U.S. patent application number 11/876696 was filed with the patent office on 2008-05-08 for pool assemblies and methods of manufacture thereof.
Invention is credited to James Joseph Beaudoin, Anthony J. Suco.
Application Number | 20080104745 11/876696 |
Document ID | / |
Family ID | 39358402 |
Filed Date | 2008-05-08 |
United States Patent
Application |
20080104745 |
Kind Code |
A1 |
Beaudoin; James Joseph ; et
al. |
May 8, 2008 |
POOL ASSEMBLIES AND METHODS OF MANUFACTURE THEREOF
Abstract
A wall panel comprises a first metallic skin, a second metallic
skin, and an insulating layer interposed therebetween. The first
and second metallic skins are attached to insulating layer with a
water-based adhesive. In one embodiment, the water-based adhesive
is a water dispersed, high solid, activated adhesive. In another
embodiment, the water based adhesive is a one hundred percent
waterborne adhesive. In another embodiment, the water-based
adhesive is a dispersion of an acrylic resin and synthetic rubber
in water.
Inventors: |
Beaudoin; James Joseph;
(Balston Spa, NY) ; Suco; Anthony J.; (Melross,
NY) |
Correspondence
Address: |
Patrick Patnode
18 Magnolia Drive
Saratoga Springs
NY
12866
US
|
Family ID: |
39358402 |
Appl. No.: |
11/876696 |
Filed: |
October 22, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60853620 |
Oct 23, 2006 |
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Current U.S.
Class: |
4/506 |
Current CPC
Class: |
E04C 2/292 20130101;
E04H 4/0043 20130101 |
Class at
Publication: |
004/506 |
International
Class: |
E04H 4/14 20060101
E04H004/14 |
Claims
1. A wall panel comprising: a first metallic skin; a second
metallic skin; and an insulating layer interposed therebetween;
wherein said first and said second metallic skins are attached to
said insulating layer with a water-based adhesive.
2. A wall panel in accordance with claim 1, wherein said first and
second metallic skins comprise an acrylic coated aluminum.
3. A wall panel in accordance with claim 1, wherein said insulating
layer comprises foam.
4. A wall panel in accordance with claim 1, wherein said insulating
layer comprises polystyrene.
5. A wall panel in accordance with claim 1, wherein said insulating
layer comprises expanded polystyrene.
6. A wall panel in accordance with claim 1, wherein said insulating
layer is between about 1 inch to about 3 inches thick.
7. A wall panel in accordance with claim 1, wherein said water
based adhesive is a water dispersed, high solid, activated
adhesive.
8. A wall panel in accordance with claim 1, wherein said water
based adhesive is a one hundred percent waterborne adhesive.
9. A wall panel in accordance with claim 1, wherein said water
based adhesive is a dispersion of an acrylic resin and synthetic
rubber in water.
10. A wall panel in accordance with claim 1, wherein said water
based adhesive is sprayable.
11. A pool panel comprising: a first metallic skin; a second
metallic skin; and an insulating layer interposed therebetween;
wherein said first and said second metallic skins are attached to
said insulating layer with a water based adhesive.
12. A pool panel in accordance with claim 11, wherein said first
and second metallic skins comprise an acrylic coated aluminum.
13. A pool panel in accordance with claim 11, wherein said
insulating layer comprises foam.
14. A pool panel in accordance with claim 11, wherein said
insulating layer comprises polystyrene.
15. A pool panel in accordance with claim 11, wherein said
insulating layer comprises expanded polystyrene.
16. A pool panel in accordance with claim 11, wherein said
insulating layer is between about 1 inch to about 3 inches
thick.
17. A pool panel in accordance with claim 11, wherein said water
based adhesive is a water dispersed, high solid, activated
adhesive.
18. A pool panel in accordance with claim 11, wherein said water
based adhesive is a one hundred percent waterborne adhesive.
19. A pool panel in accordance with claim 11, wherein said water
based adhesive is a dispersion of an acrylic resin and synthetic
rubber in water.
20. A pool panel in accordance with claim 11, wherein said water
based adhesive is sprayable.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application relates to, and claims priority from,
provisionally filed US patent application having docket number
1000-2 and Ser. No. 60/853,620, entitled POOL ASSEMBLIES AND
METHODS OF MANUFACTURE THEREOF, filed on Oct. 23, 2006, which
application is hereby incorporated by reference.
BACKGROUND
[0002] The invention relates generally to pool assemblies and
methods of manufacture thereof, and more specifically to modular
pool assemblies and methods of manufacture thereof.
[0003] Conventional pool assemblies come in many shapes and sizes.
There are two main classes of pool assemblies, above-ground and
in-ground. Above-ground pools generally comprise a frame structure,
sidewalls and a pool liner. The advantages of above-ground pools
are that the pools are cheaper than most in-ground pools, easier to
install (although often requiring some level of professional
installation) and easier to disassemble and move to other
locations. The disadvantages are that above-ground pools are less
durable, more limited in design choices and generally less
aesthetically pleasing than in-ground pools. Alternatively,
in-ground pools have much greater durability and are extremely
flexible in design choices, however, in-ground pools are also
expensive to install and they typically cannot be moved once
installed. In addition, most systems, especially above-ground
systems, are not adaptable to partially in-ground, partially
above-ground installations.
[0004] Accordingly, there is a need in the art for an improved pool
assembly that is easy to install and durable for a variety of
above-ground, in-ground or partially above-ground, partially
in-ground applications.
BRIEF DESCRIPTION
[0005] A wall panel comprises a first metallic skin, a second
metallic skin, and an insulating layer interposed therebetween. The
first and second metallic skins are attached to the insulating
layer with a water-based adhesive. In one embodiment, the
water-based adhesive is a water dispersed, high solid, activated
adhesive. In another embodiment, the water based adhesive is a one
hundred percent waterborne adhesive. In another embodiment, the
water-based adhesive is a dispersion of an acrylic resin and
synthetic rubber in water. In one embodiment, an infrared curing
system is used to cure the water-based adhesive in the wall panel
assembly.
DRAWINGS
[0006] These and other features, aspects, and advantages of the
present invention will become better understood when the following
detailed description is read with reference to the accompanying
drawings in which like characters represent like parts throughout
the drawings, wherein:
[0007] FIG. 1 is a depiction of a pool assembly in accordance with
one embodiment of the instant invention.
[0008] FIG. 2 is schematic of a wall panel in accordance with one
embodiment of the instant invention.
[0009] FIG. 3 is a flow chart depicting a process in accordance
with one embodiment of the instant invention.
[0010] FIG. 4 is another schematic of a wall panel in accordance
with one embodiment of the instant invention.
[0011] FIG. 5 is a cross-sectional schematic of a wall panel and a
spline channel piece in accordance with one embodiment of the
instant invention.
DETAILED DESCRIPTION
[0012] This invention relates generally to a pool system 10
comprising a plurality of interlocking wall panels 12, as shown in
FIG. 1.
[0013] Depending on the final pool shape, each interlocking wall
panel 12 is typically arced at a predetermined curvature and
interlocked to adjacent panels 12 using a spline system 14, as
discussed in greater detail below. Once the pool system 10 is
formed by interconnecting the wall panels 12 to complete the
design, a liner (not shown) is fitted within the shell to form a
substantially watertight skin. A coping 18 is snapped over the
upper edge of the wall panels 12 to hold the liner in place and
provide a finished appearance to the pool system 10. The pool
system 10 can be fitted with additional components, as needed, for
example a skimmer assembly, an inlet, lighting, and steps, stairs,
or ladders.
[0014] Each wall panel 12 comprises a first metallic skin 20, a
second metallic skin 22 and an insulating layer 24 interposed
therebetween, as shown in FIG. 2. The first and second metallic
skins 20, 22 typically comprise an acrylic coated aluminum. The
thickness of metallic skins 20, 22 is typically greater than about
0.010 inches and most typically between about 0.015 and 0.030
inches. The acrylic coating is resistive to corrosion and is
generally more aesthetically pleasing than the base metallic
material. The insulating layer 24 typically comprises a foam, for
example an expanded polystyrene (EPS) or the like. The thickness of
the insulating layer 24 can vary but for most applications the
insulating layer is greater than about 1 inch in thickness and
typically is between about 1.5 inches to about 3 inches in
thickness.
[0015] The first and second metallic skins 20, 22 are attached to
opposing sides of the insulating layer 24, typically with an
adhesive 26. In one embodiment, the adhesive 26 comprises a water
based adhesive, for example commercially available 3M Fastbond
Contact Adhesive or Simalfa Water-Based Adhesive. Waterbased
adhesives use water as the carrier fluid, with the adhesive
particles suspended in water, reducing the adhesive's viscosity so
that it can be applied to various substrates at varying
thicknesses. The waterbased adhesives carry little or no Volatile
Organic Compounds (VOC) and are therefore, one option for
environmentally friendly and personnel friendly manufacture of the
wall panels 12. In addition, the water-based adhesives can be
readily applied to the wall panels using a hand-held spray gun. The
resulting wall panels 12 provide a significant advantage over most
conventional pool assemblies and methods of manufacture and
construction. The wall panels are lightweight due to the tri-part
panel design, typically using lightweight aluminum skins and a foam
core and easy to handle, yet extremely durable and sturdy.
[0016] As discussed above, above-ground pools are the cheapest
construction option, as well as the easiest to build. Most
above-ground pools are made from prefabricated kits that even an
amateur can put together (though most people go with professional
installers). First, the installers level off the ground to form a
flat building surface. Then they assemble a perimeter track that
supports the outer wall made of metal, plastic or wood. Next, they
spread sand in the pool area and lay the plumbing. Finally, they
secure the vinyl liner over the pool walls, fill the pool with
water, smooth the liner and fasten it into place. As soon as they
hook up the pump and filtering system, the pool is ready to go. The
main disadvantage of this sort of pool is that it's less durable
than other designs, and generally less attractive. The wall panels
12 of the instant invention can be used to replace the conventional
outer walls of the aboveground pools. Because of the durable panel
design and the simple spline system 14, pool systems 10 using these
panels can be installed easier than conventional systems and result
in a much more durable construction than conventional metal,
plastic or wood based systems.
[0017] Another option is fiberglass pools that are made from
fiberglass-reinforced plastic and molded into a basin shape. To
install the pool, a construction crew digs an appropriately sized
hole, lays the necessary plumbing, adds some sand filler and lowers
the preformed pool structure into the hole. Then they level the
pool, hook up all the plumbing and backfill in the area around the
pool. Usually, the pool is surrounded by a concrete deck structure.
Vinyl-lined in-ground pools are a lot like aboveground pools,
structurally, but they look more like conventional in-ground
designs. The construction crew digs a hole and assembles a metal,
plastic or wood frame wall around the hole's perimeter. As in an
above-ground pool, the crew lays sand along the bottom of the hole
and secures the vinyl lining to the structural wall. These pools
are a lot cheaper than other in-ground designs, but not as durable.
Gunite pools are the most popular design in much of the United
States. To build one of these pools, the construction crew digs a
hole, puts the plumbing in place and assembles a framework grid
with steel reinforcing rods (rebar). The rebar rods are spaced
about 10 inches apart, and secured together with wire. When the
grid is in place, the crew sprays a heavy coating of gunite, a
mixture of cement and sand, around the rebar. The sprayer unit
combines dry gunite mix with water just before spraying producing a
wet concrete material. The crew trowels the gunite smooth and lets
it sit for a week or so before applying a smooth finish to the
rough surface. The most popular finish is called plaster (actually
a mixture of cement and marble sand), but a lot of people finish
their pools with special concrete paint. Gunite pools can also have
tile, exposed aggregate or even fiberglass finishes. Gunite pools
are highly durable, and they can be built in any shape or size but
they are very expensive to install. The wall panels 12 of the
instant invention can be used to replace all conventional in-ground
pool structures as well as aboveground pools. The durability of the
pool system 10 of the instant invention even allows for partially
aboveground, partially in-ground construction, permitting
homeowners with less than ideal ground conditions to install a
pool.
[0018] During manufacture, the metallic skins 20, 22 and the
insulting layer 24 are cut to the appropriate dimensions in S1.
Next in S2, an adhesive 26 is applied to a surface of each metallic
skin 20, 22 and optionally to each outer surface of the insulting
layer. The metallic skins 20, 22 and the insulting layer 24 are
then joined together to form wall panel 12. In S4, the formed wall
panels 12 are set-aside for a predetermined period of time to
permit the adhesive to adequately bond to the metallic skins 20, 22
and to the insulating layer 24.
[0019] In one embodiment, the metallic skins 20, 22 are each cut
wider than the insulating layer 24 on both sides to create a pair
of metallic lips 28 on each longitudinal axis (L) of the wall panel
12, as shown in FIG. 4. The metallic lips 28 typically extend
outward from a longitudinal edge 30 of the insulating layer 24 to
aid in the manufacture of the final wall panels 12.
[0020] As shown in FIG. 5, during final assembly the metallic lips
28 are inserted into a spline channel piece 32. The spline channel
piece 32 is typically made of extruded aluminum. Each spline
channel piece 32 includes a pair of outwardly extending wing clips
34 and a pair of recessed clip seats 36. When the spline channel
piece 32 is crimped along the path represented by the arrows ("A"),
the wing clips 34 are forced inwardly, along with the metallic lips
28 of the wall panel 12, into the recessed clips seats 36. The
crimping of the metallic lips 28 into the recessed clip seats 36
forms a strong connection between the wall panels 12 and the spline
channel piece 32.
[0021] While only certain features of the invention have been
illustrated and described herein, many modifications and changes
will occur to those skilled in the art. It is, therefore, to be
understood that the appended claims are intended to cover all such
modifications and changes as fall within the true spirit of the
invention.
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