U.S. patent application number 15/267212 was filed with the patent office on 2017-01-05 for molding system for swimming pool copings.
This patent application is currently assigned to Concrete Countertop Solutions, Inc.. The applicant listed for this patent is Concrete Countertop Solutions, Inc.. Invention is credited to Dario Joseph Baldoni, Edwin Joseph Baldoni.
Application Number | 20170002582 15/267212 |
Document ID | / |
Family ID | 53274260 |
Filed Date | 2017-01-05 |
United States Patent
Application |
20170002582 |
Kind Code |
A1 |
Baldoni; Edwin Joseph ; et
al. |
January 5, 2017 |
Molding System For Swimming Pool Copings
Abstract
A molding system for a swimming pool coping having a track for
receiving a pool liner, the molding system including a molding
platform having a flexible panel with a first side and a second
side opposite the first side, at least one lip extending from the
first side of the flexible panel configured to be received in the
track of the swimming pool coping, a plurality of mold supports
extending from the second side of the flexible panel and arranged
in a row proximate a top of the flexible panel, each mold support
having a top surface for supporting a mold block and a flange
positioned at a first end of the mold support extending
substantially perpendicularly from the top surface.
Inventors: |
Baldoni; Edwin Joseph;
(Union Dale, PA) ; Baldoni; Dario Joseph; (Boston,
MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Concrete Countertop Solutions, Inc. |
Scott Township |
PA |
US |
|
|
Assignee: |
Concrete Countertop Solutions,
Inc.
Scott Township
PA
|
Family ID: |
53274260 |
Appl. No.: |
15/267212 |
Filed: |
September 16, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14787784 |
Oct 29, 2015 |
9476215 |
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PCT/US2014/065376 |
Nov 13, 2014 |
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15267212 |
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61910478 |
Dec 2, 2013 |
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61952630 |
Mar 13, 2014 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04H 4/142 20130101;
E04H 4/141 20130101; E04H 2004/147 20130101 |
International
Class: |
E04H 4/14 20060101
E04H004/14 |
Claims
1-20. (canceled)
21. A receiver track for engaging a molding system for a swimming
pool coping, the receiver track comprising: a support having a
first side and a second side opposite the first side; a lower tab
extending from the second side of the support, the lower tab
comprising a top surface and a bottom surface; an upper tab
extending from the second side of the support and positioned above
the lower tab, the upper tab comprising a top surface and a bottom
surface; a space defined by the top surface of the lower tab and
the bottom surface of the upper tab, the space being sized and
configured for receiving a portion of the molding system; and a
track flange extending from the first side of the support, the
track flange comprising a top surface and a bottom surface, wherein
the top surfaces and/or the bottom surfaces of the lower tab, upper
tab, and track flange are substantially trapezoidal in shape.
22. The receiver track of claim 21, wherein the top surface of the
lower tab is substantially perpendicular to the second side of the
support, and wherein the bottom surface of the upper tab is oblique
to the second side of the support.
23. The receiver track of claim 21, wherein the top surface of the
lower tab and the bottom surface of the upper tab define an angle
of about 5.degree..
24. The receiver track of claim 21, wherein the top surface of the
track flange is coplanar with the top surface of the lower tab, and
wherein the bottom surface of the track flange is coplanar with the
bottom surface of the lower tab.
25. (canceled)
26. The receiver track of claim 21, wherein the lower tab is
positioned at or proximate a bottom of the support.
27. The receiver track of claim 21, wherein the upper tab is
positioned at or proximate a top of the support.
28. The receiver track of claim 21, wherein the track flange is
positioned at or proximate a bottom of the support.
29. The receiver track of claim 21, wherein the space extends
across an entire width of the receiver track.
30. A receiver track for engaging a molding system for a swimming
pool coping, the receiver track comprising: a support having a
first side and a second side opposite the first side; a plurality
of lower tabs arranged in a row and extending from the second side
of the support proximate a bottom of the support; a plurality of
upper tabs arranged in a row and extending from the second side of
the support proximate a top of the support; and a plurality of
track flanges arranged in a row and extending from the first side
of the support proximate the bottom of the support.
31. The receiver track of claim 30, wherein the receiver track
comprises an equal number of lower tabs, upper tabs, and track
flanges.
32. The receiver track of claim 30, wherein the plurality of lower
tabs and the plurality of upper tabs are configured to clip onto a
portion of the molding system.
33. The receiver track of claim 30, wherein each of the lower tabs,
the upper tabs, and the track flanges has a substantially
trapezoidal shape.
34. The receiver track of claim 30, wherein the receiver track
further comprises gaps between adjacent lower tabs, adjacent upper
tabs, and adjacent track flanges.
35. The receiver track of claim 34, wherein the gaps comprise an
acute angle from about 0.degree. to about 28.degree..
36. The receiver track of claim 34, wherein the gaps between
adjacent upper tabs are aligned with and vertically spaced from the
gaps between adjacent lower tabs.
37. A swimming pool having a coping, the coping comprising the
receiver track of claim 21.
38-41. (canceled)
42. A swimming pool having a coping, the coping comprising the
receiver track of claim 30.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 14/787,784, filed Nov. 13, 2014, which is a
U.S. National Stage of International Application No.
PCT/US2014/065376, filed Nov. 13, 2014, which claims the benefit of
U.S. Provisional Patent Application No. 61/910,478, filed Dec. 2,
2013, and U.S. Provisional Patent Application No. 61/952,630, filed
Mar. 13, 2014, all of which are incorporated herein by reference in
their entireties.
FIELD OF THE INVENTION
[0002] The present invention, according to some embodiments,
relates to a molding system for swimming pool copings. In some
embodiments, the present invention relates to a molding system for
molding a top of a swimming pool coping. In some embodiments, the
present invention provides a molding system for a swimming pool
coping particularly having a track for receiving a pool liner. In
other embodiments, the present invention provides a receiver track
for a swimming pool for receiving a molding system.
SUMMARY OF THE INVENTION
[0003] In some embodiments, the present invention includes a
molding system for swimming pool copings. In some embodiments, the
present invention includes a molding system for swimming pool
copings having a track for receiving a pool liner. In some
embodiments, a molding system for a swimming pool coping having a
track for receiving a pool liner includes a molding platform
comprising a flexible panel having a first side and a second side
opposite the first side, at least one lip extending from the first
side of the flexible panel configured to be received in the track
of the swimming pool coping when the molding platform is engaged
with the swimming pool coping, and a plurality of mold supports
extending from the second side of the flexible panel and arranged
in a row proximate a top of the flexible panel. In some
embodiments, each mold support includes a top surface for
supporting a mold block, and a flange positioned proximate an end
of the mold support extending substantially perpendicularly from
the top surface. In some embodiments, each mold support tapers in
width from the second side of the flexible panel towards the end of
the mold support. In some embodiments, the top surface of each mold
support is substantially trapezoidal in shape. In some embodiments,
the molding platform comprises a gap between each pair of adjacent
mold supports. In some embodiments, the molding system may further
include a molding block positionable on the top surface of at least
one of the plurality of mold supports, the molding block having a
mold surface configured to mold a predetermined contour into a
material.
[0004] In some embodiments, a molding system of the present
invention further includes a back panel having a front surface and
a back surface, the back panel configured to engage with the
molding platform and comprising at least one clip defining a slot
for receiving the flange of at least one of the plurality of mold
supports when the back panel is engaged with the molding platform.
In some embodiments, the at least one clip is positioned on the
back surface of the back panel. In further embodiments, the back
panel comprises at least one clip for each mold support in the
plurality of mold supports.
[0005] In further embodiments, the molding system may also include
a plurality of coping tabs extending from the first side of the
flexible panel and arranged in a row proximate a top of the
flexible panel. In some embodiments, the plurality of coping tabs
and the at least one lip define a slot for receiving a section of
the swimming pool coping when the molding platform is engaged with
the swimming pool coping. In some embodiments, the slot defined by
the plurality of coping tabs and the at least one lip tapers from
the flexible panel toward an end of the at least one lip. In some
embodiments, the plurality of coping tabs extends obliquely from
the first side of the flexible panel. In some embodiments, each of
the plurality of coping tabs comprises a pair of side edges, a top
surface extending between the pair of side edges, and a front end.
In some embodiments, the top surface of each coping tab is
contiguous with the top surface of at least one of the plurality of
mold supports. In some embodiments, each coping tab tapers in width
from the first side of the flexible panel towards the front end of
the coping tab. In some embodiments, the molding platform comprises
a gap between each pair of adjacent coping tabs. In some
embodiments, the gap between each pair of adjacent coping tabs
comprises an acute angle defined by side edges of the pair of
adjacent coping tabs.
[0006] In other embodiments, the present invention includes a
receiver track for engaging with a molding system for a swimming
pool coping. In some embodiments, the present invention includes a
swimming pool having a coping comprising a receiver track for
engaging with a molding system. A receiver track according to some
embodiments includes a support having a first side and a second
side opposite the first side, a lower tab extending from the second
side of the support, the lower tab comprising a top surface and a
bottom surface, an upper tab extending from the second side of the
support and positioned above the lower tab, the upper tab
comprising a top surface and a bottom surface, a space defined by
the top surface of the lower tab and the bottom surface of the
upper tab, the space being sized and configured for receiving a
portion of the molding system, and a track flange extending from
the first side of the support, the track flange comprising a top
surface and a bottom surface. In some embodiments, the top surface
of the lower tab is substantially perpendicular to the second side
of the support, and the bottom surface of the upper tab is oblique
to the second side of the support. In some embodiments, the top
surface of the lower tab and the bottom surface of the upper tab
define an angle of about 5.degree.. In some embodiments, the top
surface of the track flange is coplanar with the top surface of the
lower tab, and wherein the bottom surface of the track flange is
coplanar with the bottom surface of the lower tab. In some
embodiments, the top surfaces and/or the bottom surfaces of the
lower tab, upper tab, and track flange are substantially
trapezoidal in shape. In some embodiments, the lower tab is
positioned at or proximate a bottom of the support and the upper
tab is positioned at or proximate a top of the support. In some
embodiments, the space defined by the top surface of the lower tab
and the bottom surface of the upper tab extends across an entire
width of the receiver track.
[0007] In further embodiments, a receiver track includes a support
having a first side and a second side opposite the first side, a
plurality of lower tabs arranged in a row and extending from the
second side of the support proximate a bottom of the support, a
plurality of upper tabs arranged in a row and extending from the
second side of the support proximate a top of the support, and a
plurality of track flanges arranged in a row and extend from the
first side of the support proximate the bottom of the support. In
some embodiments, the plurality of lower tabs and the plurality of
upper tabs are configured to clip onto a portion of a molding
system. In some embodiments, the receiver track comprises an equal
number of lower tabs, upper tabs, and track flanges. In some
embodiments, each of the lower tabs, the upper tabs, and the track
flanges has a substantially trapezoidal shape. In some embodiments,
the receiver track further comprises gaps between adjacent lower
tabs, adjacent upper tabs, and adjacent track flanges. The gaps may
comprise an acute angle from about 0.degree. to about 28.degree.
according to some embodiments. In some embodiments, the gaps
between adjacent upper tabs are aligned with and vertically spaced
from the gaps between adjacent lower tabs.
[0008] The present invention, according to yet further embodiments,
includes a kit for molding a swimming pool coping. In some
embodiments, the kit includes a molding system having a molding
platform comprising a flexible panel having a first side and a
second side opposite the first side, at least one lip extending
from the first side of the flexible panel, a plurality of mold
supports extending from the second side of the flexible panel and
arranged in a row proximate a top of the flexible panel, each mold
support comprising a top surface for supporting a mold block and a
flange positioned proximate an end of the mold support extending
substantially perpendicularly from the top surface. In some
embodiments, the kit further includes a receiver track configured
to engage with the molding system comprising a support having a
first side and a second side opposite the first side, a lower tab
extending from the second side of the support, the lower tab
comprising a top surface and a bottom surface, an upper tab
extending from the second side of the support and positioned above
the lower tab, the upper tab comprising a top surface and a bottom
surface, and a space defined by the top surface of the lower tab
and the bottom surface of the upper tab, the space being sized and
configured for receiving the at least one lip of the molding system
when the receiver track is engaged with the molding system. In some
embodiments, the molding platform further comprises a plurality of
coping tabs extending from the first side of the flexible panel and
arranged in a row proximate a top of the flexible panel, the
plurality of coping tabs and the at least one lip defining a slot
for receiving the upper tab of the receiver track when the receiver
track is engaged with the molding system. In some embodiments, the
kit further includes a back panel having a front surface and a back
surface, the back panel configured to engage with the molding
platform and comprising at least one clip defining a slot for
receiving the flange of at least one of the plurality of mold
supports when the back panel is engaged with the molding platform.
In some embodiments, the kit further includes a molding block
positionable on the top surface of at least one of the plurality of
mold supports, the molding block having a contoured mold
surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The following detailed description of the invention will be
better understood when read in conjunction with the appended
drawings. For the purpose of illustrating the invention, there are
shown in the drawings embodiments which are presently preferred. It
should be understood, however, that the invention can be embodied
in different forms and thus should not be construed as being
limited to the embodiments set forth herein.
[0010] FIG. 1 illustrates an exemplary swimming pool in accordance
with an embodiment of the present invention;
[0011] FIG. 2 is a side cross sectional view of a molding system
engaged with a swimming pool coping in accordance with an
embodiment of the present invention;
[0012] FIG. 3 is an exploded front perspective view of a molding
platform and backing in accordance with an embodiment of the
present invention;
[0013] FIG. 4 is an exploded rear perspective view of the molding
platform and backing of FIG. 3;
[0014] FIG. 5 is an exploded side view of the molding platform and
backing of FIGS. 3 and 4;
[0015] FIG. 6 is an exploded front perspective view of a molding
platform and backing in accordance with another embodiment of the
present invention;
[0016] FIG. 7 is a top plan view of a molding platform in
accordance with another embodiment of the present invention;
[0017] FIG. 8a is a perspective view of a receiver track in
accordance with an embodiment of the present invention;
[0018] FIG. 8b is a side view of the receiver track of FIG. 8a;
[0019] FIGS. 9a and 9b are perspective views of a receiver track in
accordance with a further embodiment of the present invention;
and
[0020] FIG. 9c is a side view of the receiver track of FIGS. 9a and
9b.
DETAILED DESCRIPTION
[0021] The present invention will now be described more fully
hereinafter with reference to the accompanying Figures in which
representative embodiments are shown and wherein like reference
numerals indicate like elements throughout. The present invention
can, however, be embodied in different forms and should not be
construed as limited to the embodiments set forth herein. Rather,
these embodiments are provided to describe and enable one of skill
in the art. All publications, patent applications, patents, and
other references mentioned herein are incorporated by reference in
their entirety.
[0022] FIG. 1 illustrates a swimming pool 1 in accordance with an
embodiment of the present invention which includes an interior
space 2 configured to be filled with water. Swimming pool 1 further
includes a coping around the periphery of interior space having a
top 3 that surrounds the perimeter of interior space 2 and caps the
walls of the swimming pool which define interior space 2. Top 3
may, for example, include curved sections 3a and 3b and/or
substantially straight sections 3c in accordance with the desired
shape of interior space 2. Top 3 further includes an edge 3d which
may extend over and/or into interior space 2.
[0023] In some embodiments, swimming pool 1 further includes a pool
liner 4 that is configured to line the walls of swimming pool 1.
Pool liner 4 may be configured as a waterproof, flexible sheet and,
in some embodiments, may be made from a plastic material (e.g.,
vinyl). Referring now to FIG. 2, which shows a cross-sectional view
of an exemplary swimming pool coping in conjunction with a molding
system in accordance with an embodiment of the present invention,
the swimming pool coping includes a track 6 defining space 5
configured to receive a top section of pool liner 4. In some
embodiments, pool liner 4 includes a bead 4a or other element
configured to secure pool liner 4 with track 6. Track 6 may extend
substantially along the entire periphery of interior space 2 and
may be positioned on wall portion 7 of the swimming pool. Top 3 of
the swimming pool coping, according to certain embodiments, may be
formed from concrete or other similar material which is poured over
track 6 and wall portion 7, molded into its final desired shape,
and allowed to set.
[0024] Referring now to FIGS. 2-7, there is shown a molding system
for a swimming pool coping in accordance with exemplary embodiments
of the present invention. The molding system according to certain
embodiments of the present invention is particularly useful for
molding the top of a swimming pool coping, for example, top 3
described above. In certain preferred embodiments of the present
invention, the molding system includes a molding platform 10 that
is configured to engage with the swimming pool coping. In some
embodiments, the molding system further includes a backing 30 that
is configured to engage with molding platform 10. In further
embodiments, the molding system includes a molding block 40
positionable on molding platform 10 as will be described
herein.
[0025] As shown particularly in FIGS. 2-6, molding platform 10 in
some embodiments may include a panel 12 having a first side 12a and
a second side 12b opposite first side 12a. First side 12a and
second side 12b may be substantially rectangular in shape or may be
configured as another polygonal shape. In other embodiments, panel
12 may include one or more curved edges. In some embodiments, panel
12 is a flexible panel such that first side 12a and second side 12b
can be curved convexly and/or concavely, and is preferably
configured to substantially conform to a curvature of a swimming
pool wall. When molding platform 10 is in an unflexed or relaxed
state, according to some embodiments, each of first side 12a and
second side 12b is substantially planar.
[0026] In some embodiments of the present invention, molding
platform 10 includes one or more mold supports 16. Molding platform
10, in certain preferred embodiments, includes a plurality of mold
supports 16 that are configured to support one or more molding
blocks 40 (see, e.g., FIG. 2). Mold supports 16 may be formed
integrally with panel 12, or formed separately from panel 12 and
secured thereto using any suitable means known in the art (e.g.,
adhesive, fasteners, joinery techniques, welding, etc.). In some
embodiments, mold supports 16 are arranged in a row proximate a top
of panel 12, for example, as shown in FIGS. 3, 4, 6, and 7. In some
embodiments, mold supports 16 extend from second side 12b of panel
12 and may be substantially perpendicular to panel 12. Top surfaces
16a of the plurality of mold supports 16 are substantially coplanar
according to some embodiments, and are configured to support one or
more molding blocks 40. In some embodiments, top surfaces 16a are
continguous with the top edge of panel 12. In some embodiments, top
surfaces 16a are substantially perpendicular to second side 12b of
panel 12. In some embodiments, each mold support 16 is configured
as a cantilever having a length L1 extending from second side 12b
of panel 12. For ease of illustration FIGS. 3, 4, and 6 show only
three mold supports 16, however, it should be appreciated that
molding platform 10 may include any suitable number of mold
supports 16. In some embodiments, molding platform 10 includes at
least two mold supports 16, at least three mold supports 16, at
least four mold supports 16, at least five mold supports 16, at
least six mold supports 16, at least seven mold supports 16, at
least eight mold supports 16, at least nine mold supports 16, at
least ten mold supports 16, at least eleven mold supports 16, or at
least twelve mold supports 16. In certain preferred embodiments,
mold supports 16 are spaced evenly along the top of panel 12. In
some embodiments, each of the plurality of mold supports 16 is
configured substantially the same.
[0027] Referring again to FIGS. 3, 4, 6, and 7, in some
embodiments, adjacent mold supports 16 are separated by a gap 18.
In some embodiments, each gap 18 has a length equal to the length
of each mold support 16 (e.g., L1 in FIG. 7). In other embodiments,
gap 18 has a length shorter than the length of each mold support 16
(e.g., less than L1). Gaps 18 in some embodiments are configured to
provide a degree of clearance between adjacent mold supports 16 to
allow for molding platform 10 to be curved, for example, in
directions C1 and C2 depicted in FIG. 7. This may be advantageous
according to certain embodiments, for example, when molding
platform 10 is engaged with a swimming pool coping along a curved
section of the swimming pool (e.g., sections 3a and 3b of FIG.
1).
[0028] As further shown in FIG. 7, top surface 16a of each mold
support 16 in some embodiments may be substantially trapezoidal in
shape. According to some of these embodiments, top surface 16a has
a width that tapers from W1 to W2 as mold support 16 extends away
from panel 12, where W1 is greater than W2. In certain preferred
embodiments, each top surface 16a of the mold supports 16 is
substantially configured as an isosceles trapezoid having parallel
sides (bases) with dimensions W1 and W2, and a perpendicular
distance between the parallel sides (altitude) having a dimension
equal to L1. Mold supports 16 according to these embodiments may
further include a pair of side edges that extend between and are
obliquely angled relative to the parallel sides and which have
equal lengths greater than L1. Gap 18 may be defined by angle
.beta. formed between adjacent mold supports 16 in the plane of top
surfaces 16a according to these embodiments. In some embodiments,
angle .beta. is equal to the angle between the neighboring side
edges of adjacent mold supports 16. In some embodiments, angle
.beta. is an acute angle from about 1.degree. to about 45.degree.,
about 1.degree. to about 40.degree., about 1.degree. to about
35.degree., about 1.degree. to about 30.degree., about 1.degree. to
about 25.degree., about 1.degree. to about 20.degree., about
1.degree. to about 15.degree., about 1.degree. to about 10.degree.,
or about 1.degree. to about 5.degree.. In some embodiments, when
molding platform 10 is an unflexed or relaxed state, angle .beta.
is from about 5.degree. and about 25.degree., about 10.degree. and
about 20.degree., about 12.degree. and about 18.degree., or about
14.degree. and about 16.degree.. In one embodiment, angle .beta. is
about 14.degree..
[0029] In some embodiments, one or more of mold supports 16 of
molding platform 10 may further include a flange 20. In some
embodiments, fewer than all the mold supports 16 include a flange
20. In some embodiments, each mold support 16 includes a flange 20.
Flange 20 in some embodiments is positioned proximate an end of
mold support 16 (e.g., an end of mold support 16 furthest away from
panel 12) and may extend substantially perpendicular from top
surface 16a. In some embodiments, each flange 20 has a width
substantially equal to W2. In other embodiments, flange 20 has a
width less than W2. In some embodiments, flanges 20 are configured
to engage with backing 30 as will be described further herein.
[0030] Molding platform 10 in some embodiments of the present
invention may include one or more coping tabs 22. In some preferred
embodiments, molding platform 10 includes a plurality of coping
tabs 22. In some embodiments, the number of coping tabs 22 is less
than the number of mold supports 16. In other embodiments, the
number of coping tabs 22 is greater than the number of mold
supports 16. In some preferred embodiments, the number of coping
tabs 22 is equal to the number of mold supports 16. In some
embodiments, coping tabs 22 are arranged in a row proximate a top
of panel 12, for example, as shown in FIGS. 3, 4, 6, and 7. In some
embodiments, coping tabs 22 extend from first side 12a of panel 12.
In some embodiments, each coping tab 22 is configured as a
cantilever having a length L2 extending from first side 12a of
panel 12. In some embodiments, coping tabs 22 extend from first
side 12a of panel 12 opposite of mold supports 16. In some
embodiments, the plurality of coping tabs 22 are substantially
aligned with the plurality of mold supports 16 along the top of
panel 12, as shown for example in FIGS. 3, 6, and 7. In certain
preferred embodiments, coping tabs 22 are spaced evenly along the
top of panel 12. In some embodiments, each of the plurality of
coping tabs 22 is configured substantially the same. Coping tabs 22
may be formed integrally with panel 12 and/or mold supports 16, or
may be formed separated from panel 12 and/or mold supports 16 and
secured thereto using any suitable means known in the art (e.g.,
adhesive, fasteners, joinery techniques, welding, etc.).
[0031] Top surfaces 22a of coping tabs 22 are substantially
coplanar according to some embodiments. In some embodiments, top
surfaces 22a of coping tabs 22 are continguous with top surfaces
16a of mold supports 16. In some embodiments, top surfaces 22a of
coping tabs 22 are continguous with top surfaces 16a of mold
supports 16 and the top edge of panel 12. In some embodiments, top
surfaces 22a are substantially perpendicular to first side 12a of
panel 12. In some embodiments, top surfaces 22a are substantially
coplanar with top surfaces 16a. In other embodiments, top surfaces
22a are obliquely angled relative to first side 12a of panel 12. In
some embodiments, top surfaces 22a are obliquely angled relative to
first side 12a of panel 12 prior to engagement of molding platform
10 with the pool liner track. In some embodiments, top surface 22a
extends at an incline relative to top surface 16a. As shown in FIG.
5, in some embodiments top surface 22a of coping tab 22 lies in a
first plane and top surface 16a of molding support 16 lies in a
second plane, wherein angle .gamma. between the first plane and the
second plane is greater than 0.degree. and less than 90.degree.. In
some embodiments, angle .gamma. is about 1.degree. to about
10.degree., about 2.degree. to about 9.degree., about 3.degree. to
about 7.degree., about 4.degree. to about 6.degree., or about
5.degree..
[0032] Referring again to FIGS. 3, 6, and 7, in some embodiments,
adjacent coping tabs 22 are separated by a gap 24. In some
embodiments, each gap 24 has a length equal to the length of each
coping tab 22 (e.g., L2 in FIG. 7). In other embodiments, gap 24
has a length shorter than the length of each coping tab (e.g., less
than L2). Gaps 24 in some embodiments are configured to provide a
degree of clearance between adjacent coping tabs 22 to allow for
molding platform 10 to be curved, for example, in directions C1 and
C2 depicted in FIG. 7. This again may be advantageous according to
certain embodiments, for example, when molding platform 10 is
engaged with a swimming pool coping along a curved section of the
swimming pool (e.g., curved sections 3a and 3b of FIG. 1). In some
embodiments, gaps 24 are substantially aligned with gaps 18, for
example, as can be seen in FIG. 7.
[0033] As further shown in FIG. 7, top surface 22a of each coping
tab 22 in some embodiments may be substantially trapezoidal in
shape. According to some of these embodiments, top surface 22a has
a width that tapers from W3 to W4 as coping tab 22 extends away
from panel 12, where W3 is greater than W4. In certain preferred
embodiments, each top surface 22a of the coping tabs 22 is
substantially configured as an isosceles trapezoid having parallel
sides (bases) with dimensions W3 and W4, and a perpendicular
distance between the parallel sides (altitude) having a dimension
equal to L2. Coping tabs 22 according to these embodiments may
further include a pair of side edges that extend between and are
obliquely angled relative to the parallel sides and which have
equal lengths greater than L2. In some embodiments, L2 is less than
L1. In some embodiments, W3 is equal to W1. In further embodiments,
W4 is greater than W2. Thus, in certain embodiments,
W2<W4<W3=W1.
[0034] Gap 24 may be defined by angle .alpha. formed between
adjacent coping tabs 22 in the plane of top surfaces 22a according
to some of these embodiments. In some embodiments, angle .alpha. is
equal to the angle between the neighboring side edges of adjacent
coping tabs. In some embodiments, angle .alpha. is an acute angle
from about 1.degree. to about 45.degree., about 1.degree. to about
40.degree., about 1.degree. to about 35.degree., about 1.degree. to
about 30.degree., about 1.degree. to about 25.degree., about
1.degree. to about 20.degree., about 1.degree. to about 15.degree.,
about 1.degree. to about 10.degree., or about 1.degree. to about
5.degree.. In some embodiments, when molding platform 10 is an
unflexed or relaxed state, angle .alpha. is from about 5.degree.
and about 25.degree., about 10.degree. and about 20.degree., about
12.degree. and about 18.degree., or about 14.degree. and about
16.degree.. In one embodiment, angle .alpha. is about 14.degree..
In some embodiments, angle .alpha. is substantially equal to angle
.beta. when molding platform 10 is an unflexed or relaxed
state.
[0035] In certain embodiments of the present invention, molding
platform 10 further includes at least one lip 14 configured to be
received in space 5 defined by track 6 of the swimming pool coping
(see, e.g., FIG. 2) when molding platform 10 is engaged with the
swimming pool coping. In some embodiments, lip 14 extends from
first side 12a of panel 12. In some embodiments, lip 14 is
substantially perpendicular to first side 12a of panel 12. In some
embodiments, lip 14 is configured as a cantilever extending from
first side 12a of panel 12. In some embodiments, lip 14 has a width
substantially the same as a width of panel 12. In some embodiments,
lip 14 has a width less than the width of panel 12. In some
embodiments, lip 14 is integrally formed with panel 12. In further
embodiments, lip 14 is formed separately from panel 12 and secured
thereto using any suitable means known in the art (e.g., adhesive,
fasteners, joinery techniques, welding, etc.). In some embodiments,
molding platform 10 includes a plurality of lips 14. In some
embodiments, the plurality of lips 14 is arranged in a row on first
side 12a of panel 12. In some of these embodiments, adjacent pairs
of lips 14 are separated by gaps which, for example, may be
vertically aligned with gaps 24. In some embodiments, the plurality
of lips 14 is spaced evenly substantially across a width of first
side 12a.
[0036] As shown in FIGS. 2-6, in some embodiments lips 14 are
vertically aligned with and spaced below coping tabs 22. In some
embodiments, molding platform 10 includes an equal number of lips
14 and coping tabs 22. In some embodiments, lips 14 have a length
that is shorter than a length of coping tabs such that lips 14 do
not extend beyond the ends of coping tabs 22. In some embodiments,
coping tabs 22 and lips 14 cooperate to clip onto a portion of the
swimming pool coping in order to releaseably secure molding
platform 10 with the swimming pool coping. In some embodiments,
lips 14 and coping tabs 22 define slot 26 configured to receive a
portion of the swimming pool coping when molding platform 10 is
engaged with the swimming pool coping. As shown in FIG. 2, for
example, slot 26 located between coping tab 22 and lip 14 is
configured in some embodiments to receive a portion of track 6 of
the swimming pool coping. In some embodiments, molding platform 10
is configured to substantially prevent concrete or other materials
from entering into space 5 of track 6 where molding platform 10 is
engaged with the swimming pool coping.
[0037] As described herein, the molding system of the present
invention in some embodiments further includes a backing 30. As
shown in FIGS. 3-6, backing 30 in some embodiments includes a back
panel 32 having a front surface 32a and a back surface 32b opposite
front surface 32a. In some embodiments, back panel 32 is a flexible
panel such that front surface 32a and back surface 32b can be
curved convexly and/or concavely. When back panel 32 is in an
unflexed or relaxed state, according to some embodiments, each of
front surface 32a and back surface 32b is substantially planar. In
some embodiments, front surface 32a and back surface 32b may be
substantially rectangular in shape, or may be configured as another
polygonal shape in other embodiments. In some embodiments, back
panel 32 has width substantially equal to the width of panel
12.
[0038] Backing 30 is configured to engage with molding platform 10
according to some embodiments of the present invention. In some
embodiments, backing 30 is configured to be releaseably secured to
molding platform 10. In some embodiments, backing 30 includes one
or more securements configured to engage with one or more
components of molding platform 10 in order to secure backing 30 to
molding platform 10. In some embodiments, backing 30 is configured
to attach to flanges 20 of mold supports 16. In some embodiments,
for example, backing 30 includes at least one clip 34 configured to
attach back panel 32 with molding platform 10, preferably a
plurality of clips 34. In some embodiments, clips 34 define a slot
36 configured to receive a flange 20 when backing 30 is engaged
with molding platform 10 (see, e.g., FIG. 2). In some embodiments,
backing 30 includes a plurality of clips 34 arranged in a row on
back surface 32b of back panel 32, for example, as shown in FIG. 4.
Clips 34 may be formed integrally with back panel 32 according to
some embodiments, or clips 34 may be formed separately and secured
to back panel 32 using any suitable means known in the art (e.g.,
adhesive, fasteners, joinery techniques, welding, etc.). In some
embodiments, the number of clips 34 positioned on back panel 32 is
at least equal to the number of flanges 20 present on molding
platform 10. In some embodiments, backing 30 includes at least two
clips 34 for every flange 20 present on molding platform 10. Six
clips 34 and three flanges 20 are shown in the embodiment of FIG. 4
for ease of illustration, however, it should be understood that
other embodiments of the inventions can have fewer or more clips 34
and/or flanges 20. In other embodiments of the present invention,
backing 30 may be secured to molding platform 10 using other
suitable fasteners known in the art, for example, screws, pins,
staples, nails, adhesive tape (e.g., double-sided tape),
hook-and-loop fasteners (e.g., Velcro.RTM.), or the like, which are
capable of attaching back panel 32 to flanges 20.
[0039] With particular reference now to FIG. 6, in certain
embodiments backing 30 further includes ledge 38. In some
embodiments, ledge 38 extends from back panel 32 proximate a top of
back panel 32. In some embodiments, ledge 38 extends from front
surface 32a of back panel 32. In some embodiments, ledge 38 spans
the entire width of back panel 32. In some embodiments, ledge 38
includes a top surface 38a, a bottom surface 38b, and a thickness
therebetween. Top surface 38a of ledge 38 in some embodiments is
substantially perpendicular to front surface 32a of back panel 32.
In some embodiments, ledge 38 is configured such that top surface
38a and bottom surface 38b are not parallel. In some embodiments,
bottom surface 38b is oblique relative to top surface 38a and/or
front surface 32a. In some embodiments, the thickness of ledge 38
increases as ledge 38 extends away from back panel 32.
[0040] Referring again to FIG. 2, backing 30 in some embodiments is
preferably configured to engage with molding platform 10 such that
back surface 32b of back panel 32 abuts flanges 20 of mold supports
16 while front surface 32a of back panel 32 provides an engagement
surface for molding block 40 during use of the molding system. In
some embodiments, ledge 38 of backing 30 (see FIG. 6) further
engages with molding block 40. In some embodiments, molding block
40 snap fits under ledge 38. In some embodiments of the present
invention, molding block 40 is positioned on mold supports 16 of
molding platform 10 and abuts front surface 32a of back panel 32
during use of the molding system. In other embodiments of the
present invention, backing 30 is not utilized such that molding
block 40 may directly abut against flanges 20 of mold supports 16.
In some embodiments, molding block 40 is positioned directly on top
surface 16a of mold supports 16. In some embodiments, one or more
boards 28 are positioned between molding bock 40 and top surface
16a of mold supports 16. One or more boards 28, in some
embodiments, are configured to cover gaps 18 between adjacent mold
supports 16. In some embodiments, one or more boards 28 are also
positioned over top surface 22a of coping tabs 22 to cover gaps 24
between adjacent coping tabs 22. In some embodiments, one or more
boards 28 are configured to prevent concrete or other materials
from passing through gaps 18 and/or gaps 24 during use of the
molding system.
[0041] Molding block 40 according to certain embodiments of the
invention includes a mold surface 42 configured to mold a contour
into concrete or other material used to form top 3 of the swimming
pool coping, e.g., a predetermined contour. Mold surface 42 may
include any desired curvatures and/or patterns suitable for shaping
top 3 of the swimming pool coping. As depicted in the embodiment
shown in FIG. 2, mold surface 42 may include a profile having a
concave curvature, which would impart a convexly curved profile to
the edge 3d of top 3. However, it should be understood that mold
surface 42 in other embodiments may include a profile having convex
curvatures and/or straight portions as desired. Mold surface 42
generally faces away from flanges 20 of molding supports 16 when
molding block 40 is positioned on molding platform 10 during use.
Molding block 40 in some embodiments further includes a back
surface 44 opposite mold surface 42. In some embodiments, back
surface 44 of molding block 40 is configured to abut against front
surface 32a of back panel 32 and/or flanges 20 of mold supports 16.
Back surface 44 may include a substantially straight profile as
shown in FIG. 2 according to some embodiments. In some embodiments,
molding block 40 has a height that is substantially equal to the
height of back panel 32. In other embodiments, molding bock 40 has
a height less than the height of back panel 32. In some embodiments
where backing 30 includes ledge 38, for example as shown in FIG. 6,
molding block 40 is configured to seat against front surface 32a
below ledge 38.
[0042] In use, according to some embodiments of the present
invention, molding platform 10 is first engaged with the coping of
a swimming pool. As described herein, in some embodiments molding
platform 10 includes at least one lip 14 which is inserted into
space 5 defined by track 6 of the swimming pool coping, as shown
for example in FIG. 2. According to some of these embodiments,
coping tab 22 is positioned over track 6 such that a portion of
track 6 is received between coping tab 22 and lip 14 in slot 26. In
some embodiments, coping tab 22 is configured to bend away from lip
14 when the portion of track 6 is received within slot 26 (e.g.,
such that angle .gamma. depicted in FIG. 5 decreases). In some
embodiments, the engagement of molding platform 10 with track 6 as
described herein secures molding platform 10 to the swimming pool
coping. In some embodiments, adhesive tape or other materials
and/or fasteners may be used to facilitate securing of molding
platform 10 to the swimming pool coping. In some embodiments, front
side 12a of panel 12 is configured to abut pool liner 4 and/or wall
portion 7 when molding platform 10 is secured to the swimming pool
coping. In some embodiments, molding platform 10 is configured to
curve to match the curvature of the swimming pool walls. For
example, as described previously above, in some embodiments gaps 18
and/or gaps 24 are configured to allow bending of molding platform
10. In some embodiments, when molding platform 10 is properly
positioned, mold supports 16 extend away from track 6 and into or
over interior space 2 of the swimming pool.
[0043] After molding platform 10 is secured to the swimming pool
coping, backing 30 may be engaged with molding platform 10
according to some embodiments of the present invention. In other
embodiments, backing 30 is secured to molding platform 10 prior to
engagement of molding platform 10 with the swimming pool coping. As
described herein, backing 30 may engage with molding platform 10
using one or more clips 34 arranged on back panel 32 according to
some embodiments of the present invention. For example, in some
embodiments, flanges 20 of mold supports 16 are received in slot 36
defined by clips 34 such that back surface 32b of back panel 32
abuts flanges 20 of mold supports 16.
[0044] Molding block 40, in some embodiments, is then positioned on
molding platform 10. In some embodiments, molding block 40 is
positioned on top surface 16a of mold supports 16 such that back
surface 44 of molding block 40 faces toward backing 30 and mold
surface 42 faces toward the swimming pool coping. In some
embodiments, molding block 40 is positioned such that back surface
44 of molding block 44 abuts front surface 32a of back panel 32. In
some embodiments, molding block 40 and backing 30 are arranged such
that back panel 32 is disposed between molding block 40 and flanges
20 of mold supports 16. In some embodiments, one or more boards,
tape or other liner 28 is disposed between molding block 40 and
mold supports 16. One or more boards 28 may also be positioned over
coping tabs 22. Preferably the one or more boards 28 are sized and
shaped to cover gaps 18 and/or gaps 24 of molding platform 10.
[0045] Concrete or other material used to form top 3 of the
swimming pool coping can then be poured over wall portion 7 and
track 6, the concete or other material being at least partially
bounded by molding block 40. Preferably the amount of concrete or
other material used to form top 3 does not exceed the top of
molding block 40 and/or backing 30. As the concrete or other
material sets, it is shaped by mold surface 42 of molding block 40
to form edge 3d. In some embodiments, molding platform 10, backing
30, and molding block 40 are removed from the swimming pool coping
before the concrete or other material completely hardens, for
example, to allow the surface of the concrete or other material to
be smoothed or textured. Preferably, molding platform 10, backing
30, and molding block 40 of the molding system are reusable. In
some embodiments, for example, a molding system can be used to mold
one section of the swimming pool coping at a time. In other
embodiments, the molding system may extend along the entire
swimming pool coping. In some embodiments, a molding system of the
present invention is modular such that a plurality of molding
platforms 10, backings 30, and/or molding blocks 40 are used to
mold the swimming pool coping.
[0046] In some embodiments, molding systems of the present
invention may also be used for molding the copings of swimming
pools that do not include a track configured to receive a pool
liner. These swimming pools may include, for example, certain
concrete or fiberglass swimming pools which do not use or require a
pool liner. According to some embodiments, molding systems of the
present invention may be used with such swimming pools by providing
a receiver track adapted to receive the molding systems. In some
embodiments, the receiver track is configured to be secured to a
top periphery of the swimming pool and engage with a molding
system. The receiver track, in some embodiments, defines a slot,
groove, channel, or the like configured to receive a portion of the
molding system, for example, molding platform 10. In some
embodiments, the receiver track is preferably positioned relative
to the swimming pool such that the slot, groove, channel, or the
like is open towards the swimming pool interior. In some
embodiments, the receiver track includes one or more elements
configured to be received within slot 26 of molding platform 10. In
some embodiments, the receiver track is configured to engage with
lip 14 and/or coping tabs 22 of molding platform 10 in a manner
similar to track 6 shown in the embodiment of FIG. 2. Unlike track
6, however, the receiver track may not include any features
particularly configured to secure a pool liner (e.g., pool liner
4). For example, the receiver track may not be shaped or configured
to secure bead 4a of pool liner 4. In some embodiments, the
receiver track may be configured to be positioned on wall portion 7
in the place of track 6 in FIG. 2. In some embodiments, the
receiver track may include one or more flanges that can be secured
to wall portion 7 when the receiver track is positioned on wall
portion 7.
[0047] The receiver track and other components of the present
invention can be fabricated from a variety of materials. For
example, the receiver tracks and molding systems may be made from
or include portions made from metal, plastics, polymers, wood,
fiberglass, or composites. Other structurally sturdy materials,
preferably with a degree of flexibility, may also be used to form
components of the present invention. In some embodiments, the
receiver tracks, molding systems, and/or one or more components
thereof may be white or have a substantially light color so as to
absorb less heat than components that are black or a substantially
dark color. Components of the present invention may be
prefabricated or, in other embodiments, may be assembled by the
user. In some embodiments, the receiver tracks and molding systems
of the present invention may be provided together in kits.
[0048] FIGS. 8a and 8b show an example receiver track 50 in
accordance with one embodiment of the present invention. Receiver
track 50, in some embodiments, is particularly adapted to be used
with the molding systems described herein. In some embodiments,
receiver track 50 is configured to be used along straight sections
of a swimming pool (e.g., straight section 3c of FIG. 1). In
certain embodiments, receiver track 50 is configured to be
positioned on a wall portion surrounding the swimming pool, for
example, wall portion 7 of FIG. 2.
[0049] Receiver track 50, according to certain preferred
embodiments, defines a space 60 that is configured to receive and
engage with the molding systems described herein. Space 60 may be
configured as, for example, a gap, slot, groove, channel or the
like. In some embodiments, space 60 is configured to receive a
portion of molding platform 10. For example, space 60 may be sized
and configured to receive lips 14 and/or coping tabs 22 of molding
platform 10. Receiver track 50 is preferably positionable relative
to the swimming pool (e.g., along the swimming pool periphery) such
that space 60 opens towards the swimming pool interior. In some
embodiments, space 60 is disposed between two or more tabs, as will
be described further herein.
[0050] In some embodiments, space 60 is defined in part by a
support 52. In some embodiments, receiver track 50 includes a
support 52 having a first side 52a and a second side 52b opposite
first side 52a. First side 52a may be substantially parallel to
second side 52b according to some embodiments. In further
embodiments, support 52 extends along an entire dimension (e.g.,
width) of receiver track 50. Support 52, in some embodiments, is
substantially rigid, and first side 52a and second side 52b may be
substantially flat. In other embodiments, support 52 is flexible
such that first side 52a and second side 52b can be curved convexly
and/or concavely. In some embodiments, space 60 is defined in part
by second side 52b.
[0051] In some embodiments, receiver track 50 includes a lower tab
56. In some embodiments, lower tab 56 extends from support 52 at or
proximate the bottom of support 52. In some embodiments, lower tab
56 extends a length L3 from second side 52b of support 52. In some
embodiments, length L3 is less than length L2 of coping tabs 22. In
other embodiments, length L3 is greater than or equal to length L2
of coping tabs 22. Lower tab 56 may be integrally formed with
support 52 in some embodiments. In other embodiments, lower tab 56
is formed separately from support 52 and secured thereto using any
suitable means known in the art (e.g., adhesive, fasteners, joinery
techniques, welding, etc.). In some embodiments, receiver track 50
includes only one lower tab 56. In some embodiments, lower tab 56
has a width that extends along an entire dimension (e.g., width) of
receiver track 50 and/or support 52.
[0052] In some embodiments, lower tab 56 includes a top surface 56a
and a bottom surface 56b. Top surface 56a and bottom surface 56b
may be substantially parallel according to some embodiments. In
some such embodiments, top surface 56a and bottom surface 56b are
substantially perpendicular to second side 52b of support 52. Top
surface 56a and/or bottom surface 56b may be substantially
rectangular in shape or may be configured as another polygonal
shape (e.g., square, trapezoid, etc.). According to these
embodiments, lower tab 56 includes one or more straight edges. In
further embodiments, lower tab 56 may include one or more curved
edges.
[0053] In some embodiments, receiver track 50 includes an upper tab
58. In some embodiments, upper tab 58 extends from support 52 at or
proximate a top of support 52. In some embodiments, upper tab 58
extends from second side 52b of support 52 and is vertically spaced
above lower tab 56. Upper tab 58 may be integrally formed with
support 52 in some embodiments. In other embodiments, upper tab 58
is formed separately from support 52 and secured thereto using any
suitable means known in the art (e.g., adhesive, fasteners, joinery
techniques, welding, etc.). In some embodiments, receiver track 50
includes only one upper tab 56. In some embodiments, upper tab 58
has a width that extends along an entire dimension (e.g., width) of
receiver track 50 and/or support 52.
[0054] In some embodiments, upper tab 58 includes a top surface 58a
and a bottom surface 58b. Top surface 58a and bottom surface 58b
may be substantially parallel according to some embodiments. In
some embodiments, top surface 58a and bottom surface 58b are
substantially perpendicular to second side 52b of support 52. In
other embodiments, as illustrated in FIGS. 8a and 8b, upper tab 58
extends obliquely from second side 52b of support 52. In some
embodiments, bottom surface 58b of upper tab 58 is obliquely angled
with respect to top surface 56a of lower tab 56. In some
embodiments, bottom surface 58b of upper tab 58 and top surface 56a
of lower tab 56 define an acute angle .theta..sub.1 therebetween.
In some embodiments, .theta..sub.1 is from about 0.degree. to about
10.degree., from about 1.degree. to about 9.degree., from about
2.degree. to about 8.degree., from about 3.degree. to about
7.degree., from about 4.degree. to about 6.degree., or about
5.degree.. In some embodiments, top surface 58a and/or bottom
surface 58b may be substantially rectangular in shape or may be
configured as another polygonal shape (e.g., square, trapezoid,
triangle, etc.). According to these embodiments, upper tab 58
includes one or more straight edges. In further embodiments, upper
tab 58 may include one or more curved edges. In some embodiments,
upper tab 58 includes a front edge 58c that may be convexly curved
or radiused as shown in FIG. 8b.
[0055] In some embodiments, space 60 of receiver track 50 is
disposed between upper tab 58 and lower tab 56. More particularly,
in some embodiments, space 60 is at least partially defined by
bottom surface 58b of upper tab 58 and top surface 56a of lower tab
56. As shown in the illustrated embodiment of FIGS. 8a and 8b,
space 60 extends from second side 52b of support 52 a distance
equal to length L3. In some embodiments, space 60 further extends
along an entire dimension (e.g., width) of receiver track 50. In
some embodiments, as discussed above, space 60 is configured to
receive a portion of the molding systems described herein. In some
embodiments, space 60 is configured to receive and secure to a
portion of the molding systems in a friction fit. For example, in
some embodiments space 60 is sized and configured to receive lips
14 of molding platform 10. According to some of these embodiments,
when lips 14 are received in space 60, upper tab 58 may be received
in slot 26 of molding platform 10 between lips 14 and coping tabs
22. In some embodiments, lower tab 56 and upper tab 58 cooperate to
clip onto lips 14. In some embodiments, lips 14 and coping tabs 22
cooperate to clip onto upper tab 58. In certain variations, space
60 may be sized and configured to receive coping tabs 22. In these
embodiments, when coping tabs 22 are received in space 60, lower
tab 56 may be received in slot 26 of molding platform 10 between
lips 14 and coping tabs 22. Molding platform 10 may further be
combined with backing 30 and molding block 40 before or while
engaged with space 60 of receiver track 50. Preferably, receiver
track 50 is positioned during use such that mold supports 16 extend
into or over the interior space of the swimming pool when molding
platform 10 is engaged with receiver track 50.
[0056] In some embodiments, receiver track 50 further includes a
track flange 54 that extends from first side 52a of support 52 a
length L4. In some embodiments, length L4 is greater than length
L3. In some embodiments, length L4 is greater than length L1 of
mold supports 16. In other embodiments, length L4 is less than or
equal to length L1. In some embodiments, track flange 54 is
positioned at or proximate the bottom of support 52 and extends
opposite of lower tab 56. In some embodiments, track flange 54 is
integrally formed with support 52 and/or lower tab 56. In other
embodiments, track flange 54 is formed separately from support 52
and/or lower tab 56 and secured thereto using any suitable means
known in the art (e.g., adhesive, fasteners, joinery techniques,
welding, etc.). In the embodiment shown, receiver track 50 includes
only one track flange 54. In some embodiments, track flange 54 has
a width that extends along an entire dimension (e.g., width) of
receiver track 50 and/or support 52.
[0057] In some embodiments, track flange 54 includes a top surface
54a and a bottom surface 54b. Top surface 54a and bottom surface
54b may be substantially parallel according to some embodiments. In
certain embodiments, top surface 56a of lower tab 56 is
substantially coplanar with top surface 54a of track flange 54. In
some embodiments, bottom surface 56b of lower tab 56 is
substantially coplanar with bottom surface 54b of track flange 54.
In some such embodiments, top surface 54a and bottom surface 54b
are substantially perpendicular to first side 52a of support 52.
Top surface 54a and/or bottom surface 54b may be substantially
rectangular in shape or may be configured as another polygonal
shape (e.g., square, trapezoid, triangle, etc.). According to these
embodiments, track flange 54 includes one or more straight edges.
In further embodiments, track flange 54 may include one or more
curved edges.
[0058] In some embodiments, track flange 54 is configured to be
secured to the periphery of a swimming pool once receiver track 50
is arranged in its desired position. For example, track flange 54
may be secured to wall portion 7 in FIG. 2 when receiver track 50
is used in place of track 6. In some embodiments, track flange 54
may be secured into position by any suitable means known in the
art, for example, using screws, nail, bolts, glue, cement, tape,
etc. Preferably receiver track 50 is positioned such that space 60
opens towards the swimming pool interior. After receiver track 50
is secured into position, receiver track 50 may be engaged with the
molding system as described above.
[0059] After the molding system is engaged with receiver track 50,
the molding system may be used to mold the coping of the swimming
pool in a manner similar to the procedures described above with
respect to embodiments where the molding system is engaged with
track 6. In certain embodiments, concrete or other material used to
form the swimming pool coping can be poured over receiver track 50,
which may be left in place along the periphery of the swimming
pool. According to some of these embodiments, receiver track 50
forms a part of the finished swimming pool coping. In some
embodiments, molding platform 10, backing 30, and molding block 40
are removed from the swimming pool coping before the concrete or
other material completely hardens, for example, to allow the
surface of the concrete or other material to be smoothed or
textured.
[0060] FIGS. 9a-9c show a second example receiver track 70 in
accordance with further embodiments of the present invention for
use with the molding systems described herein. In some embodiments,
receiver track 70 is configured to be used along straight and/or
curved sections of a swimming pool. In certain embodiments,
receiver track 70 is configured to be positioned on a wall portion
of the swimming pool, for example, wall portion 7 of FIG. 2.
[0061] Receiver track 70, according to certain preferred
embodiments, defines a space 80 that is configured to receive and
engage with the molding systems described herein. Space 80 may be
configured as, for example, a gap, slot, groove, channel or the
like. In some embodiments, space 80 is configured to clip onto a
portion of molding platform 10. For example, space 80 may be sized
and configured to clip onto lips 14 and/or coping tabs 22 of
molding platform 10. Receiver track 70 is preferably positionable
relative to the swimming pool (e.g., along the swimming pool
periphery) such that space 80 opens towards the swimming pool
interior. In some embodiments, space 80 is disposed between two or
more tabs, as will be described further herein.
[0062] In some embodiments, space 80 is defined in part by a
support 72. In some embodiments, receiver track 80 includes a
support 72 having a first side 72a and a second side 72b opposite
first side 72a. First side 72a may be substantially parallel to
second side 72b according to some embodiments. In further
embodiments, support 72 extends along an entire dimension (e.g.,
width) of receiver track 70. Support 72, in some embodiments, is
substantially flexible such that first side 72a and second side 72b
can be curved convexly and/or concavely when receiver track 70 is
in a flexed state. In some embodiments, first side 72a and second
side 72b are substantially planar when receiver track 70 is an
unflexed or relaxed state. In some embodiments, space 80 is defined
in part by second side 72b.
[0063] In some embodiments, receiver track 70 includes a plurality
of lower tabs 76. For ease of illustration, the embodiment of FIGS.
9a and 9b shows four lower tabs 76. It should be appreciated,
however, that receiver track 70 may include any suitable number of
lower tabs 76 according to other embodiments. For example, in other
embodiments, receiver track 70 may include more than four lower
tabs 76. In some embodiments, receiver track 70 includes fewer than
four lower tabs 76. Preferably, receiver track 70 includes at least
two lower tabs 76.
[0064] In some embodiments, lower tabs 76 extend from support 72 at
or proximate the bottom of support 72. In some embodiments, lower
tabs 76 are arranged in an evenly spaced row along second side 72b.
In some embodiments, lower tabs 76 extend a length L5 from second
side 72b of support 72. In some embodiments, length L5 is less than
length L2 of coping tabs 22. In other embodiments, length L5 is
greater than or equal to length L2 of coping tabs 22. In some
embodiments, length L5 is equal to length L3 of receiver track 50.
Lower tabs 76 may be integrally formed with support 72 in some
embodiments. In other embodiments, lower tabs 76 are formed
separately from support 72 and secured thereto using any suitable
means known in the art (e.g., adhesive, fasteners, joinery
techniques, welding, etc.). In some embodiments, the plurality of
lower tabs 76 are positioned along an entire dimension (e.g.,
width) of receiver track 70 and/or support 72.
[0065] In some embodiments, each lower tab 76 includes a top
surface 76a and a bottom surface 76b. In certain embodiments, top
surfaces 76a of lower tabs 76 are each coplanar. Likewise, in some
embodiments, bottom surfaces 76b of lower tabs 76 are each
coplanar. Top surface 76a and bottom surface 76b may be
substantially parallel according to some embodiments. In some such
embodiments, top surface 76a and bottom surface 76b are
substantially perpendicular to second side 72b of support 72. As
shown in FIGS. 9a and 9b, top surface 76a and/or bottom surface 76b
may be substantially trapezoidal in shape. In some embodiments, top
surface 76a and/or bottom surface 76b of each lower tab 76 is
shaped as an isosceles trapezoid having a height equal to length L5
and its longer base positioned at second side 72b of support 72. In
other embodiments, top surface 76a and/or bottom surface 76b may be
configured as another polygonal shape (e.g., square, rectangle,
triangle, etc.). According to these embodiments, each lower tab 76
includes one or more straight edges. In further embodiments, each
lower tab 76 may include one or more curved edges.
[0066] In some embodiments, adjacent lower tabs 76 are separated by
a gap 77. In some embodiments, each gap 77 has a length equal to
the length of each lower tab 76 (e.g., length L5). In other
embodiments, each gap 77 has a length shorter than the length of
each lower tab 76 (e.g., shorter than length L5). Gaps 77 in some
embodiments are configured to provide a degree of clearance between
adjacent lower tabs 76 to allow for receiver track 70 to be curved,
for example, when receiver track 70 is in a flexed state. This
configuration may be advantageous according to certain embodiments,
for example, when receiver track 70 is positioned along a curved
section of the swimming pool (e.g., curved sections 3a and 3b of
FIG. 1).
[0067] As shown in FIG. 9b, gaps 77 may be defined by angle .delta.
formed between adjacent lower tabs 76 according to some
embodiments. In some embodiments, angle .delta. is equal to the
angle between the neighboring side edges of adjacent lower tabs 76.
In some embodiments, angle .delta. is an acute angle from about
0.degree. to about 45.degree., about 0.degree. to about 40.degree.,
about 0.degree. to about 35.degree., about 0.degree. to about
30.degree., about 0.degree. to about 28.degree., about 0.degree. to
about 25.degree., about 0.degree. to about 20.degree., about
0.degree. to about 15.degree., about 0.degree. to about 10.degree.,
or about 0.degree. to about 5.degree.. In some embodiments, when
receiver track 70 is in an unflexed or relaxed state, angle .delta.
is from about 5.degree. and about 25.degree., about 10.degree. and
about 20.degree., about 12.degree. and about 18.degree., or about
14.degree. and about 16.degree.. In one embodiment, angle .delta.
is about 14.degree. when receiver track 70 is in an unflexed or
relaxed state. In some embodiments, angle .delta. is substantially
equal to angle .alpha. and/or angle .beta. of molding platform 10
when molding platform 10 and receiver track 70 are both in an
unflexed or relaxed state.
[0068] Angle .delta. may be increased or decreased relative to the
angle in the unflexed or relaxed state depending on the desired
curvature of receiver track 70. For example, when receiver track 70
is used with a concavely curved section of the swimming pool (e.g.,
curved section 3b of FIG. 1), receiver track 70 may be flexed such
that the ends of lower tabs 76 converge towards each other and
angle .delta. is decreased. When receiver track is used with a
convexly curved section of the swimming pool (e.g., curved section
3a of FIG. 1), receiver track 70 is flexed such that the ends of
lower tabs 76 diverge away from each other and angle .delta. is
increased.
[0069] In some embodiments, receiver track 70 includes a plurality
of upper tabs 78. For ease of illustration, the embodiment of FIGS.
9a and 9b shows four upper tabs 78. It should be appreciated,
however, that receiver track 70 may include any suitable number of
upper tabs 78 according to other embodiments. For example, in other
embodiments, receiver track 70 may include more than four upper
tabs 78. In some embodiments, receiver track 70 includes fewer than
four upper tabs 78. In some embodiments, receiver track 70 includes
at least two upper tabs 78. In certain preferred embodiments,
receiver track 70 includes the same number of upper tabs 78 and
lower tabs 76.
[0070] In some embodiments, each upper tab 78 extend from support
72 at or proximate a top of support 72. In some embodiments, upper
tabs 78 are arranged in an evenly spaced row along second side 72b.
In some embodiments, upper tabs 78 extend from second side 72b of
support 72 and are vertically aligned with and spaced above lower
tabs 76. Upper tabs 78 may be integrally formed with support 72 in
some embodiments. In other embodiments, upper tabs 78 are formed
separately from support 72 and secured thereto using any suitable
means known in the art (e.g., adhesive, fasteners, joinery
techniques, welding, etc.). In some embodiments, the plurality of
upper tabs 78 are positioned along an entire dimension (e.g.,
width) of receiver track 70 and/or support 72.
[0071] In some embodiments, each upper tab 78 includes a top
surface 78a and a bottom surface 78b. In certain embodiments, top
surfaces 78a of upper tabs 78 are each coplanar. Likewise, in some
embodiments, bottom surfaces 78b of upper tabs 78 are each
coplanar. Top surface 78a and bottom surface 78b may be
substantially parallel according to some embodiments. In some
embodiments, top surface 78a and bottom surface 78b are
substantially perpendicular to second side 72b of support 72. In
other embodiments, as illustrated in FIGS. 9a-9c, upper tabs 78
extend obliquely from second side 72b of support 72. In some
embodiments, bottom surface 78b of upper tabs 78 is obliquely
angled with respect to top surface 76a of lower tabs 76. In some
embodiments, bottom surface 78b of upper tabs 78 and top surface
76a of lower tabs 76 define an acute angle .theta..sub.2
therebetween. In some embodiments, .theta..sub.2 is from about
0.degree. to about 10.degree., from about 1.degree. to about
9.degree., from about 2.degree. to about 8.degree., from about
3.degree. to about 7.degree., from about 4.degree. to about
6.degree., or about 5.degree..
[0072] As shown in FIGS. 9a and 9b, top surface 78a and/or bottom
surface 78b may be substantially trapezoidal in shape. In some
embodiments, top surface 78a and/or bottom surface 78b of each
upper tab 78 is shaped as an isosceles trapezoid having its longer
base positioned at second side 72b of support 72. In other
embodiments, top surface 76a and/or bottom surface 76b may be
configured as another polygonal shape (e.g., square, rectangle,
triangle, etc.). According to these embodiments, each upper tab 78
includes one or more straight edges. In further embodiments, each
upper tab 78 may include one or more curved edges. In some
embodiments, upper tabs 78 include a front edge 78c that may be
convexly curved or radiused as shown in FIG. 9c.
[0073] In some embodiments, adjacent upper tabs 78 are separated by
a gap 79. In certain preferred embodiments, gaps 79 are
substantially aligned with and vertically spaced with gaps 77. Gaps
79 in some embodiments are configured to provide a degree of
clearance between adjacent upper tabs 79 to allow for receiver
track 70 to be curved, for example, when receiver track 70 is in a
flexed state. As described, this configuration may be advantageous
according to certain embodiments, for example, when receiver track
70 is positioned along a curved section of the swimming pool (e.g.,
curved sections 3a and 3b of FIG. 1).
[0074] In some embodiments, gaps 79 are defined by an angle that is
equal to angle .delta. of gaps 77 as described above. In some
embodiments, the angle of gaps 79 is configured to increase or
decrease to the same extent as angle .delta. when receiver track 70
is being flexed. Thus, in some embodiments, the angle of gaps 79 is
an acute angle from about 0.degree. to about 45.degree., about
0.degree. to about 40.degree., about 0.degree. to about 35.degree.,
about 0.degree. to about 30.degree., about 0.degree. to about
28.degree., about 0.degree. to about 25.degree., about 0.degree. to
about 20.degree., about 0.degree. to about 15.degree., about
0.degree. to about 10.degree., or about 0.degree. to about
5.degree.. In some embodiments, when receiver track 70 is in an
unflexed or relaxed state, the angle of gaps 79 is from about
5.degree. and about 25.degree., about 10.degree. and about
20.degree., about 12.degree. and about 18.degree., or about
14.degree. and about 16.degree.. In one embodiment, the angle of
gaps 79 is about 14.degree. when receiver track 70 is in an
unflexed or relaxed state. In some embodiments, the angle of gaps
79 is substantially equal to angle .alpha. and/or angle .beta. of
molding platform 10 when molding platform 10 and receiver track 70
are both in an unflexed or relaxed state.
[0075] In some embodiments, space 80 of receiver track 70 is
disposed between upper tabs 78 and lower tabs 76. More
particularly, in some embodiments, space 80 is at least partially
defined by bottom surface 78b of upper tabs 78 and top surface 76a
of lower tabs 76. As shown in the illustrated embodiment of FIG.
9c, space 80 extends from second side 72b of support 72 a distance
equal to length L5. In some embodiments, space 80 further extends
along an entire dimension (e.g., width) of receiver track 70. In
some embodiments, as discussed above, space 80 is configured to
receive a portion of the molding systems described herein. In some
embodiments, space 80 is configured to receive and secure to a
portion of the molding systems in a friction fit. For example, in
some embodiments space 80 is sized and configured to receive lips
14 of molding platform 10. According to some of these embodiments,
when lips 14 are received in space 80, upper tabs 78 may be
received in slot 26 of molding platform 10 between lips 14 and
coping tabs 22. In some embodiments, lower tabs 76 and upper tabs
78 cooperate to clip onto lips 14. In some embodiments, lips 14 and
coping tabs 22 cooperate to clip onto upper tabs 78. In certain
variations, space 80 may be sized and configured to receive coping
tabs 22. In these embodiments, when coping tabs 22 are received in
space 80, lower tabs 76 may be received in slot 26 of molding
platform 10 between lips 14 and coping tabs 22. Molding platform 10
may further be combined with backing 30 and molding block 40 before
or while engaged with space 80 of receiver track 70. Preferably,
receiver track 70 is positioned during use such that mold supports
16 extend into or over the interior space of the swimming pool when
molding platform 10 is engaged with receiver track 70.
[0076] In some embodiments, receiver track 70 includes a plurality
of track flanges 74. For ease of illustration FIGS. 9a and 9b show
four track flanges 74, however, it should be appreciated that
receiver track 70 may include any suitable number of track flanges
74. For example, in other embodiments, receiver track 70 may
include more than four track flanges 74. In some embodiments,
receiver track 70 includes fewer than four track flanges 74. In
some embodiments, receiver track 70 includes at least two track
flanges 74. Preferably, the number of track flanges 74 is equal to
the number of lower tabs 76 and/or upper tabs 78.
[0077] In some embodiments, track flanges 74 are arranged in an
evenly spaced row along first side 72a. In some embodiments, track
flanges 74 extend from first side 72a of support 72 a distance L6.
In some embodiments, length L6 is greater than length L5. In some
embodiments, length L6 is greater than length L1 of mold supports
16. In other embodiments, length L6 is less than or equal to length
L1. In some embodiments, track flanges 74 are positioned at or
proximate the bottom of support 72 and extend opposite of lower
tabs 76. In some embodiments, track flanges 74 are integrally
formed with support 72. In other embodiments, track flanges 74 are
formed separately from support 72 and secured thereto using any
suitable means known in the art (e.g., adhesive, fasteners, joinery
techniques, welding, etc.).
[0078] In some embodiments, each track flange 74 includes a top
surface 74a and a bottom surface 74b. Top surface 74a and bottom
surface 74b may be substantially parallel according to some
embodiments. In some such embodiments, top surface 74a and bottom
surface 74b are substantially perpendicular to first side 72a of
support 72. In some embodiments, each top surface 74a of track
flanges 74 is coplanar. In some embodiments, each bottom surface
74b of track flanges 74 is coplanar. In some embodiments, top
surface 74a of track flanges 74 is coplanar with top surface 76a of
lower tabs 76. In some embodiments, bottom surface 74b of track
flanges 74 is coplanar with bottom surface 76b of lower tabs
76.
[0079] As shown in FIGS. 9a and 9b, top surface 74a and/or bottom
surface 74b may be substantially trapezoidal in shape. In some
embodiments, top surface 74a and/or bottom surface 74b of each
track flange 74 is shaped as an isosceles trapezoid having a height
equal to length L6 and its longer base positioned at first side 72a
of support 72. In other embodiments, top surface 74a and/or bottom
surface 74b may be configured as another polygonal shape (e.g.,
square, rectangle, triangle, etc.). According to these embodiments,
each track flanges 74 includes one or more straight edges. In
further embodiments, each track flange 74 may include one or more
curved edges.
[0080] In some embodiments, adjacent track flanges 74 are separated
by a gap 75. In some embodiments, each gap 75 has a length equal to
the length of each track flange 74 (e.g., length L6). In other
embodiments, gap 75 has a length shorter than the length of each
track flange 74 (e.g., shorter than length L6). Gaps 75 in some
embodiments are configured to provide a degree of clearance between
adjacent track flanges 74 to allow for receiver track 70 to be
curved. As described, this configuration may be advantageous
according to certain embodiments, for example, when receiver track
70 is positioned along a curved section of the swimming pool (e.g.,
curved sections 3a and 3b of FIG. 1). As shown in FIGS. 9a and 9b,
gaps 75 may be substantially aligned with gaps 77 in opposing
pairs.
[0081] Gap 75 may be defined by angle .epsilon. formed between
adjacent track flanges 74 according to some embodiments. In some
embodiments, angle .epsilon. is equal to the angle between the
neighboring side edges of adjacent track flanges 74. In some
embodiments, angle .epsilon. is an acute angle from about 0.degree.
to about 45.degree., about 0.degree. to about 40.degree., about
0.degree. to about 35.degree., about 0.degree. to about 30.degree.,
about 0.degree. to about 28.degree., about 0.degree. to about
25.degree., about 0.degree. to about 20.degree., about 0.degree. to
about 15.degree., about 0.degree. to about 10.degree., or about
0.degree. to about 5.degree.. In some embodiments, when receiver
track 70 is in an unflexed or relaxed state, angle .delta. is from
about 5.degree. and about 25.degree., about 10.degree. and about
20.degree., about 12.degree. and about 18.degree., or about
14.degree. and about 16.degree.. In one embodiment, angle .epsilon.
is about 14.degree. when receiver track 70 is in an unflexed or
relaxed state. In some embodiments, angle .epsilon. is
substantially equal to angle .delta. when receiver track 70 is in
an unflexed or relaxed state. In some embodiments, angle .epsilon.
is substantially equal to angle .alpha. and/or angle .beta. of
molding platform 10 when molding platform 10 and receiver track 70
are both in an unflexed or relaxed state.
[0082] Similar to angle .delta., angle .epsilon. may be increased
or decreased relative to the angle in the unflexed or relaxed state
depending on the desired curvature of receiver track 70 according
to some embodiments. For example, when receiver track 70 is used
with a convexly curved section of the swimming pool (e.g., curved
section 3a of FIG. 1), receiver track 70 may be flexed such that
the ends of track flanges 74 converge towards each other and angle
.epsilon. is decreased. When receiver track is used with a
concavely curved section of the swimming pool (e.g., curved section
3b of FIG. 1), receiver track 70 may be flexed such that the ends
of track flanges 74 diverge away from each other and angle
.epsilon. is increased. In some embodiments, when receiver track 70
is being flexed, angle increases as opposing angle .delta.
decreases and vice versa.
[0083] In some embodiments, track flanges 74 are configured to be
secured to the periphery of a swimming pool once receiver track 70
is arranged in its desired position. For example, track flanges 74
may be secured to wall portion 7 in FIG. 2 when receiver track 70
is used in place of track 6. In some embodiments, track flanges 74
may be secured into position by any suitable means known in the
art, for example, using screws, nail, bolts, glue, cement, tape,
etc. Preferably receiver track 70 is positioned such that space 80
opens towards the swimming pool interior. After receiver track 70
is secured into position, receiver track 70 may be engaged with the
molding system as described above.
[0084] After the molding system is engaged with receiver track 70,
the molding system may be used to mold the coping of the swimming
pool in a manner similar to the procedures described above with
respect to embodiments where the molding system is engaged with
track 6. In certain embodiments, concrete or other material used to
form the swimming pool coping can be poured over receiver track 70,
which may be left in place along the periphery of the swimming
pool. According to some of these embodiments, receiver track 70
forms a part of the finished swimming pool coping. In some
embodiments, molding platform 10, backing 30, and molding block 40
are removed from the swimming pool coping before the concrete or
other material completely hardens, for example, to allow the
surface of the concrete or other material to be smoothed or
textured.
[0085] In some embodiments, receiver tracks and molding systems of
the present invention can be used to mold one section of the
swimming pool coping at a time. In other embodiments, a receiver
track and molding system may extend along the entire swimming pool
coping. In some embodiments, a receiver track of the present
invention is modular such that a plurality of receiver tracks are
used with the molding system to mold the swimming pool coping. In
some embodiments, for example, both receiver track 50 and receiver
track 70 can be utilized together. In one such embodiment, receiver
track 50 is utilized along straight sections of the swimming pool
(e.g., straight section 3c of FIG. 1) and receiver track 70 is
utilized along curved sections of the swimming pool (e.g., curved
sections 3a and 3b of FIG. 1).
[0086] While the embodiments described herein are illustrative of
molding systems particularly useful for molding swimming pool
copings, the molding systems described herein are not necessarily
limited to this use. Some embodiments of the present invention may
also be used for molding copings in connection with other pools
(e.g., reflecting pools), ponds, baths, tubs, fountains, or the
like. Indeed, molding systems according to certain embodiments of
the present invention may be useful for molding other structures,
for example, walls, countertops, overhangs, eaves, curbs, or the
like. Other applications involving the molding of concrete or other
materials may also benefit from embodiments of the present
invention for at least the reasons set forth herein.
[0087] It will be appreciated by those skilled in the art that
changes could be made to the exemplary embodiments shown and
described above without departing from the broad inventive concepts
thereof. It is understood, therefore, that this invention is not
limited to the exemplary embodiments shown and described, but it is
intended to cover modifications within the spirit and scope of the
present invention as defined by the claims. For example, specific
features of the exemplary embodiments may or may not be part of the
claimed invention and various features of the disclosed embodiments
may be combined. Unless specifically set forth herein, the terms
"a", "an" and "the" are not limited to one element but instead
should be read as meaning "at least one".
[0088] It is to be understood that at least some of the figures and
descriptions of the invention have been simplified to focus on
elements that are relevant for a clear understanding of the
invention, while eliminating, for purposes of clarity, other
elements that those of ordinary skill in the art will appreciate
may also comprise a portion of the invention. However, because such
elements are well known in the art, and because they do not
necessarily facilitate a better understanding of the invention, a
description of such elements is not provided herein.
[0089] Further, to the extent that the method does not rely on the
particular order of steps set forth herein, the particular order of
the steps should not be construed as limitation on the claims. The
claims directed to the method of the present invention should not
be limited to the performance of their steps in the order written,
and one skilled in the art can readily appreciate that the steps
may be varied and still remain within the spirit and scope of the
present invention.
* * * * *