(12) United States Patent
`Saputo et al.
`
`(10) Patent No.:
`(45) Date of Patent:
`
`US 6,571,405 B1
`Jun. 3, 2003
`
`US006571.405B1
`
`(54)
`
`(75)
`
`(73)
`
`(*)
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`(21)
`(22)
`
`(63)
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`(51)
`(52)
`(58)
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`(56)
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`LARGE CAPACITY REINFORCED
`SWIMMING POOL
`
`Inventors: Richard A. Saputo, Tarzana, CA (US);
`Hua Hsiang Lin, Kowloon (HK);
`Yaw-Yuan Hsu, Taipei (TW); Jia-Hua
`Chen, Taipei (TW)
`Assignee: Intex Recreation Corp., Long Beach,
`CA (US)
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 0 days.
`
`Notice:
`
`Appl. No.: 10/040,324
`Filed:
`Oct. 16, 2001
`Related U.S. Application Data
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`2,839,762 A 6/1958 Nomura
`3,150,795 A * 9/1964 Schlumberger ......... 220/678 X
`4,538,311 A 9/1985 Hall et al.
`5,416,932 A 5/1995 Ventrice
`5,603,129 A
`2/1997 Chou
`5,652,972 A 8/1997 Chartrand
`5,736,719 A 4/1998 Lawson et al.
`5,815,853 A 10/1998 Chase
`
`* cited by examiner
`
`Primary Examiner—Robert M. Fetsuga
`(74) Attorney, Agent, or Firm—Lewis, Brisbois, Bisgaard
`& Smith LLP
`ABSTRACT
`(57)
`A large capacity reinforced swimming pool for use in an
`above-the-ground environment includes a flexible plastic
`liner for containing water. The liner includes a continuous
`sidewall and a bottom wall bonded to the sidewall by a
`Continuation-in-part of application No. 09/400,175, filed on
`joining seam. The continuous sidewall is formed from a
`Sep. 21, 1999, now abandoned.
`partial outer layer and a partial inner layer. An inflatable top
`ring is mounted to the top of the sidewall for supporting the
`Int. Cl." … E04H 4/14
`liner in an upright position. A continuous reinforcing layer
`U.S. Cl. ............................................ 4/506; 220/613
`is bonded to the continuous sidewall with a first plurality of
`Field of Search ..................... 4/506, 513; 220/613,
`continuous reinforcing seals for reinforcing the sidewall. A
`220/678
`second plurality of continuous reinforcing seals located at an
`interface between the partial outer layer and the partial inner
`layer of the sidewall functions to reinforce the sidewall.
`Each of the first and second plurality of continuous rein
`forcing seals includes at least two seals.
`
`1,961,061 A 5/1934 McCulloch
`2,529,872 A 11/1950 Hasselquist
`2,551,673 A 5/1951 Hasselquist
`
`
`
`14 Claims, 2 Drawing Sheets
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`U.S. Patent
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`Jun. 3, 2003
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`Sheet 1 of 2
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`US 6,571,405 B1
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`U.S. Patent
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`Jun. 3, 2003
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`Sheet 2 of 2
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`US 6,571,405 B1
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`FIG, 4 3&
`º
`NNNNNNNNNNNNNNNNNS
`ZZZZZZZZZZZZZZZZZ
`112
`112
`SNSSSSSSSSSSSSSSS
`126
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`108
`ZZZZZZZZZZZZZZZZZZZZZZ
`SNNNNNNNNNNNSSSSSSSNSS
`110~3.
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`110-~33
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`ZZZZZZZZZZZZZZZZZZZZZZ
`SNNNNNNNNNNNNNNNNNNNNNN
`110-~ZZZZZZZZZZZZZZZZZZZZZZ
`FIG. 5
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`1
`LARGE CAPACITY REINFORCED
`SWIMMING POOL
`
`This application is a continuation-in-part of Ser. No.
`09/400,175 filed Sep. 21, 1999 now abandoned.
`
`5
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`BACKGROUND OF THE INVENTION
`
`1. Field of the Invention
`The present invention relates to above-the-ground swim
`ming pools. More specifically, the present invention relates
`to methods and apparatus for a large capacity reinforced
`swimming pool for use above-the-ground which includes a
`continuous reinforcing layer bonded to a sidewall with a first
`plurality of reinforcing seals and a second plurality of
`reinforcing seals for reinforcing the sidewall against failing
`due to excessive water pressure.
`2. Description of the Prior Art
`The prior art is directed to methods and apparatus for
`above-the-ground, large capacity swimming pools formed
`from flexible polymeric sheeting such as polyvinylchloride
`and typically used in the out-of-doors.
`The science of dielectrically or Radio Frequency (RF)
`sealing polymeric or polyvinylchloride (PVC) materials of
`the prior art is well known in the plastics industry. The use
`of PVC sheeting for both in-the-ground and above-the
`ground pool liners has become more popular in recent years.
`The initial applications of these pool liners originated with
`the PVC sheeting being used as pond and ditch liners.
`However, the uses of PVC sheeting has been expanded. As
`the strength of above-the-ground pool liners improved
`(including those supported by a skeletonal metal or plastic
`framework and those that were unsupported), the greater the
`depth of water the prior art pool liners could support. As a
`consequence, the resulting stress and strain on the above
`the-ground prior art pool liners increased as the depth of
`water in the pool increased. Is it understood that if the stress
`and strain from the pressure created by the water in the pool
`exceeds a certain threshold, the seams (typically known as
`“joint seams”) that seal the liner sections together will leak
`or burst. This leakage in prior art pools typically occurred in
`the vertical sidewall of the liner especially when the static
`pressure of the water was augmented by the dynamic
`pressure created by people moving about in the pool.
`In the prior art, a method used to counter or offset the
`harmful effects of the excessive water pressure on the
`sidewall of the pool was to increase the wall thickness and
`thus the strength of the liner. This prior art solution applied
`to any polymeric or plastic material. Thus, if the pool liner
`was a single sheet, i.e., single-ply, of polyvinylchloride
`(PVC), then the PVC sheet could be calendered thicker
`(where calendering is the manufacturing process of produc
`ing flexible PVC sheeting). In the limit, the point of dimin
`ishing returns was reached wherein calendering a thicker or
`heavier PVC liner sheet was no longer cost effective.
`Another common technique employed in the prior art for
`producing stronger polymeric or plastic wall sheets involved
`bonding materials together in a lamination. This type of
`prior art lamination method is similar to lamination methods
`used in producing plywood sheets for the home construction
`industry.
`In the plywood lamination method, two or more layers of
`thin wood were bonded together in a lamination resulting in
`plywood strengths far exceeding the sum total of the
`strengths of the individual layers. In the case of PVC
`laminations, it has been common practice in the prior art to
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`sandwich a layer of synthetic fiber typically referred to as
`“scrim” between two PVC layers. An example of such a
`synthetic fiber sandwich known in the prior art includes a
`layer of polyester placed between two layers of PVC sheet
`ing. The sandwich was then bonded together thermally
`and/or with an adhesive solution. Various lamination wall
`thicknesses with varying strengths could be achieved by
`varying the thicknesses of the PVC sheets and/or by varying
`the per square inch thread count of the scrim.
`In the prior art, if (a) the single-ply PVC liner sheet is
`calendered thicker, or (b) the thickness of the PVC lamina
`tion is increased, unnecessarily high costs of materials are
`experienced if the increased thickness is applied to the entire
`sidewall. The strength required in the pool liner to offset the
`stress and strain of the water pressure is only required in the
`lower portion of the pool liner where the water pressure is
`the greatest. Consequently, if the increased thickness of
`materials is applied to the entire pool sidewall, the pool liner
`could be constructed to have a higher level of strength in the
`upper portion thereof then is necessary. This design of prior
`art pool liners can result in excessively high cost.
`References describing flexible swimming pools of the
`prior art refer to single flexible plastic sheet components as
`being “united”. In the prior art, “united” components or
`sections enable the flexible pool apparatus to be assembled.
`The “united” portions are typically known in the prior art as
`a “joining seam”. These “joining seams” are typically
`formed on relatively low power machines for this purpose
`(for example, ten kilowatt peak load having low pressure in
`pounds per square inch (psi) applied to PVC sheeting).
`Consequently, lower bonding heat is generated and less
`pressure is applied to the PVC sheeting materials so that all
`of the air gaps between the PVC sheet materials are not
`eliminated. The end result of this process produces a low
`power bond suitable for joining seams in products com
`prised of flexible PVC sheeting which do not require high
`strength seams or joints. Joining seams are low strength
`conventional seams known in the art and serve to join two
`or more plastic PVC pieces together. The bonding can be
`accomplished by the use of thermal, radio frequency
`(dielectric), ultrasonic and adhesive methods. In the thermal
`method, heat is employed to join (i.e., melt) the PVC
`sheeting components together. In the radio frequency or
`dielectric method, friction in the form of kinetic energy is
`generated within the PVC sheet materials that creates the
`bond. In the ultrasonic method, sound waves also create
`kinetic energy that enable the molecules of the two PVC
`sheets to marry together. Finally, use of adhesives serve to
`mechanically bond the two PVC sheets together.
`Certain prior art patent references will be mentioned
`including U.S. Pat. No. 2,529,872 to Hasselquist, U.S. Pat.
`No. 2,551,673 to Hasselquist, and U.S. Pat. No. 1,961,061 to
`McCulloch. None of these patent references are directed to
`a large capacity swimming pool capable of containing a high
`volume of water. U.S. Pat. No. 2,529,872 to Hasselquist
`entitled Collapsible Container is prior art which specifically
`refers to portable wading pools, portable baths, wash tubs,
`and stock watering tanks. The single seals disclosed in
`Hasselduist '872 are conventional “joining seams” located at
`separate locations. Seam 22 functions as a single conven
`tional joining seam to connect the sidewall to the bottom
`piece. Seam 23 serves as a single conventional joining seam
`that forms the closure of an air chamber. Seams 15, 28 and
`38 are also single conventional seams (in different
`embodiments) to serve to close an air chamber 16, 26 or 41.
`Each of these single conventional seams are located in
`different locations and assist in the assembly of the collaps
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`US 6,571,405 B1
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`ible container. They do not serve a reinforcing function. The
`air chamber 16, 26 or 41 includes a vent 27 for trapping, not
`injecting, air therein. The drawing Figs. accompanying the
`’872 patent specification illustrate two small children stand
`ing in a small child’s wading pool that has been filled by
`using a garden hose.
`U.S. Pat. No. 2,551,673 to Hasselquist entitled Collaps
`ible Container is prior art which also specifically refers to
`portable wading pools, portable storage tanks, baths, wash
`tubs, and stock watering tanks and containers. The ’673
`patent specifically refers to providing improvements in the
`Hasselduist '872 patent and thus discloses only single con
`ventional joining seams for enabling the assembly of the
`wading pool. The joining seams are separated and are not
`used in any reinforcing capacity, for example, bottom cir
`cumferential seam 11. An annular sidewall 12 exhibits a
`double-walled construction and thus any reinforcing is pro
`vided by multiple full layers of material and not a reinforc
`ing layer in combination with a plurality of reinforcing seals.
`The drawings accompanying the Hasselduist '673 patent
`also illustrate a small child’s wading pool.
`U.S. Pat. No. 1,961,061 to McCulloch entitled Collaps
`ible Bathing Pool is prior art which specifically recites
`containers for water of a collapsible and portable nature. The
`different sections of water holding material are described as
`being “suitable united” which clearly indicates that the pool
`is assembled with single conventional “joining seams”. A
`plurality of reinforcing seals is not disclosed. A reinforce
`ment of the sidewall is disclosed as being integral with one
`or more thicknesses of material from which the sidewalls are
`made. The reinforcement essentially is a separate sidewall
`layer, not a continuous reinforcing layer or strip including a
`plurality of reinforcing seals.
`Thus, there is a need in the art for a large capacity
`reinforced swimming pool which exhibits a lamination-to
`lamination bond about the horizontal perimeter of the pool
`which includes a continuous reinforcing layer and a first and
`second plurality of reinforcing seals which significantly
`improves the strength of the sidewall of the swimming pool
`against failure or bursting, while simultaneously providing a
`thin-walled, lightweight, robust, durable, flexible construc
`tion suitable for above-the-ground large capacity swimming
`pools containing a high volume of water.
`SUMMARY OF THE INVENTION
`Briefly, and in general terms, the present invention pro
`vides a new and improved large capacity reinforced swim
`ming pool for use in the above-the-ground environment
`which includes a continuous reinforcing layer in combina
`tion with a first plurality of continuous reinforcing seals and
`additionally a second plurality of continuous reinforcing
`seals, each for reinforcing a continuous sidewall and for
`preventing the failure thereof due to excessive water pres
`sure in a lower half of the large capacity reinforced swim
`ming pool.
`In a preferred embodiment, the large capacity reinforced
`swimming pool includes a flexible liner typically comprised
`of a suitable plastic such as polyvinylchloride (PVC) sheet
`ing for containing a fluid such as water. The plastic liner is
`typically circular in shape but can also exhibit other shapes
`including a rectangular shape. The plastic liner includes a
`continuous sidewall and a single-ply bottom wall fused to
`the sidewall with a joining seam. In the preferred
`embodiment, the continuous sidewall is formed from a
`partial outer layer and a partial inner layer. Mounted on top
`of the flexible liner via a joining seam is an inflatable top
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`ring that when charged with air causes the plastic liner to be
`supported in an upright position when the pool is filled with
`Water.
`In the present invention, the continuous sidewall is rein
`forced to counter the pressure applied to the sidewall of the
`plastic liner by the static and dynamic pressure of the water
`in the large capacity reinforced swimming pool. In order to
`accomplish this goal, the sidewall includes a separate con
`tinuous reinforcing layer bonded to the continuous sidewall
`via a first plurality of continuous reinforcing seals. To
`further increase the reinforcement, the continuous sidewall
`also includes a second plurality of continuous reinforcing
`seals which are located between the partial outer layer and
`the partial inner layer of the sidewall. The bottom wall is
`separately attached to the continuous sidewall at an interface
`between the partial inner layer of the continuous sidewall
`and the bottom wall by a joining seam.
`The present invention is generally directed to an above
`the-ground, large capacity reinforced swimming pool for use
`in the out-of-doors. The inventive large capacity reinforced
`swimming pool provides an attractive and economical solu
`tion to an otherwise persistent problem. The reinforcing
`components need only be applied to a lower half of the
`swimming pool where the pressure applied to the sidewall
`from the water is the greatest. Further, the reinforcing
`scheme utilized, i.e., the width of the continuous reinforcing
`seals, can be varied depending upon the size and water
`volume capacity of the pool. In its most fundamental
`embodiment, the large capacity reinforced swimming pool
`includes a flexible plastic liner for containing water. The
`liner includes a continuous sidewall and a bottom wall
`bonded to the sidewall by a joining seam. The continuous
`sidewall is formed from a partial outer layer and a partial
`inner layer. An inflatable top ring is mounted to the top of the
`sidewall for supporting the liner in an upright position. A
`continuous reinforcing layer is bonded to the continuous
`sidewall with a first plurality of continuous reinforcing seals
`for reinforcing the sidewall. A second plurality of continu
`ous reinforcing seals located at an interface between the
`partial outer layer and the partial inner layer of the sidewall
`function to reinforce the sidewall. Each of the first and
`second plurality of reinforcing seals comprise at least two
`seals.
`These and other objects and advantages of the present
`invention will become apparent from the following more
`detailed description, taken in conjunction with the accom
`panying drawings which illustrate the invention, by way of
`example.
`BRIEF DESCRIPTION OF THE DRAWINGS
`FIG. 1 is a perspective view including a cutaway portion
`of a large capacity reinforced swimming pool of the present
`invention having a flexible plastic liner and an inflatable top
`ring for causing the swimming pool to remain in the upright
`position.
`FIG. 2 is an end view in perspective of the large capacity
`reinforced swimming pool of FIG. 1 showing the detail of
`the cutaway portion including the inflatable top ring, a
`continuous sidewall having a partial outer layer and a partial
`inner layer, a continuous reinforcing layer having a first
`plurality of continuous reinforcing seals, a second plurality
`of continuous reinforcing seals, and a bottom wall.
`FIG. 3 is a top planar view of the bottom wall of the large
`capacity reinforced swimming pool of FIG. 1 showing a
`plurality of sections intended to provide reinforcing to the
`bottom portion of the large capacity reinforced swimming
`pool.
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`US 6,571,405 B1
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`5
`FIG. 4 is a cross-sectional view of the large capacity
`reinforced swimming pool of FIG. 1 taken along the line
`4–4 of FIG. 2 and showing a conventional joint seam for
`joining the partial outer layer and the partial inner layer of
`the continuous sidewall, and showing the second plurality of
`continuous reinforcing seals placed in juxtaposition to the
`conventional joint seam.
`FIG. 5 is another cross-sectional view of the large capac
`ity reinforced swimming pool of FIG. 1 taken along the line
`5—5 of FIG. 2 and showing the continuous reinforcing layer
`which includes the first plurality of continuous reinforcing
`seals with each adjacent pair of reinforcing seals separated
`by a gap of unsealed polyvinylchloride material.
`
`DESCRIPTION OF THE INVENTION
`The present invention is a large capacity reinforced swim
`ming pool 100 having a minimum of a twelve foot diameter
`and a minimum water volume capacity of one-thousand U.S.
`gallons. Typically, the diameter of and the water volume
`capacity of the large capacity reinforced swimming pool 100
`is greater. The large capacity reinforced swimming pool 100
`is designed to accommodate several persons.
`A preferred embodiment of the present invention of the
`large capacity reinforced swimming pool 100 is illustrated in
`FIGS. 1–5 herein. The large capacity reinforced swimming
`pool 100 includes a flexible plastic liner 102 having a
`continuous sidewall 104 as is clearly illustrated in FIG. 2.
`The reinforcing of the continuous sidewall 104 of the
`flexible plastic liner 102 is necessary to enable the sidewall
`104 to withstand the static and dynamic pressure applied by
`the water to a lower portion 106 of the large capacity
`reinforced swimming pool 100.
`In general, the reinforcing of the large capacity reinforced
`swimming pool 100 results from (a) bonding a continuous
`reinforcing layer 108 to the continuous sidewall 104 with a
`first plurality of continuous reinforcing seals 110, and (b)
`bonding a second plurality of continuous reinforcing seals
`112 located at an interface between a partial outer layer 114
`and a partial inner layer 116 of the continuous sidewall 104.
`The continuous reinforcing layer 108, the first plurality of
`continuous reinforcing seals 110, and the second plurality of
`continuous reinforcing seals 112 are each applied in a
`continuous horizontal fashion around the circumference of
`the large capacity reinforced swimming pool 100. This novel
`construction functions to strengthen the continuous sidewall
`104 of the flexible plastic liner 102 to counter the pressure
`applied by the large volume of water to the lower portion
`106 of the large capacity reinforced swimming pool 100.
`As shown in FIGS. 1 and 2, the flexible plastic liner 102
`is comprised of polyvinylchloride (PVC) sheeting and
`includes a bottom wall 118 in addition to the continuous
`sidewall 104. The bottom layer 118 is typically comprised of
`a sixteen gauge single-ply layer of PVC sheet material since
`the stress and strain of the water load is very low on the
`bottom of the large capacity reinforced swimming pool 100.
`The continuous sidewall 104 includes the partial outer layer
`114 and the partial inner layer 116 as is best shown in FIG.
`2. The bottom wall 118, which can have any shape including
`a circular shape as shown in FIG. 1, is bonded to the partial
`inner layer 116 of the continuous sidewall 104 in any
`suitable manner such as with a conventional joining seam
`120 to provide a leakproof construction. Mounted on and
`bonded to the top of the continuous sidewall 104 of the
`flexible plastic liner 102 is an inflatable top ring 122. The
`mounting and bonding of the inflatable top ring 122 to the
`top of the continuous sidewall 104 can be accomplished by
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`utilizing a conventional joining seam 124 as shown in FIG.
`2. The inflatable top ring 122 serves to support the continu
`ous sidewall 104 when the large capacity reinforced swim
`ming pool 100 is filled with water. The inflatable top ring
`122 is a continuous tube, i.e., one continuous chamber
`closed upon itself, comprised of plastic vinyl and having a
`single air injection port (not shown). In particular, when the
`inflatable top ring 122 is charged with air and the large
`capacity reinforced swimming pool 100 is filled with water,
`the top ring 122 (now inflated) causes the flexible plastic
`liner 102 to be supported in an upright position as is best
`shown in FIG. 1.
`We now turn our attention to a more detailed description
`of the combination of components employed in the preferred
`embodiment of the large capacity reinforced swimming pool
`100 best shown in FIG. 2. The large capacity reinforcing
`swimming pool 100 of the present invention is shaped to
`resemble essentially a round bag in the uninflated state.
`Consequently, the illustrations shown in FIGS. 1–5 are
`intended to exhibit the large capacity reinforced swimming
`pool 100 in the inflated state. The inflatable top ring 122 is
`shown mounted above and bonded to the partial outer layer
`114 of the continuous sidewall 104 via the conventional
`joining seam 124. The partial outer layer 114 of the con
`tinuous sidewall 104 extends immediately below the inflat
`able top ring 122 and downward to an interface 126 of the
`partial outer layer 114 and the partial inner layer 116. Both
`the partial outer layer 114 and the partial inner layer 116 are
`each a lamination and comprised of a 28 gauge three-ply
`sandwich. The three-ply sandwich includes two outer layers
`of Polyvinylchloride (PVC) sheeting and a middle layer
`comprised of a woven fabric such as nylon or polyester
`mesh. The woven fabric provides strength to both the partial
`outer layer 114 and the partial inner layer 116.
`Both the continuous sidewall 104 and the bottom wall 118
`are comprised of a plurality of polyvinylchloride (PVC)
`sections that are bonded together by conventional joining
`seams. These “joining seams” are typically formed on
`relatively low power machines (for example, ten kilowatt
`peak load having low pressure in pounds per square inch
`(psi) applied to PVC sheeting) for bonding PVC sheet
`components together. Consequently, lower bonding heat is
`generated and less pressure is applied to the PVC sheet
`materials so that all of the air gaps between the PVC sheet
`materials are not eliminated. The end result of this process
`produces a low power bond suitable for joining seams in
`products comprised of flexible PVC sheeting which do not
`require high strength seams or joints.
`Joining seams are low strength conventional seams
`known in the art and serve to join two or more plastic PVC
`pieces together. The bonding can be accomplished by the use
`of thermal, radio frequency (dielectric), ultrasonic and adhe
`sive methods. In the thermal method, heat is employed to
`join (i.e., melt) the PVC sheeting components together. In
`the radio frequency or dielectric method, friction is gener
`ated within the PVC sheeting materials that creates the bond.
`In the ultrasonic method, sound waves create kinetic energy
`that enable the molecules of the two PVC sheets to marry
`together. Finally, use of adhesives serve to mechanically
`bond the two PVC sheets together.
`When the large capacity reinforced swimming pool 100 is
`filled with water, the static and dynamic pressure created by
`the water places much stress and strain on the flexible plastic
`liner 102 and particularly on the continuous sidewall 104
`and the conventional joining seams that bond these compo
`ments together. The high stress/strain load caused by the
`static and dynamic pressure of the water load is particularly
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`evident in the lower portion 106 of the large capacity
`reinforced swimming pool 100. This pressure is indicated in
`FIGS. 1 and 2 by a bulge appearing in the lower portion 106
`of the large capacity reinforced swimming pool 100. In order
`to counter this situation and to avoid leaks and bursting of
`the conventional joining seams, the bottom portion 106 of
`the flexible plastic liner 102 is reinforced in the present
`invention.
`The preferred embodiment of the present invention
`includes (a) the continuous reinforcing layer 108 in combi
`nation with (b) the first plurality of continuous reinforcing
`seals 110, and further includes (c) the second plurality of
`continuous reinforcing seals 112 as the reinforcing compo
`ments. The continuous reinforcing layer 108 in combination
`with the first plurality of continuous reinforcing seals 110
`function to increase the strength of the continuous sidewall
`104 and are clearly illustrated in FIG. 2. The continuous
`reinforcing layer 108 is actually a separate layer of, for
`example, a 28 gauge three-ply laminate comprised of an
`inner and outer layer of Polyvinylchloride (PVC) sheeting
`and a middle layer of a woven fabric such as nylon or a
`polyester mesh. Thus, the continuous reinforcing layer 108
`is comprised of the same or comparable PVC sheet materials
`as that of the flexible plastic liner 102. The continuous
`reinforcing layer 108 and the partial outer layer 114 meet at
`an interface 128 as shown in FIG. 2. The continuous
`reinforcing layer 108 is shown in FIG. 2 as bonded to the
`inside of the continuous sidewall 104 with the first plurality
`of continuous reinforcing seals 110. However, it is noted that
`the continuous reinforcing layer 108 can also be bonded to
`the exterior of the continuous sidewall 104 to serve the same
`reinforcing function.
`The continuous reinforcing layer 108 which is bonded to
`the 28 gauge three-ply partial outer layer 114 is illustrated in
`FIG. 5. These sandwiched layers exhibit a double laminate
`(i.e., two three-ply laminates) which provides for a double
`wall construction in cross-section as shown in FIG. 2. In the
`preferred embodiment, the continuous reinforcing layer 108
`is bonded to the partial outer layer 114 via the first plurality
`of continuous reinforcing seals 110. As an example and not
`by way of limitation, the first plurality of continuous rein
`forcing seals 110 includes five non-contiguous seals 110 as
`shown in FIG. 5. The number of reinforcing seals 110 can
`vary depending upon the diameter and the water volume
`capacity of the large capacity reinforced swimming pool
`110. A separation or “gap” 130 is shown between each of the
`five non-contiguous seals 110 where each gap 130 represents
`a portion of the 28 gauge laminate layer that forms the
`continuous reinforcing layer 108.
`In the example illustrated in FIG. 5, the double wall
`construction includes five continuous reinforcing seals 110
`and four separations or gaps 130. The four separations or
`gaps 130 positioned between each of the five continuous
`reinforcing seals 110 enables the continuous reinforcing
`layer 108 to be flexible in response to the static and dynamic
`pressure applied by the water load. The first plurality of
`continuous reinforcing seals 110 are referred to as being
`continuous because they close upon themselves in the closed
`perimeter large capacity reinforced swimming pool 100.
`This feature is illustrated in FIG. 2 by showing the first
`plurality of continuous reinforcing seals 110 extending
`beyond the interface 128. It has been determined that to
`prevent failure of the continuous sidewall 104 due to the
`stress and strain of the water load, the first plurality of
`continuous reinforcing seals 110 must comprise at least three
`seals each having a width of one-half inch, or at least two
`seals each having a width of three-quarters of an inch.
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`US 6,571,405 B1
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`8
`The partial outer layer 114 and the partial inner layer 116
`meet at the interface 126 as shown in FIG. 2. The interface
`126 includes a double lamination comprised of a conven
`tional joining seam 132 and the second plurality of continu
`ous reinforcing seals 112 best shown in FIG. 2. The joining
`seam 132 is the conventional method utilized to assemble
`the partial outer layer 114 to the partial inner layer 116 as is
`known in the art. The second plurality of continuous rein
`forcing seals 112 are contiguous, i.e., side-by-side, and do
`not include the gaps 130 of PVC material (representing a
`portion of the 28 gauge laminate layer that forms the
`continuous reinforcing layer 108) positioned between each
`of the first plurality of continuous reinforcing seals 110.
`Also, when one of the second plurality of continuous rein
`forcing seals 112 is placed adjacent to the conventional
`joining seam 132, they are also contiguously spaced, i.e.,
`side-by-side. This design exists to ensure the integrity of the
`conventional joining seam 132 and to improve the overall
`strength of the interface 126. The second plurality of con
`tinuous reinforcing seals 112 are comprised of the same or
`comparable PVC sheet materials as that of the flexible
`plastic liner 102.
`The second plurality of continuous reinforcing seals 112
`are referred to as being continuous because they close upon
`themselves in the closed perimeter large capacity reinforced
`swimming pool 100. This feature is illustrated in FIG. 2 by
`showing the second plurality of continuous reinforcing seals
`112 extending beyond the interface 126. The dies utilized in
`forming each of the second plurality of continuous reinforc
`ing seals 112 form a flat seal with a thin ridge of the double
`lamination (six-ply sandwich material) extending upward
`between each of the continuous reinforcing seals 112. The
`double lamination of the interface 126 comprises two of the
`28 gauge three-ply sandwiches placed in juxtaposition.
`Thus, the second plurality of continuous reinforcing seals
`112 significantly increases the strength of the flexible plastic
`liner 102 at the interface 126 to resist bursting of the
`continuous sidewall 104.
`It has also been determined that to prevent failure of the
`continuous sidewall 104 due to the stress and strain of the
`water load, the second plurality of continuous reinforcing
`seals 112 must comprise at least three seals each having a
`width of one-half inch, or at least two seals each having a
`width of three-quarters of an inch. It is also noted that due
`to economics, each of the seals of the first and second
`pluralities of continuous reinforcing seals 110 and 112 are
`either one-half inch in width or three-quarters of an inch in
`width. Thus, the width of the continuous reinforcing seals
`110 and 112 are not intermixed in the same large capacity
`reinforced swimming pool 100. Further, the cross-over from
`one-half inch