Note: Descriptions are shown in the official language in which they were submitted.
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MODULAR TOOL ASSEMBLY HAVING A
VACUUM MOUNTING ARRANGEMENT
(0001] This application is a continuation-in-part of US Serial No. 10/919,569
filed
August 17, 2004, the entire contents of which is incorporated herein by
reference.
BACKGROUND
[0002] This invention relates to a modular tool assembly having a base
incorporating
a vacuum mounting arrangement for securing the modular tool assembly to a
mounting
surface.
(0003] Suction mounting devices are frequently coupled to tools utilized for
transporting materials between locations or attaching devices to surfaces.
Battery
powered suction devices are typically used in the construction and assembly
industries.
For example, auto workers frequently use handled suction devices to manipulate
panes
of automotive glass between assembly locations.
(0004] Recently, power tool manufacturers have developed common battery
arrangements that support a variety of power tools sold in a combination
package.
Such kits may include tools such as drills, saws, and flashlights.
Manufacturers are
interested in adding laser alignment products, such as laser levels to these
kits. Laser
levels have replaced chalk lines and torpedo levels as the preferred tool for
creating and
displaying a level line on a surface. These tools are commonly used for
interior
decorating projects, such as hanging pictures and installing cabinetry, and
exterior
projects, such as brick laying and deck assembly.
(0005] Laser levels are easy to set up and generate an alignment beam which
does
not mark up the mounting surface. Current laser level products are either
mounted to
an adjustable frame or are secured to a mounting surface with a fastener.
Laser levels
typically include a laser light source mounted within a housing. The laser
light source
may be rotatably mounted within the housing to allow for either horizontal or
vertical
transmission of the beam.
[0006] One limitation of current laser alignment devices is that the laser
levels
cannot be easily repositioned on surfaces once mounted. Many laser level
devices
either incorporate a pin or a fastener to mount the level on a vertical
surface to generate
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the alignment line. If the laser level is not properly aligned on the wall, a
user wilt have
to remove the device and remount in the proper position, placing additional
marks and
holes on the surface which must be patched.
j0007] !t is desirable to provide a modular tool assembly having a base
incorporating
a vacuum mounting arrangement that is configurable to support a variety of
tools,
including hooks, clamps, light sources, battery powered tools, laser leveling
devices and
similar devices. It is also desirable to provide a modular tool assembly
having a
vacuum mounting arrangement that can be easily mounted to a mounting surface
without damaging the finish of the surface. It is further desirable to provide
a monitor to
monitor the vacuum seal to ensure proper securement of the assembly to the
mounting
surface.
BRIEF SUMMARY
(0008] Accordingly, the present invention provides a modular tool assembly
having a
vacuum mounting arrangement for securing the assembly to a mounting surface.
The
modular too( assembly includes a base having upper and lower housing portions.
A
mounting seal extending from a lower portion of the housing cooperates with
the
mounting surface to define a suction mounting area therebetween. An upper
housing
portion may include a guide member having one or more receiving portions
formed
therein. Altemativeiy, the housing portion may be provided with a mounting
element to
mate with a complementary mounting element of a modular tool attachment.
(0009] A vacuum generating mechanism is disposed within the upper housing
portion. In one embodiment, the vacuum generating mechanism is electrically
connected to a power source (which may include a rechargeable power source).
In this
embodiment, the vacuum generating mechanism includes a motor and a pump
operatively driven by the motor and configured to remove air from the suction
mounting
area. In one aspect, the air may be removed through an aperture in the lower
portion of
the tool base to secure the housing to the mounting surface. A sensor may be
mounted
proximate an aperture in the lower housing portion of the tool base. The
sensor
monitors the suction mounting area and activates the pump if the sensor
detects a loss
of pressure in the suction mounting area.
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[0010] A switch that may be disposed on the upper portion of the tool base
housing
or elsewhere is operatively connected to the vacuum generating mechanism
allows a
user to activate the vacuum generating mechanism. At least one electrical
connector
may be provided in, for example, a top surface of the upper portion of the
tool base
housing to electrically connect the power source to a modular tool attachment.
[0011) A modular tool is releasably secured to a portion of the housing of the
tool
base. The modular tool may include a modular tool attachment that can be
mounted on
the base in a fixed relationship relative to the mounting surface. The modular
tool
attachment may include one or more projections extending from a tool
attachment
housing that releasably engages one or more receiving portions in a portion of
the tool
base. Alternatively, the tool attachment housing may have a complementary
mounting
element that cooperates with a mounting element provided on the housing to
releasably
secure the tool attachment housing to the base.
[0012] In one aspect of the present invention, the vacuum generating mechanism
includes a manually operable pump cooperating with the suction mounting area
to
remove air from the suction mounting area. In one aspect, the air may be
removed
through an aperture in the housing to secure the base to the mounting surface.
In an
alternative embodiment the vacuum generating mechanism includes a lever to
actuate a
vacuum pad and create an air pocket or suction between the device and the
surface on
which the device is mounted.
[0013] In another aspect of the invention, the modular tool comprises a laser
leveling
device having a housing, a laser light source disposed within the housing
operatively
connected to a power source, the laser light source including at least one
diode
projecting an alignment beam through an aperture in the housing to denote a
reference
plane along the mounting surface. One or more bubble levels may be provided on
the
laser level housing. The modular tool may also comprise a flashlight, a clamp,
a tape
measure or other measuring device, a tool holder (such as a driver bit
holder), an
alignment device, a hook, powered (including battery powered) and non-powered
tools.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FlG. 1 is an exploded perspective view of the modular tool assembly
having a
modular tool attachment reteasably secured to a tool base in accordance with
the
present invention;
[0015] FIG. 2 is a perspective view of the tool base of the modular tool
assembly in
accordance with the present invention;
[0016] FIG. 3 is a cross-sectional view of the tool base along line 3-3 of
Figure 2;
[0017] FIG. 4a is a perspective view of the laser leveling modular tool
attachment
configured for coupling to the modular tool assembly;
[0018] FIG. 4b is a perspective view of a flashlight modular tool attachment
configured for coupling to the modular tool assembly; and
[0019] FIG. 4c is a perspective view of a clamp modular toot attachment
configured
for coupling to the modular tool assembly.
[0020] FIG. 5 is a perspective view of one embodiment of the modular tool
assembly
having a modular tool attachment wherein the modular tool assembly has a
manually
operable vacuum attachment.
[0021 J FIG. 6 is a perspective view of an embodiment similar to that shown in
Fig. 5
except that the manual pump is shown in a different location.
[0022] FiG. 7 is a perspective view of one embodiment of a modular tool
assembly
having a manually operable vacuum attachment.
[0023] FIG. 8 is a perspective view of the manually operable vacuum attachment
for
use with the assembly of FIG. 7 and with the modular tool assembly and the
base
removed.
[0024] FIG. 9 is a side perspective view of the manually operable vacuum
attachment for use with the assembly of FIG. 7, with the modular tool assembly
removed, and schematically showing operation of the lever and the vacuum pad.
DESCRIPTION
[0025] Referring now to Figures 1 and 2, a modular tool assembly 10
configurable to
releasably secure a variety of portable tools, including powered and non-
powered tools,
is disclosed. Modular tool assembly 10 includes a tool base 12 incorporating a
vacuum
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mounting arrangement for securing the tool base 12 and a removably mounted
modular
tool attachment 14 to a mounting surface 16. Tool base 12 includes a housing
18
having a lower portion 20 and an upper portion 22. A suction cup or mounting
seal 24
extends from the lower housing portion 20.
(0026] A guide member 26 extends generally vertically from the lower housing
portion 20 to provide an outer mounting guide for modular tool attachment 14.
One or
more receiving portions 28 are formed in the guide member 26 to receive and
secure
one or more connecting arms or projections 30 extending from the modular tool
attachment 14. The guide member 26 cooperates with the tool housing 32 of the
modular tool attachment 14 to position and secure the too! attachment 14 on
the tool
base 12.
[0027] Referring now to Figures 1 and 4a, the modular tool attachment is a
laser
leveling device 34 adapted for attachment to the modular tool base 12. A laser
light
source (not shown) is mounted with the housing 32. The laser light source
includes at
least one diode (not shown) which projects one or more alignment beams 36
through an
opening 38 in an end wall 40 of the housing 32. In one aspect of the present
invention,
a lens 42 is provided in the opening 38 to cooperate with at least one diode
to focus the
alignment beam 36. However, it is understood that the alignment beam 36 may
project
through a standard opening in the housing 32 to denote a reference plane along
the
mounting surface 16.
(0028] In one aspect of the present invention, the laser light source is
rotatably
mounted within the housing 32 to allow a user to adjust the position of the
laser light
source once the laser level attachment 34 is placed in a fixed relationship to
the
mounting surface 16 when mounted on the tool base 12. It is understood,
however, that
the laser light source may be fixedly mounted to a portion of the housing. It
is also
contemplated that laser level attachment may include a laser light source
having a pair
of diodes in a coplanar relationship which project alignment beams through
openings in
opposing end walls of the laser level housing. Further, the laser light source
may
include a first diode which projects a first alignment beam through a first
opening in the
end or side wall of the housing and a second diode projecting a second
alignment beam
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generally perpendicular to the first alignment beam through a second opening
in an end
or side wall of the housing.
[0029] One or more bubble levels 44 can be provided such as along the top
portion
46 of the laser leveling device housing 32. The bubble levels 44, 48 assist
the operator
in positioning the laser level attachment 34 mounted on the tool base 12 to
the
mounting surface 16 to ensure that the alignment beam 36 projects across the
surface
16 at the desired angle. In one aspect of the invention shown in Figure 4a, a
pair of
bubble levels 44, 48 are provided on the top portion 46 of the laser level
housing 32 to
provide both horizontal and vertical alignment information to the operator
prior to
securement of tool assembly 10 to mounting surface 16. It is understood that a
single
bubble level disposed on the laser level housing may also be used to display
the
alignment position of the modular tool assembly.
[0030] Referring now to Figures 2 and 3, a vacuum generating mechanism 50 is
disposed within the tool base 12 to create a suction effect to secure the tool
base 12 to
the mounting surface 16. In one embodiment, the vacuum generating mechanism 50
includes a motor 52 and a vacuum pump 54 operatively connected to the motor 52
disposed within the upper housing portion 22. It is understood that the motor
52 and the
pump 54 may be formed as a single unit. A hose 56 connects an inlet 58 on the
pump
54 to an aperture 60 in the bottom surface 62 of the lower housing portion 20.
Air is
drawn through the aperture 60 by the pump 54.
[0031] A power source 64 disposed within the upper housing portion 22 is
electrically
connected to the motor 52. The power source 64 may include a rechargeable
battery
pack, such as a lithium ion or nickel cadmium battery, or removable
rechargeable or
alkaline battery. In one aspect of the present invention, one or more
electrical contacts
66 in electrical communication with the power source 64 extend through a top
surface
68 of the upper housing portion 22 to supply power to the modular tool
attachment 14.
It is also contemplated that the modular tool attachment 14 may include an
independent
power source.
[0032] The motor 52 and the pump 54 of the vacuum generating mechanism 50
cooperate with the mounting seal 24 to create a vacuum pocket or suction
mounting
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area 70 between the mounting surface 16, the mounting seal 24, and the bottom
surface 62 of the lower housing portion 20 of the tool base 12.
[0033] The mounting seal 24 is preferably a rubber suction cup that cooperates
with
the mounting surface 16 to define a vacuum pocket 70 therebetween. In one
aspect of
the present invention, the bottom surface 62 of the lower housing portion 20
is arcuately
shaped to form a cavity cooperating with the mounting seal 24 and the mounting
surface 16 to enhance the suction effect created in the vacuum pocket 70. In
this
aspect, the modular tool attachment 14 and, in particular, the mounting seal
24, is
placed into contact with a mounting surface 16 and pressed against the
mounting
surface to evaluate air from the vacuum pocket 70.
[0034] In another aspect of the present invention, air is removed from the
vacuum
pocket 70 by a pump. In one alternative, a switch 72 disposed on the upper
housing
portion 22 is operatively connected to the.pump 54 to allow a user to activate
the pump
54 to remove air from the vacuum pocket 70. The switch 72 may also control
electrical
contacts 66 supplying power to a device in the modular tool attachment 14,
thereby
controlling the activation of both the pump 54 of the vacuum generating
mechanism 50
and the modular tool attachment 14. Alternatively, the modular tool attachment
14 may
incorporate a switch that will independently operate the modular tool
attachment.
[0035] Once the user places the mounting seal 24 of the tool base 12 in
contact with
a mounting surface 16, the user actuates the switch 72, which activates the
pump 54.
The pump 54 evacuates air from the vacuum pocket 70 through the inlet 60. A
sensor
74 disposed in the bottom surface 62 of the lower housing portion 20 monitors
the
vacuum pocket 70. The sensor 74 activates the pump 54 to remove air from the
vacuum pocket 70 if the sensor detects a loss of pressure in the vacuum pocket
70.
Loss of vacuum pressure may be caused by imperfections in the mounting surface
16
or the seal 24 such as gaps or cracks that limit the effectiveness of the
mounting seal
24. The sensor 74 allows the pump 54 to compensate for the surface flaws to
ensure a
proper seal between the tool base 12 and the mounting surface 16.
[0036] A third aspect of the vacuum generating mechanism includes a manually
operable pump cooperating with the mounting seal 24 to remove air from the
vacuum
pocket 70. A switch 72a may be placed on either the lower portion 20 or the
upper
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portion 22 of the tool base as shown in Figs. 5 and 6. The switch 72a may
simply
function to evacuate air from the vacuum pocket 70 when activated, such as by
depressing the switch. Alternatively, the switch 72a may operate the pump such
that
when the switch 72a is depressed, air is evacuated from the vacuum pocket.
[0037] Referring now to Figure 4b, a second modular tool attachment is
disclosed.
In this instance, the modular tool attachment comprises a flashlight 76 having
a
flashlight head 78 and a flashlight body 80 configured for securement to the
tool base
12. The flashlight body 80 includes a handle 82 formed in a top surface 84 of
the body
80. One or more connecting arms 86 extend from the flashlight body 80 to
releasably
engage one or more receiving portions 28 in the guide member 26 of the tool
base 12.
Alternatively, the upper portion 22 such as the top surface 60 or elsewhere
may be
provided with a mounting element to engage a complementary mounting element on
the
flashlight body 80. For example, the mounting element may include a magnetic
surface,
a hook, or a complementary portion of a hook-and-loop type fastener, mating
ribs, and
other mounting elements well known in the art. The flashlight head 78 includes
a
shroud 88, a reflector 90 and a lens 92 mounted adjacent a bulb (not shown).
The
vacuum generating mechanism incorporated in the toot base 12 allows hands-free
use
of the flashlight 76 when mounted on a mounting surface 16.
(0038] Referring now to Figure 4c, a third modular tool attachment for the
modular
tool assembly of the present invention is disclosed. The third modular tool
attachment
comprises a clamp 94 having a handle 96 pivotally attached to a clamp housing
98.
The handle 96 includes a distal end forming a handle portion 100 to be grasped
by a
user and an opposed gripping portion 102 including an elongate jaw 104
provided
thereon. The handle 96 pivots about a spring biased mount 106 disposed in the
clamp
housing 98. The clamp housing 98 includes a generally horizontal jaw 108
cooperating
with a jaw 104 on the handle 96 to secure a workpiece therebetween. The clamp
housing 98 includes one or more projections 110 that releasably engage one or
more
receiving portions in guide member 26 of tool base 12. As with the flashlight
76, the
clamp housing 98 may be mounted to the upper portion 22 by engagement with a
mounting element provided on the upper portion 22.
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[0039] Referring now to Figures 1 and 4a-4c, a switch 112 provided in a wall
of 114
of the respective modular tool attachment embodiments may cooperate with a
switch 72
on the modular tool base 12 to activate the pump 54 of vacuum generating
mechanism
50.to mount the modular tool base 10 to the mounting surface 16. As described
above,
it is understood that the switch 72 may activate the laser light source of
laser leveling
device 34, the bulb of flashlight head 78 of flashlight 76, or to activate
another modular
tool attachment. Alternatively, the switch 112 may only activate the vacuum
generating
mechanism 50 while an independent switch operates the features of the modular
tool
attachments.
[0040] Referring now to FIGs. 7-9, another embodiment of the device of the
present
invention having a manual suction mounting arrangement is shown. In this
embodiment, the base 12 having a mounting seat 16 is as described above with
other
alternative embodiments. The mounting seal 16 is provided with a top surface
200, a
bottom surface 202 and a wall 204 extending from the top surface 200 to
contact the
attachment surface 16 and form a seal, as will be described below.
[0041] A lifting mechanism 210 provided on the top surface 200 of the mounting
seal
cooperates with the bottom surface 202 such that actuation of the lifting
mechanism 210
lifts the bottom surface 202 to create a cavity 70. The lifting mechanism 210
can be
provided.with a (ever 212 that extends from a portion of the tool base 12 such
that
movement of the lever 212 actuates the lifting mechanism 210. As shown in
Figures 7-
9, the lever 212 is rotated from a first position to a second position
(counter clockwise
direction) such that in the first position, there is no suction and in the
second position
there is a suction or vacuum when the cavity 70 is created.
[0042] Desirably, the lever 212 is fixed in either the first or the second
position until
manually moved to the other position. As shown in Figure 8, the lifting
mechanism 210
may include a cam 220 operatively connected to the bottom surface 202 such
that
rotation of the lever 212 causes the cam 220 and thus the bottom surface 202
to move
toward the top surface 200 and thereby create a cavity 70.
[0043] While embodiments of the invention have been illustrated and described,
it is
not intended that these embodiments illustrate and describe all possible forms
of the
invention. Rather, the words used in the specification are words of
description rather
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than limitation, and it is understood that various changes may be made without
departing from the spirit and scope of the invention.
