SPA SYSTEM WITH SECTIONAL HARD COVER

TECHNICAL FIELD

The technical field relates, in general, to spas, and more particularly to a spa system having a removable, hard cover.

BRIEF DESCRIPTION OF THE FIGURES

The features and advantages of certain embodiments will be more readily appreciated when considered in conjunction with the accompanying figures. The figures are not to be construed as limiting any of the embodiments.

FIGS. 1A and 1B are perspective views of a spa system having a spa with a spa cover according to certain embodiments.

FIGS. 1C and 1D are perspective views of sections of the spa cover for the spa system of FIGS. 1A and 1B according to certain embodiments.

FIG. 2A is a perspective view of a spa system having a spa with a spa cover according to certain embodiments.

FIGS. 2B and 2C are perspective views of sections of the spa cover for the spa system of FIG. 2A according to certain embodiments.

FIGS. 3A-3C are perspective views of a spa system with a spa cover being removed from a spa according to certain embodiments.

FIG. 4 is a perspective view of a spa system having a spa with a spa cover according to certain other embodiments.

FIG. 5 is a perspective bottom view of the spa cover of FIG. 4.

FIGS. 6A-6D are perspective views of the spa system with the spa cover being removed from the spa.

DETAILED DESCRIPTION

Hot tubs, whirlpools, spas, and the like (hereinafter “spas”) are large containers filled with water that are often used for hydrotherapy, recreation, exercise, and/or physical therapy. Many modern spas include a large tub or vessel supported by a frame or other support structure, combined with a recirculation system for passing water within the tub through one or more of a heater, chiller, filtration system, or chemical dispenser before returning the recirculated water to the interior of the hot tub. Most spas use heated water or heat the water to a desired temperature. Other spas may use chilled water or chill the water. Some spas can both heat and chill the water, depending on what is desired. Many have powerful jets to return the water to the tub in such a manner that the returned water may be used for massage purposes.

Spas often include tubs or other similar water holding vessels that are above ground and portable. However, spas may be in-ground and permanent and/or mounted flush with a surrounding surface such as a deck, floor, platform, or other fixture. Spas usually are self-contained vessels with all of the plumbing, electrical controls, and other components built inside. Many spas require no external plumbing; they may be filled with a garden hose or similar external water source. Most spas can be drained easily either by siphon or via a suitable drain plug. Portable spas may be drained for relocation to a new house or similar location.

Modern spa construction can incorporate an acrylic-based or roto-molded tub for holding the water. Acrylic-based spas typically have a shell made of fiberglass or acrylic with a wooden support frame constructed to support the shell from a floor or ground surface along an upper perimeter edge of the shell. The various components of the recirculation system can be housed within the frame, between the frame and the tub. A skirt constructed of wood veneer, polymer, or the like may be wrapped around the frame and shell to hide and protect the components of the recirculation system and to improve the aesthetic of the spa. Acrylic-based spas can have a cover of vinyl-encased foam. Roto-molded spas typically are made of polyethylene and have a tub with a combined frame and skirt molded as one piece. Spas can be made from other materials and with other methods not specifically mentioned in this disclosure.

Spa covers can provide several important safety and maintenance features for spas. Spa covers can be manufactured with high insulative qualities in order to maintain the heated or chilled state of the water within the tub. A spa cover can prevent people, children, or animals from falling into the spa when not in use. A spa cover can also help keep the spa clean when not in use. Spa covers can typically consist of one or two pieces and can be either a soft spa cover or a hard spa cover.

As used herein, a “soft spa cover” refers to a spa cover that has at least one layer of a foam material that can be wrapped in another layer of flexible material, such as but not limited to a vinyl-based material. Thus, each section of the “soft spa cover” is made by at least a two-piece construction with the foam layer being one piece of the construction and the flexible material being another piece of the construction. As used herein, a “section” of a spa cover refers to a portion of the spa cover that remains aligned with a plane when the portion is moved relative to the other portion(s) of the spa cover. For example, when one portion is rotated relative to another portion of the spa cover, this refers to two “sections” of the spa cover because the one portion (or section) is moved relative to the other portion (or section). It does not refer to a single section with rotating parts because a “section” is defined as being a portion that remains aligned with a plane. Accordingly, if one portion is rotated out of alignment with a plane of the other portion, then these would be referred to as separate sections. Sections of a soft spa cover have increased flexibility and pliability compared to a hard spa cover, which is made from a semi-rigid (or rigid) material such as a plastic (i.e., a synthetic material that can be made from a wide range of polymers such as polyethylene, PVC, nylon, etc.). In addition to the increased flexibility and pliability, a soft spa cover can be lighter in weight than a hard spa cover.

As used herein, the term “hard spa cover” means a spa cover made from a main layer of material that is more rigid than foam. The main layer of each section of the hard spa cover is formed as a one-piece construction. Other sections of the hard spa cover can be assembled together (e.g., rotationally coupled via pivots or hinges). It is to be understood that hard spa covers can also have another layer of material that is added to an external surface of the section (e.g., an insulation layer underneath the section), but the main layer of material of the individual sections are made from a one-piece construction (e.g., injection molding).

Traditionally, a user must fold one section on top of the other section and then lift the entire cover off of the spa for placement on the ground or in a storage area. Spa covers can be removed from the spa by hand by lifting the cover off the spa or with a cover lifter that, in some designs, can be mounted to the spa. However, these covers can be large and cumbersome to handle.

Soft spa covers are generally less durable than a hard spa cover. The flexible material used in soft spa covers that contains the foam layer can degrade faster than the material used in hard spa covers. The degradation of the soft spa cover can include drying and cracking of the flexible material, rotting of the flexible material, rotting of the stitching used to assemble the soft spa cover, degradation of the foam material, or tearing of the flexible material. A damaged flexible material can allow water into the foam core, which can mold and further damage the foam core. Degraded foam cores can sag causing water to pool up on the soft spa cover and not run off as desired. Accordingly, hard spa covers can provide increased sealing integrity to the spa than a soft spa cover. Moreover, hard spa covers can support more weight than soft spa covers.

Other advantages to hard spa covers are the plastic material can prevent most of the problems associated with the degradation of the materials of the soft spa covers. The hard spa covers can prevent sagging, provide enhanced sealing with the spa, hold more weight, provide better insulation, prevent rotting, and generally last for the life of the spa.

While a vinyl-wrapped foam cover can be lighter weight than a hard plastic cover, both types of covers can weigh more than an individual person can lift, which makes it difficult to remove the cover during use. For example, people who are weaker and frailer than others, such as many elderly people, may find it difficult to remove a spa cover. Moreover, a hard plastic cover can provide better protection than a soft cover, is sturdier than a soft cover, and can last longer than a soft cover. However, due to the increased weight of a hard plastic cover compared to a soft cover, a user may not be able to remove a hard plastic cover from the spa without help. Another disadvantage is that cover lifters increase the cost of a spa and are often bulky and difficult to use and maintain. In addition, it is often difficult to find a place for storing or stowing the spa cover when the spa is used. Thus, there is an ongoing need for simple and efficient hard spa covers that solve the aforementioned problems.

It has been discovered that a hard spa cover can include two or more sections. The two or more sections can be individually removed from the top of the spa. According to other embodiments, one or more sections can be folded on top of another section and the cover can be slid onto a storage rack.

FIG. 1A shows a spa system 100 having a spa 102 with a spa cover 104 positioned on top of the spa according to certain embodiments. FIG. 1A shows the spa cover having two sections. The spa cover 104 can have a first section 106 with a ledge 110 that engages a complementarily shaped ledge 114 on a second section 107 when the spa cover 104 is installed onto the spa 102. The spa cover 104 can be attached to the spa 102 by anchor clips 112 or another securement mechanism (e.g., guidance tabs and interior surfaces that engage the spa 102). Each end section 106, 107 can have multiple anchor clips 112 positioned along a side that is opposite the ledge 110, 114, respectfully. The spa cover 104 can be substantially flat. However, the spa cover 104 can also form a dome or crown, where the spa cover 104 increases in height while moving along a top surface of the spa cover 104 toward a center of the spa cover 104. When the spa cover 104 includes only two sections, then each of the two sections can span approximately half of the top of the spa. Alternatively, the first section 106 can span greater than half while the second section 107 can span less than half.

To remove the spa cover 104, the first section 106 can be rotated up generally about the ledge 110 that is engaging the ledge 114 after the anchor clips 112 have been disengaged from the spa 102. This upward rotation can disengage the ledge 110 of the first section 106 from the ledge 114 of the second section 107 and disengage the first section 106 from a portion of the spa 102. The first section 106 can then be removed and placed in a storage location (not shown). The second section 107 can be removed from the spa 102 and placed in the storage location with the first section 106 (e.g., stacked on top of each other, standing on edge next to each other, etc.).

FIG. 1B shows the spa cover 104 having three sections. The spa cover 104 can have a first section 106 with a ledge 110a that engages a complementarily shaped ledge 114a on one side of a third section 108 when the spa cover 104 is installed on to the spa 102. The spa cover 104 can have a second section 107 with a ledge 110b that engages a complementarily shaped ledge 114b on an opposite side of the third section 108 when the spa cover 104 is installed onto the spa 102. The spa cover 104 can be attached to the spa 102 by anchor clips 112 or another securement mechanism (e.g., guidance tabs and interior surfaces that engage the spa 102). Each section 106, 107 can have multiple anchor clips 112 positioned along a side that is opposite the ledges 110a, 110b, respectfully. Each of the sections 106, 107, 108 can span approximately one-third of the top of the spa. Additional sections (not shown) can be positioned between the first and second sections 106, 107, for example, the spa cover 104 can include four or more total sections.

FIGS. 1C and 1D are perspective views of first and second sections 106, 107 of the spa cover 104 for the spa system 100. The first section 106 can be substantially the same shape as the second section 107 with the first section 106 positioned on one side of the third (or center) section 108 with the second section 107 positioned on an opposite side of the third section 108 when the spa cover 104 is installed on the spa 102. The ledges 110a, 110b of the first and second sections 106, 107, respectively, can mate up to the ledges 114a, 114b of the third section 108, respectively. The ledges 110a, 110b can be protrusions of a top surface of the respective section and ledges 114a, 114b can be protrusions of a bottom surface of the respective section, such that the ledge 110a, 110b overlaps the respective ledge 114a, 114b. The ledge 110a, 110b can sealingly engage the respective ledge 114a, 114b to minimize ingress of rain or other substances into the spa 102 while the spa cover 104 is installed.

As used herein, “bottom,” when used regarding one or more sections, refers to the surface of the section that faces the interior of the spa when the section is assembled onto the spa. As used herein, “top,” when used regarding one or more sections, refers to a surface of the section that faces away from the interior of the spa when the section is assembled on to the spa.

It should be understood that the ledges 110a, 110b, 114a, 114b can be formed on any of the sections 106, 107, 108. For example, the first section 106 can have a ledge 114a formed along its side with the mating ledge 110a formed along the side of the third section 108 to which the first section 106 is engaged when installed on the spa 102. Additionally, or in the alternative, the ledges 110a, 110b can be intermittent along the side of the respective section with spaces along the side between the segments of the intermittent ledges 110a, 110b filled with intermittent ledges 114a, 114b.

The first section 106 can include guides 148a extending from a bottom surface of the section that can be used to engage an inner surface of the spa 102 and substantially prevent side-to-side movement of the first section 106 (i.e., movement parallel to the ledge 110a or 114a) when the first section 106 is installed onto the spa 102.

The second section 107 can include guides 148b extending from a bottom surface of the section that can be used to engage an inner surface of the spa 102 and substantially prevent side-to-side movement of the second section 107 (i.e., movement parallel to the ledge 110b or 114b) when the second section 107 is installed onto the spa 102.

The third section 108 can include guides 148c extending from a bottom surface of the section that can be used to engage an inner surface of the spa 102 and substantially prevent side-to-side movement of the third section 108 (i.e., movement parallel to the ledge 114a or 110a) when the third section 108 is installed onto the spa 102. These guides 148a-c can be used to stabilize the spa cover 104 when the spa cover 104 is installed on a spa 102 such that the edges overlap the sides of the spa 102. However, these guides 148a-c may not be necessary if the spa cover 104 is installed on the spa 102 and is positioned below the top of the sides of the spa 102, for example as shown in FIG. 2A. The guides 148a-c can also aid a user in determining the correct location of each section onto the spa.

The ledges 110a, 110b, 114a, 114b may have other rectangular, angular, curvilinear, tongue in groove, combinations, or like configurations for interlocking (or engaging) the adjacent sections 106, 107, 108 to each other. One or more of the ledges 110a, 110b, 114a, 114b can have a seal or similar interface to improve or facilitate the sealing engagement between the adjacent sections 106, 107, 108. When the spa cover 104 is in position on the spa 102, the anchor clips 112 or other securement mechanisms may bias the end sections 106 against the third section 108 to improve the watertight seal or connection.

To remove the spa cover 104 from the spa 102, the spa cover 104 is released from the anchor clips 112 or other attachment mechanism if used. The sections 106, 107, 108 are disconnected when lifted off the spa 102 separately and stowed. FIGS. 3A-3C illustrate removal of a spa cover 204 according to other embodiments, which can also apply similarly for removal of the spa cover 104. The spa 102 can include a rack or similar stowage equipment for storing the sections 106, 107, 108. By having separate sections, the weight of the spa cover is greatly reduced, which makes removal of the spa cover 104 from the spa 102 and placement onto the spa much easier. The separate sections can also be easier to move to a stowage or storage area because a person only has to carry one section at a time.

FIG. 2A represents a spa cover 204 according to certain other embodiments. The spa cover 204 can have a first section 206 that engages one side of a third section 208 when the spa cover 204 is installed onto the spa 202. The spa cover 204 can have a second section 207 that engages an opposite side of the third section 208 when the spa cover 204 is installed on to the spa 202. The spa cover 204 can be positioned along a horizontal plane between inner surfaces 210a, 210b of the spa 202. In this configuration, the spa cover 204 may not include guides similar to the guides 148a-c in FIG. 1C-1D because the sides of the spa cover 204 can be positioned between the inner surfaces 210a, 210b to provide a similar function. The spa cover 204 can be substantially domed or crowned. The spa cover 204 can also be a substantially flat surface. When the spa cover 204 is in position on the spa 202, an attachment mechanism can bias the end sections 206 against the middle section 208 to improve a seal or connection to adjacent sections. The seal created can help prevent small animals or insects or dirt from entering the interior of the spa.

FIG. 2B shows features of the first and second sections 206, 207, and FIG. 2B shows features of the third section 208. Although shown in FIGS. 2A-2C as including three total sections, it is to be understood that the spa cover can include only two sections or more than three sections. Selection of how many sections needed can be based, in part, on the total weight of each section depending on the material the spa cover is made from. For example, it may be desirable to have each section weigh less than 20 pounds. If the total weight of the spa cover is 50 pounds, then three sections may need to be selected. The total number of sections and dimensions of the sections can be based on the overall dimensions of the spa.

The first section 206 can include alternating notches and ledges along one side (e.g., such as the side that engages the third section 208). In FIG. 2B only two ledges 216a, 216b are positioned on opposite sides of a notch 220a. However, it should be understood that more of fewer ledges or notches can be used to interlock or engage with the third section 208. The ledges 216a, 216b can be seen as horizontal protrusions extending from the side of the first section 206 with inclined surfaces that taper downward from the top surface of the first section 206. The notch 220a can be seen as a horizontal protrusion extending from the side of the first section 206 with an inclined surface that tapers upward from a bottom surface of the first section 206. These ledges and notches are configured to interlace between mating ledges and notches (i.e., oppositely oriented protrusions) on a side of the third section 208 when the spa cover 204 is installed on the spa 202.

The second section 207 can include alternating notches and ledges along one side (e.g., such as the side that engages the third section 208). In FIG. 2B only two ledges 217a, 217b are positioned on opposite sides of a notch 220b. However, it should be understood that more of fewer ledges or notches can be used to interlock or engage with the third section 208. The ledges 217a, 217b can be seen as horizontal protrusions extending from the side of the second section 207 with inclined surfaces that taper downward from the top surface of the second section 207. The notch 220b can be seen as a horizontal protrusion extending from the side of the second section 207 with an inclined surface that tapers upward from a bottom surface of the second section 207. These ledges and notches are configured to interlace between mating ledges and notches (i.e., oppositely oriented protrusions) on an opposite side of the third section 208 from the first section 206 when the spa cover 204 is installed on the spa 202.

The third section 208 can include alternating notches and ledges along opposite sides (e.g., such as the sides that engage the first and second sections 206, 207). In FIG. 2C only two ledges 224a, 224b are positioned on opposite sides of a notch 228a along one side of the third section 208 and only two ledges 225a, 225b are positioned on opposite sides of a notch 228b along an opposite side of the third section 208. However, it should be understood that more of fewer ledges or notches can be used to interlock or engage with either one of the first and second sections 206, 207 when the spa cover 204 is installed on the spa 202.

The ledges 224a, 224b, and ledges 225a, 225b can be seen as horizontal protrusions extending from opposite sides of the third section 208 with inclined surfaces that taper upward from a bottom surface of the third section 208. The notches 226a, 226b can be seen as horizontal protrusions extending from opposite sides of the third section 208 with inclined surfaces that taper downward from the top surface of the third section 208. These ledges and notches are configured to interlace between mating ledges and notches (e.g., oppositely oriented protrusions 216a, 216b, 217a, 217b, 220a, 220b) on a side of each of the first and second sections 206, 207 when the spa cover 204 is installed on the spa 202. The third section 208 can also include tabs 222a, 222b that horizontally extend from opposite ends of the third section 208 and can mate with mating features (or recesses) of the inner surfaces 210a, 210b of the spa 202.

The protrusions 216a, 216b, 217a, 217b, 220a, 220b can have other rectangular, angular, curvilinear, tongue in groove, combinations, or like configurations for interlocking (or engaging) the adjacent sections 206, 207, 208 to each other. One or more of the protrusions 216a, 216b, 217a, 217b, 220a, 220b can have a seal or similar interface to improve or facilitate the sealing engagement between the adjacent sections 206, 207, 208.

FIGS. 3A-3C show removal of the spa cover 204 from the spa 202. These figures show a spa cover 204 that includes three sections 206, 207, 208 and illustrates at least one sequence of removing these sections from the spa 202. However, it should be understood that the spa cover 204 can comprise fewer or more sections than illustrated in FIGS. 3A-3C. For example, the spa cover 204 can include 4 sections (or two sections) with each adjacent section engaging its neighbor via the ledges and notches described above (i.e., protrusions 216a, 216b, 217a, 217b, 220a, 220b) or via other engagement features. The removal of the spa cover 204 with fewer or more sections can be similar to the description of the removal described in reference to FIGS. 3A-3C, such as removing (or installing) one section at a time.

Referring to FIG. 3A, a cover storage rack 230 can be attached on a side of the spa 202 with structural supports for holding a stack of the sections in a horizontal orientation. However, it should be understood that it is not required that the cover storage rack 230 hold the sections in a horizontal orientation. The cover storage rack 230 can be configured to hold the sections in a storage area in any orientation such as vertically, and the storage area can be spaced away from the spa 202 as opposed to being attached to the spa 202 as shown in FIGS. 3A-3C.

The cover storage rack 230 can include storage rails 232a, 232b that can be rotated from a vertically downward position to a horizontal position to receive the spa cover 204 sections and then rotated back to the vertically downward position when the spa cover 204 sections are reinstalled on the spa 202 as a spa cover 204. Alternatively, the storage rails 232a, 232b can be fixed in a horizontal or inclined position to receive the sections, without being rotatable.

To remove the spa cover 204, the first section 206 can be rotated up generally about the ledges 216a, 216b that are engaging the ledges 224a, 224b of the third section 208, respectively, (refer to FIGS. 2B and 2C) after a securement mechanism (if used) has been disengaged from the spa 102. This upward rotation can disengage the ledges 216a, 216b of the first section 206 from the ledges 224a, 224b of the third section 208 and disengage the first section 206 from a portion of the spa 102. The first section 206 can then be removed and placed (e.g., stacked on top of each other, standing on edge next to each other, etc.) in a storage location (e.g., the cover storage rack 230).

Referring to FIG. 3B, the third section 208 can be rotated up generally about the ledges 225a, 225b that are engaging the ledges 217a, 217b of the second section 207, respectively, (refer to FIGS. 2B and 2C). This upward rotation can disengage the ledges 225a, 225b of the third section 208 from the ledges 217a, 217b of the second section 207 and disengage the third section 208 from another portion of the spa 102. The third section 208 can then be removed and placed (e.g., stacked on top of each other, standing on edge next to each other, etc.) in the storage location (e.g., the cover storage rack 230).

Referring to FIG. 3C, the second section 207 can be disengaged from another portion of the spa 202 and placed (e.g., stacked on top of each other, standing on edge next to each other, etc.) in the storage location (e.g., the cover storage rack 230). As shown in FIG. 3C, the sections 206, 207, 208 are conveniently stacked on the cover storage rack 230 in a horizontal orientation that is out of the way of the spa 202 to minimize interference when the spa 202 is being used and to provide convenience when replacing the spa cover 204 onto the spa 202.

FIG. 4 shows a spa 302 with a spa cover 304 according to certain other embodiments. The spa cover 304 can include two or more sections. However, in a non-limiting embodiment, FIG. 4 shows a spa cover 304 assembled on a spa 302, with the spa cover 304 having three sections referred to as a first section 306, a second section 307, a third section 308. The first section 306 can be rotationally coupled to one side of the third section 308 by pivots 318a, 318b. These pivots 318a, 318b allow the first section 306 to be rotated (arrows 390) nearly 180 degrees about the axis 380 such that it can overlay the top surface of the third section 308 as will be explained in more detail below.

The third section 308 can include a ridge handle 310 which can extend along the side of the third section 308 that is opposite the pivots 318a, 318b. The ridge handle 310 can be continuous along the side of the third section 308 or it can be discontinuous with multiple upward facing protrusions spaced apart along the side of the third section 308. The ridge handle 310 can be used by a spa operator to slide the first section 306 and the third section 308 up onto the second section 307 when the spa cover 304 is being removed from the spa 302.

The third section 308 can also include center handles 312a, 312b which are positioned at opposite ends of the third section 308 as shown. These center handles 312a, 312b can also be used by a spa operator, in cooperation with the ridge handle 310, to slide the first section 306 and the third section 308 up onto the second section 307 when the spa cover 304 is being removed from the spa 302.

When sliding the first section 306 and the third section 308 up onto the second section 307, wheels 350a, 350b (see FIG. 5) underneath the third section 308 can engage a ramped portion of a tracks 340a, 340b, respectively, at either end of the third section 308. The third section 308 can have an inclined or curved surface 344a, 344b at each end to overlay the ramped portion of the respective tracks 340a, 340b. When the spa operator pulls (e.g., using handles 312a, 312b, 310) the third section 308 towards the second section 307, the wheels can roll up the ramped portions of the tracks 340a, 340b causing a side of the third section 308 that is adjacent the second section 307 to be lifted upward. This upward movement of the side can disengage the third section 308 from the spa 302 and break a sealing engagement with the spa 302 (if a seal is being used). As the wheels 350a, 350b roll along the tracks 340a, 340b the side of the third section 308 will be further lifted upward to be positioned above the second section 307.

As the spa operator further pulls the third section 308 over the second section 307, the wheels 350a, 350b will continue along the respective tracks 340a, 340b until the wheels 350a, 350b roll into a respective indention 342a, 342b. Weight of the third section 308 and the first section 306 (which is overlays the third section 308) will tend to hold the wheels 350a, 350b in the respective indentions 342a, 342b, thereby resisting movement relative to the second section 307 as the three sections are moved to a storage location (e.g., cover storage rack 330).

A cover storage rack 330 can be provided that can receive the spa cover 304 sections when they are moved to the storage location. The cover storage rack 330 can include storage rails 332a, 332b that can be rotated from a vertically downward position to a horizontal position to receive the spa cover 304 sections and then rotated back to the vertically downward position when the spa cover 304 sections are reinstalled on the spa 302 as a spa cover 304.

When the first section 306 has been rotated onto and above the third section 308, and the third section 308 has been pulled up and over the second section 307, the storage rails 332a, 332b can be rotated (arrows 392) about the axis 382 to a generally horizontal position. Curved portions of the storage rails 332a, 332b proximate the axis 382 cause the storage rails 332a, 332b to lift up the side of the second section 307 with the end handle 314. Raising the side of the second section 307 can disengage a seal of the second section 307 that can be sealingly engaged with the spa 302 to make it easier to move the sections onto the storage rails 332a, 332b.

When the storage rails 332a, 332b are rotated to the generally horizontal position, a guide 320a, 320b can straddle the respective ones of the storage rails 332a, 332b to help guide the second section 307 along the storage rails 332a, 332b as an operator pulls the second section 307 from the spa 302 onto the storage rails 332a, 332b.

FIG. 5 is a perspective bottom view of the spa cover 304 of FIG. 4. A seal 370 can be positioned around the inner perimeter of the spa cover 304 spanning all sections to provide a seal between a top surface 326 (see FIG. 6A) of the spa 302 and the underside of the spa cover 304. The seal 370 can have breaks at the transitions between sections 306, 307, 308, but can provide a continuous seal when the sections 306, 307, 308 are assembled on the spa 302 as the spa cover 304. The top surface 326 can extend around an outer perimeter of the spa 302 and form as raised surface from the spa 302 which can sealingly engage the seal 370 when the spa cover 304 is installed on the spa 302.

Guides 348 and the inner surfaces 360, 361a, 361b, 365a, 365b, 366 can straddle the top surface 326 around the perimeter of the spa to restrict movement of the spa cover 304 when the spa cover 304 is installed on the spa 302. The guides 348 can be positioned on an opposite side (e.g., an inner side) of the top surface 326 from the inner surfaces 360, 361a, 361b, 365a, 365b, 366 (e.g., positioned on an outer side of the top surface 326) of the spa cover 304.

Because the third section 308 can slide up and over the second section 307, when the sections are being removed from the spa 302, the inner width L2 of the third section 308 can be larger than the outer width L4 of the second section 307 to allow for the inner width L2 of the third section 308 to receive the outer width L4 of the second section 307 when the third section 308 is pulled over the second section 307.

To accommodate the larger width L2 of the third section 308, the first section 306 can have a transition surface 362a, 362b that transitions between the inner width L1 (that can be substantially equal to the inner width L3) to an inner width L2 that aligns up with the inner width L2 of the third section 308. The inner width L1 can be defined as the distance between the inner surfaces 361a and 361b. The inner width L2 can be defined as the distance between the inner surfaces 363a and 363b or the distance between the inner surfaces 364a and 364b. The inner width L3 can be defined as the distance between the inner surfaces 365a and 365b.

The guides 320a, 320b can easily be seen on the underside of the end handle 314 for guiding the second section 307 along the respective storage rails 332a, 332b. The ramped portions of the tracks 340a, 340b can also be seen with the wheels 350a, 350b engaged with the respective tracks 340a, 340b.

FIGS. 6A-6D of the spa cover 304 being removed from a spa 302. As described above, these figures illustrate the operations that can be performed when a spa cover 304 is removed from the spa 302 and stored on the cover storage rack 330. These operations can be reversed to move the spa cover 304 from the cover storage rack 330 onto the spa 302 when the spa is not in use.

Referring to FIG. 6A, the first section 306 has been rotated (arrows 390) about the axis 380 at the pivots 318a, 318b to overlay the third section 308. Rotating the first section 306 upward can reveal an interior 316 of the spa 302 as well as an inner channel 324 that is positioned on an opposite side of the top surface 326 from the outer channel 322. These channels can receive protrusions (e.g., guides 348) from an underside of the spa cover 304 to orient (or register) the spa cover 304 to the spa 302 when the spa cover 304 is assembled on the spa 302. Rotating the first section 306 upward can also disengage a portion of the seal 370 from a portion of the top surface 326. With the first section 306 positioned above the third section 308, a spa operator can use the handles 312a, 312b, or 310 to move the third section 308 toward the second section 307 causing the wheels 350a, 350b to roll up (arrows 394) the ramped portions of the respective tracks 340a, 340b and then move (arrows 396) along a horizontal portion of the tracks 340a, 340b until the wheels 350a, 350b engage the indentions 342a, 342b which tend to capture the wheels 350a, 350b.

Referring to FIG. 6B, the first section 306 has been rotated to overlay the third section 308 and the third section 308 has been moved to a position over the second section 307. At this point, a portion of the seal 370 positioned in the second section 307 can remain engaged with the top surface 326 of the spa 302. This sealing engagement can provide significant resistance to moving the second section 307 further toward the cover storage rack 330.

Referring to FIG. 6C, the storage rails 332a, 332b of the cover storage rack 330 have been rotated upward to prepare the cover storage rack 330 to receive the stack of sections 306, 307, 308 and to raise (arrows 399) the second section 307 relative to the spa 302 to thereby disengage the portion of the seal 370 positioned in the second section 307 from the top surface 326. With the seal 370 disengaged from the top surface 326 the stack of sections 306, 307, 308 can more easily moved onto the cover storage rack 330. The spa operator can then pull (arrows 398) the stack of sections 306, 307, 308 (which are guided by the guides 320a, 320b) along the storage rails 332a, 332b to position the stack of sections 306, 307, 308 on the cover storage rack 330.

Referring to FIG. 6D, the stack of sections 306, 307, 308 have been positioned over the cover storage rack 330 and the spa 302 can be ready for use. To reassemble the sections 306, 307, 308 back onto the spa 302 to form the spa cover 304, these operations related FIGS. 6A-6D can be reversed to deploy the sections 306, 307, 308 as discussed above.

It should be understood that the operations described above can also be used to store and deploy a spa cover 304 the consists of fewer or more sections than the sections 306, 307, 308 shown. For example, the spa cover 304 can include sections 306, 307 with section 306 including the wheels 350a, 350b that travel along the tracks 340a, 340b on the second section 307. In this configuration, the spa operator can be required to lift up the first section 306 until the inner surface clears the top surface 326 to allow for the first section 306 to be moved towards the cover storage rack 330. Additionally, or in the alternative, the spa cover 304 can include four or more sections and configured to be stacked (or otherwise stored) on the cover storage rack 330.

The hard spa cover can be made of a variety of hard materials, such as hard plastics. Examples of hard plastics include but are not limited to polypropylene, polyvinyl chloride, polyethylene, polycarbonate, polystyrene, acrylic polymers, high-density or low-density polyethylene, etc. The spa cover and each section of the spa cover can have a variety of dimensions that are selected based on the overall outer dimensions of the spa in order to completely cover the opening of the spa when the cover is placed on top of the spa. In this manner, the inside of the spa and water contained within are protected against the elements and prevents animals, insects, or children from getting into the spa.

One of the many advantages of the hard spa cover includes that it allows a single spa operator to remove the hard spa cover from the spa. Another advantage and as shown in FIGS. 1A, 2A, 2B is that the hard spa cover provides a watertight seal of the spa when the cover is installed on the spa and also allows the spa operator to remove each section separately from the spa and position each section one at a time in the cover storage area. This reduces the weight the spa operator has to handle at any one time to remove the hard spa cover. FIG. 4 shows a hard spa cover that provides a watertight seal of the spa when the cover is installed on the spa and also allows the spa operator to remove the hard spa cover by conveniently sliding the sections off of the spa without having to carry the entire weight of each section from spa.

Another significant advantage is the hard spa cover provides a much more sturdy and rigid cover compared to soft spa covers and does not degrade like soft spa covers. The hard spa covers allow for better sealing between the spa and the spa cover when installed on the spa. For example, the hard spa cover can provide a groove in the underside of the cover that can receive a seal, thus the seal is captured by the hard spa cover and can engage the spa whenever the hard spa cover is installed on the spa. Conversely, soft spa covers do not allow for formed recesses that can receive a seal; thus, soft covers do not create an efficient watertight seal compared to the hard spa cover. The hard spa covers can also include recesses that receive seals and can engage an adjacent section of the hard spa cover, thereby providing a better seal between the sections of the hard spa cover than is possible with soft spa covers. This increased seal integrity provides better protection against environmental elements, such as rain, snow, cold (a better seal reduces heat loss), cleaning fluids when cleaning the cover, etc.

Yet another advantage is the hard spa covers also provide better safety for the spa operator or others (e.g., adults, children, animals, etc.) than soft spa covers because the hard spa covers can support heavier loads without collapsing. This can prevent the spa operator or others from falling into the spa if they inadvertently find themselves on the spa cover.

Therefore, the apparatus, methods, and systems of the present disclosure are well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is, therefore, evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present disclosure.

As used herein, the words “comprise,” “have,” “include,” and all grammatical variations thereof are each intended to have an open, non-limiting meaning that does not exclude additional elements or steps. While compositions, systems, and methods are described in terms of “comprising,” “containing,” or “including” various components or steps, the compositions, systems, and methods also can “consist essentially of” or “consist of” the various components and steps. It should also be understood that, as used herein, “first,” “second,” and “third,” are assigned arbitrarily and are merely intended to differentiate between two or more sections, etc., as the case may be, and does not indicate any sequence. Furthermore, it is to be understood that the mere use of the word “first” does not require that there be any “second,” and the mere use of the word “second” does not require that there be any “third,” etc. Furthermore, unless expressly stated to the contrary, “or” refers to an inclusive-or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range is specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. Moreover, the indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of the element that it introduces. If there is any conflict in the usages of a word or term in this specification and one or more patent(s) or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted.

SPA SYSTEM WITH SECTIONAL HARD COVER

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