Patent Publication Number: US-6212702-B1

Title: SPA cover kit

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to convertible enclosures, and more particularly, to such enclosures for outdoor spas. 
     2. Description of the Related Art 
     Outdoor spas have enjoyed increasing popularity in recent years. These spas are usually built outside on a patio or deck. In several parts of the country, however, inclement weather, such as rain or snow, limits their use. 
     The impact of weather on the usage of a spa can be curtailed by installing a raised cover over the spa. Ideally, such covers should be elevated structures so that users of the spa may stand up in a fully upright position. The cover should be a sufficient size to slightly extend over the sides of the spa to protect users sitting on the edge of the spa. Also, the cover should be made of strong, durable material capable of withstanding normal weather conditions. 
     Typically, these covers are relatively heavy structures made of standard-size lumber which are cut and assembled on site by three or more individuals. What is needed is a spa cover made of lightweight materials that is pre-fabricated and distributed in a kit for easy assembly by only two individuals. 
     SUMMARY OF THE INVENTION 
     It is an object of the present invention to provide a raised cover for a spa. 
     It is another object of the present invention to provide such a cover that uses pre-fabricated, lightweight, durable components and can be easily connected together so that the cover can be easily and quickly assembled by only two individuals. 
     It is a further object of the present invention to provide such a cover that can be easily modified to cover additional areas immediately adjacent to the spa. 
     These and other objects are met by a lightweight, easy to assemble spa cover. The cover includes a square or rectangular-shaped cap pivotally attached at two corners to two dual hinged support posts and at the opposite corners to two fixed support posts. In one embodiment, the cap is a single unit made of lightweight, weather-proof material, such as fiberglass, which fully extends across a standard size spa. The lower end of each dual hinged support post is pivotally attached to the deck adjacent to the corners on the spa. The opposite, upper end of each dual hinged support post is pivotally attached to one corner of the cap. 
     The upper hinge means and lower hinge means are aligned on each dual hinged support post so that the cap may simultaneously pivot on the upper and lower hinge means as the dual hinged support posts pivotally rotate from a horizontal to a vertical orientation on the deck when positioning the cap over the spa. This feature is especially useful because it allows one or two workers to easily assemble the cover over the spa. 
     As the two dual hinged support posts are rotated into a vertical orientation, the free, unsupported side of the cap can be comfortably supported by one worker. The two fixed support posts are then selected, vertically aligned, and securely attached to the two unsupported corners on the cap. The lower ends of the two fixed support posts are then securely attached to the deck while the upper ends of the two fixed support posts are attached to the cap. Optional, diagonally aligned cross-braces can then be attached between the cap and each support post to further stabilize the cap. 
     The system may also include optional cover extensions that attach directly to the sides of the cap to provide additional covered areas. Each extension cover includes a lightweight cap and a pair of legs that can be easily and quickly installed. 
    
    
     DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of the spa cover system completely set up and extended over a spa. 
     FIG. 2 is a side elevational view of the spa cover system taken along line  2 — 2  shown in FIG.  1 . 
     FIG. 3 is a sectional, side elevational view of a section of the cap with a block insert attached to one corner with the upper end of the dual hinged support post pivotally attached thereto and the lower end pivotally attached to the deck. 
     FIG. 4 is a sectional, side elevational view of a section of the cap with the upper end of the fixed support post attached thereto and the lower end fixed to the deck. 
     FIG. 5 is a sectional, side elevational view of the adjustable, fixed support post. 
     FIGS. 6-8 are illustrations showing two individuals positioning and assembling the cover over the spa. 
     FIG. 9 is a top plan view of the spa cover with two optional extensions attached to two adjacent sides of the cap system. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT(S) 
     Shown in the accompanying FIGS. 1-9 is a spa cover kit  10  designed to be installed over an existing outdoor spa  8 . The kit  10  comprises a cap  20  having overall dimensions slightly larger than a standard-sized spa  8  (8′×8′) capable of covering a spa  8 , two dual hinged support posts  30 , two fixed support posts  40  and attaching hardware further described herein. 
     The cap  20  is a single, prefabricated structure made of a lightweight, weather-proof material, such as molded fiberglass. In the preferred embodiment, the cap  20  is pyramidal and includes four converging support ribs with four skylight openings  23  formed between them. Skylights  23  are made of a lightweight plastic material, such as LEXAN, a polycarbonate resin sheet material made by General Electric Corporation of New York, N.Y. 
     As shown in FIGS. 2 and 3, the two dual hinged support posts  30  are pivotally attached at their upper ends to the corners located on one side of the cap  8  by an upper hinge means. In the preferred embodiment, the upper hinge means comprises a leaf hinge  32  disposed between the upper end of the support post  30  and a wooden block  28  inserted into the pocket  24  formed on the corner of the cap  20 . The lower ends of the dual hinged support posts  30  are attached to the deck surface  90  adjacent to the comer of the spa  8  via a lower hinge means. In the preferred embodiment, the lower hinge means is a leaf hinge  34  with one leaf attached directly to the deck adjacent to a corner on one side of the spa  8 . 
     The two fixed support posts  40  are designed to be selectively attached to the corners opposite the dual hinged support posts  30  after the cap  20  is disposed over the spa  8 . In the preferred embodiment, the upper end  41  of each fixed support post  40  is inserted into a cavity formed on the corner of the cap  20 . Two perpendicularly aligned bolts  55  are then inserted through holes formed on the front and side fascia  26  of the cap  20 . After being attached to the cap  20 , the fixed support posts  40  are securely attached to the deck  90  using U-shaped holding brackets  42  and bolts  55 . Optional stabilizing straps  49  may be attached between each support post  30  and  40  and the fascias on the cap  20 . 
     The support posts  30 ,  40  are made of steel (2×2) tubing approximately  84  inches in length. The stabilizing straps  49  are approximately 1½ inches in width and 24 inches in length. 
     During assembly, the two dual hinged support posts  30  are aligned in a horizontal parallel position on one side of the spa  8  as shown in FIG.  6 . The lower ends of the two support posts  30  are then attached to the leaf hinges  34 , which, in turn, are attached to the deck  90  adjacent to two corners on the spa  8 . The cap  20  is then selected and held in a vertical position so that the wooden blocks  28  located on the two corners  22  may be connected to the upper ends of the two dual hinged support posts  30 . The upper ends of the dual hinged support posts  30  and corners  22  are connected together via the leaf hinge  32 . 
     As shown in FIGS. 7 and 8, the two dual hinged support posts  30  and the cap  20  are slowly lifted so that the dual hinged support posts  30  are disposed in an upright, vertical position and the cap  20  is disposed over the spa  8 . Because the cap  20  and support posts  30  are made of lightweight material, one worker  92  is usually able to properly position the cap  20  over the spa  8 . Once the cap  20  is properly positioned, the worker  92  is able to hold the detached side of the cap  20  so that the fixed support posts  40  may be attached by a second worker  94 . When the fixed support posts  40  are selected, the upper ends are inserted into the receiving pockets  24  located on the corners  22  of the cap  20 . As shown more clearly in FIG. 4, the upper end of the fixed support posts  40  are attached to the cap  20  using bolts  48  that extend from the fascia  26 , through the support post  40  and to the inside surface of the pocket  24 . The lower end  43  of the fixed support posts  40  are attached to a lower bracket  44  attached to the top surface of the deck  90 . 
     As shown in FIG. 5, the fixed support posts  40  may include a length adjustment means so that the cap  20  may be properly aligned in a horizontal orientation over the spa  8 . In the preferred embodiment, the length adjustment means includes a lower telescopic leg  45  that slides longitudinally inside the lower end opening of the receiving leg  46 . A bolt  47  is inserted through holes formed on the telescopic leg  45  and the receiving leg  46  to affix the legs  45 ,  46  in a fixed position. 
     The kit  10  is designed to be used with one or more optional extension covers  50  to provide additional protection over the spa. As shown in FIG. 9, an optional extension cover  50  may be attached to the front or side fascias  23  of the cap  20  to provide additional covered area around the spa  8 . The extension cover  50 , as shown in FIG. 9, includes an extension cap  51 , a pair of fixed support posts  53 , and connecting bolts  55 . The extension cap  51  has a length approximately equal to the length of the cap  20 . The extension cap  51  is a flat roof design made of durable, lightweight material similar to the cap  20 . The support posts  52  are made of steel tubing material similar to the fixed support post  40 . 
     During assembly of the extension cover  50 , the upper ends of the fixed support posts  52  are placed into pockets  54  located in the corners of the extension cap  51 . The lower ends of the fixed support posts  52  are securely attached to the deck  90  via brackets and bolts (both not shown). Bolts  58  are then used to attach the adjoining fascia surfaces  21 ,  53  of the cap  20  and the extension cap  51 , respectively, together. 
     In compliance with the statute, the invention described herein has been described in language more or less specific as to structural features. It should be understood, however, that the invention is not limited to the specific features shown, since the means and construction shown comprise only the preferred embodiments for putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the legitimate and valid scope of the amended claims, appropriately interpreted in accordance with the doctrine of equivalents.