Patent Publication Number: US-2021190239-A1

Title: Plumbing fixtures for a spa

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application Ser. No. 62/951,223, filed on Dec. 20, 2019, which is hereby incorporated reference herein in its entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to spas and plumbing fixtures therefor and, more particularly, to bulkhead connectors for a spa. 
     BACKGROUND OF THE INVENTION 
     Spas, also commonly known as hot tubs, are popular fixtures that are used in many homes. They generally include a deep, vacuum formed tub having a smooth acrylic liner that is filled with heated water and which is used for soaking and relaxation. Spas typically include water jets for therapeutic and massage purposes. 
     Typically, the acrylic liner is formed into shapes that provide a variety of seating arrangements within the tub. Each seat is usually equipped with hydrotherapy jets that allow a pressurized flow of water to be directed at various parts of a user&#39;s body. The water flow may be aerated for additional effect, and some or all of the jets may also automatically move or rotate, causing the changing pressure of the water on the body to provide a massage-like effect. 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. 
     Notably, however, spas with this type of jet system are extremely costly and time consuming to manufacture, and may be prone to leaking. In particular, 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. 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 an effort to address these issues, modular hydrotherapy systems have been developed. In such systems, the acrylic shell is constructed with depressions or hollows in the shell wall. Each of the hollows is fitted with a jet pack module on which jets or nozzles are mounted for injecting water and/or air into the interior of the spa shell. Each jet or nozzle may be connected to an air or water manifold of the jet pack module, and the manifolds are configured for fluid connection with primary water and air supply lines. Such jet pack modules therefore only require a single water supply connection and/or a single air supply connection for each seating position (i.e., a single connection between the primary water supply and the water manifold of the jet pack provides water to all of the jets on the jet pack module; similarly, a single connection between the primary air supply and the air manifold of the jet pack provides air to all of the jets on the jet pack module). Such a system also ensures that any leaks from the jets are contained within the interior volume of the spa shell, not behind the shell. This construction also allows the spa to be upgraded or repaired with new jets by an easy replacement of the jet pack module with a new one having the same or different jets. 
     In connection with the above, there is a need for specialized plumbing fixtures, namely, through bulkhead connectors, that facilitate fluid connection of each modular jet pack to the primary water and air supply lines of the spa. 
     SUMMARY OF THE INVENTION 
     It is an object of the present invention to provide fitting for a spa. 
     It is another object of the present invention to provide through bulkhead connectors for a spa. 
     It is another object of the present invention to provide through bulkhead connectors for a spa than enable the connection of modular jet packs to primary air and water supply lines of the spa. 
     These and other objects are achieved by the present invention. 
     According to an embodiment of the present invention a through bulkhead connector for a spa includes a first fitting member and a second fitting member. The first fitting member has a flange and an adapter portion extending from the flange and defining a first passageway through the adapter portion and flange, and a slot in the flange. The second fitting member is slidably receivable in the slot in the flange of the first fitting member and has a generally cylindrical body portion defining a second passageway through the second fitting member. When the second fitting member is slidably connected to the first fitting member, the first passageway and the second passageway are in alignment with one another to allow for fluid flow through the first fitting member and the second fitting member. 
     According to another embodiment of the present invention, a spa includes a shell configured to contain a volume of water, a water supply manifold positioned behind the shell, a jet pack having an array of nozzles for directing pressurized jets of water and/or air into the volume of water, and a through bulkhead connecter extending through the shell and fluidly interconnecting the water supply manifold with the jet pack. 
     According to yet another embodiment of the present invention, a through bulkhead connector for a spa includes a first fitting element having a hollow body portion and an annular flange extending from the body portion, and a grommet receivable on the body portion and having an annular flange. The grommet is receivable in an aperture in the shell of the spa such that the annular flange of the grommet forms a fluid-tight seal with the shell and such that the grommet forms a fluid-tight seal with the body portion. 
    
    
     
       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 front perspective view of a through bulkhead connector according to an embodiment of the present invention. 
         FIG. 2  is a rear perspective view of the through bulkhead connector of  FIG. 1 . 
         FIG. 3  is another perspective view of the through bulkhead connector of  FIG. 1 . 
         FIG. 4  is yet another perspective view of the through bulkhead connector of  FIG. 1 . 
         FIG. 5  is an end elevational view of the through bulkhead connector of  FIG. 1 . 
         FIG. 6  is a front perspective view of a first fitting of the through bulkhead connector of  FIG. 1 . 
         FIG. 7  is a rear perspective view of the first fitting. 
         FIG. 8  is another perspective view of the first fitting. 
         FIG. 9  is another perspective view of the first fitting, illustrating a receiving slot thereof. 
         FIG. 10  is a perspective view of a second fitting of the through bulkhead connector of  FIG. 1 . 
         FIG. 11  is a rear perspective view of the second fitting. 
         FIG. 12  is a front perspective view of the through bulkhead connector of  FIG. 1 , showing coupling of the first fitting with the second fitting. 
         FIG. 13  is a rear perspective view of the through bulkhead connector of  FIG. 1 , showing coupling of the first fitting with the second fitting. 
         FIG. 14  is another perspective view of the through bulkhead connector of  FIG. 1 , showing coupling of the first fitting with the second fitting. 
         FIG. 15  is another perspective view of the through bulkhead connector of  FIG. 1 , showing coupling of the first fitting with the second fitting. 
         FIG. 16  is an end elevational view of the through bulkhead connector of  FIG. 1 , showing coupling of the first fitting with the second fitting. 
         FIG. 17  is a perspective, transparent view of the through bulkhead connector of  FIG. 1 . 
         FIG. 18  is a side elevational view illustrating connection of a jet pack to a water supply manifold using the through bulkhead connector of  FIG. 1 . 
         FIG. 19  is a simplified schematic illustration showing connection of a jet pack to a water supply manifold using the through bulkhead connector of  FIG. 1 . 
         FIG. 20  is a perspective view of a through bulkhead connector according to another embodiment of the present invention. 
         FIG. 21  is a perspective view of a first fitting of the through bulkhead connector of  FIG. 20 . 
         FIG. 22  is another perspective view of the first fitting. 
         FIG. 23  is a perspective view of a grommet of the through bulkhead connector of  FIG. 20 . 
         FIG. 24  is another perspective view of the grommet of  FIG. 23 . 
         FIG. 25  is a simplified schematic illustration showing connection of a jet pack to a water supply manifold using the through bulkhead connector of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to  FIGS. 1-5 , a through bulkhead connector  10  according to one embodiment of the present invention is illustrated. As illustrated therein, the through bulkhead connector  10  includes a first fitting member  12  and a second fitting member slidably connected to the first fitting member  12 . As best shown in  FIGS. 6-9 , the first fitting member  12  includes a flange  16  and a generally cylindrical, hollow adapter portion  18  extending from the flange  16  and defining a passageway  20  through the adapter portion  18  and flange  16 . In an embodiment, the flange is generally U-shaped, although other configurations are possible without departing from the broader aspects of the invention. With particular reference to  FIGS. 8 and 9 , the flange  16  includes a receiving slot  22  formed therein and which is open at one end for receiving a correspondingly shaped and dimensioned portion of the second fitting member  14 , as discussed in detail below. 
     As illustrated in  FIGS. 10 and 11 , the second fitting member  14  is generally cylindrical shape and has a hollow passageway  24  extending therethrough from a first end  26  to a second end  28 . The second end  28  of the fitting, as shown in  FIG. 10 , has an enlarged diameter shoulder portion  30  that is dimensioned so as to be slidably received in the slot  22  in the flange  16  of the first fitting  12 . As shown in  FIG. 11 , the face of the second end  28  includes an annular recess or channel  32  configured to receive a resilient sealing element such as an O-ring  54  (not shown in  FIGS. 10 and 11 ). 
     Turning now to  FIGS. 12-16 , the second fitting member  14  may be selectively and removably connected to the first fitting member  12  by sliding the enlarged shoulder portion  30  of the second fitting member  14  into the slot  22  in the flange  16  of the first fitting  12 . Once connected, the passages  20 ,  24  of the first and second fitting members  12 ,  14  are aligned in the axial direction to form a continuous flowpath therethrough. The configuration of the flange  16  and slot  22 , and the complimentary shoulder portion  30 , are such that the first fitting member  12  and the second fitting member  14  cannot be decoupled by pulling them apart in the axial direction. Rather, they can only be decoupled by sliding the first fitting  12  in a direction substantially orthogonal to an axis extending through the passageway such that the enlarged shoulder portion  30  slides out of the slot  22  in the flange  16 . 
     Importantly, the bulkhead connector  10  of the present invention is specifically designed to allow for the quick and easy connection of a hot tub or spa jet pack to a water supply manifold positioned behind the wall or shell of a hot tub, as disclosed hereinafter. As is known in the art, a jet pack includes a plurality of water and/or air jets that are configured to direct pressurized water into the interior of the spa or hot tub when positioned within a seating position of the spa shell. In particular, rather than necessitating an array of jets for water and/or air to be formed in the spa shell, as is customary in the art, a single water supply line and a single air supply line may be associated with each seating position in the spa, and the plurality of air and/or water nozzles instead form part of the jet pack. Water and air are supplied to the jet pack at each seating position via the single air and water lines, and the water and air supplied to the jet packs jet packs then exits the nozzles in the front face of the jet pack and provides therapeutic benefit for a user. As is known in the art, the use of jet packs within each seating position substantially decreases the number of cutouts necessary in the spa shell, thus decreasing the number of potential leak points. In some cases, the use of jet packs may also allow different jet packs to be swapped out easily to provide easy customization of the spa experience. In particular, in some cases, jet packs having desired nozzle configurations can be easily retrofit into an existing spa. In addition, the jet packs also allow for easy repair in the event of leaking or improper functioning of the nozzles, simply by removing the damaged jet pack and installing a new one in the seating position. 
       FIGS. 18 and 19  more clearly illustrate how the through bulkhead connector  10  of the present invention enables the functionality described above. In particular, as shown therein, in an embodiment, the first fitting member  12  of the through bulkhead connector  10  is connected to or is otherwise integrated with the jet pack  50  having a plurality of nozzle  52  (e.g., air and/or water nozzles) on a front face thereof. The second fitting member  14  is connected to a fluid supply manifold such as, for example, a water supply manifold  56  positioned behind the shell  58  of the spa  60 . As shown in  FIGS. 18 and 19 , the second fitting member  14  extends through the shell  58  of the spa  60  at the seating position  62 . In an embodiment, a fluid tight seal is formed between the fitting  14  and the shell  58  using, for example, an O-ring, grommet or other sealing means. 
     Installation of jet pack  50  in the seating position  62  in the shell  58  of the spa  60  is therefore effected by slidable receiving the flange or shoulder  30  of the second fitting member  14  within the slot  22  of the flange of the first fitting member  12 . O-ring  54  seated in annular channel  32  in face  28  of the second fitting  14  therefore forms a fluid tight seal between the first fitting member  12  and second fitting member  14 . In this position, passages  20 ,  24  are aligned so that fluid communication is provided between the fluid supply manifold  56  and the interior of the jet pack  50  and nozzles  52  thereof. While  FIGS. 18 and 19  illustrate that the first fitting member  12  is interconnected with the jet pack  50  and the second fitting member is fluidly connected to the supply manifold  56  and extends through the shell  58 , in another embodiment the components may be reversed such that the first fitting  12  extends through the spa shell  58  and is fluidly connected to the fluid supply manifold  56 , and the second fitting  14  is connected to the jet pack  50 . In such case, the adapter  16  extends through the shell  58  such that the flange  16  and slot  22  are positioned on the inside/interior of the shell  58 . The jet pack  50  may then be connected to the supply manifold  56  by receiving the shoulder  30  of the second fitting member  14  in the slot  22 . In either case, simple and easy fluid connection of the jet pack  50  with the water supply manifold  56  is provided. 
     In an embodiment, the outside diameter of the external adapter  18  of the through bulkhead connector  10  may be 1.5 inches or 2 inches for interconnection with respective hard PVC plumbing fittings of a spa or hot tub. As indicated above, in one embodiment, the external adapter  18  feeds through the spa shell/tub wall and is sealed in the tub wall by a grommet that has sufficient tightness to not allow water to leak from the tub to the outside. As indicated above, the inside part of this fitting is designed to slide onto a flange built into the through bulkhead side of the fitting. There is an O-ring that is tolerenced such that when the two parts (the first fitting member  12  and the second fitting member  14 ) are assembled, provides a seal between the two parts not allowing water to leak up and in excess of 60 psi. The part is laterally slid over the bulkhead to engage the coupling to allow for the transfer of water from outside the tub to the jet arrays inside the jet seatback. This provides for easy assembly of the jet seat into place inside the jet seat cavity in the spa and provides the main feed of pressurized water to the jet array. 
     Referring to  FIG. 20 , a through bulkhead connector  100  according to another embodiment of the present invention is illustrated. As shown in  FIGS. 20-22 , the through bulkhead connector  100  includes a first fitting member  102  having a generally cylindrical body portion  110  defining a hollow passageway  112  therethrough, and an annular flange  114  extending generally perpendicularly from the body portion  110 . The body portion  110  includes a first connector end  116  on one side of the flange  114 , and a second connector end  118  on an opposite side of the flange  114 . As shown in  FIGS. 20, 23 and 24 , the through bulkhead connector  100  also includes a grommet  120  having a generally hollow sleeve  122  and an annular flange  124 . The hollow sleeve  122  is dimensioned so as to closely fit over the first connector end  116  of the body portion  110  of the first fitting member  102  such that the flange  124  of the grommet  120  abuts the flange  114  of the first fitting member. 
     In an embodiment, the through bulkhead connector allows for a ¾″ hose to be attached to it on the inside of the spa shell/tub (water side), feeds through the wall of the tub and connects to a ¾″ air hose on the outside for the tub for the purpose of diverting air out or into the spa to be used for distributing to jet arrays either in the seat inserts or in the lounger area external jets. In an embodiment, this fitting has extended barbs to allow for either smooth, soft, or hard coil containing PVC tubing to be mounted to it. It provides a seal through the tub wall thickness by the grommet so that no water leaks from the tub to the outside. 
       FIG. 25  illustrates use of the of the through bulkhead connector with a spa and shell  58  thereof, as described above. As shown therein, the grommet  120  is positioned on the body portion  110  of the first fitting member  102  such that the interior of the sleeve  122  of the grommet  120  searingly engages the outer surface of the body portion and the flange  124  sealingly engages the flange  114  of the fitting  102 . The body portion  110  is positioned in a hole  68  in the spa shell  58  (e.g., a hole in a seating position of the spa shell) such that the sleeve  122  of the grommet  120  is received in the hole  68 , and such that the flange  124  engages the sidewall of the shell  58  surrounding the hole  68  to create a fluid tight seal therewith. In an embodiment, first connector end  116  can then be connected with an air supply manifold (not shown) positioned behind the spa shell  58 , and the second connector end  118  can be fluidly connected to a jet pack, such as that shown in  FIGS. 18 and 19 , so that air can be supplied from the air supply to the jet pack. In an embodiment, the through bulkhead connector  100  can be connected to the jet pack prior to inserting the connector  100  through the hole  68  in the spa shell. 
     It is contemplated that the through bulkhead connectors  10 ,  100  disclosed herein may be utilized in concert with one another to provide fluid connections between a water supply and air supply positioned behind the spa shell, and a jet pack positioned interior to the spa shell, respectively. 
     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.