Patent Application
20090255051
The invention relates generally to recreational or therapeutic in-ground spas and pools, and more specifically to spa and/or hot-tub assemblies that insert into a pre-formed cavity to form an integrated pool/spa structure with footwell features, such as in-floor sump drain or an anti-entrapment system.
The advent of packaged pool designs in which a pool and spa (hot tub) are integrated to form a combined pool/spa system has provided designers the opportunity to design pools that are not only interesting in appearance, but functionality as well. A popular type of integrated pool/spa design is the “spillover” spa in which a spa is placed adjacent to a pool so that water from the spa spills over into the pool. This type of design often provides a desirable integration of traditionally separate pool and spa constructions, and also facilitates the addition of interesting water features, such as waterfalls or waterflows between the pool and spa.
The design and construction of integrated pool/spa systems, however, can add significant costs and complexities to a pool project. For example, the specific pool shape must be conducive to placement of an integrated or spillover spa. The spa must then be properly designed and placed in relation to the pool. With respect to specific spa design and placement, numerous factors are critical in providing the desired look and operation while allowing for installation that is not only economical, but feasible as well. Factors such as the shape of the spa and pool and the type of materials used in construction, as well as the major sub-assemblies, like plumbing and heating are typically more critical in integrated pool systems because of the need to provide a uniform look and feel between the pool and spa, and the need to provide appropriate interaction of water between the pool and spa. Whereas a pool is typically constructed on a level plot, the associated spa can be placed at various heights either level with or above the pool. This also adds a degree of complexity in the design and construction process. The cost of adding a spillover spa to a package pool product can be quite significant due to the additional excavation, plumbing, filtration, and integration requirements.
Traditional integrated pool/spa systems utilize a spa that is excavated along with the attached pool as a single in-ground system. At present, gunite pools are the most popular design in much of the United States. In this type of pool construction, a construction crew excavates a hole, installs the plumbing and assembles a framework grid with ⅜-inch steel reinforcing rods (rebar), or similar structural material. The rebar rods are usually spaced at intervals, such as four to ten inches apart, and secured together with wire. When the grid is in place, the crew sprays a heavy coating of gunite, which is a mixture of cement and sand, around the rebar. The gunite is sprayed as a wet concrete material which is troweled smooth. After being allowed to dry, which can take up to a week, a smooth finish is applied to the rough surface. The most popular finish is plaster, which can be a mixture of cement and marble sand. Alternatively, special concrete paints, tiles, exposed aggregates, vinyl or fiberglass can be used to finish the pool surfaces. The advantage of a packaged gunite pool and spa is that the system is effectively one unit and made of the same material, thereby ensuring a uniform appearance and style. Also, as an integral unit, the plumbing and heating systems are often integrated at the design and manufacturing stage, thus simplifying installation. A disadvantage of this type of system, however, is that modification of the design or replacement of any the spa components or spa surface is very difficult due to tight integration with the pool.
To accommodate integration with existing pools, a number of pre-made spillover spas have been developed. These are typically pre-cast spa units that are pre-plumbed in pre-formed shells that are designed to interface with the main filtration equipment of an existing pool. Such assemblies, however, often have various drawbacks in design, construction and installation. Although they are designed to be readily installable components, they are often not designed to provide a truly integrated, flush look with the surrounding pool structure and masonry. Consequently, they lack the uniformity of appearance that can be achieved in traditional poured concrete/gunite pool and spa systems. For example, existing non-traditional spa systems (such as acrylic or fiberglass replacement spas) often possess no integration-assisting features, and protrude from the surrounding pool/patio in an unappealing manner. For pool and spa systems that require a specific aesthetic look or structure, this lack of integration presents a significant obstacle to overcoming the associated cost of such a system.
Another drawback with many present pre-formed spa assemblies, particularly with respect to replacement spas, is that they typically do not provide for adequate attachment to the existing surrounding structure or walls (e.g., gunite). Thus, present assemblies and methods frequently require installation and positioning construction or hardware that present further cost and complexity to the installation process. These systems also often require extensive rework of the existing water-flow, suction, skimmer and/or additional water feature systems, particularly with respect to the associated or necessary flow routes, filtration and valve requirements. As a further inconvenience, present pre-formed spa assemblies do not permit masonry or other stonework to be placed flush with the spa following installation. As a result, it is readily apparent that a spa has been added to adjoining pools or other water features, thereby disturbing the aesthetic appearance of the additional spa. What is therefore needed is a pre-formed spa assembly that integrates with the surrounding landscape, such that masonry or other stonework can be placed on and around the border of the installed spa.
Recent legislature has also required that spas have various anti-entrapment features in place. For example, the Virginia Graeme Baker Pool and Spa Safety Act requires certain anti-entrapment devices or systems. What is therefore needed is a pre-formed spa assembly that complies with these recent regulations.
The invention is illustrated by way of example and not limitation in the figures of the accompanying drawings, in which like references indicate similar elements, and in which:
A spa insert and anti-entrapment system for the hot tub portion of a packaged pool system is described. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the invention. It will be evident, however, to one of ordinary skill in the art, that the invention may be practiced without these specific details. The description of preferred embodiments is not intended to limit the scope of the invention or the claims issuing therefrom.
The assembly (also “spa” or “spa assembly”) of the invention is an insert designed to fit into the spa cavity of new or existing in-ground pool structures. The spa cavity comprises an excavation or similar construction that is typically placed adjacent to a partially or fully in-ground pool structure. The completed packaged pool system comprises the pool and adjacent spa, which is arranged so that some of the water from the spa intermingles with the pool, typically by flowing into the pool via a passageway or waterfall.
Typical present known spa assemblies are comprised of pre-formed shells that typically have pre-defined, generally hemispherical upper lips. One example of such spa assemblies is the traditional fiberglass spa assemblies that have a rounded upper lip around the tub, with perhaps an extended portion that contains all of the spa controls. The curved or rounded surface is safe and comfortable to the touch, since people often lean or even sit on this upper section of the spa. Because of these uses, traditional fiberglass spas leave exposed a large portion of the fiberglass structure. These spas can only be made to match the surrounding pool structure by utilizing a particular color of fiberglass or housing material. In any case, such solutions are typically artificial and do not truly accomplish the complete integration of the spa with the surrounding environment.
Unlike stand-alone spa or “jacuzzi” structures, embodiments of the invention are intended primarily to be installed as an “insert” that becomes an integral part of built-in pool infrastructure while maintaining the uniform appearance that a traditional in-ground spa has with the surrounding masonry. An embodiment of the invention permits layering of surrounding on top of the flange surrounding the circumference of the spa insert.
As illustrated in
As an insert that can be installed directly into the framework or outer structure portion of an in-ground pool or spa, or may be installed into any types of outdoor landscaping, the footwell of the spa can be set directly on the floor of the surrounding in-ground structure. Alternatively, the footwell of the spa can be set such that in-floor sump pumps, suction systems and/or anti-entrapment systems can lead out from the bottom of the spa insert. For example, the spa insert may be constructed with a “false-bottom” or similar structure.
One will appreciate that the flat flange 126 at the spa cap allows for integral fitting to the upper wall of the surrounding structure, associated pool, or landscaping. In these embodiments, this flange could sit on the gunite portion of the spa bond beam and dam wall, and can be fastened using a variety of fastening means (e.g., stainless steel or bronze bolts or fasteners), directly to the bond beam and dam wall to prevent any movement or separation from the pool/spa shell. The flat upper flange 126 is constructed so as to support the entire weight of the spa on the rim of the gunite spa cavity. The insert is also capable of being installed in a balanced manner, supported by both the flat upper lip 126 and the bottom footwell, without the use of sandbags. In an embodiment, the flat flange provides advantages over U-shaped spa lips that remain exposed to sunlight and UV rays after construction, thereby causing discoloration of the spa insert or other degradation. The flat flange 126 in the invention may be enclosed or fully covered by masonry or other stonework, avoiding such exposure and extending the life of the spa.
For creating a waterfall-like water feature for permitting water flow into an associated pool or other landscaping, the cavity 500 also includes a spillway recess 508 that is provided to accommodate the spillway of the insert, such as spillway 124 in insert 100. This recess provides for the flush mounting of the insert within the spa, and also helps hold the insert in place while it is fitted and fastened to the cavity. It should be noted that various different spillway and spillway recess configurations are possible, depending upon the design and implementation of the spillway. For example, the spillway could be recessed within the upper portion of the cavity as shown, or it could be designed to wrap up and over the side of the cavity, or even protrude through an opening formed in the wall of the cavity, or any other similar configuration.
As stated above, the spa cavity 500 is preferably made of gunite. In an alternative embodiment, the spa cavity can be formed using poured-concrete. This method is similar to gunite, but instead of spraying concrete material around a rebar framework, concrete is poured into a wooden form. As a further alternative embodiment, the spa cavity can be manufactured from masonry block, in which walls are constructed with concrete blocks, or similar building materials.
The insert 200 also includes flange 206, which attaches and bonds to the upper edge of spa cavity 202, through a beveled or notched interface, as shown. The size of the flange 206 can be varied, depending on the size of the mating surface of the spa cavity shell that the insert rests upon. In most applications, the flange 206 will be approximately three to five inches wide. Decorative masonry, such as tiles or stones 208, can be placed on top of the flat portion of flange 206 to integrate the spa with the surrounding pool and/or environment. As previously discussed, covering flange 206 prevents exposure of the flange to harmful UV rays, preventing discoloration and extending the life of the spa insert beyond spa inserts with exposed or U-shaped lips. A notch or circumferential recess 214 can also be formed in the insert 200 to accommodate the placement of tiles or stones along the upper inside surface of the tub to further complete the “integrated” appearance of the spa.
Also illustrated in
As illustrated in
Embodiments of the present spa assembly also provide for increased user comfort. The insert assembly can be designed in several configurations other than the traditional straight walls and benches found in most in-ground spas. In most in-ground spas, there are only four to six jets, which are all typically placed at the same depth from the top of spa, with the jet “height” being adjusted by merely adjusting the height of the spa bench. Though the bench height and footwell depth are determined by the mold used to form the insert, the number of jets and their locations are virtually unlimited in the assembly shell, allowing for a much more comfortable and therapeutic spa, while maintaining the appearance and uniformity of a traditional in-ground spa. As shown in
Operating controls 325 for controlling various factors such as water temperature, jet flow, and the like can be located in a single, readily accessible window region on the side of the tub surface. Basic plumbing controls 330 can also be located in a single, readily accessible window region. The controls may be provided at a console that is separate and outside of the spa. For configurations in which the controls are placed within the spa and below the waterline of the tub, a waterproof console with touchbutton or similar controls can be provided.
Once the spa insert has been formed and installed with the appropriate plumbing fixtures, it is ready to be inserted into a spa cavity, such as cavity 500 illustrated in
As can be seen in
As shown in
In an embodiment, the spa insert 100 illustrated in
In an alternative mode of manufacture, the insert is formed by a vacuum forming method. In this method, a flat sheet of plastic is used. It is heated to a soft pliable state and placed over a vacuum mold. The vacuum created pulls the soft plastic into its final shape. After cooling, a colored gel coat is then applied and the plumbing is installed, as described above with reference to the fiberglass embodiment. Besides plastic, any comparable material, such as acrylic, resin composite, Lucite, or even carbon fiber, can be used.
The use of acrylic or fiberglass assemblies for the spa insert confers numerous benefits over current gunite spa structures. The spa assembly using an insert placed in the spa cavity can include insulation, typically foam insulated as part of the manufacturing and assembly process. The insulating material can be used as part or all of the backfilling material 204. The use of insulation provides greater energy efficiency than typical in-ground systems. For example, the insulated spa insert configuration allows the spa to heat in approximately one-quarter the time of traditional in-ground or gunite spas. Not only is this convenient and time efficient for the owner, but it is also provides a significant savings on the use of gas, propane, or other heating energy source. While a traditional in-ground spa with a cover, when heated for use will lose approximately 50% of its heat overnight due to the concrete construction and lack of insulation. An insulated assembly according to the disclosed embodiments will maintain approximately 80% of its heat in the same time period. Therefore, using the spa on consecutive days will impose a minimal cost in maintaining the desired operating temperature.
As discussed above,
One will appreciate that in the description above and throughout, numerous specific details are set forth in order to provide a thorough understanding of the invention. It will be evident, however, to one of ordinary skill in the art, that the invention may be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form to facilitate explanation. The description of the preferred embodiments is not intended to limit the scope of the claims appended hereto. Further, in the methods disclosed herein, various steps are disclosed illustrating some of the functions of the invention. One will appreciate that these steps are merely exemplary and are not meant to be limiting in any way. Other steps and functions may be contemplated without departing from this disclosure or the scope of the invention.
This nonprovisional utility patent application is a continuation-in-part application of U.S. patent application Ser. No. 10/800,044, entitled “SPA INSERT WITH FLAT UPPER FLANGE AND INTEGRAL SPILLWAY,” filed Mar. 12, 2004, and hereby incorporated by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 10800044 | Mar 2004 | US |
| Child | 12488486 | US |
