Extruded track construct component system with threaded radial bearing end pulley for swimming pool cover systems

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to swimming pool cover systems, and in particular, to extruded swimming pool track constructs which anchor a pool cover along a pool side edges and related pulleys carrying cables for cover extension and retraction.

2. Description of the Prior Art

Swimming pool cover systems typically include covers formed from flexible vinyl fabrics or interconnected rollable (hinged) rigid buoyant slats (See U.S. Pat. No. 4,577,352 Gautheron). Such pool covers float on the water surface of the pool and are anchored/supported along the sides and ends of the pool. When covering and uncovering, pool water provides a low friction surface supporting the cover which significantly reduces the effort required to move the cover across the pool.

Typically mechanical systems are utilized to draw the cover back and forth across the pool in which a cable, typically a Dacron line, is incorporated into to form a flexible beaded edge sewn or otherwise secured to the side edges of the pool cover. The beaded edge in turn is captured and slides within a C-channel of an extruded aluminum cover track. The track is secured either to the pool deck, or the underside of an overhanging coping along the sides of the pool. In new pools, the side walls of the pool frequently are constructed with integral channels for receiving the cover track and securing vinyl pool liners. (See U.S. Pat. No. 4,967,424 Stegmeier)

The cables extending from the beaded edges at the front of the cover, are trained around pulleys at the distal ends of the tracks (See U.S. Pat. No. 4,466,144 Lamb) and return in a parallel C-channel to a drive mechanism where they wind onto and unwind from cable take-up reels. The cable take-up reels are coupled to a drive mechanism for extending the cover. To uncover the pool, the drive mechanism rotatably drives a cover drum located and secured at one end of the pool for winding the pool cover around its periphery unwinding the cables from the take-up reels. (See U.S. Pat. No. 5,799,342, Last)

The front edges of flexible vinyl covers are typically secured to and supported by a rigid leading edge spanning the width of the pool for holding the front edge of the cover above the water as it is drawn back and forth across the pool. Similarly, rollable buoyant slat covers frequently include a front or floating leading edge. Leading edges are typically secured to and mechanically supported by sliders sliding in the C-channel of the cover track coupled to the cable extending from the flexible beaded edge of the cover. (See U.S. Pat. Nos. 4,939,798 & 5,950,253 Last.) Positive stops are sometimes secured at the ends of the pool cover tracks for positively arresting translation of the sliders sliding within the C-channels carrying the rigid leading edges. (See U.S. Pat. No. 5,349,707 Last.)

Wearing components of mechanical swimming pool cover systems must be replaceable. In particular, a swimming pool is a harsh environment. The water and treating chemicals are corrosive, galvanically and otherwise. Intense sunlight exposure typical of outdoor pool exacerbates deterioration of exposed components, converting pliable vinyl plastics into flaking sharp shards. Then the sliding components of the mechanical pool cover systems tend collect and concentrate floating debris and crud at wearing interfaces. Such collected and concentrated debris and crud in turn entraps dirt, dust, and sand to transform into a flowable abrasive grit which insinuates itself into every moving component of the cover system, particularly the end pulleys and related assemblies.

Replacing end pulleys in mechanical swimming pool cover systems is a particularly irksome task. Even removable end pulleys of the type described in U.S. Pat. No. 4,446,144 Lamb are difficult to replace. In particular, as noted in Lamb while a tang extending from the assembly into a channel between the respective C-channels of the extruded track promotes alignment of pulley, the extending tang does not prevent the assembly from oscillating loose when loaded. (See Lamb (supra) Col. 5, line 25—Col. 6, line 42.) The upshot is, that in practice, even the Lamb end pulley and related housing assembly should be securely bolted to or fastened at a stationary position relative to the end of the track, otherwise the oscillating loads experienced by the pulley bend or deform the pulley housing material and/or deform the end of the track.

Then as noted in Lamb (Col. 4, lines 55 to Col. 5, line 2) because of the loads experienced by such end pulley assemblies, it is generally preferable to provided bores through the assembly through which a cable is strung rather than grooves. (Lamb does point out that if stronger materials were utilized for constructing the pulley housing, grooves would be preferred.) Lamb fails to mention attendant galvanic corrosion problems between such stronger materials and aluminum swimming pool track. As a practical matter, whenever a pulley fails, unless its housing assembly is mechanically isolated from the track end, the housing is damaged and track end deformed, simply because the typical pool owners, not knowing why a cover is not properly extending/retracting, all too frequently, will overstress the system into catastrophic failure trying to make it work.

Accordingly, when an end pulley must be replaced, the either entire cable must be unstrung through the damage pulley assembly and re-threaded through the replacement pulley assembly or the cable must be cut and then spliced. The latter alternative inevitably leads to a broken or snagged cable and a pool owner demanding a replacement.

Finally, contemplate the problems confronting a repair person attempting to replace an end pulley assembly mounted on the underside of an overhanging coping along the sides of the pool, or at the end, within an extruded aluminum channel integrated into the structural side wall of the pool. (See FIG. 1, U.S. Pat. No. 5,349,707, Last.) If water is not drained from the pool, a snorkel or scuba tank would be required.

SUMMARY OF THE INVENTION

An invented track construct component system with a threaded radial bearing end pulley is described for pool cover systems that includes:

a) an extruded longitudinal cover track having

(i) a top face with a longitudinal anchoring slot and a planar base face

(ii) a C-channel with a longitudinal slot opening along an outside side edge of the cover track for capturing and holding a side edge of a pool cover and associated sliders carrying leading (front) edge structures,

(iii) a cable return channel with a longitudinal slot opening along an inside side edge of the cover track for receiving and protecting cabling connecting between the sliders/front cover corners and associated cable reels; and

b) an extruded side wall channel structure having a top channel side wall with a depending longitudinal land and a flat, bottom channel side wall adapted for and incorporated into the structure of the side wall of the pool for receiving a cover track wherein the depending longitudinal land is shaped for snuggly fitting into the longitudinal anchoring slot of the cover track; and

c) a longitudinal spacer plate adapted for and inserted between the flat, bottom flat channel side wall of the wall channel structure and the planar base face of the cover track for mechanically holding the cover track within the wall channel with its anchoring slot snuggly receiving the depending longitudinal land of the wall channel structure, and

d) a coupling plate—radial bearing end pulley assembly fastened at the distal end of each cover track.

The distal end wall of the pool includes a similar extruded end wall channel structure for accommodating the coupling plate—radial bearing end pulley assembly fastened at the distal end of each cover track.

The coupling plate—radial bearing end pulley assembly includes a novel inner annular bearing race with interior helical threads for screwing onto a perpendicularly extending, complementarily threaded, post integral with the coupling plate. The outer annular bearing race has a concave exterior, circumferential groove for receiving, carrying and returning cabling connecting between a slider/front cover corner and a cable reel.

A primary advantage of the invented extruded track construct component system with a threaded radial bearing end pulley is that a cover track can be easily removed from a wall channel structure by simply extracting the longitudinal spacer plate allowing mechanical disengagement of the depending longitudinal land in the anchoring slot of the cover track. Once the longitudinal spacer plate is extracted, distal end of the cover track can be slid diagonally sideways out of the wall channel preferably pivoting from the opposite end of the cover track proximate a cover drum and associated cable reels of the cover drive system. In this manner the radial bearing end pulley—coupling plate assembly fastened at the distal end of the cover track is exposed for easy repair or replacement.

Other advantages of the invented system relate to the ‘thinness’ and structural integrity of the radially bearing end pulley-coupling plate assembly achieved by a novel combination of a helically threaded, annular inner bearing race screwing onto a complimentary, helically threaded post for fastening the radial bearing to a coupling plate. In particular, the thickness of the end pulley-coupling plate assembly can be matched to that of the extruded pool cover track to which it is attached. Protruding shaft ends and associated retainer clips, nuts collars and the like, typical for such replaceable radial bearing end pulley assemblies are eliminated.

The invented novel combination of a helically threaded annular inner bearing race screwing onto a complimentarily threaded post as a mechanism for fastening or securing a radial bearing has similar advantages in many other types of mechanical systems utilizing radial bearings, in particular, those systems where the annular inner race of the radial bearing journals around and is stationary with respect to its mounting shaft or spindle and its annular outer race rotates relative to the inner race engaging and/or carrying a complimentary belt, cable or gear. The threaded engagement of the inner bearing race onto a post of a coupling plate eliminates the necessity for thrust bearings, annular retainer clips, bolts, collars, set screws and like typically utilized for securing such bearing assemblies onto shafts and spindles.

In mechanical systems where rotation of the radial bearing is only in one direction, the inner race and post of the invented bearing assembly can be threaded in a direction such that system rotation tightens threaded engagement of the inner race on the post.

Also in top track pool cover systems where the cover track is secured to the top surface of a deck surrounding the pool, the threaded the inner annular race of the radial bearing end pulley uniquely allows a pulley cap to be secured covering the pulley and coupling plate assembly by a complimentarily threaded flat or round head screw that screws into the inner race of the bearing.

Other features of the invented extruded track construct component system relates to postconstruction utilization of plastic plug rails conventionally used to maintain the integrity of the channels of extruded wall channel structures during pool during construction, to close the channel opening of a wall channel incorporated into the distal end wall of the pool to prevent debris capable of fouling the radial bearing end pulleys assemblies from collecting in the end wall channel.

Still other features, aspects, advantages and objects presented and accomplished by invented track construct component system and associated threaded radial bearing assembly systems will become apparent and/or be more fully understood with reference to the following description and detailed drawings of preferred and exemplary embodiments.

DESCRIPTION OF PREFERRED AND EXEMPLARY EMBODIMENTS

FIG. 1

is a perspective drawing of an extruded cover track with attached radial bearing end pulley assembly of the invented track construct component system.

FIG. 2

is a perspective view illustrating how the radial end pulley assembly is secured at the end of the cover track of the invented track construct component system.

FIGS.

3

(

a

),

3

b

,

3

c

&

3

d

are end cross section elevation views of the longitudinal components of the invented track construct component system.

FIG. 4

is an end cross section view of the longitudinal components of the invented track construct component system assembled.

FIGS. 5

a

&

5

b

are perspective views of the assembled components of the invented track construct component system where the radial bearing end pulley assembly extends beyond FIG.

5

(

a

) or within FIG.

5

(

b

) the enclosing extruded wall channel.

FIG. 6

is a cross section elevation view of the side wall of a pool showing the longitudinal components of the invented track construct component system installed.

FIGS. 7

a

,

7

b

&

7

c

are perspective renderings of the invented track construct component system illustrating procedures for insertion and extraction of the cover track from within the extruded wall channel.

FIGS. 8

a

&

8

b

are end cross section elevation views of different wall channels tracks of the invented track construct component system adapted for lined pools.

FIG. 9

is a cross section view of a flush top cover track of the type described by the Applicant in his U.S. Pat. Nos. 5,845,893 & 5,950,253.

FIG. 10

is a perspective view of a disassembled top cover track system with a cover for and the novel radial pulley coupling plate assembly at one end of deck cover track and a mechanical slider stop at the other end of the track.

FIG. 11

is a perspective of the top cover track system shown in

FIG. 12

assembled.

FIG. 12

is cross section elevation view of an extruded wall channel track for the invented track construct component system with an extruded element into which a light channeling plastic medium can be secured.

FIG. 13

is a cross section elevation views of the wall channel track shown in

FIG. 12

incorporated into the side wall structure of the pool.

FIG. 14

is a cross section elevation view of the radial bearing end pulley assembly of the invented track construct component system showing details of the novel combination of a helically threaded annular inner bearing race screwing onto a complimentarily helically threaded post as a mechanism for fastening or securing radial bearing to the coupling plate, and providing a threaded recess for receiving an anchoring screw.

FIG. 15

is a top plan view of the radial end pulley assembly of the invented track construct component system viewed looking down from reference plane

15

—

15

of

FIG. 14

showing a diametric slot and turning holes for mechanically rotating the inner bearing race for screwing onto a mounting post of a coupling plate.

DESCRIPTION OF PREFERRED AND EXEMPLARY EMBODIMENTS

FIGS. 1

,

2

,

3

a-d

,

4

and

6

show the relationship of the essential components of the invented track construct system. The extruded longitudinal cover track

11

has (i) a flat top face

12

with a longitudinal anchoring slot

13

and a planar base face

14

; (ii) a longitudinal C-channel

16

with a slot opening

17

along one side edge

18

for capturing and holding a side edge of a pool cover and associated slider of a leading (front) edge structure (not shown); (iii) a longitudinal cable return channel

19

with a longitudinal slot opening

21

parallel C-channel

16

along the opposite side edge

20

for receiving and protecting cabling connecting between a slider, front cover comer and associated cable reels (not shown). A coupling plate

22

supporting a radial bearing end pulley

23

is conventionally fastened with tapered head screws

24

and nuts

25

at the distal end of the cover track

11

at the far pool end opposite the cover drum, cable reels and drive mechanisms.

An extruded wall channel structure

26

receives the cover track

11

. The wall channel structure

26

is adapted for and incorporated into the side wall

27

(

FIG. 6

) of the pool

28

proximate the pool top

29

beneath a top deck/coping surface

30

that typically surrounds such pools. The extruded wall channel

26

structure has a top channel side wall

31

with a depending longitudinal land

32

extending toward an opposing flat, bottom channel side wall

33

and a back channel wall

37

. The facing surface of the flat bottom channel side wall

33

is riffled with small longitudinal rills

35

. The depending longitudinal land

32

is shaped to snuggly fit into the anchoring slot

13

in the top face

12

the cover track

11

. A fastening apron

15

extends coplanar with the flat, bottom channel side wall

33

oppositely from the back channel wall

37

. Holes

40

are drilled through the apron

15

for accommodating fastening nails screws or bolts

46

(

FIG. 8

a

) which hold the wall channel structure

26

in place during and after construction of the pool wall

27

.

A longitudinal spacer plate

34

is inserted between the flat, bottom channel side wall

33

of the wall channel structure

26

and the planar base face

14

of the cover track

11

for holding the cover track

11

within the wall channel

26

with the depending longitudinal land

32

mechanically fitting snuggly into the longitudinal anchoring slot

13

of the cover track

11

. The longitudinal rills

35

on the facing surface of the flat, bottom channel side wall

33

functionally increase frictional engagement with the adjacent face of longitudinal spacer plate

34

while simultaneously minimizing adhesion between the abutting surfaces. The planar base face

14

of the cover track

11

may also have rills (not shown) to enhance frictional engagement with the opposite abutting face of the longitudinal spacer plate

34

FIGS. 7

a

,

7

b

and

7

c

, illustrate the procedure for insertion and removal of a cover track

11

into and out of a wall channel structure

26

.

FIG. 7

a

shows the cover track

11

mounted and secured within the wall channel structure

26

with the longitudinal spacer plate

34

in place. The longitudinal land

34

of the wall channel

26

is received within the anchor slot

13

of the cover track

11

. To remove the cover track

11

, the longitudinal space plate

34

is first slid sidewise out of the wall channel structure

26

(

FIG. 7

b

) to allow the cover track

11

to drop down disengaging the longitudinal land

32

from the anchor slot

13

of the cover track. Once the longitudinal anchor slot

12

and longitudinal land

32

disengage, the cover track

11

is slid sideways out of the wall channel

26

(

FIG. 7

c

).

To secure the cover track

11

within the wall channel structure

26

, the procedure is reversed. The cover track

11

is slid sideways into the wall channel structure

26

and positioned such that its anchor slot

13

is aligned with the depending land

34

of the wall channel

26

. Once the cover track

11

is properly located and aligned within the wall channel

26

, the cover track

11

is lifted vertically within the channel inserting the depending longitudinal land

32

of wall channel structure

26

into the longitudinal anchor slot

13

, until its top face

12

abuts against the top channel side wall

31

of the wall channel structure. The longitudinal spacer plate

34

is then slipped sidewise into a space between the planer base face

14

of the lifted cover track

11

and the ‘rilled’ surface

35

of the flat, bottom channel side wall

33

(

FIG. 9

b

).

To facilitate placement of the cover track

11

in the wall channel

26

, the skilled designer should dimension the wall channel

26

and cover track

11

such that back wall surface

37

of the wall channel structure

26

abuts against the return channel side edge

20

of the cover track for locating and aligning the land

32

and anchor slot

13

of the respective members. It should be noted that the respective flat top and base faces

12

&

14

of the cover track

11

curve inwardly at the side edges

18

&

20

toward each to define the respective C-channel and return channels slots

17

&

21

Accordingly, when the cover track

11

is pushed sideways against back wall surface

37

of the wall channel structure

26

there will be a longitudinal space for accommodating a small amount of debris captured between the sidewise sliding cover track

11

and the back channel wall surface

37

of the wall channel structure

26

. However, the careful installer/repair person should always first clean obstructions and debris from the wall channel structure

26

before sliding in the cover track

11

.

For reasons of manufacturing economy and simplifying use, conventionally, the C-channel

16

& slot

17

and return channel

19

& slot

21

of an extruded cover track

11

comprise mirror reflections of each other, i.e., typically cover tracks are symmetrical with respect to a longitudinal vertical plane bisecting the cover track

11

as illustrated in all the figures except FIG.

9

. As the Applicant explains in U.S. Pat. Nos. 5,845,893 & 5,950,253, sometimes the advantages of a symmetrical configuration for an extruded cover track are outweighed by other mechanical factors, e.g., a need to accommodate sliders and/or to provide debris gutters. The skilled extrusion designer should appreciate that the return channel side edge

20

of the cover track

11

can be shaped of facilitate location and alignment of a cover track

11

within the wall channel

26

. In fact, the side edge

20

of the cover track

11

, the back side wall

37

of the wall channel

26

, and the longitudinal land

32

depending from the upper side wall

31

of the wall channel structure

26

can each be shaped such that mechanically lifting the cover track

11

vertically within the wall channel structure

26

, with its side edge

20

abutting against the back side wall

37

of the wall channel structure

26

, mechanically positions and aligns the cover track

11

within the wall channel structure

26

for its anchor slot

13

to receive the longitudinal land

32

depending from the top channel side wall

31

.

The process of inserting the longitudinal spacer plate

34

should be initiated at one end of the pool with the spacer plate being edged sidewise diagonally into the space between the lifted cover tack

11

and the flat, bottom side wall surface

33

in the manner illustrated in

FIG. 9

b

. The careful installer/repairman might even use small spacer pieces for holding the cover track

11

in position within the wall channel structure

26

to ease the difficulty of the insertion.

The skilled designer/installer/repair person should also recognize that the longitudinal spacer plate

34

is quite critical to the workability of the invented track construct component system. In particular, the spacer plate

34

when inserted between the base face

14

of the cover track

11

and the rilled surface

35

of the flat, bottom channel side wall

33

of wall channel structure

26

maintains mechanical engagement of the longitudinal land

32

depending from the top side wall channel

31

in the cover track anchor slot

13

. Accordingly, the spacer plate

34

should not vary significantly in thickness along its length. Materials selected for the longitudinal spacer plate

34

also should not swell or shrink appreciably over time in the expected water/chemical environment of the particular pool. Nor should the longitudinal spacer plates be composed of materials that chemically react with other elements in the pool environment including the other extruded components of the invented track construct component system. Longitudinal spacer plates

34

composed of polyvinyl chloride (PVC) with appropriate ultraviolet light opaquing additives are suitable for swimming pools environments.

Looking at

FIG. 4

, to facilitate of removal of a longitudinal spacer plate

34

from the space between the bottom planer base

14

of the cove track

11

, the plate thickness (P) of the longitudinal spacer plate

34

may be chosen to be very slightly less than difference between the width (W) measured between the top and bottom channel side walls

31

and

33

of the wall channel structure

26

and the thickness (T) of the cover track

11

, but significantly greater than the distance between the depending land and the, flat bottom channel side wall rilled surface

35

. i.e.:

{(

W

-

T

)−

H}<<P

≦(

W

-

T

),

where H is the height of the land

34

depending from the surface of the top channel side wall

31

of the wall channel structure

26

.

Thus, if depth (D) of the anchor slot

12

is slightly greater than the height (H) of the longitudinal land

32

depending from the top channel wall

31

of the wall channel

26

, the space between the base

14

of the cover track

11

bottom channel side wall

33

can be increased slightly. This makes it possible to pry the longitudinal spacer plate

32

upward first, slightly, to break any adhesion of its bottom surface with the rilled surface

35

of the flat, bottom channel side wall

33

. Once any adhesion is broken, the slight enlargement of the spacing enables the installer/repair person to easily work the longitudinal spacer plate

34

sidewise, diagonally out of the wall channel structure

26

preferable starting at an end of the particular spacer plate

34

.

Ideally the longitudinal spacer plate

34

should extend the entire length of the cover track

11

within the wall channels

26

. However, a plurality of spaced apart shorter lengths of longitudinal spacer plate

34

can be substituted for a single long length. Determining both the lengths and spacing between of such shorter spacer plates

34

, consideration should be given to anticipated forces tending to disengage the anchor slot

12

of the cover track

11

from the depending land of the wall channel structure

26

and pulling the cover track

11

out of the wall channel structure

26

. Such forces can arise from water/objects/people falling onto and being supported by the cover on the surface of the pool.

The skilled designer when considering the engagement of the anchor slot

14

of the cover track

11

and the longitudinal land

32

depending from the upper side wall

31

of the wall channel

26

, should also pay attention to existence of torque moments arising from translation of components such as sliders within the C-channel

16

supporting leading edge structures spanning the pool. Such torque moments could tend to twist the track in a vertical plane. Accordingly, any designed yield in the vertical spacing of the secured cover track

11

within the wall channel structure

26

, as discussed previously, should be determined with an objective to prevent the cover track from being deformed (bending) beyond its elastic limit. In other words, such designed for yield should not allow inelastic deformation of the cover track

11

due to expected ranges of operational forces that the invented track construct component system can be anticipated to experience during attempted extension and retraction of a pool cover in a failure (stuck) mode.

Looking again at

FIGS. 7

a

,

7

b

&

7

c

, the far end wall of the pool opposite the cover drum cable reel and drive mechanisms (distal end wall) should also structurally incorporate an extruded wall channel structure

36

(typically having the same cross section configuration as side wall channel structure

26

as shown in phantom in

FIGS. 7

a-c

) registering with the pool side wall channel structure

26

(FIG.

6

). The coupling plate-radial bearing end pulley assembly

38

fastened at the distal end of the cover track

11

may extend from the side wall channel structure

26

(

FIG. 5

a

) into the end wall channel structure

36

when mounted within a side wall channel structure

26

. Alternatively, the side wall channel structure

26

can extend beyond the end of the coupling plate-radial bearing end pulley assembly

38

fastened at the distal end of the cover track

11

as shown in

FIG. 5

b

. In the latter instance, the extruded end wall channel structure

36

would abut the opening

42

of the side wall channel structure

26

. The depth of the extruded end wall channel structure

36

should be sufficient to allow the cover track

11

with the coupling plate-radial bearing end pulley assembly

38

fastened at its distal end to be first slid sidewise and then pivoted diagonally outward for removal from the side wall channel structure

26

after the longitudinal spacer plate

34

.

Looking at

FIGS. 3

c

&

3

d

, longitudinal plastic rail plugs

39

conventionally inserted between the side walls

31

&

33

of a wall channel

26

/

36

during the construction phase of a pool to mitigate or prevent inadvertent structural deformation squeezing the channel side walls

31

&

33

together. Such rail plugs

39

typically include a hexahedral volume

41

with an integral head rail

43

. Pry grooves

44

are typically molded/extruded at the juncture of the head rail

43

and hexahedral volume to facilitate removal of the rail plug from the opening

42

of the wall channel

26

36

. The hexahedral volume

41

is dimensioned to compress slightly upon insertion into the opening

42

of the wall channel structure

36

The head rail

43

protrudes from the wall channel opening

42

and has a thickness dimension slightly less than that of the hexahedral volume

41

, preferably just about equal to the spacing between the depending land

32

and the rilled surface

35

of the flat, bottom channel side wall

33

. (See FIG.

6

).

Post pool construction, instead of being discarded, such longitudinal plastic rail plugs

39

, can be reversed and inserted into plugging the channel opening

42

of an end wall channel

36

(

FIG. 5

c

) to prevent debris from floating or splashing into the end wall channel

36

and fouling the radial bearing end pulleys coupling plate assembly

38

carrying/returning cabling connecting between the sliders/front corners of the pool cover(not shown) and cable reels (not shown) of the cover drive mechanisms (not shown) extending and retracting the cover back and forth across a pool.

Turning now to

FIGS. 8

a

&

8

b

, the extruded longitudinal wall channels structures

51

of the invented track construct component system for lined pool systems can be configured to adapt to an existing liner anchor channel structure

52

(

FIG. 8

a

), or configured to include an integral liner anchor channel

53

for new pool construction (

FIG. 8

b

).

In the adapted configuration (

FIG. 8

a

) the adapting structure

54

integrally extruded with the wall channel structure

51

extends vertically (perpendicularly) downward from the horizontal bottom side wall

33

of the wall channel receiving a cover track (not shown) then horizontally (90°) backward in a series of stepped horizontal and vertical surfaces

56

,

57

,

58

&

59

The skilled extrusion designer should appreciated that the dimensions of the respective stepped horizontal and vertical surfaces

56

-

59

are determined by those of the existing liner anchor channel structure

52

over which it seats. For example: (i) stepped horizontal and vertical surfaces

56

are dimensioned to fit over the liner anchor channel of the liner anchor channel structure of the existing liner anchor channel structure

52

; (ii) stepped horizontal and vertical surfaces

57

define a longitudinal support foot resting on the top of the anchor apron of the existing liner anchor channel structure

52

; (iii) stepped horizontal and vertical surfaces

58

define a space for accommodate heads of fastener bolts anchoring the existing liner anchor channel structure

52

to the pool top

29

; and (iv) horizontal surface

59

is the anchor apron for the extruded wall channel structure

51

.

In the new construction adaptation (

FIG. 8

b

), the liner anchor channel

53

and cover track wall channel

26

are extruded as a singe structure

51

with the liner anchor channel

53

vertically below the cover track wall channel

26

The liner anchor channel

53

includes a conventional small longitudinal upward projecting land

94

defining the bottom lip of the opening

93

into the channel. In like manner as illustrated in

FIG. 6

, the wall channel structure

51

shown in

FIG. 8

b

can be incorporated into to form a part of the pool wall structure at the top of the pool

29

below a surrounding coping/deck surface

30

.

The skilled extrusion designer should appreciate that while it is possible, it is not recommended to combine the mechanical features of a liner anchor channel and a cover track wall channel in a single channel rather than two channels as illustrated in

FIG. 8

b

.—(This could be accomplished by providing a conventional upward projecting longitudinal land at the lip of the bottom channel side wall of the cover track wall channel, and letting the cover track and associated longitudinal spacer plate function as anchor railing to hold the liner cover edge within the channel.)—In particular, combining the liner anchor channel and cover track channel into a single channel would defeat the convenience of the invented system cover track, meaning that a single channel most likely, would make it necessary to drain the pool before extracting a cover track for a simple repair/replacement of, for example, an end pulley assembly. In addition, whether or not the pool is drained, a pool liner deformed by stress, stiffened by age, and embrittled by ultraviolet radiation and chemicals would greatly complicate both the extraction, reinsertion and anchoring of the cover track within the common channel. Finally, extraction, reinsertion and re-anchoring the cover track in such single wall channel would inevitably damage the integrity of the pool liner.

RADIAL BEARING END PULLEY AND COUPLING PLATE ASSEMBLY

Referring

FIGS. 14 and 15

, the invented radial bearing end pulley assembly

23

includes an outer annular race

62

, and an inner annular race

63

. The outer annular race

62

rotates relative to the inner race

63

and includes: (i) a concave, exterior, circumferential groove

64

designed for receiving, carrying and returning cabling common to swimming pool cover systems; (ii) at least one, preferably two, interior, concave circumferential ball bearing raceway grooves

66

for circumferentially aligning and holding a plurality of ball bearings

67

; and (iii) annular end seal channels

68

cut radially into the interior wall of the race at each end of the annulus.

The inner annular race

63

is formed by a top annular member

71

pressure fitted into a bottom annular member

72

sandwiching and threading the outer annular bearing race

62

. Together, the top and bottom annular members

71

&

72

provide conventional exterior, circumferential ball bearing rolling surfaces

73

terminating with radially projecting annular shoulder lands

74

. Conventional Teflon® impregnated bearing debris seals

76

are captured and held between the inner race

63

and the outer annular race

62

within the annular end seal channels

68

by the projecting annular shoulder lands

7

of the inner annular race

63

.

A helical thread

77

is cut into the interior cylindrical surface of the top annular member

71

and is sized to screw onto a post

81

welded to and integrally extending perpendicularly from a flat coupling plate

22

. The post

81

has a complementary helical thread for screwing into the top annular member

71

of the inner annular bearing race

63

The flat coupling plate

22

preferably has a cheek area

80

surrounding the post

81

at least as large as the horizontal cross section area of the radial bearing end pulley assembly

23

carrying cabling in its concave, exterior, circumferential groove

64

. Beyond the cheek surface, the coupling plate

22

is shaped and adapted for fastening at the ends of the various different types of cover track

11

(See

FIGS. 2

,

9

,

10

&

11

).

In particular, for the wall channel cover track

11

shown in

FIG. 2

, the coupling plate

22

is at most, as wide as the cover track

11

and has a thickness less than a longitudinal spacer plate

34

. Accordingly, the coupling plate can be conventionally fastened to the planer base face

14

of the cover track

11

with tapered flat head screws

24

and nuts

25

. Preferably, for wall channel and under-coping cover tracks of the configuration illustrated in

FIGS. 1 & 2

, the distal end beyond the cheek area

80

of the coupling plated

22

is bent upward to provide a protective vertical abutment protecting the radial bearing end pulley. (See also

FIGS. 5

a

,

5

b

, &

7

a

-

7

c

.)

For extruded deck cover track

82

shown in

FIGS. 10 & 11

, the coupling plate

22

includes a tang

83

extending from the cheek area sized to snuggly insert into a central space

84

defined between the exterior walls of the C-channel

16

and the return channel

19

of the deck cover track

82

. As illustrated, the exterior walls of the C-channel

16

and return channel

19

of the deck cover track

82

each preferably include an integral longitudinal land

86

having rectangular cross section, projecting toward each other in a common plane. The tang

83

of the coupling plate is inserted below the projecting lands

86

. A screw fastener plate

87

is sized to slip snugly into the space

84

between the exterior walls of the C-channel

16

and return channel

19

above the lands

86

. The screw fastener plate

87

includes one or more threaded holes

88

for receiving a conventional tapered, flat head screw

24

. Holes

89

are drilled through the cover plate tang

83

so that the screws

24

can be threaded into the threaded holes

88

of the screw fastener plate

87

and tightened onto the lands

86

for securing the coupling plate

22

at the end of the deck cover track

82

.

The skilled installer/repair should appreciate that extending tang

83

of the coupling plate

22

is preferably not co-planer with coupling plate cheek area

80

which should bottom on the deck surface such that its proximate edges

91

abut against the end

92

of the deck cover track

82

for spacing the radial bearing pulley

23

away from such track end

92

.

In the case of flush top cover track

96

of the type described by the Applicant in his U.S. Pat. Nos. 5,845,893 & 5,950,253 shown in , the tang

83

extending from the cheek area of the coupling plate

22

is size to snuggly insert into the central space

84

defined between the exterior walls of the C-channel

16

and return channel

19

close to the flush top

97

the track

96

. In this case, holes

98

are drilled though the flush top

97

of the cover track

96

. Corresponding tang holes are drilled and threaded to receive conventional tapered, flat head screws. In this case the screws are inserted through the flush top

97

of the cover track

96

thread into and are tightened to hold the extending tang

83

against the under surface of the flush top

97

.

Looking now at

FIGS. 14

,

10

&

11

, the top member

71

of the inner annular race

63

of the radial bearing end pulley assembly

23

screws onto the post

81

welded integrally extending perpendicularly from the flat coupling plate

22

and is tightened down with the end

85

of the bottom member

72

of the inner annular race

63

seating on the surface of the cheek

80

of the coupling plate

22

. In the case of flush top cover track (

FIG. 9

) and top deck cover track (FIGS.

10

&

11

), the height of the post

81

is selected to extend only part way through the threaded inner annular race

63

when fully tightened down on the threaded post

81

. For example, the axial length L of the post

81

can be at least equal to half the axial length K of the inner annular race

63

which in turn is greater than the axial length J of the outer annular race

62

, i.e., K/2≦L<J<K. In this manner, a threaded receptacle proximate the end of such deck and flush top cover track is provided, ideally located for supporting and securing a pulley cap

100

covering and protecting the radial bearing pulley

23

and coupling plate

22

assembly by a complimentarily threaded flat or round head screw

101

that screws into the remaining threaded receptacle at the top of the threaded inner annular race

63

.

A skilled installer/repair person should appreciate that the inner annular race

63

must be adapted to be mechanically rotated manually with a wrench or equivalent tool in order to tighten the radial bearing end pulley assembly

23

securely down on the threaded post

81

. If vertical head space is minimal, a slot

79

can be cut diametrically across, or, alternatively turning holes

99

can drilled into the top face around the circumference of the top member

71

of the inner annular race

63

(See

FIG. 15

) to afford means for turning and tightening the radial bearing assembly down onto to the threaded post

81

. Where there is sufficient vertical head space, diametrically opposing flats can be milled on the top projecting annular shoulder seal land

74

such that the top member

71

can be turned with a conventional wrench. (See

FIGS. 1

,

2

&

7

a

-

7

c

)

A skilled mechanical designer should appreciate that ball bearings

67

rolling within the annulus between outer and inner annular races

62

&

63

on the exterior bearing surfaces

73

of the inner annular race

63

end pulley assembly produce a torque tending to rotate the inner annular race

63

in the same direction as the rotating outer annular race

62

. In circumstance where the rotation of the outer annular race

62

is in only one direction, the helical threads of the post

81

and interior surface of the inner annular bearing race

63

can be oriented such that such unidirectional torque tends to tighten the bearing down on the post

81

.

However, in pool cover systems, the end pulleys carrying and turning the cabling rotate in both directions. In order to prevent, the invented radial bearing end pulley assembly screwed onto a helically threaded post from loosening it is sometimes necessary to peen (deform) the threads of the post

81

slightly to prevent such loosening rotation. In the case of top deck and flush top cover track systems the under surface of the pulley cap

100

abutting against the top end face of the top member

71

of the inner annular race

63

could be configured with a socket to receive and engage an eccentrically polygonal shaped projecting annular shoulder land

74

on the top end of the top member

71

of the inner annular race

63

to prevent such rotation. Other alternatives to peening and sockets could include a conventional locking washer compressed between the bottom end face of the bottom member

72

of the inner annular race

63

and the surface of the coupling plate

22

.

Finally, the skilled designer should appreciate that the materials selected for the radial bearing an end pulley and coupling plate should be composed of steels and stainless steels that have high strength and low galvanic and chemical reactivity in the chemical environment of the particular pool.

The invented track construct component system with a threaded radial bearing end pulley has been described in context of both representative and preferred embodiments which have reference to automatic swimming pool cover systems invented and developed by the Applicant and others. It should be recognized that skilled engineers and designers can specify different cross section configurations for the extruded longitudinal components of the invented system which perform substantially the same function, in substantially the same way to achieve substantially the same result as those components described and specified above for the invented track construct component system. Similarly, the respective elements of the novel threaded radial bearing end pulley and coupling plate assembly may be configured differently, per constraints imposed by different mechanical systems, yet provide for threaded coupling of the inner race, or even the outer race, into a mechanical system which perform substantially the same function, in substantially the same way to achieve substantially the same result as those components described and specified by the Applicant above. Accordingly, while mechanical components suitable for incorporation into the invented track construct component system with a threaded radial bearing end pull are not exactly described herein, they will fall within the spirit and the scope of invention as described and set forth in the appended claims.

Number	Name	Date	Kind
2190336	Olson	Feb 1940	A
3469892	Langstroth	Sep 1969	A
3982286	Foster	Sep 1976	A
4466144	Lamb	Aug 1984	A
4486056	Brandenstein et al.	Dec 1984	A
4577352	Gautheron	Mar 1986	A
4815863	Forster	Mar 1989	A
4939798	Last	Jul 1990	A
4967424	Stegmeier	Nov 1990	A
5349707	Last	Sep 1994	A
5799342	Last	Sep 1998	A
5845343	Last	Dec 1998	A
5950253	Last	Sep 1999	A

Extruded track construct component system with threaded radial bearing end pulley for swimming pool cover systems

Information

Patent Number

Date Filed

Date Issued

Inventors

Examiners

Agents

CPC

US Classifications

Field of Search

US

International Classifications

Abstract

Description

Claims

US Referenced Citations (13)