Patent Application
20120159701
1. Field of the Invention
The present invention relates generally to a water jet assembly, and relates more specifically to a water jet assembly incorporating a slip ring for a facilitating the joining of a scallop plate facing the interior water-receiving portion of a spa shell with a water jet housing on the exterior portion of a spa shell.
2. Related Art
Conventional spas, hot tubs, whirlpool baths, swimming pools, showers and the like, hereinafter defined as hydrotherapy equipment and referred to collectively as spas, with water jets formed therein typically are constructed as a molded shell to form a water containment or fluid enclosure having a footwell or floor and an upstanding sidewall. Molded within the enclosure can be a plurality of therapy stations which may include seats or platforms for reclining. The spa shell typically is constructed of fiberglass, plastic or a similar material, or a composite of such materials.
One or more pumps usually are placed under or proximal to the spa shell to draw water from the enclosure, recirculate it, and discharge it, usually with air as an aerated water stream, into the enclosure through a plurality of nozzles or water jets of various types. The water jets usually are mounted through the spa shell in either or both of the floor and sidewall of the spa shell. Typically, water jets mounted through the sidewall are located below the maximum water line of the spa. Several water jets can be spaced about the perimeter of the artificial water structure. These water jets create jets of water to provide a massaging and therapeutic action to a human or other animal.
Spas can be preassembled, with the water jets attached to mounting holes in the spa shell. Alternatively, a spa can be purchased in an unassembled state, and the water jets can be installed into the mounting holes in the spa shell at a later time. Water jets can also be retrofitted into bathtubs or other water enclosures by creating a mounting hole in the wall of the bathtub or other water enclosure of a size and shape corresponding to the water jet equipment. After a mounting hole is fashioned to correspond to the size of the mouth of a jet housing, the water jet can be installed along with other necessary components like a pump.
The assembly and installation of a spa and related accessories must be precise in order to avoid water leakage. A conventional method of installing and sealing a water jet first requires the alignment of the mouth of a water jet housing with a mounting hole on the exterior side of a spa shell. A water jet is mounted within the water jet housing such that the water jet faces the interior of the spa. A scallop plate is then extended from the interior of the spa through the mounting hole in the spa shell. Finally, the scallop plate is screwed into place within the water jet housing to secure the water jet firmly from both sides of the spa shell. This method of installation sometimes leads to water leakage due to varying thickness in the spa shell which prevents the water jet housing and the scallop plate from reliably sealing against the spa shell.
Sealing gaskets and grommets have been used in an attempt to prevent water leakage at the edge of the mounting hole. This method involves the placement of a malleable gasket or grommet between the scallop plate and the interior side of the spa shell before the scallop plate is tightened in order to facilitate a watertight seal and to prevent leaks. As an installer screws the scallop plate into the opening in the water jet housing, the gasket, scallop plate, and interior side of the spa shell are compressed together when the threads are tightened. In theory, the flexible gasket will compensate for some variance in the cross sectional thickness of the spa shell. Although the compression of the gasket sometimes aids in the formation of a water-tight seal, it is also common for the gasket to twist and pinch as the gasket compresses. As the gasket deforms, it can become dislodged or form creases, causing water to leak from the interior of the spa through the mounting hole.
Attempts to address the problem of gasket deformation include the application of a sealant to further aid in producing a watertight contact between the gasket and both the spa shell and the scallop plate. Such methods, however, can exacerbate the problem of the gasket “walking” out of place or dislodging as the scallop plate is tightened. Further, sealants delay the pressure testing of an installed spa until the sealant has cured. In addition, the sealant can leach into the water jet and affect its performance, increasing the time and cost of the installation.
Other attempts to address the problem of gasket deformation involve the spraying of a lubricant onto the gasket, the interior spa shell, or the scallop plate. These lubricants, however, can degrade the integrity of the grommet, and can cause a dangerous, messy condition for an installer and a user of the spa, who could slip on remnants of the lubricant. Further, a lubricant must be reapplied each time the water jet is repaired, disassembled, adjusted, tightened, or reassembled. This is an additional and unnecessary step that increases the cost of a repair and again exposes individuals to a potentially hazardous condition.
Accordingly, there is a need for an improved water jet assembly and installation method to prevent water leakage. There is also a need for an improved water jet assembly and installation method that is simple, cost effective, and does not require specialized tools. There is a further need for an improved water jet assembly and installation method that does not require messy sealants or lubricants. Finally, there is a need for a water jet assembly with improved aesthetics. It is to these needs, among others, that the present invention is directed.
Briefly, the water jet assembly in accordance with the present invention provides a slip ring that is well suited for use with a typical spa. The slip ring in accordance with the present invention facilitates the uniform compression of a sealing gasket disposed between the spa shell and the opening of a water jet housing to provide a tighter, more reliable seal that reduces leakage. During water jet assembly and installation in accordance with the present invention, a slip ring can be added to the water jet assembly instead of spraying lubricant. The slip ring reduces the friction between the gasket and the scallop plate such that the rotation of the scallop plate does not cause the gasket to dislodge, deform or crease. Use of a slip ring does not degrade the integrity of the parts forming the water jet assembly, and does not cause a dangerous, messy condition. Further, while a lubricant must be re-applied each time the water jet assembly is disassembled, adjusted, tightened, or reassembled, a slip ring in accordance with the present invention eliminates this need. Further, the slip ring accommodates a tighter and more reliable seal between the gasket and the scallop plate than can be achieved using conventional systems. As such, the application of additional sealant or adhesive is not necessary in order to achieve a superior watertight seal.
The slip ring is a thin, flexible plate-like ring. The surface of the slip ring is smooth, and is cut to match the width of the gasket adjacent a lip in the scallop plate. Before the scallop plate is attached and screwed into the opening of the water jet housing, a slip ring is applied over the threaded neck of the scallop plate and fitted into the lip. Next, a gasket is applied over the threaded flange of the scallop plate and pressed firmly to contact the surface of the slip ring. Then, the scallop plate is screwed into place within the water jet housing, facilitated by the slip ring, such that the gasket is unaffected during the process and the watertight seal is enhanced.
A complete understanding of the present invention may be obtained by reference to the accompanying drawings, when considered in conjunction with the subsequent, detailed description of preferred embodiments in which like elements and components bear the same designations and numbering throughout the figures.
The water jet assembly of the present invention comprises a water jet housing, a scallop plate, a gasket, and a slip ring. In a preferred embodiment there is provided a water jet assembly that is mounted within a mounting hole disposed on the shell of a spa. A water jet housing is mounted behind the spa shell on the side of the spa enclosure that does not receive water, in an area below the maximum water line of a filled spa. Alternatively, a specialty water jet can be mounted within a wall or within another surface capable of receiving a water jet housing such that water propelled from a jet mounted outside of the spa enclosure can be received within the spa enclosure.
A slip ring is removably mounted within a lip on the back side of a scallop plate. A gasket is then removably mounted upon the flange of a scallop plate to contact the slip ring. The scallop plate/slip ring/gasket assembly is then joined with the water jet housing through the mounting hole in the spa shell and the scallop plate is twisted into place to tighten corresponding threads. As the scallop plate is tightened, the movement of the scallop plate toward the water jet housing and the spa shell cause the gasket to contact the spa shell. As the flexible gasket is compressed between the scallop plate and the spa shell, unevenness, flaws, or variations on the surface of the spa shell are filled by the gasket and a watertight seal is created.
The slip ring disposed between the gasket and the scallop plate allows for reduced-friction contact between the inner surface of the scallop plate and the high friction surface of the gasket. This reduced-friction environment allows the inner surface of the scallop plate to glide easily relative to the surface of the gasket as the scallop plate is repeatedly rotated with applied pressure, and maintains the positioning and the integrity of the gasket. Because the gasket does not dislodge or twist or crease during the tightening process, and because the properly-placed gasket provides an enhanced waterproof seal, an installer need not apply conventional lubricants or sealer when installing the water jet assembly. Further, if a repair must be made to the water jet assembly, the scallop plate can be easily removed and again replaced without the application of a lubricant when aided by the reduction in friction provided by the slip ring.
Water jet assembly 25 further includes a retainer 48. Retainer 48 is affixed to the nozzle 42 at a downstream end, or in an exemplary embodiment the nozzle 42 can be pivotally mounted in the retainer 48. Alternatively, the retainer 48 frictionally secures the nozzle 42 in a fixed, pivoting, or angular position relative to the direction of the water stream flowing through the nozzle 42. The retainer 48 may have two or more latching tabs 50 (
In an exemplary embodiment of a method in accordance with the present invention, the spa jet assembly 25 is attached to a spa shell 20 by aligning the water jet housing 40 and fitting the nozzle 42 within a mounting hole 15 disposed upon a spa 10 on the exterior side of the spa shell 20. Then, on the interior side of the spa shell 20, the flange 34 is extended through a mounting hole 15 in the spa shell 20, with the scallop plate 30 facing the interior, “wet side” of the spa 10. The flange 34 of the scallop plate 30 is fitted within the mounting hole 15 and contacted with the water jet housing 40. The scallop plate threads 30a of the flange 34 mate and join with the reciprocal scallop plate threads 30b when the scallop plate 30 is rotated. As the scallop plate 30 is rotated in a first direction, the scallop plate 30 and the water jet housing 40 get closer together. Likewise, as the scallop plate 30 is rotated in a first direction, the scallop plate 30 and the gasket 32 move closer to the spa shell 20. As the scallop plate 30 continues to be rotated in a first direction, the spa shell 20 is clamped between the water jet housing 40 and the scallop plate 30, with continued rotation making the seal tighter until the water jet assembly 25 is secure on the spa shell 20. When the scallop plate 30 is rotated in a second direction, conversely, the scallop plate 30 moves further away from the water jet housing 40 and further away from the spa shell 20. The width of the flange 34 allows for variance in the distance between the water jet housing 40 and the scallop plate 30 to accommodate varying spa shell 20 widths.
In an alternative embodiment, the gasket 32 is a u-ring having a first face 60 and second face 62, and an inner surface 64 and outer surface 66. The first face 60 of the gasket 32 contacts the scallop plate 30, and is preferably of a lesser width than the scallop plate 30 to enhance visual appeal. The second face 62 of the gasket 32 contacts the surface of the spa shell 20, and is also preferably of a width that is less than the width of the scallop plate 30 in order to further increase visual plate 30 when the gasket 32 is applied during the installation of a spa jet assembly 35. Optionally, the second face 62 of the gasket 32 can be textured to provide additional grip or suction on a spa shell 20 when the gasket 32 is fitted over the flange 34 of the scallop plate 30 and rotated in a first direction for tightening the scallop plate 30 within the water jet housing 40.
The gasket 32 is fitted around the flange 34 of the scallop plate 30 and contacts a slip ring 70 at a first face. A slip ring 70 in accordance with the present invention is a very thin, smooth, flat ring having an outer and inner edge forming a width. The width of the slip ring 70 is preferably at least as wide as the width of the first face 60 of the gasket 32, and fits within a lip 72 (
The scallop assembly 74 is then extended through the mounting hole 15 within the spa shell 20 from the interior, “wet side” of the spa 10 until the scallop plate threads 30a disposed on the flange 34 of the scallop plate 30 assembly meet the corresponding scallop plate threads 30b disposed on the water jet body 40. The scallop plate 30 is preferably secured to the water jet body 40 by firmly applying pressure in a substantially perpendicular direction relative to the surface of the spa shell 20 and twisting the scallop plate 30 in a first direction to interlock the scallop plate threads 30a with the corresponding scallop plate threads 30b. Pressure is applied to the scallop plate 30 during this step of the assembly in order to firmly press the second face 62 of the gasket 32 against the interior spa shell 20.
A firm connection between the spa shell 20 and the gasket 32, and between the gasket 32 and the scallop plate 30, is critical to ensure that water does not leak from the interior of the spa 10, past the scallop plate 30 and gasket 32, and through the mounting hole 15. Such pressure, however, without a means to reduce friction and facilitate smooth sliding between the surface of the lip 72 of the scallop plate 30 and the high-friction, gripping surface of the gasket 32, can cause creeping, twisting, deforming, and gaping of the gasket 32. Any of these conditions creates a potential passageway for the seepage of water through the mounting hole 15. Because a slip ring 70 having a low friction surface is placed between the lip 72 of the scallop plate 30 and the first face 60 of the gasket 32, an installer can twist the scallop plate 30 smoothly and easily while applying pressure until the scallop plate 30 is tightly screwed into the reciprocal scallop plate threads 30b of the water jet body 40. Further, because the slip ring 70 allows the lip 72 of the scallop plate 30 to glide across the first face 60 of the gasket 32 as it is rotated and secured, the gasket 32 does not creep, twist, deform, or gap during the tightening process. Also advantageously, if the scallop plate 30 must be removed in the future because, for example, the water jet assembly 10 must be repaired or replaced, an installer need not lubricate the gasket 32 or remove the gasket 32 to easily remove the scallop plate 30.
A slip ring 70 in accordance with the present invention is an integrally-formed, pressed, cut, stamped or molded, thin and low-friction ring. Preferably, the slip ring 70 is constructed from polypropylene, and its surfaces are buffed or polished in order to minimize friction of the faces of the slip ring 70 when contacted with another surface. A skilled artisan will recognize that the slip ring 70 can be made from materials such as polyvinylchloride or polyethelyne, or any other material capable of producing a resilient, low-friction surface.
Slip ring 70 can be made of any size, that is, width and thickness, such that it will function satisfactorily with different sizes of scallop plates 30. For example, there are different sized water jets and water jet bodies 40 that require different sized scallop plates 30. Producing an appropriately sized slip ring 70 so as to fit within the scallop plate 30 is a matter of design choice based on, for example but not limited to, the outer diameter of the flange 34 and the inner diameter of the lip 72. Further, the thickness of slip ring 70 can be dependent on the material of manufacture and/or on the size of the scallop plate 30. For example, a small scallop plate 30 may require a thinner slip ring 70 such that when the scallop plate 30 is attached to the water jet body 40 the scallop plate 30 does not protrude more than a desired amount into the spa 10. This situation may require a stronger yet thinner material of manufacture. Other situations may allow for a weaker yet thicker material of manufacture. The invention contemplates various sizes of slip rings 70 manufactured from various materials of manufacture.
When used in conjunction with a method in accordance with the present invention, a slip ring 70 is placed between the scallop plate 30 and the gasket 32 so that there is less friction between the scallop plate 30 and the gasket 32 when the scallop plate threads 30a and the reciprocal scallop plate threads 30b are tightened. The reduction of friction helps the gasket 32 stay in place without causing twisting, pinching, or other undesired movement.
During assembly and installation, a slip ring 70 can be added to a water jet assembly 25 instead of spraying lubricant, which can degrade the integrity of the parts forming the water jet assembly 25 and can cause a dangerous, messy condition for an installer and a user of the spa 10. Further, while lubricant must be re-applied each time the water jet assembly 25 is disassembled, adjusted, tightened, or reassembled, the slip ring 70 in accordance with the present invention eliminates this need. Further, because the slip ring 70 accommodates a tighter and more reliable seal with the gasket 32 than can be achieved using conventional systems, the application of additional sealant or adhesive is not necessary in order to achieve a satisfactory water-tight seal.
The above detailed description of the embodiments, and the examples, are for illustrative purposes only and are not intended to limit the scope and spirit of the invention, and its equivalents, as defined by the appended claims. One skilled in the art will recognize that many variations can be made to the invention disclosed in this specification without departing from the scope and spirit of the invention.
