POOL COVER SYSTEM AND ASSOCIATED MANUFACTURING PROCESS

BACKGROUND

This disclosure relates to a pool cover system and process of manufacturing a pool cover system wherein the pool cover allows for the pool cover to selectively overlie/cover a pool basin and support loads thereon. The system can support the loads at the same level or height as a deck surrounding a perimeter of the pool when the pool cover is fully raised/elevated, and/or selectively move within the pool basin so that the partially or fully submerged pool cover forms a pool floor to provide a variety of pool depths. Different embodiments of the present invention are disclosed herein, but it should be noted that the present disclosure may find application in related fields.

Pools have been a luxurious addition to a homestead for hundreds of years. Many pools are equipped with pool covers for a number of different reasons.

A number of pool covers are soft bodied plastic structures that extend across the length and width of the pool to completely cover the pool surface or pool basin. Typically, these soft body pool covers can be made of UV-stabilized polyethylene, polypropylene, or vinyl. Further, some of these soft body plastic covers use what are referred to as bubble covers, for example a thick plastic that includes air pockets or bubbles sealed therein for buoyancy and/or insulative effect. Like other pool covers, the bubble cover may include a UV inhibitor additive to counteract deterioration of the plastic caused by exposure to sunlight. Unfortunately, these soft body plastic covers cannot support heavy loads on top of the cover (e.g., on the order of 40 lbs/ft²) that would allow the pool cover to serve as a continuation of the deck to increase deck square footage when there is no desire to use the pool for swimming. Moreover, soft body plastic pool covers are tedious to manually put on (cover the pool surface) and take off (uncover the pool surface). Other drawbacks associated with a soft body plastic pool cover include storage of the cover, unsightly electrical and/or mechanical components (e.g., ratchet/winch, cable, reel, tie-downs, etc.) that take up space alongside the pool if an automatic or semi-automatic pool cover is used, and deterioration over time from weathering that causes undesired frequent replacement.

Another type of pool cover relates to a movable floor pool cover. Moving floor pool covers are pool covers that include a mechanism that moves (raises and lowers) the floor in the pool basin. This allows the pool owner to position the movable floor at a desired depth/height (e.g., partially or fully lowered or submerged in the pool water to provide different pool depths), or the pool floor can be positioned such that the movable pool floor is fully raised/elevated and completely overlies the water surface and the pool cover forms a continuation of and advantageously expands the usable pool deck surface.

These types of movable floor pool covers are typically very expensive and are only available to a select portion of the population of pool owners. Known weight supporting pool covers are typically fabricated as a joist and beam construction that utilizes stainless steel.

Further, these movable floor pool covers require intensive on-site construction that is often undesired.

Since these movable floor pool covers are made of metal, they also require a separate buoyant element such as a component(s) that extends the depth/volume of the cover and the component has a density that is significantly less than water. Still other pool cover manufacturers allow the cover to sink and instead have cables hanging/lifting the submerged pool cover that introduces a potential trap hazard between for example the cable and wall.

Lastly, these movable floor pool covers are inherently poor insulators.

A need exists for a pool cover system having a movable floor pool cover that is more affordable, prefabricated, doesn't require a separate buoyancy element(s), is a good insulator, and can support direct loads such as required by local codes (e.g., residential codes require on the order of 40 lbs/ft²), or whatever the particular code requires, as well as resolving still other problems with existing systems, and offering other advantages and benefits over known arrangements.

SUMMARY

There is provided a new system for a moving pool cover system for an associated pool having a predetermined surface area where the pool cover is a monocoque/monolithic (i.e., no joints/seams) structure that has no framework and exhibits a good R value (e.g., R value of 30).

More particularly, the moving pool cover system includes a pool cover having a perimeter that is configured to cover the associated pool surface area. The pool cover has a buoyant, insulating, and rigid monolithic composition. A depth control system selectively raises and lowers the pool cover of the associated pool.

A seal is operatively associated with the perimeter of the pool cover and/or the associated pool edge/wall perimeter and the seal is operatively interposed between the pool cover perimeter and the associated pool.

The pool cover is preferably a composite body with no framework, and if the composite body includes multiple portions, the individual monolithic portions are connected together but do not include a framework that extends across an interface of the individual components.

The monolithic composite body includes a plurality of closed cells.

The plurality of closed cells are preferably filled with foam.

The pool cover can support loads that satisfy the required building code, e.g., at least 40 lbs/ft².

The pool cover may include at least one of cosmetic flooring or panels that form a top surface of the pool cover, i.e., an extension or continuation of an existing deck that surrounds the associated pool, and alternatively the top surface of the pool cover may include functional aspects, e.g., solar panels could be added thereto over at least a portion of the pool cover top surface. One example would be the inclusion of embedded/walkable photovoltaic solar panels that could be used to generate and/or contribute to the DC power requirements of the motor that moves the pool cover. This provides the potential to entirely power the pool cover by solar panels, i.e., a power source that is entirely low voltage and not connected to the electrical grid, or the electricity generated thereby could be distributed elsewhere in a residence/commercial application.

The depth control system in one embodiment includes a raising/lowering mechanism that may include a winch system having a winch motor and winch drum connected to and selectively raising/lowering the pool cover.

The depth control system in one embodiment is preferably affixed to a bottom surface of the pool cover.

The depth control system may include a flexible member that engages the winch drum and is secured to the pool cover.

The flexible member of the depth control system may include at least one of a strap, rope, cable, or plastic-coated wire.

The depth control system may include at least one pulley configured to be secured to the associated pool, and use a motor for powering the depth control system, or use more than one motor to provide additional power and/or faster movement, and could also allow the floor to be sloped if desired, include separate horizontal panel portions at different heights/depths with an intermediate, interconnecting or transition panel that slopes between the different depths.

The depth control system may also include an electric winch system such as a winch motor and winch drum configured to be secured to one of a side or bottom surface of the associated pool (and if the winch system is secured to the side of the associated pool, the winch system is preferably not submerged in water).

The depth control system may alternatively include a hydraulic cylinder mounted to the bottom surface of the pool cover, a pulley mounted to the bottom of the pool cover, and a flexible member configured to be secured to a bottom surface of the associated pool.

The perimeter of the pool cover preferably includes an inflatable seal member and an inflating member that selectively inflates the inflatable seal member.

In one version, the seal member is configured to be received by the associated pool.

Another aspect of the present invention is a prefabricated pool system that includes, for example, a precast pool, a pool cover having a perimeter that is configured to cover the pool surface area, the pool cover having a buoyant, insulating, and rigid composition, a depth control system that raises and lowers the pool cover of the precast pool, and a perimeter seal operatively interposed between the pool cover perimeter and the pool.

In still another embodiment, the pool system need not necessarily be precast but could alternatively be at least a partially or fully filled, i.e., light-weight or partially filled structure such as an insulated concrete form (ICF) for reducing mass for handling and/or delivery of the pool system, or the entire pool system produced from composite.

A primary benefit of the present invention is the provision of a buoyant, rigid pool cover.

Another advantage resides in the monolithic structure of the pool cover.

Still another benefit is found in the capability of supporting loads on the order of at least 40 lbs/ft².

Yet another feature is the high insulating value of the pool cover.

A still further benefit is associated with the substantial cost savings associated with labor relating to installation of existing rigid pool cover systems.

The pool cover also limits the potential for accidents, including meeting required residential code standards for limiting intrusion of and/or preventing debris from entering into the pool; protecting the pool from weather; limiting the potential for and reducing pooling of water on the closed cover when compared to known pool cover systems; providing insulation which consequently reduces heating costs associated with heating the pool water, conserving water by reducing evaporation, reducing chemical consumption, lowering insurance costs as a result of including a cover, etc.

Still other benefits and advantages will become apparent upon reading and understanding the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1C depicts a movable pool cover system with a pool cover in first, second, and third positions in accordance with some embodiments of the present disclosure.

FIG. 2 illustrates a section through a portion of an exemplary pool cover in accordance with some embodiments of the present disclosure.

FIGS. 3A-3B depict two views of a cosmetic surface assembly of an exemplary pool cover in accordance with some embodiments of the present disclosure.

FIG. 4 illustrates another exemplary movable pool cover system in accordance with some embodiments of the present disclosure.

FIG. 5 illustrates another exemplary movable pool cover system in accordance with some further embodiments of the present disclosure.

FIGS. 6A-6C illustrate another exemplary movable pool cover system in accordance with further embodiments of the present disclosure.

FIGS. 7A-B illustrate a preferred exemplary perimeter sealing assembly in accordance with some embodiments of the present disclosure.

FIGS. 8A-8D illustrate an exemplary precast plunge pool system in accordance with some embodiments of the present disclosure.

FIGS. 9A and 9B depict the plunge pool system in FIG. 8 in open and closed configurations, respectively.

FIG. 10 illustrates use of walkable solar panels in the pool system.

FIGS. 11-16 illustrating gutter systems that maintain desired insulative features.

DETAILED DESCRIPTION

The following description with reference to the accompanying drawings is provided to assist in a comprehensive understanding of one or more embodiments of the present disclosure as defined by the claims and their equivalents. It includes various specific details to assist in that understanding but these are to be regarded as merely exemplary. Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the various embodiments described herein can be made without departing from the scope and spirit of the present disclosure. Various exemplary embodiments of the present disclosure are not limited to the specific details of different embodiments and should be construed as including all changes and/or equivalents or substitutes included in the ideas and technological scope of the appended claims. In describing the drawings, where possible similar reference numerals are used for similar elements.

The terms “include” or “may include” used in the present disclosure indicate the presence of disclosed corresponding functions, operations, elements, and the like, and do not limit additional one or more functions, operations, elements, and the like. In addition, it should be understood that the terms “include”, “including”, “have” or “having” used in the present disclosure are to indicate the presence of components, features, numbers, steps, operations, elements, parts, or a combination thereof described in the specification, and do not preclude the presence or addition of one or more other features, numbers, steps, operations, elements, parts, or a combination thereof.

The terms “or” or “at least one of A or/and B” used in the present disclosure include any and all combinations of words enumerated with them. For example, “A or B” or “at least one of A or/and B” mean including A, including B, or including both A and B.

Although the terms such as “first” and “second” used in the present disclosure may modify various elements of the different exemplary embodiments, these terms do not limit the corresponding elements. For example, these terms do not limit an order and/or importance of the corresponding elements, nor do these terms preclude additional elements (e.g., second, third, etc.) The terms may be used to distinguish one element from another element. For example, a first mechanical device and a second mechanical device all indicate mechanical devices and may indicate different types of mechanical devices or the same type of mechanical device. For example, a first element may be named a second element without departing from the scope of the various exemplary embodiments of the present disclosure, and similarly, a second element may be named a first element.

It will be understood that, when an element is mentioned as being “connected” or “coupled” to another element, the element may be directly connected or coupled to another element, and there may be an intervening element between the element and another element. To the contrary, it will be understood that, when an element is mentioned as being “directly connected” or “directly coupled” to another element, there is no intervening element between the element and another element.

The terms used in the various exemplary embodiments of the present disclosure are for the purpose of describing specific exemplary embodiments only and are not intended to limit various exemplary embodiments of the present disclosure. As used herein, the singular forms are intended to include the plural forms as well, unless the context clearly indicates otherwise.

All of the terms used herein including technical or scientific terms have the same meanings as those generally understood by an ordinary skilled person in the related art unless they are defined otherwise. The terms defined in a generally used dictionary should be interpreted as having the same meanings as the contextual meanings of the relevant technology and should not be interpreted as having inconsistent or exaggerated meanings unless they are clearly defined in the various exemplary embodiments.

This written description uses examples to describe the disclosure, including the best mode, and also to enable any person skilled in the art to make and use the disclosure. Other examples that occur to those skilled in the art are intended to be within the scope of the invention if they have structural elements that do not differ from the same concept or that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the same concept or from the literal language of the claims. Moreover, this disclosure is intended to seek protection for a combination of components and/or steps and a combination of claims as originally presented for examination, as well as seek potential protection for other combinations of components and/or steps and combinations of claims during prosecution.

FIGS. 1A-1C illustrate a movable pool cover system 100 of the present disclosure where a pool cover 102 is moved through various positions (compare FIGS. 1A, 1B, and 1C) in an associated pool 104. FIG. 1A shows the movable pool cover system 100 with the pool cover 102 at its deepest depth in the associated pool 104. In this configuration, water 106 fully preferably covers the pool cover 102 and the pool cover 102 acts as the floor of the associated pool 104. In some embodiments, the pool cover 102 is rectangularly shaped. However, in further embodiments it is to be appreciated that other geometric designs such as ovular, triangular, circular, freeform (i.e., irregularly-shaped), etc., can be provided without departing from the scope and intent of the present disclosure. The pool cover 102 has a perimeter shape to match or accommodate the perimeter shape of the associated pool 104.

FIG. 1B illustrates the pool cover 102 moved upwardly in the associated pool 104. It is to be appreciated that by utilizing a depth control system (not pictured) the pool cover 102 can be positioned anywhere between the top lip of the associated pool 104 (e.g., such as being flush with the deck that surrounds the associated pool), and a fully submerged position where a bottom surface of the pool cover 102 comes in contact with a bottom surface of the associated pool 104. As the pool cover 102 moves in the associated pool 104, the water flows between the outer perimeter of the pool cover 102 and the inner perimeter or sidewall(s) of the associated pool.

FIG. 1C depicts the pool cover 102 in a fully raised, closed deck orientation meaning that a top surface of the pool cover 102 is flush or coplanar/in-line with the top edge of the associated pool 104. This locates the upper surface of the pool cover 102 to preferably be a continuation or substantial continuation of the deck that surrounds the associated pool 104. When the pool cover 102 is in its closed deck orientation, the pool cover is capable of meeting relevant residential or building code requirements for structural deck requirements, such as supporting at least 40 lbs/ft²live load.

FIG. 2 illustrates a preferred pool cover 102 with a buoyant, insulating, and rigid, monolithic/monocoque composition in accordance with some embodiments of the present disclosure and that is capable of meeting the supporting requirement—such as at least 40 lbs/ft². A preferred arrangement of the composite pool cover 102 is formed of a fiberglass fabric that wraps around exterior edges and surfaces to form an encompassing cover body 110. Contained within the structure of the preferred pool cover 110 are a plurality of fiberglass shear webs 112 interspersed in spaced locations between a closed cell foam 114 that together fill an internal void of the surrounding fiberglass cover body. The webs 112 in the preferred arrangement span the cross-section of the void to act as rigid strengthening members or struts that compartmentalize the closed cell foam 114. As illustrated, the webs 112 are generally evenly spaced throughout the cross-section and extend over the height/depth of the pool cover to facilitate the transfer of load from an upper surface to a lower surface of the fiberglass cover body. In addition, a face sheet laminate 116 is preferably included for further strength and rigidity, and is shown as extending along an entirety of the interior surface of lower portion of the composite cover body, which in one example uses fiberglass.

The composite structure of the pool cover 102 is a unitary solid body that is buoyant such that the pool cover does not require an additional buoyancy or flotation element in order to float on the water. Advantageously, the pool cover 102 is a rigid structure that can withstand forces without deformation, i.e. capable of supporting loads of at least 40 lbs/ft². The fiberglass shear webs 112 are enclosed by the closed cell foam 114 to make the pool cover a solid body, with the cover body 110 preferably comprised of a fiberglass wrapping. The laminate can be used to coat the bottom and/or top surface of the cover body to add further strength and rigidity, and further seal the closed cells 112 from the water. In addition to providing the desired buoyancy to the pool cover 102, the composite structure and particularly the closed cell foam 114, advantageously serves as an insulator to reduce energy costs associated with heating the pool water. Advantageously, the insulative properties are effective in keeping heat both in and out of the pool.

FIGS. 3A and 3B illustrate an exemplary pool cover 102 that includes a cosmetic surface 130. For example, the cosmetic surface 130 of the pool cover can adopt a wide variety of final designs, surface finishes, etc. to meet the desired needs of the owner, and may include an assembly of flooring sections 132 provided along the top surface of the pool cover 102. The flooring sections 132 may be of tile, wood, ceramic, composite, metal, vinyl, and/or a combination thereof (and likewise other suitable materials) to provide a wide choice of surfaces that can match or enhance the surrounding pool deck when the pool cover 102 is fully raised to act as a continuation of the pool deck. The flooring sections 132 are affixed to the pool cover such as through use of an adhesive. An access panel(s) or cutout(s) 134 may also be provided in the cosmetic surface of the pool cover 102 such that the underside of the pool cover can be accessed for maintenance or repair purposes.

FIG. 4 illustrates an exemplary movable pool cover system 200 in accordance with some embodiments of the present disclosure. The movable pool cover system 200 shown here includes a pool cover 202 that is dimensionally configured to cover the entire surface area of an associated pool 204. The pool cover 202 includes at least one of a buoyant, insulating, and/or rigid body composition (for example as described above). Further the movable pool cover system 200 has a perimeter that is dimensionally configured to mate with the conformation of the associated pool 204.

The movable pool cover system 200 further includes a depth control system 206 that selectively raises and lowers the pool cover 202 relative to and within the associated pool 204. In one preferred embodiment, the depth control system 206 includes a hydraulic piston and cylinder assembly (cylinder 210 and piston 218) wherein the cylinder 210 is mounted to the pool cover 202. The hydraulic cylinder 210 is connected to a hydraulic line or hose 212 which supplies a pressurized fluid to the cylinder 210 and actuates the piston 218 to move relative to the cylinder. Pulleys 214 are mounted to the bottom of the pool cover 202 and cooperate with a flexible member 214. The flexible member 214 is preferably secured at one end thereof to a bottom surface of the associated pool 204 and secured at another end to the piston (which is indirectly secured to the bottom of the pool cover). The flexible member preferably extends around one or more pulleys as desired so that selective extension and retraction of the piston relative to the cylinder results in desired raising and lowering of the pool cover relative to the pool bottom/surrounding pool deck. The flexible member 214 may, for example, be a strap, rope, cable, a plastic-coated wire, etc., that is designed for use in the pool environment, and has sufficient engineered strength and flexibility to repeatedly raise and lower the pool cover 202 relative to the pool 204 as needed.

FIG. 5 illustrates a further embodiment of a movable pool cover system 300. The movable pool cover system 300 includes a pool cover 302 that covers substantially all of the surface area of the pool basin 304 such that the pool cover may be used as a deck when the top surface of the pool cover is aligned with the top edge of the pool basin 304. Further, the pool cover 302 acts as an insulating layer due to the insulative properties of the materials used to construct the pool cover, and because a perimeter sealing element (a preferred seal shown and described below in connection with FIG. 7) is affixed along the pool cover perimeter to seal and lock the cover in the raised position where the pool cover is essentially flush with the surrounding pool deck. The movable pool cover system 300 also includes a depth control system 306 which in this embodiment is affixed to the bottom surface of the pool cover 302. The depth control system 306 as shown in FIG. 5 includes at least one winch drum 310 powered for selective rotation by winch motor 312. The pool cover 302 is selectively raised and lowered in the pool basin 304 by the winch drum 310 engaging a flexible member 314. The flexible member 314 is configured to be received by a receiving member 316 which is affixed to the bottom surface of the pool basin 304 and the flexible member 314 is then preferably affixed to the bottom or underside surface of the pool cover 302. By returning the flexible members/ropes 314, attaching them to the underside of the pool cover/deck 302, and returning the flexible members/ropes to the location where the winch/drum 310/312 is mounted improves accessibility and allows adjustments to be easily made to the length of that terminated end and thereby ‘trim’ the level of the pool cover/deck. For example, all four (in this case) flexible members/ropes 314 can be set or adjusted to the same length/tension without having to access or dive to the floor of the pool basin 304. Also, again in this example, four flexible members/ropes 314 are arranged so that two travel in each direction so that there is no net force vector on the motor mounting.

FIG. 6A depicts still another embodiment of a moving pool cover system 400. The pool cover system 400 includes a pool cover 402 which has a plurality of pulleys or roller members 410 which are mounted to the bottom surface of the pool cover 402 and pool basin 404. These pulleys 410 are part of a depth control system 406 that includes flexible members 416 (lines, cables, etc.) that extend around the pulley arrangement 410, and select flexible members have terminal ends that are affixed to the pool floor. The flexible members 416 are secured and wrapped around winch drums 418 that are preferably positioned outside of the body of water, i.e., exteriorly of the associated pool 404, so that the flexible members are paid out or reeled in to selectively raise and lower the pool cover 402 relative to the pool 404. This arrangement also allows the pool cover 402 to be stabilized at various depths relative to the pool deck/pool bottom. In addition, by locating attachment points of the flexible members 416 at spaced locations about the pool cover 402, the pool cover can be efficiently and effectively raised and lowered, and directing all flexible members to a single location allows adjustability of the entire pool cover to be easily accomplished at the single location. By ‘looping back’ all flexible members 416 and terminating the flexible members at the deck, that is in an accessible area such as an access hatch (FIG. 6B), repair and maintenance is substantially improved without impinging on the remainder of the pool. As shown in FIG. 6B, the top plan view of the deck with the access hatch removed shows eyebolts or turnbuckles 420 that secure or ground all of the flexible members to the pool deck, and the eyebolts or turnbuckles ca be easily adjusted to trim the deck height or level from an easily accessible location. FIG. 6C further illustrates an underside of the deck and shows where the motor is mounted under the access hatch opening. This is one example of locating the motor that operates the drum/winch to which one end(s) of the flexible member(s) are secured and the use of eyebolts alongside where the other ends of the flexible member(s) are terminated.

FIGS. 7A-B depict one preferred embodiment of a perimeter sealing assembly or system 450 that includes a collapsible or an inflatable seal member 452 (or vacuum operated seal that is selectively deflated) that is received or mounted in a recess 454 of the perimeter 456 of the pool cover 458. The seal assembly 450 can be actuated by an inflating member (not shown) by changing the internal pressure of the collapsible seal member 452, or collapsed by deflating the seal member with a vacuum operated version. The collapsible seal member 452 may use a vacuum source to retract the seal member away from the wall but in its natural position the seal member will press/lock against the wall 460 of the associated pool, and particularly a recess 462 in the pool wall. This is arguably a better failsafe arrangement, i.e., if a pump fails the pool cover/platform is secured since the seal member 452 does not collapse, versus if an inflatable seal is used, if the pump fails or there is a leak then the benefit of the seal member is lost. When the seal member 452 is received in the recess 454, the seal member thereby “locks” the pool cover in position, i.e., helps to lock out the deck position. The perimeter sealing system 450 will seal along the outer perimeter of the pool cover. In some further embodiments the seal can act as an engaging mechanism when the pool cover is in the fully raised position by frictionally engaging the perimeter 456 of the pool cover 458 with the associated pool 460, e.g., by engaging a receiving feature 462 in the perimeter of the associated pool. The receipt of the seal 452 in a recess 462 of the associated pool 460 creates greater load bearing capacity provided in part by the seal, and thus would allow elimination in the use of pins, or a reduction in the number of pins, that may otherwise be provided to lock the pool cover in the fully raised position.

The sealing assembly 450 may be compartmentalized and yet the sealing assembly extends around the entire perimeter of the pool cover. In this manner, select portions of the sealing assembly 450 can be actuated at any depth, e.g., first and second opposite ends could be actuated (i.e., the seal 452 inflated at the first and second ends) and other regions of the sealing assembly are not actuated, e.g., opposite first and second sides are not actuated so that water can still pass around the perimeter of the pool cover to allow the pool sanitation system to function effectively. In that condition, the inflated seal portions provide stability, and a sturdy, solid surface that does not rock, roll, tilt, or pitch. Further, when the pool cover reaches, the fully raised (or other predetermined position), the entire perimeter of the sealing assembly 450 can be actuated and the inflated seal portions 452 are received in the associated recesses 462 to provide added stability and weight capacity. In addition to locking and weight bearing capabilities provided by the seal assembly, in some environments, sealing is a primary concern due to water shortages, and the concerns associated with evaporation of the pool water. The present sealing assembly of the pool can provide 100% sealing of the pool basin, so that there is reduced, i.e., zero evaporation, when the seal assembly is actuated in the pool closed condition. As a result, pool owners may be permitted to own larger pools if fitted with the features of the present disclosure.

A gutter assembly 470 may also form a portion of the pool wall and the gutter assembly preferably includes a gutter 472 that is surrounded by foam 474 for insulating effect. Cover or tile 476 received in recessed shoulders 478 of the pool deck overlay the gutter 472.

The buoyancy of the monolithic pool cover assists in raising the pool cover, and the flexible members restrain the pool cover in the upward movement in the water. On the other hand, when the pool cover is lowered in the water, the lines overcome the buoyant force and move the pool cover downwardly.

FIGS. 8A-8C depict a prefabricated pool system 500 in accordance with some embodiments of the present disclosure. The prefabricated system 500 includes a precast unibody pool 502 which includes an overflow gutter, an equipment room, and a surge tank. The precast pool 502 further includes a pool cover 504 that is configured to cover the precast pool basin 506 surface area. The pool cover 504 is a buoyant, insulating, and rigid composition. A depth control system is mounted, for example, to the bottom surface of the pool cover 504. In some embodiments the precast pool basin can have a hopper bottom 510. The hopper bottom 510 has sloped sides (see FIGS. 8B-8C in particular) such that debris and other contaminants naturally are collected under the pool cover 504 which maintains a cleaner surface. The prefabricated pool system 500 sometimes referred to as a plunge pool, preferably includes an equipment room 512 and surge tank 514 that receives water displaced from the pool as people enter the pool 502. The surge tank 514 advantageously acts as a reservoir from which water can be re-introduced to the pool when people exit the pool, and thus water is not “lost” to the pool deck or other area surrounding the pool or pool deck. Gutter 516 has similar structural and functional attributes to the gutter described in connection with FIGS. 7A-7B, and also to FIGS. 11-16 to be described below.

In a further embodiment (FIG. 8B), the precast pool 502 can include a perimeter water return mechanism 530 which includes a perimeter water supply which delivers flow or water so debris movement is towards the main drain 532. The arrows in FIG. 8C show the movement of water inwards and downwards over the bottom floor of the hopper 510 to keep debris moving towards the drain 532 and pump pick up and thus into the debris basket of the pump and/or the filter of the pool system. A custom extrusion 530 extends around the perimeter of the hooper floor to direct the water inwards toward the main drain 532. More particular details of one form of the custom extruded extrusion is triangular in shape (FIG. 8D) so any debris that falls on it will tumble down the slope and into the path of the flowing water and thus be directed towards the drain 532, i.e., no dead spots where debris can undesirably collect. The custom extrusion 530 downwashes the flow of water across the floor surface of the hopper bottom and aids in the cleanliness of the pool.

FIGS. 9A and 9B depict the prefabricated plunge pool system wherein the prefabricated plunge pool system is comprised of a concrete body and includes a movable pool cover system shown in the lowered (FIG. 9A) and raised (FIG. 9B) positions and access panels 540 to selectively provide an opening(s) 542 in the pool cover 504, and a unique pool system configuration of a pool 500, surge tank 514, and equipment room 512 for ‘built on site’ pools of all sizes.

There are companies that manufacture walkable solar panels (solar panels that can be walked on without adversely degrading or impacting operation of the solar panels). These may also include ‘veils’ for disguising the solar panels as decking, etc. The present disclosure may incorporate such walkable solar panels 600 into the surface of the pool cover and/or decking that surrounds the pool so that at least a portion of the surface area surrounding the pool, or all of the deck surface area, can advantageously harvest solar energy, which could then be used to operate the deck and/or the entire plunge pool operation. Alternatively, the electricity generated by the solar panels could be distributed elsewhere in a residence/commercial application.

As part of a preferred pool design, a gutter is required to collect overflow water displaced from the pool cavity. However, it is also desired to maintain the elevated insulation rating associated with the pool cover concepts of the present disclosure when a gutter assembly is included in the system. Thus, to achieve both of these goals, and as shown in different versions of the gutter assembly, FIGS. 11-15 show multi-piece gutter assemblies, while FIG. 16 provides a less labor intensive, single piece extrusion that forms a fiberglass gutter 700 surrounded or filled with foam (somewhat similar to the deck construction). This is likely to be a pultrusion form (if the gutter 700 remains formed from fiberglass) or perhaps PVC extrusion. Under either scenario, filling the form with foam 702 and including in the shape of the gutter form a recess feature 704 for the inflatable seal (FIG. 14—located in the deck (FIG. 7) to ‘lock’ in to) can achieve these goals. If the gutter has a larger/additional capacity, perhaps in a ‘pannier’ type arrangement down the side of the supporting concrete wall 706 to store the water and negate the need for a surge tank.

A control screen for the pool system may also display how much energy and/or water is being saved when the pool cover is closed. The energy savings may be compared to an open pool—perhaps displayed as kWh and Gph.

An extension of the control screen energy savings concept is to record an ongoing benefit to the environment that may be displayed as a ‘counter’ for example on a company webpage. Still another ‘setting’ for a digital display is to show in the tiles surrounding the pool, the depth of the pool at any given time, i.e. another manner of evidencing the depth location of the pool cover. Rather than numerical digits displaying the depth, another manner of conveying this information would be using images that depict the appropriate activities. Still other display features may include allowing pre-set depths to be selected. Further, the movement can then be interrupted (stopped) at any point between if desired. A user may also be able to configure the system to select a favorite depth(s) somewhat like having memory positions for the seats in many cars.

An “ice rink” option for certain climates would allow the pool depth to be set to just a few inches deep, flooded at that depth, and sealed, so that ice is formed and the pool is suitable to be used for skating.

In summary, the present disclosure provides a pool cover that reduces the use of electricity, water, and chemicals, whilst providing the best water quality. The movable pool cover provides for year-round pool use. The pool cover provides for infinitely adjustable pool depth, thereby allowing the pool to be alternately used as a reflecting pond, wading pool, games pool (e.g., water volleyball, etc.), swimming pool, diving pool, or as an extension of the surrounding pool deck.

The pool cover is fully load rated (at least 40 lb/ft²), while providing an attractive pool cover that matches or contrasts with the surrounding pool deck, and can be easily customized to accommodate the desired style or aesthetics of the owner.

A prefabricated, highly insulated, perimeter overflow, in-ground plunge pool design version is capable of being installed in mere hours while still advantageously offering the benefits of the movable pool cover.

When closed, the pool cover is positively sealed thereby saving water, chemicals, and heating costs, while keeping the water crystal clear. When open, the perimeter overflow design promotes continuous flow, around all sides of the pool to the surge tank and back. This achieves the highest sanitation results for pools.

The pool cover is a monocoque type construction, where the structure and top are monolithic. The pool cover is highly insulating (e.g., R30 value), highly buoyant, and is a prefabricated structure that is largely complete prior to shipping. The monolithic structure advantageously spans the entire width and/or length of the pool and is capable of supporting deck live loads, i.e., typically on the order of at least 40 lb/ft².

Desirably, perimeter sealing is a design feature of the movable pool cover. During movement and pool operation, water has to be able to pass from one side of the platform/deck/pool cover to the other side. In the past, this is accomplished with a perimeter gap, and at other times by providing gaps within selected area(s) of the pool cover. These gaps in prior designs offer zero insulation whereas the present invention applies the use of an inflatable seal to close gaps when the pool is not in use and so maximize insulative properties. Using the selectively actuated, inflatable seal further enhances thermally insulating the cover. The seal is preferably actuated by changing an internal pressure thereof relative to the outside. A further use of an inflatable seal around the perimeter of the ‘deck’ could be to perform the ‘lock out’ function (i.e., when the movable cover is in the fully raised position) by either of the two following methods: i) friction brake, i.e., the lockout is a function of friction coefficient and force applied; and ii) a member in shear, i.e., the seal can engage with an appropriate feature (e.g., recess) in the wall that prevents vertical movement of the pool cover. Thus, the present disclosure can use an actuated seal as a friction device, or use an actuated seal as a shear device, and can achieve these objectives by changing an internal pressure of the inflatable seal member relative to outside. the floor can be formed in a ‘hopper’ type shape, which promotes self-cleaning.

It may be that no traditional pool cleaner is required as a result of providing a pool with a ‘false floor’ that enables safe deployment of a hopper bottom that provides self-cleaning functionality. Re-introducing water to the pool vessel around the entire perimeter of the floor ensures direction of flow is towards the lower pressure central drain location of the hopper bottom. A pool with a hopper bottom and perimeter supply is designed to provide balanced flow and so to ensure water flow and so debris movement is towards the main drain. By introducing water at the bottom of the pool when the pool is ‘open’ (i.e., when the inflatable seal is deflated) and the perimeter overflow is working, then the constant flow of water upwards, around the perimeter of the pool cover, will actually limit the opportunity for debris to fall down through that same space and dirty the bottom of the pool.

Since the movable pool floor traverses up and down the pool walls, it is possible to employ a brush arrangement that will clean the walls around the perimeter of the pool as the pool floor passes up and down, yet still allow the water to flow from one side of the pool cover to the other. A movable pool floor with an arrangement of brush strips around its perimeter would effectively provide a full coverage cleaning of the walls whilst still allowing water to flow from one side to the other (i.e., top to bottom or vice-versa).

By using engaging pins between the movable pool cover (in the fully raised position where the pool cover acts as a deck structure) and the pool walls at each end, and along the long axis of the pool, could allow the pool cover to be rolled/rotated to expose the underside for major maintenance.

Upward travel of the buoyant pool cover deck can be effectively limited to thereby position the buoyant pool cover by using tethers that are effective for locking, hidden, and adjustability between the pool floor and an underside of the movable pool cover. Furthermore such tethers can be installed in a diagonal fashion so as to contribute to the accurate positioning of and thereby maximize lateral stability of the pool cover when the tethers are tensioned. The tension in these tethers i.e., when the pool cover platform is fully raised, can be effectively used to actuate some kind of seal/locking mechanism as described above.

A precast concrete pool that includes equipment, and a rigid, structural pool cover/deck such that the pool can be completely ‘hidden’ when not in use can be provided. A partially filled ICF based pool structure can also provide sufficient structure for transportation while effectively minimizing the weight that is handled during delivery/installation. The structure can be delivered in a state that facilities ease of filling the remaining cavities.

The exemplary embodiment has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the exemplary embodiment be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.

POOL COVER SYSTEM AND ASSOCIATED MANUFACTURING PROCESS

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