US20060064812A1 - Heat sealed webbing method and apparatus for pool covers - Google Patents
Heat sealed webbing method and apparatus for pool covers Download PDFInfo
- Publication number
- US20060064812A1 US20060064812A1 US11/274,380 US27438005A US2006064812A1 US 20060064812 A1 US20060064812 A1 US 20060064812A1 US 27438005 A US27438005 A US 27438005A US 2006064812 A1 US2006064812 A1 US 2006064812A1
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- United States
- Prior art keywords
- webbing
- pool cover
- heat
- cover edge
- pool
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 238000000034 method Methods 0.000 title abstract description 14
- 230000007246 mechanism Effects 0.000 claims abstract description 6
- 230000008878 coupling Effects 0.000 claims abstract 2
- 238000010168 coupling process Methods 0.000 claims abstract 2
- 238000005859 coupling reaction Methods 0.000 claims abstract 2
- 239000011324 bead Substances 0.000 claims description 22
- 239000000945 filler Substances 0.000 claims description 20
- 239000000463 material Substances 0.000 claims description 17
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 claims description 14
- 229920002554 vinyl polymer Polymers 0.000 claims description 14
- 238000010438 heat treatment Methods 0.000 claims description 6
- 238000003825 pressing Methods 0.000 claims description 5
- 238000007789 sealing Methods 0.000 abstract description 5
- 239000000126 substance Substances 0.000 description 6
- 229920004934 Dacron® Polymers 0.000 description 4
- 239000005020 polyethylene terephthalate Substances 0.000 description 4
- 230000009182 swimming Effects 0.000 description 4
- 239000011248 coating agent Substances 0.000 description 3
- 238000000576 coating method Methods 0.000 description 3
- 239000004744 fabric Substances 0.000 description 3
- 239000004033 plastic Substances 0.000 description 3
- 229920003023 plastic Polymers 0.000 description 3
- 230000010485 coping Effects 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 238000005538 encapsulation Methods 0.000 description 2
- 230000007774 longterm Effects 0.000 description 2
- 230000000737 periodic effect Effects 0.000 description 2
- 230000008439 repair process Effects 0.000 description 2
- 238000000926 separation method Methods 0.000 description 2
- 238000001816 cooling Methods 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 238000007688 edging Methods 0.000 description 1
- 230000003628 erosive effect Effects 0.000 description 1
- 230000002452 interceptive effect Effects 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 238000009958 sewing Methods 0.000 description 1
- 238000011282 treatment Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
Images
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
- E04H4/00—Swimming or splash baths or pools
- E04H4/06—Safety devices; Coverings for baths
- E04H4/10—Coverings of flexible material
- E04H4/101—Coverings of flexible material wound-up on a fixed axis
Definitions
- the present disclosure relates to swimming pool covers, and, more particularly, to a method and apparatus for attaching webbing to the edges of pool covers.
- swimming pools are commonly covered to prevent debris from entering the pool, to preserve chemical treatments in the water and to heat the pool in the case of a solar cover.
- a pool cover will extend over the entire surface of the pool during periods of non-use and then be retracted during periods of use.
- the cover may be extended and retracted by mechanical or automatic means.
- a track assembly is usually connected to or built into the walls for guiding the edges of the cover as it traverses the pool.
- the pool cover typically has some means connected along the edge of the cover interacting with the track assembly to facilitate movement of the pool cover.
- the pool cover may be fabricated from a vinyl-coated mesh made up of a dacron thread or “skrim” covered on top and bottom by vinyl coating.
- the result is a strong, durable and waterproof material that is ideal for long-term, maintenance-free use.
- the webbing may be made out of canvas or sail cloth, so that it can endure the mechanical stresses and wear placed on it as the bead slides along the tracking assembly and as weight is placed on the cover.
- the webbing may be connected to the pool cover by thread stitches running along the webbing. Although the stitches are made of strong and durable thread, they are vulnerable to wear and may eventually wear out before the cover or the webbing. This wear occurs as the result of several factors, including ultraviolet rays from sunlight, chemical corrosion from pool chemicals and the mechanical stresses described above. Accordingly, it is not unusual for periodic repairs to be required to the thread stitching in order to maintain the integrity of the connection between the webbing and the pool cover.
- An improved webbing material and method of attaching the material to the pool cover is needed to reduce maintenance on the pool cover and to increase safety and durability for the pool cover.
- the present disclosure provides an improved method for attaching border webbing to an edge of the pool cover to form a bead for guiding the webbing along an encapsulated track.
- the border webbing is heat sealed to the edge of the pool cover to form a durable attachment thereto.
- the webbing and the edge of the pool cover are made of heat sensitive material that become plastic and form a bond with the application of heat.
- One application of the disclosure comprises a method for attaching an elongated webbing member to an edge of a pool cover, wherein the edge of the pool cover is positioned so that a portion of the pool cover edge is in contact with a portion of the webbing. The portion of the pool cover edge is then heat sealed to the portion of the webbing.
- the method further comprises wrapping the webbing around an elongated filler member, so that at least one flap extends from the filler member, positioning the portion of the pool cover edge to overlap the flap, and applying heat to cause a heat seal between the portion of the pool cover edge and the flap.
- the portion of the pool cover edge and/or the flap are composed of a heat sensitive material that will form the heat seal.
- Another application comprises a pool cover having at least one pool cover edge, a webbing coupled to at least a portion of the pool cover edge by a heat seal between a portion of the webbing and a portion of the pool cover edge.
- the portion of the webbing and/or the portion of the pool cover edge may be made of a thermoactive material, such as vinyl, that becomes plastic with the application of heat, to form the heat seal.
- thermoactive material means a material that is sufficiently sensitive to heat to become pliable or plastic in consistency, so as to provide a surface appropriate for heat welding.
- the webbing may be wrapped around a filler element to form a bead, so that the bead substantially maintains its shape under mechanical stress to guide the edge of the pool cover along a mechanical track.
- Another implementation includes an apparatus for forming a webbing attached to the edge of a pool cover, comprising a positioning element for disposing a portion of the webbing in contact with a portion of the pool cover edge and a heating element for applying heat to form a heat seal between the webbing portion and the pool cover edge portion.
- Additional optional features include a pressing element for consolidating the heat seal between the webbing portion and the pool edge cover portion.
- the positioning element may provide a flap extending from the webbing to overlap the portion of the pool cover edge and form the heat seal therewith.
- the apparatus may further comprise an element for wrapping the webbing around an elongated filler element, wherein the wrapping element forms the portion of the webbing to include at least one flap extending from the filler element.
- the portion of the pool cover edge may extend between first and second flaps of the webbing.
- the heating element may include a first nozzle to apply heat to the first flap and a second nozzle to apply heat to the second flap.
- FIG. 1 is a plan view of a pool showing a pool cover guided by a tracking assembly in the pool walls;
- FIG. 2 is a perspective view of a prior art structure showing a webbing and bead formed along the edge of the pool cover and carried in the tracking assembly;
- FIG. 3 is a perspective view of a prior art structure including an edge of a pool cover sewn to a webbing and bead for attaching to the tracking assembly of FIG. 2 ;
- FIG. 4 is a perspective view of another prior art structure including an edge of a pool cover sewn to webbing and bead for attaching to the tracking assembly of FIG. 2 ;
- FIGS. 5 A-C are schematic views showing the steps involved in fabricating a webbing structure
- FIG. 6A is a perspective view showing the webbing structure connected to an edge of the pool cover
- FIG. 6B is a side view of the webbing structure shown in FIG. 6A ;
- FIGS. 7A and 7B are side views of another implementation showing a webbing structure connected to an edge of the pool cover;
- FIG. 8 is another perspective view showing the webbing structure of FIG. 6A ;
- FIG. 9 is a schematic view of an apparatus for forming the webbing structure
- FIGS. 10 and 11 are side views of the apparatus of FIG. 9 ;
- FIG. 12 is a cross-section partial view of the side views of FIGS. 10 and 11 ;
- FIG. 13 is a side view of the apparatus of FIG. 9 with part of the apparatus rotated;
- FIG. 14 is a perspective view of the apparatus of FIG. 9 with part of the apparatus rotated.
- FIG. 15 is another perspective view of the apparatus of FIG. 9 with the apparatus in operation.
- a rectangular swimming pool 10 having a pool deck 12 and coping 14 surrounding the pool.
- An automatic pool cover 16 extends from a pool cover mechanism 18 in a cover assembly box 20 disposed at one end of the pool.
- a leading edge bar 22 at the front edge of the pool cover 16 rides in a track assembly 24 along the interior walls of the pool.
- Deck 12 is generally horizontal and is preferably constructed from concrete.
- Coping 14 connects to deck 12 in a substantially coplanar fashion along the edge of deck 12 facing the interior of swimming pool 10 .
- Track assembly 24 may be of any suitable structure to retain the edge of the pool cover as it slides in the track.
- FIG. 2 shows an encapsulation track assembly 30 having an elongated chamber 32 therein.
- the pool cover 16 is connected along its edge to an elongated bead 36 comprised of a wrapped rope or filler 35 that is captured in chamber 32 .
- the pool cover 16 extends out through a slot 38 in chamber 32 .
- Chamber 32 is sufficiently large to allow the bead 36 to slip therethrough as the cover 16 moves.
- slot 38 is ample in width to allow the pool cover edge to move easily along the slot, but is small enough to restrain the bead 36 within chamber 32 .
- FIGS. 3 and 4 prior art methods are shown, wherein bead 36 is formed by wrapping an elongated webbing member 40 around rope 36 and attaching it to pool cover 16 .
- the webbing member 40 is wrapped around the rope 36 and then sewn to the edge 31 of the pool cover 16 .
- first fold portion 41 is formed along the edge 31 of the pool cover 16 and then sewn onto the webbing 40 , using a line of thread stitching 42 .
- a second fold portion 43 is formed over the top of portion 41 and a second line of thread stitching 44 is added to secure the second fold portion 43 to the webbing 40 .
- This approach requires two sewing passes but protects one of the threads from sunlight.
- first and second fold portions 41 and 43 are formed first and then sewn with two stitch lines 45 and 46 providing a double stitching through both folds in one pass, but exposing both lines of stitching to the sunlight.
- the pool cover 16 may be fabricated from a vinyl-coated mesh made up of a dacron thread or “skrim” covered on top and bottom by vinyl coating.
- the result is a strong, durable and waterproof material that is ideal for long-term, maintenance-free use.
- the webbing may be made out of canvas or sail cloth, so that it can endure the mechanical stresses and wear placed on it as the bead 36 slides along the encapsulation assembly 30 and as weight is placed on the cover 16 .
- the thread stitches 45 and 46 or 42 and 44 are vulnerable to extensive wear. Although very strong and durable thread is used and multiple stitch lines are applied, the thread may eventually wear out before the cover or the webbing. This wear occurs as the result of several factors, including ultraviolet rays from sunlight, chemical corrosion from pool chemicals and the mechanical stresses described above. Accordingly, it is not unusual for periodic repairs to be required to the thread stitching in order to maintain the integrity of the connection between the webbing and the pool cover.
- a pool cover 50 in a first step, includes a pool cover edge 51 disposed adjacent to an elongated rope or filler member 52 .
- a webbing member 55 is disposed on the other side of the rope member 52 .
- the pool cover 50 is composed of a mesh made up of a dacron thread or “skrim” covered on top and bottom by vinyl coating.
- the webbing member 55 is composed of an extremely strong and durable fabric mesh having one side 53 coated by vinyl and the other side 56 not coated by vinyl.
- an appropriate mechanism folds webbing member 55 over filler member 52 to form upper and lower flaps 57 and 58 extending above and below pool cover edge 51 .
- the surfaces 59 and 60 of flaps 57 and 58 , respectively, that are adjacent to pool cover edge 51 are part of the vinyl-coated surface 53 and extend over the vinyl-coated pool cover edge 51 .
- FIG. 5C shows a third step, wherein upper and lower flaps 57 and 58 are formed around filler member 52 to form bead 62 . Flaps 57 and 58 are rolled flush with pool cover edge 51 . Heat and pressure are applied to form a heat weld or seal 55 comprised of bonded flaps 57 and 58 bonded on either side of pool cover edge 51 .
- FIG. 6A shows a perspective view of the heat sealed webbing 55 and pool cover edge 51 according to the present disclosure.
- Bead 62 is formed by wrapping webbing 55 around the rope or filler element 52 .
- Flaps 57 and 58 are heat sealed to the pool cover edge 51 to form a strong, durable heat seal between the flaps 57 and 58 of the webbing 55 and the pool cover 50 .
- FIG. 6B shows a side view of the structure shown in FIG. 6A .
- the bead 62 formed by the elongated filler element 52 and the webbing 55 are impervious to wear along the track assembly 30 , shown in FIG. 2
- the filler element 52 is composed of a material that substantially maintains its shape when mechanical stress and tension is applied.
- the bead 36 can slide in chamber 32 along the encapsulated track 30 without risk that the bead will deform and be pulled out of the slot 38 in chamber 32 by transverse forces acting on pool cover 16 .
- FIG. 7A shows an alternative implementation of the present disclosure wherein a webbing is attached to only one side of a pool cover by heat sealing.
- a webbing member 55 a and a filler member 52 a are disposed adjacent to the edge 51 a of a pool cover 50 a .
- Webbing member 55 a has at least one side 53 a that has a surface of vinyl or other thermoactive material.
- webbing member 55 a is wrapped around filler member 52 a to form a bead 62 a .
- the top portion of webbing 55 a forms a flap 57 a lying in contact with the top surface of pool cover edge 51 a .
- the bottom portion 54 a of webbing 55 a is disposed in contact with the undersurface 53 a of webbing member 50 a .
- the adjoining surfaces of 54 a and 55 a may be connected together by heat sealing, stitching or other procedure sufficient to secure 54 a to the portion of flap 57 a as shown.
- the adjoining surfaces of flap 57 a and pool cover edge 51 a are connected together by heat sealing, using a procedure substantially the same as previously described with respect to FIGS. 5A-5C and 6 A- 6 B.
- FIGS. 7A and 7B One advantage to the implementation disclosed in FIGS. 7A and 7B is that only a single heat seal need be formed between two adjoining surfaces. This approach will be effective if the single heat seal is strong enough to withstand the wear and stress applied to the pool cover and webbing.
- FIG. 8 is another view showing pool cover 50 attached to the heat sealed webbing 55 with a beaded edging 62 . Flap 57 of webbing member 55 is securely heat sealed to pool cover 50 .
- Filler element 52 is preferably a 1 ⁇ 4 inch woven rope, but could be made of a dacron vinyl thread or any other durable material that will hold its shape when subjected to mechanical stress and tension.
- FIGS. 9-15 show one implementation of an apparatus 70 used to form the heat sealed web element 55 .
- flaps 57 and 58 are wrapped around filler element 52 and extended adjacent to the pool cover edge 51 .
- An upper heater element 76 forces hot air through nozzle 78 and out of nozzle spout 80 .
- Spout 80 rides between upper flap 57 and the upper surface of pool cover edge 51 to apply heat to both surfaces.
- a lower heater element 82 forces hot air through a nozzle 84 and out of nozzle spout 86 between lower flap 58 and the under surface of pool cover edge 51 .
- the hot air partially melts the adjoining surfaces of the pool cover edge 51 and the inside surfaces 59 and 60 , respectively, (shown in FIG. 5B ) of upper flap 57 and lower flap 58 , respectively, so that these surfaces can form heat welded connections.
- upper roller 72 and lower roller 74 press flaps 57 and 58 against pool cover edge 51 while said surfaces are heated to form secure heat seals between the surfaces, so that the web element 55 is firmly attached to the pool cover edge 51 .
- the hot air generated by heater elements 76 and 82 may be heated to a temperature of between approximately 1000-1300 degrees Fahrenheit. Fifty pounds or more of pressure may be applied by the rollers 72 and 74 to the heated flaps 57 and 58 .
- the result is an extremely strong heat weld or seam in the heat sealed web element 55 than will withstand forces that might be expected to be applied to the pool cover 50 .
- the heat seal is not susceptible to deterioration from the sunlight or from chemical erosion. Methods of constructing such an apparatus are well known to those of skill in the art.
- the heat sealed web structure 55 above and below the pool cover edge 51 is formed in one pass of the materials through the apparatus. Heat is applied to the webbing flaps 57 and 58 at substantially the same time, and the rollers 72 and 82 confirm the heat seals to complete the sealing operation. This one pass procedure minimizes the amount of labor required to form the heat sealed webbing.
- an operator may feed the webbing member 55 and the pool cover 50 to mate with each other, as further shown in FIGS. 10-12 and as described above.
- the apparatus may be manned by one person feeding the bead 52 , the webbing member 55 , and the pool cover edge 51 between rollers 72 and 74 . Accordingly, the entire structure may be quickly and efficiently formed along the edge of a pool cover 50 .
- the nozzles 78 and 84 may be rotated away from the rollers 72 and 74 when the apparatus is not in use. This action makes it easier to set up the apparatus for operation and to clean the apparatus.
- the nozzles 78 and 84 are rotated back into an aligned position, as best seen in FIG. 10 . Then nozzles 78 and 84 are slid forward toward the rollers 72 and 74 until they are in close proximity therewith, as best seen in FIG. 11 .
- FIG. 15 is another perspective view showing the apparatus 70 in operation.
- Heater element 76 and nozzle 78 have been rotated into alignment with roller 72 .
- Nozzle 78 is twisted slightly so that nozzle spout 80 will slip beneath webbing flap 57 without nozzle 78 interfering.
- a first guide member 92 guides flap 57 toward the roller 72 .
- a second guide 94 directly in front of roller 72 maintains a slight separation between flap 57 and the edge 51 of pool cover 50 . This separation provides a space for nozzle spout 80 to inject hot air into the space to partially melt the vinyl undersurface of flap 57 and the top surface of pool cover edge 51 , as previously shown in FIGS. 10-12 .
- heater element 82 and nozzle 84 seen in FIGS. 10, 11 and 13 , have also been rotated in alignment with roller 74 .
- Guides similar to guides 92 and 94 direct the webbing 55 to roller 74 , maintaining a space for nozzle spout 86 to inject heated air to partially melt the appropriate surfaces just prior to roller 74 applying pressure to confirm the heat seal between the top surface 60 of flap 58 and the under surface of pool cover edge 51 .
- the hot air coming from nozzle foot 80 and nozzle foot 86 may provide too much heat to the flaps 57 and 58 and the pool cover edge 51 .
- the upper or lower mechanisms may be offset by a a sufficient distance (not shown) to allow cooling of the flaps 57 and 58 and pool cover edge 51 between applications of hot air from the nozzle feet 80 and 86 .
- the upper mechanisms including roller 72 , heater element 76 , nozzle 78 and nozzle foot 80 might be offset longitudinally along the service line of the pool cover edge 51 by some distance from the lower roller 76 , heater element 82 , nozzle 84 and nozzle foot 86 .
- cool air may be applied to the flaps 57 and 58 and the pool cover edge 51 to allow the bond between the lower flap 58 and the pool cover edge 51 to cool and bond.
- the hot air could be applied first to the upper flap and pool cover edge 51 and then the lower flap 58 and pool cover edge 51 could be bonded further down the service line of the pool cover edge.
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Abstract
Description
- This application is a divisional of U.S. patent application Ser. No. 10/305,467, filed Nov. 26, 2002, and entitled “Heat Sealed Webbing Method and Apparatus for Pool Covers”, by Lanny R. Smith, which claims priority under 35 U.S.C. 119(e) to provisional patent application No. 60/334,094, filed Nov. 29, 2001, the contents of which are hereby incorporated by reference.
- 1. Field
- The present disclosure relates to swimming pool covers, and, more particularly, to a method and apparatus for attaching webbing to the edges of pool covers.
- 2. Background
- Swimming pools are commonly covered to prevent debris from entering the pool, to preserve chemical treatments in the water and to heat the pool in the case of a solar cover. Typically, a pool cover will extend over the entire surface of the pool during periods of non-use and then be retracted during periods of use. The cover may be extended and retracted by mechanical or automatic means. In either case, a track assembly is usually connected to or built into the walls for guiding the edges of the cover as it traverses the pool. The pool cover typically has some means connected along the edge of the cover interacting with the track assembly to facilitate movement of the pool cover.
- The pool cover may be fabricated from a vinyl-coated mesh made up of a dacron thread or “skrim” covered on top and bottom by vinyl coating. The result is a strong, durable and waterproof material that is ideal for long-term, maintenance-free use. The webbing may be made out of canvas or sail cloth, so that it can endure the mechanical stresses and wear placed on it as the bead slides along the tracking assembly and as weight is placed on the cover.
- The webbing may be connected to the pool cover by thread stitches running along the webbing. Although the stitches are made of strong and durable thread, they are vulnerable to wear and may eventually wear out before the cover or the webbing. This wear occurs as the result of several factors, including ultraviolet rays from sunlight, chemical corrosion from pool chemicals and the mechanical stresses described above. Accordingly, it is not unusual for periodic repairs to be required to the thread stitching in order to maintain the integrity of the connection between the webbing and the pool cover.
- Accordingly, there is an important need for an improved connection between the pool cover and the webbing that forms the edge bead for the pool cover. An improved webbing material and method of attaching the material to the pool cover is needed to reduce maintenance on the pool cover and to increase safety and durability for the pool cover.
- The present disclosure provides an improved method for attaching border webbing to an edge of the pool cover to form a bead for guiding the webbing along an encapsulated track. The border webbing is heat sealed to the edge of the pool cover to form a durable attachment thereto. The webbing and the edge of the pool cover are made of heat sensitive material that become plastic and form a bond with the application of heat.
- One application of the disclosure comprises a method for attaching an elongated webbing member to an edge of a pool cover, wherein the edge of the pool cover is positioned so that a portion of the pool cover edge is in contact with a portion of the webbing. The portion of the pool cover edge is then heat sealed to the portion of the webbing.
- The method further comprises wrapping the webbing around an elongated filler member, so that at least one flap extends from the filler member, positioning the portion of the pool cover edge to overlap the flap, and applying heat to cause a heat seal between the portion of the pool cover edge and the flap. Preferably, the portion of the pool cover edge and/or the flap are composed of a heat sensitive material that will form the heat seal.
- Another application comprises a pool cover having at least one pool cover edge, a webbing coupled to at least a portion of the pool cover edge by a heat seal between a portion of the webbing and a portion of the pool cover edge.
- Additionally, the portion of the webbing and/or the portion of the pool cover edge may be made of a thermoactive material, such as vinyl, that becomes plastic with the application of heat, to form the heat seal. As used herein, the term “thermoactive material” means a material that is sufficiently sensitive to heat to become pliable or plastic in consistency, so as to provide a surface appropriate for heat welding. The webbing may be wrapped around a filler element to form a bead, so that the bead substantially maintains its shape under mechanical stress to guide the edge of the pool cover along a mechanical track.
- Another implementation includes an apparatus for forming a webbing attached to the edge of a pool cover, comprising a positioning element for disposing a portion of the webbing in contact with a portion of the pool cover edge and a heating element for applying heat to form a heat seal between the webbing portion and the pool cover edge portion.
- Additional optional features include a pressing element for consolidating the heat seal between the webbing portion and the pool edge cover portion. The positioning element may provide a flap extending from the webbing to overlap the portion of the pool cover edge and form the heat seal therewith. The apparatus may further comprise an element for wrapping the webbing around an elongated filler element, wherein the wrapping element forms the portion of the webbing to include at least one flap extending from the filler element. The portion of the pool cover edge may extend between first and second flaps of the webbing. The heating element may include a first nozzle to apply heat to the first flap and a second nozzle to apply heat to the second flap.
- The above-mentioned and other features and advantages of this disclosure, and the manner of attaining them, will become more apparent and the disclosure will be better understood by reference to the following description of an example taken in conjunction with the accompanying drawings, wherein:
-
FIG. 1 is a plan view of a pool showing a pool cover guided by a tracking assembly in the pool walls; -
FIG. 2 is a perspective view of a prior art structure showing a webbing and bead formed along the edge of the pool cover and carried in the tracking assembly; -
FIG. 3 is a perspective view of a prior art structure including an edge of a pool cover sewn to a webbing and bead for attaching to the tracking assembly ofFIG. 2 ; -
FIG. 4 is a perspective view of another prior art structure including an edge of a pool cover sewn to webbing and bead for attaching to the tracking assembly ofFIG. 2 ; - FIGS. 5 A-C are schematic views showing the steps involved in fabricating a webbing structure;
-
FIG. 6A is a perspective view showing the webbing structure connected to an edge of the pool cover; -
FIG. 6B is a side view of the webbing structure shown inFIG. 6A ; -
FIGS. 7A and 7B are side views of another implementation showing a webbing structure connected to an edge of the pool cover; -
FIG. 8 is another perspective view showing the webbing structure ofFIG. 6A ; -
FIG. 9 is a schematic view of an apparatus for forming the webbing structure; -
FIGS. 10 and 11 are side views of the apparatus ofFIG. 9 ; -
FIG. 12 is a cross-section partial view of the side views ofFIGS. 10 and 11 ; -
FIG. 13 is a side view of the apparatus ofFIG. 9 with part of the apparatus rotated; -
FIG. 14 is a perspective view of the apparatus ofFIG. 9 with part of the apparatus rotated; and -
FIG. 15 is another perspective view of the apparatus ofFIG. 9 with the apparatus in operation. - Corresponding reference characters indicate corresponding parts throughout the several views. The exemplification set out herein illustrates one example, in one form, and such exemplification is not to be construed as limiting the scope of the disclosure in any manner.
- In
FIG. 1 , arectangular swimming pool 10 is shown having apool deck 12 and coping 14 surrounding the pool. Anautomatic pool cover 16 extends from apool cover mechanism 18 in acover assembly box 20 disposed at one end of the pool. Aleading edge bar 22 at the front edge of thepool cover 16 rides in atrack assembly 24 along the interior walls of the pool.Deck 12 is generally horizontal and is preferably constructed from concrete. Coping 14 connects todeck 12 in a substantially coplanar fashion along the edge ofdeck 12 facing the interior ofswimming pool 10.Track assembly 24 may be of any suitable structure to retain the edge of the pool cover as it slides in the track. -
FIG. 2 shows anencapsulation track assembly 30 having anelongated chamber 32 therein. Thepool cover 16 is connected along its edge to anelongated bead 36 comprised of a wrapped rope orfiller 35 that is captured inchamber 32. Thepool cover 16 extends out through aslot 38 inchamber 32.Chamber 32 is sufficiently large to allow thebead 36 to slip therethrough as thecover 16 moves. Likewise,slot 38 is ample in width to allow the pool cover edge to move easily along the slot, but is small enough to restrain thebead 36 withinchamber 32. - In
FIGS. 3 and 4 , prior art methods are shown, whereinbead 36 is formed by wrapping anelongated webbing member 40 aroundrope 36 and attaching it to poolcover 16. Thewebbing member 40 is wrapped around therope 36 and then sewn to theedge 31 of thepool cover 16. - In
FIG. 3 , afirst fold portion 41 is formed along theedge 31 of thepool cover 16 and then sewn onto thewebbing 40, using a line ofthread stitching 42. Asecond fold portion 43 is formed over the top ofportion 41 and a second line ofthread stitching 44 is added to secure thesecond fold portion 43 to thewebbing 40. This approach requires two sewing passes but protects one of the threads from sunlight. InFIG. 4 , first andsecond fold portions stitch lines - As previously mentioned, the
pool cover 16 may be fabricated from a vinyl-coated mesh made up of a dacron thread or “skrim” covered on top and bottom by vinyl coating. The result is a strong, durable and waterproof material that is ideal for long-term, maintenance-free use. The webbing may be made out of canvas or sail cloth, so that it can endure the mechanical stresses and wear placed on it as thebead 36 slides along theencapsulation assembly 30 and as weight is placed on thecover 16. - The thread stitches 45 and 46 or 42 and 44 are vulnerable to extensive wear. Although very strong and durable thread is used and multiple stitch lines are applied, the thread may eventually wear out before the cover or the webbing. This wear occurs as the result of several factors, including ultraviolet rays from sunlight, chemical corrosion from pool chemicals and the mechanical stresses described above. Accordingly, it is not unusual for periodic repairs to be required to the thread stitching in order to maintain the integrity of the connection between the webbing and the pool cover.
- Looking now at FIGS. 5A-C, a preferred application of the method of the present disclosure is shown. As shown in
FIG. 5A , in a first step, apool cover 50 includes apool cover edge 51 disposed adjacent to an elongated rope orfiller member 52. Awebbing member 55 is disposed on the other side of therope member 52. Preferably thepool cover 50 is composed of a mesh made up of a dacron thread or “skrim” covered on top and bottom by vinyl coating. Thewebbing member 55 is composed of an extremely strong and durable fabric mesh having oneside 53 coated by vinyl and theother side 56 not coated by vinyl. - As shown in
FIG. 5B , in a second step, an appropriate mechanism (not shown) foldswebbing member 55 overfiller member 52 to form upper andlower flaps pool cover edge 51. Thesurfaces flaps cover edge 51 are part of the vinyl-coatedsurface 53 and extend over the vinyl-coatedpool cover edge 51. -
FIG. 5C shows a third step, wherein upper andlower flaps filler member 52 to formbead 62.Flaps pool cover edge 51. Heat and pressure are applied to form a heat weld or seal 55 comprised of bondedflaps pool cover edge 51. -
FIG. 6A shows a perspective view of the heat sealedwebbing 55 andpool cover edge 51 according to the present disclosure.Bead 62 is formed by wrappingwebbing 55 around the rope orfiller element 52.Flaps pool cover edge 51 to form a strong, durable heat seal between theflaps webbing 55 and thepool cover 50. -
FIG. 6B shows a side view of the structure shown inFIG. 6A . Preferably, thebead 62 formed by theelongated filler element 52 and thewebbing 55 are impervious to wear along thetrack assembly 30, shown inFIG. 2 , and thefiller element 52 is composed of a material that substantially maintains its shape when mechanical stress and tension is applied. Thus, as shown inFIG. 2 , thebead 36 can slide inchamber 32 along the encapsulatedtrack 30 without risk that the bead will deform and be pulled out of theslot 38 inchamber 32 by transverse forces acting onpool cover 16. -
FIG. 7A shows an alternative implementation of the present disclosure wherein a webbing is attached to only one side of a pool cover by heat sealing. Awebbing member 55 a and afiller member 52 a are disposed adjacent to theedge 51 a of apool cover 50 a.Webbing member 55 a has at least oneside 53 a that has a surface of vinyl or other thermoactive material. - As shown in
FIG. 7 A-B,webbing member 55 a is wrapped aroundfiller member 52 a to form abead 62 a. The top portion of webbing 55 a forms aflap 57 a lying in contact with the top surface ofpool cover edge 51 a. Thebottom portion 54 a ofwebbing 55 a is disposed in contact with the undersurface 53 a ofwebbing member 50 a. The adjoining surfaces of 54 a and 55 a may be connected together by heat sealing, stitching or other procedure sufficient to secure 54 a to the portion offlap 57 a as shown. The adjoining surfaces offlap 57 a andpool cover edge 51 a are connected together by heat sealing, using a procedure substantially the same as previously described with respect toFIGS. 5A-5C and 6A-6B. - One advantage to the implementation disclosed in
FIGS. 7A and 7B is that only a single heat seal need be formed between two adjoining surfaces. This approach will be effective if the single heat seal is strong enough to withstand the wear and stress applied to the pool cover and webbing. -
FIG. 8 is another view showingpool cover 50 attached to the heat sealedwebbing 55 with a beaded edging 62.Flap 57 ofwebbing member 55 is securely heat sealed topool cover 50.Filler element 52 is preferably a ¼ inch woven rope, but could be made of a dacron vinyl thread or any other durable material that will hold its shape when subjected to mechanical stress and tension. -
FIGS. 9-15 show one implementation of anapparatus 70 used to form the heat sealedweb element 55. As best seen inFIGS. 10-12 , flaps 57 and 58 are wrapped aroundfiller element 52 and extended adjacent to thepool cover edge 51. Anupper heater element 76 forces hot air throughnozzle 78 and out ofnozzle spout 80.Spout 80 rides betweenupper flap 57 and the upper surface ofpool cover edge 51 to apply heat to both surfaces. Similarly, alower heater element 82 forces hot air through anozzle 84 and out ofnozzle spout 86 betweenlower flap 58 and the under surface ofpool cover edge 51. - Looking particularly at
FIG. 12 , the hot air partially melts the adjoining surfaces of thepool cover edge 51 and the inside surfaces 59 and 60, respectively, (shown inFIG. 5B ) ofupper flap 57 andlower flap 58, respectively, so that these surfaces can form heat welded connections. As seen inFIGS. 10 and 11 ,upper roller 72 andlower roller 74 press flaps 57 and 58 againstpool cover edge 51 while said surfaces are heated to form secure heat seals between the surfaces, so that theweb element 55 is firmly attached to thepool cover edge 51. - The hot air generated by
heater elements rollers heated flaps web element 55 than will withstand forces that might be expected to be applied to thepool cover 50. The heat seal is not susceptible to deterioration from the sunlight or from chemical erosion. Methods of constructing such an apparatus are well known to those of skill in the art. - Moreover, the heat sealed
web structure 55 above and below thepool cover edge 51, as described above, is formed in one pass of the materials through the apparatus. Heat is applied to the webbing flaps 57 and 58 at substantially the same time, and therollers - In operation, an operator may feed the
webbing member 55 and thepool cover 50 to mate with each other, as further shown inFIGS. 10-12 and as described above. The apparatus may be manned by one person feeding thebead 52, thewebbing member 55, and thepool cover edge 51 betweenrollers pool cover 50. - Referring now to
FIGS. 13 and 14 , it can be seen that thenozzles rollers nozzles FIG. 10 . Then nozzles 78 and 84 are slid forward toward therollers FIG. 11 . -
FIG. 15 is another perspective view showing theapparatus 70 in operation.Heater element 76 andnozzle 78 have been rotated into alignment withroller 72.Nozzle 78 is twisted slightly so thatnozzle spout 80 will slip beneathwebbing flap 57 withoutnozzle 78 interfering. Afirst guide member 92guides flap 57 toward theroller 72. Asecond guide 94 directly in front ofroller 72 maintains a slight separation betweenflap 57 and theedge 51 ofpool cover 50. This separation provides a space fornozzle spout 80 to inject hot air into the space to partially melt the vinyl undersurface offlap 57 and the top surface ofpool cover edge 51, as previously shown inFIGS. 10-12 . - An substantially identical operation occurs on the underside of
apparatus 70. Although not shown,heater element 82 andnozzle 84, seen inFIGS. 10, 11 and 13, have also been rotated in alignment withroller 74. Guides (not shown) similar toguides webbing 55 toroller 74, maintaining a space fornozzle spout 86 to inject heated air to partially melt the appropriate surfaces just prior toroller 74 applying pressure to confirm the heat seal between thetop surface 60 offlap 58 and the under surface ofpool cover edge 51. - It is understood that variations of the above preferred implementation might be employed within the scope of the disclosure. For example, in some cases the hot air coming from
nozzle foot 80 andnozzle foot 86 may provide too much heat to theflaps pool cover edge 51. In such case the upper or lower mechanisms may be offset by a a sufficient distance (not shown) to allow cooling of theflaps pool cover edge 51 between applications of hot air from thenozzle feet - Thus, the upper mechanisms, including
roller 72,heater element 76,nozzle 78 andnozzle foot 80 might be offset longitudinally along the service line of thepool cover edge 51 by some distance from thelower roller 76,heater element 82,nozzle 84 andnozzle foot 86. In the interim space, cool air may be applied to theflaps pool cover edge 51 to allow the bond between thelower flap 58 and thepool cover edge 51 to cool and bond. Conversely, the hot air could be applied first to the upper flap andpool cover edge 51 and then thelower flap 58 andpool cover edge 51 could be bonded further down the service line of the pool cover edge. - Although the above applications are representative of the present disclosure, other applications will be apparent to those skilled in the art from a consideration of this specification and the appended claims, or from a practice of the applications of the disclosure. It is intended that the specification and applications therein be considered as exemplary only, with the present disclosure being defined by the claims and their equivalents.
Claims (22)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/274,380 US20060064812A1 (en) | 2001-11-29 | 2005-11-14 | Heat sealed webbing method and apparatus for pool covers |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US33409401P | 2001-11-29 | 2001-11-29 | |
US10/305,467 US6991700B2 (en) | 2001-11-29 | 2002-11-26 | Heat sealed webbing method and apparatus for pool covers |
US11/274,380 US20060064812A1 (en) | 2001-11-29 | 2005-11-14 | Heat sealed webbing method and apparatus for pool covers |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/305,467 Division US6991700B2 (en) | 2001-11-29 | 2002-11-26 | Heat sealed webbing method and apparatus for pool covers |
Publications (1)
Publication Number | Publication Date |
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US20060064812A1 true US20060064812A1 (en) | 2006-03-30 |
Family
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Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
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US10/305,467 Expired - Lifetime US6991700B2 (en) | 2001-11-29 | 2002-11-26 | Heat sealed webbing method and apparatus for pool covers |
US11/274,380 Abandoned US20060064812A1 (en) | 2001-11-29 | 2005-11-14 | Heat sealed webbing method and apparatus for pool covers |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
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US10/305,467 Expired - Lifetime US6991700B2 (en) | 2001-11-29 | 2002-11-26 | Heat sealed webbing method and apparatus for pool covers |
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US (2) | US6991700B2 (en) |
Cited By (11)
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US20100199417A1 (en) * | 2009-02-09 | 2010-08-12 | Shebek Michael J | Reel for an automatic pool cover assembly |
USD791966S1 (en) | 2016-01-28 | 2017-07-11 | North Star Technology International Limited | Swimming pool |
USD793576S1 (en) | 2016-02-02 | 2017-08-01 | North Star Technology International Limited | Swimming pool |
USD794214S1 (en) | 2016-02-11 | 2017-08-08 | North Star Technology International Limited | Swimming pool |
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USD794212S1 (en) | 2016-01-28 | 2017-08-08 | North Star Technology International Limited | Swimming pool |
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USD800919S1 (en) | 2016-02-11 | 2017-10-24 | North Star Technology International Limited | Swimming pool |
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US7114297B2 (en) * | 2002-01-16 | 2006-10-03 | Pool Cover Specialists National, Inc. | Radius corner plate for a pool |
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US8584271B2 (en) * | 2007-12-13 | 2013-11-19 | Pool Cover Specialists National, Inc. | Corner plate for holding a pool liner |
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US20110067791A1 (en) * | 2009-09-24 | 2011-03-24 | Karyn Bussman | Outdoor furniture, pool and pool-related equipment coverings and methods of production thereof |
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US20190106309A1 (en) * | 2017-10-05 | 2019-04-11 | MCF Distributing, LLC | Shield Assembly For Basket Of Aerial Work Platform |
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US20100199417A1 (en) * | 2009-02-09 | 2010-08-12 | Shebek Michael J | Reel for an automatic pool cover assembly |
USD791966S1 (en) | 2016-01-28 | 2017-07-11 | North Star Technology International Limited | Swimming pool |
USD794212S1 (en) | 2016-01-28 | 2017-08-08 | North Star Technology International Limited | Swimming pool |
USD793576S1 (en) | 2016-02-02 | 2017-08-01 | North Star Technology International Limited | Swimming pool |
USD794213S1 (en) | 2016-02-02 | 2017-08-08 | Horizon Marketing International Limited | Swimming pool |
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USD800340S1 (en) | 2016-11-03 | 2017-10-17 | North Star Technology International Limited | Swimming pool |
Also Published As
Publication number | Publication date |
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US20030097709A1 (en) | 2003-05-29 |
US6991700B2 (en) | 2006-01-31 |
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