Prefabricated Pool Shell With Embedded Inserts for Fast Installation
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Solution Overview
Problem
Traditional techniques for producing structural elements for inground pools cannot be utilized for prefabricated pools manufactured offsite, limiting the installation efficiency and cost-effectiveness of smaller pools.
Innovation Solution
A prefabricated pool design featuring a pool shell formed from a settable material with inserts that are physically held in position by the set material, using attachment and locking portions to prevent removal and rotation, combined with reinforcing elements and a method of production that includes locating inserts in a mould, pouring settable material, and allowing it to set, to create a structurally sound and transportable pool shell.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional techniques for producing structural elements adjacent inground pools are used, then structural integrity can be achieved, but installation time and cost increase significantly
Solution Approach 1:
The pool structure is divided into modular components (pool shell, sidewalls, floor) that are pre-manufactured as separate units. These segments are produced offsite using standardized molds and then assembled at the installation location, enabling parallel production and significantly reducing on-site installation time compared to traditional monolithic construction methods.
Solution Approach 2:
Structural elements including the pool shell, sidewalls, and floor are pre-manufactured offsite before delivery to the installation location. Inserts are embedded during the pre-manufacturing process, and reinforcement structures are prepared in advance. This preliminary preparation eliminates time-consuming on-site construction activities while maintaining structural integrity.
2Productivity
If prefabricated pools are manufactured offsite, then installation time is reduced, but traditional production techniques cannot be utilized
Solution Approach 1:
The pool shell and sidewalls are designed with universal attachment features (inserts with standardized threading and locking mechanisms) that can accommodate various types of attachments (fencing, covers, equipment mounts). This multi-functionality allows a single prefabricated unit to serve multiple purposes and adapt to different installation requirements without requiring custom manufacturing for each application.
Solution Approach 2:
The design incorporates adjustable parameters including insert positioning (at various heights and locations), insert types (different threading patterns and locking mechanisms), and shell dimensions. These parameter variations enable the same basic manufacturing process to produce pools tailored to different site requirements while maintaining the benefits of offsite production.
3Strength
If inserts are embedded in the pool shell, then structural elements can be securely attached, but the settable material must fully encapsulate the inserts
Solution Approach 1:
The insert structure is designed with nested components where the attachment portion (threaded hole) is nested within the insert body, and the locking portion is nested within the attachment portion. The settable material is then nested around these nested components, fully encapsulating them within the pool shell. This nested arrangement maximizes attachment strength while minimizing the volume of settable material required compared to solid embedding methods.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables the efficient production and transportation of prefabricated pools, reducing installation time and costs by utilizing a settable material with inserts to secure structural elements, while ensuring structural integrity and ease of assembly.
Implementation Method 1
the pool shell being formed from a settable material wherein the one or more sidewalls include one or more inserts, the one or more inserts being physically held in position by the set settable material
Data Source
AI summary
A prefabricated pool comprising: a pool shell having one or more sidewalls; the pool shell being formed from a settable material wherein the one or more sidewalls include one or more inserts, the one or more inserts being physically held in position by the set settable material.