylindrical.

35. The device ofclaim 29, wherein the adhesive is a removable pressure-sensitive adhesive.

36. The device ofclaim 29, wherein the housing pivots about an axis perpendicular to the first plane.

37. The device ofclaim 36, wherein the housing pivots about an axis perpendicular to the second plane.

38. The device ofclaim 29, wherein the housing pivots about an axis perpendicular to a third plane that intersects the first plane at a second angle.

39. The device ofclaim 29, wherein the housing pivots about an axis perpendicular to the second plane.

40. A kit for a light generating device with a base, comprising:

a container defining a volume of space;

a base positioned within the volume of space, the base comprising an attachment structure; and

a light generating device positioned within the volume of space so as to be unattached to the base, wherein the attachment structure can be used for mounting the light generating device to an external surface.

41. The kit ofclaim 40, wherein the base further comprises a connection structure for mounting the light generating device to the external surface.

42. The kit ofclaim 40, wherein the light generating device generates a laser beam.

43. The kit ofclaim 42, wherein the light generating device generates the laser beam with an asymmetric intensity.

44. The kit ofclaim 42, wherein the light generating device generates light in the shape of a fan.

45. The kit ofclaim 44, wherein the light generating device comprises a housing with at least one flat surface extending along a first plane and the fan substantially lies within a second plane that intersects the first plane at an angle.

46. The kit ofclaim 40, wherein the attachment structure comprises an adhesive for attaching the device to the external surface.

47. The kit ofclaim 41, wherein the connection structure comprises a pin for attaching the device to the external surface.

48. A kit for a leveling device with a base, comprising:

a container defining a volume of space;

a base positioned within the volume of space, the base comprising an attachment structure for mounting the light generating device to an external surface; and

a leveling device positioned within the volume of space so as to be unattached to the base.

49. The kit ofclaim 48, wherein the base further comprises a connection structure for mounting the light generating device to the external surface.

50. The kit ofclaim 48, wherein the attachment structure comprises an adhesive for attaching the light generating device to the external surface.

51. The kit ofclaim 48, wherein the connection structure comprises a pin for attaching the light generating device to the external surface.

52. The kit ofclaim 48, wherein the leveling device further comprises an automatic leveler selected from the group consisting of a pendulum, a cantilevered tilt mechanism, an electronic leveler, and a shaft held between journals.

53. A method of aligning an object with a light beam, the method comprising:

positioning a light generator adjacent to a surface;

adhesively mounting the light generator to the surface;

generating light from the light generator along a direction of propagation so that a line is formed along the surface; and

placing an object so that a portion of the object is aligned by the light.

54. The method ofclaim 53, wherein the line is interruptible in that should an impediment be positioned on the line, the line will be present on either side of the impediment, and wherein the generating comprising actuating a switch from a first position to a second position and causing light to be generated.

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