Abstract:
A low friction pool cover reel to assist in retrieval and deployment of swimming pool covers onto the surface of water in a swimming pool.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     This present application claims priority to pending provisional patent application, Ser. No. 60/727,771, filed Oct. 19, 2005. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     The present invention relates generally to pool cover reels which permit the deployment and retrieval of protective and/or thermal covers onto the surface of water in swimming pools.  
         [0003]     Outdoor and indoor residential and commercial swimming pools typically have large surface areas which are exposed to the ambient environment. With outdoor swimming pools in particular, thermal or protective covers are frequently employed to prevent extraneous matter from falling into the swimming pool, such as dust, leaves, insects, etc, to retain heat within the water of the pool by reducing the exposed water surface area, or to act as a radiant heat source to transfer heat from the sun&#39;s energy to the water within the swimming pool. Because of their large surface area, most pools require relatively large spans of cover material, which are, accordingly, difficult to handle and manipulate during both deployment and retrieval.  
         [0004]     Swimming pool cover reels are known in the art as devices which permit a swimming pool cover to be attached to a rotating axle, then wound about the axle by rotation of the axle to retrieve the cover, or deployed by simply pulling an exposed end of the swimming pool cover from a coiled spool on the rotating axle over the water and thus, deploying the cover from the reel device.  
         [0005]     It has been found, however, that for large pool covers, e.g., those having widths between fourteen to twenty two feet, and lengths between about thirty-five to fifty feet, or larger, deployment and retrieval of the covers presents a particularly cumbersome issue and requires greater effort on the part of the user to reel the cover onto the reel device. Examples of pool cover reels known in the art are shown in U.S. Pat. Nos. 4,467,978, 5,636,808 or D265391.  
         [0006]     Many swimming pool cover reel devices are fabricated of plastics, which over prolonged exposure to sunlight and outdoor environmental changes, loses its structural and functional properties, making deployment and retrieval of a swimming pool cover extremely difficult.  
         [0007]     Thus, it has been recognized that a swimming pool cover reel device which permits the easy deployment and retrieval of a swimming pool cover onto the surface of water in a swimming pool, and which is capable of withstanding exposure to an outdoor ambient environment without having deteriorating performance is desirable. Summary of the Invention  
         [0008]     It is, therefore, a principal objective of the present invention to provide a swimming pool cover reel assembly which is easy to use, made of structural materials having excellent resistance to environmental damage, and mechanical properties to minimize flexing of the device and optimize ease of reeling and unreeling the swimming pool cover therefrom.  
         [0009]     A further objective of the present invention is to provide a swimming pool cover reel assembly which includes terminal supports for a rotatable axle spanning between the terminal supports, the terminal supports permitting the rotatable axle to be in spaced apart relation above the ground or pool decking, while providing for mounting of a handle to transfer a rotary force to the rotatable axle at least one of the terminal supports.  
         [0010]     It is a further objective of the present invention to provide means for both manual and motor-driven rotation of the rotatable axle.  
         [0011]     It is a further objective of the present invention to provide a bearing assembly through which the rotatable axle passes and which permits very low friction rotation of the rotatable axle which is suitable for both manual and motor-driven rotation of the rotatable axle.  
         [0012]     These and other objects, features and advantages of the present invention will be more apparent from the following more detailed disclosure of the invention taken with reference to the accompanying figures. 
     
    
     BRIEF DESCRIPTION OF THE FIGURES  
       [0013]      FIG. 1  is a perspective, partially exploded view of the inventive swimming pool cover reel assembly.  
         [0014]      FIG. 2  is a cross-sectional view taken along line  2 - 2  of  FIG. 1 .  
         [0015]      FIG. 3  is a cross-sectional view taken along line  3 - 3  of  FIG. 1 , showing a bearing assembly.  
         [0016]      FIG. 4  is a cross-sectional view taken along line  4 - 4  of  FIG. 1 , showing a web member in phantom.  
         [0017]      FIG. 5  is a perspective view showing an alternative configuration for a terminal support frame member.  
         [0018]      FIG. 6  is a partial cross-sectional side elevational view of an anchoring assembly for securing the swimming pool cover reel assembly to a pool deck. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0019]     The inventive pool cover reel device  10  is illustrated generally in  FIG. 1 . Pool cover reel device  10  consists generally of a pair of upstanding support members  12 . Each of the upstanding support members  12  may be fabricated of box or tubular metal members configured at a generally inverted T-shape, triangular shape, Z-shape, C-shape, Y-shape or other suitable shape suitable for supporting the device  10 . An exemplary alternative generally Y-shape for the upstanding support members  12  is depicted in  FIG. 5 . In accordance with a preferred embodiment, each upstanding support member  12  has a linear base member  13  and may be provided with casters or wheels  15  to allow for ready movement of the device  10  over the ground or pool deck. In accordance with an alternate preferred embodiment of the present invention, each of the upstanding support members  12  preferably has an extendable section which permits raising or lowering of the extendable section the device  10  relative to the base member  13 . For swimming pools having diving boards, such as low-profile diving boards having a height of about eighteen inches or less, it is desirable that the upstanding support members  12  have sufficient height between the base member  13  and the top of the support member  12  to have the device  10  clear a diving board.  
         [0020]     Pool cover reel device  10  further consists of a plurality of tubular members  16 , a plurality of drive transfer members  18 , synonymously referred to as web members, a handcrank shaft  22 , a second shaft member  24 , a plurality of bearing members  28  retained within tubular housings  17  coupled to each of the support members  12 , and at least two retaining collars  26 . Each of the plurality of tubular members consists generally of an elongate open tubular member having at least a pair of recessed regions  30  as illustrated in  FIG. 4  which is a cross-sectional view taken along line  4 - 4  of  FIG. 1 . Each of the recessed regions  30  are preferably positioned in diametric opposition such that there is about a 180 degree separation between the recessed regions  30 . Each of the recessed regions end in shoulder abutments  32 .  
         [0021]     Each of the drive transfer or web members  18  has a generally X-shape and consists generally of a central generally tubular hub  36 , a plurality of radially extending rib members  38  each of which terminates in a head member  40  which is oriented generally perpendicular to the rib member  38  to which it is joined. Each of the head members  40  preferably have a curvature corresponding generally to the curvature of the inner diameter of the tubular member  16 . A web member  18  is concentrically joined within a central longitudinal opening of a tubular member  16  such that each head member  40  is in abutting relationship with the shoulder abutments  32 . In this manner, the shoulder abutments  32  prevent relative movement between the web member  18  and the tubular member  16  while transferring rotational forces from the tubular hub  36  to the shoulder abutments  32  to rotate the tubular member  16  about the axis of the tubular hub  36 .  
         [0022]     The device  10  is assembled by concentrically joining a web member  18  and a tubular member  16  such that a portion of the web member  18  extends beyond an open end of the tubular member  16  into which the web member is concentrically engaged. A second tubular member  16  is then concentrically joined over the exposed portion of the web member  18  and brought into abutting relationship with the first tubular member  16 . The required width for the reel device  10  will determine the number of tubular members  16  and web members  18  which are required to span the width of the pool and accommodate the width of the pool cover being mounted onto the device  10 . The tubular members  16  which are positioned adjacent the support members  12  have web members  18  concentrically joined therein, except that instead of leaving an exposed portion of these terminal web members  18 , the terminal web members  18  are either co-terminus with the tubular member  16  or slightly recessed within the central longitudinal opening of the tubular member  16 .  
         [0023]     The joined tubular members  16  and web-members  18  are then brought into co-axial alignment with the tubular housings  17  and bearings  28  retained therein. On a first end of the device  10 , the handcrank shaft  22  is inserted through the bearings  28  and tubular housing  17  of a first support member  12  such that it projects outwardly from opposing ends of the tubular housing  17 . A first end of the joined tubular members  16  and web-members  18  is brought into engagement with a projecting end of the handcrank shaft  22  such that the tubular hub  36  is concentrically engaged onto the projecting end of the handcrank shaft  22 . A retaining member (not shown) is then preferably passed through the tubular member  16 , the tubular hub  36 , the projecting end of the handcrank shaft  22  and secured by a locking member (not shown) to prevent disengagement of the tubular member  16  and web member  18  from the handcrank shaft  22  and, thereby, join the elements in a fixed relationship and permit transfer of rotational force from the handcrank shaft  22  to the web-members  18  and tubular members  16 . A retaining collar  26  positioned on an opposing end of the handcrank shaft  22  is then brought into abutting relationship with the tubular housing  17  to restrict relative movement between the support member  12 , the handcrank shaft  22  and the concentrically joined tubular members  16  and web members  18 .  
         [0024]     At an end of the device  10  opposite the handcrank shaft  22 , a second shaft member  24  is passed concentrically through a second set of bearings  28  mounted in a second tubular housing  17  on a second support member  12  such that a second end projects co-axially toward the handcrank shaft  22 . An opposing end of the concentrically joined tubular members  16  and web members  18  is joined to the second end of the second shaft  24  by concentrically engaging the tubular hub  36  with the second end of the second shaft  24  and securing the resulting assembly with a retaining member and locking member as described above. Again, a collar  26  is brought into abutting relationship with the second tubular housing  17  to restrict relative movement between the conjoined members.  
         [0025]     It is preferable to secure each of the head members  40  relative to the tubular member  16 , such as by employing self-taping screws which pass through the tubular member  16  and each head member  40 . To facilitate accurately passing the screws into the tubular member  16  and web member  18 , it is desirable to provide scribe lines or other indicia to both properly position and orient the screws and to aid in engaging the screws with the tubular member  16  and web member  18 . Two sets of securing screws may be employed, with a first set being proximate an end portion of the tubular members  16  to which a web member  18  is concentrically joined, and a second set being longitudinally spaced along the longitudinal axis of the assembly. In accordance with a most preferred embodiment of the invention, the first set of securing screws are placed about two inches from an end of the a tubular member  16  and the second set of securing screws are placed about twelve inches from an end of the tubular member  16 .  
         [0026]     Each of the web members  18  and each of the support members  12  are preferably made from 6105 T-5 aluminum, while each of the tubular members  16  are preferably fabricated of 6063T-5 aluminum. Aluminum is the preferred material for the tubular members  16 , the web members  18  and the support members  12  due to its light weight, ease of manufacture, structural properties and resistance to the ambient environment. Those skilled in the art will understand and appreciate, however, that alternative materials may be used in the construction of the component parts of the present invention.  
         [0027]     In accordance with a preferred embodiment of the present invention, the second shaft member  24  has an exposed end which is adapted to be engaged with a small electric motor, such being engaged within a collet on a drive shaft or engaged in an electrical drill head, to permit a motor to drive the rotational movement of the tubular members  16  to retrieve a pool cover. The exposed end of the second shaft member  24  may be swedged to impart recesses suitable for engaging a driving member joined to an electrical drill, or may be formed into hexagonal, square or other shape suitable for engagement with a drive socket.  
         [0028]     Also in accordance with a preferred embodiment of the present invention, the bearings  28  are preferably very low friction, non-leaking packed bearings which do not require re-packing with grease.  FIG. 3  depicts a cross-sectional view of a preferred bearing assembly  28  in accordance with the present invention. In accordance with the best mode of practicing the invention, at least four bearing assemblies  28  are employed in the device  10  of the present invention, with two bearing assemblies  28  being engaged in each tubular housing  17  on each support member  12 . A first bearing assembly  28  is concentrically engaged in a first open end of the tubular housing  17 , while a second bearing assembly  28  is concentrically engaged in a second opposing open end of the tubular housing  17 .  
         [0029]     Each of the bearing assemblies  28  consists generally of an inner housing  50  and an outer housing  52 . The inner housing is generally tubular and has a central bore  51  which passes through a longitudinal axis of the bearing assembly  28 . The central bore  51  concentrically accommodates the handcrank shaft  22  therethrough. The inner housing  50  has a first circumferential recess  53  formed on an outer diametric surface thereof. The outer housing  52  is generally tubular and has a second circumferential recess  55  formed on an inner diametric surface thereof, and has a seating flange  54  which projects radially outward from an end surfaced thereof to permit abutting engagement with an open end of tubular housing  17 . A seal seat  57  is preferably provided to provide a sealing engagement between the outer housing  52  of the bearing assembly  28  and the tubular housing  17 . Suitable seals, such as  0 -ring seals, are well known in the art. It is preferable that each of the bearing assemblies  28  are friction or interference fit within the inner diameter of the tubular housing  17 .  
         [0030]     A desirable aspect of the present invention is to select the materials for the tubular housing  17  and the bearing assemblies  28  such that the materials have substantially similar coefficient&#39;s of thermal expansion and matching eccentricities to ensure a sealed fit therebetween under manufacturing conditions and various environmental condition.  
         [0031]     A plurality of spherical ball bearings  58 , preferably mounted in a race  60 , are provided and positioned in an intermediate space formed between the inner housing  50  and the outer housing  52 . The plurality of spherical ball bearings  58  track in both the first circumferential recess  53  and second circumferential recess  55  about the circumference of the inner housing  50  and outer housing  52 . Alternative types of bearings  58 , including, for example, cylindrical bearings may be employed. Similarly, the bearings may be single or plural row bearings so long as there are a sufficient number of corresponding circumferential recesses formed in the inner housing  50  and outer housing  52 .  
         [0032]     Seals  56  are preferably provided between the inner housing  50  and the outer housing  52  to seal the intermediate space in which the plurality of spherical ball bearings  58  operate. The intermediate space is preferably packed with an appropriate lubricant to provide low friction movement of the plurality of spherical ball bearings  58  and race  60  with respect to the first circumferential recess  53  and the second circumferential recess  55 . Suitable materials for seals  56  are well known in the art. It is preferable that the intermediate space between the inner housing  50  and the outer housing  52  be sealed in such a manner as to avoid leaking of lubricant from the intermediate space, and avoid the need to clean or repack the spherical ball bearings  58  or the intermediate space between the inner housing  50  and outer housing  52 .  
         [0033]     In accordance with one embodiment of the invention, the plurality of drive transfer or web members  18  are provided in a plurality of different lengths. A first length of web member  18  is utilized as an interconnection member to interconnect adjacent pairs of tubular members  16  and support the junction between the adjacent pairs of tubular members  16  in a manner which resists sag or flexure of the joined tubular members  16 . A second length of web member  18  is utilized as a drive member, and is engaged in the opposing terminal ends of terminal tubular members and is intended only to interconnect with the handcrank shaft  22  on one end of device  10  and another drive web member  18  is intended to interconnect with the second shaft member  24  at an opposing terminal end of the device  10 . Thus, the handcrank shaft  22  is engaged only with a first drive web member  18 , while the second shaft member  24  is engaged only with a second drive web member  18  at an opposing end of the device  10 . Actuation of the handcrank shaft  22 , transfers a rotational force through the first drive web member  18 , which imparts a rotary force to the tubular members  16  interconnected with the first lengths of web members  18 , thereby transferring the rotary force along the entire length of the device  10 . The entire assembly of web members  18  and tubular members  16  freely rotates about second shaft member  24  on bearing assembly  28 .  
         [0034]     The swimming pool cover is attached by detachable straps to the plurality of tubular members  16 , such that rotation of the tubular members  16  causes a reeling or coiling of the swimming pool cover onto the tubular members  16 .  
         [0035]     Finally, as illustrated in  FIG. 6 , it is desirable to anchor the swimming pool cover reel assembly  10  to a surface such as pool decking in order to secure the pool cover reel assembly  10  in a fixed position relative to the swimming pool. While the pool cover reel assembly  10  may be mounted on locking casters as depicted in  FIG. 5 , it is also preferable to fixedly secure the assembly  10  to a fixed surface such as pool decking. This may be accomplished by providing an anchoring assembly  70  which anchors the assembly  10  by securing the base member  13  to a fixed surface  72  such as pool decking. Such may be accomplished by drilling a closed hole in the fixed surface  72  and mounting a threaded ferrule  74  into the closed hole such that it is substantially flush with the fixed surface  72 . An anchoring member  76  is provided having a threaded end  78  and an upper end terminated in a handle  84  or other means for rotating the anchoring member  76 . Anchoring member  76  is passed vertically through the base member  13  through an opening  77  passing therethrough. A spring seat  82  and corresponding compression spring  80  are provided such that the anchoring member  76  passes through the spring  80  and the spring seat  82 , with the spring  80  seating against the spring seat  82  on one end thereof and against the handle  84  at another end thereof. The anchoring member  76  is capable of reciprocating movement within spring  80  and opening  77  to be brought into engagement with the threaded ferrule  74  and threadedly engaged therewith to secure the assembly  10  to the fixed surface  72 .  
         [0036]     While the present invention has been described with reference to its preferred embodiments, those of ordinary skill in the art will understand and appreciate that variations in size, dimension, material selection, geometry or the like may be made without departing from the intended scope of the invention.