U.S. patent application number 10/995919 was filed with the patent office on 2006-05-25 for support structure for a spa.
Invention is credited to Wade Spicer.
Application Number | 20060107454 10/995919 |
Document ID | / |
Family ID | 36459566 |
Filed Date | 2006-05-25 |
United States Patent
Application |
20060107454 |
Kind Code |
A1 |
Spicer; Wade |
May 25, 2006 |
Support structure for a spa
Abstract
A support structure for a spa includes a plastic base member
which has an upper wall portion and a lower wall portion which are
spaced apart. The base member defines a base pocket of insulating
space which extends throughout a substantial portion of the base
member. A pair of plastic side members and a pair of plastic end
members are attached to the base member. The side members and the
end members each have an inside wall portion and an outside wall
portion which are also spaced apart which define a wall pocket of
insulating space which extends throughout a portion of each of
these members. The base member, side members and end members form a
support structure adapted to receive and support a spa shell. Any
type of insulating material may be placed into the insulating
pockets of space. Accessory devices in the form of towel warmers
and fold away steps are provided in openings in the support
structure.
Inventors: |
Spicer; Wade;
(Northumberland, PA) |
Correspondence
Address: |
Thomas R. Shaffer
5 East Third Street
PO Box 509
Coudersport
PA
16915
US
|
Family ID: |
36459566 |
Appl. No.: |
10/995919 |
Filed: |
November 22, 2004 |
Current U.S.
Class: |
4/541.1 |
Current CPC
Class: |
A61H 33/0087
20130101 |
Class at
Publication: |
004/541.1 |
International
Class: |
E04H 4/00 20060101
E04H004/00; A47K 3/00 20060101 A47K003/00; A47K 3/10 20060101
A47K003/10 |
Claims
1. A support structure for a spa comprising: a) a plastic base
member, said base member having an upper wall portion, a lower wall
portion and a spacing means to keep said upper wall portion and
said lower wall portion in a spaced apart relationship, said wall
portions defining a base pocket of insulating space which extends
throughout a substantial portion of said base member; and b) a pair
of plastic side members and a pair of plastic end members attached
to said base member, said side members and said end members each
having an inside wall portion, an outside wall portion and a
spacing means to keep said inside wall portions and said outside
wall portions in a spaced apart relationship, said wall portions
defining a wall pocket of insulating space which extends throughout
a portion of each of said side members and each of said end
members, said base member, side members and end members forming a
support structure adapted to receive and support a spa shell.
2. A support structure according to claim 1 wherein said spacing
means is a perimeter wall portion.
3. A support structure according to claim 1 wherein said base
pocket of insulating space and said wall pocket of insulating space
are each fully enclosed.
4. A support structure according to claim 1 wherein said wall
pocket of insulating space and said base pocket of insulating space
are filled with air.
5. A support structure according to claim 1 wherein said wall
pocket of insulating space and said base pocket of insulating space
are filled with an insulating foam material.
6. A support structure for a spa according to claim 1 wherein said
upper wall portion and said lower wall portion of said base member
each have corrugations therein to provide added strength.
7. A support structure for a spa according to claim 6 wherein said
corrugations are in the form of a waffle like corrugation
pattern.
8. A support structure for a spa according to claim 1 wherein said
upper wall portion of said base member is formed to have upwardly
extending L-shaped corner posts to aid in positioning and
supporting said end members and said side members onto said base
member.
9. A support structure for a spa according to claim 1 wherein said
upper wall portion of said base member is formed to have upwardly
extending inner posts and upwardly extending outer posts to aid in
positioning and supporting inside wall and outside wall members of
said end members and of said side members onto said base
member.
10. A support structure for a spa according to claim 1 wherein said
end members and said side members are bolted together and are
bolted to said base member.
11. A support structure for a spa according to claim 1 wherein said
outside walls of said side and end members constitute the outermost
side and end surfaces of a fully assembled spa.
12. A support structure for a spa according to claim 1 wherein said
outside walls of said side and end members include decorative
elements.
13. A support structure for a spa according to claim 1 wherein said
outside walls of said side and end members include a decorative
element in the form of a corner pillar.
14. A support structure for a spa according to claim 1 wherein said
side members and said end members have interlocking tabs to aid in
proper positioning of said members during assembly and to aid in
securing said members together.
15. A support structure for a spa according to claim 1 wherein said
side members and said end members have openings therein.
16. A support structure according to claim 15 wherein said at least
one opening is covered by an insulating door member.
17. A support structure according to claim 15 wherein said at least
one opening is received by an accessory device.
18. A support structure according to claim 17 wherein said
accessory device is a towel warming chamber.
19. A support structure according to claim 17 wherein said
accessory device is a set of steps.
20. A support structure according to claim 17 wherein said
accessory device is pivotally mounted in said opening.
21. A spa comprising: a) a plastic base member, said base member
having an upper wall portion, a lower wall portion and a spacing
means to keep said upper wall portion and said lower wall portion
in a spaced apart relationship, said wall portions defining a base
pocket of insulating space which extends throughout a substantial
portion of said base member; b) a pair of plastic side members and
a pair of plastic end members attached to said base member, said
side members and said end members each having an inside wall
portion, an outside wall portion and a spacing means to keep said
inside wall portions and said outside wall portions in a spaced
apart relationship, said wall portions defining a wall pocket of
insulating space which extends throughout a portion of each of said
side members and each of said end members; and c) a spa shell
received by and supported by said support structure.
22. A spa comprising at least one side member which has an opening
therein received by an accessory device having at least one flat
surface, said accessory device pivotal from a closed position
wherein said accessory device remains inward of said side member
and said flat surface encloses said opening to an open position
wherein said accessory device extends outward of said side member
and may be utilized for an accessory function.
23. A support structure according to claim 22 wherein said
accessory device is a towel warming chamber.
24. A support structure according to claim 22 wherein said
accessory device is a set of steps.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a support structure for a
spa. More specifically, the present invention relates to a support
structure for a spa which includes a plastic base member and
plastic side and end members to support a spa shell without the
need for a wooden frame or any other type of sub-frame.
[0003] 2. Prior Art
[0004] The construction of spas is well known in the art.
Typically, a spa is created by forming a wooden sub-frame made out
of wooden two by fours (or possibly a metal support frame or truss
members) with an exterior wooden wanes coating or the like attached
as an outer surface. Alternatively, a sub-frame made with two by
fours or the like can be created which is coated on the outside
with a form of plastic single wall panels. The wooden support frame
typically then receives a formed acrylic or other type of plastic
spa shell as is well known in the art.
SUMMARY OF THE INVENTION
[0005] The present invention eliminates the need for a wooden or
any other type of sub-frame and provides a number of benefits and
advantages over the prior art. For example, in the present
invention, by utilizing interconnecting plastic base members and
side and end members, the cost of building the wooden frame is
completely avoided. Further, because each of the plastic components
of the present invention has a double wall design, a pocket of
space is created within such components which can be filled with an
insulating material such as air or a foam insulation. The double
wall construction significantly adds strength to the structure
eliminating the need for the wooden (or other) frame or sub-frame.
Such added strength makes is easier to lift the spa with a fork
lift or the like without damaging the spa and makes it easier to
safely transport the spa without causing damage. Further, by
providing pockets of space (which may or may not be fully enclosed)
between the double wall construction, each of the outer shell
components are extremely well insulated both with respect to noise
as well as to temperature. By providing a double wall molded
plastic base member with an insulating pocket of space, the spa is
insulated from ground temperatures, is more resistant to the water
and mud, and is more resistant to termites and rodents than
existing spas.
[0006] In its simplest form, the support structure for a spa
comprises a plastic base member, said base member having an upper
wall portion, a lower wall portion and a spacing means preferably
in the form of a perimeter wall portion, said wall portions may or
may not fully enclose a base pocket of space which extends
throughout a substantial portion of said base member between the
upper wall portion and the lower wall portion; and a pair of
plastic side members and a pair of plastic end members attached to
said base member, said side members and said end members each
having an inside wall portion, an outside wall portion and spacing
means preferably in the form of a perimeter wall portion, said wall
portions may or may not fully enclose a wall pocket of space which
extends throughout a portion of each of said side members and each
of said end members between said inner and outer wall portions,
said base member, side members and end members forming a support
structure adapted to receive and solely support an spa shell which
is typically formed of acrylic or other type of plastic or
composite material. Preferably, said pockets of space contain
either air or an insulating foam material.
[0007] Preferably, said upper wall portion and said lower wall
portion of said base member each have corrugations therein to
provide added strength. Preferably, said corrugations are in the
form of a waffle like corrugation pattern.
[0008] Preferably, said upper wall portion of said base member is
formed to have upwardly extending L-shaped corner posts to aid in
positioning and supporting said end members and said side members
onto said base member. Preferably, said upper wall portion of said
base member is formed to have upwardly extending inner posts and
upwardly extending outer posts to aid in positioning and supporting
inside wall and outside wall members of said end members and of
said side members onto said base member.
[0009] Preferably, said end members and said side members are
bolted together and are bolted to said base member.
[0010] Preferably, said outside walls of said side and end members
constitute the outermost side and end surfaces of a fully assembled
spa. Preferably, said outside walls of said side and end members,
because they are made of molded plastic, can be formed to include
any conceivable type or kind of decorative elements.
[0011] Preferably, said side members and said end members have
interlocking tabs to aid in proper positioning of said members
during assembly and to aid in securing said members together.
[0012] Preferably, said side members and said end members have
openings therein to receive door members to provide access to an
interior of the support structure or to receive accessing devices
such as a towel warmer or set of steps which are pivotally mounted
in said openings.
[0013] Preferably, a spa shell is received by and solely supported
by said support structure to create a fully functional spa.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a perspective view of a rectangular spa assembly
including an installed spa shell.
[0015] FIG. 2 is a perspective view of the rectangular spa assembly
of FIG. 1 showing the bottom thereof.
[0016] FIG. 3 is a perspective view of an interconnected end
members and a side member shown partly in cross section.
[0017] FIG. 4 is a perspective view of an outside wall portion of a
side member.
[0018] FIG. 5 is a perspective view of an inside wall portion of a
side member.
[0019] FIG. 6 is a perspective view of a towel warming
accessory.
[0020] FIG. 7 is a perspective view of an accessory device in the
form of a pair of steps.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] Referring to the figures, the present invention includes a
support structure 10 for a spa which includes a base member 300, a
pair of end portions 100 and a pair of side members 200. A spa
shell 20 which is preferably formed of acrylic but may be formed of
any suitable plastic material or other impermeable material is
fully supported by the end members 100, side members 200 and base
member 300. The spa shell 20 is designed to hold water for use of
the spa.
[0022] Referring to FIGS. 4 and 5, an end member 100 is shown. End
member 100 has an outside wall 110, an inside wall 120 and a
perimeter wall portion 115 which fully encloses an air pocket 117.
End member 100 has an outer surface formed in the shape of a
decorative column 150 although it will be obvious to those of skill
in the art that any type of kind of decorative element may be
molded or otherwise formed into the outer surface of the end
members 100 and side members 200. A series of tabs 130, 132, 134
and 136 are utilized to aid in interconnecting end members 100 with
side members 200, base member 300 and spa shell 20. An opening 160
is provided to allow for the placement of a removable insulated
door to provide a means of access to the inside of the support
structure.
[0023] Alternatively, opening 160 may be utilized to receive an
accessory device. It is envisioned that an accessory device may
take the form of a towel warming container in the form of container
400 or 450 or may take the form of a set of steps as shown at
500.
[0024] The towel warming accessory 400 includes a handle 402, a
face plate 404 having an outer flat surface, a mounting flange 406,
a pivotal connection 408, a container portion 410 which receives
towels and a door member 412 to provide access to the interior of
the container 410.
[0025] The accessory device in the form of a set of steps 500
includes a handle 502, a face plate 504 having an outer flat
surface, a mounting flange 506, a pivotal mounting device 508 and a
pair of steps 520 and 530. It will be obvious that once the handle
502 is pulled downwardly, the steps 520 and 530 will be placed in a
horizontal position allowing a user to step on said steps 520 and
530 to gain access to the interior of the spa shell 20. It is noted
that the accessory devices are preferably pivotally attached and
open in the manner illustrated by towel warmer device 400 as shown
in FIG. 2. When closed, the face plate 504 covers the opening 160
with the steps 520 and 530 located inward of a side wall 200 (or
end wall 100) in which they are mounted. In a open position, the
steps 520 and 530 extend outward of a side wall 200 (or end wall
100) in which they are mounted. Thus, while in a closed position,
the accessory device is located completely inside the spa walls and
does not impede or interfere with lawn maintenance or other
activities around the perimeter of the spa.
[0026] It is to be understood that the side members 200 may be
identical to the end members 100 in which case the spa would be a
square. Alternatively, the side members 200 may be longer than end
members 100 in which case the spa will be rectangular in shape.
Obviously, variations can be made to accommodate any shaped spa
desired by the provision of additional pieces with different angles
of interconnection. In the figures, the end member and side member
components have the same corresponding last two digits, but side
member components are prefaced by the number 200 rather than the
number 100 which is utilized for an end member component. For
example, tabs 130 and 134 on end member 100 are identified to tabs
230 and 234 on side member 200.
[0027] A base member 300 as best shown in FIGS. 2 and 3 has an
upper wall portion 302, a lower wall portion 304, each of which are
provided with a waffled pattern 310 of corrugations to add strength
to such wall portions. A perimeter wall portion 306 interconnects
the upper wall portion 302 and the lower wall portion 304 enclosing
a pocket of insulating space 308 between said walls. It will be
obvious to those of ordinary skill in the art that the pocket of
insulating space 308 may be fully enclosed (as shown) or may be
left partially open to allow air to flow into and out of said
pocket. Further, it will be obvious that said pocket of insulating
space may be filled with air or alternatively with an insulating
foam material or any other insulating material which provides
insulation from sound and temperature. The upper wall portion 302
of the base member 300 is formed to have upwardly extending
L-shaped corner posts 320 which in combination with upwardly
extending inner posts 340 and outer posts 330 aid in positioning
and supporting the end members 100 and side members 200 onto the
base member 300. As shown, end members 100, side members 200 and
base member 300 are all formed of plastic and each include a fully
enclosed air pocket which provides insulation from sound and
temperature. While an air pocket is presently preferred, some
manufactures or users may prefer the pockets of insulating space to
be filled with an insulating foam material. Such a foam material
may provide superior insulating properties and may add to the
overall strength of the structure, but will add some additional
weight to the spa.
[0028] While we have shown and described the presently preferred
embodiment of our invention, the invention is not limited thereto
and may be otherwise variously practiced within the scope of the
following claims:
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