Patent Publication Number: US-8112951-B2

Title: Permanent form assembly and method for swimming pool user support structures

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to swimming pools. Particularly, the present invention relates to user support structures within swimming pools. 
     2. Description of the Prior Art 
     In-ground swimming pools naturally have sides or sidewalls that are substantially vertical. The average swimming pool has vertical sidewalls that extend downwardly several feet from an upper surface of the pool deck. To facilitate entering and exiting a swimming pool, a swimming pool has some sort of ladder, steps, or the like to assist one in getting into and out of the pool. Generally, permanent steps are provided at a shallow end of in-ground swimming pools. In some pools, a swimmer&#39;s bench may also be included along a portion of a vertical sidewall typically in the shallow end. The bench provides a structure in the swimming pool where a swimmer may sit and relax while remaining in the water without having to tread water or to stand whereby the swimmer&#39;s upper torso is completely out of the water. 
     Presently, it is relatively common to use various types of interior steps or stairs in a swimming pool for swimmers to gain access to and exit the swimming pool. A well recognized style of interior steps is known as a “wedding cake” step form. In certain types of swimming pools such as ones constructed of concrete or gunite, permanent interior steps and or benches are often built on site by constructing a step or bench form. The step or bench form is filled with concrete and, when the concrete has set and dried, the step or bench form is removed. The cost of manufacturing concrete steps is expensive and labor intensive, requiring highly skilled workers for construction. A concrete step, however, is advantageous for concrete or gunite type pools and when there is a need for variations in the step shape or size. 
     A problem is presented when concrete steps are used for vinyl liner type swimming pools. With these type of pools, it is difficult to accurately measure and build a conforming liner to cover the concrete steps due to the variability and the unique shapes and sizes of poured concrete steps. 
     As an alternative to poured concrete steps, on-piece molded plastic steps have been designed and used. These prefabricated step modules are carried to the site and readily installed. One type of step module is formed of acrylic and/or fiberglass laminates or vinyl covered metal. These types of step modules are relatively strong and will generally adequately support the weight of an adult. The drawback to such step modules is their tendency to delaminate, splinter, corrode, or puncture. 
     Because of these problems and other considerations, stair modules are now predominantly prefabricated, unitary structures formed from some type of suitable plastic composite or the like that can withstand temperature related expansion and contraction. Such materials, however, are generally relatively flexible so that the steps may yield under a person&#39;s weight, thereby giving the person an insecure feeling. Additionally, the structural integrity of such stair modules may be compromised. 
     There have been devised various support structures to reinforce the steps of such prefabricated plastic stair modules. Stacked blocks or bricks have been used for support, but this requires footers and building the support from the ground up requiring shims for leveling. Other examples of such support structures may include support posts having bearing plates or pads connected to their upper ends which are placed under the stair tread, or a longitudinal stiffening member which is bonded to the pieces at a serrated surface on the underside of the stair tread. Another type of known support structure includes unitary support braces formed of a suitable plastic material which are strategically situated under the stair module treads. Each support brace has a plurality of horizontal step supports corresponding in number to the stair treads. Extending vertically from the horizontal step supports are integral tabs that are positioned to register unto slots formed within transverse stiffening ribs on the underside of the stair treads. 
     Therefore, what is needed is permanent form system that can accommodate many sizes and styles of swimming pool stairs and benches. 
     SUMMARY OF THE INVENTION 
     It is an object of the present invention to provide permanent form system that can accommodate many sizes and styles of swimming pool user support structures including, but not limited to, stairs, benches and combinations thereof. It is another object of the present invention to provide a permanent form system that does not require highly skilled workers of construction. It is a further object of the present invention to provide a permanent swimming pool user support structures that are relatively inexpensive and easy to install. 
     The present invention achieves these and other objectives by providing a permanent form system and method for creating and forming swimming pool user support structures within an in-ground swimming pool that uses vinyl liners. 
     The permanent form system of the present invention may be an assembly or a kit. The difference is that the assembly is already assembled while the kit requires assembly. 
     In one embodiment of the present invention, the permanent form assembly is a permanent form kit. The kit includes one or more of a vertical elongated support, one or more of a lateral brace, a plurality of support structure risers, and a plurality of fasteners. The one or more of a vertical elongated support has a pool wall flange extending laterally from the vertical support that is adapted for fixedly securing the pool wall flange to one of a pool wall or a vertical support brace. The one or more of a lateral brace has a longitudinal brace body, a vertical support end connected to the vertical elongated support and a riser support end where the lateral brace is adapted to extend laterally from the pool wall. Each of the risers has a riser inside surface, a smooth riser outside surface, a first riser end, and a second riser end. The first riser end is adapted for fixedly securing to the riser support end of the lateral brace and the second riser end is adapted for fixedly securing to one of a first riser end of another support structure riser, the pool wall or the riser outside surface of another support structure riser. 
     In another embodiment of the present invention, there is included a support brace having first and second support brace ends adapted to directly attach one of the first and second support brace ends to one of a pair of intersecting pool walls. The support brace also includes a central support brace portion adapted for fixedly attaching to the vertical elongated support. 
     In still another embodiment of the present invention, the lateral brace is integrally-formed with the vertical elongated support from a single piece of material. 
     In a further embodiment of the present invention, each of the plurality of support structure risers has either a hem or a bracing flange formed along a longitudinal edge. 
     In yet another embodiment of the present invention, each of the plurality of risers has a first riser end flange that extends laterally from the riser inside surface at first and second riser ends. 
     In another embodiment of the present invention, the lateral brace includes a riser spacing slot that is adapted for receiving a longitudinal side of one of the plurality of support risers. 
     In another embodiment of the present invention, the permanent form assembly includes a vertical brace support that is adapted to attach and support one or more of the lateral braces along the longitudinal brace body of the lateral brace. 
     The structure of the permanent form assembly is such that, when a filler is disposed within the space created by the permanent form assembly, the only visible component is the outside surface of the risers. The filler forms a platform that functions as the stair tread in a stair-style assembly and as a seat surface in a bench-style assembly. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front perspective view of one embodiment of the present invention showing a permanent form for pool stairs along a side of a pool. 
         FIG. 2  is a front perspective view of another embodiment of the present invention showing a permanent form for pool stairs in a corner of a pool. 
         FIG. 3  is a perspective view of one embodiment of a lateral brace or a vertical support of the present invention. 
         FIG. 4  is a side plan view of one embodiment of a riser of the present invention showing a laterally extending flange. 
         FIG. 5  is an enlarged partial view of the embodiment of the riser illustrated in  FIG. 4  of the present invention showing a hemmed edge. 
         FIG. 6  is an enlarged top view of one embodiment of two adjacent risers showing the assembly of the risers to a lateral brace. 
         FIG. 7  is a front perspective view of another embodiment of the present invention showing an assembled permanent form for a bench in a swimming pool. 
         FIG. 8  is a front view of another embodiment of a brace of the present invention. 
         FIG. 9  is a top view of the brace shown in  FIG. 8 . 
         FIG. 10  is a side view of another embodiment of a riser of the present invention showing a lateral flange and a top edge flange. 
         FIG. 11  is an enlarged partial view of the embodiment of the riser illustrated in  FIG. 10  and showing the top, inwardly directed flange. 
         FIG. 12  is a front perspective view of the present invention illustrated in  FIG. 7  showing a support filler installed in the volume space between the risers and the pool wall. 
         FIG. 13  is a front perspective view of the present invention showing a combination pool stairs and bench permanent forms. 
         FIG. 14  is a perspective view of another embodiment of the present invention showing a pool stair permanent form with straight risers in a curved pool wall location. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The preferred embodiment(s) of the present invention is illustrated in  FIGS. 1-14 .  FIG. 1  shows one embodiment of a permanent form  10  for creating a swimming pool user support structure. Permanent form assembly  10  includes one or more of a vertical, elongated support  30 , one or more of a lateral brace  50  and a plurality of support structure risers  70 . Permanent form assembly  10  is shown fixedly attached to a flat wall  2  of a swimming pool  5  that is used to create interior steps known as “wedding cake” steps. Vertical elongated support  30  and lateral brace  50  are generally made of a rigid material while the plurality of support structure risers  70  may be made of either rigid or bendable material, preferably bendable material. 
     Vertical elongated support  30  is fixedly attached to wall  2  of swimming pool  5  along its longitudinal length with one end (not shown) of vertical elongated support  30  resting on a bottom  3  of swimming pool  5 . Vertical elongated support  30  has a wall attaching surface  31  and a lateral brace connecting surface  32 . Vertical elongated support  30  may be solid, tubular or angular. Preferably, vertical elongated support  30  is an angular bracket, more preferably an L-shaped bracket, such as a piece of angle iron having one flange of the L-shaped member connected to wall  2  and a second flange of the L-shaped member that is lateral to the first flange providing a connecting surface for lateral brace  50 . 
     Lateral brace  50  has a longitudinal brace body  51 , a vertical support end  52  and a riser support end  53 . Lateral brace  50  is provided in various lengths based on the number of stairs to be installed. The first or lowest step has the longest lateral brace  50  in permanent form assembly  10  while the topmost step has the shortest lateral brace  50 . Optionally, lateral brace  50  may include one or more riser spacing slots  55  in the longitudinal brace body  51 . Riser spacing slot  55  is configured to receive a portion of a bottom longitudinal edge  84  of support structure riser  70 . It is also contemplated that an optional lateral end brace  56  may be used if pre-assembly of the permanent form  10  is preferred. Optional lateral end brace  56 , when used, would preferably be attached between the plurality of risers at the riser ends that attach to the pool wall. The use of optional lateral end braces  56  allows pre-assembly of the permanent mold assembly, which can then be easily placed into position before coupling to the pool wall and may facilitate the step-forming process. 
     Support structure riser  70  has a riser body  72  with a first riser end  73 , a second riser end  74 , an outside surface  75 , and an inside surface  76 . As can be seen from  FIG. 1 , support structure riser  70  has first riser end  73  connected to wall  2  or to a second riser end  74  of an abutting riser  70 . Where two or more steps are formed, riser  70  of each additional step is supported along a bottom riser edge  84  by lateral brace  50  of riser  70  of the immediately lower step. 
     Permanent form assembly  10  creates a volume space  100  between wall  2  and inside surface  76  of the plurality of risers  70 . A filler (not shown) is filled within space  100  to provide step platforms that function as stair risers and a strong form over which a pool liner (not shown) is installed. The filler may be poured concrete or a porous, loose-packed material with a poured concrete cap or platform over the porous, loose-packed material. Examples of porous, loose-packed material include stones, sand and the like. 
     Turning now to  FIG. 2 , there is illustrated the embodiment shown in  FIG. 1  adapted for use in a pool corner. Permanent form assembly  10  includes all of the same components as previously discussed, which are the vertical elongated support  30 , the lateral brace  50  and a plurality of support structure risers  70 . A cross support  40  is securely attached laterally to vertical elongated support  30 . Cross support  40  has a cross support central portion  41 , a first cross support end  42  and a second cross support end  43 . Cross support central portion  41  is securely attached to wall attaching surface  31  of vertical elongated support  30  while first cross support end  42  is securely attached to wall  2  and second cross support end  43  is securely attached to wall  2 ′. One or more of cross support  40  may be used to stabilize vertical elongated support  30  before the filler is placed within space  100 . Like  FIG. 1 , optional lateral end braces  56  are shown and may be used particularly when pre-assembly of the permanent form assembly is desired. 
       FIG. 3  shows one embodiment of vertical elongated support  30 . In this embodiment, vertical elongated support  30  is an angularly-shaped member having wall support flange  33  with wall support surface  31  and a brace support flange  34  with a brace support surface  32  that extends laterally from wall support flange  33 . A plurality of openings  35  may optionally be included in wall support flange  33  and brace support flange  34  to facilitate the assembly of permanent form assembly  10 . It should be understood that vertical elongated support  30  may have other shapes such as U-shaped, V-shaped, tubular-shaped or any configuration that presents at least one wall support surface  31  and one or more brace support surfaces  32  capable of securely attaching the vertical support  30  to a swimming pool wall  2  or a cross support  40  and one or more lateral braces  50  to the vertical support  30 . 
       FIG. 4  shows a side view of one embodiment of riser  70 . Riser  70  includes a riser outside surface  75  that is smooth and a riser lateral flange  77  that extends from second riser end  74 . Riser lateral flange  77  is shorter than the height of riser  70  so that all of riser lateral flange  77  is contained with the space  100  when assembled in permanent form assembly  10 . Riser lateral flange  77  may optionally include a plurality of riser flange openings  88  for receiving fasteners (not shown). On the opposite end (first riser end  73 ), there is also a riser lateral flange  78  that is similar to riser lateral flange  77 . In one embodiment of riser  70 , an optional top longitudinal edge  79  is formed by a hem  80 . 
       FIG. 5  shows an enlarged view of hem  80 . Hem  80  is formed by bending the longitudinal side towards riser inside surface  76  onto itself to present a rounded top longitudinal edge  79 . The purpose of hem  80  is to present a smooth riser edge transition from the smooth outside surface  75  so that no sharp edges are exposed to the pool liner (not shown) that will cover permanent form assembly  10 . Alternately, the top edge  79  may be rounded by grinding, polishing, etc. 
       FIG. 6  shows an enlarged view of the connection point between a pair of adjacent risers  70  and a lateral brace  50 . A fastener  90  fixedly secures riser lateral flange  78  of first riser end  73  of riser  70 ′, riser lateral flange  77  of second riser end  73  of riser  70 ″ and riser brace end  53  to each other. It should be understood that the position of lateral brace  50  and riser lateral flanges  77 ,  78  shown in  FIG. 6  may be changed so that lateral brace  50  may be on either said of lateral flanges  77 ,  78  and, in the case where lateral brace  50  is not tubular but an angularly-shaped bracket with a brace flange  54 , brace flange  54  may also be positioned between riser lateral flanges  77 ,  78 . Any fastener known in the art may be used to secure the lateral brace ends  52 ,  53  to vertical support  30  and risers  70 , respectively. 
       FIG. 7  illustrates another embodiment of the permanent form assembly of the present invention. In this embodiment, permanent form assembly  10 ′ creates a bench within a swimming pool upon which a swimmer may sit and still remain in the water. Permanent form assembly  10 ′ includes one or more of a vertical, elongated support  30 , one or more of a lateral brace  50  and a plurality of support risers  70 ′. Although  FIG. 7  shows a bench-style permanent form assembly  10 ′ configured into a corner of a swimming pool, it should be appreciated that the bench-style permanent form assembly  10 ′ may be along a middle portion of a straight wall  2 , along two lateral walls  2 , along a curved wall, or any combination since the preferred risers  70 ′ can be easily bent to shape. Another embodiment of the vertical elongated support  30  and lateral brace  50 , which is better shown in  FIGS. 8 and 9 , may be optionally used with the bench-style embodiment of  FIG. 7 . 
     Turning now to  FIG. 8 , there is shown a front view of this alternate embodiment. Vertical elongated support  30  and lateral brace  50  are integrally formed and, preferably, are a unitary brace and support structure  130 . Unitary brace and support structure  130  is typically formed from one material that has a planar body  132  and a lateral flange  135  along one of two opposing edges  133 ,  134 . Planar body  132  performs the function of the lateral brace  50  while lateral flange  135  on edge  133  performs the function of the vertical elongated support  30  and opposing edge  134  performs the function of brace riser end  53 . This is better shown in  FIG. 9 , which is a top view of unitary brace and support structure  130 . 
     Turning now to  FIG. 10 , there is illustrated a side view of an alternative riser  170  that is usable for straight step assemblies or straight risers for the bench-style permanent form assembly  10 ′. Riser  170  includes a riser outside surface  75  that is smooth and a riser lateral flange  77  that extends from second riser end  74 . Riser lateral flange  77  is shorter than the height of riser  170  so that all of riser lateral flange  77  is contained within the space  100  when assembled in permanent form assembly  10 ′. Riser lateral flange  77  may optionally include a plurality of riser flange openings  88  for receiving fasteners (not shown). On the opposite end (first riser end  73 ), there is also a riser lateral flange  78  that is similar to riser lateral flange  77 . In this embodiment of riser  170 , a top longitudinal edge  79  is optionally formed by an inwardly angled riser edge flange  82 . It is noted, however, that the inwardly angled riser edge flange  82  may be a separate component that is coupled to an inside surface  76  of riser  170 . To provide further structural support, riser  170  may optionally include a base flange  72  that laterally extends from the bottom of riser  170  inwardly from riser inside surface  76 . Base flange  72  may be a separate flange that is connectable to riser  170  or may be formed by bending the bottom, longitudinal edge. 
       FIG. 11  shows an enlarged view of riser edge flange  82 . Riser edge flange  82  is formed by bending the longitudinal side towards riser inside surface  76  forming an acute angle between riser edge flange  82  and riser inside surface  76  to present a rounded top longitudinal edge  79 . As with hem  80 , the purpose of riser edge flange  82  is to present a smooth riser edge transition from the smooth outside surface  75  so that no sharp edges are exposed to the pool liner (not shown) that will cover permanent form assembly  10 ′.  FIG. 12  shows a bench-style permanent form assembly  10 ′ with a filler  200  within space  100  and forming a bench platform  202 . The bench-style form assembly shown in  FIG. 12  would be ready for installation of a pool liner. 
       FIG. 13  illustrates a combination stair-style and bench-style permanent form assembly  300 . In this illustration, a corner stair permanent form assembly  10  is shown but it should be understood that the combination may also be assembled along a straight pool wall as well. Permanent form assembly  300  includes a stair-style form assembly  10  and a bench-style form assembly  10 ′. Stair-style form assembly  10  includes vertical elongated support  30  with support cross brace  40 , a plurality of lateral braces  50  and a plurality of risers  70 . Bench-style form assembly  10 ′ includes a plurality of unitary brace and support structures  130  and a plurality of risers  70 ′. In this combination form assembly  300 , a riser  70   a  of the plurality of risers  70 ′ that connects to stair-style form assembly  10  has a lower portion removed to accommodate placement of a lower portion  70   b  of riser  70   a  against a step riser  70  of a lower stair and an upper portion  70   c  extending to and against a step riser  70  of a second stair. Each of the lower portion  70   b  and the upper portion  70   c  has a lateral flange for securing each portion  70   b ,  70   c  to risers  70  of the lower stair and the second stair, respectively. 
       FIG. 14  illustrates another embodiment of the present invention.  FIG. 14  shows a permanent form assembly  400  that is a stair-style form incorporating straight stairs in a curved portion of swimming pool wall  2 . This permanent form assembly  400  includes a plurality of vertical elongated supports  30 , a plurality of lateral braces  50  and a plurality of risers  70 . Optionally, a vertical brace support  37  may be connected between the lateral brace  50  of one step to the lateral brace  50  of a lower or upper step. As with all previous embodiments, permanent form assembly  400  creates a volume space  100  between wall  2  and inside surface  76  of the plurality of risers  70 , which receives a filler (not shown) to complete the assembly prior to installing a pool liner. Additionally, the plurality of risers  70  may include top longitudinal edge  79  with an optional inwardly angled riser edge flange  82 . To provide further structural support, riser  70  may further optionally include a base flange  72  that laterally extends from the bottom of riser  70  inwardly from a riser inside surface  76 . Base flange  72  may be a separate flange that is connectable to riser  170  or may be formed by bending the bottom, longitudinal edge. The inclusion of optional flanges  82  and  72  on risers  70  that are used for straight-faced stairs provides additional structural support to the assembly. It should be further noted that straight stairs may also be used along straight pool walls and may further include rounded riser corners. 
     The preferred materials used to make or form the various components of the permanent form assembly of the present invention include stainless steel or structural composites. The only requirement is that the material used has sufficient structural strength to hold and retain the filler. 
     The present invention has many advantages over prior art concrete and molded swimming pool stairs and benches. The permanent form assembly  10 ,  10 ′ and  400  can be packaged into a compact kit form with fasteners and instructions for easy assembly when installing an in-ground swimming pool. No special skills are required to assemble the permanent form assembly. Unlike concrete forms that must be made, set up, concrete poured into the form and allowed to set, and then the concrete forms removed, the present invention is left in place and the pool liner is disposed over the form. Unlike pre-formed, molded steps, no additional structural support is required after the filler is placed into the form assembly of the present invention. 
     A further advantage of one embodiment of the present invention is the use of bendable risers so that any shape (i.e. straight, arcuate, S-shaped, etc.) can be formed. The step risers  70  can be manufactured as one size where a stair-style assembly would simply include a plurality of risers needed for making a user-selected stair configuration, while the bench risers  70 ′ can also be manufactured as one size. Because all of the risers  70  are flat and the curved risers are formed on site during assembly, the risers  70  are stackable along with the lateral braces  50  and the vertical elongated support  30 . 
     Another advantage is that with a limited number of different components (i.e. 2 different risers, 3 different lateral braces for 3 stair steps, and 1 type vertical support if desired), the permanent form system or assembly of the present invention allows a large number of stair and bench styles to be assembled. Because the components are standardized, no special skills are required to manufacture a structural form. A user need only follow the assembly instructions that accompany a permanent form kit. This reduces labor costs both in respect of skill level and time required, thus, making the addition of steps/stairs and/or a bench within a swimming pool less expensive than prior art methods. 
     Although the preferred embodiments of the present invention have been described herein, the above description is merely illustrative. Further modification of the invention herein disclosed will occur to those skilled in the respective arts and all such modifications are deemed to be within the scope of the invention as defined by the appended claims.