Patent Publication Number: US-9845607-B2

Title: Cover assembly for a spa

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent Ser. No. 13/661,537, entitled “SPA HAVING A VERTICALLY ACTUATABLE COVER ASSEMBLY,” filed on Oct. 26, 2012, which claims the benefit of U.S. Provisional Application Ser. No. 61/553,665, filed on Oct. 31, 2011, both of which are herein incorporated by reference in their entireties. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to spas and, more particularly, to a sub-frameless spa having a vertically actuatable cover assembly and support structure for the same. 
     BACKGROUND OF THE INVENTION 
     The construction of spas is well known in the art. Typically, a spa is created by forming a wooden sub-frame made out of wood two-by-fours (or possibly a metal support frame or truss members) with an exterior wooden wanes coating or the like attached as an outer surface. Alternatively, a sub-frame made with two-by-fours or the like can be created which is coated on the outside with a form of plastic single wall panels. The wooden support frame typically then receives a formed acrylic or other type of plastic spa shell, as is well known in the art. 
     Existing sub-frame type spas may also include covers for preventing contamination due to environmental debris, such as leaves, pollen and the like, to prevent excess evaporation when the spa is not in use, and to act as a safety measure to prevent animals and children from falling into the water. Conventional spa covers may be fabric covered foam structures which rest atop the spa and are slid off the spa or are folded up when the spa is in use, or can be vertically movable covers that prevent contamination when resting atop the spa in a lowered position, and as a roof when in a raised position. U.S. Pat. No. 6,718,566 to Wilson and U.S. Pat. Nos. 7,600,271 and 7,614,093 to Piche et al. disclose various vertically movable covers for sub-frame type spas and lifting mechanisms therefor. 
     Notably, improvements in spa design and construction have eliminated the need to utilize wooden or any other type of sub-frame as a spa support structure. For example, U.S. Pat. No. 7,784,120 discloses a sub-frameless support structure for a spa that provides for cost savings, added strength and efficiency as compared to sub-frame type spas. Existing vertically movable covers, while being generally suitable for use with spas having a wooden or other sub-frame, are not readily adaptable to spas that are devoid of a sub-frame support structure. 
     In view of the above, there remains a need for a robust spa support structure that is capable of supporting a vertically movable cover assembly without the need for a sub-frame. There is also a need for a spa assembly having a vertically extendable cover assembly that allows access to components of the cover assembly within the support structure without removal of the spa shell or deconstruction of the spa support structure. 
     SUMMARY OF THE INVENTION 
     It is an object of the present invention to provide a sub-frameless spa having a vertically actuatable cover assembly. 
     It is another object of the present invention to provide a sub-frameless spa having a support structure for a vertically actuatable cover assembly. 
     It is another object of the present invention to provide a sub-frameless spa having a support structure for a vertically actuatable cover assembly that allows for easy access to components of the cover assembly within the support structure. 
     A spa according to the present invention includes a shell and a support structure including a base member, a plurality of side members and a plurality of end members to support the shell without the need for a sub-frame. The spa also includes a cover and a plurality of lifting members for supporting the cover. The lifting members are actuatable between a lowered position in which the cover is positioned generally atop the shell and an elevated position in which the cover is spaced from the shell and the support structure. The lifting members are secured to at least one of the side members and the end members. 
    
    
     
       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 top view of spa having a vertically actuatable cover assembly according to an embodiment of the present invention. 
         FIG. 2  is a perspective bottom view of the spa of  FIG. 1 , illustrating the cover assembly in a raised position. 
         FIG. 3  is a cross-sectional, perspective view of the spa of  FIG. 1 , illustrating a cover assembly lifting mechanism. 
         FIG. 4  is a perspective top view of the spa of  FIG. 1 , showing the cover assembly in a lowered position. 
         FIG. 5  is a cross-sectional perspective view of the spa of  FIG. 1 , with the cover assembly in a lowered position. 
         FIG. 6  is a perspective view of the sub-frameless support structure of the spa of  FIG. 1 . 
         FIG. 7  is a perspective view of the sub-frameless support structure of  FIG. 6 , showing the bottom thereof. 
         FIG. 8  is a perspective view of an interconnected end member and side member, shown partly in cross-section, of the sub-frameless support structure of  FIG. 6 . 
         FIG. 9  is a perspective view of an outside wall portion of a side member of the support structure. 
         FIG. 10  is a perspective view of an inside wall portion of a side member of the support structure. 
         FIG. 11  is a perspective view of a towel-warming accessory. 
         FIG. 12  is a perspective view of an accessory device in the form of a set of steps. 
         FIG. 13  is a perspective view of a spa having a retractable cover, in accordance with an alternative embodiment of the present invention. 
         FIG. 14  is a cross-sectional, perspective view of the spa of  FIG. 13 , illustrating the cover in a covered position. 
         FIG. 15  is a cross-sectional, perspective view of the spa of  FIG. 13 , illustrating the cover in a retracted position. 
         FIG. 16  is a perspective view of a mounting mechanism of the retractable cover. 
         FIG. 17  is an enlarged view of the mounting mechanism of  FIG. 16 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to  FIGS. 1-5 , a spa  10  having a vertically actuatable cover assembly according to an embodiment of the present invention is shown. As shown therein, the spa  10  includes a spa cabinet  12  and a cover assembly  14 . The cover assembly  14  includes a cover  16  supported on lifter arms  18 , positioned at each corner of the spa  10 . The lifter arms  18  elevate the cover  16  from a lowered position, as shown in  FIG. 5 , wherein the cover  16  rests atop of or adjacent to a top edge of the spa  10 , to a raised position, as shown in  FIGS. 1 and 2 , wherein the cover  16  is supported in an elevated position over the spa cabinet  12 , in the manner discussed hereinafter. 
     As best shown in  FIGS. 6-8 , the spa cabinet  12  generally defines the support structure of the spa  10  and includes a pair of end members  100 , a pair of side members  200 , and a base member  300 . The spa cabinet  12  may generally take the form of sub-frameless spa cabinet disclosed in U.S. Pat. No. 7,784,120 to Spicer, which is incorporated by reference herein in its entirety. A spa shell  20  which is preferably formed of acrylic but may be formed of any suitable plastic material or other impermeable material is fully supported by the end members  100 , side members  200  and base member  300 . The spa shell  20  is designed to hold water for use of the spa. As best shown in  FIGS. 1-3 and 6 , the spa shell has a plurality of through-holes  22  that are sized and shaped to accept the lifter arms  18  therethrough. 
     With further reference to  FIG. 3 , the lifter arms  18  are telescoping, generally hollow members that house actuation members  24  which support the cover  16  and employ a lifting means, such as a rack and pinion system or a tension member and rotatable guides, powered by a motor, as is known in the art. As shown therein, the cover assembly  14 , therefore, includes a lifter mechanism motor  26  having output shafts that are connected to drive shafts  28 . The drive shafts  28  are located in recessed spaces  30  in the base member  300  and drive the actuation members  24  within the lifter arms  18 , as discussed in detail below. 
     Referring to  FIG. 6-10 , the particular construction of the spa cabinet  12  is shown. As best shown in  FIGS. 9 and 10 , an end member  100  is shown. End member  100  has an outside wall  110 , an inside wall  120 , and a perimeter wall portion  115  that fully encloses an air pocket  117 . End member  100  has an outer surface formed in the shape of a decorative column  150 , although it will be obvious to those of skill in the art that any type or kind of decorative element may be molded or otherwise formed into the outer surface of the end members  100  and side members  200 . A series of tabs  300 ,  302 ,  304  and  306  are utilized to aid in interconnecting end members  100  with side members  200 , base member  300 , and spa shell  14 . An opening  160  is provided to allow for the placement of a removable insulated door to provide a means of access to the inside of the spa cabinet. 
     Alternatively, opening  160  may be utilized to receive an accessory device. It is envisioned that an accessory device may take the form of a towel warming container in the form of container  400 , as shown in  FIG. 11 , or a set of steps  450 , as shown in  FIG. 12 . 
     As best shown in  FIG. 11 , the towel warming accessory  400  includes a handle  402 , a face plate  404  having an outer flat surface, a mounting flange  406 , a pivotal connection  408 , a container portion  410  that receives towels, and a door member  412  to provide access to the interior of the container  410 . 
     As best shown in  FIG. 12 , the set of steps  450  includes a handle  452 , a face plate  454  having an outer flat surface, a mounting flange  456 , a pivotal mounting device  458 , and a pair of steps  460  and  462 . Once the handle  452  is pulled downwardly, the steps  460  and  462  will be placed in a horizontal position allowing a user to step on said steps  460  and  462  to gain access to the interior of the spa shell  14 . The accessory devices are preferably pivotally attached to the end members  100  of the spa cabinet  12 , although other mean of attachment known the art are also possible. In a open position, the respective accessory devices  400 ,  450  extend outward of a side member  200  (or end member  100 ) in which they are mounted. Moreover, while in a closed position, the accessory devices  400 ,  450  are located completely inside the spa walls and do not impede or interfere with lawn maintenance or other activities around the perimeter of the spa. 
     In an embodiment, the length of the side members  200  may be identical to the length of the end members  100 , in which case the spa is square in shape. In another embodiment, the side members  200  are longer than end members  100  in which case the spa is rectangular in shape. Other variations can be made to accommodate any shaped spa desired by the provision of additional pieces with different angles of interconnection. In the figures, the end member and side member components have the same corresponding last two digits, but side member components are prefaced by the number  200  rather than the number  100 , which is utilized for an end member component. For example, tabs  130  and  134  on end member  100  are identified to tabs  230  and  234  on side member  200 . 
     With further reference to  FIGS. 6 and 7 , base member  300  has an upper wall portion  302  and a lower wall portion  304 , each of which are provided with a waffled pattern  310  of corrugations to add strength to such wall portions. A perimeter wall portion  306  interconnects the upper wall portion  302  and the lower wall portion  304  enclosing a pocket of insulating space  308  between said walls. The pocket of insulating space  308  may be fully enclosed (as shown) or may be left partially open to allow air to flow into and out of said pocket. Further, it will be obvious that said pocket of insulating space may be filled with air or alternatively with an insulating foam material or any other insulating material to provide insulation from sound and temperature. The upper wall portion  302  of the base member  300  is formed to have upwardly extending L-shaped corner posts  320  that, in combination with upwardly extending inner posts  340  and outer posts  330 , aid in positioning and supporting the end members  100  and side members  200  onto the base member  300 . As shown, end members  100 , side members  200 , and base member  300  are all formed of plastic and each include a fully enclosed air pocket which provides insulation from sound and temperature. While an air pocket is presently preferred, some manufactures, or users may prefer the pockets of insulating space to be filled with an insulating foam material. Such a foam material may provide superior insulating properties and may add to the overall strength of the structure, but will add some additional weight to the spa. 
     The lifting mechanism for raising and lowering the cover  16 , i.e., the actuation members  30 , may be any type of lifting mechanism known in the art. For example, in an embodiment, the actuation members  30  are a rack and pinion assisted by a cable and pulley, as disclosed in U.S. Pat. No. 7,614,093, which is hereby incorporated by reference in its entirety. In another embodiment, the actuation members  30  may be a chain and a plurality of sprockets assisted by a cable and pulley, as also disclose in U.S. Pat. No. 7,614,093. As noted above, regardless of the particular type of actuation members utilized to vertically move the cover  16  between a raised position and a lowered position, the actuation members  30  may be housed within telescoping lifter arms  18  so as to esthetically cover the actuation members  30 . 
     Optionally, a biasing means, such as a hydraulic cylinder, may be utilized to assist the actuation members  30  to reduce load of the full weight of the cover  18  on the motor  24 . 
     Turning once again to  FIGS. 1-4 , the cover  16  is of a generally pyramidal-shape and has a foam core surrounded by a substantially rigid plastic outer shell. As will be readily appreciated, this shape is particularly advantageous for deck-integrated spas (where the top of the spa is generally level with the top surface of a deck) to prevent persons or animals from walking or lying on the cover  16  and to minimize the amount of snow, ice and other debris buildup on the cover  16 . 
     As best shown in  FIG. 3 , the cover  16  has a top wall  32  and an inner wall  34 . The top and inner walls  32 ,  34  are constructed from a plastic with an insulation  36  therebetween. As shown therein, the inner wall  34  has a cross-sectional profile that is complimentary to, but different from the top wall  32 . As best shown in  FIG. 4 , the top wall  32  is divided into quadrants  36  and has multiple surfaces that are angled with respect to each other. In particular, each quadrant  36  has a trough  38  that is sloped downward from a top center of the cover to an outer edge, and has angled surfaces that are sloped inward toward the trough  38 . As will be readily appreciated, the particular shape and configuration and of the top wall  32 , including the trough  38 , functions to clear snow, debris, and water from the cover  16 . 
     The inner wall  34  has a mating spa shell portion  40  that is shaped to substantially mate with a portion of an upper surface of the spa shell  20 . In operation, in the lowered position, the cover  16  forms a seal with a top surface of the spa shell  20  and with the upper surface of the spa support structure/cabinet  12 . In an embodiment, a deformable seal element may be positioned along an inner periphery of the cover  16  that mates with either the spa shell  20  or a top surface of the cabinet  12 . In an embodiment, the cover has an outer lip that is sized and shaped to rest against the cabinet  12  to form a seal therebetween, and which is stepped or otherwise complimentary in shape to the outer edge of the spa shell  20  to form a seal therebetween. 
     The inner wall  34  may include a domed recess  42  over the recessed portion of the spa shell  20 . In an embodiment, a light source is affixed within the cover  16  and is located along the domed surface  42  of the cover  16  to provide light to occupants of the spa  10 . It is envisioned that the light source may be located anywhere along the cover. 
     At each corner of the cover  16 , a recess  44  extends upward into the cover and is sized and shaped to accept a top portion of the telescoping lifter arms  18 . It is envisioned that the lifter arms  18  and actuating members  30  be connected to the cover  16  with a permanent fastening means or by a removable fastening means. In another embodiment, the cover  16  rests on, but is not positively fastened to, the lifter arms  18  or actuating members  30 . 
     In an embodiment, the cover  16  may include a removably attached safety section that has an interference fit with the cover  16 . In an embodiment, one of the quadrants  36  or a portion thereof may be removable to provide access to the interior of the spa  10 . 
     Importantly, the base  300  includes moulded impressions  46  at the corners thereof, as best shown in  FIG. 8 , that are configured to receive the ends of the actuation members  30  and lifter arms  18 . As will be readily appreciated, the moulded impressions  46  in the base  300  serve to locate and retain the actuation members  30 . In addition, the actuation members  30  are directly fastened to either an end member  100  or a side member  200  using brackets or the like. This is in stark contrast to existing vertically movable covers which require a wood sub-frame to support the lifting mechanism. By locating the actuating members  30  within the impressions  46 , and by fastening them directly to the side members  100  or end members  200  of the spa cabinet  12 , structural strength and rigidity of both the cover assembly  14  and the spa cabinet  12 , is increased. 
     In addition, the fact that the actuation members  30  and lifter arms  18  extend through the spa shell  20  via complimentary shaped through-holes  22  provides increased structural strength, rigidity and support to the cover assembly  14 , as a whole. In particular, the cover assembly  14  is affixed to the cabinet  12  and supported by at least three points of contact with the spa: (1) contact with the base  300  of the cabinet  12  via the impressions  46 , (2) contact with either the end members  100  or side members  200  of the cabinet  12  via direct fastening (e.g., through a connecting bracket), and (3) contact with the rigid spa shell  20  through through-holes  22 . Importantly, these three points of contact obviate the need to provide a separate sub-frame to support the cover assembly  14 , including the associated lifting mechanism. Moreover, the fact that these three points of support occur at different heights (i.e., from the base member  300  to the top surface of the spa shell  20 ), provides for increased structural strength and sturdiness of the cover assembly  14  as compared to existing cover assemblies that utilize points of fixation below the top surface of the spa shell. 
       FIGS. 13-15  illustrate a spa having a removable cover assembly  500  according to an alternative embodiment of the present invention. As shown therein, the spa  500  includes a spa cabinet  502  and a cover assembly  504 . The spa cabinet is generally the same as the spa cabinet  12  and defines the support structure of the spa. In particular, the cabinet  502  is a sub-frameless spa and includes a pair of end members  100 , a pair of side members  200 , and a base member  300 . In addition, like the spa  500  described above, spa  500  includes a spa shell  20  which is preferably formed of acrylic, but may be formed of any suitable plastic material or other impermeable material, and which is fully supported by the end members  100 , side members  200  and base member  300 . The spa shell  20  is designed to hold water for use of the spa  500 . 
     As shown therein, the cover assembly  504  includes a first cover member  506  and a second cover member  508 . Each cover member  506 ,  508  is pivotally attached to the spa cabinet  502  and is movable between a closed position, in which the cover member  506 ,  508  rests atop the cabinet  12  and shell  20 , and an open position, in while the cover member  506 ,  508  rests adjacent to the sides of the spa  500  to permit access to the spa  500 . In particular, each cover member  506 ,  508  is pivotally connected to the spa cabinet  12  via a mounting mechanism  510 . The mounting mechanism  510  is best shown in  FIGS. 16 and 17 . 
     As shown therein, the mounting mechanism  510  is generally U-shaped and includes a pair of opposed mounting brackets  512 , a pair of gas springs or shocks  514 , and a pair of lifting arms  516  connected to the mounting brackets via a rotating guide  518 . A pivot arm  520  is connected at one end to an end of the rotating guide  518  opposite the lifting arm  516 , and at the other end to the gas spring  514 . A tie bar  522  is connected to a distal end of the lifting arms  516  and extends therebetween. 
     As best shown in  FIG. 14 , the mounting brackets  512  are attached to the interior sidewalls of the cabinet  12  of the spa  5000  by screws, although other means of attachment known in the art may also be utilized without departing from the broader aspects of the present invention. The rotating guides  518  extends through apertures in the sidewalls such that the lifting arms  516  are positioned outside of the cabinet  12 . The tie bar  522  extends through the respective cover members  506 ,  508  at generally a midpoint thereof, as shown in  FIGS. 13 and 14 . 
     Importantly, the cover members  506 ,  508  may rotate or pivot about an axis defined by the tie bar  522 . In addition, the cover members  506 ,  508  (and the lifting arms  516 ) may rotate about an axis defined by the rotating guide  518 . In this respect, the cover members  506 ,  508  each have two points of rotation (i.e., at opposing ends of the lifting arms  516 ). In operation, the cover members  506 ,  508  pivot about these two points so that a user can move the cover member  506 ,  508  between an open position and a closed position. As best shown in  FIG. 14 , in the closed position, the gas springs  514  are compressed such that they exert a generally upwards biasing force on the cover members  506 ,  508 . As will be readily appreciated this biasing force is not enough to lift cover members  506 ,  508  from their engagement with the top of the cabinet  12  and/or spa shell  20 . When a user moves the cover members  506 ,  508  from the closed position to an open position, the upwards biasing force exerted by the gas springs  514  assists the user in doing so, effectively decreasing the amount of effort required to retract the cover members  506 ,  508 . 
     In particular, the assist mechanism of the gas springs  514  provides mechanical assisting forces for lifting and rotating one half of the cover assembly  504  (e.g., first cover member  504  or second member  506 ) onto the side of the spa cabinet  12  from a closed position to the open position. The assist mechanism also provides a closing force to maintain the half of the cover assembly  504  (e.g., first cover member  504  or second member  506 ) in a closed position. The gas spring  514  and the pivot arm  520  are aligned in an over center cam locking position when the cover member  504 ,  506  is in a closed position. As a result, a downward force is applied to the cover member  504 ,  506  acting through the lifting arms  516  and tie bar  522  in the closed position. 
     In addition, rotating one of the cover member  506 ,  508  up and to the side of the cabinet  12  un-aligns the gas spring  514  with the pivot arm  520  and allows the gas spring  514  to provide the mechanical assisting forces to the pivot arm  520 , which compels both the pivot arm  520  and the lifting arm  516  to rotate with respect to the mounting bracket  514 . As the lifting arm  516  rotates, the tie bar  522  is lifted up and to the side of the cabinet  12 . 
     As best shown in  FIGS. 13 and 14 , each cover member  506 ,  508  includes a pair of stops  524  that extend from a bottom thereof. When the cover members  506 ,  508  are moved to their respective open positions, the stops  524  contact the top surface of the shell  20  or the top surface of the cabinet  12 , thereby limiting downwards travel of the cover members  506 ,  508  and retaining them in a desired retracted position, as shown in  FIG. 13 . 
     As also shown in  FIG. 13 , the cover members  506 ,  508  include overlapping or interlocking structures that form a seal therebetween when in the closed position. In an embodiment, each member  506 ,  508  of the cover  504  is formed from a hard plastic shell with a hollow interior cavity. In an embodiment, the interior cavity may be filled with foam or other insulating material to aid in water heat retention. 
     Importantly, the retractable cover assembly of the present invention is easy to open and tucks down out of the way of users of the spa  500 , thereby saving space. 
     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.