Abstract:
A combination of an enclosure and a treated foam design and a method of manufacturing a treated foam design and combining the foam design with an enclosure consisting of a pool cage having vertical and horizontal aluminum tubing sections. After the enclosure (cage) is measured, the measurements are entered into an auto cad program and the cad file is entered into a computer controlled contour cutter. The colonnade pieces are then painted. The columns, cornices and trim contain depressions to fit around and conceal the tubing sections or tent poles. The aesthetically formed foam columns, cornices and trim are attached to the enclosure structure with a construction adhesive.

Description:
RELATED INVENTION 
     The instant invention is a Continuation-In-Part of U.S. patent application Ser. No. 10/704,405, Filed Nov. 10, 2003, abandoned. 
    
    
     1. FIELD OF THE INVENTION 
     The present invention relates generally to building structures and more particularly to shaped and treated foam designs, attached to screened enclosures and a method for the beautification of screened enclosures by use of shaped and treated foam designs, such as polystyrene, attached by adhesive magnets, adhesives, and/or hardware to aluminum pool cages or lanais. 
     2. RELATED ART 
     All pool enclosures heretofore known are utilitarian structures lacking aesthetic appeal. The art has long provided pool enclosures where fastening screws, screen-retailing rubber splines, and the like are exposed to view. These structures are often attached to beautiful homes and serve to cheapen the home. Attractive or pleasing-to-the-eye pool enclosures having aesthetic means for covering utilitarian bolts and the like are not found in the prior art. 
     There are a number of prior art products that are related to the subject invention as exemplified by the following patents. 
     U.S. Pat. No. 5,193,322 discloses an elongated base molding, a trim recess, a trim molding fitted within the trim recess and retention inserts in the base molding for holding the trim molding in place. 
     U.S. Pat. No. 5,444,956 discloses trim molding in which a base molding member is provided with tracks for retaining movable inserts with a first insert and a second insert providing a background visible through the cut portions of the first insert, thereby enabling a plurality of different cut portions and background combinations to be obtained. 
     U.S. Pat. No. 6,138,417 discloses a roof structure covered by a plurality of easily removable panels of screen or translucent or tinted glass or plastic covering material for ease of installation and removal of panels in case of unusually high snow fall or high winds. 
     U.S. Pat. No. 6,192,643 discloses a pool enclosure system which includes a plurality of extension members for providing posts and beams the collectively form a pool enclosure when assembled; each of the extrusion members has at least a first wall with an attachment means formed thereon along a predetermined extent thereof. 
     U.S. Pat. No. 6,206,965 to Rao et al. discloses apparatus for coating a decorative workpiece. 
     U.S. Pat. No. 6,446,399 to Lecours discloses a pre-fabricated curved-profile architectural element and method for pre-fabricating the item. 
     U.S. Patent Application Publication No. 20040045239 to Milu discloses architectural building products and methods for their manufacture. 
     None of the above mentioned references disclose nor suggest the pool enclosure/tent having a plurality of tubing sections/tent poles making up the walls and roof section of the enclosure as disclosed and claimed by the instant invention 
     There is a clear need in the pool enclosure industry for a system that provides a pool enclosure having the appearance of a work of art rather than just a utilitarian structure. The needed pool enclosure additions would enhance the appearance of the finest homes and add significant value thereto, rather than detract therefrom as is the case with the system known prior to this disclosure. Furthermore, the strength of the attached foam provides additional support and rigidity to protect the pool cage from strong winds. 
     However, at the time the present invention was made, the need for aesthetics was not apparent to the pool enclosure industry nor was there anything in the art that would have suggested to workers of ordinary skill in the art how a beautiful pool enclosure could be built. 
     SUMMARY OF THE INVENTION 
     It is believed apparent from a consideration of these references that none of them, taken either singly or in combination, disclose or suggest the features of the present invention. 
     A primary feature of the present invention is the beautification of screened enclosures and tents by use of shaped and treated foam designs, attached to the enclosures and tents by adhesives and adhesive magnets and or hardware to aluminum cages or lanais. 
     A plurality of aesthetic foam columns and foam trim are placed over the framework of the pool cage on the inside and/or outside of the cage. The foam may have many architectural columns and the trim (contoured shapes) may be placed either around the column and the column is set inside the contoured trim or it is made solid and the column is placed on top of the contoured trim. In addition, the type of architectural columns may be used to beautify large tents of the type used at large gatherings or events. The decorative trim of the invention is preferably made from polystyrene, such as “Styrofoam™”, and is attached to the pool cage structure by either adhesives, magnets or VELCRO™ (hook and loop). Hardware may also be used. The easily removable foam trim of the invention is especially important when the cage screen must be replaced. 
     The instant invention is manufactured using a unique process and system for marketing, designing and a unique method for manufacturing the foam columns and foam trim. After measuring the screen enclosure or Lanai, the measurements are entered into a program called AUTO CAD LT. After the auto Cad design is complete, the auto Cad is entered into Adobe Photo Shop to be rendered for the client&#39;s approval. The Cad file is entered into a machine called a Computer Controlled Contour Cutter (CCCC). 
     In a preferred embodiment, a two pound foam is used to provide a superior product for the colonnades. Shapes to create the colonnade are cut by the contour cutter and then custom fit to the enclosure. Once the pieces are custom fit, they are returned to the manufacturer for coating. Colonnade pieces are then painted and then attached to the existing screen enclosure or lanai with a construction adhesive. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the drawings: 
         FIG. 1   a  (PRIOR ART), a perspective view of a prior art pool cage. 
         FIG. 1   b , is a perspective view of a pool cage showing the shaped and treated foam designs of the invention attached to a pool cage. 
         FIG. 2 , is a perspective view of a pool cage showing an alternative design of the invention attached to a pool cage. 
         FIG. 3 , is a sectional view showing the attachment of a shade fitted inside the foam cornice of the invention. 
         FIG. 4 , is a detailed sectional view of the mounting of a shade fitted inside the foam cornice of the invention. 
         FIG. 5  is a top, sectional view of the attachment of a foam column to a vertical member of a pool cage. 
         FIG. 6 , is a top, sectional view of the attachment of a foam column to two sides of a vertical column of a pool cage. 
         FIG. 7 , is a side view of a first design of a foam column. 
         FIG. 8  is a side view of a second design of a foam column. 
         FIG. 9 , is a perspective view of the foam column of the invention being attached to a tent pole. 
         FIG. 10 , is a top, sectional view of the foam column being strapped to a tent pole. 
         FIG. 11 , is a top, sectional view of the foam column being attached to a tent pole with opposing magnets. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1   a , the PRIOR ART drawing shows the basic structure of a typical pool enclosure  14  (pool cage) before the improvements of the invention are added. The frame of the pool cage  14  is composed of a plurality of vertical sections of rectangular aluminum tubing  15 , a plurality of sections of horizontal aluminum tubing  12  attached between and connecting the vertical tubing sections  15 , the base tubing  13 , the top cap tubing  10  and the roof tubing  11 . The exterior of the aluminum tubing used in the pool cage  14  contains screen engaging means (not shown) which are easily removable when the screening must be replaced. 
     In the first embodiment of the invention shown in  FIGS. 1   a - 8 , the foam cornices  17  are shown attached to the top cap tubing  10  ( FIGS. 3 and 4 ). The foam columns  16  and  24  are shown mounted over the vertical tubing  15  ( FIG. 5 ). Also attached to the foam cornices  17 , are short lengths of decorative trim  18  to further decorate the inside of the pool cage  14 . The decorative trim  18  may be made from STYROFOAM™ (polyethylene) and may be attached to cornice  17  by either magnet clips, adhesives, or hook and loop. In a preferred embodiment, the cornices  17  are attached to the top cap tubing  10  with adhesives. 
       FIGS. 3 and 4  are sectional views showing the attachment of a shade  19  fitted inside the foam cornice  21  and held in place with magnet clips or hook and loop  41 . A shade or curtain  19  is shown suspended from the cornice  17  by magnet clip or VELCRO™ (hook and loop). The shade  19  may be attached to the top cap tubing  10  without the cornice  17  if the user would prefer. In either case, the shade  19  will be attached by magnet clip or hook and loop  41 . 
     Foam trim  23 , known in the trade as “the cookie” is placed either around the column  16  and the column  16  is set inside the trim  23  or it is made solid and the column  16  is placed on top of the trim  23 . This allows for many different architectural designs. The trim  23  can be cut into any shape. The trim  23  is also cut so it can be placed over the aluminum frame  13 . The columns  16  and  24  are cut as at  22  to fit over the horizontal aluminum cage frame  12  and will be attached by either magnets, adhesives, clips or VELCRO™ for easy removal so screens can be maintained. Foam columns  16  and  24  may be made in any shape, design, size or architectural design. The back side of the foam columns  16  and  24  are cut so that the columns may be placed over and attached to the frame  12 . If it is desired to cover the outside of the cage  14 , the column  16  may be cut in half and the back side of the frame  15  will have the other half of the column  16  attached. The columns  16  may be any size depth trims that are desired. 
       FIG. 2  is a perspective view of an alternative design of the invention attached to a pool cage  14 . The magnets or clips, adhesives or VELCRO™ are placed in a depression,  21 ′( FIG. 4 ) at the top  21  of the foam cornice  40 . The cornice  40  is then fastened to the existing aluminum cage tubing  10 . The attachment of the foam cornice  40  along the entire length and width of the cage  14  provides decoration and additional strength to protect the cage  14  against high winds. 
     The foam cornice  40  may also be cut in the center from side to side to form a depression  41 , deep enough for placement of the shade or curtain  19  and an arch  34  is formed to further decorate the cornice  40 . 
       FIG. 5  is a top, sectional view of the attachment of a foam column  16  to a vertical member tubing  15  with a clip, magnet or VELCRO™  41 . The column  16  is attached to the inside of the pool cage  14  to hold the foam column to the cage  14  and be removable for cage  14  care, such as for example, to replace the screening or if hurricane winds are expected. 
       FIG. 6  is a top, sectional view of the attachment of a foam column  16  and column  16   a  to two sides of a vertical column  15  of a pool cage  14 . In this alternative embodiment, screws  27  are used to fasten the styrofoam columns  16  and  16   a  to the vertical column  15  of pool cage  14 . The screws  27  may be magnets to hold the two columns  16  and  16   a  together. 
       FIGS. 7 and 8  show two distinct styles of the foam column  16  and a second style of column  24 . Since the foam is molded, the styles available to a designer are infinite. 
       FIG. 9  is a perspective view of the foam column  38  being attached to a series of tent poles. The two halves of the column  38 , first half  28  and  29  are assembled on tent pole  32 . 
       FIG. 10  is a top, sectional view of the two halves  28  and  29  being strapped to a tent pole  32  with a strap  34 . The tent pole  32  fits into the void  33  formed in each of the halves  28  and  29 . 
       FIG. 11  is a top, sectional view of the two halves  30  and  31  being attached to each other with opposing magnets  35  and  36  attached at opposite ends of void  37  formed in halves  30  and  31 . 
     The finished assembly, unlike all prior art pool enclosures, has no visible fastening members. The enclosure has the smooth appearance of a molded product, complete with a draw shade to provide privacy. Assembly is easy, due to the snap fittings between the sundry parts. The nature of the structure and the ease of casting foam parts to length enables contractors to build the enclosure quickly and hence economically. 
     To start the process of the invention, the designer and client decide on a style, and the screen enclosure or lanai is measured. After measuring the screen enclosure, the measurements are entered into AUTO CAD LT. After the auto Cad design is complete, the auto Cad is entered into adobe Photo shop to be rendered for the client&#39;s approval. The cad file is then entered into a computer controlled contour cutter, such as for example, the Horizontal Fast Wire Computer-Controlled Contour Cutter manufactured by “Demand Foam Cutting Systems”, Alpharetta, Ga. 
     A preferred embodiment of the instant invention is made from a two pound foam for all of the materials to produce a superior quality product for the colonnades. A typical foam is produced by “Future Form”, Bradenton, Fla. and has typical physical properties such as thermal resistance, strength properties, and moisture resistance. 
     Shapes to create the colonnade are cut by the contour cutter and then taken to the site for a custom fit. Once the pieces for the colonnade are custom fit to the cage, they are returned to the shop for coating. The coating process is done with a “Poly-Spray™ Polyurea System”. The automatic gun is the newest, state-of-the-art dispensing gun. An eps/puf foam “hardcoat” is applied from the poly sprayer onto the two pound foam. This application assures protection to the foam and provides strength and durability. The process used includes: 
     Materials
         Step 1. EPS/PUF foam   Step 2. STYROTHANE™ Series (Hard Coat)   Step 3. OPTIONAL FINISHES
           A) Architectural Coating   B) Scenic Paint
 
The spray applied, instant cure STYROTHANE™ produces a hard, protective shell which seals the foam while preserving the slightest details and contours of the piece.
   
               

     After the primer is applied, a texture coat is then applied. A preferred coating is an “Aggregate Textured, 100% Acrylic-Based DPR “Dirt Pickup Resistant” Finish”. A source for the DPR is Dryvit Systems, Inc., West Warwick, R.I. 
     Colonnade pieces are then painted and sent to the client&#39;s pool cage or lanai for final installation. ACRI-SHIELD™ sold by Porter Paints, Louisville, Ky. The paint gives a mildew resistant coating and resists dirt pickup. 
     A construction adhesive is used to attach the colonnade to the existing screen enclosure or lanai. A preferred adhesive is HANDI-STICK™ Construction Adhesive manufactured by Fomo Products, Inc., Norton Ohio. The adhesive is a unique polyurethane based foam, which also is an effective hole filler and insulating sealant. 
     The finished assembly, unlike all prior art pool enclosures, has no visible fastening members. The enclosure has the smooth appearance of a molded product, complete with a draw down shade to provide privacy. Assembly is easy, due to the snap fittings or adhesive between the sundry parts. The modular nature of the structure and the ease of casting foam parts to length enables contractors to build the enclosure quickly and hence economically. 
     The striking beauty of the novel enclosure greatly enhances the value of the house to which it is connected. 
     It will be seen that the objects set forth above, and those made apparent from the foregoing description, are efficiently attained. Since certain changes may be made in the foregoing construction without departing from the scope of the invention, it is intended that all matters contained in the foregoing construction or shown in the accompanying drawings shall be interpretive as illustrative and not in a limiting sense. 
     It is also to be intended that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.