Abstract:
A combination foldable spa cover and lifting device including a folding spa cover with integral lifting sockets and a lifting device having a pair of first ends pivotally connectable to a spa structure, and second ends having engagement shafts keyed to the lifting sockets such that a folded spa cover is easily lifted and displaced to one side of the spa structure by pivot of the lifting device and transport of the folded spa cover.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    This invention relates to improvements in spa covers with lifting devices and combines a spa cover and a lifting device, preferably of the type disclosed in my U.S. Pat. No. 5,974,599, issued Nov. 2, 1999. The spa cover lifting device of the referenced patent was further improved in U.S. Pat. No. 6,158,063, issued Dec. 12, 2000, which includes a spring assist for the pivotal lifting device that is preferred for the combination spa cover and lift unit of this invention.  
           [0002]    The foldable spa cover and lift unit of this invention integrates the lifting device with a foldable spa cover to improve the appearance and functionality of the combination. In addition the combined unit insures that the design of the lifting mechanism is coordinated with the design of a particular foldable spa cover.  
           [0003]    Spa covers come in a variety of different configurations adapted to conform to the open top of a spa. Typically, a heated spa has a spa structure or housing that supports an insulated spa cover to retain the heat of the spa water during periods of non-use. A conventional spa cover comprises a thick, insulated foam pad covered with a protective, impervious casing. Because the spa cover can become unwieldy, the modern spa cover is typically foldable along a center fold to facilitate removal and replacement. This folding feature of the modern spa cover was used to advantage in the spa cover lifting devices described in the referenced U.S. Pat. Nos. 5,974,599 and 6,158,063. A spa cover lifting device eases the burden of removing and replacing the spa cover by use of a pivoting lifting frame that is connected to the spa structure.  
           [0004]    In previous embodiments the lifting device has a cross member that spans the spa cover and takes advantage of the fold in the cover to engage the cover when lifting the folded cover to a convenient vertical storage position or returning the folded cover from the storage position to the top of the spa. In such a system the lifting frame has two arms that are pivotally mounted to the spa structure and support a cross member over the top of the spa cover. Although not fixed to the spa cover, the lifting frame is effectively connected to the cover when the cover is folded over the cross member of the frame. During periods of non-use, when the cover is unfolded and lying flat on the top of the spa structure, the cross member rests on the top of the cover and detracts from the appearance of the cover. In certain instances the weight of the cross member and lifting arms can deform the top of the cover. Additionally, when the spa cover lifting frame is sold as a kit, the frame must be provided with adjustment mechanisms in order to adapt the frame to a particular cover and spa structure.  
           [0005]    The integrated spa cover and lifting device of this invention enables the spa cover to be engaged at the sides thereby eliminating the unattractive and potentially damaging cross member. Additionally, with a part of the lifting mechanism incorporated into the cover, an adjustable cross member is not required and the frame parts are reduced in number and cost. In preferred embodiments of the improved combination spa cover and lifting device, the spa cover includes engagement sockets having a keyway for keying the lifting frame to the spa cover. In this manner, the spa cover and lifting device are sold as a package. This ensures that the lifting device sold with the spa cover is an authorized device and designed to maximize style and operability. These and other features of the improved spa cover and lift unit will become apparent from the following summary and detailed description of the preferred embodiments.  
         SUMMARY OF THE INVENTION  
         [0006]    The foldable spa cover and lift unit of this invention combines a foldable spa cover with an integral lifting mechanism for conveniently removing and replacing an insulated covering for a heated spa.  
           [0007]    The term “spa” is used to generally describe a hot tub or other bath facility with a whirlpool that is customarily used at home or in an apartment or condominium complex. In general, the volume of water in the spa is maintained heated for an extended period of time and it is therefore desirable to cover the spa with a cover that provides thermal insulation for the heated water to reduce the cost of reheating the water to the desired temperature. In addition, the insulated spa cover provides protection of the contained water from contamination with debris.  
           [0008]    The lifting mechanism includes a frame apparatus that is in part pivotally connected to the spa structure or housing of the spa. The frame apparatus preferably has telescopic side elements as disclosed in the referenced patents to permit adjustment of the frame apparatus to fit spas of different size and configuration.  
           [0009]    A conventional spa is typically constructed with an inner water container with external water heating and circulating systems to circulate heated water in the container. The inner container and circulating conduits are typically housed in a cabinet or in a support pedestal which provides an exterior surface for attaching the lifting apparatus. Details of the internal construction of the spa are omitted in this description as being unnecessary to the structure and operation of the combination spa cover and lift unit of this invention.  
           [0010]    The spa cover used in this invention is a folding type that includes a thick, padded cover piece that is essentially provided in two half segments connected together by a hinge seam for folding to facilitate the removal, replacement and storage of the cover. At least one of the segments of the folding cover includes an internal cross support to prevent the cover from sagging when spanning a spa structure. In this invention the supporting internal cross member in at least one of the cover segments is utilized for anchoring an interconnection mechanism for engaging the distal ends of the arm members of the frame apparatus. The lifting device not only assists in removal and replacement of the cover, but is designed to conveniently store the folded cover in a suspended vertical position at the side of the spa to preserve the form of the cover piece and maintain the cover in an elevated position above the ground. The lifting device thereby minimizes the handling of the spa cover during use of the spa which avoids damage and greatly extends the useful life of the cover. These and other advantages will become apparent upon a consideration of the detailed description that follows.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0011]    [0011]FIG. 1 is a perspective view of the foldable spa cover and lift unit installed on a spa structure.  
         [0012]    [0012]FIG. 2 is a perspective view, partially in cross-section, of a half-cover segment of the spa cover with a first embodiment of an interconnection mechanism between the spa cover and the lifting device for the spa cover and lift unit of FIG. 1.  
         [0013]    [0013]FIG. 3A is a first cross-sectional view of a portion of the interconnection mechanism of FIG. 2 with the shaft assembly in engagement with the socket assembly.  
         [0014]    [0014]FIG. 3B is a second cross-sectional view of a portion of the interconnection mechanism of FIG. 2 with the shaft assembly in engagement with the socket assembly.  
         [0015]    [0015]FIG. 4 is a perspective view of a second embodiment of an interconnection mechanism of FIG. 1 illustrating the manner of interconnecting the shaft assembly with the socket assembly.  
         [0016]    [0016]FIG. 5 is a partial cross-sectional view of the interconnection mechanism of FIG. 4.  
         [0017]    [0017]FIG. 6 is a side elevational view of the spa cover and lift unit installed on a spa structure illustrating a first position in displacing the folded spa cover from the spa structure.  
         [0018]    [0018]FIG. 7 is a side elevational view of the spa cover and lift unit installed on a spa structure illustrating a second position in displacing the folded spa cover from the spa structure.  
         [0019]    [0019]FIG. 8 is a side elevational view of the spa cover and lift unit installed on a spa structure illustrating a third storage position of the folded spa cover at the side of the spa structure.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0020]    The combination foldable spa cover and lifting device is shown in FIG. 1 as a unit and designated generally by the reference numeral  10 . The spa cover and lifting unit  10  includes a foldable spa cover  12  and a lifting device  14  installed on a typical spa  16 . The spa  16  includes a generally rectangular housing structure forming an outer cabinet  18  to which the lifting device  14  is mounted and a perimeter top  20  on which the spa cover  12  is seated.  
         [0021]    The foldable spa cover in FIG. 1 is shown in its unfolded position covering the perimeter top  20  of the spa  16 . The cover is fabricated of a thick insulating material covered with a weather resistant and water impervious sheeting material. To minimize the weight of the spa cover  12 , the thickness of the cover tapers from the center fold  22  to the outer edges  24 . The spa cover  12  preferably includes a perimeter skirt  25  along the perimeter top  20  to improve the insulating seal of the spa cover  12  when seated on the spa  16 .  
         [0022]    The spa cover lifting device  14  comprises a frame apparatus  26  with a pair of side arms  28  pivotally mounted on brackets  30  on each of two opposing sides of the spa housing  18 . The mounting brackets  30  are preferably of the type disclosed in my U.S. Pat. Nos. 5,974,599 and 6,158,063. It is to be understood that other configurations of the side arms  28  and mounting brackets  30  can be provided for the spa cover and lifting unit  10  of this invention.  
         [0023]    The side arms  28  of the frame apparatus  26  include a distal end  32  having a shaft assembly  34  that engages a socket assembly  36  (not visible) allowing opposite sides of the folded spa cover to be pivotally engageable with the side arms  28  for lifting a folded spa cover  12  from the spa housing  18  when placing the spa cover into its storage position. To limit the travel of the frame apparatus  26 , the lifting device  14  includes a pair of tethers  38  which are attached to the pivotal side arms  28  and anchored to the housing structure  18  by a tether bracket  40 . The spa cover  12  includes two cover segments  46  and  48  which are first folded together before the frame apparatus  26  is lifted in an arcuate path to the storage position shown in FIG. 8. Different embodiments of the spa cover and lifting unit  10  having alternate means of pivotally interconnecting the side arms  28  of the frame apparatus  26  to opposite sides of the spa cover  12  are disclosed in FIGS.  2 - 5 .  
         [0024]    The combination of the spa cover  12  and the lifting device  14  includes an interconnection mechanism  44  that joins the two components into the integral cover and lift unit  10  of this invention. The interconnection mechanism  44  in the preferred embodiments pivotally joins the shaft assembly  34  and socket assembly  36  with a keyed interconnection to ensure that the frame apparatus  26  includes the approved design of the lifting device  14  for the cover and lift unit  10 .  
         [0025]    Referring now to FIG. 2, one embodiment of the interconnection mechanism  44  is shown with reference to one of the half-cover segments  46  of the spa cover  12 . The other half-cover segment  48 , shown in FIG. 1 is fabricated without the interconnection mechanism  44  and is simply carried by the mechanized half-cover segment  46  when folded on top of the half segment  46  and displaced by the lifting device  14 . The lifting device  14  includes a pair of side arms  28  with the distal end  32  connected to the shaft assembly  34  in the form of a cylindrical pin  50  having a keyway  52  in the form of a groove along the end portion  54  of the pin  50  that engages a cooperating projecting key  56  in the socket assembly  36 , as shown in the cross section of FIG. 3A. The socket assembly  36  is constructed with a cylindrical tube segment  58  that has a mounting bracket  60  fixed to a rigid U-channel  62  embedded into the insulating core  66  of the half-cover segment  46 . The rigid U-channel  62  provides a stiffener for the spa cover  12  and in combination with the side arms  28  forms completes the frame apparatus  26 . The rigid U-channel  62  is secured to the core  66  of the half-cover segment  46  by tape  68  that encircles the core  66  and U-channel  62  at a plurality of locations. It is to be understood that other means can be utilized to incorporate the U-channel  62  to the half-cover segment  46  of the spa cover  12 . The core  66 , U-channel  62  and tape  68  are encased in a covering material such as vinyl to protect the internal parts of the spa cover from the elements.  
         [0026]    To ensure that the pin  50  of the shaft assembly  34  can pivot with respect to the keyed tube segment  58 , which functions as a bearing, the pin  50  has a necked-down segment  70  having a depth approximately equal to that of the depth of the keyway groove  52 . The short key  56  is wholly positioned in the necked-down segment  70  when the pin  50  is fully inserted into the tube segment  58 . In such position, the flange  72  at the base of the projecting pin  50  abuts the end  74  of the tube  58 . It is to be understood that the pin  50  could include a projecting key and the tube segment  58  include an inside groove as a keyway with similar effect.  
         [0027]    In addition, the interconnection mechanism  44  includes a means for maintaining the longitudinal position of the pin  50  in the tube segment  58 . This is provided by a semi-circular groove  76  around the pin  50  located adjacent to but displaced from the flange  72 . This groove  76  is engaged by an O-ring  78  as shown in the cross-sectional view of FIG. 3B.  
         [0028]    In FIGS. 3A and 3B, the cross-sectional representations depict the shaft assembly  34  fully installed into the socket assembly  36 . In FIG. 3A, the necked-down segment  70  of the pin  50  locates the projecting key  56  wholly within the necked-down segment  70  enabling the tube segment  58  to pivot relative to the pin  50 . As shown in FIG. 3A, the bracket  60  is secured into a slot  80  in the U-channel  62  to fix the position of the tube segment  58  relative to the half segment  46  of the spa cover  12 . As described, the core  66  is wrapped by tape  68  and encompassed in a casing  82  of rugged, impervious and weather resistant material such as a vinyl and cloth composite. The casing  82  of the first half-cover segment  46  is coupled to the casing  84  of the other or second half-cover segment  48 , shown in part, by a seam  86  which provides a hinge for folding the carried segment over the carrier segment. In general, a single U-channel  62  is required to support the two half-cover segments  42  and prevent the segments from sagging when spanning the open top  20  of the spa  16 .  
         [0029]    In FIG. 3B, the cross -section is taken at the  0 -ring  78  which engages the semi-circular groove  76  in the pin  50  and the groove  76  around the pin  50 . In this manner the pin  50  can be pressed into the tube segment  58  with the O-ring releasably engaging the pin  50  to permit relative rotational movement, but to restrict relative axial displacement of the pin and tube segment in the interconnection mechanism  44 . At least one of the two sets of pin and tube segment combinations includes a key and keyway elements to insure that the approved lifting device is used with the spa cover.  
         [0030]    Referring now to FIGS. 5 and 6, a second embodiment of the interconnection mechanism  44  for the coupling of the spa cover  12  and lifting device  14  is shown. In the partially exploded view of FIG. 4, the interconnection mechanism includes a socket assembly  36  in the form of a tube segment  90  having a flattened portion  92  hinged to a mounting plate  94  that is fixed to the end of the rigid U-channel  62  by rivets  96 . The tube segment  90  of FIG. 4. is shown in an uplifted position for purposes of illustration in depicting how the flattened portion  92  provides a keyway for the co-operating pin  94  at the distal end  32  of the side arm  28 . The pin  94  includes a complimentary flattened portion  100  when inserting the shaft assembly  34  into the socket assembly  36  with the flattened portion  100  of the pin  94  aligned with the flattened portion of the tube segment. Normally, as shown in FIG. 5, the tube segment  90  is tucked under the rigid U-channel  62  allowing limited articulation of the shaft assembly  34  relative to the socket assembly  36 . In this embodiment, the relative pivot of the spa cover and lifting device is a complex motion about the axis of the hinge pin  102 . To releasably engage the shaft assembly  34  with the socket assembly  36 , the pin  94  of the shaft assembly  34  is equipped with a pair of spring loaded buttons  104  spaced on the flat portion  100  of the pin  94 . The spring loaded buttons engage a pair of complimentary recesses in the form of holes  106  in the flattened portion  92  of the tube segment  90 . The arrangement shown in FIG. 4 is for purposes of illustration and the interconnection mechanism  44  upon assembly is arranged as shown in FIG. 5 with the pin  94  and tube segment  90  located within a cavity  106  in the foam core  66 .  
         [0031]    In the preferred embodiments of the spa cover and lift unit  10 , the interconnection mechanism  44  is located at the sides  108  of the transported half-cover segment  46  adjacent the center fold  22  with the interconnection mechanism  44  and cross-support, U-channel  62  sealed by the casing  82 .  
         [0032]    In operation, the spa cover and lift unit  10  of this invention operates similar to the spa cover lifting device of U.S. Pat. No. 5,974,599, as schematically shown in FIGS. 6, 7 and  8 . As schematically illustrated in FIG. 6, the carried segment  48  is folded on top of the transport or carrier segment  46 . The carrier segment  46  is coupled to the side arm  28  on each side of the cover segment. One side arm is manually lifted to the position shown in FIG. 7. As the side arms  28  are further pivoted, the folded spa cover  12  is lowered to the side of the spa housing  18  and retained by the tether  38  in the vertical position illustrated. As reverse procedure is followed to reposition the folded spa cover over the perimeter top  20  of the spa  16  to the position shown in FIG. 6. From there, the carried cover segment  48  is simply folded away from the carrier segment  46  to complete the covering of the spa.  
         [0033]    It is to be understood that the key embodiments of the spa cover and lift unit disclose alternate means of implementing the operational features that render the spa cover and lift unit of this invention a desirable improvement over the unique lifting devices disclosed in my U.S. Pat. Nos. 5,974,599 and 6,158,063.  
         [0034]    While, in the foregoing, embodiments of the present invention have been set forth in considerable detail for the purposes of making a complete disclosure of the invention, it may be apparent to those of skill in the art that numerous changes may be made in such detail without departing from the spirit and principles of the invention.