US20060117680A1

US20060117680A1 - Decorative swimming pool joint and draining system

Info

Publication number: US20060117680A1
Application number: US11/283,639
Authority: US
Inventors: Jimmy Dill; Tariq Malik
Original assignee: W R Meadows Inc
Current assignee: W R Meadows Inc
Priority date: 2004-11-22
Filing date: 2005-11-21
Publication date: 2006-06-08

Abstract

A novel swimming pool deck drainage system and expansion joint that are adapted to be cast into a concrete pool deck surface. The drainage system is designed to properly drain water from pool overflow and rain water from the decking while enhancing the aesthetics of the swimming pool deck. The drainage system provides an effective drainage for pool decks and effectively collects and carries water away quickly from pool decks and other patio areas. The joint system protects against cracking and buckling of the concrete deck surface. The decorative swimming pool joint and drainage systems are formed using a co-extrusion process. The drain and joint systems are made from an exterior grade of PVC. While the drain and joint components are being extruded, a cap stock made from ASA (weatherable ABS) material is extruded and fused into the top of the drain and joint. The cap stock material includes a base color and seed resin mixed with the ASA to provide a wood grain appearance. The product, when cast into the concrete decking, has the appearance of wood and is provided in assorted wood grains and colors.

Description

RELATED APPLICATIONS

This application claims priority from U.S. Provisional Application Ser. No. 60/630,066 filed on Nov. 22, 2004.

BACKGROUND

The disclosure relates to the field of art pertaining to drainage systems for pools, and more specifically to a pool deck structure that provides for decorative and attractive wood-looking joint and drainage systems for concrete swimming pool decks. Swimming pools, especially those built in-ground, are known to have large deck structures, typically made of concrete, surrounding the swimming pool. These deck structures are usually pitched in a direction away from the swimming pool in order to direct pool water runoff and rain water runoff away from the swimming pool and towards a drainage device located about or within the pool deck structure.
Advancements have been made regarding these drainage devices including changing the material for these drainage devices to polyvinyl chloride (PVC) and incorporating a replacement cover for easier maintenance. Drainage systems provide an effective drainage for pool decks and effectively collect and carry water away quickly from pool decks and other patio areas. When designing a pool, the water from overflow must be drained effectively. The major disadvantage of the present drains and joints is that their appearance is unattractive and plain and typically takes the appearance of the white PVC plastic.
Decorative pool decks are becoming very common and popular and it has become desirable to develop an effective, decorative, wood looking pool deck drainage and joint system to enhance the aesthetics of swimming pool decks.

SUMMARY

The present disclosure relates to a novel swimming pool deck structure channel and joint that are adapted to be cast into the pool deck surface and are designed to properly drain water from pool and rain water runoff from the decking while enhancing the aesthetics of the swimming pool deck. The drainage system provides an effective drainage for pool decks and effectively collects and carries water away quickly from pool decks and other patio areas. The joint system protects against cracking and buckling of the concrete deck surface. The decorative swimming pool joint and drainage systems are formed using a co-extrusion process. The drain and joint systems are made from an exterior grade of PVC. While the drain and joint components are being extruded, a cap stock made from ASA (weatherable ABS) material is extruded and fused into the top of the drain and joint. The cap stock includes a base color and seed resin mixed with the ASA to provide a wood grain appearance. The product, when cast in the concrete decking, has the appearance of wood and can be manufactured in assorted wood grains and colors.
Other features and advantages of the invention will be set forth in part in the description which follows in the accompanying drawings, where the embodiments of the disclosure are described and shown, and in part will become apparent upon examination of the following detailed description taken into conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Above-mentioned and other features of this disclosure in the manner of obtaining them will become more apparent and the disclosure itself will be best understood by reference to the following description of elements of the disclosure taken in conjunction with the accompanying drawings in which:
FIG. 1 is a perspective view of a decorative swimming pool drainage system of the present invention;
FIG. 2 is cross-sectional view of the swimming pool drainage system taken along lines 2-2 of FIG. 1;
FIG. 3 is a perspective view of a drain cap of the present invention;
FIG. 4 is a perspective view of an expansion joint of the present invention;
FIG. 5 is a cross-sectional view of the expansion joint taken along lines 5-5 of FIG. 4;
FIG. 6 is a perspective view of an expansion joint cap of the present invention.

DETAILED DESCRIPTION

While the present invention will be described fully herein with reference to the accompanying drawings, in which a particular embodiment is shown, it is to be understood that the person skilled in the art may modify the disclosure herein described while still achieving the desired result of this disclosure. Accordingly, the description that follows is to be understood as a broad and informative disclosure directed to persons skilled in the appropriate art and not as limitations on the present disclosure.
Referring now to the drawings, FIGS. 1 and 2 illustrate a decorative swimming pool drainage system 10 that is adapted to be cast with the concrete deck 11 surrounding an in ground swimming pool. The decorative swimming pool drainage system 10 is preferably made from polyvinyl chloride (PVC) but other similar plastics may be used including CPVC, PP, PE, HDEP, and EVA. The drainage system 10 includes a top wall 12 that is adapted to be positioned slightly below the top surface 13 of the concrete decking 11.
The drainage system 10 also includes a bottom wall 14 spaced apart from the top wall 12. Maintaining the position of the top and bottom walls 12, 14, are a first side wall 16 and a spaced-apart second side wall 18. The first and second side wall 16,18, along with the bottom wall 14 form a channel 20 that is adapted to transport pool runoff and rain water to a sewer or the pool filtration system. The pool drainage system 10 is positioned within the concrete decking 11 so that the bottom wall 14 maintains a slight slope to allow collected water to gravitate to a desired location. The pool drainage system 10 also acts as an expansion joint to permit movement of adjacent sections of concrete decking 1l. The side walls 16, 18 are designed to flex to allow for concrete expansion.
The pool side walls 16,18 include a recessed center portion 22 that includes an outwardly extending lip 24 that runs longitudinally along the length of the center portion 22. The lip 24 of the side wall 16,18 and center portion 22 are adapted to engage the concrete decking 11 to prevent the removal of the pool drainage system 10 from the concrete decking. The lip 24 is also useful for preventing frost heave when the system 10 in colder climates. Stepped inward from the side walls 16,18 are a pair of supports 26,28. The supports 26,28 are connected to the first and second side wall 16,18 at a first end and are secured to the inside surface 30 of the top wall 12. The supports 26,28 are designed to strengthen the top wall 12 so that deformation or damage does not occur.
The top wall 12 of the pool drainage system 10 includes a planar top surface 32. The top wall 12 of the pool draining system 10 includes a plurality of elongated slots 34 that create a plurality of openings from the planar top surface 32 to the inside surface 30 to permit pool overflow water and rain water to enter the channel 20. The slots 34 are dimensioned to prevent unwanted debris such as leaves and other material from entering the drainage system 10. The top wall 12 of the pool draining system 10 and is formed by a co-extrusion process wherein a cap stock made from ASA (weatherable ABS) material is extruded along with the PVC and is fused into the top of the drainage system 10. The planar top surface 32 is formed of the cap stock and includes a base color and a seed resin mixed in to provide a wood grain appearance. The overall product, when cast in concrete, will have the overall appearance of wood. The planar top surface 32 of the top wall 12 can be formed from cap stock thermoplastics including, but not limited to, acrylonitrile butadiene styrene (ABS, PS and ASA) acrylonile styrene acylate.
FIG. 3 illustrates a removable drain cap 36. The removable drain cap 36 is adapted to be used in connection with a drain already installed in the concrete decking 11. The drain cap 36 includes a horizontally disposed top plate 38 and a pair of horizontally spaced vertical supports 40. The vertical supports 40 are oriented parallel with respect to one another and are designed to be positioned within the channel formed in the concrete decking 11. The top plate 38 is connected to the top side 42 of the vertical supports 40 and is relatively plainer. The top plate 38 includes a top surface 44 and a spaced apart bottom surface 46. The top surface 44 of the top plate 38 is formed of a cap stock and is adapt to be co-extruded with the remaining portion of the drain cap 36.
The drain cap 36 is preferably made from poly vinyl chloride (PVC) but other similar plastics may be used including CPVC, PP, PE, HDEP and EVA. The co-extruded cap stock material can be selected from a group of thermoplastics including, but not limited to, acrylonitrile butadine styrene (ABS, PS, ASA). The plastic material for the cap stock is mixed with a base color and a seed resin in a ratio to provide a wood grain appearance. The light and dark regions of the wood grain pattern are created by the base color and seed resin. The drain cap 36 is designed so that it can be removed to clear debris from the drainage channel between the concrete decking 11 or can be replaced if worn.
FIGS. 4 and 5 illustrate an expansion joint 48 that is designed to be cast with the concrete decking 11 to permit the decking 11 to expand and contract during changes of temperature. The expansion joint 48 is preferably extruded from thermoplastic including PVC, CPVC, PP, PE, HDEP and EVA. The expansion joint 48 includes a top wall 50 having a top side.52 on a spaced apart bottom side 54. The expansion joint 48 also includes a first side wall 56 and a spaced apart second sidewall 58. The first and second sidewalls include a first end 60 and a spaced apart second end 62. The first end 60 of the first and second sidewall 56, 58 are attached to the bottom side 54 of the top wall 50. The second end 62 of the first and second side walls 56, 58 taper inward and interconnect at a bottom edge 64. The first and second sidewalls 56 and 58 both include an outwardly extending lip 66 that is adapted to engage the concrete to prevent the expansion joint 48 from moving from its position.
The expansion joint 48 also includes a horizontal rib 68 that is parallel to the top wall 50 and is connected at first and second ends 60, 62 at the first and second sidewalls 56, 58. The horizontal rib 68 prevents the inward movement of the first and second side walls 56, 58 to prevent degradation of the expansion joint 48. The expansion joint 48 also includes a co-extruded cap stock on the top side 52 of the expansion joint 48 that is formed from the thermo-plastic group including, but not limited to, acrylonitrile butadiene stuyrene (AVS, PS, ASA). The top side 52 of the expansion joint is finished by adding a base color and seed resin in a mixture to provide a wood grained appearance to the top side 52 of the expansion joint 48.
FIG. 6 of the present application illustrates an expansion joint cap 74 that is designed to be positioned over an expansion joint that had been cast with the concrete decking 11. The expansion joint cap 74 includes a top wall 76 and first and second side walls 78, 80. The top wall 76 of the expansion joint cap 74 includes a top side 82 and a spaced part bottom side 84. The first and second side walls 78, 80 are connected to the bottom side 84 of the top wall 76 at a first end 86. The first and second side walls 78, 80 are tapered inward such that when the expansion joint cap 74 is positioned over the top of an expansion joined, the first and second sidewall 78, 80 grippenly engaged the expansion joint to retain the position of the expansion joint cap. The top side 82 of the expansion joint cap includes a cap stock that is co-extruded with a base material. The cap stock is selected from a group of thermoplastics including but not limited to acrylonitrile butadiene styrene (ABS, PS, ASA).
In use the swimming pool drainage system 10 and the expansion joint 48 are cast with the concrete decking surrounding a swimming pool and are permanently installed once the concrete sets. The cap stock is UV resistant so that the exposed wood grain appearance will retain its appearance for years without fading or cracking. The drain cap 36 and expansion joint cap 74 are removable in the event they become damaged or the owner would like to replace the caps with one having a different wood grain appearance.
Various features of the disclosure have been shown and described in connection with the illustrated embodiment, however, it is understood that these arrangements merely illustrate, and that the disclosure is to be given its fullest interpretation.

Claims

1. A co-extruded polymer deck joint for use with poured concrete decking, said deck joint comprising:

a substantially horizontal top wall partially formed from a first polymer, said top wall having a top surface formed of a second polymer, said second polymer being mixed with color and a seed resin to form an aesthetic pattern on the top surface of the top wall;

a pair of sidewalls connected to the top wall at a first end, said side walls adapted to be cast in the concrete such that only the top wall is primarily visible when installed in the concrete, said sidewalls formed of said first polymer; and

said sidewalls and said top wall being co-extruded to form the polymer deck joint having an aesthetic pattern.

2. The co-extruded polymer deck joint of claim 1, wherein the second polymer is extruded with the first polymer so that the second polymer is fused to the first polymer within the top surface.

3. The co-extruded polymer deck joint of claim 1, wherein the first polymer material is selected from a group of thermoplastics including, PVC, CPVC, PP, PE, HDEP and EVA.

4. The co-extruded polymer deck joint of claim 1, wherein the second polymer material is selected from a group of thermoplastics including Acrylonitrile Butadiene Styrene, Poly-Styrene and Acylonitrile Styrene Acylate.

5. A co-extruded polymer deck drain for use with concrete decking, said deck drain comprising:

a top wall partially formed from a first polymer, said top wall including a plurality of openings to permit drainage;

a bottom wall opposing the top wall, the bottom wall formed from said first polymer;

a pair of generally vertical walls interconnecting said top and bottom walls, said bottom and side walls adapted to be cast in concrete and form a channel for the collection of water; and

said to wall including a top surface formed of a second polymer co-extruded with the first polymer, said second polymer combined with color and seed resin to form an aesthetic pattern on the top surface of the top wall, wherein the aesthetic pattern remains visible when the deck drain is cast with the concrete decking.

6. The co-extruded polymer deck drain of claim 5, wherein the second polymer is extruded with the first polymer so that the second polymer is fused to the first polymer within the top surface.

7. The co-extruded polymer deck drain of claim 5, wherein the first polymer material is selected from a group of thermoplastics including, PVC, CPVC, PP, PE, HDEP and EVA.

8. The co-extruded polymer deck drain of claim 5, wherein the second polymer material is selected from a group of thermoplastics including Acrylonitrile Butadiene Styrene, Poly-Styrene and Acylonitrile Styrene Acylate.

9. A co-extruded polymer deck drain and expansion joint for use with poured concrete decking to drain water on the decking and permit expansion and contraction, said deck drain and joint each comprising:

a pair of sidewalls connected to the top wall at a first end, said side walls adapted to be cast in the concrete such that only the top wall is primarily visible when installed in the concrete, said sidewalls extruded from said first polymer;

an outwardly extending lip formed on an outside surface of the sidewalls, the lip adapted to aid in retaining the deck drain and expansion joint within the concrete; and

said sidewalls and said top wall being co-extruded to form the polymer deck drain and expansion joint having an aesthetic pattern.

10. The co-extruded polymer deck drain and expansion joint of claim 9, wherein the second polymer is extruded with the first polymer so that the second polymer is fused to the first polymer within the top surface.

11. The co-extruded polymer deck drain and expansion joint of claim 9, wherein the first polymer material is selected from a group of thermoplastics including, PVC, CPVC, PP, PE, HDEP and EVA.

12. The co-extruded polymer deck drain and expansion joint of claim 9, wherein the second polymer material is selected from a group of thermoplastics including Acrylonitrile Butadiene Styrene, Poly-Styrene and Acylonitrile Styrene Acylate.