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RELATED APPLICATIONS  
       [0001]    This application is a continuation-in-part of U.S. patent application Ser. No. 09/848,406, filed May 04, 2001. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    This invention relates to a solar blanket roller assembly and, in particular, a solar blanket roller assembly which is intended to be installed and stored below the surface of the surrounding deck of a pool.  
         BACKGROUND OF THE INVENTION  
         [0003]    In the past, solar blankets have been used to cover swimming pools in order to reduce the amount of heat lost from the pool. Typically, the solar blanket consists of a floating plastic or foam mat which is cut to a size and shape generally corresponding to the surface of the pool. The solar blanket is stretched over the surface of the pool during periods when the pool is not in use. When the pool is intended to be used, the solar blanket is often stored on a roller assembly which consists of an elongated roller shaft which mounts a wheel at each of its ends, with one end of the blanket physically coupled to the shaft by a series of flexible straps. Typically, the solar blanket is removed from the pool surface by winding it for storage about the elongated roller shaft. The wheels provided at each end of the roller shaft enable the shaft, together with the solar blanket stored thereon, to roll along the top of the pool deck. Once the solar blanket has been removed from the pool surface, the entire roller assembly is moved via the wheels away from the pool area for storage. To return the solar blanket back onto the surface of the pool, the entire roller assembly is again rolled back into a position adjacent to the pool surface, and the solar blanket is unrolled from the roller shaft and onto the surface of the pool.  
           [0004]    Because the roller assembly rests directly on the top of the pool deck, it is an inconvenience to move the entire roller assembly away from and back to the pool area. Furthermore, the roller assembly may disadvantageously hinder movement about the pool and could present an obstruction which could otherwise injure a pool user.  
           [0005]    In addition, the placement of conventional roller assemblies on top of the deck takes up room that could otherwise be used for other activities, and also may be aesthetically unpleasing either when the solar blanket is rolled up for storage or when it is deployed over the pool surface.  
           [0006]    In colder climates conventional solar blanket storage assemblies present a further disadvantage in that given their size, they are often difficult to store during the winter months. Often the roller shaft may be fifteen feet or more in length, necessitating that the solar blanket be either stored outside with the roller assembly, or detached therefrom and stored elsewhere.  
         SUMMARY OF THE INVENTION  
         [0007]    Accordingly, it is an object of this invention to at least partially overcome the disadvantages of the prior art. Thus, it is an object of this invention to provide an improved type of solar blanket roller assembly which is installed below the grade or deck of a pool.  
           [0008]    Another object of the invention is to provide a roller assembly for a solar blanket which permits simplified deployment and storage of the solar blanket over the surface of an in-ground pool.  
           [0009]    A further aspect of the invention is to provide a solar blanket assembly which enables a solar blanket to be stored immediately adjacent to the edge of a pool without otherwise obstructing or hindering movement about the pool deck area.  
           [0010]    Another object of the invention is to provide a method by which a roller assembly for a swimming pool solar blanket may be installed easily and quickly in a position substantially below the grade of the surface or deck surrounding the pool.  
           [0011]    The present invention includes a solar blanket and roller assembly for use with an in-ground swimming pool. The roller assembly comprises a longitudinally elongated housing which, most preferably, has a length selected at least one to two feet longer than the lateral width of the pool. The housing defines an elongated interior cavity having a dimension selected to enable the storage of the solar blanket in a rolled configuration therein. A rotatable roller shaft or spindle is provided within the housing. The spindle has a length corresponding to or greater than the width of the blanket and is configured to be manually electrically, pneumatically and/or hydraulically journalled in rotation. Thus the solar blanket may be coupled to the spindle and wound into the housing by selectively rotating the spindle.  
           [0012]    An elongated opening extends substantially the longitudinal length of the housing and allows the solar blanket to be drawn from or wound into the housing for deployment or storage. Optionally, a lid or cover may be provided which may be opened or closed to permit or prevent access into the housing interior.  
           [0013]    In use, the housing is recessed into the ground and positioned with its elongated opening oriented upward so that the housing opening is generally flush with the grade or deck surface immediately surrounding the pool.  
           [0014]    Accordingly, in one aspect, this invention resides in a below-deck solar blanket roller assembly comprising: a rotatable roller shaft for rolling and unrolling a solar blanket, the shaft having first and second ends and a longitudinal axis extending in a longitudinal direction; a non-rotatable protective housing or casing having first and second ends, wherein the housing is spaced radially from the roller shaft, surrounds the roller shaft, and extends in the longitudinal direction, and wherein the housing has an elongated opening extending in the longitudinal direction; first end support supporting the first shaft end and positioning the first shaft end inside and relative to the housing; second end shaft support supporting the second shaft end and positioning the second shaft end inside and relative to the housing; first end wall closing the first end of the casing; second end wall closing the second end of the housing; a drive coupler engaging a portion of the roller shaft for receiving rotational energy from a source to rotate the roller shaft.  
           [0015]    In another aspect the present invention resides in a below-deck solar blanket roller assembly comprising:  
           [0016]    a rotatable roller shaft for rolling and unrolling a solar blanket, the shaft having first and second ends and a longitudinal axis extending in a longitudinal direction;  
           [0017]    a non-rotatable protective casing having first and second ends and extending in the longitudinal direction, the casing has a diameter selected such that the casing is spaced radially from the roller shaft, and wherein the casing has a knock-out portion removable to form an elongated opening extending in the longitudinal direction;  
           [0018]    a first end support for supporting the first shaft end and positioning the first shaft end inside and relative to the casing;  
           [0019]    a second end shaft support for supporting the second shaft end and positioning the second shaft end inside and relative to the casing;  
           [0020]    a power coupler at an end of the roller shaft for receiving power from a source to rotate the roller shaft.  
           [0021]    In a further aspect the present invention resides in a solar blanket roller assembly for installation substantially below the deck of a pool, comprising:  
           [0022]    a rotatable roller shaft for rolling and unrolling a solar blanket, the shaft having first and second ends and a longitudinal axis extending in a longitudinal direction;  
           [0023]    a non-rotatable protective casing having first and second ends, the casing being elongated in the longitudinal direction and being spaced radially from said roller shaft, said casing further comprising,  
           [0024]    at least one extruded segment being elongated along an axis having a longitudinally extending knock-out portion in an upper region thereof which is removable to form part of an elongated opening, and  
           [0025]    a first end support for supporting and positioning the first shaft end inside the casing,  
           [0026]    a second end support for supporting and positioning said second shaft end inside the casing, and  
           [0027]    a drive spaced towards one end of said roller shaft and being selectively operable to rotate said roller shaft.  
           [0028]    In yet another aspect the present invention resides in a method of installing a below-deck solar blanket roller assembly for a swimming pool, the roller assembly comprising,  
           [0029]    a roller shaft for rolling and unrolling a solar blanket thereon, said roller shaft extending along a longitudinal axis from a first end to a second end,  
           [0030]    a non-rotatable protective casing having first and second end portions, the casing being elongated in the longitudinal direction and being spaced radially from said roller shaft, said casing further comprising,  
           [0031]    a first extruded segment and a second extruded segment, each of said first and second segments having a longitudinally extending knock-out portion in an upper region thereof which is removable to form part of an elongated opening,  
           [0032]    a first end support for supporting and positioning the first shaft end inside the casing,  
           [0033]    a second end support for supporting and positioning said second shaft end inside the casing, and  
           [0034]    a drive spaced towards one end of said roller shaft and being selectively operable to rotate said roller shaft,  
           [0035]    the roller assembly being installed by,  
           [0036]    coupling said first extruded segment to said second extruded segment with the knockout portion of said first segment substantially aligned with said knock-out portion of said second segment,  
           [0037]    positioning said casing in a trench adjacent the pool with the knock-out portions oriented upwardly and substantially flush with a surface of the deck,  
           [0038]    backfilling about the casing, and  
           [0039]    removing said knock-out portions to form an elongated opening.  
           [0040]    More preferably, the casing further includes a lid, and said method further comprises,  
           [0041]    hingely coupling said lid at a position adjacent to said first segment knock-out portion and said second segment knock-out portion, so as to be pivotally movable between first and second positions to substantially close or open said elongated opening; and wherein  
           [0042]    the step of backfilling about said casing comprises pouring a settable concrete about said casing, and  
           [0043]    following backfilling about the casing, the hinge is moved from said first position to the second position.  
           [0044]    Further aspects of the invention will become apparent upon reading the following detailed description and drawings which illustrate the invention and preferred embodiments of the invention.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0045]    In the drawings, which illustrate embodiments of the invention:  
         [0046]    [0046]FIG. 1 shows a partial cross-sectional end view of a first embodiment of a solar blanket roller assembly installed recessed flush with a swimming pool deck, and with a solar blanket housed therein in a storage position;  
         [0047]    [0047]FIG. 2 shows the cross-sectional view of FIG. 1 with the solar blanket deployed from within the roller assembly and overlying the surface of the pool.  
         [0048]    [0048]FIG. 3 is a partial perspective end view of a first idler end of the solar blanket roller assembly shown in FIG. 1 with the solar blanket removed for clarity;  
         [0049]    [0049]FIG. 4 is a partial schematic front view of a solar blanket roller assembly of FIG. 1 with the solar blanket removed for clarity;  
         [0050]    [0050]FIG. 5 illustrates an enlarged partial schematic end view of the second other drive end assembly used in the roller assembly of FIG. 1;  
         [0051]    [0051]FIG. 6 illustrates a schematic exploded view of the drive assembly of FIG. 5;  
         [0052]    [0052]FIG. 7 illustrates an enlarged partial schematic end view of the idler end assembly used in the roller assembly of FIG. 1;  
         [0053]    [0053]FIG. 8 illustrates an enlarged end view of the retaining clamp used in coupling the solar blanket to the roller assembly spindle;  
         [0054]    [0054]FIG. 9 illustrates a perspective view of the hand crank used in the operation of the roller assembly;  
         [0055]    [0055]FIG. 10 is a partial schematic view of a roller assembly in accordance with a second embodiment of the invention;  
         [0056]    [0056]FIG. 11 is a partial perspective cut-away view of a solar blanket roller assembly housing in accordance with another embodiment of the invention with the solar blanket removed for clarity;  
         [0057]    [0057]FIG. 12 is a partial perspective cut-away view of a solar blanket roller assembly in accordance with another embodiment of the invention, with the solar blanket removed for clarity;  
         [0058]    [0058]FIG. 13 is a cross-sectional end view of a solar blanket roller assembly housing in accordance with a further embodiment of the invention;  
         [0059]    [0059]FIG. 14 is a partial cross-sectional view showing one way in which the roller assembly of FIG. 12 may be installed;  
         [0060]    [0060]FIG. 15 is a partial cross-sectional view showing another way in which the solar blanket roller assembly of the present invention may be installed;  
         [0061]    [0061]FIG. 16 is a perspective end view of the roller assembly housing illustrating a housing levelling bracket in accordance with a further embodiment of the invention;  
         [0062]    [0062]FIG. 17 is a schematic side view of a roller assembly and spindle housing sections prior to assembly and packaged as part of a kit;  
         [0063]    [0063]FIG. 18 is a cross-sectional end view of the housing section shown in FIG. 17 taken along line  18 - 18 ′;  
         [0064]    [0064]FIG. 19 is an exploded view of the roller assembly housing, lid, hinge and drive assembly; and  
         [0065]    [0065]FIGS. 20 a  and  20   b  illustrate a side and end view of a cardboard insert used in the initial installation of the roller assembly housing.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0066]    [0066]FIG. 1 illustrates a cross-sectional view of the portion of a concrete patio or deck  4  which borders and most typically surrounds an in-ground swimming pool  6 . As will be described hereafter, a roller assembly  10  for use in storing and deploying a solar blanket  8  is recessed into the deck  4  adjacent to the end  7  of the pool  6 . Although final positioning may vary, most preferably the solar blanket roller assembly  10  is positioned so that its uppermost surface is substantially flush with the surface of the deck  4 , and approximately 0.5 to 3 feet from the pool end  7 . When rolled for storage, the solar blanket  8  is thus stored in a position recessed below the surface of the deck  4  so as not to present a tripping hazard, or otherwise create an aesthetically unsightly appearance.  
         [0067]    The solar blanket  8  may be of a conventional design, typically consisting of a flexible plastic membrane which has a series of discreet air pockets integrally formed therein to provide the blanket  8  with sufficient buoyancy to enable it to be floated on the water surface  9  of the swimming pool  6 . The roller assembly  10  is configured to enable the solar blanket  8  to be coiled for storage therein so that the blanket  8  is contained entirely within the solar blanket roller assembly  10  beneath the surface of the deck  4 .  
         [0068]    As is shown in FIG. 2, the solar blanket roller assembly  10  enables the solar blanket  8  to be selectively unwound from the coiled storage position shown in FIG. 1, and stretched across the water surface  9  when the pool  6  is not in use.  
         [0069]    [0069]FIGS. 2 and 4 show best the construction of the roller assembly  10 . Preferably, the entire solar blanket roller assembly  10  extends in a longitudinal direction LD one to two feet past each edge of the pool end  7 , and in the case of a typical residential pool installation will have a length of between about 14 and 26 feet, so as to permit the solar blanket  8  to be housed therein. The roller assembly  10  includes an elongated cylindrical roller spindle or shaft  12 , an elongated generally cylindrical casing or housing  18  and a spindle drive assembly  13 . The shaft  12  is rotatably mounted at each of its ends at  14 , 16  (shown best in FIGS. 5 and 7) within the elongated generally cylindrical housing  18 . The roller shaft  12  or spindle is formed from a number of hollow extruded aluminum spindle segments  12   a , 12   b  (FIG. 4) which are each typically about 6 to 12 feet in length. The shaft segments  12   a , 12   b  are joined to each other by inserting a cylindrical connector segment  23  into the adjacent open ends of each shaft segment  12   a , 12   b , and thereafter inserting screws (not shown) to couple each segment  12   a , 12   b  to the connector  23 . Once the spindle segments  12   a , 12   b  are assembled, the completed roller shaft  12  extends in the longitudinal direction LD from its first end  14  to the second end  16  along longitudinal axis L A  (FIG. 4). It is to be appreciated that although the tubular spindle segments  12   a , 12   b  most preferably have a length selected at between about 6 and 12 feet for shipping convenience, the number of tube segments  12   a , 12   b  and final length of the shaft  12  will ultimately depend upon the width of the solar blanket  8  which is to be installed.  
         [0070]    A rearward most edge  15  (FIG. 2) of the solar blanket  8  is attached directly to the spindle  12 . The blanket  8  may be attached to the spindle  12  by suitable means including rivets, screws, glues, touch fasteners or ties.  
         [0071]    Most preferably, however, the edge  15  of the blanket  8  is secured to the shaft  12  in a clamp-fit arrangement by means of an elongated aluminum retaining bar  19  (FIG. 8) which is coupled to the spindle  12  by screws  21 . As will be described, in use of the roller assembly  10 , the solar blanket  8  is coiled about the spindle  12  through its selective rotation by the drive assembly  13 .  
         [0072]    As shown best in FIGS. 2 and 4, the housing  18  has a generally cylindrical profile and extends in the longitudinal direction LD (FIG. 4), a marginal distance past each spindle end  14 , 16 . In a preferred embodiment, the housing  18  formed from a series of extruded metal, PVC or other plastic segments or sections  18   a , 18   b  (see FIG. 4) which are joined in axial alignment. In the cross-section shown in FIG. 2, the housing  18  is illustrated having radial diameter D which is marginally greater than the maximum diameter d 1  (see FIG. 1) of the solar blanket  8  when rolled for storage about the spindle  12 . With roller assemblies for use with most residential pools, the housing  18  will have a radial diameter of between about 1 and 2 feet, and more preferably about 15 inches. As a result, the housing  18  is spaced radially about and generally surrounds the roller shaft  12 .  
         [0073]    An elongated opening  24  is provided through the uppermost extent of the housing  18 . The opening  24  extends in the longitudinal direction LD a distance at least as wide as the lateral width of the blanket  8 . The opening  24  is sized to enable the blanket to be unwound from the coiled position about the roller shaft  12  and stretched across the water surface  9  as for example is shown in FIG. 2. Preferably, the opening  24  has a width of between about 3 and 8 inches and more preferably approximately 5.5 inches.  
         [0074]    The edge portions of the housing extrusion which define the longitudinal sides of the opening  24  extend away from each other as a pair of outwardly extending flanges  25   a , 25   b . In addition to defining an uppermost surface of the housing  18 , the flanges  25   a , 25   b  provide a lip under which concrete is backfilled to assist in anchoring the housing  18  in the desired position recessed into the pool deck  4  (FIG. 2).  
         [0075]    [0075]FIG. 4 shows best each longitudinal end  20 , 22  of the housing  18  being sealingly closed by an end cover  34 , 36 . It is to be appreciated that the end covers  34 , 36  have a profile selected to correspond to the interior cross-sectional profile of each extruded housing section  18   a , 18   b . The end covers  34 , 36  may be formed of PVC or other plastics and/or metals and secured in place by an appropriate plastic cement, or by mechanical fasteners such as screws or the like.  
         [0076]    As shown best in FIGS. 1 and 2, an extruded aluminium cover or lid  50  is provided over the opening  24 . The lid  50  is connected to the edge of the opening  24  which is furthest from the pool  6  by one or more piano hinges  27 . Although not essential, for ease of shipment, the lid  50  preferably is also formed from a series of extruded aluminium segments each having a length of between about 7 and 12 feet and which are connected by a series of splines. The lid  50  covers the elongated opening  24  in the housing  18 . The lid  50  is movable relative to the hinge  27  from a first position (as shown in FIG. 1) where the elongated opening  24  in the housing  18  is closed to a second position where the lid  50  is moved to an orientation extending radially outward of the housing  18  where the elongated opening  24  in the housing  18  is open (as shown in FIG. 14) to permit access into the interior of the housing. As shown in FIG. 1, the lid  50  and the piano hinges  27  have a profile selected so that when closed, the lid  50  lies substantially flush with both the flanges  25   a , 25   b  and the surface of the deck  4  when the solar blanket  8  is coiled about the spindle  12  in a storage configuration.  
         [0077]    The roller spindle  12  is rotatably supported within the housing  18  by means of a pair of spindle end supports  26 , 30 . The first end supports  26  the first shaft end  14  and also positions the first shaft end  14  inside the housing  18  in approximately coaxial alignment therewith. Preferably the first end support  26  supports the first end  14  through a bearing assembly  28  or other suitable device to permit easy rotation of the roller shaft  12 . Similarly, the second end shaft support  30  supports the second shaft end  16  and which positions the second shaft end  16  inside the housing  18  in coaxial alignment therewith. Once again, a bearing assembly  32  or other suitable device is provided to permit easy rotation of the roller shaft  12  about the axis LA.  
         [0078]    In a simplified construction, as shown in FIGS. 5 and 7, the bearing assemblies  28 , 32  each consist of a galvanized steel L bracket  31  which in assembly, are mounted to a plate  41  (FIG. 2) supported by a pair of flanges  27   a , 27   b  (FIG. 18) which are integrally formed with the housing extrusion. Each of the bearing assemblies  28 , 32  further include a respective bushing  29 , 33  which rotatably supports a stainless steel pivot shaft  35  positioned so as to project axially from each end  14 , 16  of the spindle  12 . As is shown best in FIG. 2, in the preferred embodiment of the invention, the plate  41  used in the first end support  26  comprises a rigid piece of galvanized metal extending from first extended flange  27   a  formed on the inner peripheral wall of the housing  18  to the second flange  27   b  on the inner peripheral wall of the housing  18  which is opposite thereto. Similarly, the plate  41  used in the second end support  30  is comprised of a similar rigid piece of galvanized metal extending from the flange  27   a  at a longitudinally displaced position on the inner peripheral wall of the housing  18  to an opposing position on the flange  27   b . It is to be appreciated that the housing  18  extrusion may alternately include an axially extending extruded boss, groove, ridge or the like to assist in locating and retaining the plate  41  within the housing  18 .  
         [0079]    Preferably, the rigid plates  41  of each support  26 , 30  are aligned in a plane parallel to a plane defined by the longitudinal axis LA and an axis orthogonal to the longitudinal axis. In a more preferred embodiment of the invention, in the final assembly of the roller assembly  10  each of the plates  41  is provided in a generally horizontal arrangement, as for example is shown in FIG. 2.  
         [0080]    [0080]FIG. 5 illustrates best the drive assembly  13  as including a nylon horizontal bevel gear  37 , a second nylon bevel gear  39  and drive shaft  40 . The horizontal bevel gear  37  is rotatably mounted to the bracket  31  of the bearing assembly  28  for rotation about a vertical axis A 2 -A 2 . The second bevel gear  39  is fixedly mounted to the pivot shaft  35  which projects from the spindle end  14  in meshing engagement with the gear  37 . The drive shaft is coupled to the horizontal bevel gear  37  in alignment with the vertical axis A 2 -A 2  whereby the rotation of the shaft  40  about the axis A 2 -A 2  rotates the gears and turns the spindle  12  about the axis LA. As shown best in FIG. 9, a hand crank  43  is provided to permit the manual rotation of the drive shaft  40 . The hand crank  43  has at its lowermost end a socket  45  for use in engaging the uppermost end of the shaft  40 . More preferably, the tooth spacing of the bevel gears  37 , 39  is selected to rotate the spindle  12  360° with every 2 to 3 turns of the crank  43 .  
         [0081]    To permit the drainage of any water which may enter into the housing  18  as the solar blanket  8  is coiled for storage, a series of drain holes  47  (FIG. 2) are formed at spaced locations along the bottom of the housing  18 . It is to be appreciated that the drain holes  47  allow any pool water which is carried into the housing  18  with the solar blanket  8  to flow outwardly from the housing interior and into a weeping bed of crushed gravel  39  and tile  41  (FIG. 1). The sealing of the housing ends  20 , 22  and drain holes  47  are preferred in order to keep as much dirt and other debris as possible from entering the housing  18  after the housing  18  has been installed, and thereafter to permit the periodic cleaning of the roller assembly  10 .  
         [0082]    With the roller assembly  10  configuration of FIGS.  1  to  9  to move the solar blanket  8  to a storage position coiled about the spindle  12  and contained within the housing  18 , a user would open the lid  50  and fit the socket  45  of hand crank  43  over the drive shaft  40 . With the hand crank  43  so positioned, the crank  43  would be turned in a horizontal plain to rotate the bevel gears  37 , 39  and spindle  12 . As the spindle  12  turns, the solar blanket  8  is pulled from the pool surface  9  into the housing  18  coiling about the spindle  12  to the storage position shown in FIG. 1. Once the solar blanket  8  is coiled in the housing  18 , the lid  50  is thereafter closed, clearing the surface of the deck  4  from any obstructions or tripping hazards. It is to be appreciated that in deploying the solar blanket  8 , the lid  50  is simply reopened, and the user grasps and pulls the free edge of the solar blanket  8  unrolling it off the spindle  12  and across pool  6 .  
         [0083]    Although FIGS.  1  to  9  describe the roller assembly  10  as being operated by means of a hand crank  43 , the invention is not so limited. Other power sources used to return the blanket  8  to a rolled position may also be used. By way of on-limiting example, an alternate embodiment of the invention is shown in FIG. 10. In FIG. 10, the power source could be a suitable electric motor, such as a low voltage electrical motor  90 . The electric motor  90  could be positioned within the housing  18  or outside the housing  18 . In either case, there would be suitable power linkage  92  from the electric motor  90  used to translate rotational power to the pivot shaft  35 .  
         [0084]    The power linkage  92  may be any suitable power coupler, including something as simple as a hole in the end of the roller shaft  12  to receive a similarly-shaped insert from the output shaft of the motor  90 . Also, the power linkage  92  could further include a sprocket, gear, or longitudinal extender.  
         [0085]    In an alternative embodiment shown in FIG. 10, the roller shaft  12  and the housing  18  are substantially the same as discussed above and shown in FIGS. 1 and 9 with the exception of the supports used to rotatably mount the first end support  126  as shown in FIG. 10 is comprised of a support member  142  which is aligned in a plane defined by two axes which are orthogonal to each other and also orthogonal to the longitudinal axis LA. For example, as shown in FIG. 10, the two axes which are orthogonal to each other are the vertical axis YA and the Z axis ZA which comes transversely out of the paper of FIG. 10. In this embodiment, the second end support  130  similarly comprises a rigid support member  148  which is aligned in a plane defined by two axes which are orthogonal to each other and also orthogonal to the longitudinal axis. Also, in order to have roller shaft  12  rotate most easily, each of the support members  142 , 148  support bearing assemblies  128 .  
         [0086]    As may be seen in FIG. 11, in still a further embodiment of the invention, the housing  18  may further include a number or longitudinally spaced reinforcing ribs  55 . The reinforcing ribs  55  provide the housing  18  with increased rigidity and assist in anchoring the housing  18  against movement. In FIG. 11, the opening  24  in the housing  18  is defined by first edge  52  and second edge  54  in place of flanges  25   a , 25   b . As may be seen in FIG. 12, the lid  50  may be hinged to the housing  18  in the area adjacent to the first edge  52 .  
         [0087]    Optionally, a blanket protector  56  may be hinged to the housing  18  in an area adjacent to the second edge  54 . The blanket protector  56  rotatably moves from a first position located substantially within the housing  18  to a second position radially outward from the housing  18  as shown in FIG. 12 during the deployment or storage of the blanket  8 .  
         [0088]    As is shown in FIG. 14, blanket protector  56  protects the solar blanket  8  as the solar blanket  8  is either unwound from the roller shaft  12  or wound back up onto the roller shaft  12 . In particular, in use, the lid  50  and protector  56  are both moved to their respective open position shown in FIG. 14 when the operator desires to either unroll the solar blanket  8  from the roller shaft  12  and place the solar blanket over the surface of the pool  6  or, alternatively, when an operator wants to roll the solar blanket  8  back onto the roller shaft  12 . When the solar blanket  8  is either entirely rolled onto the roller shaft  12  or when the solar blanket  8  is positioned over the pool surface, the operator will typically close the lid  50  so as to cover the elongated opening  24 , primarily for safety reasons but also for aesthetic reasons.  
         [0089]    Although not essential, the lid  50  may also have a “V” shape cross-section so that it wedges into the opening  24  and is at least partially supported by the first and second edges  52  and  54  of the opening  24 . Alternatively, the lid  50  could be partially supported by the flanges  25   a , 25   b  (as shown in FIG. 2).  
         [0090]    In a preferred embodiment, the housing  18  is formed from PVC plastic, primarily to provide strength and rigidity to the housing  18 . Alternatively, in another embodiment, the housing  18  could be formed from an aluminium or other plastic extrusion, as well as galvanized steel or other corrosive-resistant metal. In this embodiment, the casing need not be circular in cross-section. For example, the housing  18  could have a generally square or hexagonal lateral cross-sectional shape as shown in FIG. 13, or some other suitable cross-sectional shape.  
         [0091]    In a pool  6  that is at least partially surrounded by a deck  4 , the roller assembly  10  is intended to be installed substantially below the deck surface  4 . The housing  18  is oriented such that the opening  24  in the housing  18  is either substantially flush with the deck surface  4  or is otherwise aligned with an opening  66  (FIG. 14) in the deck  4 . In one embodiment, the opening  66  in the deck  62  is spaced away from a portion of the deck  68  which is immediately adjacent to the pool  64 . Preferably the portion of the deck  68  immediately adjacent to the pool  64  is supported by the pool wall  70 . In a more preferred embodiment of the invention, the opening  66  in the deck is spaced between the portion of the deck  68  immediately adjacent to the pool  64  and a deck portion  72  distant from the pool  64 . In one possible construction, the deck portion  72  distant from the pool  64  is supported by a deck support  74 .  
         [0092]    In another embodiment of the invention shown in FIG. 15, the housing  18  is oriented such that the opening  24  in the housing  18  is aligned with an opening  76  in the pool wall  70 .  
         [0093]    In FIG. 1, the housing  18  is shown as being supported on a pair of extruded support legs  58 , however, other support constructions are also possible. In the embodiment shown in FIG. 16, the housing  18  is supported by a pair of casing supports  178  comprised of a suitable block, concrete or brick structure underneath each of the first and second end of the housing  18 . For example, in FIG. 16, the casing support  178  comprises a vertical concrete support member  180 . Preferably, the vertical concrete support member  180  is formed by pouring concrete into a plastic tube or sonotube, and wherein the vertical concrete support member  180  is supported by a suitable footing  182 .  
         [0094]    Preferably, each casing support  178  furthermore has a casing leveller. In one embodiment, the casing leveller, as shown in FIG. 16, comprises a relatively short length of pipe  184  which is moveable up and down on the vertical concrete support member  180 . The top portion  186  of the pipe  184  is shaped to receive the housing  18 . The pipe  184  can be moved up and down on the vertical concrete support member  180  to adjust the height of the particular end of the housing  18 . Adjustable screws  186  are tightened and forced into the vertical concrete support member  180  to fix the pipe  184  and the housing  18  at the desired height. Other support configurations are, however, possible.  
         [0095]    The roller assembly  10  of the present invention lends itself to sale in kit form and its installation and assembly together with a solar blanket  8  at a swimming pool site is described best with reference to FIGS. 1 and 17 to  20 .  
         [0096]    Following or concurrently with the installation of the pool  6 , a trench approximately 18 inches wide and 20 inches deep is formed parallel to the pool end  7  (FIG. 1), approximately 12 to 24 inches from the edge of the pool  6 . The bottom of the trench is either lined with drainage tile  51  and/or a sufficient deep layer of crushed gravel  48  to provide an effective weeping bed to remove and accumulate water from within or around the roller assembly  10 .  
         [0097]    Although not essential, in a preferred embodiment, the roller assembly  10  is shipped as a partially pre-assembled kit. In kit form, each of spindle sections  12   a  and  12   b  have their respective ends  14 , 16  and the drive assembly  13  pre-mounted on their respective supports  26 , 30  which have also been pre-attached to a respective housing section  18   a , 18   b . FIG. 17 shows the partially pre-assembled kit for the spindle section  12   a  as being pre-mounted within housing section  18   a , and packaged within a cardboard box  82  for shipment. Within the box  82  are also packaged the connector  23  used to couple the spindle sections  12   a , 12   b  together, the hand crank  43  and miscellaneous connecting hardware (not shown). As is shown, the end cap  34  has also been factory positioned over the end  20  of the housing section. Although not shown, it is to be appreciated that the remaining spindle section  12   b  and housing section  18   b  would be packaged in a like manner.  
         [0098]    The free ends of the spindle sections  12   a , 12   b  are held in place by a respective corrugated cardboard form  80  shown best in FIGS. 17 and 20 a  and  20   b . The cardboard form has a profile which corresponds to the internal cross-section profile of the housing  18 . The cardboard forms  80  maintain the proper alignment of the spindle sections  12   a , 12   b  and provide additional lateral support to the housing  18  to offset any lateral pressure which occurs following the pouring of concrete  166  into place about the housing  18 .  
         [0099]    Initially, the individual housing sections  18   a , 18   b  are unpacked from the box  82  and axially aligned with the open ends of each section  18   a , 18   b  which are remote from the covered ends  20 , 22  juxtaposed. The housing sections  18   a , 18   b  are secured to each other by inserting fasteners through either welded or co-extruded loops  86  (FIG. 18) formed along the outer sides of the sections  18   a , 18   b . As shown best in FIG. 18, at the time of this extrusion, each section  18   a , 18   b  extends continuously in the redial direction and further includes a planar PVC cut-out or knock-out portion or piece  88 . The knock-out portion  88  is integrally formed with the extrusion and seals the opening  24  along its length. In addition to preventing debris and/or concrete from entering the housing  18  during installation, the use of a knock-out piece  88  and the formation of the housing  18  as a radially continuous extrusion, provides the housing sections  18   a , 18   b  with increased structural integrity which resists deformation or distortion during installation.  
         [0100]    Following the assembly of the housing  18 , the aluminium lid  50  is next installed. The lid  50  may be a unitary construction, but more preferably consist of a number of individual sections having the identical cross-sectional profile, and which for ease of storage and shipping have an elongated length corresponding to that of the housing sections  18   a , 18   b . The sections of the lid  50  are assembled to the housing  18  by means of the hinges  27 . Alternately, the lid sections could be pre-assembled to an individual housing section  18   a , 18   b  prior to shipping of the roller assembly  10  to the end consumer. Simultaneously with the coupling of the housing  18 , lid sections are joined together by inserting a spline (not shown) in a dovetail profile groove  89  (FIG. 2) extruded in the aluminium lid  50 .  
         [0101]    Following the assembly of the housing  18  and lid  50 , the housing  18  is lowered into the trench with its lower positioning brackets  58  resting on the gravel bed  58 . Once the housing  18  is so positioned, final adjustment is made to ensure that the upper flanges  25   a , 25   b  are level with the deck surface  4 , and the longitudinal axis of the housing  18  is aligned with the pool edge  7 . Concrete  166  (or other suitable backfill material) is then poured as backfill about the housing  18 , over the brackets  58  and under the flanges  25   a , 25   b  to permanently secure the housing  18  in place.  
         [0102]    Immediately following the pouring of the concrete  166 , the lid  50  is opened and moved to a vertical orientation. It has been found that the movement of the lid  50  about the knuckle of the hinge  27  acts to straighten the PVC housing  18  and remove any twisting or bending. The PVC knock-out  88  is left in place until the concrete  166  has set both to maximize the rigidity of the housing  18  and to prevent concrete from entering the housing and otherwise fouling the spindle  12  or drive assembly  13 .  
         [0103]    Following the setting of the concrete  166 , the knockout  88  is removed by either punching out, trimming with a knife or cutting with a circular or other power saw to thereby clear the opening  24 . After the knock-out  88  is removed, the cardboard braces  80  are next removed from the housing interior. The spindle sections  12   a , 12   b  are then joined by inserting the connector segment  23  in the open end of each spindle section  12   a ,  12   b  in the manner described.  
         [0104]    Following the assembly of the spindle  12 , the end  15  of a sheet of solar blanket material which is sized larger than that of the surface of the pool  6  is fastened to the spindle  12  by the clamping bar  19  (FIG. 8). With the end  15  of the blanket so secured, the spindle  12  is positioned in the desired rotatably mounted position within the housing  18  with the pivot shaft  35  at each of its ends  14 , 16  rotatably coupled to a respective end support  26 , 30 . The solar blanket form is then stretched across the pool  6  and is thereafter trimmed to exactly follow the contour of the pool surface  9 . Following trimming, the solar blanket  8  and roller assembly  10  is thereafter ready for use.  
         [0105]    It will be understood that, although various features of the invention have been described with respect to one or another of the embodiments of the invention, the various features and embodiments of the invention may be combined or used in conjunction with other features and embodiments of the invention as described and illustrated herein.  
         [0106]    Although this disclosure has described and illustrated certain preferred embodiments of the invention, it is to be understood that the invention is not restricted to these particular embodiments. Rather, the invention includes all embodiments which are functional or mechanical equivalents of the specific embodiments and features that have been described and illustrated herein. For a definition of the invention, reference may be had to the appended claims.

Summary:
A below-deck solar blanket roller assembly is installed below the deck of a pool. The roller assembly includes a rotatable roller shaft for rolling and unrolling a solar blanket and a non-rotatable protective casing which surrounds the roller shaft. The roller assembly is intended to be installed below the deck of a pool. This invention at least partially overcomes some of the disadvantages of typical solar blanket rollers that are installed on the surface of the pool deck, such as inconvenience in moving the entire above-deck assembly away from and back to the pool area. The below-deck solar blanket roller assembly provides an aesthetically pleasing and safe alternative to solar blanket roller assemblies installed above the pool deck.