Pool and spa shells and methods of manufacture

Abstract

A pool shell comprising a pool shell body including an angled feature, wherein the angled feature defines an open region on an underside of the pool shell body. The pool shell may further comprise an insert positioned in the open region for providing structural support to the angled feature. The pool shell may further comprise an overlaying member positioned over the open region such that the insert is positioned between the underside of the pool shell body and the overlaying member, wherein the overlaying member is a substantially flat material for defining an exterior ramp surface extending over the open region defined by the angled feature.

1 . A pool shell, comprising:
 a pool shell body comprising a feature defining an open region on an underside of the pool shell body; and   
       a reinforcement component positioned to substantially cover the open region and comprising a substantially planar surface for defining a ramp surface extending over the open region. 
     
     
         2 . The pool shell of  claim 1 , wherein the reinforcement component extends along a length of the feature. 
     
     
         3 . The pool shell of  claim 1 , wherein the reinforcement component comprises an insert that at least partially fills in the open region. 
     
     
         4 . The pool shell of  claim 3 , wherein a portion of the insert abuts at least a portion of the feature. 
     
     
         5 . The pool shell of  claim 3 , wherein the insert comprises a foam material. 
     
     
         6 . The pool shell of  claim 1 , wherein:
 the feature comprises a first edge and a second edge; and   wherein the reinforcement component extends from the first edge to the second edge to enclose the open region on the underside of the pool shell body.   
     
     
         7 . The pool shell of  claim 6 ,
 wherein the feature includes a tread and riser and wherein the first edge corresponds to a first end of the tread and the second edge corresponds to a first end of the riser.   
     
     
         8 . A pool shell, comprising:
 a pool shell body comprising a feature defining an open region on an underside of the pool shell body;   
       a stiffener component arranged on at least a portion of the feature; and
 an overlaying member positioned over the open region, wherein the overlaying member comprises a substantially planar surface for defining a ramp surface extending over the open region. 
 
     
     
         9 . The pool shell of  claim 8 , wherein the overlaying member extends along a length of the feature. 
     
     
         10 . The pool shell of  claim 8 , wherein the stiffener component comprises at least one of a fiberglass composite material, a high-density foamcore, plasticore, finolex, urethane foam, blackboard, carbon fiber, wood, polymer, or metal. 
     
     
         11 . The pool shell of  claim 8 , further comprising an insert positioned between the stiffener component and the overlaying member. 
     
     
         12 . The pool shell of  claim 8 , wherein:
 the feature comprises a first edge and a second edge; and   wherein the overlaying member extends from the first edge to the second edge to enclose the open region on the underside of the pool shell body.   
     
     
         13 . A method of manufacturing a pool shell comprising the steps of:
 providing a pool shell having a feature defining an open region on an underside of the pool shell; and   positioning a reinforcement component in the open region defined by the feature;   
       wherein the reinforcement component defines a ramped surface that encloses at least a portion of the open region. 
     
     
         14 . The method of  claim 13 , wherein the reinforcement component extends along a length of the feature. 
     
     
         15 . The method of  claim 13 , wherein the reinforcement component comprises an insert that at least partially fills in the open region. 
     
     
         16 . The method of  claim 15 , wherein a portion of the insert abuts at least a portion of the feature. 
     
     
         17 . The method of  claim 13 , wherein:
 the feature comprises a first edge and a second edge; and   wherein the reinforcement component extends from the first edge to the second edge to enclose the open region on the underside of the pool shell.   
     
     
         18 . The method of  claim 13 , further comprising:
 applying a reinforcement layer over the reinforcement component for securing the reinforcement component in the open region.   
     
     
         19 . The method of  claim 18 , wherein the reinforcement layer comprises at least one of a resin or a fiberglass material. 
     
     
         20 . The method of  claim 14 , further comprising:
 applying a cover over the reinforcement component, wherein the cover is a fabric material comprising a fiberglass material.