U.S. patent application number 17/453677 was filed with the patent office on 2022-02-24 for system, method and apparatus for drywall joint detection and measurement.
The applicant listed for this patent is CERTAINTEED GYPSUM, INC.. Invention is credited to Brice Dubost, Rachel Z. Pytel, Sidath S. Wijesooriya.
Application Number | 20220057196 17/453677 |
Document ID | / |
Family ID | |
Filed Date | 2022-02-24 |
United States Patent
Application |
20220057196 |
Kind Code |
A1 |
Dubost; Brice ; et
al. |
February 24, 2022 |
SYSTEM, METHOD AND APPARATUS FOR DRYWALL JOINT DETECTION AND
MEASUREMENT
Abstract
A system for visually enhancing a surface. For example, the
system may include an assembly that may be configured to project a
laser line across at least a portion of the surface. Versions of
the laser line may be projected at an angle of incidence relative
to a plane defined by the surface. For example, the angle of
incidence may be in a range of about 5 degrees to about 60 degrees.
In one version, the laser line may be substantially perpendicular
to a central axis of the surface. In addition, the laser line may
enable enhanced, qualitative user visualization of the surface and
non-planar distortion in the surface.
Inventors: |
Dubost; Brice; (Newton,
MA) ; Wijesooriya; Sidath S.; (Wayland, MA) ;
Pytel; Rachel Z.; (Newton, MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
CERTAINTEED GYPSUM, INC. |
Malvern |
PA |
US |
|
|
Appl. No.: |
17/453677 |
Filed: |
November 5, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15709669 |
Sep 20, 2017 |
11199399 |
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17453677 |
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62397127 |
Sep 20, 2016 |
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International
Class: |
G01B 11/25 20060101
G01B011/25; G06T 7/00 20060101 G06T007/00; G06T 7/521 20060101
G06T007/521; G06T 7/62 20060101 G06T007/62; G01B 11/30 20060101
G01B011/30 |
Claims
1. A method of preparing a surface, the method comprising: (a)
constructing a wall having panels that engage at intersections; (b)
detecting a planarity and non-planarity of the intersections, and
adjusting non-planar intersections into planar intersections; (c)
applying material to the planar intersections to conceal the planar
intersections and form joints; and then (d) detecting a planarity
and non-planarity of the joints, and adjusting non-planar joints
into planar joints.
2. The method of claim 1, wherein step (a) comprises fastening the
panels to a frame to form the wall.
3. The method of claim 1, wherein step (b) comprises: visually
enhancing a geometry of the intersections by projecting a laser
line across the intersections.
4. The method of claim 3, wherein the laser line is substantially
perpendicular to the intersections.
5. The method of claim 4, wherein the laser line enables enhanced,
qualitative user visualization of the intersections and non-planar
distortion in the intersections relative to a plane defined by the
wall.
6. The method of claim 1, wherein adjusting non-planar
intersections into planar intersections in step (b) comprises
moving the panels.
7. The method of claim 1, wherein step (b) comprises: (1)
projecting a laser image across the intersections; (2) positioning
or simulating a reference guide on the wall adjacent to the laser
image; (3) digitally imaging the laser image and the reference
guide; and (4) processing the digital images and quantifying the
geometry of the intersections based on the digital images,
parameters of the laser image and the reference guide, such that a
quality of the intersections is determined.
8. The method of claim 1, wherein the panels are drywall
panels.
9. The method of claim 8, wherein step (c) comprises at least one
of taping, applying plaster or joint compound, wiping, washing, and
wet or dry sanding the planar intersections.
10. The method of claim 1, wherein step (d) comprises: visually
enhancing a geometry of the joints by projecting a laser line
across the joints, the laser line is substantially perpendicular to
the joints.
11. The method of claim 10, wherein the laser line enables
enhanced, qualitative user visualization of the joints and
non-planar distortion in the joints relative to a plane defined by
the wall.
12. The method of claim 1, wherein step (d) comprises: (1)
projecting a laser image across the joints; (2) positioning or
simulating a reference guide on the wall adjacent to the laser
image; and (3) digitally imaging the laser image and the reference
guide.
13. The method of claim 12, wherein step (d) further comprises
processing the digital images and quantifying the geometry of the
joints based on the digital images such that a quality of the
joints is determined.
14. The method of claim 12, wherein step (d) further comprises
processing the digital images and quantifying the geometry of the
joints based on the parameters of the laser image such that a
quality of the joints is determined.
15. The method of claim 12, wherein step (d) further comprises
processing the digital images and quantifying the geometry of the
joints based on the reference guide such that a quality of the
joints is determined.
16. The method of claim 12, wherein step (d) further comprises
processing the digital images and quantifying the geometry of the
joints based digital images, parameters of the laser image and the
reference guide, such that a quality of the joints is
determined.
17. The method of claim 8, wherein adjusting non-planar joints into
planar joints in step (d) comprises wet or dry sanding.
18. The method of claim 8, wherein adjusting non-planar joints into
planar joints in step (d) comprises taping.
19. The method of claim 8, wherein adjusting non-planar joints into
planar joints in step (d) comprises applying plaster or joint
compound.
20. The method of claim 8, wherein adjusting non-planar joints into
planar joints in step (d) comprises wiping and washing the
non-planar joints.
Description
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application is a continuation of U.S. patent
application Ser. No. 15/709,669, entitled "SYSTEM, METHOD AND
APPARATUS FOR DRYWALL JOINT DETECTION AND MEASUREMENT," by Brice
Dubost et al., filed Sep. 20, 2017, which claims priority under 35
U.S.C. .sctn. 119(e) to U.S. Provisional Patent Application No.
62/397,127, entitled "SYSTEM, METHOD AND APPARATUS FOR DRYWALL
JOINT DETECTION AND MEASUREMENT," by Brice Dubost et al., filed
Sep. 20, 2016, which applications are assigned to the current
assignee hereof and incorporated herein by reference in their
entireties.
BACKGROUND OF THE INVENTION
Field of the Disclosure
[0002] The present invention relates in general to gypsum panels
and, in particular, to a system, method and apparatus for detecting
and measuring drywall joints.
Description of the Related Art
[0003] Conventional joints between drywall or wall board panels
include an intersection between panels. A joint also may include
any materials applied at or adjacent to the intersection to
increase its mechanical stability and to reduce the appearance of
the intersection.
[0004] Interior residential and commercial drywall joints typically
are completed at one of three different levels of quality or
finish. For example, a "Level 3" finish, as is known to those of
ordinary skill in the art, includes tape embedded in joint compound
at all joints and interior angles, which are immediately wiped with
a joint knife leaving a thin coating of joint compound over all
joints and interior angles. One separate coat of joint compound is
applied over all joints and interior angles. Fastener heads and
accessories are covered with two separate coats of joint compound.
The surface shall be smooth and free of tool marks and ridges. A
"Level 4" finish includes everything in a Level 3 finish, however
an additional separate coat of joint compound is applied over all
flat joints and one separate coat of joint compound is applied over
Interior angles. Fastener heads and accessories are covered with
three separate coats of joint compound. At the highest level of
quality, a "Level 5" finish includes everything in a Level 4
finish. In addition, a thin skim coat of joint compound or a
material manufactured especially for this purpose, is applied to
the entire surface.
[0005] Accordingly, conventional drywall levels of finish are
merely prescriptive in nature. They substantially require only a
list of steps to be completed, rather than being qualitatively or
quantitatively defined. Although prescriptive definitions of
drywall finishes are workable, more precise and accurate tools and
methods of defining different levels of drywall finishes continue
to be of interest.
SUMMARY
[0006] Embodiments of a system, method and apparatus for a laser
system for visually enhancing a geometry of a joint between panels
that form at least a portion of a wall are disclosed. For example,
the system may include an assembly configured to be positioned on a
surface other than the wall itself. The assembly may be configured
to project a laser line across at least a portion of the wall and
the joint. Versions of the laser line may be projected at an angle
of incidence relative to a plane defined by the wall. For example,
the angle of incidence may be in a range of about 5 degrees to
about 60 degrees. In one version, the laser line may be
substantially perpendicular to the joint. In another version, the
laser line may be substantially perpendicular to a central axis of
a surface that may or may not include the joint. In addition, the
laser line may enable enhanced, qualitative user visualization of
the joint and non-planar distortion in the joint relative to the
plane defined by the wall.
[0007] Embodiments of a system for measuring a geometry of a joint
between panels that form at least a portion of a wall also are
disclosed. For example, the system may include an assembly
configured to be positioned on a surface other than the wall
itself. The assembly may be configured to project a laser line
across at least a portion of the wall and the joint. The laser line
may be projected at an angle of incidence relative to a plane
defined by the wall. For example, the angle of incidence can be in
a range of about 5 degrees to about 60 degrees. The laser line also
may be substantially perpendicular to the joint. In a version, the
laser line can enable enhanced, qualitative user visualization of
the joint and non-planar distortion in the joint relative to the
plane defined by the wall. The system can include a reference guide
configured to be located on the wall adjacent to the laser line.
The reference guide can include a physical reference guide, a
virtual reference guide, or a combination thereof. The system may
have a camera configured to digitally image the laser line and the
reference guide. In addition, the system may include a computer
configured to be coupled to the camera and quantify the geometry of
the wall based on the digital images, parameters of the laser line,
the reference guide and a distance between the camera and the wall,
such that a quality of the joint is measured.
[0008] Embodiments of a method of assessing a geometry of a joint
between drywall panels on a wall may include the following:
projecting a laser image across the joint; positioning a reference
guide on the wall adjacent to the laser image; digitally imaging
the laser image and the reference guide; and processing the digital
images and quantifying the geometry of the joint based on the
digital images, parameters of the laser image and the reference
guide, such that a quality of the joint is determined.
[0009] In an alternate embodiment, a method of preparing a surface
may include constructing a wall having panels that engage at
intersections; detecting a planarity and non-planarity of the
intersections, and adjusting non-planar intersections into planar
intersections; applying material to the planar intersections to
conceal the planar intersections and form joints; and then
detecting a planarity and non-planarity of the joints, and
adjusting non-planar joints into planar joints.
[0010] The foregoing and other objects and advantages of these
embodiments will be apparent to those of ordinary skill in the art
in view of the following detailed description, taken in conjunction
with the appended claims and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] So that the manner in which the features and advantages of
the embodiments are attained and can be understood in more detail,
a more particular description may be had by reference to the
embodiments thereof that are illustrated in the appended drawings.
However, the drawings illustrate only some embodiments and
therefore are not to be considered limiting in scope as there may
be other equally effective embodiments.
[0012] FIG. 1 is a schematic front view of an embodiment of a laser
system.
[0013] FIG. 2 is a schematic side view of the laser system of FIG.
1.
[0014] FIG. 3 is a side view of another embodiment of a laser
system.
[0015] FIG. 4 is an enlarged, schematic side view of still another
embodiment of a laser system.
[0016] FIG. 5 is a schematic side view of the laser system of FIG.
4.
[0017] FIG. 6 is a schematic front view of the laser system of FIG.
5.
[0018] FIG. 7 is a schematic side view of another embodiment of a
laser system.
[0019] FIG. 8 is a schematic front view of the laser system of FIG.
7.
[0020] FIG. 9 is a schematic side view of another embodiment of a
laser system.
[0021] FIG. 10 is a schematic front view of the laser system of
FIG. 9.
[0022] FIGS. 11A, 11B and 11C are schematic side, top and isometric
views, respectively, of another embodiment of a laser system.
[0023] FIG. 12 illustrates an exemplary portable device executing a
plurality of exemplary applications.
[0024] The use of the same reference symbols in different drawings
indicates similar or identical items.
DETAILED DESCRIPTION
[0025] Embodiments of a system, method and apparatus for drywall
joint detection and measurement are disclosed. As will be described
herein, the claimed invention can enable user visualization of
something (e.g., a joint) that is difficult to see or not readily
visible to become readily visible and, if desired, qualitatively
and/or quantitatively evaluated.
[0026] In some embodiments, a system for visually enhancing a
geometry of a joint 103 (FIGS. 1 and 2) between panels 105 that
form at least a portion of a wall 107 is disclosed. In an example,
the system may include an assembly 101 configured to be positioned
on a surface 109. The surface 109 may comprise a surface other than
the wall 107 itself. The assembly 101 may be configured to project
a laser line 111 across at least a portion of the wall 107 and the
joint 103. Although a vertical wall is shown in the drawings, the
wall 107 could be a horizontal wall, a ceiling, or an angled wall,
such as a gabled wall or gabled ceiling. Accordingly, the laser
line 111 can be horizontal and the system may be configured to
visually enhance the geometry of a vertical joint. Alternatively,
the laser line can be vertical and the system may be configured to
visually enhance the geometry of a horizontal joint. In other
versions, the joint may not be horizontal and nor vertical, and the
laser line can still be perpendicular to the joint regardless of an
orientation of the joint. The laser line 111 may be a continuous
line or a discontinuous line, such as a dashed or dotted line.
[0027] While the assembly 101 is shown resting on a floor in FIGS.
1 and 2, the assembly 101 may be affixed to a tripod or other
stand. Moreover, the assembly 101 may be mounted on, or otherwise
hung from, a ceiling. In such an aspect, the assembly 101 may be
mounted upside down and may project the laser line 111 in a
downward direction away from the assembly 101. In another aspect,
the assembly 101 can be mounted on a wheeled stand that a user, or
finisher, can easily move as he or she moves along the wall to
apply wall compound. Moreover, the assembly 101 can be mounted on a
bracket, or clamp, that can be affixed to scaffolding, a ladder, a
lift, or other similar device. The bracket, or clamp, can be
magnetic or mechanical. In yet another aspect, the assembly 101 can
be sufficiently small in size that it can be mounted to the
finisher, e.g., to the belt of the finisher or on a helmet worn by
the finisher.
[0028] Further, the laser line 111 may include multiple horizontal
lines or multiple vertical lines. In the alternative, the laser
line 111 may include a grid of horizontal lines and vertical lines.
The grid lines may be spaced apart a predetermined
distance--vertically and horizontally. For example, the grid lines
may have a grid spacing that is greater than or equal to 0.5 feet.
In another aspect, the grid spacing may be greater than or equal to
1.0 feet, such as greater than or equal 1.5 feet, greater than or
equal to 2.0 feet, greater than or equal to 2.5 feet, greater than
or equal to 3.0 feet. In another aspect, the grid spacing may be
less than or equal to 8.0 feet. Further, the grid spacing may be
less than or equal to 7.5 feet, such as less than or equal to 7.0
feet, less than or equal to 6.5 feet, less than or equal to 6.0
feet, less than or equal to 5.5 feet, less than or equal to 5.0
feet, less than or equal to 4.5 feet, less than or equal to 4.0
feet, or less than or equal to 3.5 feet. It is to be understood
that the grid spacing can be with a range between, and including,
any of the minimum or maximum values for the grid spacing described
herein.
[0029] In another aspect, the laser line 111 can include a single
line that scans up and down or side to side. Further, the laser
line 111 can include a plurality of lines that are concentrated at
eye level to the user.
[0030] Although the system is illustrated with a single joint 103,
the laser system also may be configured to simultaneously visually
enhance geometries of a plurality of joints 103. Moreover, the
system may be configured to simultaneously visually enhance a wall
geometry of an entirety of the wall 107. Depending on the
application, the assembly 101 may be configured to be positioned
against the wall 107 or away from the wall 107. For example, the
assembly 101 may positioned at a distance away from the wall 107 in
a range of, e.g., about 0 inches to about 48 inches.
[0031] Embodiments of the laser line 111 may include a length L,
such as a prescribed length. For example, the length of the laser
line 111 can be at least about 0.1 meters, such as at least about
0.25 meters, or even at least about 0.5 meters. In other versions,
the length of laser line 111 can be not greater than about 10
meters, such as not greater than about 9 meters, not greater than
about 8 meters, not greater than about 7 meters, not greater than
about 6 meters, not greater than about 5 meters, not greater than
about 4 meters, or even not greater than about 3 meters. Other
versions of the length of laser line 111 can be in a range between
any of these values.
[0032] In some versions, the assembly 101 may emit the laser line
111 at a fan angle 112 (FIG. 1). For example, the fan angle 112 can
be at least about 10 degrees, such as at least about 20 degrees, or
even at least about 30 degrees. In other versions, the fan angle
112 can be not greater than about 160 degrees, such as not greater
than about 150 degrees, or even not greater than about 140 degrees.
Other versions of the fan angle 112 can be in a range between any
of these values.
[0033] In some versions, the laser line 111 may be projected at an
angle of incidence 113 (FIG. 2) relative to a plane defined by the
wall 107. Embodiments of the angle of incidence 113 can be at least
about 1 degree. In other versions, the angle of incidence 113 can
be at least about 2 degrees, such as at least about 3 degrees, at
least about 4 degrees, at least about 5 degrees, at least about 10
degrees, at least about 15 degrees, or even at least about 20
degrees. In other embodiments, the angle of incidence 113 can be
not greater than about 60 degrees. In other examples, the angle of
incidence 113 can be not greater than about 55 degrees, such as not
greater than about 50 degrees, not greater than about 45 degrees,
or even not greater than about 40 degrees. In still other
embodiments, the angle of incidence 113 can be in a range between
any of these values.
[0034] In some versions, the laser line 111 can be substantially
perpendicular to the joint 103. Embodiments of the laser line 111
may enable enhanced, qualitative user visualization of the joint
103, and non-planar distortion in the joint 103 relative to the
plane defined by a nominal surface of the wall 107. Versions of the
laser line 111 may enable visualization of distortion as a slope of
the joint 103. For example, the slope may be defined as a maximum
dimension D (shown exaggerated in FIG. 2; e.g., a protrusion or a
recession) of the joint 103 that is perpendicular to the plane
defined by the wall 107, divided by half of a maximum width W (FIG.
1) of the joint 103 that is parallel to the plane and perpendicular
to an intersection between the panels 105. In one example, the
slope can be not less than about 0.00001 mm. In another example,
that distortion (e.g., the maximum dimension D) can be as small as
0.1 mm from the plane defined by the wall 107.
[0035] In some versions, the assembly 101 also may include leveling
means 115 (FIG. 3). The leveling means 115 may be configured to
enable a user to manual level (e.g., with respect to gravity or
vertical) the assembly 101. For example, the leveling means 115
comprises elevation screws. In other versions, the assembly 101 may
be configured to be self-leveling. In some examples, a laser 117
(FIG. 4) of the assembly 101 may be mounted to a pendulum 119. The
pendulum 119 may include one, two or three degrees of freedom.
Versions of the pendulum 119 may include magnetic braking. An
example of magnetic braking is depicted at:
http://video.mit.edu/watch/mit-physics-demo-pendulum-and-magnet-3078/,
which is incorporated herein by reference in its entirety.
[0036] Embodiments of the assembly 101 may include a mirror 120
(FIG. 3). For example, mirror 120 may be configured to redirect the
laser line 111 at the wall 107. In some versions, the mirror 120
may be oriented at an angle with respect to a mean plane of the
wall 107. In some versions, the angle of the mirror 120 can be in a
range of about 45 degrees to about 60 degrees.
[0037] As shown in FIGS. 11A-11C, embodiments of the assembly 101
also may include a wall alignment feature 121. The wall alignment
feature 121 may be configured to set at least one of distance of
the assembly 101 from the wall 107 and orientation of the assembly
101 relative to the wall 107. For example, the wall alignment
feature 121 may include extensions configured to engage the wall
107. In some versions, the extensions may be configured to engage
the wall 107 and set orientation by perpendicularly aligning the
assembly 101 relative to the wall 107. In one embodiment, the
extensions may comprise retractable rods.
[0038] As shown in FIG. 2, the system also may include a camera 131
and a computer 133 coupled to the camera 131. In some versions, the
camera 131 and computer 133 may be combined in a single device,
such as a smart phone.
[0039] In FIG. 12, an embodiment of a portable device 102 may
include a wearable smart phone communications device (e.g.,
computer 133) that executes multiple applications. For example,
portable device 133 executes a wireless communications application
(e.g., telephony application 104), a content delivery application
106 (e.g., camera 131), and other applications 108. Computer 133
may include a battery system 408, and a processor 410 configured to
execute instructions stored in memory system 412. Portable device
102 may include subscriber identity module 414 and connectivity
system 406 to facilitate wireless or wired communications
consistent with one or more protocols for wide area networks. Such
networks may include a satellite or terrestrial wide area network
using, e.g., Long-Term Evolution (LTE), second-Generation (2G),
third-Generation (3G), fourth-generation (4G), LTE-Advanced, LTE in
unlicensed spectrum (LTE-U), Global System for Mobile
Communications (GSM), Enhanced Data rates for GSM Evolution (EDGE),
High Speed Packet Access (HSPA), Universal Mobile
Telecommunications System (UMTS), and Worldwide Interoperability
for Microwave Access (WiMax) wireless communications, or other
wireless communications protocols, which use one or more of Code
Division Multiple access (CDMA), Time Division Multiple Access
(TDMA), Frequency Division Multiple Access (FDMA), Wideband CDMA
(WCDMA), Orthogonal Frequency Division Multiple Access (OFDMA), or
other suitable communications techniques), local area networks
(e.g., Institute of Electrical and Electronics Engineers (IEEE)
802.11 standard-compliant networks), or other network protocols.
Sensors 402 and display system 404 may be configured to communicate
with a user, although other input and output devices (e.g.,
keyboard) may be included.
[0040] Examples of the computer 133 may be configured to quantify
the geometry of the joint 103 based on a digital image from the
camera 131. In some versions, the geometry may be quantified by
expressing the non-planar distortion of the joint 103 along the
laser line 111, and defining a width W (FIG. 1) of the joint 103
and a slope of edges of the joint 103.
[0041] Embodiments of the system may further comprise a reference
guide. For example, the reference guide may be configured to be
located on the wall 107 adjacent to the laser line 111.
Alternatively, the reference guide may be a virtual reference guide
that is simulated by the computer 131. Versions of the reference
guide may include one or more of the following: an object
configured to be physically mounted to the wall (e.g., ruler); a
pre-defined image projected on the wall (e.g., fiducial marker);
and a laser image projected on the wall. In one example, the laser
image may be configured to be analyzed by a computer using a Hough
transform to retrieve perspective information and/or line
location.
[0042] The computer 133 may be configured to be coupled to the
camera 131 and quantify the geometry of the wall 107 based on the
digital images, parameters of the laser line 111, the reference
guide and a distance between the camera 131 and the wall 107, such
that a quality of the joint 103 is measured. Examples of the
parameters of the laser line 111 may include length, non-linear
distortion, etc. See, e.g.,
https://www.picotronic.de/picopage/en/product/detail/code/70115369
for an example. The angle of camera 131 may be orthogonal to a mean
plane of the wall 107.
[0043] As shown in FIGS. 4-6, the assembly 101 may include a
plurality of lasers 117. Thus, in some examples, the laser image of
the reference guide may include a plurality of laser images, such
as at least 3 laser images. In the illustrated embodiment, the
laser image comprises additional laser lines 135. Some versions of
the additional laser lines 135 may be parallel to each other.
Optionally, the additional laser lines 135 may be configured to be
substantially perpendicular to the joint 103. Alternatively, the
assembly 101 may consist of only one laser 117.
[0044] As shown in FIGS. 7 and 8, the additional laser lines 135
may be at different angles with respect to the assembly 101. In an
example, each of the additional laser lines 135 may be at an angle
of separation relative to an adjacent laser line 135, and the
angles of separation can be identical, as shown. In contrast, the
additional laser lines 135 can be at a same angle with respect to
the assembly 101, as shown in FIGS. 4 and 5.
[0045] FIGS. 9 and 10 depict an embodiment of the system wherein
the laser image comprises a grid 141 of laser dots. In an example,
the grid 141 of laser dots may comprise a wavelength of light that
differs from that of the laser line 111. In some versions,
horizontal and vertical distances between the laser dots may be
configured to be calculated by the computer 133 (FIG. 2) based on
the digital image from the camera 131.
[0046] In some embodiments of the system, the assembly 101 may be
configured to not rotate about an axis perpendicular to the surface
109 on which the assembly 101 is positioned. Embodiments of a
method of assessing a geometry of a joint 103 between drywall
panels 105 on a wall 107 also is disclosed. For example, the method
may include projecting a laser image across the joint 103;
positioning a reference guide (e.g., such as those described
herein) on the wall 107 adjacent to the laser image; digitally
imaging the laser image and the reference guide; and processing the
digital images and quantifying the geometry of the joint 103 based
on the digital images, parameters of the laser image and the
reference guide, such that a quality of the joint 103 is
determined.
[0047] In some versions, the projecting step may include projecting
a plurality of laser images across the joint 103. Embodiments of
the positioning step may include at least one of: physically
mounting an object to the wall; projecting a pre-defined image
projected on the wall; and projecting a laser image on the wall. In
an example, the digitally imaging step may comprise using a camera
131, and the final step may include quantifying the geometry of the
joint 103 further based on a distance between the camera 131 and
the wall 107. Alternatively, a geometry of a plurality of joints,
or a geometry of an entirety of the wall also may be
quantified.
[0048] In another embodiment, a method of preparing a surface is
disclosed. For example, the method may include constructing a wall
107 having panels 105 that engage at intersections; detecting a
planarity and non-planarity of the intersections, and adjusting
non-planar intersections into planar intersections (e.g., by moving
the panels); applying material to the planar intersections to
conceal the planar intersections and form joints; and then
detecting a planarity and non-planarity of the joints, and
adjusting non-planar joints into planar joints.
[0049] In some versions, the constructing step may include
fastening the panels 105 to a frame to form the wall 107. The
detecting steps may include visually enhancing a geometry of the
intersections or joints by projecting a laser line 111 across the
intersections or joints, the laser line is substantially
perpendicular to the intersections or joints, and the laser line
enables enhanced, qualitative user visualization of the
intersections or joints and non-planar distortion in the
intersections or joints relative to a plane defined by the wall
107. Versions of the applying material step and adjusting step may
include at least one of taping, applying plaster or joint compound,
wiping, washing, and wet or dry sanding the planar
intersections.
[0050] It can be appreciated that the system for visually enhancing
a geometry of a joint as described herein can be calibrated to
various finishing tools, e.g., a drywall flat box or other drywall
finishing box. The system can provide recommendations to the
finishing tool if a problem is detected. For example, if a
particular joint is underfilled, the system can instruct a finisher
to set the finishing tool to "4" and re-coat the joint. In another
example, if one side of a particular joint is low, the system can
instruct the finisher to add compound to the low side of the joint.
By inputting the type of finishing box being used, a type of joint
compound being used, or a combination thereof, the system will be
able to provide instructions to a particular finishing tool based
on the type of finishing tool being used and based on the type of
joint compound being used.
[0051] It can be appreciated that the system described herein can
also be used to check the flatness of other objects. For example,
the system can be used to check the forward alignment of the front
faces of adjacent studs. Further, the system can be used to check
the flatness of drywall prior to coating the drywall with compound.
In another aspect, the system can be used to check the level of
insulation fill, i.e., whether sprayed or blown-in insulation
completely fills the volume between adjacent studs up to the faces
of the studs. In still another aspect, the system can be used to
check the flatness or straightness of two surfaces that meet at a
corner and check that the corner has a consistent angle along the
length of the corner. For any of the uses described herein, the
system can provide a visual check and quantify whether the visual
check passes or fails a predetermined threshold selected by a
user.
[0052] Still other versions may include one or more of the
following embodiments:
[0053] Embodiment 1. A laser system for visually enhancing a
geometry of a surface, the system comprising:
[0054] an assembly configured to project a laser line across at
least a portion of the surface, the laser line is projected at an
angle of incidence relative to a plane defined by the surface, the
angle of incidence is in a range of about 1 degree to about 60
degrees, the laser line is substantially perpendicular to a central
axis of the surface, and the laser line enables enhanced,
qualitative user visualization of the surface and non-planar
distortion in the surface.
[0055] Embodiment 2. The laser system of any of these embodiments,
wherein the surface includes a joint between two gypsum panels, a
wall, a face of one or more wall studs, a surface of insulation, or
a combination thereof.
[0056] Embodiment 3. The laser system of any of these embodiments,
wherein the wall comprises a vertical wall, a ceiling, or an angled
wall.
[0057] Embodiment 4. The laser system of any of these embodiments,
wherein the assembly comprises a plurality of lasers.
[0058] Embodiment 5. The laser system of any of these embodiments,
wherein the assembly further comprises leveling means configured to
enable a user to manual level the assembly.
[0059] Embodiment 6. The laser system of any of these embodiments,
wherein the leveling means comprises elevation screws.
[0060] Embodiment 7. The laser system of any of these embodiments,
wherein the assembly is configured to be self-leveling.
[0061] Embodiment 8. The laser system of any of these embodiments,
wherein a laser of the assembly is mounted to a pendulum.
[0062] Embodiment 9. The laser system of any of these embodiments,
wherein the pendulum is magnetically braked.
[0063] Embodiment 10. The laser system of any of these embodiments,
wherein the pendulum has two degrees of freedom.
[0064] Embodiment 11. The laser system of any of these embodiments,
wherein the assembly further comprises a surface alignment feature
configured to set at least one of distance of the assembly from the
surface and orientation of the assembly relative to the
surface.
[0065] Embodiment 12. The laser system of any of these embodiments,
wherein the surface alignment feature comprises extensions
configured to engage the surface.
[0066] Embodiment 13. The laser system of any of these embodiments,
wherein the extensions are configured to engage the surface and set
orientation by perpendicularly aligning the assembly relative to
the surface.
[0067] Embodiment 14. The laser system of any of these embodiments,
wherein the extensions comprise retractable rods.
[0068] Embodiment 15. The laser system of any of these embodiments,
wherein the laser line has a length in a range of about 0.1 meters
to about 10 meters.
[0069] Embodiment 16. The laser system of any of these embodiments,
wherein the assembly emits the laser line at a fan angle in a range
of about 10 degrees to about 160 degrees.
[0070] Embodiment 17. The laser system of any of these embodiments,
wherein the laser system is configured to simultaneously visually
enhance geometries of a plurality of joints.
[0071] Embodiment 18. The laser system of any of these embodiments,
wherein the laser system is configured to simultaneously visually
enhance a wall geometry of an entirety of the wall.
[0072] Embodiment 19. The laser system of any of these embodiments,
wherein the laser line is horizontal and the system is configured
to visually enhance the geometry of a vertical joint.
[0073] Embodiment 20. The laser system of any of these embodiments,
wherein the laser line is vertical and the system is configured to
visually enhance the geometry of a horizontal joint.
[0074] Embodiment 21. The laser system of any of these embodiments,
wherein the joint is not horizontal and not vertical, and the laser
line is perpendicular to the joint regardless of an orientation of
the joint.
[0075] Embodiment 22. The laser system of any of these embodiments,
wherein the assembly comprises a mirror configured to redirect the
laser line at the surface.
[0076] Embodiment 23. The laser system of any of these embodiments,
wherein the mirror is oriented at an angle with respect to a mean
plane of the surface, and the angle is in a range of about 45
degrees to about 60 degrees.
[0077] Embodiment 24. The laser system of any of these embodiments,
wherein the laser line enables visualization of distortion as a
slope of the surface, and the slope is defined as a maximum
dimension of the joint that is perpendicular to the plane defined
by the wall, divided by half of a maximum width of the joint that
is parallel to the plane and perpendicular to an intersection
between the panels.
[0078] Embodiment 25. The laser system of any of these embodiments,
wherein the slope is not less than about 0.00001.
[0079] Embodiment 26. The laser system of any of these embodiments,
further comprising a camera and a computer coupled to the camera,
wherein the computer is configured to quantify the geometry of the
joint based on a digital image from the camera.
[0080] Embodiment 27. The laser system of any of these embodiments,
wherein the geometry is quantified by expressing the non-planar
distortion of the joint along the laser line, and defining a width
of the joint and a slope of edges of the joint.
[0081] Embodiment 28. The laser system of any of these embodiments,
wherein the assembly is configured to be positioned away from the
surface at a distance in a range of about 0 inches to about 48
inches.
[0082] Embodiment 29. The laser system of any of these embodiments,
further comprising a reference guide configured to be located on
the surface adjacent to the laser line.
[0083] Embodiment 30. The laser system of any of these embodiments,
wherein the reference guide comprises at least one of: [0084] an
object configured to be physically mounted to the surface; [0085] a
pre-defined image projected on the surface; and [0086] a laser
image projected on the surface.
[0087] Embodiment 31. The laser system of any of these embodiments,
wherein the laser image is configured to be analyzed by a computer
using a Hough transform.
[0088] Embodiment 32. The laser system of any of these embodiments,
wherein the laser image comprise at least 3 laser images.
[0089] Embodiment 33. The laser system of any of these embodiments,
wherein the laser image comprises additional laser lines.
[0090] Embodiment 34. The laser system of any of these embodiments,
wherein the additional laser lines are parallel to each other.
[0091] Embodiment 35. The laser system of any of these embodiments,
wherein the additional laser lines are configured to be
substantially perpendicular to the joint.
[0092] Embodiment 36. The laser system of any of these embodiments,
wherein the additional laser lines are at different angles with
respect to the assembly.
[0093] Embodiment 37. The laser system of any of these embodiments,
wherein each of the additional laser lines are at an angle of
separation relative to an adjacent laser line, and the angles of
separation are identical.
[0094] Embodiment 38. The laser system of any of these embodiments,
wherein the additional laser lines are at a same angle with respect
to the assembly.
[0095] Embodiment 39. The laser system of any of these embodiments,
wherein the laser image comprises a grid of laser dots.
[0096] Embodiment 40. The laser system of any of these embodiments,
wherein the laser dots comprise a wavelength of light that differs
from that of a laser line.
[0097] Embodiment 41. The laser system of any of these embodiments,
wherein horizontal and vertical distances between the laser dots
are configured to be calculated by a computer based on a digital
image from a camera.
[0098] Embodiment 42. The laser system of any of these embodiments,
wherein the assembly does not rotate about an axis perpendicular to
the surface on which the assembly is positioned.
[0099] Embodiment 43. The laser system of any of these embodiments,
wherein the assembly consists of only one laser.
[0100] Embodiment 44. A system for measuring a geometry of a
surface, the system comprising: [0101] an assembly configured to
project a laser line across at least a portion of the surface, the
laser line is projected at an angle of incidence relative to a
plane defined by the surface, the angle of incidence is in a range
of about 1 degree to about 60 degrees, the laser line is
substantially perpendicular to a central axis of the surface, and
the laser line enables enhanced, qualitative user visualization of
the surface and non-planar distortion in the surface; and [0102] a
reference guide configured to be located on the surface or
simulated adjacent to the laser line.
[0103] Embodiment 45. The system of any of these embodiments,
further comprising [0104] a camera configured to digitally image
the laser line and the reference guide; and 1
[0105] a computer configured to be coupled to the camera and
quantify the geometry of the surface based on the digital images,
parameters of the laser line, the reference guide and a distance
between the camera and the surface, such that a quality of the
surface is measured.
[0106] Embodiment 46. The system of any of these embodiments,
wherein the reference guide comprises a virtual reference
guide.
[0107] Embodiment 47. The system of any of these embodiments,
wherein the surface is a joint between two adjacent gypsum panels
and the geometry is quantified by expressing the non-planar
distortion of the joint along the laser line, defining a width of
the joint, measuring a slope of edges of the joint, or a
combination thereof.
[0108] Embodiment 48. The system of any of these embodiments,
wherein the assembly comprises a plurality of lasers.
[0109] Embodiment 49. The system of any of these embodiments,
wherein the assembly further comprises leveling means configured to
enable a user to manual level the assembly.
[0110] Embodiment 50. The system of any of these embodiments,
wherein the leveling means comprises elevation screws.
[0111] Embodiment 51. The system of any of these embodiments,
wherein the assembly is configured to be self-leveling.
[0112] Embodiment 52. The system of any of these embodiments,
wherein a laser of the assembly is mounted to a pendulum.
[0113] Embodiment 53. The system of any of these embodiments,
wherein the pendulum is magnetically braked.
[0114] Embodiment 54. The system of any of these embodiments,
wherein the pendulum has two degrees of freedom.
[0115] Embodiment 55. The system of any of these embodiments,
wherein the assembly further comprises a surface alignment feature
configured to set at least one of distance of the assembly from the
surface and orientation of the assembly relative to the
surface.
[0116] Embodiment 56. The system of any of these embodiments,
wherein the surface alignment feature comprises extensions
configured to engage the wall.
[0117] Embodiment 57. The system of any of these embodiments,
wherein the extensions are configured to engage the surface and set
orientation by perpendicularly aligning the assembly relative to
the surface.
[0118] Embodiment 58. The system of any of these embodiments,
wherein the extensions comprise retractable rods.
[0119] Embodiment 59. The system of any of these embodiments,
wherein the laser line has a length in a range of about 0.1 meters
to about 5 meters.
[0120] Embodiment 60. The system of any of these embodiments,
wherein the assembly emits the laser line at a fan angle in a range
of about 10 degrees to about 160 degrees.
[0121] Embodiment 61. The system of any of these embodiments,
wherein the system is configured to simultaneously visually enhance
geometries of a plurality of joints.
[0122] Embodiment 62. The system of any of these embodiments,
wherein the system is configured to simultaneously visually enhance
a wall geometry of an entirety of the wall.
[0123] Embodiment 63. The system of any of these embodiments,
wherein the laser line is horizontal and the system is configured
to visually enhance the geometry of a vertical joint.
[0124] Embodiment 64. The system of any of these embodiments,
wherein the laser line is vertical and the system is configured to
visually enhance the geometry of a horizontal joint.
[0125] Embodiment 65. The system of any of these embodiments,
wherein the joint is not horizontal and is not vertical, and the
laser line is perpendicular to the joint regardless of an
orientation of the joint.
[0126] Embodiment 66. The system of any of these embodiments,
wherein the assembly comprises a mirror configured to redirect the
laser line at the surface.
[0127] Embodiment 67. The system of any of these embodiments,
wherein the mirror is oriented at an angle with respect to a mean
plane of the surface, and the angle is in a range of about 45
degrees to about 60 degrees.
[0128] Embodiment 68. The system of any of these embodiments,
wherein the assembly is configured to be positioned away from the
surface at a distance in a range of about 0 inches to about 48
inches.
[0129] Embodiment 69. The system of any of these embodiments,
wherein the reference guide comprises at least one of: [0130] an
object configured to be physically mounted to the surface; [0131] a
pre-defined image projected on the surface; and 1
[0132] a laser image projected on the surface.
[0133] Embodiment 70. The system of any of these embodiments,
wherein the laser image comprise at least 3 laser images.
[0134] Embodiment 71. The system of any of these embodiments,
wherein the laser image comprises additional laser lines.
[0135] Embodiment 72. The system of any of these embodiments,
wherein the additional laser lines are parallel to each other.
[0136] Embodiment 73. The system of any of these embodiments,
wherein the additional laser lines are configured to be
substantially perpendicular to the joint.
[0137] Embodiment 74. The system of any of these embodiments,
wherein the additional laser lines are at different angles with
respect to the assembly.
[0138] Embodiment 75. The system of any of these embodiments,
wherein each of the additional laser lines are at an angle of
separation relative to an adjacent laser line, and the angles of
separation are identical.
[0139] Embodiment 76. The system of any of these embodiments,
wherein the additional laser lines are at a same angle with respect
to the assembly.
[0140] Embodiment 77. The system of any of these embodiments,
wherein the laser image comprises a grid of laser dots.
[0141] Embodiment 78. The system of any of these embodiments,
wherein the laser dots comprises a wavelength of light that differs
from that of a laser line.
[0142] Embodiment 79. The system of any of these embodiments,
wherein horizontal and vertical distances between the laser dots
are configured to be calculated by a computer based on the digital
image from the camera.
[0143] Embodiment 80. The system of any of these embodiments,
wherein the camera and the computer are combined in a single
device.
[0144] Embodiment 81. A method of assessing a geometry of a joint
between drywall panels on a wall, the method comprising: [0145] (a)
projecting a laser image across the joint; [0146] (b) positioning
or simulating a reference guide on the wall adjacent to the laser
image; [0147] (c) digitally imaging the laser image and the
reference guide; and [0148] (d) processing the digital images and
quantifying the geometry of the joint based on the digital images,
parameters of the laser image and the reference guide, such that a
quality of the joint is determined.
[0149] Embodiment 82. The method of any of these embodiments,
wherein step (a) comprises projecting a plurality of laser images
across the joint.
[0150] Embodiment 83. The method of any of these embodiments,
wherein step (b) comprises at least one of: [0151] physically
mounting an object to the wall; [0152] projecting a pre-defined
image projected on the wall; and [0153] projecting a laser image on
the wall.
[0154] Embodiment 84. The method of any of these embodiments,
wherein step (c) comprises using a camera, and step (d) comprises
quantifying the geometry of the joint further based on a distance
between the camera and the wall.
[0155] Embodiment 85. The method of any of these embodiments,
wherein step (d) comprises quantifying a geometry of a plurality of
joints.
[0156] Embodiment 86. The method of any of these embodiments,
wherein step (d) comprises quantifying a geometry of an entirety of
the wall.
[0157] Embodiment 87. The method of any of these embodiments,
wherein the laser image is projected from an assembly, and the
method further comprises the assembly self-leveling.
[0158] Embodiment 88. The method of any of these embodiments,
wherein the laser image is projected from an assembly, and the
method further comprises the assembly magnetically-braking.
[0159] Embodiment 89. The method of any of these embodiments,
wherein the laser image is projected from an assembly, and the
method further comprises aligning the assembly perpendicular to the
wall.
[0160] Embodiment 90. The method of any of these embodiments,
wherein the laser image is a laser line.
[0161] Embodiment 91. A method of preparing a surface, the method
comprising: [0162] (a) constructing a wall having panels that
engage at intersections; [0163] (b) detecting a planarity and
non-planarity of the intersections, and adjusting non-planar
intersections into planar intersections; [0164] (c) applying
material to the planar intersections to conceal the planar
intersections and form joints; and then [0165] (d) detecting a
planarity and non-planarity of the joints, and adjusting non-planar
joints into planar joints.
[0166] Embodiment 92. The method of any of these embodiments,
wherein step (a) comprises fastening the panels to a frame to form
the wall.
[0167] Embodiment 93. The method of any of these embodiments,
wherein step (b) comprises: [0168] visually enhancing a geometry of
the intersections by projecting a laser line across the
intersections, the laser line is substantially perpendicular to the
intersections, and the laser line enables enhanced, qualitative
user visualization of the intersections and non-planar distortion
in the intersections relative to a plane defined by the wall.
[0169] Embodiment 94. The method of any of these embodiments,
wherein adjusting non-planar intersections into planar
intersections in step (b) comprises moving the panels.
[0170] Embodiment 95. The method of any of these embodiments,
wherein step (b) comprises: [0171] (1) projecting a laser image
across the intersections; [0172] (2) positioning or simulating a
reference guide on the wall adjacent to the laser image; [0173] (3)
digitally imaging the laser image and the reference guide; and
[0174] (4) processing the digital images and quantifying the
geometry of the intersections based on the digital images,
parameters of the laser image and the reference guide, such that a
quality of the intersections is determined.
[0175] Embodiment 96. The method of any of these embodiments,
wherein the panels are drywall panels, and step (c) comprises at
least one of taping, applying plaster or joint compound, wiping,
washing, and wet or dry sanding the planar intersections.
[0176] Embodiment 97. The method of any of these embodiments,
wherein step (d) comprises: [0177] visually enhancing a geometry of
the joints by projecting a laser line across the joints, the laser
line is substantially perpendicular to the joints, and the laser
line enables enhanced, qualitative user visualization of the joints
and non-planar distortion in the joints relative to a plane defined
by the wall.
[0178] Embodiment 98. The method of any of these embodiments,
wherein step (d) comprises: [0179] (1) projecting a laser image
across the joints; [0180] (2) positioning or simulating a reference
guide on the wall adjacent to the laser image; [0181] (3) digitally
imaging the laser image and the reference guide; and [0182] (4)
processing the digital images and quantifying the geometry of the
joints based on the digital images, parameters of the laser image
and the reference guide, such that a quality of the joints is
determined.
[0183] Embodiment 99. The method of any of these embodiments,
wherein the panels are drywall panels, and adjusting non-planar
joints into planar joints in step (d) comprises at least one of wet
or dry sanding, taping, applying plaster or joint compound, wiping
and washing the non-planar joints.
[0184] Embodiment 100. A laser system for visually enhancing a
geometry of a joint between panels that form at least a portion of
a wall, the system comprising: [0185] an assembly configured to be
positioned on a surface other than the wall itself, the assembly is
configured to project a laser line across at least a portion of the
wall and the joint, the laser line is projected at an angle of
incidence relative to a plane defined by the wall, the angle of
incidence is in a range of about 1 degree to about 60 degrees, the
laser line is substantially perpendicular to the joint, and the
laser line enables enhanced, qualitative user visualization of the
joint and non-planar distortion in the joint relative to the plane
defined by the wall.
[0186] Embodiment 101. A system for measuring a geometry of a joint
between panels that form at least a portion of a wall, the system
comprising: [0187] an assembly configured to be positioned on a
surface other than the wall itself, the assembly is configured to
project a laser line across at least a portion of the wall and the
joint, the laser line is projected at an angle of incidence
relative to a plane defined by the wall, the angle of incidence is
in a range of about 1 degree to about 60 degrees, the laser line is
substantially perpendicular to the joint, and the laser line
enables enhanced, qualitative user visualization of the joint and
non-planar distortion in the joint relative to the plane defined by
the wall; [0188] a reference guide configured to be located on the
wall or simulated adjacent to the laser line; [0189] a camera
configured to digitally image the laser line and the reference
guide; and [0190] a computer configured to be coupled to the camera
and quantify the geometry of the wall based on the digital images,
parameters of the laser line, the reference guide and a distance
between the camera and the wall, such that a quality of the joint
is measured.
[0191] This written description uses examples to disclose the
embodiments, including the best mode, and also to enable those of
ordinary skill in the art to make and use the invention. The
patentable scope is defined by the claims, and may include other
examples that occur to those skilled in the art. Such other
examples are intended to be within the scope of the claims if they
have structural elements that do not differ from the literal
language of the claims, or if they include equivalent structural
elements with insubstantial differences from the literal languages
of the claims.
[0192] Note that not all of the activities described above in the
general description or the examples are required, that a portion of
a specific activity may not be required, and that one or more
further activities may be performed in addition to those described.
Still further, the order in which activities are listed are not
necessarily the order in which they are performed.
[0193] In the foregoing specification, the concepts have been
described with reference to specific embodiments. However, one of
ordinary skill in the art appreciates that various modifications
and changes can be made without departing from the scope of the
invention as set forth in the claims below. Accordingly, the
specification and figures are to be regarded in an illustrative
rather than a restrictive sense, and all such modifications are
intended to be included within the scope of invention.
[0194] As used herein, the terms "comprises," "comprising,"
"includes," "including," "has," "having" or any other variation
thereof, are intended to cover a non-exclusive inclusion. For
example, a process, method, article, or apparatus that comprises a
list of features is not necessarily limited only to those features
but may include other features not expressly listed or inherent to
such process, method, article, or apparatus. Further, unless
expressly stated to the contrary, "or" refers to an inclusive-or
and not to an exclusive-or. For example, a condition A or B is
satisfied by any one of the following: A is true (or present) and B
is false (or not present), A is false (or not present) and B is
true (or present), and both A and B are true (or present).
[0195] Also, the use of "a" or "an" are employed to describe
elements and components described herein. This is done merely for
convenience and to give a general sense of the scope of the
invention. This description should be read to include one or at
least one and the singular also includes the plural unless it is
obvious that it is meant otherwise.
[0196] Benefits, other advantages, and solutions to problems have
been described above with regard to specific embodiments. However,
the benefits, advantages, solutions to problems, and any feature(s)
that may cause any benefit, advantage, or solution to occur or
become more pronounced are not to be construed as a critical,
required, or essential feature of any or all the claims.
[0197] After reading the specification, skilled artisans will
appreciate that certain features are, for clarity, described herein
in the context of separate embodiments, may also be provided in
combination in a single embodiment. Conversely, various features
that are, for brevity, described in the context of a single
embodiment, may also be provided separately or in any
subcombination. Further, references to values stated in ranges
include each and every value within that range.
* * * * *
References