U.S. patent application number 10/889621 was filed with the patent office on 2004-12-30 for array of water jets for in-ground spas.
Invention is credited to Williams, Jack.
Application Number | 20040261168 10/889621 |
Document ID | / |
Family ID | 33096920 |
Filed Date | 2004-12-30 |
United States Patent
Application |
20040261168 |
Kind Code |
A1 |
Williams, Jack |
December 30, 2004 |
Array of water jets for in-ground spas
Abstract
An array of water jets that does not utilize hoses between the
water supply inlet and each individual jet and provides a
multiple-jet experience for in-ground spa users. The array of jets
include a water-containing structure having at least a front and
back that define an interior cavity into which water flows and
becomes pressurized. The front panel has a plurality of water
outlets disposed thereon while, preferably, the back panel has a
water or a water and air inlets. Accordingly, water (and air) flow
hoselessly from the inlet(s) to the plurality of water outlets such
that a water-jet effect is achieved.
Inventors: |
Williams, Jack; (Tucson,
AZ) |
Correspondence
Address: |
QUARLES & BRADY STREICH LANG, LLP
ONE SOUTH CHURCH AVENUE
SUITE 1700
TUCSON
AZ
85701-1621
US
|
Family ID: |
33096920 |
Appl. No.: |
10/889621 |
Filed: |
July 12, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10889621 |
Jul 12, 2004 |
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10404391 |
Apr 1, 2003 |
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6804841 |
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Current U.S.
Class: |
4/492 |
Current CPC
Class: |
E04H 4/14 20130101 |
Class at
Publication: |
004/492 |
International
Class: |
E04H 004/00 |
Claims
What is claimed is:
1. A combination in-ground spa and water jet array, comprising: an
in-ground spa made at least partially from cementitious material; a
water-containing structure including a front panel joined to a back
panel, wherein the in-ground spa contacts at least said back panel
of said water-containing structure; a water inlet adapted to
provide water flow into said water-containing structure; and a
plurality of water outlets disposed within said front panel.
2. The combination of claim 1, wherein water flows hoselessly from
said water inlet to and out of said plurality of water outlets into
said in-ground spa.
3. The combination of claim 1, wherein said plurality of water
outlets further include a water-jet fitting disposed thereon.
4. The combination of claim 1, wherein said front panel is
substantially convex.
5. The combination of claim 1, wherein said front panel is
substantially concave.
6. The combination of claim 1, wherein said cementitious material
comprises gunite.
7. The combination of claim 1, wherein said water-containing
structure is inset into a wall of said in-ground spa such that said
front and back panels are contacted by said cementitious materials
at least along an edge thereof.
8. The combination of claim 1, wherein said water-containing
structure defines an interior cavity through which water flows and
becomes pressurized, said interior cavity being devoid of any pipes
or hosing.
9. The combination of claim 1, wherein said water inlet further
includes an air inlet adapted to provide air flow into said
water-containing structure.
10. The combination of claim 9, wherein said water inlet and said
air inlet merge at a venturi.
11. A method for constructing a water jet array for an in-ground
spa made with cementitious material, comprising the steps of: (a)
providing a water-containing structure including a front panel and
a back panel, a water inlet adapted to provide water flow into said
water-containing structure, and a plurality of water outlets
disposed within said front panel; and (b) installing said
water-containing structure in said in-ground spa such that the
in-ground spa contacts at least the back panel of said
water-containing structure.
12. The method of claim 11, wherein water flows hoselessly from
said water inlet to and out of said plurality of water outlets into
said in-ground spa.
13. The method of claim 11, wherein said plurality of water outlets
further include a water-jet fitting disposed thereon.
14. The method of claim 11, wherein said front panel is
substantially convex.
15. The method of claim 11, wherein said front panel is
substantially concave.
16. The method of claim 11, wherein said cementitious material
comprises gunite.
17. The method of claim 11, wherein the water-containing structure
of step (b) is inset into a wall of said in-ground spa such that
said front and back panels are contacted by said cementitious
material at least along an edge thereof.
18. The method of claim 11, wherein said water-containing structure
defines an interior cavity through which water flows and becomes
pressurized, said interior cavity being devoid of any pipes or
hosing.
19. The method of claim 11, wherein said water inlet further
includes an air inlet adapted to provide air flow into said
water-containing structure.
20. The method of claim 19, wherein said water inlet and said air
inlet merge at a venturi.
Description
REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation-in-part of U.S. patent application
Ser. No. 10/404,391, now U.S. Pat. No. ______, filed on Apr. 1,
2003.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates generally to water jets for spas and
the like and more particularly to apparatuses that house a
plurality of water jets for installation in cementitious
(in-ground) spas.
[0004] 2. Description of the Related Art
[0005] Recreational bathing units, such as spas, "hot tubs,"
whirlpools, and the like, have become increasingly popular in
recent years. Most recreational bathing units are constructed as
"above-ground" (as opposed to "in-ground") models and typically
include a molded shell that serves to contain water, with seats,
shelves and other features molded into the shape of the shell. The
shell is usually made from plastic, fiberglass, or a composite
material. One or more pumps housed under the shell draw water
contained in the shell and re-circulate it through a variety of
"pressure nozzles," e.g., so-called hydrotherapy or water jets.
[0006] The water jets are usually mounted in the shell under the
water line, and are designed to provide a comforting or therapeutic
effect to a person in the spa. One typically installs a water jet
in an above-ground spa by making a hole in the shell, and fixing
the jet in the hole by a use of seals, adhesives, welding
compounds, etc. Water supply lines from the pumps to the jets are
usually flexible hose connections or rigid PVC piping. After the
jets and tubing are in place, a foam-like material is blown into
the empty spaces to provide thermal and sound insulation. This
general construction method has been utilized very successfully,
and is currently almost universally used in the above-ground spa
industry.
[0007] As the demand for spas has increased, so too has the demand
for more features. Indeed, one of the most popular options
presently is the multiple-jet bank or array. An array of jets is a
single structure that houses a plurality of water jets such that
the jets are concentrated in a particular area of the spa, thus
increasing the level of comfort or therapeutic massage felt by the
spa user. For example, in U.S. Pat. No. 6,092,246, Ludlow describes
and illustrates a removable panel of jets plumbed from a single
water and air inlet. Like the other jets found in above-ground
spas, Ludlow's array of water jets contains hoses that carry the
water from the inlet pipe, through the array interior and to the
jets fittings.
[0008] While multiple water jets are commonly featured in higher
end above-ground spas, up until now (and for a variety of cost and
construction-related reasons as discussed further below), in-ground
spas are only plumbed with single water jets. This is because the
water and air supply pipes of in-ground spas extend into the ground
and through concrete reinforcing bar ("rebar") and cementitious
material (e.g., gunite), making the plumbing of multiple pipes for
multiple water jets very labor intensive (see FIGS. 1 and 2).
Moreover, a high degree of precision and coordination between the
cement and steel contractors and the plumber is required if water
jet location and alignment are to be satisfactory after the cement
is poured. Obviously, plumbing or jet installation mistakes are
difficult and expensive to fix once the in-ground spa hardens.
[0009] Simply adding an array of jets designed for use in an
above-ground spa (such as Ludlow's) would not provide a good
solution due to the complexity of installation of Ludlow's hollow
pod structure. Furthermore, poor workmanship or defects in the hose
materials that link each jet to the water supply line can cause
leaks. In fact, even ordinary wear and tear tends to flex hosing
joints and seals and eventually open them up to form leaks.
Therefore, the more tubing or piping utilized in an array of jets,
the higher the probability over time of a leak occurring.
[0010] The amount of horsepower that water and air pumps can supply
to an above-ground spa versus an in-ground spa is generally much
less. This difference limits the number and type of water jet
arrays that can usefully be installed in an above-ground spa. For
example, the jet arrays installed in many above-ground spas feature
"mini-jets" due to the fact that the piping must be small enough to
supply sufficient water velocity. In-ground spas typically do not
have such constraints because the pumps utilized therewith are not
housed within a spa shell and can therefore be much larger and more
powerful. This also means that the water jet array and any piping
it contains must be able to withstand the higher water pressure
produced by a relatively high horse power in-ground spa pump.
[0011] For the foregoing reasons, neither the Ludlow patent nor any
other reference is known to disclose or suggest the installation of
above-ground "jet pods" or jet arrays in a cementitious (in-ground)
spa. Thus, there remains a need in the art for an array of water
jets that is adapted specifically for in-ground spa use, is
inexpensive to manufacture, easy to install, and is less prone to
leakage due to a structure that obviates the need for hose
connections between the jets and the water supply.
SUMMARY OF THE INVENTION
[0012] The invention relates in general to an array of water jets
that does not utilize hoses between the water supply inlet pipe and
each individual jet, making it especially suitable for in-ground
spa use. More particularly, the invention relates to a
water-containing structure having a front and a back panel, thus
defining an interior cavity through which water flows to the
in-ground spa. The front panel has a plurality of water outlets
disposed thereon while, preferably, the back panel has a water or a
water and air inlets. A venturi also may be included where the
water and air lines merge such that aeration of the water occurs
(the merger of the water and air lines may take place within the
water-containing structure or outside of it). Accordingly, water
(and air) flow hoselessly from the inlet(s) to the plurality of
water outlets such that a water-jet effect is achieved. Of course,
each water outlet may be provided with a variety of pressure
nozzles or jet fittings.
[0013] Thus, the present invention provides an array of water jets
that uses no hoses within the internal cavity of the
water-containing structure to connect the water supply to the water
outlets. This is an improvement over the existing art because there
are no hoses or hose fittings within the array to break or leak.
Moreover, the invention is simple to install on a single water
supply pipe and can be either inset into the spa wall or connected
to the spa wall surface.
[0014] In one embodiment, the water-jet array of the invention is
substantially rectangular in cross-section, having a front panel
and a back panel connected by four sidewalls, and can be installed
such that the front panel is flush with the spa-wall interior
surface. In another embodiment, the array features a front panel
that is concave and is thus suitable for mounting on a water supply
pipe such the array extends from the spa-wall interior surface to
form, for example, a neck or back massage station. Still another
embodiment features a front or back panel that is convex.
Practically any size array or number of arrays or jets can be
accommodated provided the water pump is sufficient to supply the
desired water pressure.
[0015] Therefore, it is a primary objective of the invention to
provide a water-jet array that requires water to flow hoselessly
from a supply inlet to a plurality of water-jet outlets.
[0016] Further, an object of the invention is to provide a
water-jet array that is installed as a single unit and without
additional plumbing.
[0017] Another object of the invention is to provide a water-jet
array that is easy to install in a spa constructed from
cementitious materials.
[0018] Still another object of the invention is to provide a
water-jet array that is inexpensive to manufacture.
[0019] Yet another object of the invention is to provide a
water-jet array that minimizes the possibility of leakage and
related repair expense.
[0020] Various other purposes and advantages of the invention will
become clear from its description in the specification that
follows. Therefore, to the accomplishment of the objectives
described above, this invention includes the features hereinafter
fully described in the detailed description of the preferred
embodiments, and particularly pointed out in the claims. However,
such description discloses only some of the various ways in which
the invention may be practiced.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 depicts a perspective view of a prior art plumbing
arrangement for a single water jet.
[0022] FIG. 2 shows an exploded perspective view of a prior art
water-jet assembly in relation to the water supply pipe of FIG.
1.
[0023] FIG. 3 depicts a front elevational view of a preferred
embodiment of the invention.
[0024] FIG. 4 depicts a rear elevational view of the same
embodiment of the invention shown in FIG. 3.
[0025] FIG. 5 shows in cross-section a view taken along line 5-5 of
the embodiment illustrated in FIG. 3.
[0026] FIG. 6 depicts a cut-away view of a cementitious spa-wall to
reveal a side elevational view of a second embodiment of the
invention as it appears installed.
[0027] FIG. 7 illustrates a front perspective view of a third
embodiment of the invention inset into the wall of an in-ground
spa.
[0028] FIG. 8 shows a front perspective view of a fourth embodiment
of the invention.
[0029] FIG. 9 shows a top plan view of a fifth embodiment of the
invention.
[0030] FIG. 10 shows a variation of the embodiment shown in FIG.
8.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] The invention generally relates to an array of water jets
that is specially designed for in-ground spas in that it does not
utilize hoses between the water supply and each individual jet.
More particularly, the invention includes a water-containing
structure having at least a front and a back panel, preferably
front and back panels joined by four side walls. The front panel
has a plurality of water outlets, which provide openings in which
water flows though a jet fitting attached to the outlet (or may
simply gush if no jet fitting is in place). Preferably, the back
panel has a water inlet or water and air inlets, though these may
also be disposed through one or more side walls.
[0032] Turning to FIGS. 1 and 2, a depiction of a typical related
art water-jet for in-ground pools is shown. The construction of
even a rudimentary in-ground spa involves the use of rebar 2 that
is covered by a cementitious material, such as concrete or gunite
(not shown). Because of this, a spa contractor typically will
install a single water jet in a given location by inserting a water
inlet-pipe 3 through the rebar 2. The inlet pipe 3 is then coupled
with and sealed to a water supply pipe 4 and an air supply pipe 6
at a joint 8. The assembled components (pipes 3, 4, and 6 and joint
8) are then fastened to the rebar 2 with several ties 10. After the
end of pipe 3 is covered by a cap 12 and pressure tested,
cementitious material is poured out to dotted line 14, thereby
encasing everything except the end of pipe 3.
[0033] As shown in FIG. 2, a hole 16 must be chipped in
cementitious material 18 to allow the installation of a collar 20
at the end of pipe 3. The collar 20 typically is bonded to the pipe
3, which is then cut so that is will be flush with the surface of
cementitious material 18. The collar 20 provides a foundation for
further components, such as a retaining ring and a wall fitting
(not shown). The hole 16 is then re-plastered and a water jet
fitting 22 installed as shown by arrow 24.
[0034] Due to this common and labor-intensive method of in-ground
spa-jet construction (and the fact that the in-ground spa
contractor usually subcontracts work to a separate plumber, steel
contractor, and cement contractor), the installation of multiple
pipes for multiple jets can become a complicated and ineffective
exercise as the subcontractors usually are not precise in their
work. Indeed, it is the inventor's experience that the plumber and
steel and cement contractors perform their respective tasks at
different times and without regard for what the other has done or
will need to do. Accordingly, pipes are bent out of position or
simply installed at a level or location that does not match the spa
owner's expectations. Due to the cost and hassle of fixing these
errors, single water-jets are the only available option for
practically all in-ground spas unless a customer is willing to
spend tens-of-thousands of dollars extra to have the spa custom
built with each contractor working in coordination with the
other.
[0035] Turning to FIG. 3, an array of jets 28 according to the
invention is shown. As seen in this front elevational view, the
array includes a front panel 30 in which a plurality of jets 31
have been disposed. Preferably the front panel 30 has water outlets
32 onto which jet fittings 34 have been placed. The jet fittings 34
may be practically any known in the art, leading to an in-ground
spa that can include, for example, adjustable, massaging, and/or
hand held jets.
[0036] As shown in back elevational view in FIG. 4, the invention
further includes a back panel 36. Preferably, the back panel 36 has
a water inlet disposed thereon, such as opening 38. However, most
preferably, a pipe stub 40 is molded on (or attached) to opening 38
to facilitate the joining of the array 28 to an existing water
supply pipe.
[0037] Turning to FIG. 5, a cross-sectional view of the embodiment
of FIG. 3 taken along line 5-5 is shown. The front panel 30, back
panel 36, and four side walls 44 (two of which are visible in this
view) form a water-containing structure 46 that defines an interior
cavity 48. Thus, water flows from a supply source into the cavity
48 through an inlet (in this case, pipe 40), becomes pressurized
within the cavity 48, and is ejected through the jet fittings 34 of
water outlets 32.
[0038] A partially cut-away section of an in-ground spa is shown in
FIG. 6. Here, an array of jets 52 has been sealed into a gunite spa
wall 54 with a "brown-in mixture" (i.e. a concrete fill) 56. A
two-inch water and air inlet pipe 58 produces flow into the
water-containing structure 60 and out through water outlets 62,
which protrude slightly from the spa interior finish 64. Although
not illustrated herein, it would be understood by one skilled in
the art that the water-containing structure of the invention may be
fashioned in various ways without departure from the invention. For
example, while the water-containing structure 60 may be formed as a
single piece, it is preferably formed from two halves that are
joined by a PVC weld, can be molded into different shapes, and can
contain water outlets of various sizes or shapes. Thus, the
preferred embodiment should not be construed to limit the invention
to the particular structure just described.
[0039] Turning to FIG. 7, a front perspective view (with back,
bottom, and interior components shown in phantom line) of a third
embodiment is illustrated. In this embodiment, a water-jet array 70
is installed in a concrete wall 72 of an in-ground spa so that the
front panel 74 containing water outlets 76 is flush with the
interior of the spa. Openings 78 and 80 in the rear panel 81 allow
water inlet pipe 82 and air inlet pipe 84 into the interior cavity
85 of water-containing structure 86. Pipes 82 and 84 may merge at a
venturi 88, thereby increasing aeration of water 90.
[0040] FIG. 8 illustrates a fourth embodiment of the invention in
front perspective view. The array of jets 92 is mounted to a water
inlet pipe (not show) projecting from the surface of the tiles 94
of the in-ground spa. The water-containing structure 96 includes a
convex front panel 98, a back panel (not shown), and four side
walls 100 that connect the front and back panels. Two adjustable
water jets 102 are mounted on front panel 98. The convex shape and
location of the water jets make this particular array ideal for
neck and back massage applications.
[0041] Turning to FIG. 9, a plan view of a fifth embodiment of the
invention is shown. Here, the array of jets 104 include water
outlets 106 disposed upon front panel 108. A convexly shaped back
panel 110 is joined to front panel 108, thereby forming an interior
cavity (not shown). A water inlet 112 is provided in back panel 110
to receive water for filling the interior cavity.
[0042] FIG. 10 shows a variation of the embodiment illustrated in
FIG. 8. A water-jet array 120 is installed on a wall 122 of an
in-ground spa so that the front panel 124 containing water outlets
126 protrudes into the interior of the spa. An opening (not shown)
in the rear of array 120 allows water to flow inward from water
inlet pipe 128. Pump 130 transports water that is aerated by air
introduced through air inlet pipe 132, which preferably merges with
water inlet pipe 128 at a venturi 134 disposed therein.
[0043] Given the ease of installation and variety of
water-containing structure and jet configurations that may be
utilized, it will be readily appreciated that invention can be
placed on walls, floors, seats, i.e., practically anywhere in or on
the interior of an in-ground spa.
[0044] To give further guidance for the installation of the
invention, the following example utilizing the embodiment shown in
FIG. 7 is provided. However, the example is only illustrative and
is not meant to limit the invention to a specific method of
installation.
EXAMPLE
[0045] After excavation of the spa, a plumbing line from the water
pump or circulation system is stubbed to the location where the
array of jets will be installed. Optionally, an air line can also
be stubbed to the same location. A STYROFOAM form is then placed
over the capped pipe(s) to provide a hollow into which a jet array
of the invention is placed after the cementitious materials are
poured or sprayed.
[0046] Steel reinforcing bars are next added around the perimeter
of the spa and at locations where further structural definition
will take place (e.g., seats, contours, separation walls, etc.).
The cementitious material is then applied to the rebar and around
the STYROFOAM form to create the spa structure.
[0047] After the cementitious materials have hardened (at the
preparation of the spa interior finish phase), the STYROFOAM form
is removed and disposed of. The end caps of the water (and air)
pipes are removed, and the inlet(s) of the array of jets of the
invention are bonded to the existing supply pipe(s). The space
around the side walls of the water-containing structure is then
browned-in to stabilize the array and to seal out water, thus
preventing seepage from the spa in and behind the back panel of the
water-containing structure. If desired, the entire jet array (i.e.,
the front panel) may also be brown-in to the spa wall such that
only the water outlets protrude from the wall surface. The interior
finish of the spa is then completed, and jet fittings may be added
to the water outlets (if not previously installed).
[0048] As will now be clear from the description above, the
water-jet array of the invention has many advantages over currently
existing jets for in-ground spas. Its simple construction and
inlet/outlet openings make installation straightforward. Moreover,
the lack of hoses (or even pipes in some embodiments) inside the
cavity of the water-containing structure minimizes the possibility
that leaks and related damage may occur. Furthermore, the
"hoseless" design of the invention allows its use with high power
water pumps without worrying about wear and tear on hoses or hose
joints or seals. Preferably, the water-containing structure of the
invention is constructed from acrylic materials. However, any
suitably durable and corrosion-resistant material may be utilized.
All of these features make the water-jet array of the invention
ideal for in-ground spa installation and years of reliable use.
[0049] Various changes in the details and components that have been
described may be made by those skilled in the art within the
principles and scope of the invention herein described in the
specification and defined in the appended claims. Therefore, while
the present invention has been shown and described herein in what
is believed to be the most practical and preferred embodiments, it
is recognized that departures can be made therefrom within the
scope of the invention, which is not to be limited to the details
disclosed herein but is to be accorded the full scope of the claims
so as to embrace any and all equivalent processes and products.
* * * * *