The invention relates to a spa tub and cabinet assembly and, in particular, a spa tub and cabinet assembly that incorporates a base pan, an indexed frame assembly, and a system for assembling the frame and the spa shell on the base pan.
Typical spa tubs are constructed from a fiberglass or plastic shell forming the spa tub basin, which is supported on a surrounding cabinet. The cabinet is typically constructed from a wooden frame. Decorative panels and finishes are assembled on the frame to define the cabinet structure around the spa shell. Manufacturing the spa cabinet in this manner is a substantially labor-intensive process since the wooden frame must be assembled by hand. Large tolerances in the components are required to accommodate deviation in the manufacturing and molding processes.
Shipping and installation of the completed spa is also time and labor-intensive because the weight of the spa shell may not be evenly distributed on the frame, causing deflection of the frame.
According to an example of the present disclosure, a spa assembly is provided. The spa assembly includes a base pan; at least one support member connected to and extending upward from the base pan; and a spa shell supported on the base pan and the at least one support member, the spa shell including a bottom and at least one side defining an open internal volume of the spa shell, an interior surface oriented toward the open internal volume, and an opposing exterior surface. The bottom of the spa shell and the base pan comprise corresponding interlocking features configured to align the spa shell within the base pan.
According to another example of the present disclosure, a spa assembly is provided. The spa assembly includes a base pan; at least one support member connected to and extending upward from the base pan; and a spa shell supported on the base pan and the at least one support member, the spa shell including a bottom and at least one side defining an open internal volume of the spa shell, an interior surface oriented toward the open internal volume, an opposing exterior surface, and a rim surrounding the at least one side. The rim has a recess formed therein, the recess being configured to receive a top of the at least one support member.
According to another example of the present disclosure, a spa assembly is provided. The spa, assembly includes a base pan and a frame assembly. The frame assembly includes a plurality of support members connected to the base pan, and a top rail connected to the support members and extending around a perimeter of the spa assembly. The spa assembly further includes a spa shell supported on the base pan and the frame assembly, the spa shell including a bottom and at least one side defining an open internal volume of the spa shell, an interior surface oriented toward the open internal volume, and an opposing exterior surface; a plurality of insulative panels connected to the frame assembly, wherein the plurality of insulative panels encloses the spa assembly around the at least one side of the spa shell; and a plurality of clips configured to connect the plurality of insulative panels to the plurality of support members.
According to another example of the present disclosure, a spa assembly is provided. The spa assembly incudes a base pan; at least one support member connected to and extending upward from the base pan; a spa shell supported on the base pan and the at least one support member, the spa shell including a bottom and at least one side defining an open internal volume of the spa shell, an interior surface oriented toward the open internal volume, and an opposing exterior surface; and at least one pallet member. A bottom surface of the base pan has at least one recess formed therein, the at least one recess being configured to receive the at least one pallet member therein.
According to another example of the present disclosure, a method of assembling a spa is provided. The method includes providing a base pan, at least one support member, and a spa shell, wherein the base pan includes interlocking features and the spa shell includes a bottom and at least one side defining an open internal volume of the spa shell, an interior surface oriented toward the open internal volume, an opposing exterior surface, and a rim surrounding the at least one side, the rim defining an internal cavity; connecting the at least one support member to the base pan such that the at least one support member extends upward from the base pan; applying a foam material to at least a portion of the exterior surface of the bottom of the spa shell; forming interlocking features in the foam material applied to the bottom of the spa shell, the interlocking features in the foam material corresponding to the interlocking features of the base pan; applying a foam material to the internal cavity defined by the rim; forming a recess in the foam material in the internal cavity of the rim; and installing the spa shell on the base pan and the at least one support member such that the spa shell is supported by the base pan and the at least one support member. The installing step includes engaging the interlocking features of the base pan with the interlocking features in the foam material applied to the bottom of the spa shell to align the spa shell within the base pan and engaging a top of the at least one support member within the recess in the foam material in the internal cavity of the rim.
These and other features and characteristics of the present invention, as well as the methods of operation and functions of the related elements of structures, and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following description and with reference to the accompanying drawings, all of which form a part of this specification, wherein like reference numerals designate corresponding parts in the various figures. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only, and are not intended as a definition of the limits of the invention. As used in the specification and the claims, the singular form of “an”, and “the” include plural referents unless the context clearly dictates otherwise.
For purposes of the description hereinafter, the terms “end”, “upper”, “lower”, “right”, “left”, “vertical”, “horizontal”, “top”, “bottom” “lateral” “lateral”, “longitudinal”, and derivatives thereof shall relate to the invention as it is oriented in the drawing figures. However, it is to be understood that the invention may assume various alternative variations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings and described in the following specification are simply exemplary embodiments or aspects of the invention. Hence, specific dimensions and other physical characteristics related to the embodiments or aspects disclosed herein are not to be considered as limiting.
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According to one example, the anchors 24 are arranged in the base pan 20 to define indexed positions for the plurality of support members 31 in the base pan 20. According to another example, the support members 31 may have numbered slots along their length to identify equipment bracket location positioning.
According to one example of the present disclosure, the support members 31 and the pieces 33, 34 of the top rail 32 of the frame assembly 30 are manufactured via injection molding and/or extrusion processes from a polymeric material, in particular a combination of virgin and regrind ABS material. As discussed above, the support members 31 and the pieces 33, 34 of the top rail 32 are manufactured to be an exact fit with each other and with the base pan 20 such that the support members 31 and the pieces 33, 34 may be assembled with each other and with the base pan 20 in a snap-together manner with no separate fasteners or with a minimal number of separate fasteners being required and also with no jigs.
It is to be appreciated that by manufacturing the base pan 20 and the frame assembly 30 from polymeric material, the spa assembly 10 is provided with a longer-lasting, more durable construction because the polymeric materials are not subject to rot and degradation over time as wood material may be. Further, the polymeric materials do not require the application of preservatives, stains or paint for protection.
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It is to be appreciated that the foam material 46 applied to the bottom 41 of the spa shell 40 and the foam material 49 applied to the hollow interior of the rim 48 of the spa shell 40 may be replaced with a different molded or formable material that may be easily shaped to incorporate the interlocking features 47 and the at least one recess or groove 50. For instance, a molded thermoplastic material may be applied to the bottom 41 of the spa shell 40 and to the rim 48, which is shaped prior to or during application to the spa shell 40. Alternatively, the spa shell 40 may be formed such that the interlocking features 47 and the at least one recess or groove 50 are formed directly into the material of the spa shell 40 either during the molding process for the spa shell 40 or during subsequent machining.
Common prior art spa assemblies have poor alignment and offset between the spa shell and the frame assembly/base due, in part, to the lack of structural engagement between the spa shell and the frame assembly/base, to the large assembly variances in the shell and frame systems, and the design differences in siding systems. The engagement between the bottom 41 of the spa shell 40 and the base pan 20 and between the rim 48 of the spa shell 40 and the top rail 32 of the frame assembly 30 aligns and interlocks the spa shell 40 within the base pan 20 and the frame assembly 30. These engagements allow for the spa shell 40 to be more fully supported and integrated with the structure of the base pan 20 and the frame assembly such that deflection, i.e., racking, of the base pan 20 and the frame assembly 30 with respect to the spa shell 40 is limited or eliminated. Further, the stack-up height of the spa shell 40, the frame assembly 30, and the base pan 20 can be made more consistent between individual spa assemblies 10. Additionally, assembly of the spa assembly 10 may be simplified and performed more efficiently because the spa shell 40 will align with the frame assembly 30 and the base pan 20 in only a single position, and the fit between the spa shell 40, the frame assembly 30, and the base pan 20 may be provided with a tighter tolerance.
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According to the example, the at least one support member includes a frame assembly 30, and the frame assembly 30 includes a plurality of support members 31 connected to the base pan 20 and a top rail 32 connected to the support members 31 and extending around a perimeter of the spa assembly 10.
The base pan 20 may include a plurality of anchors 24 formed therein. The anchors 24 are configured to connect the plurality of support members 31 to the base pan 20. The anchors 24 are arranged in the base pan to define indexed positions for the plurality of support members 31 in the base pan 20. The method further includes connecting the, plurality of support members 31 to the base pan 20 at the indexed positions.
The step of forming the recess 50 in the foam material 49 in the internal cavity of the rim 48 includes forming a groove 50 in the foam material 49. The step of engaging the top of the at least one support member within the recess 50 in the foam material 49 in the internal cavity of the rim 48 includes engaging the top rail 32 of the frame assembly 30 within the groove 50 in the foam material 49.
The method may further include providing a plurality of insulative panels 35 and enclosing the spa assembly 10 around the at least one side 42 of the spa shell 10 by connecting the plurality of insulative panels 35 to the frame assembly 30.
According to one example of the present disclosure, the entirety of the manufacturing of the spa assembly 10 or substantial portions of the manufacturing of the spa assembly 10 may performed in a mechanized manner by one or more robotic devices. For instance, robotics may be utilized throughout the molding and vacuum forming processes for the spa shell 40, the base pan 20, and the individual pieces of the frame assembly 30. Further, robots may be utilized to apply the foam material 46, 49 to the bottom 41 and the rim 48 of the spa shell 40 and to machine the interlocking features 47 and the recess 50 in the foam material 46, 49. The frame assembly 30 may also be assembled on the base pan 20 by robots. The ability to manufacture the spa assembly 10 through the use of robots serves to reduce the labor costs associated with manufacture of the spa assembly 10 and reduces production errors through the consistent performance of the steps in the manufacturing process. The use of robots in the manufacturing process also reduces material waste in the manufacturing process, since tolerances may be reduced and material variance in the production of the spa assemblies 10 can be reduced or eliminated.
Further examples of the present disclosure will now be described in the following number clauses.
Clause 1: A spa assembly (10), comprising: a base pan (20); at least one support member connected to and extending upward from the base pan (20); and a spa shell (40) supported on the base pan (20) and the at least one support member, the spa shell (40) comprising a bottom (41) and at least one side (42) defining an open internal volume (43) of the spa shell (40), an interior surface (44) oriented toward the open internal volume (43), and an opposing exterior surface (45), wherein the bottom (41) of the spa shell (40) and the base pan (20) comprise corresponding interlocking features (23, 47) configured to align the spa shell (40) within the base pan (20).
Clause 2: The spa assembly (10) according to clause 1, wherein the exterior surface (45) of the bottom (41) of the spa shell (40) has a formable material (46) applied to at least a portion thereof, the interlocking features (47) being formed in the formable material (46).
Clause 3: The spa assembly (10) according to clause 2, wherein the formable material comprises a foam material (46).
Clause 4: The spa assembly (10) according to any one of clauses 1-3, wherein the spa shell (40) further comprises a rim (48) surrounding the at least one side (42), and wherein the rim (48) has a recess (50) formed therein, the recess (50) being configured to receive a top of the at least one support member.
Clause 5: The spa assembly (10) according to clause 4, wherein the rim (48) defines an internal cavity having a formable material (49) applied thereto, the recess (50) being defined in the formable material (49).
Clause 6: The spa assembly (10) according to clause 5, wherein the formable material comprises a foam material (49).
Clause 7: The spa assembly (10) according to any one of clauses 1-6, wherein the at least one support member comprises a frame assembly (30), the frame assembly (30) comprising: a plurality of support members (31) connected to the base pan (20); and a top rail (32) connected to the support members (31) and extending around a perimeter of the spa assembly (10).
Clause 8: The spa assembly (10) according to clause 7, wherein the base pan (20) comprises a plurality of anchors (24) formed therein, the anchors (24) being configured to connect the plurality of support members (31) to the base pan (20), and wherein the anchors (24) are arranged in the base pan (20) to define indexed positions for the plurality of support members (31) in the base pan (20).
Clause 9: The spa assembly (10) according to clause 8, wherein each of the plurality of support members (31) comprises a lower portion (311) with a foot (312) defined at an end thereof, wherein the foot (312) of each of the plurality of support members (31) comprises a resilient tab (313) extending therefrom, and wherein the resilient tab (313) is configured to engage a respective one of the anchors (24) in the base pan (20) to retain the lower portion (311) between the anchor (24) and an upstanding rim (22) of the base pan (20).
Clause 10: The spa assembly (10) according to any one of clauses 7-9, wherein the spa shell (40) further comprises a rim (48) surrounding the at least one side (42), and wherein the rim (48) has a groove (50) formed therein, the groove (50) being configured to receive the top rail (32) therein.
Clause 11: The spa assembly (10) according to any one of clauses 7-10, wherein the top rail (32) comprises an assembly of interconnected rail pieces (33, 34).
Clause 12: The spa assembly (10) according to any one of clauses 7-11, wherein a plurality of insulative panels (35) is connected to the frame assembly (30) and the plurality of insulative panels (35) encloses the spa assembly (10) around the at least one side (42) of the spa shell (10).
Clause 13: The spa assembly (10) according to clause 12, wherein the frame assembly (30) comprises a plurality of clips (36) configured to connect the plurality of insulative, panels (35) to the plurality of support members (31).
Clause 14: The spa assembly (10) according to clause 12 or 13, further comprising a ventilation system (60) configured to exchange a volume of air within the enclosed spa assembly (10) with an exterior of the spa assembly (10).
Clause 15: The spa assembly (10) according to any one of clauses 1-14, further comprising at least one pallet member (70), wherein a bottom surface (25) of the base pan (20) has at least one recess (26) formed therein, the at least one recess (26) being configured to receive the at least one pallet member (70) therein.
Clause 16: The spa assembly (10) according to any one of clauses 1-15, further comprising a plurality of spa components and accessories (80), wherein the base pan (20) and the at least one support member are configured to provide mounting locations for placement of the plurality of spa components and accessories (80).
Clause 17: A spa assembly (10), comprising: a base pan (20); at least one support member connected to and extending upward from the base pan (20); and a spa shell (40) supported on the base pan (20) and the at least one support member, the spa shell (40) comprising a bottom (41) and at least one side (42) defining an open internal volume (43) of the spa shell (40), an interior surface (44) oriented toward the open internal volume (43), an opposing exterior surface (45), and a rim (48) surrounding the at least one side (42), wherein the rim (48) has a recess (50) formed therein, the recess (50) being configured to receive a top of the at least one support member.
Clause 18: The spa assembly (10) according to clause 17, wherein the rim (48) defines an internal cavity having a formable material (49) applied thereto, the recess (50) being defined in the formable material (49).
Clause 19: The spa assembly (10) according to clause 18, wherein the formable material comprises a foam material (49).
Clause 20: The spa assembly (10) according to any one of clauses 17-19, wherein the bottom (45) of the spa shell (40) and the base pan (20) comprise corresponding interlocking features (23, 47) configured to align the spa shell (40) within the base pan (20).
Clause 21: The spa assembly (10) according to any one of clauses 17-20, wherein the at least one support member comprises a frame assembly (30), the frame assembly (30) comprising: a plurality of support members (31) connected to the base pan (20); and a top rail (32) connected to the support members (31) and extending around a perimeter of the spa assembly (10).
Clause 22: The spa assembly (10) according to clause 21, wherein the recess (50) in the rim (48) comprises a groove (50), the groove (50) being configured to receive the top rail (32) therein.
Clause 23: A spa assembly (10), comprising: a base pan (20); a frame assembly (30), the frame assembly (30) comprising: a plurality of support members (31) connected to the base pan (20); and a top rail (32) connected to the support members (31) and extending around a perimeter of the spa assembly (10); a spa shell (40) supported on the base pan (20) and the frame assembly (30), the spa shell (40) comprising a bottom (41) and at least one side (42) defining an open internal volume (43) of the spa shell (40), an interior surface (44) oriented toward the open internal volume (43), and an opposing exterior surface (45); a plurality of insulative panels (35) connected to the frame assembly (30), wherein the plurality of insulative panels (35) encloses the spa assembly (10) around the at least one side (42) of the spa shell (40); and a plurality of clips (36) configured to connect the plurality of insulative panels (35) to the plurality of support members (31).
Clause 24: The spa assembly (10) according to clause 23, wherein the bottom (41) of the spa shell (40) and the base pan (20) comprise corresponding interlocking features (23, 47) configured to align the spa shell (40) within the base pan (20).
Clause 25: Thu spa assembly (10) according to clause 23 or 24, wherein the spa shell (40) further comprises a rim (48) surrounding the at least one side (42), and wherein the rim (48) has a groove (50) formed therein, the groove (50) being configured to receive the top rail (32) therein.
Clause 26: A spa assembly (10), comprising: a base pan (20): at least one support member connected to and extending upward from the base pan (20); a spa shell (40) supported on the base pan (20) and the at least one support member, the spa shell (40) comprising a bottom (41) and at least one side (42) defining an open internal volume (43) of the spa shell (40), an interior surface (44) oriented toward the open internal volume (43), and an opposing exterior surface (45); and at least one pallet member (70), wherein a bottom surface (25) of the base pan (20) has at least one recess (26) formed therein, the at least one recess (26) being configured to receive the at least one pallet member (70) therein.
Clause 27: The spa assembly (10) according to clause 26, wherein the bottom (41) of the spa shell (40) and the base pan (20) comprise corresponding interlocking features (23, 47) configured to align the spa shell (40) within the base pan (40).
Clause 28: The spa assembly (10) according to clause 26 or 27, wherein the at least one support member comprises a frame assembly (30), the frame assembly (30) comprising: a plurality of support members (31) connected to the base pan (20); and a top rail (32) connected to the support members (31) and extending around a perimeter of the spa assembly (10).
Clause 29: The spa assembly (10) according to clause 28, wherein the spa shell (40) further comprises a rim (48) surrounding the at least one side (42), and wherein the rim (48) has a groove (50) formed therein, the groove (50) being configured to receive the top rail (32) therein.
Clause 30: The spa assembly (10) according to clause 28 or 29, wherein a plurality of insulative panels (35) are connected to the frame assembly (30) and the plurality of insulative panels (35) enclose the spa assembly around the at least one side (42) of the spa shell (40).
Clause 31: A method of assembling a spa (10), comprising: providing a base pan (20), at least one support member, and a spa shell (40), wherein the base pan (20) comprises interlocking features (23) and the spa shell (40) comprises a bottom (41) and at least one side (42) defining an open internal volume (43) of the spa shell (40), an interior surface (44) oriented toward the open internal volume (43), an opposing exterior surface (45), and a rim (48) surrounding the at least one side (42), the rim (48) defining an internal cavity; connecting the at least one support member to the base pan (20) such that the at least one support member extends upward from the base pan (20); applying a foam material (46) to at least a portion of the exterior surface (45) of the bottom (41) of the spa shell (40); forming interlocking features (47) in the foam material (46) applied to the bottom (41) of the spa shell (40), the interlocking features (47) in the foam material (46) corresponding to the interlocking features (23) of the base pan (20); applying a foam material (49) to the internal cavity defined by the rim (48); forming a recess (50) in the foam material (49) in the internal cavity of the rim (48); and installing the spa shell (40) on the base pan (20) and the at least one support member such that the spa shell (40) is supported by the base pan (20) and the at least one support member, wherein the installing step comprises engaging the interlocking features (23) of the base pan (20) with the interlocking features (47) in the foam material (46) applied to the bottom (45) of the spa shell (40) to align the spa shell (40) within the base pan (20) and engaging a top of the at least one support member within the recess (50) in the foam material (49) in the internal cavity of the rim (48).
Clause 32: The method according to clause 31, wherein the at least one support member comprises a frame assembly (30), the frame assembly (30) comprising: a plurality of support members (31) connected to the base pan (20); and a top rail (32) connected to the support members (31) and extending around a perimeter of the spa (10).
Clause 33: The method according to clause 32, wherein the base pan (20) comprises a plurality of anchors (24) formed therein, the anchors (24) being configured to connect the plurality of support members (31) to the base pan (20), and wherein the anchors (24) are arranged in the base pan (20) to define indexed positions for the plurality of support members (31) in the base pan (20), and wherein the method further comprises connecting the plurality of support members (31) to the base pan (20) at the indexed positions.
Clause 34: The method according to clause 32 or 33, wherein the step of forming a recess (50) in the foam material (49) in the internal cavity of the rim (48) comprises forming a groove (50) in the foam material (49), and wherein the step of engaging the top of the at least one support member within the recess (50) in the foam material (49) in the internal cavity of the rim (48) comprises engaging the top rail (32) of the frame assembly (30) within the groove (50) in the foam material (49).
Clause 35: The method according to any one of clauses 32-34, further comprising: providing a plurality of insulative panels (35); and enclosing the spa (10) around the at least one side (42) of the spa shell (40) by connecting the plurality of insulative panels (35) to the frame assembly (30).
It is to be understood that the invention may assume various alternative variations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the specification, are simply exemplary embodiments or aspects of the invention. Although the invention has been described in detail for the purpose of illustration based on what is currently considered to be the most practical and preferred embodiments or aspects, it is to be understood that such detail is solely for that purpose and that the invention is not limited to the disclosed embodiments or aspects, but, on the contrary, is intended to cover modifications and equivalent arrangements that are within the spirit and scope thereof. For example, it is to be understood that the present invention contemplates that, to the extent possible, one or more features of any embodiment or aspect can be combined with one or more features of any other embodiment or aspect.
The present application claims priority to U.S. Provisional Patent Application No. 62/463,767, filed on Feb. 27, 2017, which is incorporated herein by reference in its entirety.
Number | Date | Country | |
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62463767 | Feb 2017 | US |