Abstract:
Spa side panels are trapezoidally-shaped and mounted in respective grooves defined by adjacent tapered corner pieces and their mounting brackets to accommodate differences in coefficients of expansion of the respective parts and prevent structural damage. Angled force transfer members are configured to mate with swept back side surfaces of a spa base pan to achieve a pedestal appearance, and the bottom surface of the base pan is constructed to reduce heat transfer to the spa support surface.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional of and claims the benefit of and priority to U.S. patent application Ser. No. 14/263,144 filed Apr. 28, 2014 entitled “Portable Spa Construction” which claims the benefit of and priority to U.S. Provisional Application Ser. No. 61/927,396, filed Jan. 14, 2014, of the same title, the contents of each of which is hereby incorporated by reference herein in its entirety. 
    
    
     BACKGROUND OF THE DISCLOSURE 
     Field of the Disclosure 
     The subject disclosure relates to spas, tubs, and the like and more particularly to an improved portable spa structure and the construction thereof. 
     Related Art 
     Portable spas have become quite popular as a result of their ease of use and multiplicity of features such as varied jet and seating configurations. 
     SUMMARY 
     The following is a summary of description of illustrative embodiments of a new spa structure, and more particularly a new portable spa structure. It is provided as a preface to assist those skilled in the art to more rapidly assimilate the detailed design discussion which ensues and is not intended in any way to limit the scope of the claims which are appended hereto in order to particularly point out the invention. 
     According to an illustrative embodiment, a spa structure is provided comprising a plurality of corner pieces, each positioned at a respective corner of the structure and a plurality of trapezoidal shaped side panels positioned between the corner pieces. Each side panel is positioned with its respective side edges located in grooves defined by the corner pieces and their mounting brackets such that each side panel may move or slide both horizontally and vertically with respect to the corner pieces and other structural parts so as to accommodate expansion or contraction of the side panels. In this configuration, a lower edge of each side panel is held in place by a plurality of panel clips, each of which is pivotable into and out of a panel retaining position, which facilitates panel installation and disassembly. 
     Such an illustrative structure may further include a generally rectangular base pan of smaller width and length than a generally rectangular outer upper rim of the spa, with the base pan being centrally positioned within and beneath the outer upper rim and including a plurality of downwardly and inwardly swept back lower side surfaces extending from the lower edges of the side panels to lower edges of the base pan. A plurality of vertical support members are configured to support an upper rim of a spa shell, and a plurality of angled force transfer members are attached at respective lower ends of the vertical support members to transfer force from each respective vertical support member to an inner bottom surface of the base pan. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a portable spa according to an illustrative embodiment; 
         FIG. 2  is a perspective view illustrating the internal structure of the spa of  FIG. 1 ; 
         FIG. 3  is an inverted perspective view of illustrative frame structure of the spa of  FIG. 1 ; 
         FIG. 4  is an inverted perspective view of the spa of  FIG. 1  with side panels removed; 
         FIG. 5  is a perspective view illustrating a bottom pan component of the spa of  FIG. 1 ; 
         FIG. 6  is a perspective fragmentary view illustrating internal support members of the spa of  FIG. 1  according to an illustrative embodiment; 
         FIG. 7  is a perspective view illustrating assembly of angled force transfer member components according to an illustrative embodiment; 
         FIG. 8  is a top perspective view of an illustrative angled force transfer member; 
         FIG. 9  is a side perspective view of respective halves of an angled force transfer member according to an illustrative embodiment; 
         FIG. 10  is a side view illustrating internal structure of a first half of the illustrative angled force transfer member; 
         FIG. 11  is a side view illustrating internal structure of a second half of the illustrative angled force transfer member; 
         FIG. 12  is a first side view of the assembled angled force transfer member; 
         FIG. 13  is a second side view of the assembled angled force transfer member; 
         FIG. 14  is a front view of the assembled angled force transfer member; 
         FIG. 15  is a back view of the assembled angled force transfer member; 
         FIG. 16  is a fragmentary perspective view illustrating a corner portion of the spa of  FIG. 1 ; 
         FIG. 17  is a fragmentary front view of the corner portion of  FIG. 17 ; 
         FIG. 18  is a fragmentary side perspective view of the spa of  FIG. 1  with a side panel removed; 
         FIG. 19  is a perspective view of an illustrative embodiment of a panel clip in an “open” position; 
         FIG. 20  is a perspective view of the panel clip of  FIG. 19  in an “closed” position; 
         FIG. 21  is a side view of a latch component of the panel clip of  FIG. 19 ; 
         FIG. 22  is a front view of a latch component of  FIG. 21 ; 
         FIG. 23  is a rear perspective view of a pivot component of the panel clip of  FIG. 19 ; 
         FIG. 24  is a front perspective view of the pivot component of  FIG. 23 ; 
         FIG. 25  is a rear view of the panel clip of  FIG. 19 ; 
         FIG. 26  is a rear view of the panel clip of  FIG. 25  wherein the latch component has moved to the right in the Figure; 
         FIG. 27  is a top view of the panel clip of  FIGS. 25 and 26  in the “open” position; 
         FIG. 28  is a fragmentary perspective view of the panel clip in a “closed” position; 
         FIG. 29  is a second fragmentary view of the panel clip of  FIG. 28 ; 
         FIG. 30  is a front schematic view illustrating installation of a side panel according to an illustrative embodiment; and 
         FIG. 31  is a front schematic view illustrating the side panel of  FIG. 30  in the installed position. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  illustrates a portable spa  11  having a spa shell  13 , side panels, e.g.,  15 ,  17  and tapered corner fascia pieces, e.g.,  19 ,  21 ,  23 . The spa shell  13  has a generally rectangular rim  12  about its upper periphery and includes various features such as jets, e.g.  25 ,  27 , a filter compartment  29  and a remote control  31 . As may be seen, the lower edges  33  of the side panels  15 ,  17  do not extend to the bottom edges  35  of the corner pieces  19 ,  21 ,  23  but rather terminate at a distance “d” ( FIG. 2 ) above the slab, deck, ground or other surface  30  on which the spa rests, such distance “d” being, for example, 6 inches in one embodiment. In the illustrative embodiment, the corner pieces, e.g.,  19 ,  21 ,  23 , are slightly spaced above, and do not contact, the surface  30 . Additionally, as shown in  FIGS. 30 and 31 , the side panels  15 ,  17  are trapezoidal in shape in one illustrative embodiment. 
     The spa  11  further includes a base pan  39  shown in  FIGS. 2, 4, and 5 . As may be seen, the lower peripheral side surfaces  37  of the base pan  39  are recessed inwardly or swept back from the side panel edges  33  to provide a pedestal effect, giving the appearance that the spa  11  contacts the floor  36  only at its four corners and at the recessed edge  36  of the base pan  39 . The spa base pan  39  itself has four corners  40 , each of which lies within and is concealed by a respective corner fascia piece, e.g.  19 ,  21 ,  23 . As seen in  FIG. 4 , the bottom of the base pan  39  further includes a grid work of rectangular areas  41  which include recessed fins or “thermal separators” , e.g. 43 ( FIG. 5 ). The grid work is defined by perpendicularly disposed ribs  45 ,  47 , whose flat bottom surfaces also rest on the surface  30 . The rib and thermal separator structure on the bottom of the base pan  39  minimizes the surface area of the base pan  39  which is in contact with the surface  30  and, hence, reduces heat transfer from the spa  11  to the surface  30 . 
     As shown in  FIGS. 2 and 3 , in order to support the spa shell  13 , vertical support members  51  are provided to which are attached angled force transfer members  53 , for example, by gluing, snap-fitting, or other fastening mechanism.  FIG. 6  particularly shows the inter-fitting relationship of the base pan side surface  37  and the force transfer members  53  according to an illustrative embodiment. As may be seen, the side surface  37  has an inner horizontally disposed top step  42  and a horizontally disposed lower step  44 . The angled force transfer member  53  includes a stepped edge  46  shaped to mate with the top step  42 . The stepped edge  46  forms into an angled surface  48 , which rests on the swept back surface  37 . The angled surface  48  continues into a second step  243 , which mates with the lower step  44 . A slot or channel  50  is further formed in the base pan  39  and snugly receives a foot portion  34  of the angled force transfer member  53 . Mating surfaces of the base pan surface  37  and the force transfer member  53  may be glued, snap-fitted, or otherwise fastened together in position in various embodiments. 
     In one embodiment, the vertical support member  51  and the angled force transfer member  53  may be fabricated of extruded ABS plastic and injection molded ABS plastic, respectively. The base pan  39  may be a thermoformed ABS plastic sheet. Other materials and fabrication techniques may of course be used in other embodiments. 
     In one embodiment, the force transfer member  53  may be a two piece component comprising respective halves  131 , 133 , as shown in  FIGS. 7 to 15 . The halves  131 ,  133 , are mated together utilizing two tabs  141 ,  143 , formed on the first half  131  and two tabs  150 ,  151  formed on the second half  133 . These tabs  141 ,  143 ;  150 ,  151  may be seen in  FIGS. 11 and 10 , respectively. 
     As further shown in  FIG. 10 , the interior  137  of the second half  133  of the force transfer member  53  may have height markers, e.g. “ 29 ”, “ 33 ”, “ 36 ”, “ 38 ” molded or formed therein or applied thereto and located adjacent respective slots  139   a ,  139   b ,  139   c , and  139   d  to indicate the particular spa rim height which can be accommodated by utilizing a particular slot. In operation, the two tabs  150 ,  151  on half  133  (e.g.  FIG. 10 ) slide into one of the four groove pairs  135   a ,  134   a ;  135   b ,  134   b ;  135   c ,  134   c ;  135   d ,  134   d , of the respective outer side surfaces of the first half  131  to select a particular height, while the tabs  141 ,  143  enter into a pair of holes or apertures  147 ,  149  ( FIG. 9 ) of the second half  133 . Thus, the first half  131  of the force transfer member  53  can be telescoped between positions - 38 -, - 36 -, - 33 -, - 28 - to increase or decrease the length of the angled force transfer member  53  and can be locked in position by the tabs  150 ,  151 , as further described below. 
     The manner in which the first and second halves  131 ,  133  of the force transfer member  53  are attached together is further illustrated in  FIG. 7 . As may be seen, the tab  150  is riding in the second groove  135   c . The tab  151  is also riding in a generally parallel groove  134   c  on the opposite side of the first half  131 . At the same time, the tabs  141 ,  143  of the first half are passing through grooves  139   b ,  140   b  ( FIG. 10 ) of the second half  133 , thereby selecting the height of -33- inches. When the tabs  150 ,  151 , reach the end of the respective grooves  135   c ,  134   c , they snap down over the side surface  136  of the component  131 , e.g., as shown in  FIG. 12 , to hold the respective halves  131 ,  133  together. At the same time, the tabs  141 ,  143  enter a pair of the slots  147 ,  149 , as illustrated in  FIG. 13 , to further hold the assembly together. It may be noted that  FIGS. 12 and 13  illustrate the -28- inch assembly position, whereas the assembly shown in  FIG. 7  would result in tabs  150 ,  151  being positioned one groove up ( 135   c ,  134   c ) and the tabs  141 ,  143  being positioned one slot down from the positions shown in  FIGS. 12 and 13 . 
     As shown in  FIGS. 10 and 11 , for example, the first half  131  has a tongue  171  and a cavity  174  formed in its interior, and the second half  133  has a cavity  172  and a tongue  173  formed in its interior. When the first and second halves  131 ,  133  are mated together, the tongue  171  on the interior of the first half  131  fits into the cavity  172  in the second half  133 , while the tongue  173  of the second half  133  fits into the cavity  174  formed in the first half  131 . The first half  131  further has an open or “cut-out” area  162  of rectangular cross-section formed therein ( FIG. 7 ). In one embodiment, the area  162  has a shape identical to that of area  161  ( FIG. 9 ). Additional open or hollow areas, e.g.,  164  and area  165  ( FIG. 8 ), are formed in the components  131 ,  133  to capture foam sprayed into the interior of the spa shell to thereby create a rigid foam/plastic structure. 
     As shown in  FIG. 8 , the illustrative force transfer member  53  has an upper receptacle  241  of generally rectangular cross-section formed as a part thereof having a rectangular rim  247  and a hollow interior  343 . First and second u-shaped projections  201 ,  202  are formed in the hollow interior  343 . In one embodiment, the lower end of a vertical support member  51  is configured to snugly mate or snap fit with the structure of the receptacle  241 . 
     The illustrative embodiment is further constructed such that each side panel  15 ,  17 , may be slid into position and retained in place without abutting or being attached to the corner pieces  19 ,  21 ,  23  or other spa structure. For this purpose, corner piece groove structures  65  are provided as shown in  FIGS. 16 and 17 , and three panel clips  69  are positioned along a lower surface  72  of the base pan  39 , as shown in  FIG. 18 . While three panel clips  69  are shown in  FIG. 18 , the number of clips could be one, two, or more in various embodiments. 
       FIG. 16  illustrates attachment of one of the tapered corner pieces  19  to respective vertical support members  51  using a number of “U”-shaped brackets  105 . A first leg of each bracket  105  attaches to the support member  51  and a second leg attaches to the corner piece  19 . The length “L” of the first leg of each bracket  105  increases as the edge  107  of the corner piece  19  tapers away downwardly. In one embodiment, the angle θ ( FIG. 17 ) between the corner piece&#39;s tapered edge  107  and the vertical is an acute angle, for example, such as six or seven degrees. The increasing bracket length effectively defines a gap or groove  65  between the brackets  105  and the corner piece  19  which lies along the dashed line  109 , effectively paralleling the tapered outside edge  107 . In the illustrative embodiment, the same type of groove  65  is formed by U-shaped brackets  105  associated with each of the other three corner pieces, e.g.,  21 ,  23 . 
     The structure and operation of the panel clips  69  is further illustrated in  FIGS. 19-27 . Each panel clip  69  includes a pivot component  73  ( FIGS. 23, 24 ) and a latch component  75  ( FIGS. 21, 22 ). The latch component  75  has a hook-shaped back  79 , which is unitarily formed with a front portion  80  having first and second lips  81 ,  83 , whose inner surfaces define a channel  85 . The hook-shaped back  79  includes a slot  87  and an elongated opening  89 . 
     As shown in  FIGS. 23 and 24 , the pivot component  73  has an arcuate back surface  78  from which project two bosses  120  through which are formed respective holes  77 . As illustrated in  FIGS. 28 and 29 , respective screws or other fasteners  82  are inserted through the holes and into a side surface  72  of the molded base pan  39 . The bosses  120  cause the arcuate back surface  78  to be spaced apart from the side surface  72  such that the latch component  75  can slide with respect to the pivot component  73 . Thereafter, the latch component  75  may be pivoted from the open position shown in  FIG. 19  to the locked position shown in  FIGS. 20, 28 , and  29  in which the channel  85  is oriented vertically so as to retain and prevent downward movement of the bottom edge of a panel  33  of a panel  15  while allowing the panel  15  to move laterally. 
       FIGS. 25-27  illustrate the operation of the panel clips  69  in more detail.  FIG. 25  is a back view of the clip  69  in the locked position of, e.g.,  FIGS. 20 and 28 . In this position, the right boss  120  of the pivot component  73  extends through the opening  89 , and the left boss  120  extends through the slot  87 . Hence, the latch component  75  cannot pivot due to the abutment of the bosses  120  with the respective adjacent surfaces of the opening  89  and the slot  87 . In this position, in an illustrative embodiment, the screws  82  have further been tightened down to hold the components  73 ,  75  in the locked position. 
       FIG. 26  is also a back view of the clip  69 , but in this case, the screws  82  have been unloosened slightly, and the latch component  75  has been moved to the right such that the left boss  120  has moved out of the slot  87 , and the right boss  120  has moved into position over a cut-out area  123  formed in the latch component  75 . In such position, the latch component  75  is free to pivot with respect to the pivot component  73 . 
       FIG. 27  is a top view of the clip  69  after the latch component  75  has been pivoted to the unlocked position of  FIG. 19 . In this position, the right boss  120  has pivoted into the cut out area  123  of the latch component  75 , and the left boss  120  lies adjacent an outer leg  124  of the latch component  75 . 
     The structure thus far described facilitates a side panel mounting method illustrated in  FIGS. 30 and 31 . As shown in  FIG. 30 , the spa  11  is positioned or raised off the mounting surface  30 . A trapezoidal side panel  15  is then inserted upwardly such that its upper corners and its sides slide into the grooves  65  defined by brackets  105  and the corner pieces  19 ,  21 . The panel  15  is then slid further upwardly until its top edge  102  passes behind the rim  12 . At that point, the panel clips  69  are each moved into the locked position shown in  FIGS. 20, 28, and 29  and the screws  82  are tightened to locking position. 
     The just-described side panel mounting method has the advantage that the side panels e.g.  15  are not rigidly attached to the corner pieces e.g.  19 ,  21 ,  23  or other structure, and therefore the panels e.g.  15  may expand and contract with temperature variations without the exertion of forces which would distort or otherwise damage the panels e.g.  15  if they were not free to expand or contract vertically or horizontally. This method has particular advantages in certain embodiments where the corner pieces, e.g.,  19 , are made of plastic and the side panels e.g.  15  are constructed of wood or of a plastic which has a coefficient of expansion which is different than that of the corner piece plastic. In such embodiments, the side panels e.g.  15  may expand or contract as much as half-inch in very hot or cold conditions, which would likely damage the spa structure, for example, by warping or cracking the panels  15 . 
     Those skilled in the art will appreciate that various adaptations and modifications of the just described preferred embodiment can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein.