WO2008011398A1 - Layout laser assembly - Google Patents

Abstract

A layout laser assembly projects a plurality of parallel laser light beams across a subfloor, wall or ceiling at regularly spaced intervals. In the application of wood strip flooring installations, the points at which the laser light intersects the wood strips indicate the preferred locations at which a nail is to be placed. In several embodiments, optical elements are supported on movable carriages to allow the spacing between adjacent laser light tabs to be adjusted. Depending upon the type and width of wood strip floors being laid, the direction and spacing of underlying floor joists, and other factors, it may be necessary to more closely space or more distantly space the nails. The subject assembly can be adapted for use in identifying high and low spots upon a work surface, and can facilitate the precision layout of tiles on floors, walls and ceilings. Connectors can be used to extend the length of the assembly or to navigate corners.

Description

LAYOUT LASER ASSEMBLY

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority to U.S. Provisional Application entitled LAYOUT LASER having serial number 60/807,542 filed My 17, 2006.

BACKGROUND OF THE INVENTION Field of the Invention

[0002] The invention relates to a tool and method for installing multi-piece floor, wall and/or ceiling covering materials such as wood strip, tile, vinyl and plastic squares. More particularly, the invention relates to a layout tool capable of projecting multiple parallel beams of collimated light across a sub floor, wall or ceiling surface to provide reference guidelines at regularly spaced intervals indicating placement of fasteners, or otherwise with which to arrange tiles and the like. Related Art

[0003] Although the installation of flooring (whether wood strip, tile or vinyl), wall and ceiling tiles for residential and commercial application has been largely touted as an easy "do-it-yourself project by Home and Garden Television programs, it is in fact quite complicated to achieve professional results. In the instance of wood strip floors, many installers fail to achieve quality results for one of two reasons: Either they have not adequately prepared the sub floor by leveling unacceptably high or low spots, or they have not placed the anchoring fasteners at specified intervals.

[0004] According to techniques common in the industry, an installer of wood strip, tile and vinyl flooring may depend upon their vision and/or sense of feel to determine whether the underlying surface is sufficiently smooth enough to accept the installation of hard wood flooring strips or tile or vinyl squares. However, even the trained eye of a professional installer is not always reliable, and can be deceived in certain lighting conditions. Furthermore, do-it-yourself and/or novice installers of finish flooring are much more likely to overlook unacceptably high or low spots in a sub floor. As a result, floor squeaks, uneven surfaces and/or poor fitting joints will result. Such problems are extremely difficult to correct after the finish covering has been installed. [0005] With regard to the problems associated with uneven fastener spacings, the current work method followed by most professional installers of wood strip flooring is to snap chalk lines on the sub floor at the manufacturer's indicated spacing intervals. The chalk lines serve as visual guides to indicate where fasteners should be placed. For example, if eight inch nail spacings are indicated for a particular wood floor installation, the installer will strike the chalk line in a sequence of stripes spaced eight inches apart. Commonly, these stripes are placed perpendicular to the underlying floor joists. The same method is used for indicating straight lines for tile and vinyl installation either on the floor or walls. However, numerous shortcomings exist with regard to the current chalk line procedures. First of all, it is a time consuming, two person process which is made even more difficult if the work surface is very large. Secondly, chalk lines tend to wear away quickly, especially in traffic areas. If a chalk line is snapped incorrectly on the first attempt, it can be confusing and messy to snap an overlying, corrected chalk line. Furthermore, chalk lines can be difficult to see in low light conditions, especially if the chalk supply is running low in the marking tool. [0006] It is difficult to overstate the harmful effects resulting from the failure to properly install a floor or wall covering, such as wood strip, tile or vinyl. Today's pre-fϊnished wood floors demand tight-abutting joints along their entire length, and consistently smooth sub floors to achieve a professional fit. Most building standards permit a deviation in sub floor height, i.e., low spots and high spots, of no more than three-sixteenths of an inch. Mistakes often result from poor installation techniques, the leading cause of which is inadequate floor preparation and/or improper fastener spacing. Often, the only solution to a poorly installed floor is a complete tear out and reinstallation using all new materials. The cost associated with such remedial action will more than double the initial project cost. Because such remedial action is the result of installation negligence, it is often the installer (who may be a small business owner) that bears the remedial expenses. Or, in the case of a do-it-yourselfer, the home owner must live with the poor workmanship if they are not willing to undertake the necessary remedial action.

[0007] Accordingly, there is a need for an apparatus and method to assist the installer of wood and other flooring, as well as wall and ceiling materials, that will facilitate the preparation of a sub floor, wall or ceiling and then indicate proper fastener spacings at intervals specified by the appropriate authority. SUMMARY QF THE INVENTION

[0008] The subject invention provides a solution to the shortcomings and disadvantages found in current installation techniques for wood strip and other type floor, wall and ceiling covering materials. Specifically, the subject invention comprises a layout laser assembly for creating a custom-spaced visual alignment grid on a work surface, the alignment grid consisting of plural parallel beams of collimated light stripes on the work surface. The assembly comprises an elongated rail establishing a generally linear guide track along the length thereof. A plurality of optical devices project respective beams of collimated light perpendicular to the length of the rail. A carriage is operatively associated with each of the plurality of optical devices. Each carriage interacts with the guide track for movement along the length of the rail, whereby the spacing of the plural parallel beams of collimated light projecting from the rail can be custom-spaced one from another by re-locating each carriage along the guide track to a new selected position. Custom-spacing of the light beams can be especially helpful in situations where non-typical spacings are required, such as in the case of angled underlying floor joists.

[0009] According to another aspect of the invention, a method is provided for fixing wood strips to a sub floor using regularly spaced mechanical fasteners. The method comprises the steps of providing a generally planar sub floor having opposed starting and ending sides. A plurality of individual wood strips, all having a common width, are provided. The method includes laying a first flooring course along the starting side of the sub floor by arranging a plurality of the wood strips in end-to-end fashion on top of the sub floor. A plurality of collimated beams of light are generated from the ending side of the sub floor. The plural beams of collimated light are oriented such that all of the beams are parallel to one another and project toward the starting side of the sub floor. Visual intersection points are created by crossing the plural beams of collimated light with the first flooring course. A mechanical fastener is forcibly driven through the first flooring course and into the sub floor at or adjacent each visual intersection point to anchor the first flooring course permanently to the sub floor. The method further includes laying a second flooring course directly alongside the first flooring course by arranging a plurality of the wood strips in end-to-end fashion on top of the sub floor. Visual intersection points are then created on the second flooring course by crossing the plural beams of collimated light with the second flooring course. And the method finally includes forcibly driving a mechanical fastener through the second flooring course and into the sub floor at or adjacent each visual intersection point therealong to anchor the second flooring course permanently to the sub floor. And so forth until the sub floor is covered with wood strips.

[0010] According to yet another aspect of the invention, a layout laser device is provided. This layout laser device is adapted to be used in concert with other like layout laser devices slidably carried on an elongated rail. The layout laser device comprises a carriage including at least two spaced guide features that are adapted to maintain the carriage in a translating motion condition while sliding longitudinally along the rail. A laser light generator is affixed to the carriage for projecting a collimated beam of light perpendicularly relative to the guide features. And a locking device is provided for releasably securing the carriage to the rail to temporarily immobilize the carriage in an adjusted position along the length of the rail.

BRIEF PESCRIPTION OF THE DRAWINGS

[0011] These and other features and advantages of the present invention will become more readily appreciated when considered in connection with the following detailed description and appended drawings, wherein:

[0012] Figure 1 is a simplified perspective view illustrating the installation of wood strip flooring upon a sub floor with the aid of a layout laser according to the subject invention; [0013] Figure 2 is a schematic view depicting a laser light generator projecting a single beam of collimated light toward an aligned series of beam-splitting optical elements; [0014] Figure 3 is a fragmentary perspective view of a layout laser according to one embodiment of the subject invention, including an adjustable spring clamp carried in a C- shaped channel, with a beam-splitting prism supported in the spring clamp and movable along the channel length so as to re-orient the position of collimated light projected perpendicularly from the channels;

[0015] Figure 4 is a fragmentary view of two channel sections of the layout laser rail being coupled together in end-to-end fashion so as to extend the length of the layout laser device; [0016] Figure 5 is a simplified cross-sectional view through a sub floor having low and high spots which are indicated by the layout laser of the subject invention; [0017] Figure 6 is a perspective view illustrating the arrangement of the layout laser in a corner of a work space with the projected beams of laser light intersecting in a grid-like pattern to highlight low and high spots; [0018] Figure 7 is a perspective view of a corner connecter according to the subject invention as illustrated in Figure 6;

[0019] Figure 8 is a fragmentary perspective view of a first alternative embodiment of the subject invention;

[0020] Figure 9 is a fragmentary perspective view of a second alternative embodiment of the subject invention;

[0021] Figure 10 is a fragmentary perspective view of a third alternative embodiment of the subject invention;

[0022] Figure 11 is a perspective view of the subject layout laser affixed in a vertical plane to project a grid pattern of collimated light on a vertical wall surface; and

[0023] Figure 12 is a perspective view of the subject layout laser attached to a ceiling for projecting stripes of collimated light along the ceiling's surface.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0024] Referring to the Figures, wherein like numerals indicate like or corresponding parts throughout the several views, a floor covering layout laser assembly according to the subject invention is generally shown at 14 in Figure 1. Here, the assembly 14 is shown positioned along the intersection of a back wall 16 and a sub floor 18. The sub floor 18 is a generally planer expanse having one side designated a starting side and an opposite side designated an ending side. A designation of starting and ending sides is generally arbitrary, however in the case of wood strip flooring the opposed starting and ending sides will generally be opposed from one another in the direction of the underlying floor joists (not shown). This is so that the courses of wood strip to be laid upon the sub floor 18 will be arranged perpendicular to the underlying structural members. Thus, the layout laser assembly 14 is placed along the ending side of the sub floor so that it projects a plurality of regularly-spaced, collimated beams of light 20 across the surface of the sub floor 18. The laser light beams 20 can be observed, unaided, as parallel stripes extending perpendicularly across the sub floor 14, relative to the back wall 12 as viewed from Figure 1.

[0025] Courses of wood strip flooring 22 are laid on the sub floor 18 and fastened, one at a time, to the sub floor 18 using nails 24 or other mechanical fastening elements. Generally, a toe-nailing technique will be used to embed the nails 24 through an outer "tongue" edge of the strip flooring 22. Of course, other nailing or fastener techniques may be used, including a face-nailing technique common for beginning and end courses. The nails 24 or other mechanical fastening devices can be used in combination with other fastening methods, including adhesives, cleats or any other approved technique. The nails 24 are placed at or very near to the visual intersection point at which each laser beam 20 collides with the leading strip of flooring 22. The regular spacing of fasteners 24 will ensure a strong, structural connection to the sub floor 18. If a laser beam 20 terminates at or nearly adjacent to the cut end of a wood strip, it may be necessary to locate the nail 24 a sufficient distance away from the cut end to avoid splitting. Otherwise, the visual intersection points created by the laser beams 20 are effective to indicate nail 24 spacing intervals in accordance with a manufacturer's specifications.

[0026] Referring now to Figure 2, a schematic representation of the subject layout laser assembly 14 is illustrated. The schematic representation here describes the assembly 14 as including a laser light generating device 26 capable of projecting an intense, single beam 28 of laser light along a linear path. At regularly spaced intervals along the path of the main beam 28, are positioned mirrors, prisms, or other optical devices capable of diverting a portion of the laser light in a path perpendicular to the main beam 28. The exemplary beam splitting prisms are here generally indicated at 30, but hereafter more generally referred to as optical elements 30 for receiving the collimated main beam 28 projected parallel to the length of the assembly 14 and then re-directing that collimated main beam 28 to a perpendicular orientation thus forming one of the projected laser beams 20. According to the schematic representation shown in Figure 2, the non-diverted portion of laser light 28 passes through the optical element 30 and continues along its original course, parallel to the length of the assembly 14, until it encounters the next optical element 30. A portion of the light energy is diverted perpendicularly again, with the remaining portion of laser energy continuing along the original linear course of the main beam 28. According to this technique, multiple beams of laser light 20 radiate perpendicularly from the main beam 28, at selectively spaced intervals.

[0027] Those of skill in the field of physics and optics will readily appreciate many alternative techniques for transposing the collimated main beam 28 into a plurality of perpendicularly oriented projecting beam 20. For example, the collimated main beam 28 can be divided into a plurality of parallel beams using an etalon or a diffractive element in combination with a converging lens. Examples of this technique may be found in U.S. Patent number 5, 912, 738 to Chason, et al, issued June 15, 1999, the entire disclosure of which is hereby incorporated by reference. Other techniques may also be known, such as directing the main beam 28 to a bank of optical fibers which are then individually routed along the length of the assembly 14 and affixed so as to direct the emanating laser beams 20 in the desired parallel configurations. Optical wave guides can be used in a somewhat similar fashion. Generally stated, many other techniques can be employed as an optical element 30 for receiving the collimated main beam 28 of light, which is oriented parallel to the length of the assembly 14, and redirecting that main collimated beam 28 in a perpendicular orientation to form one of the projected laser beams 20. [0028] Referring still to Figure 2, shades 32 or other light-blocking devices can be selectively deployed so that desirable beam spacing increments are readily achievable. Thus, it is not necessary that the light emanating from each optical element 30 be permitted to project across the sub floor 18. Similarly, a flap 34 can be placed at the far end of the assembly 14 to terminate the main beam 28 at the terminus of the assembly 14. [0029] As best shown in Figures 3 and 4, the layout laser assembly 14 may include an elongated rail 36 having a generally C-shaped configuration. Of course, other rail 36 configurations are possible, such as illustrated in Figures 9 and 10, with the C-shaped version depicted here forming but one exemplary embodiment. According to this design, each optical element 30 is carried in a movable carriage, generally indicated at 38. Thus, the carriage 38 is operatively associated with each optical element 30, and interacts directly with the guiding track-like feature of the rail 36 for establishing sliding movement or pick-and- place along the length of the rail 36.

[0030] In this embodiment, the carriage 38 is shown in the form of a spring clamp made from a resilient spring steel or other flexible, highly resilient material. The carriage 38 includes guide features shown here in the form of notches 40, 42 which are adapted to maintain the carriage 38 in a translating motion condition while sliding longitudinally along the rail 36. More specifically, in this version where the rail 36 has a C-shaped configuration, the notches 40, 42 engage respective flanges 44 adjacent the open slot of the rail 36. The spring clamp version of the carriage 38 has a generally v-shaped configuration, and when pinched together disengages from the flanges 44 so as to allow easy sliding along the rail 36. When a desired position has been reached, the spring clamp can be relaxed, with its notches 40, 42 biting into the flanges 44 to hold a fixed position. The optical element 30 is carried in the carriage 38, with multiple such movable carriages 38 being used in concert on the same length of rail 36. Those of skill in the art will appreciate other clamping designs which may include thumb screws, iever locks, camming devices, ratcheting designs, spring detents, pin-in-hole systems, and the like. In this manner, the main beam of collimated light 28 projected from a single laser generating device 26 can be split from and projected perpendicularly via the optical element 30 at any location along the length of the rail 36. Alternatively, the optical element 30 here may comprise a self-energizing laser beam generating device that is carried within the carriage 38.

[0031] Various indicia 46 can be marked on the outside of the rail 36 or at other convenient locations to make calibrated positioning of the optical elements 30 convenient. The indicia 46 can be color coded or otherwise visually indicative of a particular spacing pattern. For example, each indicia 46 at 8 inch intervals may be colored green, whereas, indicia 46 spaced at 12 inch intervals may be colored red, etc. Of course, other techniques, including actual length measurements carried out in English or metric units can be provided instead of, or together with, the coded indicia 46. Furthermore, a more sophisticated indicia system is illustrated by way of example in the second alternative embodiment shown in Figure 9.

[0032] Preferably, the length of each rail 36 is conducive to transportability from one job site to the next. For this reason, lengths in the 4 foot to 8 foot range are considered generally convenient to handle. However, so that large work spaces can be accommodated, it may become necessary to gang several rails 36 in end-to-end fashion. This can be accomplished using any form of basic end-to-end connection system. In Figure 4, a highly illustrative, exemplary male-female connection system is shown wherein a female end fitting, generally indicated at 48 is attached to one end of the rail 36. The female end fitting 48 is sized to receive the leading end 50 of the next adjacent rail 36 as a complimentary male shaped structure. The female end fitting 48 may be provided with a simple swinging enclosure flap 34 that automatically moves out of the way as the leading male end 50 of the next rail 36 is inserted into the female end fitting 48. The flap 34, as described previously, serves to block or prevent the escape of the main beam of collimated light 28 from the rail 36 when the female end fitting 48 is at the extreme end of the layout laser assembly 14. If necessary, the female end fitting 48 may include a retention feature to hold the leading end 50 securely in position, such as a self-locking clip, detent, or the like. Another variation of the female end fitting 48 (not shown) may include a construction which does not obstruct the open slot of the C-shaped rail 36 so that the carriage 38 can travel across the fitting from one rail 36 to the next. Yet another example of a male-female connection system is illustrated in Figure 9. [0033] Referring still to Figure 4, the female end fitting 48 may include a feature for securing the assembly 14 to the sub floor 18. For example, this feature may comprise a tab 52 through which a fastening screw 54 extends. The screw 54 may be of the "captured" type so that it cannot readily disengage from the tab 52. Of course, other anchoring methods can be used, and need not of necessity be combined with a female end fitting 48. Although not shown, the anchoring feature can be combined with a fine tuning adjustment system which allows the angular and/or lateral condition of the rail 36 to be minutely adjusted and thereby control the pattern of laser beams 20 projected across the sub floor 18. Thus, this fine tuning feature could operate as a leveling device for adjusting the vector of the collimated beam 20 in a vertical plane without disrupting its perpendicular projection relative to the rail 36. Such a leveling device would be used in lieu of self-leveling optical devices and arrangements as described in connection with alternative embodiments below. [0034] Continuing still with reference to Figure 4, a level indicator 56 may be included atop the female end fitting 48, or in any other convenient location, to indicate when the rail 36, or more specifically the laser beams 20, have been fine tuned to a preferred condition relative to level. The level indicator 56 is shown here as a bubble type level, however, digital, water or other types of leveling and orientation devices can be used to accomplish calibration of the laser beams 20. hi yet another variation, the optical elements 30 may be of the self leveling type which react to gravitation for establishing properly oriented beams 20 of laser light.

[0035] Figure 5 depicts a laser beam 20 emanating from the layout laser assembly 14 and projecting across an excessively uneven sub floor 18. hi particular, the sub floor 18 includes a low spot 58 and a high spot 60. Preferably, the laser beam 20 is oriented so as to strafe across the sub floor 18 in an uninterrupted condition thereby producing a continuous stripe of laser light across the sub floor 18. However, when the beam 20 encounters the low spot 58, a temporary interruption in the projected beam will be apparent. In other words, the laser beams 20 will skip across the depressed low spot 58, reuniting with the sub floor 18 at the far side of the low spot 58. Similarly, when encountering the high spot 60, the laser beams 20 will strike the up-hill edge of the high spot 60, and abruptly terminate. The downward, or leeward side of the high spot 58 will be eclipsed. If the particular optical element 30 is selected to be of the type which projects a fanning beam pattern (as indicated in Figure 9), the laser beam 20 may terminate at the top or peak of the high spot 60, but will not continue down its back side. [0036] Figure 6 displays yet another application of the subject layout laser assembly 14, wherein it is arranged in a corner 62 with the laser beams 20 overlaying a grid-like pattern upon the sub floor 18. In this case, a corner connector, generally indicated at 64, joins two rails 36 at right angles. The corner connector 64 includes a male end 66 and a female end 68 adapted to connect respective end sections of the rails 36. The corner connector 64 is provided with an internal mirror 70 or other light manipulating device for re-directing the main beam 28. As with the female end fitting 48, the corner connector 64 may also include an anchoring device such as the tab 72 and screws 74 combination depicted, or any other suitable arrangement.

[0037] Referring again to Figure 6, the beams of laser light 20 are projected across the sub floor 18 in a cross-hatch pattern. When the laser beams 20 encounter the low spot 58 or the high spot 60, their striping patterns on the sub floor 18 are interrupted as described previously. Therefore, the installer can visually inspect the sub floor 18 and see quite easily if there is a low spot 58 or a high spot 60. If uneven surfaces are thus detected, appropriate action can be taken to fill the low spots 58 and reduce the high spots 60 so that the finished flooring 22 can be installed to professional quality standards.

[0038] Figure 8 depicts a simplified, yet equally effective first alternative embodiment of the subject layout laser assembly 14', wherein prime designations are used to indicate like or corresponding parts to those discussed previously. Here, the rail 36' includes a series of cradles 76 spaced at regular intervals and sized to receive individual laser light generators 30'. In this configuration, the rail 36' is laid on the sub floor 18, adjacent the back wall 16, in the manner depicted in Figure 1. The optical devices 30' are then selectively switched on and positioned in cradles 76 corresponding to the desired spacing intervals for the nailing pattern. In the example of Figure 8, the spacing between adjacent cradles 76 may, for example, be 4 inches each. Since the optical devices 30' are shown placed in every other cradle 76, the spacing between adjacent optical devices 30' will be 8 inches. If the optical devices 30' are placed in every third cradle 76, the spacing between adjacent light beams 20' will be 12 inches, and so forth.

[0039] Those of skill will readily appreciate other variations of this invention, including a hybrid of the Figures 3 and 8 versions depicted here. Such hybrid versions are depicted in the second and third alternative embodiments of the invention as illustrated in Figures 9 and 10. Considering the second alternative embodiment of Figure 9, wherein double prime designations are used to indicate like or corresponding parts to those discussed previously, a carriage 38" the optical device 30" each comprise a self-contained laser light generator of the kind including a battery (not shown) and an individual on/off switch 78. The carriage 38" is represented by a cuff-like sliding member which rests over the top of the rail 36". The rail 36" is here shown including grooves 80 on either side of the rail 36", in which guide features 40" and 42" register to maintain orientation and prevent disassociation between the carriage 38" and the rail 36". The guide features 40", 42" thus maintain the carriage 38" in a translating motion condition while sliding longitudinally along the rail 36". The optical device 30" may be of the type which is designed to project a downwardly fanning beam 20, which thereby eliminates or at least reduces the need for leveling. For this technique, reference is made to U.S. Patent number 6,202,312 in the name of Rando, issued March 20, 2001, the entire disclosure of which is hereby incorporated by reference. As an alternative to the fanning beam pattern, wherein the entire beam 20" is contained within a vertical plane, the laser generating device may be of the self-leveling type which is well known in the art. For an example of a self-leveling beam device, reference may be had to U.S. Patent number 5,459,932 in the name of Rando et al, issued October 24, 1995, the entire disclosure of which is hereby incorporated by reference.

[0040] A locking device 82 is provided for releasably securing each carriage 38" to the rail 36" to temporarily immobilize the carriage 38" in a custom-oriented position along the length of the rail 36". Whereas in the embodiment depicted in Figure 3 the locking device comprised the spring-like nature of the carriage 38 combined with the biting notches 40, 42, in this second alternative embodiment of the invention, the locking device 82 comprises a knob screw 84 which is threaded through a receiving nut 86 affixed to the carriage 38". Thus, as the knob screw 84 is twisted in a tightening direction, the tip of the knob screw 84 bear upon the upper surface of the rail 36", thereby temporarily locking it in position. However, those of skill will immediately appreciate various other locking device configurations which may function in equally or perhaps more efficient ways to temporarily immobilize the carriage 38" relative to the rail 36". For example, alternative locking device configurations may include cam lever locking devices, detent or ratcheting members, magnets, pin-in-hole arrangements, and the like.

[0041] The end-to-end coupling arrangement for ganging one rail 36" to another so as to elongate the assembly 14" is here depicted as a keyhole-shaped female fitting 48" on one end of the rail 36" which is adapted to mate with a male leading end 50" which is illustrated in phantom at the far right side of Figure 9, Of course, many other εnd-to-end connectiøa schemes may be used to lengthen the assembly 14" in appropriate situations. Likewise, corner connectors (not shown) can also be used to join one rail 36" to another rail 36" to form an inside comer, an outside corner, a curve, or other non-linear orientation. [0042] A variation on the indicia 46" as illustrated here in Figure 9, wherein identifiers for a first spacing are indicated by the numeral 6 superimposed over a circular background. These may be considered first spacing indicia which are represented by regularly spaced icons visibly affixed to the rail 36" at a first narrow longitudinal spacing interval. These may then represent 6 inch spacings, for example. The carriage 38" may then include counter indicia 88 which correspond to these first spacing indicia icons as a similar numeral 6 superimposed over a circular background. If a floor installer desires a 6 inch spacing between the laser beams 20", each carriage 38" is then moved so that its counter indicia 88 aligns directly adjacent the first spacing indicia 46" on the rail 36". Similarly, a second spacing indicia is represented by regularly spaced icons visibly affixed to the rail 36" at a second wide longitudinal spacing interval. These may be represented by the numeral 8 set in a triangular background, or by the numeral 10 set in a triangular background, or by the numeral 12 set in a star background. Any one of these second spacing indicia represent a different calibration setting. Counter indicia 88 are likewise affixed to the carriage 38" so that, appropriate alignment or calibration can be quickly and easily achieved by a user in the field. In the example of Figure 9, the carriage 38" is shown aligned upon the rail 36" adjacent a second spacing indicia numeral 8 set in a square background. [0043] Of course, the assembly 14" will include a plurality of carriages 38", each supporting its own laser generating device 26". So that all of the laser generating devices 26" can be functionally implemented at the minimum spacing intervals, it is important that the overall longitudinal width of the carriages 38" be less than or equal to the first narrow longitudinal spacing interval which, in Figure 9, is represented by the numeral 6 set in a circular background. Thus, it is possible to position a carriage 38" at every one of the smallest spacing intervals scribed along the rail 36" because the overall longitudinal width of each carriage 38" is not greater then the smallest spacing interval. However, other spacing configurations may dictate a larger or smaller overall longitudinal width of each carriage 38".

[0044] hi Figure 10, a third alternative embodiment of the subject invention is illustrated, wherein triple prime designations are used for convenience to indicate like or corresponding parts to those introduced previously. This embodiment is intended to make use of readily available pieces of tongue and groove wood strip flooring to fashion the rail 36'". Various trade associations, including the National Wood Flooring Association and related associations and councils have established industry standards which generally assure that the groove and tongue features on the wood strip will comply with expected dimensional standards. In Figure 10, the tongue is illustrated at 90, whereas the groove is shown at 92. in this embodiment, the carriage 38'" generally resembles that described in connection with the second alternative embodiment of Figure 9, however, the one guide feature 40'" is adapted to engage the tongue 90 and the other guide feature 42'" registers within the groove 92. Preferably, these guide features 40'", 42'" are made from a stiff yet resilient material such as molded plastic or spring steel, which enables the carriage 38'" to be attached and removed from the rail 36'" midway along its length. Thus, the one guide feature 40'" includes a pry lip 94 with which a user can catch hold by fingertips or tool and resiliently flex the guide feature 40'" sufficiently away from the tongue 90 so as to facilitate attachment and removal.

[0045] Although not shown, it is fully contemplated that connectors may be used to gain multiple rails 36'" together in end-to-end fashion, or to bend around corners as in preceding examples. In this example, the locking device 82'" is again illustrated by a knob screw 84"' which interacts through a nut 86'" affixed to the body of the carriage 38'". The tip of the knob screw 84'" is shown including a spike 96 to quickly grab into the soft, wooden surface of the rail 36'". However, this embodiment of the locking device 82'" is merely exemplary, and may instead be formed by any of various other constructions and designs as mentioned previously.

[0046] Figure 11 is a perspective view depicting how the layout laser assembly 14 might be affixed in a vertical plane to project a grid pattern of laser light on a vertical wall 16. In this view, the ceiling is indicated at 98. Using attachment methods similar to those described above, together with the corner connector 64, the resulting cross-hatching pattern of laser stripes 20 may be used to identify low 58 and high 60 spots on the wall 16, as well as for establishing reference guides for the later placement of tile pieces or the like. [0047] Figure 12 is a perspective view showing the subject layout laser assembly 14 attached horizontally along the top of a wall 16 for projecting stripes of laser light along the ceiling surface 98. Again, attachment methods including screws 54, 74 or other devices can anchor the assembly 14 in position. The stripes of laser light 20 can be aligned along the underlying ceiling joists (not shown) or at other advantageous locations to aid the installer of a ceiling covering material.

[0048] Accordingly, a layout laser assembly 14, 14', 14", 14'" and installation method according to the subject invention will be especially beneficial to professional installers of wood strip and other flooring, wall and/or ceiling tile pieces to ensure that the pieces are attached at regular intervals and/or spaced appropriately apart to meet manufacturers' specifications. Furthermore, the assembly 14 can be used in the preparation stages to readily identify low 58 and high 60 spots prior to the actual laying of the wood strips 22, tiles or other floor/wall/ceiling covering numbers.

[0049] The foregoing invention has been described in accordance with the relevant legal standards, thus the description is exemplary rather than limiting in nature. Variations and modifications to the disclosed embodiment may become apparent to those skilled in the art and fall within the scope of the invention. Accordingly the scope of legal protection afforded this invention can only be determined by studying the following claims.

Claims

What is claimed is:

1. A layout laser assembly for creating a custom-spaced visual alignment system on a work surface consisting of plural parallel beams of collimated light stripes on the work surface, said assembly comprising: an elongated rail establishing a generally linear guide track along the length thereof; a plurality of optical devices for projecting respective beams of collimated light perpendicular to the length of said rail; and a carriage operatively associated with each of said plurality of optical devices, said carriage interacting with said guide track for repositioning placement along the length of said rail, whereby the spacings of the plural parallel beams of collimated light projecting from said rail can be custom-spaced one from another by moving each said carriage to a new selected position along the length of said guide track.

2. The assembly of Claim 1 further including a locking device for releasably securing each said carriage to said rail to temporarily immobilize said carriage in a custom-spaced position along the length of said rail.

3. The assembly of Claim 2 wherein said locking device includes a spring.

4. The assembly of Claim 2 wherein said locking device includes a knob screw.

5. The assembly of Claim 1 wherein said optical device includes an optical element for receiving a collimated main beam of light oriented parallel to the length of said rail and redirecting at least a portion of the collimated main beam to a perpendicular orientation.

6. The assembly of Claim 1 wherein said optical device includes a laser light generator.

7. The assembly of Claim 6 wherein said laser light generator includes an on/off switch.

8. The assembly of Claim 1 wherein said rail has first and second ends, one of said first and second ends including a male coupling feature and the other of said first and second ends including a female coupling feature, whereby said rail is able to connect in end-to-end fashion with another like rail by directly connecting said male coupling feature of one said rail with said female coupling feature of the other said rail.

9. The assembly of Claim 8 further including a light blocking flap associated with one of said first and second ends.

10. The assembly of Claim 8 further including a corner connector for joining said first end of one said rail to said second end of another said rail in a non-linear relationship.

11. The assembly of Claim 10 wherein said corner connector includes a mirror.

12. The assembly of Claim 1 further including a selectively dep lovable shade operatively associated with at least one of said optical devices.

13. The assembly of Claim 1 further including a leveling device for adjusting the vector of the collimated beam within a vertical plane without disrupting the perpendicular projection of the collimated beam relative to said rail.

14. The assembly of Claim 13 further including a level indicator.

15. The assembly of Claim 1 further including a first spacing indicia represented by regularly spaced icons visibly affixed to said rail at a first narrow longitudinal spacing interval, and a second spacing indicia represented by regularly spaced icons visibly affixed to said rail at a second wide longitudinal spacing interval which is greater than said first narrow longitudinal spacing interval.

16. The assembly of Claim 15 wherein each said carriage has a common overall longitudinal width as measured parallel to the length of said rail, and wherein said overall longitudinal width is not greater than said first narrow longitudinal spacing interval.

17. A method for affixing wood strips to a sub floor using regularly spaced-apart mechanical fasteners, said method comprising the steps of: providing a generally planar subfloor having opposed starting and ending sides; providing a plurality of individual wood strips having a common width; laying a first flooring course along the starting side of the subfloor by arranging a plurality of the wood strips in end-to-end fashion on the subfloor; generating a plurality of collimated beams of light from adjacent the ending side of the subfloor; orienting the plural beams of collimated light such that the beams are parallel to one another and project toward the starting side of the subfloor; creating visual intersection points on the first flooring course by crossing the plural beams of collimated light with the first flooring course; forcibly driving a mechanical fastener through the first flooring course and into the subfloor at each visual intersection point to anchor the first flooring course permanently to the subfloor; laying a second flooring course directly alongside the first flooring course by arranging a plurality of the wood strips in end-to-end fashion on the subfloor; creating visual intersection points on the second flooring course by crossing the plural beams of collimated light with the second flooring course; and forcibly driving a mechanical fastener through the second flooring course and into the subfloor at each visual intersection point to anchor the second flooring course permanently to the sub floor.

18. The method of Claim 17 wherein said step of orienting the plural beams includes adjusting the spacing between adjacent beams.

19. The method of Claim 18 wherein said step of adjusting the spacing includes maintaining a common spacing between all beams of collimated light.

20. The method of Claim 18 wherein said step of adjusting the spacing includes releasably securing the beams in an adjusted position to prevent unintended movement.

21. The method of Claim 17 wherein said step of generating a plurality of collimated beams of light includes manipulating the respective beams into a fan-shaped pattern contained within a generally vertical plane.

22. The method of Claim 17 wherein said step of generating a plurality of collimated beams of light includes dividing a single main beam into plural parallel beams using at least one optical element.

23. A layout laser device adapted to be used in concert with other like layout laser devices slidably mounted on an elongated rail, said layout laser device comprising: a carriage including at least two spaced guide features adapted to maintain said carriage in a translating motion condition while sliding longitudinally along the rail; a laser light generator affixed to said carriage for projecting a collimated beam of light perpendicularly relative to said guide features; and a locking device for releasably securing said carriage to the rail to temporarily immobilize said carriage in an adjusted position along the length of the rail.

24. The device of Claim 23 wherein the rail comprises a length of industry-standard tongue and groove wood strip flooring, and wherein said guide features include a male member adapted to register within the groove of the rail and a female member adapted to register around the tongue of the rail.

25. The device of Claim 24 wherein at least one of said male and female members is resiliently flexible so as to facilitate attachment and removal from the rail.