Abstract:
A wall panel comprises a first metallic skin, a second metallic skin, and an insulating layer interposed therebetween. The first and second metallic skins are attached to insulating layer with a water-based adhesive. In one embodiment, the water-based adhesive is a water dispersed, high solid, activated adhesive. In another embodiment, the water based adhesive is a one hundred percent waterborne adhesive. In another embodiment, the water-based adhesive is a dispersion of an acrylic resin and synthetic rubber in water.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application relates to, and claims priority from, provisionally filed US patent application having docket number 1000-2 and Ser. No. 60/853,620, entitled POOL ASSEMBLIES AND METHODS OF MANUFACTURE THEREOF, filed on Oct. 23, 2006, which application is hereby incorporated by reference. 
     
    
     BACKGROUND  
       [0002]     The invention relates generally to pool assemblies and methods of manufacture thereof, and more specifically to modular pool assemblies and methods of manufacture thereof.  
         [0003]     Conventional pool assemblies come in many shapes and sizes. There are two main classes of pool assemblies, above-ground and in-ground. Above-ground pools generally comprise a frame structure, sidewalls and a pool liner. The advantages of above-ground pools are that the pools are cheaper than most in-ground pools, easier to install (although often requiring some level of professional installation) and easier to disassemble and move to other locations. The disadvantages are that above-ground pools are less durable, more limited in design choices and generally less aesthetically pleasing than in-ground pools. Alternatively, in-ground pools have much greater durability and are extremely flexible in design choices, however, in-ground pools are also expensive to install and they typically cannot be moved once installed. In addition, most systems, especially above-ground systems, are not adaptable to partially in-ground, partially above-ground installations.  
         [0004]     Accordingly, there is a need in the art for an improved pool assembly that is easy to install and durable for a variety of above-ground, in-ground or partially above-ground, partially in-ground applications.  
       BRIEF DESCRIPTION  
       [0005]     A wall panel comprises a first metallic skin, a second metallic skin, and an insulating layer interposed therebetween. The first and second metallic skins are attached to the insulating layer with a water-based adhesive. In one embodiment, the water-based adhesive is a water dispersed, high solid, activated adhesive. In another embodiment, the water based adhesive is a one hundred percent waterborne adhesive. In another embodiment, the water-based adhesive is a dispersion of an acrylic resin and synthetic rubber in water. In one embodiment, an infrared curing system is used to cure the water-based adhesive in the wall panel assembly. 
     
    
     DRAWINGS  
       [0006]     These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:  
         [0007]      FIG. 1  is a depiction of a pool assembly in accordance with one embodiment of the instant invention.  
         [0008]      FIG. 2  is schematic of a wall panel in accordance with one embodiment of the instant invention.  
         [0009]      FIG. 3  is a flow chart depicting a process in accordance with one embodiment of the instant invention.  
         [0010]      FIG. 4  is another schematic of a wall panel in accordance with one embodiment of the instant invention.  
         [0011]      FIG. 5  is a cross-sectional schematic of a wall panel and a spline channel piece in accordance with one embodiment of the instant invention.  
     
    
     DETAILED DESCRIPTION  
       [0012]     This invention relates generally to a pool system  10  comprising a plurality of interlocking wall panels  12 , as shown in  FIG. 1 .  
         [0013]     Depending on the final pool shape, each interlocking wall panel  12  is typically arced at a predetermined curvature and interlocked to adjacent panels  12  using a spline system  14 , as discussed in greater detail below. Once the pool system  10  is formed by interconnecting the wall panels  12  to complete the design, a liner (not shown) is fitted within the shell to form a substantially watertight skin. A coping  18  is snapped over the upper edge of the wall panels  12  to hold the liner in place and provide a finished appearance to the pool system  10 . The pool system  10  can be fitted with additional components, as needed, for example a skimmer assembly, an inlet, lighting, and steps, stairs, or ladders.  
         [0014]     Each wall panel  12  comprises a first metallic skin  20 , a second metallic skin  22  and an insulating layer  24  interposed therebetween, as shown in  FIG. 2 . The first and second metallic skins  20 ,  22  typically comprise an acrylic coated aluminum. The thickness of metallic skins  20 ,  22  is typically greater than about 0.010 inches and most typically between about 0.015 and 0.030 inches. The acrylic coating is resistive to corrosion and is generally more aesthetically pleasing than the base metallic material. The insulating layer  24  typically comprises a foam, for example an expanded polystyrene (EPS) or the like. The thickness of the insulating layer  24  can vary but for most applications the insulating layer is greater than about 1 inch in thickness and typically is between about 1.5 inches to about 3 inches in thickness.  
         [0015]     The first and second metallic skins  20 ,  22  are attached to opposing sides of the insulating layer  24 , typically with an adhesive  26 . In one embodiment, the adhesive  26  comprises a water based adhesive, for example commercially available 3M Fastbond Contact Adhesive or Simalfa Water-Based Adhesive. Waterbased adhesives use water as the carrier fluid, with the adhesive particles suspended in water, reducing the adhesive&#39;s viscosity so that it can be applied to various substrates at varying thicknesses. The waterbased adhesives carry little or no Volatile Organic Compounds (VOC) and are therefore, one option for environmentally friendly and personnel friendly manufacture of the wall panels  12 . In addition, the water-based adhesives can be readily applied to the wall panels using a hand-held spray gun. The resulting wall panels  12  provide a significant advantage over most conventional pool assemblies and methods of manufacture and construction. The wall panels are lightweight due to the tri-part panel design, typically using lightweight aluminum skins and a foam core and easy to handle, yet extremely durable and sturdy.  
         [0016]     As discussed above, above-ground pools are the cheapest construction option, as well as the easiest to build. Most above-ground pools are made from prefabricated kits that even an amateur can put together (though most people go with professional installers). First, the installers level off the ground to form a flat building surface. Then they assemble a perimeter track that supports the outer wall made of metal, plastic or wood. Next, they spread sand in the pool area and lay the plumbing. Finally, they secure the vinyl liner over the pool walls, fill the pool with water, smooth the liner and fasten it into place. As soon as they hook up the pump and filtering system, the pool is ready to go. The main disadvantage of this sort of pool is that it&#39;s less durable than other designs, and generally less attractive. The wall panels  12  of the instant invention can be used to replace the conventional outer walls of the aboveground pools. Because of the durable panel design and the simple spline system  14 , pool systems  10  using these panels can be installed easier than conventional systems and result in a much more durable construction than conventional metal, plastic or wood based systems.  
         [0017]     Another option is fiberglass pools that are made from fiberglass-reinforced plastic and molded into a basin shape. To install the pool, a construction crew digs an appropriately sized hole, lays the necessary plumbing, adds some sand filler and lowers the preformed pool structure into the hole. Then they level the pool, hook up all the plumbing and backfill in the area around the pool. Usually, the pool is surrounded by a concrete deck structure. Vinyl-lined in-ground pools are a lot like aboveground pools, structurally, but they look more like conventional in-ground designs. The construction crew digs a hole and assembles a metal, plastic or wood frame wall around the hole&#39;s perimeter. As in an above-ground pool, the crew lays sand along the bottom of the hole and secures the vinyl lining to the structural wall. These pools are a lot cheaper than other in-ground designs, but not as durable. Gunite pools are the most popular design in much of the United States. To build one of these pools, the construction crew digs a hole, puts the plumbing in place and assembles a framework grid with steel reinforcing rods (rebar). The rebar rods are spaced about 10 inches apart, and secured together with wire. When the grid is in place, the crew sprays a heavy coating of gunite, a mixture of cement and sand, around the rebar. The sprayer unit combines dry gunite mix with water just before spraying producing a wet concrete material. The crew trowels the gunite smooth and lets it sit for a week or so before applying a smooth finish to the rough surface. The most popular finish is called plaster (actually a mixture of cement and marble sand), but a lot of people finish their pools with special concrete paint. Gunite pools can also have tile, exposed aggregate or even fiberglass finishes. Gunite pools are highly durable, and they can be built in any shape or size but they are very expensive to install. The wall panels  12  of the instant invention can be used to replace all conventional in-ground pool structures as well as aboveground pools. The durability of the pool system  10  of the instant invention even allows for partially aboveground, partially in-ground construction, permitting homeowners with less than ideal ground conditions to install a pool.  
         [0018]     During manufacture, the metallic skins  20 ,  22  and the insulting layer  24  are cut to the appropriate dimensions in S 1 . Next in S 2 , an adhesive  26  is applied to a surface of each metallic skin  20 ,  22  and optionally to each outer surface of the insulting layer. The metallic skins  20 ,  22  and the insulting layer  24  are then joined together to form wall panel  12 . In S 4 , the formed wall panels  12  are set-aside for a predetermined period of time to permit the adhesive to adequately bond to the metallic skins  20 ,  22  and to the insulating layer  24 .  
         [0019]     In one embodiment, the metallic skins  20 ,  22  are each cut wider than the insulating layer  24  on both sides to create a pair of metallic lips  28  on each longitudinal axis (L) of the wall panel  12 , as shown in  FIG. 4 . The metallic lips  28  typically extend outward from a longitudinal edge  30  of the insulating layer  24  to aid in the manufacture of the final wall panels  12 .  
         [0020]     As shown in  FIG. 5 , during final assembly the metallic lips  28  are inserted into a spline channel piece  32 . The spline channel piece  32  is typically made of extruded aluminum. Each spline channel piece  32  includes a pair of outwardly extending wing clips  34  and a pair of recessed clip seats  36 . When the spline channel piece  32  is crimped along the path represented by the arrows (“A”), the wing clips  34  are forced inwardly, along with the metallic lips  28  of the wall panel  12 , into the recessed clips seats  36 . The crimping of the metallic lips  28  into the recessed clip seats  36  forms a strong connection between the wall panels  12  and the spline channel piece  32 .  
         [0021]     While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.