Patent Abstract:
Box apparatus is provided for containing a pool cover assembly to cover a swimming pool, comprising an elongated plastic box. The box apparatus comprises a plurality of sections of substantially identical unitary molded plastic members, a plurality of coupling elements to couple the sections together to form an elongated box with two sides, a bottom, an open top and at least one open end, and an end piece fastened to the box to close the open end. A method is provided for forming a pool cover box to contain a pool cover assembly for covering a swimming pool, comprising forming an elongated plastic box.

Full Description:
FIELD OF INVENTION 
     The present disclosure relates to swimming pools, and, more particularly, to pool cover box apparatuses and methods. 
     BACKGROUND 
     Swimming pool covers are often used for keeping the water free of trash, to shield the water from sunlight that could degrade protective chemicals in the water and for other purposes. Automatic pool covers are often preferable over manually-operated covers, because the cover can be easily extended when the pool is not in use and retracted during use. In most cases, a pool cover box is located at one end of the pool to hold the cover, motor, winding reel and cable. 
       FIG. 1  shows a generalized schematic of a swimming pool  10  having a pool deck  12  and coping walls  14  surrounding the pool  10 . A pool cover  16  extends from a pool cover assembly  18  in a pool cover box  20  disposed at one end of the pool  10 . A leading edge bar  22  at the front edge of the pool cover  16  rides in a track encapsulation  24  along the interior walls of the pool  10 . Pool cover assembly  18  includes a pool cover motor  21  and a cover wind-up cylinder  26 . When the pool  10  is not in use, leading edge bar  22  pulls cover  16  from pool cover box  18  across the length of swimming pool  10 . To use the swimming pool  10  the cover  16  is retracted by the pool cover assembly  18  into a cover assembly box  20  causing leading edge bar  22  to also retract into the assembly box  20 . 
       FIG. 2  shows a prior art pool cover assembly  18  and pool cover box  20  in cross-section. A bracket assembly  30  is mounted to the back wall  32  of box  20  to support a lid  34  mounted over a trough  35  in the box  20 . A reel  36  is disposed in the trough  35  of box  20  to roll up or unwind the pool cover  16  as it retracts or extends through a space  38 . 
     Prior pool cover boxes have been made in several varieties, such as concrete boxes poured in place or wooden boxes, usually constructed on site. A concrete box is very expensive to make, since it must be formed and poured on location. Also, as a plastic pool cover is extended and retracted relative to the pool and the box, it rubs against parts of the concrete box, wearing the pool cover prematurely. A wooden box is extremely heavy and difficult to maneuver into place. Furthermore, a wooden box tends to deteriorate and warp in the weather, requiring repair and replacement. Metal boxes have also been constructed, but the weight involved makes such boxes cumbersome and expensive. 
     SUMMARY 
     In one implementation of the present disclosure, a box apparatus is provided for containing a pool cover assembly to cover a swimming pool, comprising an elongated plastic box. 
     In another implementation, a box apparatus is provided for containing a pool cover assembly to cover a swimming pool. The box comprises a plurality of sections of substantially identical unitary molded plastic members, a plurality of coupling elements to couple the sections together to form an elongated box with two sides, a bottom, an open top, at least one open end, and an end piece fastened to the box to close the open end. 
     In another implementation, a method is provided for forming a pool cover box to contain a pool cover assembly for covering a swimming pool, comprising forming an elongated plastic box. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above-mentioned features and other features and advantages of this disclosure will become more apparent and the disclosure will be better understood by reference to the following description of an exemplary implementation taken in conjunction with the accompanying drawings, wherein: 
         FIG. 1  is a generalized schematic view of a pool showing the location of a pool cover assembly and pool cover box; 
         FIG. 2  is a partial cross-sectional view of a conventional pool cover box and cover assembly; 
         FIG. 3  is a perspective view of the pool cover box according to one implementation of the present disclosure; 
         FIG. 4  is a perspective view of a front portion of the pool cover box shown in  FIG. 3 ; 
         FIG. 5  is a perspective view of a back portion of the pool cover box shown in  FIG. 3 ; 
         FIG. 6  is a plan view of a portion of the pool cover box shown in  FIG. 3 ; 
         FIG. 7  is a perspective view of the bottom of the pool cover box shown in  FIG. 3 ; 
         FIG. 8  is a partial plan view showing the use of a splice piece in assembling sections of the pool cover box shown in  FIG. 3 ; and 
         FIG. 9  is a partial perspective view showing partially assembled sections of the pool cover box shown in  FIG. 3 . 
         FIG. 10  is a perspective view showing the assembled sections shown in  FIG. 9 ; and 
         FIG. 11  is a partial perspective view showing reinforcement of the assembled sections shown in  FIG. 9 . 
     
    
    
     Throughout the drawings, identical reference numbers may designate similar, but not necessarily identical, elements. The examples herein illustrate selected implementations of the disclosure in certain forms, and such exemplification is not to be construed as limiting the scope of the disclosure in any manner. 
     DETAILED DESCRIPTION 
     Referring now to  FIGS. 3 ,  4  and  5 , perspective views are shown of a pool cover box  40  according to an implementation of the present disclosure. Looking first at  FIG. 3 , pool cover box  40  is a thermoplastic molded box having sides  41  and  42  and inside surfaces, including bottom  44 , formed from the same molded plastic piece. Box  40  may be made of any moldable thermoplastic material, such as ABS or polyethylene and may have a thickness of approximately one quarter inch. Box  40  may be composed of multiple sections that are separately molded and then fastened together, as will be discussed later. Although the length varies greatly, it is likely that box  40  may be in the range of 16–24 feet long, comprising sections of 8 feet or 4 feet, which may be cut to whatever specific length may be needed, as discussed later. The box may be about 14 inches deep by 14 inches wide. A plurality of ribs  46  are spaced along the length of box  40 , each rib  46  running transversely from side  41  to the bottom  44  of box  40 . 
     End pieces  52  and  54  are coupled to walls  41  and  42  at opposite ends of the pool cover box  40 . End piece  52  is formed with a lip  55  to form part of a frame structure  51  extending around the periphery of end piece  52 . An enclosure member  53  is recessed from frame structure  51  and closes off the end of the pool cover box  40 . 
     As shown in  FIG. 4 , elongated support members  47  and  48  run longitudinally along the sides  41  and  42  of the box  40 . Support members  47  and  48  may be formed with sections of hollow square metal tubing  49  and  50  which are molded into the sides  41  and  42  of pool cover box  40  to provide strength and to maintain the integrity of the pool cover box  40 . Tubing  49  and  50  may be single pieces each running the length of a section of the pool cover box  40 . Tubing  49  and  50  may be one inch by two inches in transverse profile and may extend the length of a section, which could be four or eight feet long. The plastic material forming sides  41  and  42  is wrapped around the metal tubing  49  and  50  and attached to the outside of sides  41  and  42 . Metal tubing  49  and  50  also provides a solid material on which to attach brackets and other members needed to dispose lids over the cover box. 
       FIG. 4  is a close-up partial perspective view of pool cover box  40  showing end piece  52  in more detail. Frame structure  51  forms a hexagon or a rough U-shape with a top having a width which is approximately the same as the width of the pool cover box. As used herein and in the appended claims, U-shape shall be broadly understood to mean any shape which includes two side portions and a bottom. Enclosure member is recessed from structure  51 . End piece  52 , as well as end piece  54  ( FIG. 5 ) are sized and shaped to conform to the inner shape of the pool cover box  40 . Accordingly, end pieces  52  and  54  can be moved along the length of box  40  to provide whatever custom length of the box may be needed. After an end piece  52  or  54  has been moved, any excess portion of the box  40  (not shown) can be removed by cutting off that portion. The lip  55  at the top of end piece  52  adds strength to the piece. 
       FIG. 5  shows end piece  54  in more detail. End piece  54  is substantially identical to end piece  52  and conforms to the size and shape of the inner dimensions of box  40 . Accordingly, piece  54  may also be moved along the length of box  40  to provide whatever length may be desired. The excess part of the box (not shown) may be cut off or simply left alone. End piece  54  also has a top lip  56  and an external frame structure (not shown) substantially identical to structure  51 , to provide strength to end piece  54 . 
       FIG. 6  is a partial plan view of box  40  showing the bottom  44  and inside surfaces  58  and  59  of side  41 . Ribs  46  are spaced along the length of box  40  and run transversely across surfaces  58  and  59  and a portion of bottom  44 . Ribs  46  add strength to the sides  41 ,  42  and the inner surface of the bottom  44  of pool cover box  40 . Ribs  46  are similarly disposed on the inside surfaces of side  42 . 
       FIG. 7  is a partial perspective view showing part of side  42  and the outside  45  of bottom  44 . Ribs  46  are also apparent on the outside of pool cover box  40 . An elongated flap  69  runs below support member  48  and is integral with the material used to form the pool cover box  40 . Flap  69  is the extended portion of plastic that extends around metal tube  50  to form support member  48 . Screws  43  extend through side  42  and flap  69  to secure end piece  52 . 
       FIG. 8  is a partial plan view showing part of a section  70  of the pool cover box. Sides  72  and  74  include elongated support members  76  and  78 , substantially the same as support members  47  and  48  shown in  FIG. 3 . Although not shown, support members  76  and  78  include hollow square metal tubing similar to tubing  49  and  50  shown in  FIG. 3 . In order to couple section  70  to an adjoining section (not shown), channel members  80  and  82  are inserted into the hollow metal tubing in support members  47  and  48 . Channel members  80  and  82  may be U-shaped metal members sized to fit inside of the hollow metal tubing (not shown). Channel members  80  and  82  may be about 18 inches long and may be made of channel-shaped steel. 
     Referring now to  FIG. 9 , section  70  is shown in partially completed assembly with an adjoining section  90  of pool cover box. Channel members  80  and  82  have been inserted into the hollow metal tubing (not shown) of elongated support members  86  and  88 . Accordingly, channel members  80  and  82  function to splice the adjoining sections  70  and  90  together. 
       FIG. 10  is a plan view, showing sections  70  and  90  joined together. Sections  70  and  90  may be joined together in a butt joint. Only a faint line for a joint  92  can be seen where sections  70  and  90  abut. The box  40  may be made watertight by taping, caulking or otherwise sealing the joint  92 . Selective water tightness may be desirable in order to drain water out of the box  40  only at selected drains, thereby preventing water seeping into areas where water might be injurious. Likewise, making the box watertight may be desirable to keep water from seeping into box  40 , thereby causing rust or deterioration in the pool cover assembly. 
       FIG. 11  is a plan view of the bottom  94  of sections  70  and  90 . The joint  92  may likewise be taped, caulked or otherwise sealed from the outside of the box  40 . Moreover, the coupling between sections  70  and  90  may be strengthened by attaching a channel member  96  to bottom  94  so as to extend longitudinally along bottom  94  across joint  92 . Other channel members (not shown) may be coupled on the bottom  94  transversely around the joint to strengthen the coupling of adjoining sections. A plurality of screws or other fasteners  98  are connected to the undersides of support members  76  and  86 , near the joint  92  to secure the channel member  80  relative to the support members  76  and  86  (see  FIG. 9 ). Similarly, screws (not shown) are connected to the undersides of support members  78  and  88  (see  FIG. 9 ) to secure the channel member  82  relative to the support members  78  and  88 . 
     Fabrication of the pool cover box of the present disclosure is carried out by conventional vacuum form processes. The entire pool cover box of the present disclosure can be fabricated in a single process, including forming the support members with the hollow steel tubes therein. Assembly of adjoining sections may require only a few minutes of assembly time, and an entire pool cover box may be fully assembled in a matter of minutes, rather than hours required to fabricate prior art pool cover boxes. 
     It should be understood that other types of plastic fabrication of the pool cover box fall within the scope of the present disclosure. Thus, the subject pool cover box may also be made from vacuum molded sections that are individually formed and then fastened together. Moreover, the pool cover box may also be made by injection molding the plastic box, in one or more sections and then fastening the sections together. Other such plastic fabrication methods may be used to make a pool cover box with the scope of the present disclosure. 
     The apparatus and methods described above provide a number of advantages over prior art pool cover boxes. The thermoplastic pool cover box is much more light-weight and portable than prior boxes. One eight foot section could easily be lifted and positioned where needed. In contrast, a metal or wood box of comparable size might weigh two to three times or more than the present box. The pool cover box of the present disclosure may be assembled in sections of 4 feet, 8 feet or may even be provided in 2 feet increments. In addition, the pool cover box may be further adjusted in length by moving one or both of the ends. 
     In addition, the pool cover box of the present disclosure is relatively easy and fast to fabricate, being manufactured in a single vacuum form molding process. Further, the present pool cover box, being made of a thermoplastic material, is durable and impervious to weather. Moreover, the thermoplastic material of the pool cover box does not abrade or prematurely wear out the pool cover. The elongated support members running along the sides of each section of the box provide substantial rigidity and strength. Further, the channel members functioning as splices within the hollow steel members provide strength to the coupling sections, as do the channel members on the underside of the box attached across adjoining sections of the box. The waterproof nature of the pool cover box of the present disclosure keeps stray water from seeping into the box and prevents water from flowing out, except at specified drains. 
     While this disclosure has been described as having a preferred design, the present disclosure can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the disclosure using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this disclosure pertains and which fall within the limits of the appended claims.

Technology Classification (CPC): 8