Permanent form assembly and method for swimming pool user support structures

A permanent form assembly and method for creating and forming swimming pool user support structures within a swimming pool includes one or more of a vertical elongated support, one or more of a lateral brace, and a plurality of support structure risers that when assembled create a permanent support structure form having a volume for receiving a filler within the volume.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to swimming pools. Particularly, the present invention relates to user support structures within swimming pools.

2. Description of the Prior Art

In-ground swimming pools naturally have sides or sidewalls that are substantially vertical. The average swimming pool has vertical sidewalls that extend downwardly several feet from an upper surface of the pool deck. To facilitate entering and exiting a swimming pool, a swimming pool has some sort of ladder, steps, or the like to assist one in getting into and out of the pool. Generally, permanent steps are provided at a shallow end of in-ground swimming pools. In some pools, a swimmer's bench may also be included along a portion of a vertical sidewall typically in the shallow end. The bench provides a structure in the swimming pool where a swimmer may sit and relax while remaining in the water without having to tread water or to stand whereby the swimmer's upper torso is completely out of the water.

Presently, it is relatively common to use various types of interior steps or stairs in a swimming pool for swimmers to gain access to and exit the swimming pool. A well recognized style of interior steps is known as a “wedding cake” step form. In certain types of swimming pools such as ones constructed of concrete or gunite, permanent interior steps and or benches are often built on site by constructing a step or bench form. The step or bench form is filled with concrete and, when the concrete has set and dried, the step or bench form is removed. The cost of manufacturing concrete steps is expensive and labor intensive, requiring highly skilled workers for construction. A concrete step, however, is advantageous for concrete or gunite type pools and when there is a need for variations in the step shape or size.

A problem is presented when concrete steps are used for vinyl liner type swimming pools. With these type of pools, it is difficult to accurately measure and build a conforming liner to cover the concrete steps due to the variability and the unique shapes and sizes of poured concrete steps.

As an alternative to poured concrete steps, on-piece molded plastic steps have been designed and used. These prefabricated step modules are carried to the site and readily installed. One type of step module is formed of acrylic and/or fiberglass laminates or vinyl covered metal. These types of step modules are relatively strong and will generally adequately support the weight of an adult. The drawback to such step modules is their tendency to delaminate, splinter, corrode, or puncture.

Because of these problems and other considerations, stair modules are now predominantly prefabricated, unitary structures formed from some type of suitable plastic composite or the like that can withstand temperature related expansion and contraction. Such materials, however, are generally relatively flexible so that the steps may yield under a person's weight, thereby giving the person an insecure feeling. Additionally, the structural integrity of such stair modules may be compromised.

There have been devised various support structures to reinforce the steps of such prefabricated plastic stair modules. Stacked blocks or bricks have been used for support, but this requires footers and building the support from the ground up requiring shims for leveling. Other examples of such support structures may include support posts having bearing plates or pads connected to their upper ends which are placed under the stair tread, or a longitudinal stiffening member which is bonded to the pieces at a serrated surface on the underside of the stair tread. Another type of known support structure includes unitary support braces formed of a suitable plastic material which are strategically situated under the stair module treads. Each support brace has a plurality of horizontal step supports corresponding in number to the stair treads. Extending vertically from the horizontal step supports are integral tabs that are positioned to register unto slots formed within transverse stiffening ribs on the underside of the stair treads.

Therefore, what is needed is permanent form system that can accommodate many sizes and styles of swimming pool stairs and benches.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide permanent form system that can accommodate many sizes and styles of swimming pool user support structures including, but not limited to, stairs, benches and combinations thereof. It is another object of the present invention to provide a permanent form system that does not require highly skilled workers of construction. It is a further object of the present invention to provide a permanent swimming pool user support structures that are relatively inexpensive and easy to install.

The present invention achieves these and other objectives by providing a permanent form system and method for creating and forming swimming pool user support structures within an in-ground swimming pool that uses vinyl liners.

The permanent form system of the present invention may be an assembly or a kit. The difference is that the assembly is already assembled while the kit requires assembly.

In one embodiment of the present invention, the permanent form assembly is a permanent form kit. The kit includes one or more of a vertical elongated support, one or more of a lateral brace, a plurality of support structure risers, and a plurality of fasteners. The one or more of a vertical elongated support has a pool wall flange extending laterally from the vertical support that is adapted for fixedly securing the pool wall flange to one of a pool wall or a vertical support brace. The one or more of a lateral brace has a longitudinal brace body, a vertical support end connected to the vertical elongated support and a riser support end where the lateral brace is adapted to extend laterally from the pool wall. Each of the risers has a riser inside surface, a smooth riser outside surface, a first riser end, and a second riser end. The first riser end is adapted for fixedly securing to the riser support end of the lateral brace and the second riser end is adapted for fixedly securing to one of a first riser end of another support structure riser, the pool wall or the riser outside surface of another support structure riser.

In another embodiment of the present invention, there is included a support brace having first and second support brace ends adapted to directly attach one of the first and second support brace ends to one of a pair of intersecting pool walls. The support brace also includes a central support brace portion adapted for fixedly attaching to the vertical elongated support.

In still another embodiment of the present invention, the lateral brace is integrally-formed with the vertical elongated support from a single piece of material.

In a further embodiment of the present invention, each of the plurality of support structure risers has either a hem or a bracing flange formed along a longitudinal edge.

In yet another embodiment of the present invention, each of the plurality of risers has a first riser end flange that extends laterally from the riser inside surface at first and second riser ends.

In another embodiment of the present invention, the lateral brace includes a riser spacing slot that is adapted for receiving a longitudinal side of one of the plurality of support risers.

In another embodiment of the present invention, the permanent form assembly includes a vertical brace support that is adapted to attach and support one or more of the lateral braces along the longitudinal brace body of the lateral brace.

The structure of the permanent form assembly is such that, when a filler is disposed within the space created by the permanent form assembly, the only visible component is the outside surface of the risers. The filler forms a platform that functions as the stair tread in a stair-style assembly and as a seat surface in a bench-style assembly.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The preferred embodiment(s) of the present invention is illustrated inFIGS. 1-14.FIG. 1shows one embodiment of a permanent form10for creating a swimming pool user support structure. Permanent form assembly10includes one or more of a vertical, elongated support30, one or more of a lateral brace50and a plurality of support structure risers70. Permanent form assembly10is shown fixedly attached to a flat wall2of a swimming pool5that is used to create interior steps known as “wedding cake” steps. Vertical elongated support30and lateral brace50are generally made of a rigid material while the plurality of support structure risers70may be made of either rigid or bendable material, preferably bendable material.

Vertical elongated support30is fixedly attached to wall2of swimming pool5along its longitudinal length with one end (not shown) of vertical elongated support30resting on a bottom3of swimming pool5. Vertical elongated support30has a wall attaching surface31and a lateral brace connecting surface32. Vertical elongated support30may be solid, tubular or angular. Preferably, vertical elongated support30is an angular bracket, more preferably an L-shaped bracket, such as a piece of angle iron having one flange of the L-shaped member connected to wall2and a second flange of the L-shaped member that is lateral to the first flange providing a connecting surface for lateral brace50.

Lateral brace50has a longitudinal brace body51, a vertical support end52and a riser support end53. Lateral brace50is provided in various lengths based on the number of stairs to be installed. The first or lowest step has the longest lateral brace50in permanent form assembly10while the topmost step has the shortest lateral brace50. Optionally, lateral brace50may include one or more riser spacing slots55in the longitudinal brace body51. Riser spacing slot55is configured to receive a portion of a bottom longitudinal edge84of support structure riser70. It is also contemplated that an optional lateral end brace56may be used if pre-assembly of the permanent form10is preferred. Optional lateral end brace56, when used, would preferably be attached between the plurality of risers at the riser ends that attach to the pool wall. The use of optional lateral end braces56allows pre-assembly of the permanent mold assembly, which can then be easily placed into position before coupling to the pool wall and may facilitate the step-forming process.

Support structure riser70has a riser body72with a first riser end73, a second riser end74, an outside surface75, and an inside surface76. As can be seen fromFIG. 1, support structure riser70has first riser end73connected to wall2or to a second riser end74of an abutting riser70. Where two or more steps are formed, riser70of each additional step is supported along a bottom riser edge84by lateral brace50of riser70of the immediately lower step.

Permanent form assembly10creates a volume space100between wall2and inside surface76of the plurality of risers70. A filler (not shown) is filled within space100to provide step platforms that function as stair risers and a strong form over which a pool liner (not shown) is installed. The filler may be poured concrete or a porous, loose-packed material with a poured concrete cap or platform over the porous, loose-packed material. Examples of porous, loose-packed material include stones, sand and the like.

Turning now toFIG. 2, there is illustrated the embodiment shown inFIG. 1adapted for use in a pool corner. Permanent form assembly10includes all of the same components as previously discussed, which are the vertical elongated support30, the lateral brace50and a plurality of support structure risers70. A cross support40is securely attached laterally to vertical elongated support30. Cross support40has a cross support central portion41, a first cross support end42and a second cross support end43. Cross support central portion41is securely attached to wall attaching surface31of vertical elongated support30while first cross support end42is securely attached to wall2and second cross support end43is securely attached to wall2′. One or more of cross support40may be used to stabilize vertical elongated support30before the filler is placed within space100. LikeFIG. 1, optional lateral end braces56are shown and may be used particularly when pre-assembly of the permanent form assembly is desired.

FIG. 3shows one embodiment of vertical elongated support30. In this embodiment, vertical elongated support30is an angularly-shaped member having wall support flange33with wall support surface31and a brace support flange34with a brace support surface32that extends laterally from wall support flange33. A plurality of openings35may optionally be included in wall support flange33and brace support flange34to facilitate the assembly of permanent form assembly10. It should be understood that vertical elongated support30may have other shapes such as U-shaped, V-shaped, tubular-shaped or any configuration that presents at least one wall support surface31and one or more brace support surfaces32capable of securely attaching the vertical support30to a swimming pool wall2or a cross support40and one or more lateral braces50to the vertical support30.

FIG. 4shows a side view of one embodiment of riser70. Riser70includes a riser outside surface75that is smooth and a riser lateral flange77that extends from second riser end74. Riser lateral flange77is shorter than the height of riser70so that all of riser lateral flange77is contained with the space100when assembled in permanent form assembly10. Riser lateral flange77may optionally include a plurality of riser flange openings88for receiving fasteners (not shown). On the opposite end (first riser end73), there is also a riser lateral flange78that is similar to riser lateral flange77. In one embodiment of riser70, an optional top longitudinal edge79is formed by a hem80.

FIG. 5shows an enlarged view of hem80. Hem80is formed by bending the longitudinal side towards riser inside surface76onto itself to present a rounded top longitudinal edge79. The purpose of hem80is to present a smooth riser edge transition from the smooth outside surface75so that no sharp edges are exposed to the pool liner (not shown) that will cover permanent form assembly10. Alternately, the top edge79may be rounded by grinding, polishing, etc.

FIG. 6shows an enlarged view of the connection point between a pair of adjacent risers70and a lateral brace50. A fastener90fixedly secures riser lateral flange78of first riser end73of riser70′, riser lateral flange77of second riser end73of riser70″ and riser brace end53to each other. It should be understood that the position of lateral brace50and riser lateral flanges77,78shown inFIG. 6may be changed so that lateral brace50may be on either said of lateral flanges77,78and, in the case where lateral brace50is not tubular but an angularly-shaped bracket with a brace flange54, brace flange54may also be positioned between riser lateral flanges77,78. Any fastener known in the art may be used to secure the lateral brace ends52,53to vertical support30and risers70, respectively.

FIG. 7illustrates another embodiment of the permanent form assembly of the present invention. In this embodiment, permanent form assembly10′ creates a bench within a swimming pool upon which a swimmer may sit and still remain in the water. Permanent form assembly10′ includes one or more of a vertical, elongated support30, one or more of a lateral brace50and a plurality of support risers70′. AlthoughFIG. 7shows a bench-style permanent form assembly10′ configured into a corner of a swimming pool, it should be appreciated that the bench-style permanent form assembly10′ may be along a middle portion of a straight wall2, along two lateral walls2, along a curved wall, or any combination since the preferred risers70′ can be easily bent to shape. Another embodiment of the vertical elongated support30and lateral brace50, which is better shown inFIGS. 8 and 9, may be optionally used with the bench-style embodiment ofFIG. 7.

Turning now toFIG. 8, there is shown a front view of this alternate embodiment. Vertical elongated support30and lateral brace50are integrally formed and, preferably, are a unitary brace and support structure130. Unitary brace and support structure130is typically formed from one material that has a planar body132and a lateral flange135along one of two opposing edges133,134. Planar body132performs the function of the lateral brace50while lateral flange135on edge133performs the function of the vertical elongated support30and opposing edge134performs the function of brace riser end53. This is better shown inFIG. 9, which is a top view of unitary brace and support structure130.

Turning now toFIG. 10, there is illustrated a side view of an alternative riser170that is usable for straight step assemblies or straight risers for the bench-style permanent form assembly10′. Riser170includes a riser outside surface75that is smooth and a riser lateral flange77that extends from second riser end74. Riser lateral flange77is shorter than the height of riser170so that all of riser lateral flange77is contained within the space100when assembled in permanent form assembly10′. Riser lateral flange77may optionally include a plurality of riser flange openings88for receiving fasteners (not shown). On the opposite end (first riser end73), there is also a riser lateral flange78that is similar to riser lateral flange77. In this embodiment of riser170, a top longitudinal edge79is optionally formed by an inwardly angled riser edge flange82. It is noted, however, that the inwardly angled riser edge flange82may be a separate component that is coupled to an inside surface76of riser170. To provide further structural support, riser170may optionally include a base flange72that laterally extends from the bottom of riser170inwardly from riser inside surface76. Base flange72may be a separate flange that is connectable to riser170or may be formed by bending the bottom, longitudinal edge.

FIG. 11shows an enlarged view of riser edge flange82. Riser edge flange82is formed by bending the longitudinal side towards riser inside surface76forming an acute angle between riser edge flange82and riser inside surface76to present a rounded top longitudinal edge79. As with hem80, the purpose of riser edge flange82is to present a smooth riser edge transition from the smooth outside surface75so that no sharp edges are exposed to the pool liner (not shown) that will cover permanent form assembly10′.FIG. 12shows a bench-style permanent form assembly10′ with a filler200within space100and forming a bench platform202. The bench-style form assembly shown inFIG. 12would be ready for installation of a pool liner.

FIG. 13illustrates a combination stair-style and bench-style permanent form assembly300. In this illustration, a corner stair permanent form assembly10is shown but it should be understood that the combination may also be assembled along a straight pool wall as well. Permanent form assembly300includes a stair-style form assembly10and a bench-style form assembly10′. Stair-style form assembly10includes vertical elongated support30with support cross brace40, a plurality of lateral braces50and a plurality of risers70. Bench-style form assembly10′ includes a plurality of unitary brace and support structures130and a plurality of risers70′. In this combination form assembly300, a riser70aof the plurality of risers70′ that connects to stair-style form assembly10has a lower portion removed to accommodate placement of a lower portion70bof riser70aagainst a step riser70of a lower stair and an upper portion70cextending to and against a step riser70of a second stair. Each of the lower portion70band the upper portion70chas a lateral flange for securing each portion70b,70cto risers70of the lower stair and the second stair, respectively.

FIG. 14illustrates another embodiment of the present invention.FIG. 14shows a permanent form assembly400that is a stair-style form incorporating straight stairs in a curved portion of swimming pool wall2. This permanent form assembly400includes a plurality of vertical elongated supports30, a plurality of lateral braces50and a plurality of risers70. Optionally, a vertical brace support37may be connected between the lateral brace50of one step to the lateral brace50of a lower or upper step. As with all previous embodiments, permanent form assembly400creates a volume space100between wall2and inside surface76of the plurality of risers70, which receives a filler (not shown) to complete the assembly prior to installing a pool liner. Additionally, the plurality of risers70may include top longitudinal edge79with an optional inwardly angled riser edge flange82. To provide further structural support, riser70may further optionally include a base flange72that laterally extends from the bottom of riser70inwardly from a riser inside surface76. Base flange72may be a separate flange that is connectable to riser170or may be formed by bending the bottom, longitudinal edge. The inclusion of optional flanges82and72on risers70that are used for straight-faced stairs provides additional structural support to the assembly. It should be further noted that straight stairs may also be used along straight pool walls and may further include rounded riser corners.

The preferred materials used to make or form the various components of the permanent form assembly of the present invention include stainless steel or structural composites. The only requirement is that the material used has sufficient structural strength to hold and retain the filler.

The present invention has many advantages over prior art concrete and molded swimming pool stairs and benches. The permanent form assembly10,10′ and400can be packaged into a compact kit form with fasteners and instructions for easy assembly when installing an in-ground swimming pool. No special skills are required to assemble the permanent form assembly. Unlike concrete forms that must be made, set up, concrete poured into the form and allowed to set, and then the concrete forms removed, the present invention is left in place and the pool liner is disposed over the form. Unlike pre-formed, molded steps, no additional structural support is required after the filler is placed into the form assembly of the present invention.

A further advantage of one embodiment of the present invention is the use of bendable risers so that any shape (i.e. straight, arcuate, S-shaped, etc.) can be formed. The step risers70can be manufactured as one size where a stair-style assembly would simply include a plurality of risers needed for making a user-selected stair configuration, while the bench risers70′ can also be manufactured as one size. Because all of the risers70are flat and the curved risers are formed on site during assembly, the risers70are stackable along with the lateral braces50and the vertical elongated support30.

Another advantage is that with a limited number of different components (i.e. 2 different risers, 3 different lateral braces for 3 stair steps, and 1 type vertical support if desired), the permanent form system or assembly of the present invention allows a large number of stair and bench styles to be assembled. Because the components are standardized, no special skills are required to manufacture a structural form. A user need only follow the assembly instructions that accompany a permanent form kit. This reduces labor costs both in respect of skill level and time required, thus, making the addition of steps/stairs and/or a bench within a swimming pool less expensive than prior art methods.