1. Field of the invention
This invention relates to the design and construction of spa covers and the reinforcement thereof. The use of spas has become widespread, and most spas are equipped with covers which when closed prevents debris, rain and the like from contaminating the tub water. The cover further serves to retain heat within the tub.
To facilitate customer handling and storage the cover is made in two sections, half and half, and joined by a flexible flap, thus each half can be reinforced separately.
Some spa owners have expressed an interest in reinforced covers for various reasons. Spa owners who live in cold climates would like a stronger cover to support the heavy snow pack. Some spa owners want a stronger cover to prevent a collapse if an uninvited guest should climb atop of the spa cover.
Many types of spa covers have been designed and manufactured in recent years. Also, many more large spas are now being sold, which require larger covers. This has resulted in problems with covers sagging in the middle after a few years use.
Many owners have bought cover lifters to help raise and remove the spa covers. Thus, adding a few pounds of reinforcement to the cover would not be a burden to the lifter system, and would help keep the cover from sagging.
2. Description of Related Art
I have searched many patents under 4/498,580,584. I did not find any references to structural reinforcing members. The search included: Zell U.S. Pat. No. 6,886,187, Minnick U.S. Pat. No. 6,618,868, Bussey U.S. Pat. No. 6,385,791, Ziebert U.S. Pat. No. 6,112,340, Gray U.S. Pat. No. 6,374,433, Brown U.S. Pat. No. 6,047,415, Pucci U.S. Pat. No. 5,974,600, Pesterfield U.S. Pat. No. 5,783,019, Aragona U.S. Pat. No. 4,246,663, Wendt U.S. Pat. No. 4,236,259.
FIG. (1) is a side view of the spa cover showing a cross section taken through one reinforcing member.
FIG. (2) is a top view of the spa cover showing layout of the grooves.
FIG. (3) is a cross section of the spa cover showing reinforcing members installed in the grooves.
FIG. (4) is a cross section of the spa cover showing the reinforcing members installed in the drilled holes.
FIG. (5) is a side view of the straight reinforcing member.
FIG. (6) is a side view of the drop center reinforcing member.
A new design of a spa cover, Variation I. We start with a foam core (41) and cut to size for an individual spa. Next we make the end cap (43), using sheet metal we cut to length and break each edge to form a channel. Then we select the size reinforcing member (42) we need and cut to length. We then use a router to groove (44) the foam core to accept the reinforcing members (42). We then assemble the above parts and slip the flexible cover over the assembly to hold everything in place.
In variation II of this design we bore holes (45) through the foam core and insert the reinforcing members (42).
In variation III of this design we use reinforcing members with a drop center (