US20040181867A1 - Hot tub assembly - Google Patents
Hot tub assembly Download PDFInfo
- Publication number
- US20040181867A1 US20040181867A1 US10/393,725 US39372503A US2004181867A1 US 20040181867 A1 US20040181867 A1 US 20040181867A1 US 39372503 A US39372503 A US 39372503A US 2004181867 A1 US2004181867 A1 US 2004181867A1
- Authority
- US
- United States
- Prior art keywords
- cover
- foam
- frame
- hollow beams
- impact
- 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
- 239000006260 foam Substances 0.000 claims abstract description 27
- 239000000463 material Substances 0.000 claims abstract description 22
- 230000003014 reinforcing effect Effects 0.000 claims abstract description 10
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 15
- 239000008188 pellet Substances 0.000 claims description 7
- 238000000034 method Methods 0.000 claims description 6
- -1 polypropylene Polymers 0.000 claims description 6
- 229910052782 aluminium Inorganic materials 0.000 claims description 5
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 5
- 229910052751 metal Inorganic materials 0.000 claims description 4
- 239000000203 mixture Substances 0.000 claims description 4
- 239000004800 polyvinyl chloride Substances 0.000 claims description 4
- 239000004698 Polyethylene Substances 0.000 claims description 3
- 239000004743 Polypropylene Substances 0.000 claims description 3
- 238000002156 mixing Methods 0.000 claims description 3
- 229920000573 polyethylene Polymers 0.000 claims description 3
- 229920001155 polypropylene Polymers 0.000 claims description 3
- 229920000915 polyvinyl chloride Polymers 0.000 claims description 3
- 239000004033 plastic Substances 0.000 claims description 2
- 229920003023 plastic Polymers 0.000 claims description 2
- 239000004744 fabric Substances 0.000 claims 2
- 239000002184 metal Substances 0.000 claims 2
- 238000010521 absorption reaction Methods 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 3
- 239000005871 repellent Substances 0.000 description 2
- 239000004677 Nylon Substances 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 229920006328 Styrofoam Polymers 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 230000001066 destructive effect Effects 0.000 description 1
- 239000011152 fibreglass Substances 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 239000011120 plywood Substances 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 230000004044 response Effects 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000008261 styrofoam Substances 0.000 description 1
- 230000001225 therapeutic effect Effects 0.000 description 1
- 238000009827 uniform distribution Methods 0.000 description 1
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 1
- 229920002554 vinyl polymer Polymers 0.000 description 1
- 238000005406 washing 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
- E04H4/08—Coverings consisting of rigid elements, e.g. coverings composed of separate or connected elements
Definitions
- the invention relates to liquid containing reservoirs, and particularly, to insulated covers or lids configured to close a recreational hot spa, hot tub or pool.
- Covers or lids cover majority of pools, hot tubs or spa during nonuse. Among multiple reasons necessitating the use of covers, the safety of the spa users and the efficient water use are dominant issues requiring particular consideration.
- the safety of the spa users during the spa's nonuse is directed to the structural strength of the cover.
- the cover's structure includes an open-cell foam laminated with a layer of fiberglass.
- the reinforced cover exhibits satisfactory load-carrying characteristics, it may have a few disadvantages.
- the price of the reinforced cover escalates with strength and durability.
- the major disadvantage of the known reinforced covers is their progressively increasing weight as a result of water absorption. The weight of the cover may double and triple within a few years. Accordingly, multiple cover lift mechanisms, associated with a cumbersome and expensive structure, have been developed fir assisting in the installation and removal of spa covers.
- the present invention is directed to providing such a cover, particularly a spa cover, by having a reinforcing metallic element, an inner impact-absorbing layer of material and an outer water-repellent layer of material integrated in a foam structure.
- a reinforcing metallic element which is preferably a frame made from aluminum.
- the use of a closed-cell foam covered by a water-repellent layer of material effectively minimizes the water absorption problem.
- the resulting structure is light, durable and cost efficient.
- inventive spa cover is manufactured in accordance with an inventive method providing for cost-effective manufacturing of the covers.
- the method allows for rapid blending of reinforcing elements, foam pellets and inner and outer skins to produce a cover having the desired size and shape.
- an object of the invention to provide a cover configured to improve the safety of the users of recreational and therapeutic water reservoirs as well as to improve the water and air impermeability and to decrease evaporative losses of the body of water stored in water reservoirs.
- Another object of the invention is to provide the inventive cover with a reinforcing structure configured to support substantial loads while easily blending with multiple structural components of the cover to allow for a light, difficult to crack covering structure.
- a further object of the invention is to provide a multi-component structure configured to form the cover characterized by the improved resistance to water absorption.
- Another object of the invention is to provide a cost-efficient method for producing the inventive cover.
- FIG. 1 is a partially broken perspective view of the inventive cover
- FIG. 2 is a cross section of the inventive cover
- FIG. 3 is one of possible configurations of the reinforcing structure of the inventive cover.
- FIG. 4 is a float chart illustrating the inventive method of manufacturing of the cover, as shown in FIG. 1.
- Inventive cover 10 is configured to provide the increased resistance to loads directed transversely to the top of the cover and the improved water impermeability while creating the environment conducive to substantially retaining heat within the body of water.
- a inner frame 12 is embedded within a body 26 made of pellets which are heat and pressure processed to form foam.
- the inner frame 12 may include a pair of longitudinal beams 14 bridged by cross beams 16 all preferably made from aluminum. Other configurations of the frame 12 can be easily implemented within the scope of the invention provided such a modified configuration will be stress resistant. Depending on shape and size of a spa, additional beams 18 may be provided on and extend transversely to one of the longitudinal beams 14 to create the half of the cover 10 having thus multiple points of support. Generally, the cover 10 including two identical halves has a dome-shaped structure with a thickened central region tapering toward its periphery to allow the rain or washing water to escape.
- the inventive structure of spa cover 10 is manufactured in accordance with inventive method, as illustrated in FIG. 4.
- an inner skin 22 made from mesh material is stretched over the top or bottom of the frame 12 .
- the inner skin 22 includes polymeric material, such as nylon, a wire mesh made from aluminum or steel can be successfully used in the inventive method and structure.
- the use of the inner skin 22 is advantageous for substantially uniform distribution of excessive loads impacted upon the cover 10 over its entire structure. In practical terms, the inner skin 22 prevents the cover 10 from cracking. As the foam body crushes in response to an impact, the inner peak redirects the peak of the crashing foam mass over a larger area of the cover 10 . The larger the area, the less destructive the impact.
- the entire assembly is placed in a mold for heat and pressure treatment. As the temperature rises, the pellets 26 located all around the frame 12 blend therewith and expand as much as the size of the stretched bag 20 would allow it. The process lasts for the predetermined period of time sufficient to allow the mass of pellets to blend with the frame and to expand the bag 20 , made from reinforced PVC, to the desired size. As a result, the cover 10 has a rigid, light structure of the predetermined size and shape.
- the beams 14 and 16 each may have at least one opening 24 . Since the beams preferably have an I shape, the pallets filling the space between the sides of each beam above and below a cross portion 30 as well as the space defined between the adjacent longitudinal 14 and cross 16 beams, expand through the openings 24 to uniformly integrate or blend with the frame 12 .
- the beams 14 each have an increased thickness in the central cross portion 30 varying within a 4-6 mm range.
- the foam body may be made from polypropylene, polyethylene, or PVC
- the frame 12 can include plywood or rigid plastic materials capable of withstanding elevated temperatures prevailing in the mold.
- the outer skin used for forming the bag 20 can include vinyl and other suitable materials.
- the shapes of the structural components can be different from those disclosed. For instance, instead of I-beams, any polygonal or annular cross-section of a hollow beam allowing the pallets to fill the interior of the beams can be used as well.
Abstract
A cover for a spa is configured to have an outer bag blended with a body of foam integrated with a reinforcing frame and an impact-resistant layer of material starched over the reinforcing frame and embedded in the body of foam.
Description
- 1. Field of the Invention
- The invention relates to liquid containing reservoirs, and particularly, to insulated covers or lids configured to close a recreational hot spa, hot tub or pool.
- 2. Background of the Related Prior Art
- Covers or lids cover majority of pools, hot tubs or spa during nonuse. Among multiple reasons necessitating the use of covers, the safety of the spa users and the efficient water use are dominant issues requiring particular consideration.
- The safety of the spa users during the spa's nonuse is directed to the structural strength of the cover. The ability of the spa cover to withstand substantial loads usually associated with children and adults, who treat the cover as a playground, may prevent an unfortunate accident. To reinforce a spa cover, which is usually made from Styrofoam, the cover's structure includes an open-cell foam laminated with a layer of fiberglass.
- While the reinforced cover exhibits satisfactory load-carrying characteristics, it may have a few disadvantages. On one hand, the price of the reinforced cover escalates with strength and durability. Hover, the major disadvantage of the known reinforced covers is their progressively increasing weight as a result of water absorption. The weight of the cover may double and triple within a few years. Accordingly, multiple cover lift mechanisms, associated with a cumbersome and expensive structure, have been developed fir assisting in the installation and removal of spa covers.
- Concomitantly, as the reinforced cover gains the weight, the rate of water absorption increases as well. Therefore, a frequent water supply associated with increased power consumption necessary to warm water up to the desired temperature and to maintain this temperature render the use of the space inefficient.
- Hence, a need exists for a water-tank, such as a spa or hot tub, having a load-resistant cover, which provides good thermal insulation without a dramatic gain in weight over time.
- The present invention is directed to providing such a cover, particularly a spa cover, by having a reinforcing metallic element, an inner impact-absorbing layer of material and an outer water-repellent layer of material integrated in a foam structure. One of the advantages of the inventive structure is the increased strength contributed by the metallic element, which is preferably a frame made from aluminum. The use of a closed-cell foam covered by a water-repellent layer of material effectively minimizes the water absorption problem. The resulting structure is light, durable and cost efficient.
- The inventive spa cover is manufactured in accordance with an inventive method providing for cost-effective manufacturing of the covers. In particular, the method allows for rapid blending of reinforcing elements, foam pellets and inner and outer skins to produce a cover having the desired size and shape.
- It is, therefore, an object of the invention to provide a cover configured to improve the safety of the users of recreational and therapeutic water reservoirs as well as to improve the water and air impermeability and to decrease evaporative losses of the body of water stored in water reservoirs.
- Another object of the invention is to provide the inventive cover with a reinforcing structure configured to support substantial loads while easily blending with multiple structural components of the cover to allow for a light, difficult to crack covering structure.
- A further object of the invention is to provide a multi-component structure configured to form the cover characterized by the improved resistance to water absorption.
- Another object of the invention is to provide a cost-efficient method for producing the inventive cover.
- The above and other objects, features and advantages will be come more readily from the description of the preferred inventive embodiment illustrated by the following drawings, in which:
- FIG. 1 is a partially broken perspective view of the inventive cover;
- FIG. 2 is a cross section of the inventive cover;
- FIG. 3 is one of possible configurations of the reinforcing structure of the inventive cover; and
- FIG. 4 is a float chart illustrating the inventive method of manufacturing of the cover, as shown in FIG. 1.
-
Inventive cover 10, as illustrated in FIGS. 1 and 2, is configured to provide the increased resistance to loads directed transversely to the top of the cover and the improved water impermeability while creating the environment conducive to substantially retaining heat within the body of water. Ainner frame 12 is embedded within abody 26 made of pellets which are heat and pressure processed to form foam. - The
inner frame 12 may include a pair oflongitudinal beams 14 bridged bycross beams 16 all preferably made from aluminum. Other configurations of theframe 12 can be easily implemented within the scope of the invention provided such a modified configuration will be stress resistant. Depending on shape and size of a spa, additional beams 18 may be provided on and extend transversely to one of thelongitudinal beams 14 to create the half of thecover 10 having thus multiple points of support. Generally, thecover 10 including two identical halves has a dome-shaped structure with a thickened central region tapering toward its periphery to allow the rain or washing water to escape. - The inventive structure of
spa cover 10 is manufactured in accordance with inventive method, as illustrated in FIG. 4. After theframe 12 has been formed, aninner skin 22 made from mesh material is stretched over the top or bottom of theframe 12. Although, as shown in FIG. 2, theinner skin 22 includes polymeric material, such as nylon, a wire mesh made from aluminum or steel can be successfully used in the inventive method and structure. The use of theinner skin 22 is advantageous for substantially uniform distribution of excessive loads impacted upon thecover 10 over its entire structure. In practical terms, theinner skin 22 prevents thecover 10 from cracking. As the foam body crushes in response to an impact, the inner peak redirects the peak of the crashing foam mass over a larger area of thecover 10. The larger the area, the less destructive the impact. - Having placed the
frame 12, theinner skin 22 and thepellets 26 into thebag 20, the entire assembly is placed in a mold for heat and pressure treatment. As the temperature rises, thepellets 26 located all around theframe 12 blend therewith and expand as much as the size of the stretchedbag 20 would allow it. The process lasts for the predetermined period of time sufficient to allow the mass of pellets to blend with the frame and to expand thebag 20, made from reinforced PVC, to the desired size. As a result, thecover 10 has a rigid, light structure of the predetermined size and shape. - As shown in FIGS. 1 and 3, the
beams cross portion 30 as well as the space defined between the adjacent longitudinal 14 and cross 16 beams, expand through theopenings 24 to uniformly integrate or blend with theframe 12. Advantageously, thebeams 14 each have an increased thickness in thecentral cross portion 30 varying within a 4-6 mm range. - Materials used in the present invention are not limited to the above-disclosed materials. For example, the foam body may be made from polypropylene, polyethylene, or PVC, whereas the
frame 12 can include plywood or rigid plastic materials capable of withstanding elevated temperatures prevailing in the mold. The outer skin used for forming thebag 20 can include vinyl and other suitable materials. Similarly, the shapes of the structural components can be different from those disclosed. For instance, instead of I-beams, any polygonal or annular cross-section of a hollow beam allowing the pallets to fill the interior of the beams can be used as well. - A variety of further modifications and improvements of the inventive cover can be envisioned to one of ordinary skills. Therefore, the invention is limited only to the claims appended hereto.
Claims (15)
1. A cover for a reservoir adapted to store water at elevated temperatures, comprising a body of foam and a frame embedded in the body to reinforce the closure.
2. The cover of claim 1 , wherein the frame includes at least a pair of longitudinal hollow beams and at least one hollow cross beam extending between and coupled to the longitudinal hollow beams to define multiple pockets within the body of foam between the hollow beams.
3. The cover of claim 2 , wherein the hollow beams are made from aluminum and each having a polygonal or annular shape extending through the body of foam.
4. The cover of claim 2 , wherein the hollow beams are made from aluminum and each having an I cross-section configured to have a pair of longitudinal sides and a cross portion having a thickness varying within 4-6 mm range.
5. The cover of claim 2 , further comprising at least one impact-resistant layer made from mesh material stretched over and coupled to the hollow beams of the frame and blended with the body of foam to prevent concentration of force produced by an external impact upon the cover and to minimize the risk of forming a crack in the cover.
6. The cover of claim 5 , wherein the body of foam is made from polymeric material adapted to expand at elevated temperatures to form a rigid mass of foam, the hollow beams each having at least one opening configured to allow the expanding polymeric material to flow there through to provide the cover with an integrated structure.
7. The cover of claim 6 , wherein the body of foam is made from material selected from the group consisting of polypropylene, polyethylene, or PVC.
8. The cover of claim 6 , wherein the impact-resistant layer is made from a woven mesh material selected from metal wire, fabric or plastic.
9. The cover of claim 7 further comprising an outer bag configured to receive the body of foam reinforced with the embedded frame and impact resistant layer and configured to expand to the predetermined size and shape at elevated temperatures to accommodate the expanding polymeric material constituting the body of foam.
10. The cover of claim 9 , wherein the bag is made from reinforced PVC.
11. A cover for a spa or hot tub, comprising:
a body of foam made from pellets expandable at elevated temperatures;
a reinforcing frame embedded within the body of foam;
at least one layer of mesh material embedded within the body of foam and stretched over and coupled to frame; and
an outer bag receiving the body of foam with the embedded reinforcing frame and the at least one layer of mesh material and configured to expand to a predetermined size and shape and blend with the pellets at the elevated temperatures to wrap around and blend with the body of foam.
12. The cover of claim 11 , wherein the body of foam is made from material selected from the group consisting of polypropylene, polyethylene, or PVC.
13. The cover of claim 11 , wherein the frame includes at least a pair of longitudinal hollow beams and at least one hollow cross beam extending between and coupled to the longitudinal hollow beams to define multiple pockets within the body of foam between the hollow beams, each of the hollow beams being provided with a respective opening to allow the pallet to flow through at the elevated temperatures to form an integral structure of the cover.
14. The cover of claim 1 1, wherein the bag and the impact resistant layer are made from a woven mesh material selected from fabric or metal.
15. A method of forming a cover for a spa, comprising the steps of:
forming an outer bag configured to have an interior;
providing a reinforcing frame including a plurality of beams;
stretching an impact-resistant layer of mesh material;
inserting the frame with the stretched impact resistant layer into the outer bag and filling the interior of the bag with pallets made from polymeric material capable of expanding at elevated temperatures to form a body of foam embedding the frame and the impact reinforcing layer and blending with the bag to form a rigid, light structure of the cover.
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/393,725 US20040181867A1 (en) | 2003-03-21 | 2003-03-21 | Hot tub assembly |
PCT/US2004/008754 WO2004085769A1 (en) | 2003-03-21 | 2004-03-22 | Hot tub assembely |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/393,725 US20040181867A1 (en) | 2003-03-21 | 2003-03-21 | Hot tub assembly |
Publications (1)
Publication Number | Publication Date |
---|---|
US20040181867A1 true US20040181867A1 (en) | 2004-09-23 |
Family
ID=32988210
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/393,725 Abandoned US20040181867A1 (en) | 2003-03-21 | 2003-03-21 | Hot tub assembly |
Country Status (2)
Country | Link |
---|---|
US (1) | US20040181867A1 (en) |
WO (1) | WO2004085769A1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20120045602A1 (en) * | 2010-08-18 | 2012-02-23 | Armacell Enterprise Gmbh | Protected expanded polyalkylidene terephthalates |
Citations (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3954926A (en) * | 1971-06-03 | 1976-05-04 | Fritz Wilhelm Pahl | Method of molding a composite reinforced foamed product |
US3970324A (en) * | 1973-03-05 | 1976-07-20 | American Marine Industries, Inc. | Foam-filled, cellular structural product |
US4078293A (en) * | 1975-02-13 | 1978-03-14 | Aine Harry E | Method of making rigid swimming pool cover |
US4122203A (en) * | 1978-01-09 | 1978-10-24 | Stahl Joel S | Fire protective thermal barriers for foam plastics |
US4857374A (en) * | 1988-11-15 | 1989-08-15 | Perry Gary L | Structurally strong, non vapor, non moisture absorbing, spa/hot tub cover |
US5619759A (en) * | 1995-06-07 | 1997-04-15 | Softub, Inc. | Insulated cover for a hot tub |
US5802630A (en) * | 1996-04-15 | 1998-09-08 | Softub, Inc. | Insulated cover for a hot tub |
US5970530A (en) * | 1998-04-28 | 1999-10-26 | Softub, Inc. | Hinged cover for a spa tub |
US5974600A (en) * | 1998-10-15 | 1999-11-02 | Hercules Products, Inc. | Spa cover |
US6093358A (en) * | 1998-01-27 | 2000-07-25 | Lear Corporation | Method of making an expandable gap filling product |
-
2003
- 2003-03-21 US US10/393,725 patent/US20040181867A1/en not_active Abandoned
-
2004
- 2004-03-22 WO PCT/US2004/008754 patent/WO2004085769A1/en active Application Filing
Patent Citations (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3954926A (en) * | 1971-06-03 | 1976-05-04 | Fritz Wilhelm Pahl | Method of molding a composite reinforced foamed product |
US3970324A (en) * | 1973-03-05 | 1976-07-20 | American Marine Industries, Inc. | Foam-filled, cellular structural product |
US4078293A (en) * | 1975-02-13 | 1978-03-14 | Aine Harry E | Method of making rigid swimming pool cover |
US4122203A (en) * | 1978-01-09 | 1978-10-24 | Stahl Joel S | Fire protective thermal barriers for foam plastics |
US4857374A (en) * | 1988-11-15 | 1989-08-15 | Perry Gary L | Structurally strong, non vapor, non moisture absorbing, spa/hot tub cover |
US5619759A (en) * | 1995-06-07 | 1997-04-15 | Softub, Inc. | Insulated cover for a hot tub |
US5802630A (en) * | 1996-04-15 | 1998-09-08 | Softub, Inc. | Insulated cover for a hot tub |
US6093358A (en) * | 1998-01-27 | 2000-07-25 | Lear Corporation | Method of making an expandable gap filling product |
US5970530A (en) * | 1998-04-28 | 1999-10-26 | Softub, Inc. | Hinged cover for a spa tub |
US5974600A (en) * | 1998-10-15 | 1999-11-02 | Hercules Products, Inc. | Spa cover |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20120045602A1 (en) * | 2010-08-18 | 2012-02-23 | Armacell Enterprise Gmbh | Protected expanded polyalkylidene terephthalates |
US9334380B2 (en) * | 2010-08-18 | 2016-05-10 | Armacell Enterprise Gmbh & Co. Kg | Protected expanded polyalkylidene terephthalates |
Also Published As
Publication number | Publication date |
---|---|
WO2004085769A1 (en) | 2004-10-07 |
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Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: STEALTH INDUSTRIES LTD., CHINA Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:BONELLI, JONATHAN J.;COWDELL, MATT;SACCOCCIO, MITCHELL;REEL/FRAME:013896/0607;SIGNING DATES FROM 20030307 TO 20030310 |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |