Abstract:
A wall and buttress construction for swimming pools in which deck support extensions can be secured to the top of the buttresses. The wall includes a plurality of panels having end flanges at the sides of the panels, and a double slotted peg is provided. One of the slots is shorter to receive a wedge when a peg is placed through two abutting panel end flanges, and the other slot being longer to accommodate a wedge when the peg is being used to join a brace as well as two abutting end flanges. The end flanges have elongated openings therethrough for receiving the pegs that are oriented diagonally, rather than either vertically or horizontally. The elongated openings, pegs and wedges are easily visible/accessible for inserting pegs as a result of the diagonal orientation.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     The present application claims the benefit of U.S. Provisional Patent Application No. 60/517,509, entitled “POOL,” which was filed Nov. 5, 2003, and U.S. Provisional Patent Application No. 60/533,184, entitled “POOL,” which was filed Dec. 30, 2003, the entire contents of each of which are hereby incorporated herein by reference. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     The present invention relates to pools, especially larger pools typically referred to as swimming pools. However, the invention could be used to produce so-called swim spas, wading pools or the like.  
         [0003]     A major breakthrough in pool construction occurred in about 1993, when Polynesian Pools, Inc. introduced the pool disclosed in U.S. Pat. No. 5,400,555. This is a so-called “vinyl liner” pool, in which the poolside walls are molded of high impact polystyrene. Each panel has top, bottom and end panel flanges, which can be secured to each other and to molded structural plastic braces projecting rearwardly from the wall panels. The fasteners for securing these components together comprise fasteners, each of which includes an elongated slot. One of the fasteners is integral with the pool brace, but other fasteners, while molded with the brace, are separable and are used as separate members. The integral peg protrudes through receiving apertures in the panel end flanges. The separate fasteners are passed through apertures in the brace and the panel end flanges. A peg having an inclined leading edge is then driven into the slot in the key to securely hold the abutting panels and the brace together. The slotted fasteners and pegs were made of nylon.  
         [0004]     Others have since emulated this design. Some employ braces which project further away from the pool wall, i.e. a full two or three feet, in order to give greater support to a concrete or other deck placed above the braces around the perimeter of the pool. These wider braces are difficult to work with, however, since one normally does not want to have to “overdig” more than about two feet beyond the nominal edge of the pool where the walls are placed. If the braces extend two or three feet from the wall, one has to dig further at least in the area of the braces in order to accommodate the greater length.  
       SUMMARY OF THE INVENTION  
       [0005]     The present invention comprises a wall and buttress construction for swimming pools in which deck support extensions can be secured to the top of the buttresses.  
         [0006]     In another aspect of the invention, the wall includes a plurality of panels having end flanges at the sides of the panels, and a double slotted peg is provided. One of the slots is shorter to receive a wedge when a peg is placed through two abutting panel end flanges, and the other slot being longer to accommodate a wedge when the peg is being used to join a brace as well as two abutting end flanges.  
         [0007]     Preferably the end flanges have elongated openings therethrough for receiving the pegs that are oriented diagonally, rather than either vertically or horizontally. They are much more easily visible/accessible for inserting pegs as a result of the diagonal orientation.  
         [0008]     In another aspect of the invention, the wall panels themselves are reinforced with intersecting parabolic arches on the back surfaces thereof. In yet another aspect of the invention, the buttresses are provided with a plurality of plumbing saddles for receiving plumbing lines to plumb the swimming pool. In addition, the buttresses also preferably have oversized rebar holes, approximately three times the diameter of rebar, to make it easier to slide long lengths of rebar into the buttresses to facilitate anchoring the walls in the ground or in concrete footings.  
         [0009]     These and other aspects, features and advantages of the invention will be more fully understood and appreciated by reference to the written specification and appended drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]      FIG. 1  is a partially fragmentary perspective view of a pool according to one aspect of the present invention;  
         [0011]      FIG. 2  is an exploded perspective view of a portion of the pool of  FIG. 1 ;  
         [0012]      FIG. 3  is a perspective view of a portion of the pool of  FIG. 1 ;  
         [0013]      FIG. 4  is a fragmentary, perspective view of a peg and wedge that may be utilized to interconnect adjacent panels of the pool;  
         [0014]      FIG. 5  is a fragmentary view showing the peg and wedge in the assembled condition;  
         [0015]      FIG. 6  is a plan view of the peg;  
         [0016]      FIG. 7  is a plan view of the wedge;  
         [0017]      FIG. 8  is a partially fragmentary, perspective view of a deck support extension;  
         [0018]      FIG. 9  is a fragmentary, perspective view of a buttress and deck support;  
         [0019]      FIG. 10  is a side view of a buttress and deck extension;  
         [0020]      FIG. 10A  is a fragmentary cross-sectional view of an upper portion of the pool wall;  
         [0021]      FIG. 11  is a partially fragmentary, exploded perspective view of a buttress and optional tube into which concrete can be poured to provide additional support;  
         [0022]      FIG. 12  is a fragmentary, perspective view of a buttress and anchor;  
         [0023]      FIG. 13  is a perspective view of a portion of a pool and a buttress that includes leveling pads;  
         [0024]      FIG. 14  is a perspective view of a first leveling pad having a first height;  
         [0025]      FIG. 15  is a perspective view of a second leveling pad having a second height that is greater than the height of the first leveling pad of  FIG. 14 ;  
         [0026]      FIGS. 16A-16E  are partially schematic views illustrating the different spacing heights that can be achieved utilizing the first and second leveling pads of  FIGS. 14 and 15 ; and  
         [0027]      FIG. 17  is a partially schematic view illustrating another leveling pad arrangement. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0028]     For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in  FIG. 1 . However, it is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.  
         [0029]     With reference to  FIG. 1 , pool  1  includes a plurality of panels  2  forming a wall  10  and a liner  3 . As described in more detail below, adjacent panels  2  can be quickly and easily interconnected utilizing pegs  25  and wedges  26  to form a strong and durable structure. The panels may be curved panels  4  having a relatively large or small radius, forming inside or outside corners. The panels  2  may include a cutout  5  that can be removed for installing a skimmer  6 . One or more buttresses  7  may be interconnected to the panels  2  to provide additional support. Also, a concrete deck  8  extends around the pool, and is supported by the buttresses  7  as described in more detail below. With reference to  FIG. 2 , each panel  2  includes a wall  12 , an upper flange  13 , lower flange  14 , and vertically extending side flanges  15 . Parabolic ribs  16  and horizontal ribs  17  extend across the wall  12  to provide structural support. A circular rib  18  extends around a cutout  19  for mounting of a light (not shown). The panels  2  and buttress  7  are made of a polymer material having a tough outer skin and inner cellular structure providing a very strong and durable pool structure. Conventional coping  9  extends around the top edge of wall  10  and overlaps the joints formed at adjacent panels  2  to thereby reinforce the wall structure and align adjacent panels  2 . As also discussed in more detail below, coping  9  secures the upper edge  11  ( FIG. 10A ) of the pool liners to the panels  2 .  
         [0030]     Each side flange  15  includes a plurality of openings  20  therethrough (see also  FIGS. 3 and 4 ), and each buttress  7  includes a plurality of tabs or extensions  21 . Each tab  21  also has an opening  20  therethrough having the same shape, size, and orientation as openings  20  in flanges  15  of panels  2 . Openings  20  are in the form of an elongated slot having an enlarged center portion  20 . Slots  20  are preferably oriented at about a 45° angle relative to the vertical walls  12  of panels  2 . Pegs  25  extend through openings  20 , and a wedge  26  extends through a selected one of the openings  27  and  28  in wedge  25  to securely and tightly interconnect adjacent panels  2 . Alternately, conventional threaded nylon fasteners (not shown) may be inserted through the enlarged center portion  22  of openings  20  to interconnect the adjacent panels  2 .  
         [0031]     If a pair of adjacent panels  2  are directly interconnected without a buttress  7 , the peg  25  is inserted through the openings  20  of the adjacent side flanges  15  of the panels  2 , until extension  29  contacts sidewall surface  30  ( FIG. 4 ) of side flange  15 . Wedge  26  is then inserted through the shorter opening  28  to interconnect the adjacent panels  2 . If a buttress  7  is to be interconnected to the panels  2 , the tabs  21  of the buttresses  7  are positioned adjacent the side surface  30  with the opening  20  of tab  21  in alignment with the openings  20  of the side flanges of the panels  2 . The peg  25  is then inserted through the openings  20  in the tabs  21  and side flanges  15 , and wedge  26  is inserted into the longer slot  27  in peg  25 . Thus, the different lengths of the slots  27  and  28  permit the peg  25  to be utilized for interconnecting adjacent panels  2  either with or without a buttress  7 . The side surface  31  of vertical flanges  15  of panels  2  are substantially smooth and uninterrupted, such that adjacent surfaces  31  abut one another when adjacent panels  2  are interconnected. The peg  25  and wedge  26  provide alignment for adjacent panels, such that additional alignment features are not required.  
         [0032]     With further reference to  FIG. 6 , peg  25  includes a central web portion  34  and a smoothly radiused thicker edge portion  35  that extends around the peg  25  to provide additional strength. Similarly, thicker radiused portions  36  extend around openings  28  to provide additional strength. Tapered surfaces  38  and  39  form a pointed end portion  37  of peg  25 . The tapered edges  38  and  39  facilitate insertion of the peg  25  in openings  20 , and also bring adjacent openings  20  into alignment during assembly. An end or head  40  distributes forces if a hammer or the like is used to tap or drive the peg  25  into openings  20 .  
         [0033]     With further reference to  FIG. 7 , wedge  26  includes a central web portion  41  and thicker, radiused edge portions  42  that provide additional strength. End  45  of wedge  26  includes a first tapered edge  43  and second tapered edge  44 . Edge portion  46  is tapered less than edge portion  44 , and provides a tight wedging action when wedge  26  is inserted into opening  27  or  28  of peg  25 . End or head  47  provides for distribution of forces if a hammer or the like is utilized to securely drive the wedge  26  into the opening  27  or  28  of peg  25 . Tapered edges  43  and  44  at end  45  facilitate insertion of wedge  26  and further contribute to quick and easy assembly of pool  1 . Edge  42 A may be serrated to provide a secure, high friction engagement with openings  27 ,  28  of peg  25  to ensure that wedge  26  does not become dislodged. Wedge  26  is preferably inserted into slot  27  or  28  in peg  25  in the orientation shown in  FIG. 4 , such that edge  46  contacts surface  30  of flange  15 . Alternately, wedge  26  may be installed in an orientation as illustrated in  FIG. 5 , wherein serrated edge  42 A contacts surface  30  of flange  15 . The peg  25  and wedge  26  are made of a polycarbonate material that provides sufficient strength to structurally interconnect adjacent panels  2  and buttress  7 , and also provides impact resistance to prevent cracking during installation.  
         [0034]     The peg  25  and wedge  26  provide for very quick and secure interconnection of adjacent panels  2  and buttresses  7 . Also, the angle of opening  20  ensures that the peg  25  and wedge  26  can be easily seen by the builder even if there is limited space between the wall  10  and the adjacent earth. Also, the wedge  26  tightly draws the adjacent panels  2  together. Side flanges  15  may be provided with five openings  20  including upper openings  20 A and  20 B ( FIG. 3 ), a central opening  20 C, and lower openings  20 D and  20 E. The upper and lower pairs of openings are spaced apart a distance “A”, and openings  20 B and  20 D are spaced a distance that is twice as great (“2A”). Tabs  21  of buttress  7  are also spaced such that openings  20  through tabs  21  of buttress  7  align with the openings  20 A,  20 B,  20 D and  20 E in side flanges  15  of panels  2 .  
         [0035]     During assembly, a pair of adjacent panels  2  are positioned side-by-side, and a peg  25  is inserted through central openings  206  of the adjacent panels  2 . A wedge  26  is then inserted through smaller opening  28  of peg  25 . After the panels are interconnected at central openings  206 , a buttress  7  is positioned with tabs  21  adjacent a side flange  15  of one of the panels  2 , with opening  20  through tab  21  aligned with openings  20  of panels  2 . Pegs  25  are then inserted through openings  20  in tab  21  and flanges  15 , and a wedge  26  is then inserted in larger opening  27  to thereby interconnect the panels  2  and buttress  7 .  
         [0036]     With further reference to  FIGS. 8-10 , buttresses  7  include an outer vertical structural portion  49 , an inner vertical portion  51 , and inner structural portions  50  that extend at angles to form a structurally strong and rigid “X” configuration. As described in more detail below, upper horizontal structure  52  may provide support for a concrete deck  8 , and lower structure  53  provides for routing of plumbing. Upper portion of buttress  7  includes a pair of horizontally extending horizontal flanges  56  ( FIG. 8 ) forming a pair of horizontal slots  57  on opposite sides of buttress  7 . A deck support extension  54  has a generally flat C-shaped cross section. During assembly, extension  54  slides onto buttress  7  with end portions or flanges  58  of extension  54  received in slots  57 . Extension  54  is made of steel or other suitable material providing strength and durability. The deck support extension permits the concrete that is used to form deck  8  to be poured prior to compaction of soil  59  to provide for rapid construction of the pool. Buttresses  7  are preferably about 14 inches wide, and flanges  15  of panels  2  are about 4 inches wide. Extension  54  is about 30 inches long, such that a standard concrete deck  8  extends about 2 inches beyond end  54 A (see also  FIG. 10 ) of extension  54 . The concrete material preferably extends downwardly around extension  54  and an upper part of buttress  7 . Rebar  64  may be positioned transversely on top of extensions  54  ( FIG. 9 ) such that it becomes embedded in the concrete deck  8  when the concrete is poured.  
         [0037]     With reference to  FIG. 10 , lower structure  53  of buttress  7  includes at least two plumbing cradles  60  that support pipes  61  (see also  FIG. 1 ) for skimmer  6 , filters and/or other such components. As illustrated in  FIG. 13 , buttress  7  may include three plumbing cradles  60  to support additional pipes or other lines. Rebar  64  (see also  FIGS. 11 and 12 ) may extend through openings  62  and/or openings  63  in buttress  7  to provide additional structural support. The rebar  64  may also extend through a concrete footing  65  ( FIG. 10 ) to provide additional structural reinforcement. The lower portions of buttresses  7  are embedded in footing  65  to anchor and support the pool structure. A pair of extensions  67  slidably receive and retain a stake  66  that further secures and anchors the buttress  7 . Openings  68  (see also  FIG. 3 ) in lower flange  14  of panels  2  receive a stake  69  that may be made from rebar to further anchor the panels  2 . As illustrated in  FIG. 10A , coping  9  includes a channel that receives an enlarged, barbed edge  11  of lining  3  to thereby secure the liner  3  to the panels  2 . Self-tapping screws  77  attach coping  9  to upper flanges  78  of panel  2 . Coping  9  also provides a form/support for concrete deck  8 . Coping  9  is preferably made of a rigid corrosion resistant material such as aluminum.  
         [0038]     With further reference to  FIG. 11 , a polymer (e.g., PVC) or cardboard tube  70  may be used to form a concrete pilaster to support the deck  8  and buttress  7 . Tube  70  is first cut to the proper length, and a notch  71  is then cut into an upper edge  70 A of tube  70 . Buttress  7  includes a downwardly opening upper hook  100  (see also  FIG. 8 ) and an upwardly opening lower hook  101 . During assembly, upper end  70 A of tube  70  is positioned adjacent outer surface  72  of buttress  7 , and tube  70  is shifted upwardly such that hook  100  is positioned in notch  71 . Lower end  70 B of tube  70  is then rotated inwardly towards buttress  7 , and tube  70  is then shifted downwardly until lower end  70 B engages lower hook  101 . Tube  70  is then rotated about its longitudinal axis to shift notch  71  away from upper hook  100 , thereby attaching tube  70  to buttress  7 . Concrete may then be poured into the tube  70  to form a pilaster that provides additional structural support for the deck  8 .  
         [0039]     With further reference to  FIG. 12 , a “deadman anchor”  73  may be secured to the buttress  7  by an adjusting rod  74  and conventional hardware  75 .  
         [0040]     With further reference to  FIG. 13 , a buttress  80  may be molded to include a first leveling pad  81 , and a second leveling pad  82 . The leveling pads  81  and  82  are originally secured to the buttress  80  by a plurality of small runners  83  formed during the molding process. The leveling pads  81  and  82  may be removed from the buttress  80  by breaking the runners  83 . As described in more detail below, the leveling pads  81  and  82  may be positioned under a lower flange  84  of buttress  80  to provide support during assembly of the pool  1 . The buttress  80  may also include a known stake anchoring pin  85 , and may include a third plumbing cradle  86 .  
         [0041]     With reference to  FIG. 14 , the first leveling pad  81  includes a first portion  88  having a height H 1  that is about 0.50 inches, and a relatively thin portion  89  having a height H 2  that is about 0.25 inches. Sidewalls  90  and  91  are relatively thin to reduce the amount of material needed to fabricate the leveling pad  81 , and also to provide for quicker cooling, shorter molding cycle times, and reduced distortion during fabrication.  
         [0042]     With further reference to  FIG. 15 , the second leveling pad  82  includes a relatively large portion  93  having a height H 3  that is about 0.75 inches, and a relatively thin portion  94  that has a height H 2  of about 0.25 inches. The leveling pad  82  includes sidewall portions  90  and  91  that are relatively thin to facilitate fabrication in substantially the same manner as described above in connection with the leveling pad  81  of  FIG. 14 .  
         [0043]     During assembly of the pool  1 , the leveling pads  81  and  82  may be positioned under the lower flange  84  of buttress  80  to provide support. Various spacer heights can be achieved utilizing the leveling pads  81  and  82  as illustrated in  FIGS. 16A-16E . With reference to  FIG. 16A , a height of 0.25 inches can be achieved utilizing either the first leveling pad  81  or the second leveling pad  82  by positioning the thin portion  89  or  94  having a height H 2  under the lower flange  84  of buttress  80 . As illustrated in  FIG. 16B , a spacer height of 0.50 inches can be achieved by positioning the larger portion  88  of leveling pad  81  having a height H 1  (0.50 inches) under the flange  84  of buttress  80 . With reference to  FIG. 16C , a height of 0.75 inches can be achieved by positioning the thick portion  93  of the second leveling pad  82  having a height H 3  (0.75 inches) under the flange  84  of buttress  80 . A spacer height of 1.00 inches can be achieved by positioning the thin portion  89  of first leveling pad  81  on the thick portion  93  of leveling pad  82  to thereby provide a height H 4  (1.00 inches) that is equal to H 2  (0.25 inches) plus H 3  (0.75 inches). Finally, a height H 5  of 1.25 inches can be achieved by positioning the large portion  88  having a height of 0.50 inches of first leveling pad  81  on the large portion  93  having a height H 3  (0.75 inches) of the second leveling pad  82  as illustrated in  FIG. 16E .  
         [0044]     The leveling pads  81  and  82  thereby provide a very quick and easy way to level the buttress  80  and pool  1  during fabrication. By utilizing the different heights and combinations of leveling pads illustrated above, a wide range of spacer heights can be achieved. It will be readily apparent that additional height combinations may be achieved utilizing additional leveling pads  81  and  82  from additional buttresses  80 . Alternately, additional leveling pads could be separately supplied. Also, it will be readily apparent that the heights of the leveling pads may be different heights than the examples discussed about to provide proper spacing if required.  
         [0045]     With further reference to  FIG. 17 , a pair of wedge blocks  97  may also be utilized to provide for spacing below a buttress. Wedge blocks  97  include a flat surface  98  and an angled surface  99 . In use, the angled surfaces  99  contact one another, such that the overall height H provided by the blocks  97  can be adjusted by horizontally shifting of the blocks  97  relative to one another. Also, the edges  99  may include a plurality of steps shown in dashed lines. The steps  96  on blocks  97  engage one another to provide adjustment for the height H without sliding of the blocks  97  relative to one another.  
         [0046]     A pool according to the present invention may be quickly constructed, and also provides a very durable and secure structure. The buttresses, wall components, and peg and wedge connectors are constructed of a durable, non-corrosive material that also provides for a durable structure. The panels may have a wide variety of shapes, such as 90° inside and outside corners of relatively small or relatively large radiuses. Also, the panels may have a 135° configuration to provide for octagons “Lazy Grecians”, “Lazy L&#39;s”, or a wide variety of other configurations as required for a particular application.