U.S. patent application number 11/456588 was filed with the patent office on 2008-02-14 for hot tub cover including modular core.
Invention is credited to William D. Scott.
Application Number | 20080034491 11/456588 |
Document ID | / |
Family ID | 39049047 |
Filed Date | 2008-02-14 |
United States Patent
Application |
20080034491 |
Kind Code |
A1 |
Scott; William D. |
February 14, 2008 |
HOT TUB COVER INCLUDING MODULAR CORE
Abstract
A hot tub cover including at least one core module including a
jacket and at least one core module within the jacket. Each core
module is fabricated from a plurality of rigidly interconnected
core elements. In the disclosed embodiment, the core elements are
extruded and include dovetail elements at their edges enabling the
core elements to slide together.
Inventors: |
Scott; William D.;
(Sevierville, TN) |
Correspondence
Address: |
WARNER NORCROSS & JUDD LLP
900 FIFTH THIRD CENTER, 111 LYON STREET, N.W.
GRAND RAPIDS
MI
49503-2487
US
|
Family ID: |
39049047 |
Appl. No.: |
11/456588 |
Filed: |
July 11, 2006 |
Current U.S.
Class: |
4/498 |
Current CPC
Class: |
E04H 4/08 20130101 |
Class at
Publication: |
4/498 |
International
Class: |
E04H 4/00 20060101
E04H004/00 |
Claims
1. A hot tub cover comprising: at least one core module including a
plurality of rigidly interconnected core elements, each core
element being a single unitary piece including connector means for
connecting the core element to at least one adjacent core element;
and a jacket enclosing said core.
2. The hot tub cover of claim 1 wherein each element includes upper
and lower surfaces spaced from one another.
3. The hot tub cover of claim 1 further comprising: at least two of
said core modules; and a hinge interconnecting said core
modules.
4. The hot tub cover in claim 3 wherein each core module includes a
hinged edge and a peripheral edge, said upper surfaces collectively
sloping downwardly from said hinged edge to said peripheral
edge.
5. The hot tub cover of claim 1 wherein said core elements are
slidably interconnected by male and female dovetails.
6. The hot tub cover of claim 2 wherein each core element further
includes a plurality of spaced ribs extending between said upper
and lower surfaces of said element, said spaced ribs defining a
plurality of openings between said upper and lower surfaces.
7. The hot tub cover of claim 6 further comprising an insulating
material between said ribs.
8. A hot tub cover core module comprising a plurality of rigidly
interconnected core elements.
9. The hot tub cover core module of claim 8 wherein each of said
core elements is a single unitary piece including connector means
for connecting said core element to at least one adjacent core
element.
10. The hot tub cover core module of claim 9 wherein each connector
means comprises a dovetail component.
11. The hot tub cover core module of claim 8 wherein each core
element includes upper and lower surfaces spaced from one
another.
12. The hot tub cover core module in claim 11 wherein each core
element includes a plurality of spaced ribs extending between said
upper and lower surfaces of said element said spaced ribs defining
a plurality of openings between said upper and lower surfaces.
13. The hot tub cover core module in claim 12 further comprising an
insulating material between said upper and lower surfaces.
14. The hot tub cover core module in claim 11 wherein said upper
and lower surfaces of each core element are non-parallel.
15. A hot tub cover kit comprising: a plurality of core elements
adapted to be rigidly interconnected to form a core module; and a
water resistant jacket.
16. The hot tub cover kit of claim 15 wherein: said elements have
non-parallel upper and lower surfaces; and said elements are
arranged into a substantially straight stack with said elements
alternating.
17. A method of manufacturing a hot tub cover comprising the steps
of: providing a plurality of core elements adapted to be rigidly
interconnected; rigidly interconnecting the core elements to
provide a core module; and enclosing the core module within a
jacket.
18. The method of claim 17 wherein each of the core elements is a
single piece.
19. The method of claim 18 wherein said providing step includes
extruding each of the core elements.
20. The method of claim 17 wherein the interconnecting step
includes: aligning a male dovetail of a first element with a female
dovetail of a second element; and sliding the male and female
dovetails relative one another.
21. A method of shipping a hot tub cover comprising the steps of:
providing a hot tub having an interior; placing a plurality of core
elements within the interior of the hot tub, the elements adapted
to be rigidly interconnected to form a core module that cannot lit
within the interior of the hot tub; shipping said hot tub with the
core elements within the hot tub, whereupon the elements can be
subsequently removed from the hot tub and rigidly interconnected
into a core capable of covering the hot tub.
22. The method of shipping of claim 21 wherein: the hot tub is
rectangular; and said placing step includes placing the plurality
of elements diagonally within the hot tub.
23. The method of shipping of claim 21 wherein: each core element
includes non-parallel upper and lower surfaces; and said placing
step includes alternating the orientation of the elements so that
they form a substantially straight stack.
24. The method of claim 21 further comprising the step of:
packaging said plurality of core elements.
25. The method of claim 21 wherein each core element includes at
least one dovetail element adapted to interfit with a dovetail
element on another core element.
26. A method of shipping a hot tub cover comprising the steps of:
providing a plurality of core elements each having planar,
non-parallel upper and lower surfaces; stacking the plurality of
core elements in alternating fashion to form a substantially
straight stack despite the non-parallel upper and lower surfaces;
packaging the stack; shipping the stack.
27. The method of claim 26 wherein said providing step includes
providing each core element with at least one dovetail element
adapted to interfit with a dovetail element on another core
element.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a cover for spas, hot tubs,
and the like and more particularly to an improved core for such
covers.
[0002] In order to provide insulation, limit pollution, and reduce
the risk of accidents, it is desirable to cover the open top of a
spa or hot tub. For example, one particularly effective cover
having a rigid plastic core is illustrated and described in U.S.
Publication 2005/0086731 dated Apr. 28, 2005 and entitled "Cover
for Hot Tub, Spa, or the Like." This cover includes two separate
core halves and a watertight jacket enclosing the core halves and
providing a hinge between the two halves. Therefore, the core
halves can fold together to aid in removal of the cover.
[0003] Although a notable advance in the art, this cover is not
without it drawbacks. First, the two large core halves exceed the
size limits of conventional carriers (e.g. United Parcel Service
and the U.S. Postal Service), which makes shipping by conventional
carriers expensive. This additional costs reduces the effective
practical market for the cover both domestically and
internationally.
SUMMARY OF THE INVENTION
[0004] The aforementioned problems are overcome by the present
invention wherein a cover for a hot tub or spa includes one or more
core modules each including a plurality of rigidly interconnected
core elements. The core elements can be separated for shipping. The
core elements can be readily assembled following shipping into the
one or more core modules.
[0005] The disassembled core elements can be easily and
economically shipped. For example, the core elements can be shipped
as a compact stack of unassembled elements. The compact stack
typically will not exceed the normal-shipping-cost size limitations
of common carriers, and therefore will be accorded normal shipping
costs. Alternatively, the unassembled elements can placed within a
hot tub or spa that is being shipped. When the elements are shipped
within a hot tub, the potential for damage during shipping is
significantly reduced.
[0006] After shipping, the elements are easily rigidly
interconnected to form one or more core modules of the hot tub
cover. The assembly can be accomplished by either a professional
installer or a consumer. A jacket also is included with the shipped
core elements so that the core modules can be enclosed within the
jacket to complete the cover.
[0007] These and other objects, advantages, and features of the
invention will be more fully understood and appreciated by
reference to the description of the current embodiment and the
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a perspective view of the hot tub cover of the
present invention installed on a hot tub.
[0009] FIG. 2 is a fragmentary section view taken along line 2-2 of
the hot tub cover including die adjacent core modules and the
jacket.
[0010] FIG. 3 is a perspective view of one of the core modules with
the core elements staggered from one another.
[0011] FIG. 4 is a side view of the cover with portions of the
vinyl jacket removed to reveal the core module.
[0012] FIG. 5 is a sectional view of a core element with a male
dovetail element and a female dovetail element.
[0013] FIG. 6 is a top plan view of the core elements placed within
the hot tub for shipping.
[0014] FIG. 7 is a perspective view of the core elements stacked
and packaged for shipping.
DESCRIPTION OF THE CURRENT EMBODIMENT
[0015] A hot tub cover constructed in accordance with a current
embodiment of the invention is illustrated in the drawings and
generally designated 12. The cover 12 generally includes a vinyl
jacket 14 and two plastic core modules 16. Each core module 16 in
turn includes a plurality of rigidly interconnected elements 70.
The vinyl jacket 14 encloses the core modules 16. The jacket 14
includes an integral living hinge 22 that enables the cover 12 to
fold onto itself (i.e. "in half").
[0016] As illustrated in FIG. 1, the cover 12 is covers a hot tub
10. Although a hot tub is shown in the drawings, the cover is
equally usable with a spa or any other unit containing water. The
use of "hot tub" in this specification is intended to include spas
and such other units. The illustrated hot tub 10 is rectangular,
but the hot tub could be any other desired shape. The cover 12 is
shaped and dimensioned to fit over the entire opening 11 of the hot
tub 10.
[0017] The jacket 14 is well known to those skilled in the art. In
the current embodiment, the jacket 14 is made of a marine grade
vinyl, or another high-strength waterproof fabric. The jacket 14 is
large enough to enclose the rigid core modules 16, and the jacket
includes an integral living hinge 22, a front edge 24, a rear edge
26, and a pair of opposite lateral edges 28. In the current
embodiment, the jacket 14 is capable of being opened and closed to
receive and to enclose the core 16 by conventional means such as a
zipper or similar mechanism (not shown). The jacket 14 may also
include attachments (not shown) such as snaps that attach the cover
12 to the hot tub 10 when the cover 12 is installed, and/or straps
that facilitate grasping and movement of the cover.
[0018] Each core module 16 is comprised of a plurality of rigidly
interconnected core elements 70. In the current embodiment, each
core module 16 is comprised of four such core elements 70a, 70b,
70c, and 70d. The core element 70a is adjacent the hinge 22 and is
the thickest core element. The core element 70d is remote from the
hinge 22 and is the thinnest core element. The collective upper
surfaces of the core elements 70 slope from the hinge 22 to the
lateral edge 28 so that rain and other water will run off the cover
12.
[0019] Each element 70 is currently made from a thermoformable
polymer such as ABS, HDPE, or PVC. Another other suitable material
also may be used. The element 70 is shaped to rigidly interconnect
with other elements to form the core 16. Each element 70 extends
from an inner edge 36 to an outer edge 37. Each core module 16a,
16b extends from an inner edge 20 to an outer edge 21. The outer
edge 21 is adjacent the outer edge 28 of the jacket 14. The
elements 70 are substantially parallel to the hinge 22. The front
edge 36 and the rear edge 37 of each element 70 form a portion of
the front edge 42 and the rear edge 44 respectively of the core 16.
The front edge 42 and rear edge 44 are adjacent the front 24 and
rear 26 edges respectively of the jacket 14.
[0020] In tire current embodiments each element 70 includes an
upper surface 30, a lower surface 32, a front edge 36, a rear edge
37, and a plurality of ribs 18 extending therebetween. The ribs 18
extend from the front edge 36 to the rear edge 37 of the core 16.
Further in the current embodiment, each core element 70 is
extruded, so that each core element is a single unitary piece.
Other suitable manufacturing techniques also may be used.
[0021] In the current embodiment, each core element 70 includes at
least one dovetail element 80f or 80m. The core element 70a
includes a female dovetail element 80f. The core elements 70b and
70c each include both a male dovetail element 80m and a female
dovetail element 80f. The core element 70d includes a male dovetail
element 80m. The dovetail elements or dovetails 80 extend from the
front edge 36 to the rear edge 37 of the core 16. The shape,
dimensions, and tolerances of the male and female dovetails 80 of
each core element 70 correspond to the corresponding dovetails of
the adjacent element(s) such that all the elements slidably
interconnect to form the core 16. The dovetails 80 provide a means
of rigidly interconnecting the core elements in a simple,
efficient, and low-cost construction. It is envisioned that other
known means of rigidly interconnecting could be used in place of
the dovetails.
[0022] Optionally, the open spaces 40 between the ribs 18 can be
filled with an insulating foam (not shown) or other insulating
material to further enhance the thermal properties of the cover
12.
[0023] To interconnect two adjacent core elements 70, the male
dovetail 80m of one element 70 is aligned with the female dovetail
80f of the other element. The two elements are then slid
longitudinally relative to one another until the front edges 36 and
rear edges 37 are aligned. This process is repeated for multiple
elements to form the core 16.
[0024] The core module 16 may be a replacement for a previous core
component such that it is inserted into an existing jacket, or the
core module 16 may be inserted into a brand new jacket 14 of the
desired dimensions. The jacket 14 is closed about the core 16 and
placed over the opening of a hot tub 10. Removal of the cover 12
consists of folding the cover 12 back about the hinge 22 and
pulling the cover off the hot tub 10.
[0025] The multiple element design allows the unassembled elements
90 to be separated and placed or stacked within the hot tub 10
during shipping. Spacers or an abutting formation can be utilized
in placing or stacking the unassembled elements 90. Currently, the
core elements 70 are stacked alternately upper surface 30 to upper
surface 30 with front edges 36 and inner edges 60 substantially
aligned such that the stack 80 forms a substantially straight
stack. The stacked elements may be wrapped in stretch wrap, shrink
wrap, cardboard, or some other shipping material to keep the
stacked elements 90 stacked and to minimize the potential for
damage to the hot tub 10.
[0026] A hot tub cover kit includes a water resistant jacket 14 and
multiple elements 70 capable of being rigidly interconnected to
form the core module 16.
[0027] Regardless of die shipping configuration and method, the
core elements 70 must assembled following shipping to form die core
module 16. The core module(s) 16 then are slid into the cover 14,
and the cover is closed using the zipper or other closure
mechanism.
[0028] The present invention provides several advantages. First the
core elements 70 can be shipped more easily and more economically
than previous covers. Second, the core elements 70 can be placed
inside a hot tub for shipment, further reducing costs and also
reducing die potential for damage to the core elements.
[0029] The above descriptions are those of current embodiments of
the invention. Various alterations and changes can be made without
departing from the spirit and broader aspects of the invention as
defined in the appended claims, which are to be interpreted in
accordance with the principles of patent law including the doctrine
of equivalents. Any reference to claim elements in the singular,
for example, using the articles "a," "an," "the" or "said," is not
to be construed as limiting the element to the singular.
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