Patent Publication Number: US-6209586-B1

Title: Aggregate retaining device for drain covers

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to drain covers for swimming pools and spas, and more particularly to an apparatus for applying an exposed aggregate or plaster finish to the top surface of drain covers. 
     2. Description of the Related Art 
     Drain openings are typically formed on the bottom of most conventional swimming pools so that water can be removed from the pool and circulated through a filtration system. The openings generally extend through the floor of the pool and are connected to drain pipes that are configured to transport water from the pool to a filtering device. Furthermore, a recirculation pump is typically used to remove water from the pool through the drains, down the drain pipes, and into the filtration system wherein the water is filtered and cleaned before being transported back into the pool through the return lines. 
     Disadvantageously, however, the drain openings are generally unsightly and can pose as a safety hazard for swimmers. In particular, the suction created by the large volume of water passing through the drains is known to cause a whirlpool vortex wherein the force of the vortex can be strong enough to pull down and trap swimmers near the drains. Furthermore, it can be appreciated that a swimming pool tends to lose some of its aesthetic appeal when the floor of the pool is dotted with numerous drain openings. To address these problems, various anti-vortex drains and covers have been developed to reduce the suction around the drains while at the same time enhance the aesthetic appeal of the pool. 
     In particular, the standard drain cover currently used for most swimming pools is a circular anti-vortex drain cover. The cover is adapted to be positioned over a generally circular drain opening and comprises a top surface that is relatively flat and a plurality of side openings that serve as passage ways for water to flow from the pool into the drain opening. Furthermore, the cover is made from plastic material and is generally available only in a limited number of colors such as black, white, and shades of gray. 
     Consequently, the standard drain covers often do not match the surface finish of the swimming pool as the surface finish of the pools can be made from a wide variety of colors and textures. In particular, the standard drain covers will appear conspicuously out of place when set against the surface finish of swimming pools having a plaster or exposed aggregate finish wherein the color of the surface is custom blended to the taste of the pool owner. Likewise, the standard drain covers also appear undesirably conspicuous when they are positioned over drain openings formed on the bottom of spas that are decorated with a colored plaster or exposed aggregate finish. 
     To address this problem, drain cover assemblies have been created that are designed with the intent of making the cover less conspicuous and more uniform with the surface finish of the pool or spa. In particular, there are existing covers made from a clear plastic material wherein the transparency of the plastic is likely to make the cover less noticeable and allow the cover to blend in with the surface finish of the pool or spa. Disadvantageously, however, the transparent covers do not properly conceal the drain pipes underneath the covers and therefore leave the unsightly pipes exposed to plain view. It can be appreciated that visible drain pipes on the bottom of a swimming pool or spa are sometimes even more unappealing than drain covers that do not match the color and texture of the surface finish of the pool. 
     Hence, from the foregoing, it will be appreciated that there is a need for a drain cover for swimming pools or spas that is less conspicuous. To this end, there is a particular need for an apparatus or a method for matching a drain cover to the surrounding surface. 
     SUMMARY OF THE INVENTION 
     The aforementioned needs are satisfied by the apparatus for forming an exposed aggregate or plaster surface finish on drain covers of the present invention. In one aspect, the apparatus of the present invention comprises an aggregate retaining member wherein the retaining member is positioned adjacent an upper surface of a pool drain cover such that the retaining member retains aggregate material on the upper surface of the pool drain cover. Preferably, the retaining member is attached to the drain cover through the use of fasteners or screws. Preferably, the retaining member extends about an outer perimeter of the upper surface of the drain cover so as to define a cavity in which the aggregate material can be positioned and wherein the retaining member exerts a force against the aggregate material to retain the aggregate material in the cavity adjacent the upper surface. 
     In another embodiment, the retaining member extends outward from the plane of the upper surface while simultaneously extending inward towards the center of the upper surface of the drain cover such that an outer edge of the retaining member is positioned over the plane of the upper surface. Preferably, the retaining member is formed of a clear material so that the aggregate material is visible through the retaining member to thereby camouflage the retaining member. 
     Furthermore, the retaining member comprises at least one reinforcing member that extends across the cavity defined by the retaining member wherein the at least one reinforcing member is coupled to the inner walls of the retaining member so as to increase the structural rigidity of the retaining member. Preferably, the at least one reinforcing member is recessed in the cavity so as to be located a distance less than the first distance from the upper surface so that when the aggregate material is positioned within the cavity, the aggregate material covers the at least one reinforcing member. 
     In another embodiment, the present invention comprises a pool drain cover assembly wherein the assembly comprises a base member, a cap member, and an retainer positioned adjacent an upper surface of the cap member so as to form a cavity on the upper surface wherein aggregate material is retained in the cavity on the upper surface of the cap member. Preferably the aggregate material is positioned within the cavity so as to be in contact with the upper surface of the cap member and the inner surfaces of the retainer. 
     In one embodiment, the pool drain cover assembly can be formed by attaching the base member, cap member, and retainer together through the use of fasteners. In another embodiment, the retainer can be molded as an integral part of the cap member. Preferably, the upper surface of the drain cover is coated with an exposed aggregate material that is substantially identical to the surface finish of the swimming pool. In particular, the retaining member retains the aggregate on the upper surface of the cap member so as to make the aggregate appear as the color and texture of the cover assembly. In contrast to the conventional drain covers that are available in only a selected number of colors, the pool drain cover assembly of the present invention can be easily made into a wide variety of colors and textures to match the surface finish of the swimming pool. Advantageously, the drain cover assembly is camouflaged in the same color and texture as the swimming pool so as to not detract from the aesthetic appeal of the pool. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a general perspective view of one embodiment of a conventional drain cover assembly for swimming pools and spas; 
     FIG. 2 is a general perspective view of one embodiment of an aggregate retaining device of the present invention; 
     FIG. 3 is a top down view of the aggregate retaining device of FIG. 2; 
     FIG. 4 is a general perspective view of the aggregate retaining device of FIG. 2 mounted on the drain cover assembly of FIG. 1; 
     FIG. 5 is the drain cover assembly of FIG. 4 wherein an exposed aggregate surface is formed on a top surface of the drain cover. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Reference will now be made to the drawings wherein like numerals refer to like parts throughout. As will be described hereinbelow, the apparatus of the preferred embodiment provides a means of applying a plaster or exposed aggregate surface finish onto a top surface of a drain cover for swimming pools or spas. 
     FIG. 1 shows an embodiment of a conventional anti-vortex drain cover assembly  100  that is commonly used to cover drain openings of swimming pools and spas. As FIG. 1 illustrates, the drain cover assembly  100  is generally circular in shape and comprises a base  102  and a cap  104  wherein the cap  104  is mounted onto the base  102  in a well known manner. Furthermore, the base  102  is generally ring-shaped and comprises a side wall  106  defining an outer perimeter of the base  102 . The base member  102  also defines a central opening  105 . The side walls  106  of the base member  102  are typically positioned within a drain opening in the pool or spa such that water can flow through the central opening  105  into the drain. 
     Preferably, a lip  110  extends perpendicularly outward from an upper edge of the side wall  106  so as to create a mounting surface  112  for the cap  104 . Furthermore, a plurality of first openings  114   a ,  114   b  are formed on the mounting surface  112  wherein the openings  114   a ,  114   b  are configured to receive a plurality of mounting screws that are typically used to affix the cap  104  to the base  102 . 
     As FIG. 1 further illustrates, the cap  104  of the cover assembly  100  is also generally circular in shape and comprises an upper surface  116 , a bottom rim  120 , and a plurality of side openings  118  designed for water to pass through. In particular, the bottom rim  120  of the cap  104  is adapted to rest on the mounting surface  112  of the base  102  when the cap  104  is mounted to the base  102 . Furthermore, the bottom rim  120  comprises a plurality of second openings  122   a ,  122   b  that are configured to align with the corresponding first openings  114   a ,  114   b  on the mounting surface  112  so that a mounting screw or other fastener can be inserted into each pair of aligned openings so as to secure the top cover  104  onto the base  102 . 
     In one embodiment, the cover assembly  100  can be installed over a drain opening by positioning the ring-like base  102  around the drain in a manner such that the side wall  106  of the base  102  is completely imbedded in the surrounding concrete while the lip  110  of the base  102  remains above ground and encircles the drain opening. Preferably, the cap  104  is then mounted onto the base  102  via screws or other types of fasteners so that the drain opening is effectively concealed by the cap  104  while water from the pool is directed to flow through the side openings  118  of the cap  104  and down the drain. 
     Typically, the upper surface  116  of the cover is open to plain view when the cover assembly  100  is installed in a pool. It is therefore desirable to select drain covers with colors that substantially match the surface finish of the pool in order to preserve the overall aesthetic appeal of the pool. However, drain cover assemblies known in the art are typically available in only a limited number of colors such as black, white, or gray. Consequently, drain covers installed in most swimming pools do not match the surface finish of the pool as it is economically impractical to paint each drain cover in a color that matches the surface finish of a particular pool. Moreover, the standard drain covers are known to appear especially out of place when installed in swimming pools having an exposed aggregate finish wherein the color of the aggregate is custom blended. 
     As will be described in greater detail below, the drain cover of the illustrated embodiment provides a novel apparatus for and method of eliminating the color mismatch between the drain covers and the surface finish of swimming pools. In particular, the preferred embodiment provides an aggregate retaining device wherein the device is mounted on the drain cover and enables the top surface of the drain cover to be coated with a plaster or an exposed aggregate finish wherein the color and texture of the finish is substantially identical to the particular surface finish of the pool. In contrast to the conventional drain covers known in the art, the present invention provides a drain cover that is camouflaged in substantially the same color and texture as the surface finish of the swimming pool or spa so as to enhance the aesthetic appeal of the pool or spa. 
     With reference to FIG. 2, a perspective view of an aggregate retaining device  124  of the preferred embodiment is shown. As is illustrated in FIG. 2, the aggregate retaining device  124  is a generally ring shaped structure that is mounted adjacent the upper surface  116  of the drain cover  100  in a manner to be described in greater detail below. Preferably, the device  124  comprises a sidewall  126  wherein the sidewall  126  defines a generally circular opening  125 . Furthermore, the device  124  is dimensioned so that its sidewall  126  is mounted adjacent the outer perimeter of the upper surface  116  of the drain cover  100  and extend upward from the plane of the upper surface  116  so as to form a cavity adjacent the upper surface  116 . As will be described in greater detail below, the cavity is subsequently filled with an aggregate material wherein the aggregate material is retained within the cavity by the side wall  126 . 
     As FIG. 2 further illustrates, the side wall  126  of the retaining device  124  is also configured to slope inwardly toward the center of the opening  125  as it extends outward from the plane of the upper surface  116 . The inwardly sloped side wall  126  is more effective in mechanically retaining the aggregate and preventing the aggregate from being displaced. While the preferred embodiment describes a generally circular aggregate retaining device, the device can assume a variety of other shapes without departing from the scope of the invention. 
     As is also shown in FIG. 2, the retaining device  124  further comprises a plurality of mounting brackets  134   a ,  134   b  wherein each bracket is a generally Z-shaped structure that is dimensioned to affix the retaining device  124  to the cover assembly  100 . In particular, a first end  136   a ,  136   b  of the bracket  134   a ,  134   b  is attached to the side wall  126  while a second end  140   a ,  140   b  of the device  124  is configured to rest on the rim  120  of the cover assembly  100 . Preferably, the second end  140   a ,  140   b  is a positioned horizontally over the second opening  122   a ,  122   b  on the rim  120  of the cap  104  so that a third opening  142   a ,  142   b  formed on the second end  140   a ,  140   b  of the bracket  134   a ,  134   b  aligns with the second opening  122   a ,  122   b  on the rim  120  of the cover assembly  100 . Preferably, a mounting screw or fastener is inserted into the aligned openings so as to secure the retaining device  124  onto the cover assembly  100 . Advantageously, the aggregate retaining device  124  can be easily mounted onto a conventional standard drain cover by utilizing existing mounting holes on the cover. However, it can be appreciated that different types of fastening devices can be used to mount the aggregate retaining device  124  onto the cover assembly  100  in other embodiments of the present invention. 
     As FIG. 2 further shows, a plurality of reinforcing members  144   a ,  144   b  is positioned across the opening  125  of the aggregate retaining device  124  so as to provide structural support in a manner to be described in greater detail below. FIG. 2 shows each reinforcing member  144   a ,  144   b  extending across a diameter of the opening  125  in a manner so as to form a generally cross-shaped configuration. Furthermore, the plane defined by the reinforcing members  144   a ,  144   b  is slightly recessed from the plane defined by the top edge of the aggregate retaining device  124 . Preferably, the reinforcing members  144   a ,  144   b  are designed to rest in the aggregate material inside the cavity defined by the opening  125  so as to mechanically reinforce the aggregate material such that people standing on the drain in the pool are less likely to damage or crack the aggregate material. 
     Furthermore, a plurality of clips  146   a ,  146   b  are formed in a well known manner on the bottom surface  130  of the retaining device  124  wherein the clips  146   a ,  146   b  are designed to engage an outer edge  138  of the top surface of the cover assembly  100  so as to further secure the retaining device  124  onto the cover assembly  100 . While the aggregate retaining device  124  of the preferred embodiment is adapted for an anti-vortex drain cover, it can be appreciated that the retaining device  124  can be configured for a wide variety of other types of drain covers without departing from the scope of the invention. 
     FIG. 3 illustrates a top down view of the above described aggregate retaining device  124 . As FIG. 3 illustrates, the aggregate retaining device  124  of the illustrated embodiment is generally circular in shape and comprises two mounting brackets  134   a ,  134   b  that are attached to the outer surface of the retaining device  124  and positioned diametrically across from each other. Furthermore, FIG. 3 shows the second end  140   a ,  140   b  of the device having the openings  142   a ,  142   b  configured for mounting screws. 
     FIG. 4 illustrates a general perspective view of the above described aggregate retaining device  124  mounted on the drain cover assembly  100  of the preferred embodiment. As is shown in FIG. 4, the bottom surface  130  of the retaining device  124  rests adjacent the outer perimeter of the upper surface  116  of the cover assembly  100  so as to define a cavity  150  that will be filled with aggregate material. Preferably, the device  124  is fixedly attached to the cover assembly  100  via mounting screws or fasteners as described in detail above. As it is shown above, the aggregate retaining device  124  is simple to implement as it is designed to utilize existing parts on a standard drain cover and does not require additional tools or processing. While the device of the present invention is adaptable to any drain cover having a general top surface, the device can also be made as an integral part of a drain cover assembly in other embodiments of the invention. 
     FIG. 5 shows the drain cover assembly  100  of the present invention wherein its top surface is coated with a plaster or aggregate finish. As is shown in FIG. 5, an aggregate material is filled into the cavity  150  created by the retaining device  124 , using tools and techniques that are well known in the art. In particular, the aggregate material used is substantially identical to the surface finish  152  of the pool. As is shown in FIG. 5, the top surface of the cover assembly is thus made to resemble the pool surface in color and texture. 
     The aggregate retaining device  124  retains the aggregate material as a result of the aggregate material being positioned adjacent the upper surface  116  of the cover  104  and the outer perimeter of the aggregate material being positioned underneath the inner surfaces  131  of the ring  124 . As discussed above, the inner surfaces  131  of the ring  124  are preferably angled inward towards the center of the opening  125 . Hence the inner surfaces  131  exert a downward force against the outer perimeter of the aggregate material  152 . When the aggregate material  152  dries in the cavity  150 , the bonding between the aggregate material results in the aggregate material being essentially a solid mass. Since the outer perimeter of the aggregate material  152  is captured by the inner surfaces  131  of the ring  124  against the upper surface  116  of the cover  104 , the aggregate material  152  is retained adjacent the upper surface  116  of the cover  104 . 
     In one embodiment, the cover assembly  100  and the aggregate retaining device are made from a clear plastic material such as polycarbonate. The clear material camouflages the aggregate retaining device  124  so that only the aggregate surface of the cover is visible. As FIG. 5 illustrates, the drain cover  100  with an aggregate finish on the top is not conspicuous and conform with the surface finish of the pool. Furthermore, the device provides a convenient way for the user to apply the aggregate surface so that the drain covers can be made to any type of plaster or exposed aggregate finish. 
     Although the foregoing description of the preferred embodiment of the present invention has shown, described and pointed out the fundamental novel features of the invention, it will be understood that various omissions, substitutions, and changes in the form of the detail of the apparatus as illustrated as well as the uses thereof, may be made by those skilled in the art, without departing from the spirit of the invention. Consequently, the scope of the invention should not be limited to the foregoing discussions, but should be defined by the appended claims.