Structurally strong, non vapor, non moisture absorbing, spa/hot tub cover

• US 4,857,374 A
• Filed: 11/15/1988
• Issued: 08/15/1989
• Est. Priority Date: 11/15/1988
• Status: Expired due to Term

• Current Assignee: Watkins Manufacturing Corporation (Masco Corporation)
• Original Assignee: Gary L. Perry
• Inventors: Perry, Gary L.
• Primary Examiner(s): Van Balen, William J.
• Application Number:
  US07/272,513
• Time in Patent Office: 273 Days
• Field of Search: 4/498, 428/71, 428/76, 428/247, 428/314.4, 428/314.8, 428/316.6, 428/317.1, 428/317.7
• US Class Current: 428/71
• CPC Class Codes: A61H 33/00 Bathing devices for special therapeutic or hygienic purposes A61H35/00 takes precedence; sprays acting on a body or body part not immersed in water A61H9/00; means for washing bed-ridden persons A61G7/0005; for sub aquatic intestinal cleaning A61M9/00; isolation chambers A61M21/0094; electric or magnetic baths, applying ionised fluids A61N1/44 ; heater for bath tubs F24H1/54
• CPC Class Codes: E04H 4/084 with lifting mechanism
• CPC Class Codes: Y10T 428/233 Foamed or expanded material encased
• CPC Class Codes: Y10T 428/249976 Voids specified as closed
• CPC Class Codes: Y10T 428/249981 Plural void-containing components
• CPC Class Codes: Y10T 428/249982 With component specified as adhesive or bonding agent

Abstract

A spa/hot tub cover is structurally strong to essentially completely cover an opening of a spa/hot tub except for a limited vent, and withstand a person'"'"'s weight. In so doing the spa/hot tub cover itself will not absorb vapor, moisture, or water, and thereby not become heavier because of the containment of moisture. The interior of the spa/hot tub cover has several barriers to any possible absorption of vapor, moisture, or water, whereby, if an outside or outer barrier is punctured, only a small quantity of vapor, moisture, or water, will be absorbed. At a central portion of this cover, commencing from the top and continuing on down through to the bottom, the following layers of an overall lamination are: a top weatherable plastic; a contact cement serving as a sealant and adhesive; an expanded polystyrene shaped to define the shape of the spa/hot tub cover; a contact cement serving as a sealant and adhesive; a polypropylene scrim foil; a contact cement; a closed cell foam of polyethylene; and then a bottom polyester fabric reinforced polyvinylchloride. The laminations of this central portion continue on to the periphery of each spa/hot tub cover. Where subsequent fasteners may be received, aluminum angles are selectively positioned about this periphery. The polypropylene scrim foil continues up and over the periphery of these laminations. The bottom polyester fabric reinforced polyvinylchloride also continues up alongside the periphery of these laminations. A vinyl angle is adhered about the top corner of the periphery of these laminations having a leg horizontally overlapping the periphery edge of the weatherable plastic and having a leg vertically overlapping the upturned portions of the polyester fabric reinforced polyvinylchloride. A sealing bead is located where the horizontal overlapping leg of the angle is positioned on the top weatherable plastic and where the vertical overlapping leg of the angle is positioned on the polyester fabric reinforced polyvinylchloride, thereby completing the assembly of this structurally strong, non vapor, non moisture absorbing, spa/hot tub cover. This cover in various embodiments has a sloping water draining top surface, has multiple sections, has hinges, has handles, and/or has gas spring actuators used during removal and replacement.

Claims

1. A structurally strong, non vapor, non moisture absorbing, spa/hot tub cover, comprising the assembled combination of laminations of materials, adhesives, sealants, and both aluminum and plastic angle reinforcements arranged as follows:

(a) an overall shape defining volume of expanded polystyrene cut or formed as a cover to match the respective top planar opening of a particular spa/hot tub;

(b) a complete surrounding layer of contact cement adhered to all the surfaces of the expanded polystyrene and dried to become an impervious vapor, moisture, and water, barrier to keep the expanded polystyrene dry;

(c) selected lengths of aluminum angle placed at selected places about the periphery of the expanded polystyrene and adhered thereto to serve as places to receive fasteners, later selected to hold in place selected items such as handles and hinges;

(d) a continuous polypropylene scrim foil adhered to and extending throughout the entire bottom, entire sides, and entire peripheral top edges of the expanded polystyrene, being secured by contact cement;

(f) a continuous closed cell foam of polyethylene extending entirely underneath the continuous polypropylene scrim foil and adhered thereto in selected places;

;

(g) a continuous thermally stable and gas impermeable polyvinylchloride polyester laminate extending entirely underneath the continuous closed cell foam, and entirely up and alongside the side edges of the continuous closed cell foam and the side edges of the continuous polypropylene scrim foil, and adhered thereto;

(h) a continuous weatherable plastic extending entirely over the contact cement coated overall shape defining volume of expanded polystyrene, the top edge of aluminum angles, the folded over edge of the continuous polypropylene scrim foil, and adhered to all of them;

(i) A cyanoacrylate instant adhesive spread near all the edges of the continuous weatherable plastic;

(j) a plastic angle positioned about all the top and side edges of the continuous weatherable plastic and adhered thereto via the cyanoacrylate instant adhesive, and about the top and side portions of the upturned portions of the continuous thermally stable and gas impermeable polyvinylchloride polyester laminate and adhered thereto via the cyanoacrylate instant adhesive; and

(k) a continuous sealing bead of a weatherable plastic in an applying solution of methylene chloride located where the plastic angle stops above the continuous weatherable plastic and where the plastic angle stops by the polyester reinforced laminate, to create a vapor, moisture, and water seal.

2. A structurally strong, non vapor, non moisture absorbing spa/hot tub cover, as claimed in claim 1, wherein the overall shape defining volume of expanded polystyrene has a sloping top surface eliminating a possibility of standing water on this completed cover.

3. A structurally strong, non vapor, non moisture absorbing, spa/hot tub cover, as claimed in claim 1, wherein the overall shape defining volume of expanded polystyrene is made in two pieces and hinges are used to join the two pieces together.

4. A structurally strong, non vapor, non moisture absorbing spa/hot tub cover, as claimed in claim 2, wherein the overall shape defining volume of expanded polystyrene is made in two pieces and hinges are used to join the two pieces together.

5. A structurally strong, non vapor, non moisture absorbing, spa/hot tub cover, as claimed in claim 1, wherein the continuous weatherable plastic is a composition of styrene-acrylonitrile copolymers.

6. A structurally strong, non vapor, non moisture absorbing, spa/hot tub cover, as claimed in claim 1, wherein before the continuous weatherable plastic is adhered in place, the underside surface thereof is wiped with methylene chloride and then sprayed with a contact cement.

7. A structurally strong, non vapor, non moisture absorbing, spa/hot tub cover, as claimed in claim 1, has a gas spring accessory used during the removal thereof from the top of a spa/hot tub.

8. A structurally strong, non vapor, non moisture absorbing, spa/hot tub cover, as claimed in claim 2, has a gas spring accessory used during the removal thereof from the top of a spa/hot tub.

9. A structurally strong, non vapor, non moisture absorbing, spa/hot tub cover, as claimed in claim 3, has a gas spring accessory used during the removal thereof from the top of a spa/hot tub.

10. A structurally strong, non vapor, non moisture absorbing, spa/hot tub cover, as claimed in claim 4, has a gas spring accessory used during the removal thereof from the top of a spa/hot tub.

11. A structurally strong, non vapor, non moisture absorbing, spa/hot tub cover, as claimed in claim 3, wherein each piece has a gasket which extends along the hinges joining the two pieces together.

12. A structurally strong, non vapor, non moisture absorbing, spa/hot tub cover, as claimed in claim 4, wherein each piece has a gasket which extends along the hinges joining the two pieces together.

13. A structurally strong, non vapor, non moisture absorbing, spa/hot tub cover, as claimed in claim 11, wherein the ends of each gasket are formed to provide a vent, so a vacuum will not form under the spa/hot tub cover when the spa/hot tub is covered.

14. A structurally strong, non vapor, non moisture absorbing, spa/hot tub cover, as claimed in claim 12, wherein the ends of each gasket are formed to provide a vent, so a vacuum will not form under the spa/hot tub cover when the spa/hot tub is covered.

15. A structurally strong, non vapor, non moisture absorbing, spa/hot tub cover, as claimed in claim 1, comprising, in addition, at least one handle to be used in raising and lowering this spa/hot tub cover, which is secured at an aluminum angle location along the side of this cover.

16. A structurally strong, non vapor, non moisture absorbing, spa/hot tub cover, as claimed in claim 15, wherein the handle, in turn, comprises:

(a) a portion of rope having ends;

(b) two fairleads each receiving an end of the rope;

(c) fasteners to secure the fairleads to the side of the spa/hot tub cover; and

(d) radially expanded portions of the rope ends being formed, following their passage through a respective fairlead, to thereby insure these rope ends will not pull back through the fairleads, thereby completing the assembly of the handle.

17. A structurally strong, non vapor, non moisture absorbing, spa/hot tub cover, as claimed in claim 13, comprising, in addition, at least one handle, in turn comprising:

(a) a portion of rope having ends;

(b) two fairleads each receiving an end of the rope;

(c) fasteners to secure the fairleads to the side of the spa/hot tub cover; and

(d) radially expanded portions of the rope ends being formed, following their passage through a respective fairlead, to thereby insure these rope ends will not pull back through the fairleads, thereby completing the assembly of the handle.

18. A structurally strong, non vapor, non moisture absorbing, spa/hot tub cover, as claimed in claim 14, comprising, in addition, at least one handle, in turn comprising:

(a) a portion of rope having ends;

(b) two fairleads each receiving an end of the rope;

(c) fasteners to secure the fairleads to the side of the spa/hot tub cover; and

(d) radially expanded portions of the rope ends being formed, following their passage through a respective fairlead, to thereby insure these rope ends will not pull back through the fairleads, thereby completing the assembly of the handle.

19. A structurally strong, non vapor, non moisture absorbing, spa/hot tub cover, comprising the assembled combination of laminations of materials, adhesives, sealants arranged as follows:

(a) an overall shape defining volume of expanded polystyrene cut or formed as a cover to match the respective top planar opening of a particular spa/hot tub;

(b) a complete surrounding layer of contact cement adhered to all the surfaces of the expanded polystyrene and dried to become an impervious vapor, moisture, and water, barrier to keep the expanded polystyrene dry;

(c) a continuous polypropylene scrim foil adhered to and extending throughout the entire bottom, entire sides, and entire peripheral top edges of the expanded polystyrene, being secured by contact cement;

(d) a continuous closed cell foam of polyethylene extending entirely underneath the continuous polypropylene scrim foil and adhered thereto;

(e) a continuous thermally stable and gas impermeable polyvinylchloride polyester laminate extending entirely underneath the continuous closed cell foam, and entirely up and alongside the side edges of the continuous closed cell foam and the side edges of the continuous polypropylene scrim foil, and adhered thereto;

(f) a continuous weatherable plastic extending entirely over the contact cement coated overall shape defining volume of expanded polystyrene, the folded over edge of the continuous polypropylene scrim foil, and the top edge of the thermally stable and gas impermeable polyvinylchloride polyester laminate, and adhered to all of them; and

(g) a continuous sealing bead of a weatherable plastic in an applying solution of methylene chloride located where the continuous weatherable plastic terminates to create a vapor, moisture, and water seal.

20. A structurally strong, non vapor, non moisture absorbing, spa/hot tub cover, comprising the assembled combination of laminations of materials, adhesives, sealants, arranged as follows:

(a) an overall shape defining volume of expanded polystyrene cut or formed as a cover to match the respective top planar opening of a particular spa/hot tub;

(b) a complete surrounding layer of contact cement adhered to all the surfaces of the expanded polystyrene and dried to become an impervious vapor, moisture, and water, barrier to keep the expanded polystyrene dry;

(c) a continuous polypropylene scrim foil adhered to and extending throughout the entire bottom, entire sides, and entire peripheral top edges of the expanded polystyrene, being secured by contact cement;

(d) a continuous closed cell foam of polyethylene extending entirely underneath the continuous polypropylene scrim foil and adhered thereto;

(e) a continuous thermally stable and gas impermeable polyvinylchloride polyester laminate extending entirely underneath the continuous closed cell foam, and entirely up and alongside the side edges of the continuous closed cell foam and the side edges of the continuous polypropylene scrim foil, and adhered thereto; and

(f) a continuous weatherable plastic extending entirely over the contact cement coated overall shape defining volume of expanded polystyrene, and the folded over edge of the continuous polypropylene scrim foil, and adhered to them.