Portable spa construction

Abstract

Spa side panels are trapezoidally-shaped and mounted in respective grooves defined by adjacent tapered corner pieces and their mounting brackets to accommodate differences in coefficients of expansion of the respective parts and prevent structural damage. Angled force transfer members are configured to mate with swept back side surfaces of a spa base pan to achieve a pedestal appearance, and the bottom surface of the base pan is constructed to reduce heat transfer to the spa support surface.

Claims

1. Apparatus comprising: a plurality of corner pieces, each positioned at a respective corner of a spa structure; and a plurality of side panels; wherein the spa structure is configured such that at least a first of the side panels may expand or contract both vertically and horizontally without damaging the spa structure; wherein the first side panel is positioned with respective first and second sides located behind respective first and second corner pieces and with its top edge slidably positioned behind a top portion of the spa structure; and wherein a lower edge of the first side panel is retained by at least one panel clip in a manner which prevents downward movement of the side panel but permits lateral movement of the side panel, the at least one panel clip having a latch component which is pivotable into and out of a side panel retaining position.

2. The apparatus of claim 1 wherein said first and second corner pieces each have a tapered side edge, wherein said first side panel is trapezoidal in shape, and wherein the respective side edges of the first side panel reside in respective first and second grooves, the first groove being defined by the first corner piece and a first bracket attaching the first corner piece to the spa structure and the second groove being defined by the second corner piece and a second bracket attaching the second corner piece to the spa structure.

3. The apparatus of claim 1 wherein the spa structure further comprises: a spa shell having a generally rectangular outer upper rim; a generally rectangular base pan of smaller width and length than the generally rectangular outer upper rim, the base pan being centrally positioned beneath and within the perimeter of the outer upper rim; the base pan including a plurality of swept back side surfaces, each extending from a respective lower edge of a respective side panel to a lower edge of the base pan; a plurality of vertical support members configured to support the upper rim of the spa shell; and a plurality of force transfer members angled to transfer force from a respective vertical support member to an interior bottom surface of the base pan.

4. The apparatus of claim 3 wherein the plurality of swept back surfaces create a visual appearance of a pedestal.

5. The apparatus of claim 3 wherein the at least one panel clip comprises: a pivot component having an arcuate back surface and right and left bosses projecting therefrom, the right and left bosses facilitating attachment of the pivot component to a surface of said base pan; and wherein the latch component has a hook-like portion configured to pivotally mate with said arcuate back surface.

6. The apparatus of claim 3 wherein each force transfer member comprises a first half and a second half configured to slidably mate such that the length of the force transfer member can be selectively adjusted, the first half having a rectangular receptacle formed as a part thereof for receiving an end of a vertical support member, the second half having a foot of rectangular cross-section extending therefrom and shaped and dimensioned to mate with a groove in said base pan.

7. The apparatus of claim 2 wherein the taper of the side edge of each corner piece lies at an acute angle to the vertical.

8. The apparatus of claim 3 wherein the base pan comprises a plurality of recessed fin regions in its bottom surface configured to reduce heat transfer to a surface upon which the base pan rests.

9. The apparatus of claim 1 comprising first and second panel clipseach retaining the first side panel in a manner which prevents downward movement of the side panel but permits lateral movement of the side panel, and each having a latch component which is pivotable into and out of a side panel retaining position.

10. The apparatus of claim 1 comprising first, second, and third panel clips retaining the first side panel in a manner which prevents downward movement of the side panel but permits lateral movement of the side panel and each having a latch component which is pivotable into and out of a panel retaining position.

11. The apparatus of claim 5 wherein, in a locked position, the right boss of the pivot component extends through an opening in the latch component and the left boss of the pivot component extends through a slot in the latch component such that the latch component cannot pivot due to abutment of the left and right bosses with respective adjacent surfaces of the slot and the opening.

12. The apparatus of claim 11 wherein first and second screws fasten the pivot component to an adjacent surface and are tightenable so as to hold the pivot and latch components in the locked position.

13. The apparatus of claim 12 wherein the pivot and latch components are further configured such that when the first and second screws are untightened, the latch component can move to the right such that the left boss moves out of the slot, and the right boss moves into position over a cut-out area formed in the latch component such that the latch component is free to pivot with respect to the pivot component.

14. The apparatus of claim 13 wherein the pivot and latch components are further configured such that the pivot component is pivotable to an open position wherein the right boss resides in the cut-out area of the latch component, and the left boss lies adjacent an outer leg of the latch component.

15. The apparatus of claim 3 wherein a swept back side surface of the base pan has an inner horizontally disposed top step and a horizontally disposed lower step and wherein the force transfer member includes a stepped edge shaped to mate with the top step, the stepped edge forming into an angled surface which rests on the swept back side surface, and wherein the angled surface continues into a second step which mates with the lower step.

16. The apparatus of claim 15 wherein a slot or channel is further formed in the base pan and snugly receives a foot portion of the force transfer member.

17. The apparatus of claim 1 wherein the at least one panel clip comprises: a pivot component having an arcuate back surface and right and left bosses projecting therefrom; and wherein the latch component comprises a hook-like portion configured to pivotally mate with said arcuate back surface.

18. The apparatus of claim 17 wherein, in a locked position, the right boss of the pivot component extends through an opening in the latch component and the left boss of the pivot component extends through a slot in the latch component such that the latch component cannot pivot due to abutment of the left and right bosses with respective adjacent surfaces of the slot and the opening.

19. The apparatus of claim 18 wherein first and second screws fasten the pivot component to an adjacent surface and are tightenable to hold the pivot and latch components in a locked position.

20. The apparatus of claim 19 wherein the pivot and latch components are further configured such that when the first and second screws are untightened, the latch component is moveable to the right such that the left boss moves out of the slot, and the right boss moves into position over a cut-out area formed in the latch component such that the latch component is free to pivot with respect to the pivot component.

21. The apparatus of claim 20 wherein the pivot and latch components are further configured such that the pivot component is pivotable to an open position wherein the right boss resides in the cut-out area of the latch component, and the left boss lies adjacent an outer leg of the latch component.

22. A spa structure comprising: a first side panel positioned with respective first and second sides located behind respective first and second corner pieces of the spa structure and with a top edge positioned behind a top portion of the spa structure; and wherein a lower edge of the first side panel is retained by at least one panel clip in a manner which prevents downward movement of the side panel but permits lateral movement of the side panel, the at least one panel clip comprising a pivot component attached to the spa structure and a latch component pivotally engaged with the pivot component, the latch component being pivotable into and out of a side panel retaining position.

23. The spa structure of claim 22 wherein: the pivot component has an arcuate back surface and right and left bosses projecting therefrom; and the latch component comprises a hook-like portion configured to pivotally mate with said arcuate back surface.

24. The spa structure of claim 23 wherein, in a locked position, the right boss of the pivot component extends through an opening in the latch component and the left boss of the pivot component extends through a slot in the latch component such that the latch component cannot pivot due to abutment of the left and right bosses with respective adjacent surfaces of the slot and the opening.

25. The spa structure of claim 24 wherein first and second screws fasten the pivot component to an adjacent surface and are tightenable so as to hold the pivot and latch components in a locked position.

26. The spa structure of claim 25 wherein the pivot and latch components are further configured such that when the first and second screws are untightened, the latch component is moveable to the right such that the left boss moves out of the slot and the right boss moves into position over a cut-out area formed in the latch component such that the latch component is free to pivot with respect to the pivot component.

27. The spa structure of claim 26 wherein the pivot and latch components are further configured such that the pivot component is pivotable to an open position wherein the right boss resides in the cut-out area of the latch component, and the left boss lies adjacent an outer leg of the latch component.

28. A spa structure comprising: a plurality of corner pieces, each positioned at a respective corner of a spa structure; a plurality of side panels; a panel clip; wherein a first side panel is positioned with respective first and second sides located behind respective first and second corner pieces and with a top edge of the first side panel slidably positioned behind a top portion of the spa structure; and wherein a lower edge of the first side panel is retained by at least one panel clip in a manner which prevents downward movement of the side panel but permits lateral movement of the side panel, the at least one panel clip having a latch component which is pivotable into and out of a panel retaining position.

29. A spa structure comprising: a first side panel positioned with respective first and second sides located behind respective first and second corner pieces of the spa structure and with a top edge positioned behind a top portion of the spa structure; and wherein a lower edge of the first side panel is retained by at least one panel clip in a manner which prevents downward movement of the side panel but permits lateral movement of the side panel, the at least one panel clip having a latch component which is pivotable into and out of a side panel retaining position.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a perspective view of a portable spa according to an illustrative embodiment;

(2) FIG. 2 is a perspective view illustrating the internal structure of the spa of FIG. 1;

(3) FIG. 3 is an inverted perspective view of illustrative frame structure of the spa of FIG. 1;

(4) FIG. 4 is an inverted perspective view of the spa of FIG. 1 with side panels removed;

(5) FIG. 5 is a perspective view illustrating a bottom pan component of the spa of FIG. 1;

(6) FIG. 6 is a perspective fragmentary view illustrating internal support members of the spa of FIG. 1 according to an illustrative embodiment;

(7) FIG. 7 is a perspective view illustrating assembly of angled force transfer member components according to an illustrative embodiment;

(8) FIG. 8 is a top perspective view of an illustrative angled force transfer member;

(9) FIG. 9 is a side perspective view of respective halves of an angled force transfer member according to an illustrative embodiment;

(10) FIG. 10 is a side view illustrating internal structure of a first half of the illustrative angled force transfer member;

(11) FIG. 11 is a side view illustrating internal structure of a second half of the illustrative angled force transfer member;

(12) FIG. 12 is a first side view of the assembled angled force transfer member;

(13) FIG. 13 is a second side view of the assembled angled force transfer member;

(14) FIG. 14 is a front view of the assembled angled force transfer member;

(15) FIG. 15 is a back view of the assembled angled force transfer member;

(16) FIG. 16 is a fragmentary perspective view illustrating a corner portion of the spa of FIG. 1;

(17) FIG. 17 is a fragmentary front view of the corner portion of FIG. 17;

(18) FIG. 18 is a fragmentary side perspective view of the spa of FIG. 1 with a side panel removed;

(19) FIG. 19 is a perspective view of an illustrative embodiment of a panel clip in an open position;

(20) FIG. 20 is a perspective view of the panel clip of FIG. 19 in an closed position;

(21) FIG. 21 is a side view of a latch component of the panel clip of FIG. 19;

(22) FIG. 22 is a front view of a latch component of FIG. 21;

(23) FIG. 23 is a rear perspective view of a pivot component of the panel clip of FIG. 19;

(24) FIG. 24 is a front perspective view of the pivot component of FIG. 23;

(25) FIG. 25 is a rear view of the panel clip of FIG. 19;

(26) FIG. 26 is a rear view of the panel clip of FIG. 25 wherein the latch component has moved to the right in the Figure;

(27) FIG. 27 is a top view of the panel clip of FIGS. 25 and 26 in the open position;

(28) FIG. 28 is a fragmentary perspective view of the panel clip in a closed position;

(29) FIG. 29 is a second fragmentary view of the panel clip of FIG. 28;

(30) FIG. 30 is a front schematic view illustrating installation of a side panel according to an illustrative embodiment; and

(31) FIG. 31 is a front schematic view illustrating the side panel of FIG. 30 in the installed position.

DETAILED DESCRIPTION

(32) FIG. 1 illustrates a portable spa 11 having a spa shell 13, side panels, e.g., 15, 17 and tapered corner fascia pieces, e.g., 19, 21, 23. The spa shell 13 has a generally rectangular rim 12 about its upper periphery and includes various features such as jets, e.g. 25, 27, a filter compartment 29 and a remote control 31. As may be seen, the lower edges 33 of the side panels 15, 17 do not extend to the bottom edges 35 of the corner pieces 19, 21, 23 but rather terminate at a distance d (FIG. 2) above the slab, deck, ground or other surface 30 on which the spa rests, such distance d being, for example, 6 inches in one embodiment. In the illustrative embodiment, the corner pieces, e.g., 19, 21, 23, are slightly spaced above, and do not contact, the surface 30. Additionally, as shown in FIGS. 30 and 31, the side panels 15, 17 are trapezoidal in shape in one illustrative embodiment.

(33) The spa 11 further includes a base pan 39 shown in FIGS. 2, 4, and 5. As may be seen, the lower peripheral side surfaces 37 of the base pan 39 are recessed inwardly or swept back from the side panel edges 33 to provide a pedestal effect, giving the appearance that the spa 11 contacts the floor 35 only at its four corners and at the recessed edge 36 of the base pan 39. The spa base pan 39 itself has four corners 40, each of which lies within and is concealed by a respective corner fascia piece, e.g. 19, 21, 23. As seen in FIG. 4, the bottom of the base pan 39 further includes a grid work of rectangular areas 41 which include recessed fins or thermal separators 43. The grid work is defined by perpendicularly disposed ribs 45, 47, whose flat bottom surfaces also rest on the surface 30. The rib and thermal separator structure on the bottom of the base pan 39 minimizes the surface area of the base pan 39 which is in contact with the surface 30 and, hence, reduces heat transfer from the spa 11 to the surface 30. In one embodiment, a wavelike shape is imparted to the ribs, assisting in the minimizing the contact area.

(34) As shown in FIGS. 2 and 3, in order to support the spa shell 13, vertical support members 51 are provided to which are attached angled force transfer members 53, for example, by gluing, snap-fitting, or other fastening mechanism. FIG. 6 particularly shows the interfitting relationship of the base pan side surface 37 and the force transfer members 53 according to an illustrative embodiment. As may be seen, the side surface 37 has an inner horizontally disposed top step 42 and a horizontally disposed lower step 44. The angled force transfer member 53 includes a stepped edge 46 shaped to mate with the step 42. The stepped edge 46 forms into an angled surface 48, which rests on the swept back surface 37. The angled surface 48 continues into a second step 43, which mates with the lower step 44. A slot or channel 50 is further formed in the base pan 39 and snugly receives a foot portion 34 of the angled force transfer member 53. Mating surfaces of the base pan surface 37 and the force transfer member 53 may be glued, snap-fitted, or otherwise fastened together in position in various embodiments.

(35) In one embodiment, the vertical support member 51 and the angled force transfer member 53 may be fabricated of extruded ABS plastic and injection molded ABS plastic, respectively. The base pan 39 may be a thermoformed ABS plastic sheet. Other materials and fabrication techniques may of course be used in other embodiments.

(36) In one embodiment, the force transfer member 53 may be a two piece component comprising respective halves 131,133, as shown in FIGS. 7 to 15. The halves 131, 133, are mated together utilizing two tabs 141, 143, formed on the first half 131 and two tabs 150, 151 formed on the second half 133. These tabs 141, 143; 150, 151 may be seen in FIGS. 11 and 10, respectively.

(37) As further shown in FIG. 10, the interior 137 of the first half 131 may have height markers, e.g. 29, 33, 36, 38 molded or formed therein or applied thereto and located adjacent respective slots 139a, 139b, 139c, and 139d to indicate the particular spa rim height which can be accommodated by utilizing a particular slot. In operation, the two tabs 150, 151 on half 133 (e.g. FIG. 10) slide into one of the four groove pairs 135a, 134a; 135b, 134b; 135c, 134c; 135d, 134d, of the respective outer side surfaces of the first half 131 to select a particular height, while the tabs 141, 143 enter into a pair of holes or apertures 147, 149 (FIG. 9) of the second half 133. Thus, the first half 131 can be telescoped between positions -38-, -36-, -33-, -28- to increase or decrease the length of the angled force transfer member 53 and can be locked in position by the tabs 150, 151, as further described below.

(38) The manner in which the first and second halves 131, 133 are attached together is further illustrated in FIG. 7. As may be seen, the tab 150 is riding in the second groove 135c. The tab 151 is also riding in a generally parallel groove 134c on the opposite side of the first half 131. At the same time, the tabs 141, 143 of the first half are passing through grooves 139b, 140b (FIG. 10) of the second half 133, thereby selecting the height of -33- inches. When the tabs 150, 151, reach the end of the respective grooves 135c, 134c, they snap down over the side surface 136 of the component 131, e.g., as shown in FIG. 12, to hold the respective halves 131, 133 together. At the same time, the tabs 141, 143 enter a pair of the slots 147, 149, as illustrated in FIG. 12, to further hold the assembly together. It may be noted that FIGS. 12 and 13 illustrate the -28- inch assembly position, whereas the assembly shown in FIG. 7 would result in tabs 150, 151 being positioned one groove up (135c, 134c) and the tabs 141, 143 being positioned one slot down from the positions shown in FIGS. 12 and 13.

(39) As shown in FIGS. 10 and 11, for example, the first half 131 has a tongue 171 and a cavity 174 formed in its interior, and the second half 133 has a cavity 172 and a tongue 173 formed in its interior. When the first and second halves 131, 133 are mated together, the tongue 171 on the interior of the first half 131 fits into the cavity 172 in the second half 133, while the tongue 173 of the second half 133 fits into the cavity 174 formed in the first half 131. The first half 131 further has an open or cut-out area 162 of rectangular cross-section formed therein (FIG. 7). In one embodiment, the area 162 has a shape identical to that of area 161 (FIG. 9). Additional open or hollow areas, e.g., 164 and area 165 (FIG. 8), are formed in the components 131, 133 to capture foam sprayed into the interior of the spa shell to thereby create a rigid foam/plastic structure.

(40) As shown in FIG. 8, the illustrative angle force transfer member 53 has an upper receptacle of generally rectangular cross-section formed as a part thereof having a rectangular rim 47 and a hollow interior 143. First and second u-shaped projections 201, 202 are formed in the hollow interior 143. In one embodiment, the lower end of a vertical support member 51 is configured to snugly mate or snap fit with the structure of the receptacle 141.

(41) The illustrative embodiment is further constructed such that each side panel 33 may be slid into position and retained in place without abutting or being attached to the corner pieces 19, 21, 23 or other spa structure. For this purpose, corner piece groove structures 65 are provided as shown in FIGS. 16 and 17, and three panel clips 69 are positioned along a lower surface 72 of the base pan 39, as shown in FIG. 18. While three panel clips 69 are shown in FIG. 18, the number of clips could be one, two, or more in various embodiments.

(42) FIG. 16 illustrates attachment of one of the tapered corner pieces 19 to respective vertical support members 51 using a number of U-shaped brackets 105. A first leg of each bracket 105 attaches to the support member 51 and a second leg attaches to the corner piece 19. The length L of the first leg of each bracket 105 increases as the edge 107 of the corner piece 19 tapers away downwardly. In one embodiment, the angle (FIG. 17) between the corner piece's tapered edge 107 and the vertical is an acute angle, for example, such as six or seven degrees. The increasing bracket length effectively defines a gap or groove 65 between the brackets 105 and the corner piece 19 which lies along the dashed line 109, effectively paralleling the tapered outside edge 107. In the illustrative embodiment, the same type of groove 65 is formed by U-shaped brackets 105 associated with each of the other three corner pieces, e.g., 21, 23.

(43) The structure and operation of the panel clips 69 is further illustrated in FIGS. 19-27. Each panel clip 69 includes a pivot component 73 (FIGS. 23, 24) and a latch component 75 (FIGS. 21, 22). The latch component 75 has a hook-shaped back 79, which is unitarily formed with a front portion 80 having first and second lips 81, 83, whose inner surfaces define a channel 85. The hook-shaped back 79 includes a slot 87 and an elongated opening 89.

(44) As shown in FIGS. 23 and 24, the pivot component 73 has an arcuate back surface 78 from which project two bosses 120 through which are formed respective holes 77. As illustrated in FIGS. 28 and 29, respective screws or other fasteners 82 are inserted through the holes and into a side surface 72 of the molded base pan 39. The bosses 120 cause the arcuate back surface 78 to be spaced apart from the side surface 72 such that the latch component 75 can slide with respect to the pivot component 73. Thereafter, the latch component 75 may be pivoted from the open position shown in FIG. 19 to the locked position shown in FIGS. 20, 28, and 29 in which the channel 85 is oriented vertically so as to retain and prevent downward movement of the bottom edge of a panel 33 while allowing the panel 33 to move laterally.

(45) FIGS. 25-27 illustrate the operation of the panel clips 69 in more detail. FIG. 25 is a back view of the clip 69 in the locked position of, e.g., FIGS. 20 and 28. In this position, the right boss 120 of the pivot component 73 extends through the opening 89, and the left boss 120 extends through the slot 87. Hence, the latch component 75 cannot pivot due to the abutment of the bosses 120 with the respective adjacent surfaces of the opening 89 and the slot 87. In this position, in an illustrative embodiment, the screws 82 have further been tightened down to hold the components 73, 75 in the locked position.

(46) FIG. 26 is also a back view of the clip 69, but in this case, the screws 82 have been unloosened slightly, and the latch component 75 has been moved to the right such that the left boss 120 has moved out of the slot 87, and the right boss 120 has moved into position over a cut-out area 123 formed in the latch component 75. In such position, the latch component 75 is free to pivot with respect to the pivot component 73.

(47) FIG. 27 is a top view of the clip 69 after the latch component 75 has been pivoted to the unlocked position of FIG. 19. In this position, the right boss 120 has pivoted into the cut out area 123 of the latch component 75, and the left boss 120 lies adjacent an outer leg 124 of the latch component 75.

(48) The structure thus far described facilitates a side panel mounting method illustrated in FIGS. 30 and 31. As shown in FIG. 30, the spa 11 is positioned or raised off the mounting surface 30. A trapezoidal side panel 33 is then inserted upwardly such that its upper corners and its sides slide into the grooves 65 defined by brackets 105 and the corner pieces 19, 21. The panel 33 is then slid further upwardly until its top edge 102 passes behind the rim 12. At that point, the panel clips 69 are each moved into the locked position shown in FIGS. 20, 28, and 29 and the screws 82 are tightened to locking position.

(49) The just-described side panel mounting method has the advantage that the side panels 33 are not rigidly attached to the corner pieces e.g. 15, 17, 19 or other structure, and therefore the panels 33 may expand and contract with temperature variations without the exertion of forces which would distort or otherwise damage the panels 33 if they were not free to expand or contract vertically or horizontally. This method has particular advantages in certain embodiments where the corner pieces, e.g., 17, are made of plastic and the side panels 33 are constructed of wood or of a plastic which has a coefficient of expansion which is different than that of the corner piece plastic. In such embodiments, the side panels 33 may expand or contract as much as half-inch in very hot or cold conditions, which would likely damage the spa structure, for example, by warping or cracking the panels 33.

(50) Those skilled in the art will appreciate that various adaptations and modifications of the just described preferred embodiment can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein.