U.S. patent application number 12/035306 was filed with the patent office on 2009-08-27 for panel systems for spas.
Invention is credited to Mark W. Jolley, Victor Lee Walker.
Application Number | 20090211011 12/035306 |
Document ID | / |
Family ID | 40996861 |
Filed Date | 2009-08-27 |
United States Patent
Application |
20090211011 |
Kind Code |
A1 |
Walker; Victor Lee ; et
al. |
August 27, 2009 |
Panel Systems for Spas
Abstract
Panel systems are provided where the panels are constrained
relative to a spa, but can be readily removed from the spa to
permit replacement of the panels. The panels can be constrained
prior to removal, such as using flanges which are attachable
relative to the frame of the spa.
Inventors: |
Walker; Victor Lee;
(Murietta, CA) ; Jolley; Mark W.; (Carlsbad,
CA) |
Correspondence
Address: |
FITCH EVEN TABIN & FLANNERY
120 SOUTH LASALLE STREET, SUITE 1600
CHICAGO
IL
60603-3406
US
|
Family ID: |
40996861 |
Appl. No.: |
12/035306 |
Filed: |
February 21, 2008 |
Current U.S.
Class: |
4/506 ;
29/428 |
Current CPC
Class: |
E04H 4/005 20130101;
E04H 4/0043 20130101; Y10T 29/49826 20150115 |
Class at
Publication: |
4/506 ;
29/428 |
International
Class: |
E04H 4/14 20060101
E04H004/14 |
Claims
1. A spa comprising: a vessel for containing water; a frame
supporting the vessel; and a skirt extending at least partially
around the frame, the skirt including a removable panel constrained
from removal by flanges adjacent the panel.
2. The spa of claim 1, wherein the flanges are provided adjacent
side edges of the panel.
3. The spa of claim 2, wherein at least one of the flanges adjacent
side edges of the panel is removably attached relative to the frame
to permit the panel to be removed when the one of the flanges is
removed.
4. The spa of claim 1, wherein the flanges are provided adjacent
side and bottom edges of the panel.
5. The spa of claim 1, wherein the flanges include a depending
flange of the vessel adjacent a top edge of the panel.
6. The spa of claim 1, wherein the flanges are adjacent top and
bottom edges of the panel and have a base portion and a
constraining portion, the panel having a maximum height between the
top and bottom edges less than a maximum height between the base
portions of the flanges adjacent the top and bottom edges of the
panels.
7. The spa of claim 6, wherein the maximum height between the base
portion of the flange adjacent the top edge of the panel and the
outer portion of constraining portion of the flange adjacent the
bottom edge of the panel is greater than the maximum height of the
panel.
8. The spa of claim 1, wherein at least one attachment means is
provided for generally securing the panel to the frame.
9. The spa of claim 8, wherein the attachment means constrains
movement of the panel relative to the frame in some but not all
directions.
10. The spa of claim 8, wherein the attachment means constrains
movement of the panel relative to the frame.
11. A removable panel system usable as part of a skirt surrounding
a vessel of a spa, the system comprising: a panel having top,
bottom and side edges; and flanges positionable adjacent at least a
pair of opposite edges of the panel, the flanges each having a
constraining portion configured to at least partially constrain the
panel from removal.
12. The removable panel system of claim 11, wherein the flanges are
positioned with a spacing and the panel has a height such that the
panel can be moved toward one of the flanges to clear the
constraining portion of the other of the flanges for removal of the
panel.
13. The removable panel system of claim 11, wherein a pair of side
flanges are positioned adjacent the side edges of the panel and
configured to constrain the panel.
14. The removable panel system of claim 11, wherein the flanges are
attachable relative to a frame supporting a vessel of a spa.
15. The removable panel system of claim 14, wherein at least one
attachment means is provided for generally securing the panel to
the frame.
16. A method of removing a panel of a skirt of a spa constrained at
least in part at a pair of opposing edge portions thereof, the
method comprising: shifting the panel to free one of the edge
portions of the panel from constraint while the other of the edge
portions of the panel remains constrained; and then shifting the
panel to free the other of the edge portions of the panel from
constraint to permit removal of the panel.
17. The method of claim 16, wherein the step of shifting the panel
to free the other of the edge portions of the panel from constraint
includes shifting the panel is a generally opposite direction from
the step of shifting the panel to free the one of the edge portions
of the panel.
18. The method of claim 16, wherein top and bottom edge portions of
the panel are constrained prior to the steps of shifting the
panel.
19. The method of claim 18, wherein side edge portions of the panel
are constrained prior to the steps of shifting the panel, and
further including the step of freeing at least one of the side
edges of the panel from constraint prior to the steps of shifting
the panel to free the top and bottom edge portions from constraint.
Description
FIELD
[0001] This application relates to panel systems for spas, and in
particular panel systems usable with spas having a skirt
surrounding a frame supporting a vessel for containing water.
BACKGROUND
[0002] Spas, including hot tubs and jetted bath tubs, often are
constructed of a vessel or shell for containing water and that is
supported in a frame. To provide an attractive appearance and hide
pumps, jets and interconnecting piping and the like from view, the
frame can include a surrounding decorative skirt. This skirting has
been constructed out of different types of wood arranged, for
instance, for a wainscoting-type or other tongue-and-groove
appearance and attached to the frame.
[0003] The appearance of the wood skirt, such as the stain, color
or type of wood, could be selected when the spa was originally
built. However, changes to the appearance of the skirt were
limited. While the skirt could be repainted or sanded and
restrained, those options can be time consuming and do not permit
convenient changes in the appearance of the skirt, such as to
update the skirt to match a new location for the spa or a new
decorating scheme of the surrounding environment.
[0004] Another disadvantage of wood skirts is the costs and time
for manufacturing. To make the wood skirts, the multiple slats of
the skirt are often assembled and attached to the frame, and the
wood skirt sanded, stained and/or painted. Those steps can be
labor-intensive, can require special ventilation during the
process, as well as add time needed for the stain or paint to dry
after initial application or between coatings when multiple
coatings are applied.
[0005] Yet another disadvantage of wood skirts is that they can
require maintenance and can be difficult to repair if damaged. The
maintenance can involve labor-intensive reapplication of stain,
sealing or protecting layers to maintain the visual appearance of
the wood skirt. Even when maintained, the environment in which the
spa is used can degrade the appearance of the skirt, particularly
when used outdoors. For instance, the wood skirt can be exposed to
water from the spa, water from yard irrigation systems, direct
sunlight, and a wide variation of temperature changes, in addition
to impacts from lawnmowers and lawn care tools, damage during
shipping and the like. Those environmental factors can also make it
difficult for a portion of the wood skirt to be replaced or
repaired, such as if damaged, as the same stains and paints may not
match the existing, weathered appearance. This can necessitate
redoing the entire wood skirt to have a wood skirt of a consistent
appearance.
[0006] Skirts made of synthetic materials have been used, but often
mimic wood in appearance and application. That is, synthetic
slats--such as those joined in a tongue-and-groove arrangement--can
still be labor-intensive to assemble and attach to the frame. The
customization options for the synthetic skirts can be limited, and
replacing an existing skirt to update an appearance can also be
labor-intensive, as such skirts are often screwed directly to the
frames and/or adhesively attached to adjacent portions of the
skirts or the frame. In order to gain access to the inner workings
of the spa disposed behind the skirt, doors were formed in the
skirt or portions of the skirt were unscrewed and removed. Both of
these are disadvantageous, the former because it can mar the visual
appearance of the spa and the latter because it can be
time-consuming.
SUMMARY
[0007] A panel system is provided that includes a panel that can be
readily removed from the spa. The panel is constrained from
removal, such as using one or more flanges, but the constraints can
be at least partially removed and/or the panel shifted relative to
the constraints to permit the panel to be removed when desired. The
flanges can be attached relative to a frame supporting a vessel of
the spa, and the removable panel can be part of a skirt at least
partially extending about the frame.
[0008] In order to install or remove a panel, the panel can be
shifted away from one of the flanges so that it is no longer
constraining the panel, then the panel can be shifted in a
different direction away from another of the flanges to permit
removal of the panel. The ability to readily remove a panel and
substitute a different panel can permit the spa to have its visual
appearance changed, to permit replacement of a damaged panel, and
can facilitate customized manufacturing of spas in a modular
manner.
[0009] In one aspect, the panel is generally free to float within
its constraints, advantageously permitting the panel to expand and
contract without necessarily buckling or otherwise deforming. In
another aspect, the floating of the panel can be constrained in one
or more directions, such as by using hardware attached between the
panel and the frame or skirt.
[0010] Panels which may be used as part of the panel system are
also provided. The panels can be made of synthetic materials that
are able to withstand the environment in which spas are used
without significantly degrading, thereby providing for a longer
life span of the panels without substantial maintenance being
required. The panels can be customized with different visual
graphics, whether shapes, images or the like, by removing portions
of the panels. The removed portions can expose underlying portions
of the panels, such as with different appearance properties, to
provide panels that have two or more tones or even see
through-windows that can be illuminated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective view of a spa having a skirt
surrounding a frame supporting a vessel for containing water and
showing a plurality of removable panels of the skirt;
[0012] FIG. 2 is partially exploded perspective view one of the
removable panels of the spa of FIG. 1 showing flanges used for
constraining the panel;
[0013] FIG. 3 is a detailed view of area III of FIG. 2 showing a
tab and slot connector mountable between the frame and the
removable panel;
[0014] FIG. 4 is a section view of the removable panel, frame,
vessel and flanges of FIG. 2 taken along line IV-IV and showing an
optional lighting device;
[0015] FIG. 5 is an exploded perspective view of a multipart panel
suitable for use with the spa of FIG. 1 and having an outward layer
with a plurality of openings through which the inward layer is
visible;
[0016] FIG. 6 is a section view of a composite panel suitable for
use with the spa of FIG. 1 and having a removed portion in an
outward layer to display an underlying inward layer of the
panel;
[0017] FIG. 7 is a section view of a panel suitable for use with
the spa of FIG. 1 and having a removed portion filled in with a
different material; and
[0018] FIG. 8 is a section view of a composite panel suitable for
use with the spa of FIG. 1 and having an outward layer with a
decorative profile.
DETAILED DESCRIPTION OF THE DRAWINGS
[0019] Panels and panel systems are provided that provide improved
decorative appearances, are formed of weatherable, low-maintenance
materials, reduced time for manufacture and assembly, and/or are
readily substituted to change the appearance of the spa. In
particular, the panel system can permit reduced time for assembly
to the spa, as well as interchangeability to permit the decorative
appearance of the spa to be changed. The panel system includes a
panel that is part of a skirt of the spa. The panel is typically
constrained from removal from the spa, but can readily be removed
from its constraints to permit replacement with a different panel,
such as to change the appearance of the spa or to replace a damaged
panel. The panels, which may or may not be used in conjunction with
the panel system, are preferably formed of durable synthetic
materials and have a variety of configurations that provide for
improved visual appearances and simplified manufacturing.
[0020] Turning first to the panel system, a spa 10 incorporating
the system is depicted in FIGS. 1-4. The spa 10 includes a vessel
or shell 12 for containing water. It is this vessel 12 that a user
of the spa can sit in during use of the spa 10. The vessel 12 has a
body 16 including a depressed well that is surrounded by a
peripheral lip 14. The vessel 12 is supported by a frame 20 that
extends around the vessel 12. The frame 20 can include vertical
supports 24 extending between peripheral, horizontal supports 22
and the flange 14 of the vessel 12. A skirt 30 is attached to and
surrounds the frame 20, both to provide a decorative appearance and
to enclose the inner workings of the spa 10, which can include
pumps, heaters, piping and the like. Part of the skirt 30 includes
a plurality of removable panels 34. The skirt 30 also includes
corner panels 32 that are attached to the frame 20. The removable
panel 34 is typically constrained relative to the remainder of the
skirt 30, but can be readily removed to permit another panel to be
substituted or for access to the inner workings of the spa 10.
[0021] In the illustrated example, the panels 34 are constrained
using several flanges adjacent side edges of the panels 34, as
shown in the exploded view of FIG. 2. Included are a pair of
flanges 36 adjacent lateral side edges of the panel 34, as well as
a bottom flange 38 adjacent the bottom edge of the panel 34. The
top edge of the panel 34 is positioned to fit in a recess of the
vessel 12 between the lip 14 and the body 16, the lip 14 of which
functions as a flange. When assembled, the flanges 14, 36 and 38
constrain all four edges of the panel 34. While the term "flange"
is used, any similar constraining structures can be used that
restrict outward removal of the panel 34 from the spa 10, such as
u-shaped members, brackets or the like. Further, although each
flange 36 and 38 is depicted as being formed from a single member,
a plurality of different members, such as a plurality of pins,
brackets or the like, can also be used to constrain the panel 34.
Also, the flanges 36 and 38 can be built into other parts of the
spa 10, as opposed to being separate members. For instance, a
groove or flange could be formed in portions of the spa adjacent
the panel 34, such as the frame 20 or the corner skirt portions
32.
[0022] As shown in the section view of FIG. 4, the flanges 36 and
38 can include a base 45 with an upstanding leg 44 and a depending
leg 43. The depending leg 43 can be attached to the frame 20 or
remainder of the skirt 30. The base 45 can restrict lateral
movement of the panel 34, in the case of the flanges 36 adjacent
the lateral side edges of the panel 34, or can restrict vertical
movement of the panel 34, in the case of the flange 38 adjacent the
bottom edge of the panel 34. The upstanding leg 44 of the flanges
36 and 38 can restrict movement of the panel 34 away from the spa
10. The flanges 36 and 38 can be directly attached to the frame 20,
or can be attached relative to the frame 20 via intermediate
portions of the skirt 30, such as the skirt corner panels 32. In
particular, the bottom flange 38 can be attached to the horizontal
support 22 of the frame 20, and the side flanges 36 can be attached
to either or both of the skirt corner panels 32 and the vertical
supports 24 of the frame 20. The flanges 36 and 38 can be attached
to the spa 10 using screws or other such fasteners. To this end,
preformed screw holes can be disposed in the flanges 36 and 38 to
facilitate assembly.
[0023] The panel 34 preferably, though not necessarily, is
generally free to float within the confines of the flanges 14, 36
and 38. This floating can accommodate expansion and contraction of
the panel 34, such as during temperature changes. This can assist
in reducing buckling of the panel 34. The panel 34 may be
constrained to a greater degree in one direction than another, such
as to a greater degree in lateral directions and opposed to
vertical directions. Separate from the constraining flanges 36, 38
and lip 14, the panel 34 can also be attached relative to the spa
10. For example, hardware may be attached to the panel 34 that can
be joined, hung or secured to hardware attached relative to the spa
10. In the illustrated example, the hardware can include a tab 40
attached to the back of the panel 34 and a bracket 42 attached to
the vertical support 24, as illustrated in FIG. 3, or vice versa.
The bracket 42 can project outwardly from the vertical support 24
to effectively form a slot between a portion of the bracket 42 and
the vertical support 24 that is configured to receive the tab 40.
When the tab 40 is inserted in the slot bounded by a portion of the
bracket 42 and the vertical support 24, the panel 34 is essentially
hung relative to the frame 20. That is, the panel 34 is constricted
from side-to-side movement and downward movement (toward the
horizontal supports 22 of the frame 20), but is free to move
upwardly. Depending upon the particular configuration of the tab 40
and bracket 42, the panel 34 may also be constrained by the
hardware from movement outwardly from the spa 10. Other types of
hardware can be used, including hardware that restricts movement in
all directions.
[0024] To assemble the panel 34 to the spa 10, the bottom flange 38
can first be attached to the horizontal supports 22. The panel 34
can then be inserted between the lip 14 of the vessel 12 and the
bottom flange 38. The distance between a base portion of the lip
and the base 45 of the bottom flange 38, and in particular the
distance between the upstanding leg 44 and the recess of the lip 14
is such that the panel 34 can clear the upstanding leg 44 when the
upper edge portion is within the lip 14. In one example, the upper
edge portion of the panel 34 can be inserted at a slight angle into
the recess of the lip 14, which can permit the bottom edge portion
of the panel 34 to clear the upstanding leg 44 of the bottom flange
38 as the bottom edge portion of the panel 34 is pivoted to a
position past the upstanding leg 44 and toward the spa 10. The
panel 34 can then be allowed to move downward so that it is resting
on the base 45 of the bottom flange 38, while being constrained
from outward movement by both the upstanding leg 44 of the bottom
flange 38 and the lip 14 of the vessel 12. If the tab-and-slot
fastener is being used, then the tab 40 can also be slid into the
slot formed between the bracket 42 and the vertical support 24 to
further constrain the panel 34. The side flanges 36 can then
optionally be attached to the spa 10 to constrain the adjacent the
side edge portions of the panel 34.
[0025] In order to remove the panel 34 from the spa 10, one or both
side flanges 36, if present, can be removed. If only one of the
side flanges 36 is removed, then the panel 34 can be laterally
slide away from the other of the side flanges 36. Once
unconstrained by the side flanges 36, the panel 34 can be shifted
upwardly toward the lip 14 of the vessel 12 to free the bottom edge
portion of the panel 34 from constraint by the upstanding leg 44 of
the bottom flange 38. Once free, the bottom edge portion of the
panel 34 can be pivoted outwardly while the upper edge portion
remains in the recess of the lip 14. Next, the outwardly-pivoted
panel 34 can be shifted downwardly to free the upper edge portion
of the panel 34 from the lip 14 of the vessel 12. In this manner,
the panel 34 can be readily removed, and, using the steps described
above, replaced with the same or a different panel 34. Although
these steps have been described with inserting or shifting the
upper edge portion of the panel 34 into the recess of the lip 14
first, the opposite sequence could also be utilized for insertion
and removal of the panel 34.
[0026] The simplified assembly steps for attaching the panel 34
relative to the spa 10 and the modularity of the panels can promote
faster assembly of the spa 10. Further, a plurality of different
panels 34 can be stocked, permitting for customization of the spas
10 during manufacture by using different panels to provide
different visual appearances of the spas 10. Indeed, the sizes of
the panels can be standardized for more than one type of spa 10,
further reducing the number of different parts needed to assemble
the spa. A reduced number of fasteners can be utilized, as the
panels 34 are not attached at an excess number of locations to the
spa 10. After assembly of the spa 10, the removable panels 34
permit end-users or installers of the spas 10 to readily substitute
panels 34, whether to repair the spa 10 or to change the visual
appearance thereof.
[0027] The use of the flanges 36 and 38 permits decorative
structures to be incorporated into the flanges to enhance the
visual appearance and functionality of the spa 10. For example, a
series of lights 46, such as LEDs, can be optionally inserted into
apertures 46 in the base 45 of the bottom flange 38 or into other
flanges. The lights can provide an attractive visual appearance to
the spa 10, such as by highlighting the panel 34, and can identify
the perimeter of the spa 10.
[0028] Turning now to the panels themselves, the panels can be
configured to provide for different visual appearances, while also
taking into account ease of manufacturing. In one example, the
panel 34 can have decorative openings formed therethrough, and a
back panel 52 can be attached or positioned adjacent the rearward
side of the panel 34, as illustrated in FIG. 5. The back panel 52
can have a different color and/or texture from the panel 34,
thereby permitting the different color and/or texture to be visible
through the openings 50 in the panel 34 to effectively provide a
two-toned panel. In one example, the back panel 52 can be
translucent. When lighting is positioned behind the back panel 52,
the openings 50 in the panel 34 can be illuminated.
[0029] In another example, the panel may be formed to have at least
an outer layer 56 and an inner layer 54, such as using coextrusion
techniques. The outer and inner layers 56 and 54 may have different
appearance properties, such as color, texture, and/or translucency,
such that when the inner layer 54 is exposed the panel is
two-toned. The inner layer 54 can be exposed by removing a portion
of the outer layer 56, essentially creating a window or other
opening 58 in the outer layer 56. The outer layer 56 can be
partially removed using CNC-machining, for instance, to create
geometric shapes or designs, such as those illustrated in FIGS. 1,
2 and 5. Furthermore, the panel can have more than two layers with
different appearance properties, permitting three or more
appearance properties in a single panel.
[0030] In yet another example, the panel may have a single layer or
a primary layer 60 that is removed, such as using CNC-machining, to
form a recess 62. The recess 62 can be left open, or the recess can
be filled in using an epoxy or other filler to provide a different
appearance property, as depicted in FIG. 7. In another variation of
the panel, the panel can have one or more layers 66, 68 and 70, as
depicted in FIG. 8, with the outermost layer 68 being a textured
skin that can be formed to resemble rocks or stone, by way of
example. The three-dimensional appearance of the graphics formed in
the panels, such as when openings are formed in the panel or in an
outer layer of the panel, or when different depths of material are
removed, can further enhance the decorative aspects of the
panels.
[0031] The panels described herein can be made of a variety of
synthetic materials. Preferably, the materials can withstand the
water, chemical and UV environment that spas 10 are often used in,
without significant color or other degradation. An example of a
suitable material is high density polyethylene (HDPE). The flanges
36 and 38 can also be made of like materials. The panels can be
made using extrusion techniques, which can advantageously also form
the grooves depicted in the panels of FIGS. 1-3 and 5. The panels
could also be made of an extruded or otherwise shaped vinyl
substrate, which can be primed and coated with an adhesive, then a
skin or film material applied (such as using a wrapping machine,
including a wrapping machine from RENOLIT AG). The skin or film can
have protective or decorative properties. Panels having different
appearance properties can be made using coextrusion techniques. The
outer, textured skin 68 can be formed of acrylonitrile butadiene
styrene (ABS), and can be made using thermoforming techniques and
then laminated or otherwise attached to the other layer or layers
of the panel. While the panels are depicted in the figures as being
rectangular, other shapes, such as ovular, circular, or
multi-sided, can be used with suitable modifications to the
constraining flanges or other constraining elements.
[0032] From the foregoing, it will be appreciated that panels and
panel systems, and methods of manufacture and use, are disclosed
herein that provide for advantages in terms of assembly,
maintenance and visual appearance. However, the disclosure is not
limited to the aspects and embodiments described hereinabove, or to
any particular embodiments. For instance, while described with
respect to spas, other types of devices can also be used, such as
bath tubs, showers, or other vessels having skirts. Also, while
specific types of panels are described herein, other types of
panels can be used with the panel systems.
* * * * *