Abstract:
A spa cover that seats against a rim of a spa to seal heat and steam within the spa. The spa cover includes a first panel having a first inner edge and a second panel having a second inner edge. A hinge moveably attaches between the first inner edge and the second inner edge to permit movement of the first cover and second cover relative to one another between an open position and a closed position. The hinge forms a seal between the inner edges of the first and second panels.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is related to U.S. Provisional Patent Application No. 60/938,631 filed May 17, 2007 from which priority is claimed, and is hereby incorporated by reference. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH 
       [0002]    Not Applicable. 
       BACKGROUND OF THE INVENTION 
       [0003]    The present invention is generally directed to a cover and, more particularly to a cover for a spa having partitions and a sealing hinge assembly. 
         [0004]    Portable electric spas (hot tubs) or in-ground spas are increasingly popular additions to many homes for relaxation, therapeutic, and entertainment purposes. The increased ownership of spas has correspondingly increased interest in spa accessories such as thermometers, umbrellas, vacuums, filters, and covers. One of the first accessories purchased is typically the cover. In fact, many times the consumer purchases the cover from the retailer along with the spa. 
         [0005]    Spa covers are placed over the top of the spa when not in use to provide thermal insulation, limit contamination of the water, and prevent people or animals from falling accidentally into the spa. Conventional spa covers typically consist of two closed cell Styrofoam® slabs surrounded by a sewn vinyl covering and connected with a flexible vinyl hinge. This structure provides a generally flat cover that rests on top of the spa. 
         [0006]    However, conventional spa covers have several disadvantages. For example, water and steam can penetrate the covering and soak into the foam. This deteriorates the cover, encourages growth of mold and mildew, and increases the cover weight which makes the cover cumbersome to use and less energy efficient. In addition, the foam&#39;s weak structural characteristics significantly limit the amount of weight conventional covers can withstand without collapsing. Therefore, a child or animal that crawls onto such a cover may bow or break it. What is more, the exposure to natural elements and water over time further weaken the foam and cause the cover to sag. Also, in many cases, the hinge connecting the two cover halves does not form a proper seal. As a result, heat and water can escape through this opening. In addition to the weak structural characteristics of foam covers, the handles, protective edge skirting, and safety labels are sewn on. This thread, over time, weakens and many of these required features unravel or detach over time. Furthermore, conventional covers are labor intensive to manufacture. Because of these poor characteristics, conventional covers generally have a short lifespan of about three years. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0007]    In the accompanying drawings which form part of the specification: 
           [0008]      FIG. 1  is an orthographic view of a spa with a spa cover in a closed position in accordance with and embodying the present invention; 
           [0009]      FIG. 2  is an orthographic view of the spa with the spa cover in an open position; 
           [0010]      FIG. 3  is a top view of the spa cover in the closed position; 
           [0011]      FIG. 4  is a bottom view of the spa cover in the closed position; 
           [0012]      FIG. 5  is a side view of the spa cover in the closed position; 
           [0013]      FIG. 6  is an orthographic exploded view of a cover panel; 
           [0014]      FIG. 7  is an enlarged orthographic exploded view of the cover panel; 
           [0015]      FIG. 8  is an enlarged orthographic view of an engaging member and receiving member; 
           [0016]      FIG. 9  is an enlarged orthographic perspective view of the security member engaged with the cover panel; 
           [0017]      FIG. 10  is an orthographic view of the hinge assembly in the partially open position; 
           [0018]      FIG. 11  is an enlarged orthographic partial view of the hinge assembly in the closed position; 
       
    
    
       [0019]    Corresponding reference numerals indicate corresponding parts throughout the several figures of the drawings. 
       DETAILED DESCRIPTION 
       [0020]    The following detailed description illustrates a preferred embodiment of the cover of the present disclosure by way of example and not by way of limitation. The description clearly enables one skilled in the art to make and use the cover, describes several embodiments, adaptations, variations, alternatives, and uses of the cover, including what is presently believed to be the best mode. Additionally, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangements of components set forth in the following description or illustrated in the drawings. The cover is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. 
         [0021]    As shown in  FIGS. 1-11 , an embodiment of the present invention, generally referred to as a spa cover  10 , seats against a rim of a spa shell A to cover the spa shell A. The spa cover  10  includes a pair of panels  12  pivotally connected by a hinge assembly  14  that allows the panels  12  to move between a closed position ( FIG. 1 ) that covers the spa shell A and an open position ( FIG. 2 ) that allows access to the spa shell A. A soft protective cushion or seal  15 , such as felt, rubber or other suitable material, along a lower edge of the cover  10  creates a seal between the spa cover  10  and the spa shell A for retaining steam and heat within the spa shell A. In addition, the seal  15  prevents damage from scratching to the spa shell A during use. 
         [0022]    Each panel  12  is generally rectangular in shape having a lower surface  16 , and a generally tapered upper surface  18  that tapers downwardly from an inner edge  20  towards an outer edge  22  ( FIGS. 3-6 ). Drain grooves  24  defined in the upper surface  18  are preferably positioned generally parallel with the taper of the upper surface  18  to enhance drainage of water off the spa cover  10  ( FIG. 3 ). However, those skilled in the art will recognize that drain grooves  24  are advantageous, but are not required, and any other arrangements of drain grooves  24  can be used, such as ornamental designs. If desired, indicia  25  can be molded into on one or more of the panels  12 , such as trademarks, instructions, logos, images, and the like. 
         [0023]    Each panel  12  includes a pair of end partitions  26  coupled with opposite sides of an intermediate partition  28  ( FIG. 6 ). Engaging members  30  extend from each side  32  of the intermediate partition  28  to couple with corresponding receiving members  34  of the end partitions  26  ( FIGS. 7-8 ). In the embodiment of  FIGS. 1-11 , the engaging member  30  is a generally cylindrical protrusion with a detent  38  extending from a front face  40 . The receiving member  34  is a correspondingly cylindrical slot  42  with a notch  44  for engaging the detent  38 . However, any suitable engaging and receiving members that couple the partitions together can be used, such as fasteners, adhesive, dowels, keyways, dovetails, and the like. In addition, alternate embodiments can place the engaging members  30  on the end partitions  26  and the receiving members  34  on the intermediate partition  28  or any combination thereof. Also, those skilled in the art will recognize that the panel  12  can comprise any number and arrangement of partitions, including, but not limited to two or more. 
         [0024]    Attachment members  46  attach, such as with fasteners, adhesive, and the like, across a seam  48  between the end partitions  26  and the intermediate partition  28  to further secure and seal the partitions  26  and  28  together and provide support and structural integrity along the seam  48  ( FIG. 7 ). Moreover, the attachment members  46  compensate for any variances in the seam  48  due to thermal expansion, defects, or other factors. In the embodiment of  FIGS. 1-11 , the attachment members  46  are generally rectangular strips made of a rigid material, such as metal or plastic, but can be any suitable shape, size or material. Preferably, the attachment members  46  attach to both the upper surface  18  and lower surface  16  of the panel  12  and are positioned near the outer edge  22  of the panel  12 . However, alternate embodiments can use other arrangements of attachment members  46 . For a flush fit with the outer surface, the attachment members  46  insert into recessed areas  50  of the partitions  26  and  28 . If desired, indicia  52  can be imprinted on the attachment members  46 , such as trademarks, instructions, logos, images, and the like. 
         [0025]    Handles  54  located on the outer edge  22  of each partition  26  and  28  can be engaged to move the panel  12  between the open position and closed position ( FIG. 9 ). Each panel  12  defines channels  56  on the outer edge  22  each with a traversing crosspiece  57 . Security members  58 , such as a self-locking strap having Velcro®, a clasp, or other suitable fastener, engage with the crosspiece  57  to secure the spa cover  10  in place to the spa shell A. For purposes of assembly, the crosspiece  57  can be integrally molded with the panels  12  or produced separately to be attached to the panel  12 . 
         [0026]    The partitions  26  and  28  are preferably constructed from a molded plastic material using any appropriate method, such as injection molding, rotational molding, blow molding, thermoforming, vacuum forming, and the like. Any appropriate plastic material can be used, including, but not limited to, high density polyethylene (HDPE), polypropylene, propylene, or acrylonitrile butadiene styrene. When fully assembled, none of the partitions  26  and  28  have any openings and such lack of openings prevents the entrance of any water. Although the partitions  26  and  28  may have mounting holes for mounting a skirt  66 , they can be sealed with self-sealing fasteners  70 , such as Bulbtite® rivets. Alternatively, the partitions  26  and  28  may have standoffs or stubs to mount the skirt  66 . 
         [0027]    Projections  60  extend upwardly from the lower surface  18  of each partition  26  and  28  and contact the upper surface  16  at a junction  62 , sometimes referred to as a tack-off or kiss-off ( FIG. 7 ). The projections  60  are located at designated positions to function as supports within the partitions  26  and  28 . In the embodiment of  FIGS. 1-11 , the projections  60  are preferably positioned so that the junctions  62  align with the drain grooves  24 . For aesthetic purposes, this arrangement reduces the appearance of the junctions  62  on the upper surface  16  of the panel  12 . Preferably, there are enough projections  60  of a suitable size and shape arranged within the partition  26  and  28  to at least support the weight of an average person. However, those skilled in the art will recognize that any number, size, shape, and any arrangement of projections  60  can be used. In alternate embodiments, the partitions  26  and  28  can be constructed to have enough structural support so that the projections  60  and tack-off s are not required. For example, the partitions  26  and  28  may have an internal structure of supportive material, such as rigid foam or other suitable materials known in the art. 
         [0028]    The interior space  64  of the partitions is hollow ( FIG. 7 ). A gas within the interior space, such as air, functions as insulation to enhance the ability of the spa cover  10  to prevent heat loss from the spa. The gas should be sealed within the interior space  64  so that the gas is preferably non-flowing or “dead”. Alternatively, the interior space can be filled with a solid insulation, such as expanded polypropylene or expanded polystyrene foam. 
         [0029]    A flexible protective skirt  66  extends downwardly from the outer edge of each panel  12  to beyond the plane of the lower surface  18  of each panel  12  so that the skirt  66  overhangs the rim of the spa shell when the cover  10  is in the closed position ( FIGS. 1-6 ). The skirt  66  is arcuately shaped with flat upper portion  68  that attaches to the outer edge  22  of the panel  12  with fasteners  70  or other suitable means, such as adhesive, clips, or welding. The skirt  66  is preferably made from an elastomer material, such as ethylene propylene diene monomer rubber (EPDM). However, other materials can also be used, such as thermoplastic vulcanizate (TPV), thermoplastic elastomer (TPE), or thermoplastic olefinic (TPO). 
         [0030]    The hinge assembly  14  includes an opposing pair of generally C-shaped channels  74  attached to respective inner edges  20  of the panels  12 , such as with a friction fit or fasteners ( FIGS. 1-2  and  10 - 11 ). The upper end of each channel  74  defines a flange  76  for engaging a hinge member  78 . The generally rectangular hinge member  78  extends between the panels  12  and includes a slot  79  along each end to frictionally engage with each flange  76 , such as by crimping. Gaskets  80  extend lengthwise from the lower surface  82  of the hinge member  78  to seat against respective channels  74 . A second set of gaskets  84  attach lengthwise along an outer surface  86  of each opposing C-shaped channel  74 . The second set of gaskets  84  are positioned to seat against each other when the cover  10  is in the closed position. A third set of gaskets  88  attach vertically along the inner edge of each panel  12  and are positioned to seat against each other when the cover  10  is in the closed position. This arrangement of gaskets  80  and  84  prevent the escape of moisture and heat through the hinge assembly  14 . The hinge member  78  is preferably made from an elastomer material such as ethylene propylene diene monomer rubber (EPDM). However, other materials can also be used, such as thermoplastic vulcanizate (TPV), thermoplastic elastomer (TPE), or thermoplastic olefinic (TPO). 
         [0031]    Changes can be made in the above constructions without departing from the scope of this disclosure, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. For example, the spa cover  10  can include an automated lifter that mechanically removes and replaces the cover  10  onto the spa.