Patent Abstract:
A below-deck solar blanket roller assembly is installed below the deck of a pool. The roller assembly includes a rotatable roller shaft for rolling and unrolling a solar blanket and a non-rotatable protective casing which surrounds the roller shaft. The roller assembly is intended to be installed below the deck of a pool. This invention at least partially overcomes some of the disadvantages of typical solar blanket rollers that are installed on the surface of the pool deck, such as inconvenience in moving the entire above-deck assembly away from and back to the pool area. The below-deck solar blanket roller assembly provides an aesthetically pleasing and safe alternative to solar blanket roller assemblies installed above the pool deck.

Full Description:
FIELD OF THE INVENTION  
         [0001]    This invention relates to a solar blanket roller assembly and, in particular, a solar blanket roller assembly which is intended to be installed below the deck of a pool.  
         BACKGROUND OF THE INVENTION  
         [0002]    In the past, solar blankets have been used to cover swimming pools in order to reduce the amount of heat lost from the pool. Typically, the solar blanket has a size and shape corresponding to the surface of the pool. The solar blanket is put on the surface of the pool when the pool is not in use. When the pool is intended to be used, the solar blanket is typically rolled up onto a roller shaft. Typically, there are wheels at each end of the roller shaft and the entire roller assembly is rolled along the top of the pool deck. When the solar blanket has been removed from the pool surface, the entire roller assembly is moved away from the pool area. When it is desired to place the solar blanket back onto the surface of the pool the entire roller assembly is rolled to a position adjacent to the pool surface and the solar blanket is unrolled from the roller shaft and put back onto the surface of the pool. Because the roller assembly can be operated only on the top of the pool deck, it is an inconvenience to move the entire roller assembly away from and back to the pool area. Also, with the roller assembly on top of the deck, it takes up room that could otherwise be used for other activities. Also, the roller assembly is not particularly pleasing to look at, either when the solar blanket is rolled up or when it is unrolled.  
         SUMMARY OF THE INVENTION  
         [0003]    Accordingly, it is an object of this invention to at least partially overcome the disadvantages of the prior art. Thus, it is an object of this invention to provide an improved type of solar blanket roller assembly which is installed below the deck of a pool.  
           [0004]    Accordingly, in one of its objects, this invention resides in a below-deck solar blanket roller assembly comprising: a rotatable roller shaft for rolling and unrolling a solar blanket, the shaft having first and second ends and a longitudinal axis extending in a longitudinal direction; a non-rotatable protective casing having first and second ends, wherein the casing is spaced radially from the roller shaft, surrounds the roller shaft, and extends in the longitudinal direction, and wherein the casing has an elongated opening extending in the longitudinal direction; first end support supporting the first shaft end and positioning the first shaft end inside and relative to the casing; second end shaft support supporting the second shaft end and positioning the second shaft end inside and relative to the casing; first end wall closing the first end of the casing; second end wall closing the second end of the casing; power coupler at an end of the roller shaft for receiving power from a source to rotate the roller shaft.  
       
    
    
       [0005]    Further aspects of the invention will become apparent upon reading the following detailed description and drawings which illustrate the invention and preferred embodiments of the invention.  
       BRIEF DESCRIPTION OF THE DRAWINGS  
       [0006]    In the drawings, which illustrate embodiments of the invention:  
         [0007]    [0007]FIG. 1 is a partial prospective section view along line  1 - 1  as shown in FIG. 2;  
         [0008]    [0008]FIG. 2 is a partial sectional view along the vertical axis of an embodiment of the invention;  
         [0009]    [0009]FIG. 3 is a partial sectional view along the vertical axis of another embodiment of the invention;  
         [0010]    [0010]FIG. 4 is a partial, prospective, cut-away view of another embodiment of the invention;  
         [0011]    [0011]FIG. 5 is a partial, prospective, cut-away view of another embodiment of the invention;  
         [0012]    [0012]FIG. 6 is one preferred embodiment of the casing of the invention;  
         [0013]    [0013]FIG. 7 is a partial cross-sectional view showing one way in which the invention may be installed;  
         [0014]    [0014]FIG. 8 is a partial cross-sectional view showing another way in which the invention may be installed;  
         [0015]    [0015]FIG. 9 is a prospective view showing some aspects of an embodiment of the invention;  
         [0016]    [0016]FIG. 10 is a blow-out prospective view showing some aspects of a preferred embodiment of the invention;  
         [0017]    [0017]FIG. 11 is a blow-out prospective view showing some aspects of a preferred embodiment of the invention; and  
         [0018]    [0018]FIG. 12 is an end view of a preferred embodiment of the invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0019]    A below-deck solar blanket roller assembly of the present invention is shown partially in FIGS. 1 and 2. The roller assembly  10  comprises a rotatable roller shaft  12  for rolling and unrolling a solar blanket  88  (as seen in FIG. 7). The solar blanket  88  is attached by suitable means, such as rivets, screws, glues, glue, touch fasteners or ties, to the roller shaft  12 . The roller shaft  12  has a first end  14  and a second end  16  and a longitudinal axis LA extending in a longitudinal direction LD.  
         [0020]    The roller assembly  10  also includes a non-rotatable protective casing  18  having a first end  20  and a second end  22 .  
         [0021]    The casing  18  is spaced radially from the roller shaft  12 . The casing  18  surrounds the roller shaft  12 . The casing  18  extends in the longitudinal direction LD. The casing  18  has an elongated opening  24  extending in the longitudinal direction LD. The solar blanket  88  passes through the opening  24  from the roller shaft  12  to the pool  64  (as seen in FIG. 7).  
         [0022]    The roller assembly  10  also comprises a first end support  26  which supports the first shaft end  14  and which also positions the first shaft end  14  inside the casing  18  relative to the casing  18 . Preferably the first end support  26  supports the first end  14  through a bearing assembly  28  or other suitable device to permit easy rotation of the roller shaft  12 .  
         [0023]    Similarly, there is a second end shaft support  30  supporting the second shaft end  16  and which positions the second shaft end  16  inside the casing  18  relative to the casing  18 . Once again, there is a bearing assembly  32  or other suitable device to permit easy rotation of the roller shaft  12 .  
         [0024]    There is a first end wall  34  closing the first end  14  of the casing  18 .  
         [0025]    Also, there is a second end wall  36  closing the second end  16  of the casing  18 .  
         [0026]    In a preferred embodiment, the first end wall  34  sealingly closes the first end  20  of the casing  18  and the second end wall  36  sealingly closes the second end  22  of the casing. This is preferred in order to keep as much dirt and other debris as possible from entering the casing  18  after the casing  18  has been installed.  
         [0027]    There is a power coupler  38  at an end of the roller shaft  12  for receiving power from a source to rotate the roller shaft  12 .  
         [0028]    The source of power could be human energy. For example, there could be a manual crank positioned away from the casing. A human operator would turn the crank and the crank would be suitably coupled to the power coupler  38  such as through a chain and sprocket or through suitable gears.  
         [0029]    Alternatively, the power source could be a suitable electric motor, such as a low voltage electrical motor  90  (as shown in FIG. 2). The electric motor  90  could be positioned within the casing  18  or outside the casing  18 . In either case, there would be suitable power linkage  92  from the electric motor  90  to the power coupler  38 .  
         [0030]    The power coupler  38  is any suitable power coupler, including something as simple as a hole in the end of the roller shaft  12  to receive a similarly-shaped insert from the power linkage from the power source. Also, the power coupler  38  could include a sprocket, gear, or longitudinal extender.  
         [0031]    The casing  18  has an inner peripheral wall  40 . In one embodiment of the invention, the first end support  26  comprises a first rigid support member  42  extending from a first position  44  on the inner peripheral wall  40  of the casing  18  to a second position  46  on the inner peripheral wall  40  of the casing  18 .  
         [0032]    Similarly, the second end support  30  is comprised of a similar second rigid support member  48  extending from a third position on the inner peripheral wall  40  of the casing  18  to a fourth position on the inner peripheral wall  40  of the casing  18 .  
         [0033]    Preferably, each of the rigid support members  42  and  48  is aligned in a plane parallel to a plane defined by the longitudinal axis LA and an axis orthogonal to the longitudinal axis, as for example as shown by the first rigid support member  42  in FIG. 1.  
         [0034]    In a more preferred embodiment of the invention, each of the support members  42  and  48  is horizontal, such as the first rigid support member  42  as shown in FIG. 1.  
         [0035]    In an alternative embodiment, the roller shaft  12  and the casing  18  are substantially the same as discussed above and shown in FIGS. 1 and 2, however, the first end support  126  as shown in FIG. 3 is comprised of a support member  142  which is aligned in a plane defined by two axes which are orthogonal to each other and also orthogonal to the longitudinal axis LA. For example, as shown in FIG. 3, the two axes which are orthogonal to each other are the vertical axis YA and the Z axis ZA which comes transversely out of the paper of FIG. 3.  
         [0036]    In this embodiment, the second end support  130  similarly comprises a rigid support member  148  which is aligned in a plane defined by two axes which are orthogonal to each other and also orthogonal to the longitudinal axis.  
         [0037]    Also, in order to have roller shaft  12  rotate most easily, each of the support members  142  and  148  support bearing assemblies  128 .  
         [0038]    In another embodiment, as shown in FIG. 4, there is a lid  50  associated with the casing  18 . The lid  50  covers the elongated opening  24  in the casing  18 . The lid  50  is movable from a first position (as shown in FIG. 4) where the elongated opening  24  in the casing  18  is closed to a second position where the lid  50  is radially outward of the casing  18  where the elongated opening  24  in the casing  18  is open (as shown in FIG. 5).  
         [0039]    As may be seen in FIG. 1, the opening  24  in the casing  18  is defined by first edge  52  and second edge  54 . As may be seen in FIG. 4, the lid  50  may be hinged to the casing  18  in the area adjacent to the first edge  52 .  
         [0040]    Also, a blanket protector  56  may be hinged to the casing  18  in an area adjacent to the second edge  54  such that the blanket protector  56  rotatably moves from a first position the casing  18  to a second position radially outward from the casing  18  as shown in FIG. 5.  
         [0041]    The blanket protector  56  protects the solar blanket  88  as the solar blanket  88  is either unwound from the roller shaft  12  or wound back up onto the roller shaft  12 .  
         [0042]    The lid  50  is moved to the open position when the operator desires to either unroll the solar blanket  88  from the roller shaft  12  and place the solar blanket over the surface of the pool or, alternatively, when an operator wants to roll the solar blanket  88  back onto the roller shaft  12 . When the solar blanket is either entirely rolled onto the roller shaft  12  or when the solar blanket  88  is positioned over the pool surface, the operator will typically close the lid  50  so as to cover the elongated opening  24 , primarily for safety reasons but also for aesthetic reasons.  
         [0043]    Preferably the lid  50  has a “V” shape in cross-section so that it wedges into the opening  24  and is at least partially supported by the first and second edges  52  and  54  of the opening  24 . Also, the lid  50  can be partially supported by lips  58  and  60  (as shown in FIG. 5).  
         [0044]    In a preferred embodiment, the casing  18  is formed from plastic, corrugated pipe, primarily to provide strength and rigidity to the casing  18 , as shown if FIG. 4.  
         [0045]    Alternatively, in another preferred embodiment, the casing is formed from galvanized metal. In this embodiment, the casing need not be circular in cross-section. For example, the casing  18  could have a generally hexagonal shape as shown in FIG. 6, or some other suitable cross-sectional shape.  
         [0046]    In yet a further embodiment of the invention, the casing  18  can be formed from extruded plastic. In essence, the plastic is extruded into the desired shape of the casing  18  as shown generally in FIGS.  1  to  3 . In a further preferred embodiment, the casing  18  could be extruded to include the lips  58  and  60  which are on the edges  52  and  54  of the opening  24  (as best seen in FIG. 5).  
         [0047]    In a pool  64  that is at least partially surrounded by a deck  62 , the roller assembly  10  is intended to be installed below the deck  62 . In a preferred embodiment, the casing  18  is oriented such that the opening  24  in the casing  18  is aligned with an opening  66  in the deck  62 . Preferably, the opening  66  in the deck  62  is spaced away from a portion of the deck  68  which is immediately adjacent to the pool  64 . Preferably the portion of the deck  68  immediately adjacent to the pool  64  is supported by the pool wall  70 . In a more preferred embodiment of the invention, the opening  66  in the deck is spaced between the portion of the deck  68  immediately adjacent to the pool  64  and a deck portion  72  distant from the pool  64 . Preferably the deck portion  72  distant from the pool  64  is supported by a deck support  74 .  
         [0048]    In another embodiment of the invention, the casing  18  is oriented such that the opening  24  in the casing  18  is aligned with an opening  76  in the pool wall  70 , as shown in FIG. 8.  
         [0049]    In a preferred embodiment of the invention, the casing is supported by a pair of casing supports  78  as shown in FIG. 9. Preferably the casing support  78  is comprised of a suitable block, concrete or brick structure underneath each of the first and second ends  20 ,  22  of the casing  18 . For example, in FIG. 9, the casing support  78  comprises a vertical concrete support member  80 . Preferably, the vertical concrete support member  80  is formed by pouring concrete into a plastic tube or sonotube. Preferably, the vertical concrete support member  80  is supported by a suitable footing  82 .  
         [0050]    The casing  18  is supported by a first casing support at the first end  20  of the casing  18  and by a second casing support at the second end  22  of the casing  18 .  
         [0051]    Preferably, each casing support  78  has a casing leveller.  
         [0052]    In one embodiment, the casing leveller, as shown in FIG. 9, comprises a relatively short length of pipe  84  which is moveable up and down on the vertical concrete support member  80 . The top portion  86  of the pipe  84  is shaped to receive the casing  18 . The pipe  84  can be moved up and down on the vertical concrete support member  80  to adjust the height of the particular end  20 ,  22  of the casing  18 . Adjustable screws  86  are tightened and forced into the vertical concrete support member  80  to fix the pipe  80  and the casing  18  at the desired height.  
         [0053]    It will be understood that, although various features of the invention have been described with respect to one or another of the embodiments of the invention, the various features and embodiments of the invention may be combined or used in conjunction with other features and embodiments of the invention as described and illustrated herein.  
         [0054]    Although this disclosure has described and illustrated certain preferred embodiments of the invention, it is to be understood that the invention is not restricted to these particular embodiments. Rather, the invention includes all embodiments which are functional or mechanical equivalents of the specific embodiments and features that have been described and illustrated herein.

Technology Classification (CPC): 4