Abstract:
A spa according to the present invention includes a shell having a plurality of seating positions formed in the shell, a base supporting the shell, and a hydrotherapy system configured to draw a fluid from the spa and inject the fluid back into said spa as at least one a pressurized jet. The hydrotherapy system includes a pump for circulating the fluid and a jet pod arranged in at least one of the seating positions and in fluid communication with the pump.

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to spas and, more particularly, to pressurized manifold and jet system for a spa. 
     BACKGROUND OF THE INVENTION 
     Spas, also commonly known as hot tubs, are generally deep vacuum formed tubs having a smooth acrylic interior surface or liner. The tubs are provided with a number of fixtures including water jet assemblies that provide hydrotherapy to users of the spa when the spa is filled with water. 
     Spas are typically manufactured by heating an acrylic sheet to a forming temperature, stretching the sheet onto a mold, and holding the sheet against the mold by applying a vacuum between the mold surface and the sheet. After forming the acrylic liner, holes are then manually cut through the liner for various components including the water jets. A typical spa may include anywhere from 30-120 or more water jets, and construction of the spa requires cutting 30-120 holes in the acrylic liner to accommodate the jets. Once the cutouts for the jets have been made, jet assemblies must be placed in each cutout, which includes placing a gasket between a wall fitting of the jet assembly and the interior surface of the tub, providing the wall fitting through the cutout, and threading a jet valve body onto the wall fitting from the back of the tub such that the wall fitting and the jet valve body sandwich the tub wall. A bead of caulk is utilized to seal the jet valve body to the back of the tub wall. 
       FIGS. 1 and 2  illustrate the back of a prior art spa and, in particular, illustrate a plurality of jet assemblies  12  that are mounted in cutouts in the spa liner  14 . As shown therein, each jet assembly  12  includes fittings for connecting a water supply line  16  and an air supply line  18  thereto. Each air supply line  18  is connected to a pressurized air source (not shown), and each water supply  16  line is connected to a water manifold  20 . In operation, water is drawn from the tub by a pump, passed through a heating element to heat the water to a desired temperature, and delivered to the manifold  20  and supply lines  16  to the jet assemblies  12 . Water supplied to the jets  12  is mixed with air from the air supply lines  18  to make the stream from the jets  12  more robust. 
     Notably, however, spas with this type of circulation system are extremely costly and time consuming to manufacture, and are prone to leaking. In particular, making each cutout and assembling and mounting upwards of 120 jet assemblies by hand is extremely time consuming and tedious and often requires two people. Moreover, each jet assembly, each fitting on each jet assembly for the water and air lines, and each connection to the water manifold is a potential leak point. As will be readily appreciated, this presents upwards of 360 or more possible places in the spa that leaks may occur. Moreover, existing spas are especially leak-prone where metal components are used (due to corrosion). 
     From a business standpoint, therefore, spas are extremely time consuming and costly to manufacture due to the manual labor necessary to install each individual jet assembly and the dedicated water and air supply lines for each jet. Moreover, repair and warranty costs are often a concern, mostly due to the high number of potential leakage points, as discussed above. 
     In addition, spas of this type typically require the use of two 5 hp motors to run the pumps that push the water through the circulation system. This requirement stems mainly from the high degree of hydraulic impedance resulting from the many twists and turns of the numerous water supply lines. As will be readily appreciated, therefore, the use of two motors, or a single motor having a higher output, adds additional costs to the spa as a whole. 
     In view of the above, there remains a need for a jet system for a spa that is less prone to leakage, lowers impedance and decreases overall repair and warranty costs. In addition, there is a need for a jet system for a spa that can be easily customized to provide a desired degree and type of hydrotherapy. 
     SUMMARY OF THE INVENTION 
     It is an object of the present invention to provide a jet system for a spa. 
     It is another object of the present invention to provide a jet system for a spa in the form of a pressurized manifold. 
     It is another object of the present invention to provide a jet system for a spa having fewer components. 
     It is another object of the present invention to provide a jet system for a spa having components that are less prone to corrosion. 
     It is another object of the present invention to provide a jet system for a spa that is less prone to leakage than existing systems. 
     It is another object of the present invention to provide a jet system for a spa that lowers hydraulic impedance. 
     It is another object of the present invention to provide a jet system for a spa that decreases overall repair and warranty costs. 
     It is another object of the present invention to provide a jet system for a spa that can be easily customized. 
     In an embodiment, a spa according to the present invention includes a shell having a plurality of seating positions formed in the shell, a base supporting the shell, and a hydrotherapy system configured to draw a fluid from the spa and inject the fluid back into said spa as at least one a pressurized jet. The hydrotherapy system includes a pump for circulating the fluid and a jet pod arranged in at least one of the seating positions and in fluid communication with the pump. 
     In another embodiment, a spa includes a shell having a plurality of seating positions formed in the shell, a base supporting the shell, and at least one jet pod arranged in each of the seating positions. Each of said jet pods includes a generally hollow body having an inlet configured to accept a supply of water and a plurality of outlet apertures configured to deliver a plurality of streams of pressurized water to an interior of the spa. 
     In yet another embodiment, a jet pod assembly for a spa is provided. The jet pod assembly includes a generally hollow body defined by a plurality of sidewalls and opposed front and rear walls, an inlet aperture formed in the rear wall, and a plurality of outlet apertures formed in the front wall. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention will be better understood from reading the following description of non-limiting embodiments, with reference to the attached drawings, wherein below: 
         FIG. 1  is a perspective view illustrating a prior art jet system for a spa. 
         FIG. 2  is another perspective view illustrating the prior art jet system of  FIG. 1 . 
         FIG. 3  illustrates a jet system for a spa according to an embodiment of the present invention. 
         FIG. 4  is a perspective view of a jet pod of the jet system of  FIG. 3 . 
         FIG. 5  is a perspective view of a connection between a water supply line and the jet pod of  FIG. 4 . 
         FIG. 6  is an exploded, perspective view of wall fittings of the jet system utilized to connect the jet pod to the water supply line. 
         FIG. 7  is a perspective view of the wall fittings of the jet system of  FIG. 6 , shown in an assembled state. 
         FIG. 8  is another view of the wall fittings of the jet system of  FIG. 6 , shown in an assembled state. 
         FIG. 9  is a perspective view of a male fitting utilized to connect the jet pod to the wall fittings. 
         FIG. 10  illustrates the jet pod and wall fittings mounted to the shell of a spa. 
         FIG. 11  is an enlarged view of the wall fittings mounted to the shell of a spa. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to  FIGS. 3-5 , a spa having a jet system  100  according to an embodiment of the present invention is shown. The spa may be of any type known in the art, and generally includes a base and an acrylic shell  112  supported by the base, as discussed above. Typically, the acrylic shell  112  of the spa is formed into shapes that provide a variety of seating arrangements within the spa. In an embodiment, each seating area within the spa may include a recess  114  for accommodating a jet pod  116  therein. In particular, as best shown in  FIG. 5 , the acrylic shell  112  may be vacuum formed with interior recessed areas  114  dimensioned to receive a jet pod  116  of the jet system  100  therein. 
     In an embodiment, the recessed areas  114  may be deep enough to fully accommodate the jet pod  116  therein such that the front face of the jet pod is generally coplanar with the inner surface of the acrylic shell  112 . Alternatively, the jet pods  116  may be mounted on stand-offs (not shown) on the inner surface of the shell  112 . In an embodiment, each seating area within the spa may include a recess  114  for accommodating a jet pod  116 . In other embodiments, each seating area within the spa may include a plurality of recesses  114  for accommodating multiple jet pods  116  therein. 
     As shown in  FIG. 3 , the jet pods  116  are secured to the acrylic shell, in position within the recesses  114 , utilizing an array of fittings  118 , as discussed hereinafter. 
     With specific reference to  FIG. 4 , each jet pod  116  is a generally hollow body formed from plastic having a single, large inlet aperture (not shown) on a rear side thereof and an array of small exit apertures  120  on a front side thereof. The jet pods  116  may be formed by rotational molding, although other methods known in the art may also be utilized without departing from the broader aspects of the present invention. While the jet pods  116  are illustrated as being substantially rectangular in shape, the jet pods  116  may be produced in a variety of shapes designed to match the recesses  114  in the shell  112 , without departing from the broader aspects of the present invention. Notably, the array of apertures  120  in the front face of the jet pod  116  may take any configuration such that circulated, pressurized water within the pod  116  may be ejected through the apertures  120  to provide hydrotherapy to a user of the spa. 
     With further reference to  FIG. 3 , and with reference to  FIGS. 6-8 , the integration of the jet pods  116  with the spa will be discussed hereinafter. As noted above, the jet pods  116  are mounted to the shell  112  of the spa within the recessed areas  114  utilizing an array of fittings  118 . In particular, the array of fittings include a nut  122 , a first gasket  124 , a wall fitting  126 , a second gasket  128 , an inner fitting  130  and a manifold fitting  132 . The wall fitting  126  is generally cylindrical in shape and includes an externally threaded body portion  134  and an annular flange  136  formed adjacent to one end of the body portion. The body portion  134  is dimensioned so as be threadedly received by nut  122 , and is also internally threaded so as to mate with inner fitting  130 , as discussed hereinafter. 
     During installation the first gasket  124  is positioned on the body portion  124  of the wall fitting  126  adjacent the annular flange  136 . The body portion  124  is then provided through an aperture in the shell  112  within the recessed area  114  thereof. Nut  122  is then threaded onto the body portion  134  and tightened until the flange  138  of the nut  122  and the flange  136  of the wall fitting  126  sandwich the shell  116  therebetween.  FIG. 5  illustrates the wall fitting  126  retained in position within recessed portion  114  of the shell  112  by the nut  122 . Prior to or after installing the wall fitting  126 , second gasket  128  is inserted into the flange end of the wall fitting  134 . Inner fitting  130  is then threaded into the wall fitting  126  adjacent to the flange end thereof to retain the second gasket  130  in place.  FIG. 11  shows the second gasket  128  retained in position between the wall fitting  126  and the inner fitting  130 .  FIGS. 7 and 8  illustrate the assembled position of the array of fittings  118  (the shell  112  of the spa being omitted for illustrative purposes). 
     With reference to  FIG. 9 , a detailed view of the male fitting  132  is shown. As illustrated therein, the male fitting  132  is generally conical in shape and has a plurality of steps. The fitting  132  is externally threaded at one end thereof and is configured to mate with a corresponding threaded aperture in the rear of the jet pod  116  (see  FIG. 3 ). Adjacent to each of the steps is a raised, peripheral ring  140  that functions to retain the male fitting  132  within the wall fitting  126  as described below. After the wall fitting  126 , gaskets  124 ,  128 , nut  122  and inner fitting  130  have been secured in place on the spa shell  112 , the end of the male fitting  132  is inserted into the inner fitting  130  and wall fitting  126  until one or both of the peripheral rings  140  are urged past the second gasket  128  in the wall fitting  126 . 
     Once urged past the gasket  128 , the male fitting  132  and the jet pod  116  attached thereto are retained in place, as shown in  FIG. 10 . In particular, peripheral ring  140 , and its engagement with gasket  128 , prevents the male fitting  132  (and jet pod  116 ) from being disengaged from its seated position within the wall fitting  126  when water is circulated. As also shown in  FIG. 10 , each recess  114  may include a mounting surface or mounting standoffs that are attached with adhesive to the shell  112 . The jet pods  116  may then be attached to the mounting standoffs to secure them in place within the recesses  114 . Importantly, this manner of attaching the jet pods  116  to the spa shell  116  obviates any need to use mechanical fasteners which may increase the potential for leaks. 
     Referring once again to  FIG. 5 , once the jet pods  116  are secured in place within the recesses  114  in the seating positions formed the shell  112  utilizing the array of fittings  118 , a water supply line  142  may be connected to each of the wall fittings  126  on the back side of the shell  112 . 
     In an embodiment, the fittings  118  are formed from plastic such as PVC, although other materials known to resist corrosion may also be utilized without departing from the broader aspects of the present invention. In addition, the first and second gaskets  124 ,  128  are formed from deformable plastic or other deformable material. Importantly, the jet pods  116  themselves and the array of fitting  118  utilized to connected each jet pod  116  to the shell  112  of the spa are manufactured from materials that won&#39;t corrode. As will be readily appreciated, this eliminates any potential for leakage due to corrosion of any of the components, thereby decreasing the potential for needed repairs. 
     In operation, water is drawn from the spa by a pump, passed through a heating element to heat the water to a desired temperature, and delivered to one or more supply manifolds (not shown). The water may then be distributed through the water supply lines  142  to each of the jet pods  116 . In an embodiment, the heated water may also be mixed with pressurized air, as is known in the art. In this manner, the heated water flows through the shell  112  of the spa and into the jet pods  116 . This creates a pressurized vessel which releases pressure through the apertures  120  in the front face of the jet pods  116 , thereby providing hydrotherapy jets of a water that impinge upon the body of a user seated in the spa in one of the seating arrangements. 
     Importantly, pressurized jet pods  116  produce the same effects as traditional hydrotherapy spa jets but are much less costly and time consuming to install. In particular, the apertures  120  on the front face of the jet pods  116  function in a manner substantially similar to, and take the place of, the numerous individual jets of traditional spas. Instead of manually cutting out apertures and installing numerous individual hydrotherapy jets for each seating arrangement (and up to 120 jets per spa), however, only a single jet pod  116  need be installed for each seating arrangement. As will be readily appreciated, this greatly decreases the labor and time needed to install the jet system for the spa. 
     Moreover, as there are generally only one or two jet pod assemblies  116  per seating arrangement, there are many less potential leakage points as compared with traditional jet systems having numerous individual jets per seating arrangement. Indeed, while there is generally only one water supply line  142  for each seating arrangement, and thus only a single potential leakage point per seating arrangement, existing hydrotherapy systems have separate water supply lines for each individual jet, and thus a potential leakage point at the connection points between each individual jet and its water supply line. In addition, because the jet pods  116  and fittings  118  are formed from plastic or other corrosion-resistant material, leakage due to corrosion is all but eliminated. As a result, repair and warranty costs over the life of the spa are may be greatly decreased. 
     In connection with this, because there are fewer water supply lines  142  (due to the fact that there are a limited number of jet pods  116  in each spa), hydraulic impedance is much lower. As a result, a spa employing the jet system of the present invention can be operated utilizing a single motor, or a motor with a lesser output than would be required with traditional spas, thereby decreasing the cost of the spa as a whole. 
     In addition to the benefits described above, the jet system  100  according to the present invention provides a level of customization heretofore unknown in the art. In particular, the jet pods  116  may be manufactured with different exit aperture configurations that provide varied hydrotherapy experiences for a user. As such, if a user wants a different hydrotherapy experience (e.g., a more pointed application of water pressure, higher pressure, or lower pressure, etc.), the user can simply select a jet pod  116  configured to deliver the desired experience. The jet pod  116  in the seating position may then simply be swapped out for the alternative jet pod simply by disengaging the male fitting  132  (and jet pod  116 ) from the second gasket  128  and wall fitting  126  and inserting the new jet pod into place. In this manner, changing the hydrotherapy experience at a seating position may be as easy as swapping a single jet pod  116  configured to deliver one hydrotherapy experience for another jet pod  116  configured to deliver another hydrotherapy experience. 
     Although this invention has been shown and described with respect to the detailed embodiments thereof, it will be understood by those of skill in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed in the above detailed description, but that the invention will include all embodiments falling within the scope of this disclosure.