Patent Application
20110271436
One embodiment of this invention provides a method for manufacturing an above-ground heated pool used for swimming resistance exercise (exercise and swim spa), with an optional attached hot tub.
Large pools using jets to create a resistance current to swim against have long been known and are widely used. These types of exercise systems have been manufactured as above-ground and in-ground units for a couple of decades. Swim spas or exercise pools of this type have been traditionally manufactured utilizing in-ground concrete construction, or for above-ground versions (which can also be manufactured for in-ground use), with fiberglass shells, vacuum formed acrylic sheet reinforced with ABS, or fiberglass or vacuum-formed polyethylene. The above-ground versions need a separately-manufactured cabinet to support the shell.
Smaller hot tubs manufactured utilizing the rotational molding process have been made for many years, but no one has yet produced a swim spa, for the purposes of swimming against a powerful current of water, designed to provide resistance for endurance training The equipment usually needed to mold a rotationally molded swim spa is known as a rock-n-roll rotational molding machine. Although, a traditional bi-axel, or offset arm on an exceptionally large carousel, swing or clamshell rotational molding machine, is also possible. U.S. Pat. No. 5741453, by Kennedy, filed Nov.-7-1995, teaches a “Method for making rotationally molded SPA”, as an example of the prior art.
The advantages provided by this invention (as one embodiment) include a cost effective method of construction, over traditional methods for manufacturing swim/exercise spas. Additionally, the rotationally-molded swim spa can support the addition of an integrated separate water vessel, used primarily for relaxation, that can maintain a separate water temperature from the swim spa section of the whole system. This separate section can be molded together with the swim spa section, to create one contiguous molded piece, or it can be molded separately and mechanically attached, so that the swim spa can be sold individually, or optionally with the additional hot tub unit.
One embodiment of this invention provides a method for manufacturing an above-ground heated pool used for swimming resistance exercise (exercise and swim spa), with an optional attached hot tub. Additionally, the rotationally-molded swim spa can support the addition of an integrated separate water vessel, used primarily for relaxation, that can maintain a separate water temperature from the swim spa section of the whole system.
As an individual swim resistance system (as one embodiment), the swim spa can be 8′ to 20′ in length, 3′ to 6′ in height, and 5′ to 9′ in width (as an example). These dimensions provide for a typical area and water volume for swimming and other exercise activities.
The optional segregated hot tub area can be of any size (as one embodiment), to accommodate one or more individuals, however, at a typical, lower range/ dimensions, it can be 4′ to 10′ in length, 29″ to 6′ in height, and 4′ to 9′ in width (as an example).
However, the sizes mentioned here are typical ranges for some embodiments, as examples, and the invention covers any size, big or small, for the method of manufacturing the system/ object (swim and exercise spas).
“Wikipedia.org” (on the Internet) has a very descriptive section about “Rotational molding”, also known as roto-molding (as prior art), as detailed here: It is a molding process for creating many kinds of hollow items. A heated hollow mold is filled with a charge of material. Then, it is slowly rotated (usually around two perpendicular axes), causing the softened material to disperse and stick to the walls of the mold. In order to maintain even thickness throughout the part, the mold continues to rotate at all times 4 during the heating phase (and to avoid deformation during the cooling phase). The system generally comprises molds, an oven, a cooling chamber, and mold spindles.
The rotational molding process is a high-temperature, low-pressure plastic-forming process that uses heat and biaxial rotation (i.e., angular rotation on two axes) to produce hollow, one-piece parts. Here are some of the methods and equipment, from prior art, as described by “Wikipedia.org” (on the Internet):
A typical rotational molding process consists of 4 phases, as described by “www.Wikipedia.org” (on the Internet):
A typical material used (as described by “www.Wikipedia.org”) is cross-linked polyethylene (PE), linear low density polyethylene (LLDPE), high density polyethylene (HDPE), PVC plastisols, nylons, polypropylene, polyvinyl chloride, and polycarbonate.
In one embodiment, the spa shell, floor, walls, etc, are all molded as one piece.
The swim resistance system (as one embodiment) is made up of one or more motors attached to water pumps, suction fittings, a filtration system, and jets, which interconnect to each other, to provide the directed stream of water used to provide the resistance for the exercise.
The material of the swim spa may comprise one or more of the following: plastic, elastic material, wood, alloy, metal, magnetic material, ferromagnetic material, wool, fabric, clothing, porous material, absorbing, non-absorbing material, mixture, combination, smooth material, coarse material, carved material, molded material, transparent, translucent, opaque material, natural, synthetic material, flexible, rigid material, uniform, non-uniform material, embedded material (embedded with e.g. water pipes or heater wires), hollow material, or reinforced material (e.g. with metal bar, fabric, or mesh).
The shape of the swim spa may be one or more of the following: oval, rectangle, square, straight, curved, circular, multiple cross sections, or single cross section, comprising one or more of the following: multiple jets, single jet, multiple flows, single flow, with flow meter, with holes or grids in the wall to remove or dampen down the waves, recycle mechanism, cleaning mechanism, floating object(s), submerged object(s), walking exercises, with floating tube, with floating jacket, with floating belt, light, underwater light, dancing light monitored by a computer, with music synchronization, multiple lights, gradual changing lights, rainbow lights, lasers, or any combination of the above.
Figures show various embodiments for the current invention, with the current/water flow indicated by arrows in the longitudinal direction of the swim spa, possibly going on either directions (for different embodiments), with diagonal directions, at different angles at 3-dimensional coordinates, changing or fixed, with different speed and pressure, variable or fixed, in terms of time and coordinate, as different embodiments, for different nozzles or openings, fixed or rotating, periodically or irregularly/randomly.
SPA section (200) attaches to swim section (201) at their facing sides (257 and 256, respectively). In one example, the connecting assembly comprises of attachment boards/shims (262, 263), e.g., plywood, that are pressed or attached together via a mechanism such as knots and bolts (264).
Recessed surfaces (260, 261) of swim section and SPA section at their edges, respectively, provide a cavity (252) for insertion and connection (251) by an esthetic piece (250), e.g., a roto-plastic shim. This can also seal the joint. In one embodiment, as shown in 270, the esthetic piece covers (271) the edges (272 and 273) of the SPA and swimming sections. In one embodiment, the edges of SPA and swimming sections (272 and 273) are protruded upwards, to help prevent water getting between the sections.
A platform support (254), e.g., a plywood, is attached (255) or placed under the swim section (201) and SPA section (200). This, for example, can provide leveling and stability to the connecting sections, as well as distributing the weight more evenly.
One or more connecting boards/rods/shims (e.g., 330, 332, 334) are placed (e.g., 340, 341) in the channels (e.g., molded) (e.g., 320, 321) of SPA section and swim section. In one embodiment, the connecting boards are attached to SPA section and swim section by bolts. In one embodiment, the boards provide support and alignment/leveling for the connection between SPA section and swim section. In one embodiment, 2 or 3 “2×4” boards are connected (e.g., bolted) to the bottom inside molded channels for support.
In one embodiment, we have a swim spa, with one or more of the following features:
Any variations of the teachings above are also meant to be covered and protected by this current application.
This application is a continuation of (related to) the provisional application Ser. No. 61/332,818, filed 10-May-2010, with the same title, inventor(s), and assignee.
| Number | Date | Country | |
|---|---|---|---|
| 61332818 | May 2010 | US |
