Spa cover

Abstract

A cover for a spa is disclosed which is made of a foam core with a geotextile layer and a polyurea layer. The cover is sufficiently strong to prevent individuals or animals from falling into the spa yet light enough to allow for easy removal. The cover also provides a great amount of insulation for the water in the spa order to maximize the efficiency of the spa's heating system.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of the filing date of U.S. Provisional Patent Application No. 60/783,926 filed Mar. 20, 2006, the disclosure of which is hereby incorporated herein by reference.

BACKGROUND OF THE INVENTION

Outdoor hot tubs, also commonly referred to as spas, have become increasingly popular with homeowners and vacationers in recent years. The term “spa” typically refers to large tubs or small pools that are filled with water and heated. Spas typically include a heating element which maintains the water in the spa at a user-desired temperature. They may be located outdoors and include forceful jets of water. Spas are typically made of acrylic or acrylic-reinforced plastics in shapes that allow a plurality of individuals to be seated within the spa. The heated water of the spa and the jets that propel and circulate the water within the spa have been touted as useful for relaxation, hydro therapy, and meditation.

Because a typical spa is heated and located outdoors, it is necessary to cover the spa when it is not in use. A spa cover serves to prevent rain and debris, such as falling leaves, from entering the spa. The cover should also insulate the spa because effective insulation of the heated water greatly improves the energy efficiency of the spa.

Typical spa covers generally include a foam core surrounded by a vinyl sheet goods or wrap. The foam core may be broken into more than one section so that the cover may be folded for removal. A typical problem with covers of this type is the amount of effort required to remove the cover from the spa.

Another significant problem with foam covers is that the vinyl wrap is easily torn. This often leads to water seeping into the cover and occasionally even soaking into the foam, rendering the cover extremely heavy and difficult to handle. Further, the interior of the covers often collect moisture or water resulting from steam which rises from the surface of the spa water. Thus, in many instances the cover becomes sufficiently heavy that the user needs to employ a mechanical device, such as a lift, to remove the cover from the spa. This cumbersome process inhibits the ability of the user to easily remove the cover of the spa and conveniently enjoy the spa.

Other typical spa covers include clear plastic covers that have air pockets in them. These clear covers serve to allow sunlight to penetrate the cover in order to heat the water in the spa. Although these covers are easily removable, they do not provide enough insulation to the spa and thus they require the spa to use excess energy to maintain the temperature of the water.

In addition to the drawbacks described above, many of the existing spa covers have serious safety concerns. For example, if a child is walking along a deck and steps on a covered spa the spa cover may not be rigid enough to support the child and the child may fall into the spa, and in some cases, become entrapped with the spa cover. Wandering wildlife such as deer or family pets have also been known to fall into covered spas.

Thus, there exists a need for a spa cover which may be added to the spa and removed from the spa with sufficient ease, to insulate the spa to prevent heat loss, to prevent debris from falling into the spa and safely protect the spa from safety hazards. In addition, the cover is a necessary safety feature for children and animals.

SUMMARY OF THE INVENTION

The present invention addresses these needs by providing a spa cover with a foam core and a superior coating which is durable and light in weight. The coating prevents the foam from taking and retaining any additional moisture from the environment. This characteristic allows the spa cover to maintain substantially its original weight throughout the cover's lifetime.

The present invention is directed to a spa cover that has a foam core which provides insulation for the heated water contained in the spa. The spa cover preferably has a polymer, e.g., neoprene layer to protect the foam core and add extra insulation. The neoprene layer preferably extends over the entire top surface of the spa cover and extends over the sides of the spa cover as well. A protective polymer coating is then sprayed over the entire surface of the spa cover, including the neoprene layer and the foam core. The protective coating creates a weatherproof and lasting maintainable surface.

In one embodiment, the invention comprises a spa cover comprising a core having a top surface and a bottom surface, a layer of material applied to the top surface of the core, and a substantially water impermeable coating provided over the layer of material and encapsulating the core.

In another embodiment, the present invention comprises a method of making a spa cover for a spa having a predetermined size and shape comprising providing a foam core having top and bottom surface, said core configured to accommodate the size and shape of said spa; providing a flexible material over the top surface of the foam core; and providing a substantially water impermeable coating over the flexible material and the block.

In still another embodiment, a spa cover, includes a body comprising, a rigid foam center, a woven layer of polymer material substantially encasing the center, and a polymer layer substantially encasing the woven layer.

Further, in an embodiment of the present invention, a spa cover includes a body comprising, a rigid foam center, a layer substantially encasing the center, and a polyurea layer substantially encasing the layer.

Lastly, another embodiment of the present invention includes a spa cover having: a body comprising, a rigid foam center having a top, a bottom and two sides, a first woven layer of polymer material substantially covering the top and two sides, a flexible flange formed along an edge of the body for reliably coupling the body to a spa, and a polymer layer substantially encasing the first woven layer and the bottom of the foam center.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of a portion of a spa cover according to one embodiment of the present invention.

FIG. 2 is a cross-sectional view of a spa cover according to an embodiment of the invention.

FIG. 3 is a perspective view of one segment of a segmented spa cover according to one embodiment of the present invention.

FIG. 4 is a perspective cutout view of the spa cover according to an embodiment of the invention.

FIG. 5 is a perspective view of a segmented spa cover according to an embodiment of the present invention.

FIG. 6 is a cross-sectional view of another embodiment of a spa cover as placed on a spa according to the present invention.

FIG. 7 is a side view of a coping type spa cover according to an embodiment of the invention.

FIG. 8 is a cross-sectional view of another embodiment of a spa cover according to the present invention.

FIG. 9 is a side view of a coping type spa cover according to an embodiment of the present invention.

FIG. 10 is a larger cross-sectional view of the spa cover depicted in FIG. 8.

FIG. 11 is a cross sectional view of a floating type spa cover according to yet another embodiment of the present invention.

FIG. 12 is a cross-sectional view of a spa cover which comprises more than one segment according to one embodiment of the present invention.

FIG. 13 is a cross-sectional view of a segmented spa cover according to one embodiment of the present invention.

FIG. 14 is a cross-sectional view of another embodiment of a spa cover according to the present invention.

FIG. 15 is a cross sectional view of another embodiment of the spa cover.

FIG. 16 is a side view of a fastening system according to an embodiment of the present invention.

DETAILED DESCRIPTION

The present invention relates to embodiments of a cover for a spa or pool. In this regard, the cover is also adaptable to unheated spas or pools, artificial ponds and the like. It is also contemplated that the cover is suitable for use on decks or other surfaces that encompass in ground or above ground pools and spas. The cover preferably has a foam core to provide insulation to the spa. The foam core is preferably cut to the size of the spa with a slight flange around the outer edge of the cover for accepting the wall or edge of the spa. The flange may also have anchors or straps to enable the spa cover to be secured to the spa and/or surrounding deck. The foam may be any type of foam known in the art but is preferably a lightweight foam such as, for example an Expanded Polystyrene Foam (EPS). The foam core may contain reinforcing elements, such as rods, tubes, or beams, which add support to the foam core and prevent the foam core from breaking under additional loads such as for example, heavy snows or animals walking on the cover.

The top and sides of the foam core are preferably covered with at least one layer of material such as a geotextile material, neoprene or other polymers. The geotextile or neoprene creates a shock absorbing substrate beneath the finished coat. In addition, it provides a smooth sprayable substrate for the outer finish coat. In alternative embodiments, the material layer may be made of a fabric or a synthetic material. The cover is then coated with a protective coating, such as a plastic or polymer coating such as polyurea to render the cover impervious to water or moisture infiltration. The cover is preferably light enough to pull on and off the spa with relative ease.

A pure polyurea coating/elastomer is that derived from the reaction product of an isocyanate component and a synthetic resin blend component. The isocyanate can be aromatic or aliphatic in nature. It can be monomer, polymer, or any variant reaction of isocyanates, quasi-prepolymer or a prepolymer. The prepolymer, or quasi-prepolymer, can be made of an amine-terminated polymer resin, or a hydroxyl-terminated polymer resin.

Polyurea sets and hardens very rapidly, reducing or elimating long waits for the coating to set. This also makes the coating easy to work with as the coating does not run. It is very resistant to ultraviolet radiation, which is advantageous for spa covers as they will be exposed to a great deal of sunlight and ultraviolet radiation. It exhibits a high degree of moisture resistance and is one of the toughest polymers available. The polyurea requires that it be applied under high pressure and high temperatures. Thus, it is a material with a spray type application.

One embodiment of the present invention will now be described with reference to FIG. 1, which depicts a cross-sectional view of a spa cover 10 as placed on top of a spa 70. The spa cover 10 preferably comprises a foam core 20. The foam core 20 is preferably made of expanded polystyrene having a typical density between 1.25 and 4.00 pounds per cubic foot or more. Preferably, the density will be about 1.5 pounds per cubic foot. The foam may also be made of other suitable polymers such as polyethylene, polypropylene, or polyurethane. The foam core 20 is cut or molded to the specific size and shape of the spa 70, and shaped around its edge to rest on the upper edge 72 of the spa. Although customizable, the spa cover 10 may also be fabricated for standard size spas.

A first layer 30 of polymer material such as neoprene or geotextile is adhered over the top surface and sides of the foam core 20. By way of example, the first layer 30 has a thickness of between about 10-20 mils, and is adhered using a suitable adhesive such as a contact adhesive. The first layer 30 provides a sprayable surface having a soft cushion-like feel after the final exterior coating is applied. The first layer 30 is somewhat moldable, at least so that it can be wrapped around the corners and other details of the core 20. A second layer 40 of, preferably, also a geotextile or neoprene may be adhered to the top of the spa cover 10, as well as the sides of the spa cover 10 forming a skirt or flange 73 as depicted in FIG. 1. The skirt 73 and the second layer 40 may also be adhesively bonded to the underlying first layer 30. By way of example, the skirt 73 and second layer 40 may have a thickness of about ¼ inch or less. The thickness may also vary therefrom, if so desired. The skirt 73 may be made from other materials such as vinyl or other more flexible or light weight materials. The skirt 73, as a separate strip, substantially or entirely encircles the perimeter of the core 20.

Geotextiles are permeable fabrics. Modern geotextiles are usually made from a synthetic polymer such as polypropylene, polyester, polyethylenes and polyamides. Geotextiles can be woven, knitted or non-woven. As the use of geotextile fabrics has expanded there has been the introduction of geotextile composites and the development of products such as geogrids and meshes. These materials may be referred to as geosynthetics and each configuration—geonets, geogrids and others—can yield certain benefits in geotechnical and environmental engineering design. (The terms geotextile and geosynthetic as used herein are interchangeable). Types of geotextiles include: geomembranes and geogrids. Geomembranes are impermeable membranes used widely as cut-offs and liners. Geomembranes are made of various materials including Low-Density Polyethylene (LDPE), High-Density Polyethylene (HDPE), Polyvinyl Chloride (PVC) and polypropylene (PP). Another type of geomembrane is bituminous geomembrane, which is a layered product of glass and bitumem-impregnated non-woven geotextile. Each type of geomembrane material has different characteristics which affect installation procedures, lifespan and performance. For example, PVC geomembranes are very flexible and as a result can conform to uneven surfaces without being punctured. Polypropylene is susceptible to UV radiation and should not be used in where it will be exposed to sunlight or it will become brittle.

Geogrids are meshes typically made of a regular pattern of tensile elements usually made of a fairly rigid type of plastic. These are used to strengthen fill materials in geotechnical applications. They provide increased shear strength at soil strata interfaces. Their tensile strength can prevent or decrease the degree of differential settlement in by transmitting load over a larger area, diminishing the vertical stress—and subsequent compression—in the soil.

Because the foam has imperfections, it is not preferred to spray any water impervious coatings directly on the foam. Furthermore, it is not desired to apply the coating directly on the foam because the coating is preferably applied under using high temperatures. Under such high temperatures, when the coating contacts a much cooler foam, there are undesired reacations, generally related to the natural moisture present in the foam. These undesirable reactions cause bubbles and uneven distribution of the coating. Thus, it is preferable to provide a substrate on the foam to apply the coating to. Providing a layer of a geotextile, usually by attaching the geotextile with an adhesive, provides a strong, smooth surface or substrate for spraying a coating. The geotextile provides excellent strength and additional rigidity to the cover. The geotextile is also capable for being used to form the scrim, skirt or flange for the cover.

Although various types of geotextiles or geosynthetics may be used, TERETEX HBG 16 (TM) is preferred in an embodiment of the present invention. This material may be purchased from BP Amoco.

The second layer 40 may be omitted as desired or, alternately, layers in addition to the first and second layers may be utilized. Although the second layer 40 is shown adjacent portions of the first layer, the second layer 40 may be disposed adjacent the entire surface of the first layer 30, as desired. Further, the second layer 40 may disposed toward the center of the spa cover 10 to facilitate run off of precipitation.

The first layer 30, the second layer 40 and skirt 73 may be coated with a flexible but rigid material to form a monolithic outer coating 60. The solid outer coating 60 preferably adheres to the first and second layers 30 and 40, respectively, and to a bottom surface 22 of the foam core 20 to form a continuous monolithic water-impervious barrier completely encasing the spa cover 10.

A rubber or polymer cap 50 may be added to a bottom edge 24 of the spa cover 10 to provide a trim piece or molding. The cap 50 may be in the nature of a U-shaped strip that is adhered along the bottom edge 24 of the skirt 73 using any suitable adhesive or compression. The cap 50 forms a seal between the cover 10 and the sides of the spa 70. The spa cover 10 may also include a flexible rubber or polymer gasket 80 to provide an extra seal between the water in the spa 70 and the outside environment. The flexible rubber gasket 80 is preferably located on an underside of the spa cover 10 where the spa cover 10 will rest on a ledge 74 of the spa 70.

The first and second layers 30, 40, respectively, serve to support and protect the foam core 20. The first and second layers 30 and 40, are preferably made of a geotextile or neoprene foam with a density of 4 to 6 pounds per cubic foot. Alternatively, the first and second layers 30 and 40 may be formed of a cross link or non-cross link polyethylene. In yet other embodiments, the first and second layers 30 and 40 may be made of polyester, urethane foam, or sponge rubber. These materials will also provide additional insulation to the water in the spa.

The outer coating 60 is preferably made of an aliphatic polyurea. In alternative embodiments, the outer coating 60 may be made of aromatic polyurea, hypolon, PVC, polyethylene, plastic, polyurethane, or any other rigid material as known in the art.

The outer coating 60 may be applied by spray coat techniques. However, the outer coating 60 may be provided as a polymer sheet that is heated and vacuum formed or wrapped around the entire core 20. Alternately, the outer coating 60 may be vacuum formed over the underside of the core 20, while the remainder of the core 20 is spray coated. Thus, various techniques may be used.

The purpose of the outer coating 60 is to protect the spa cover 10 and to provide rigidity to the spa cover 10 which allows the spa cover 10 to be easily pulled on and off of the top of the spa 70. The outer coating 60 also protects the spa 70 from water and other debris which may fall onto the top of the spa cover 10. Further, the outer coating 60 prevents water from being absorbed into the foam core 20 of the spa cover 10. This prevents the spa cover 10 from taking on extra weight and prevents mold from growing within the spa cover 10 or developing odors.

Although, the above-mentioned materials are discussed in connection with one embodiment of the invention, one skilled in the art would recognize that the various materials mentioned throughout the application may be used for any of the embodiments discussed in any combination. The various materials and substances discussed in each embodiment may be used for similar layers in any of the other embodiments. For example, the various materials mentioned for the outer coating 60 in the above embodiment may be used for the protective coating in any of the examples mentioned herein.

The shape of the spa cover 10 is preferably convex on an upper surface 12 of the spa cover 10. This convex upper surface 12 allows precipitation such as rain or snow, to easily run off the spa cover 10. The spa cover 10 is preferably thick enough to allow sufficient insulation for the spa 70 and provide sufficient rigidity to allow a large person or animal to stand on top of the spa cover 10. The foam core 20 may be a solid foam that is cut from a block or may be a spray foam that is sprayed into a mold configured in the shape of the spa cover 10.

If desired, a spa cover 10 may be divided into segments which are joined by a hinge. This arrangement is advantageous where a spa exceeds a predetermined size and a one-piece cover would be unwieldy. A segmented cover may fold over on itself for easy removal from a spa. FIGS. 2 and 3 depict a cross-sectional and a perspective view of a detached first segment 14 of a spa cover 10 that has been segmented. The first segment 14 preferably has a continuous rubber seal or gasket 80, such as a refrigerator gasket, that is adhered to a sidewall 82 of the first segment 14 to provide a seal between this first segment 14 and another segment 15. The other segment 15 may be attached to this first segment 14 with a hinge (not shown). In alternative embodiments, the rubber seal 80 may be replaced with a gasket, foam strip, or any other flexible mechanism for forming a seal.

The segments may also be coupled using a buckle 16, as shown in FIG. 2. The buckle 16 may be any type of buckle as desired. For example, a strap buckle, or a side release buckle may be used. Further, the buckle 16 may contain a key way for accommodating a key. This ensures that the buckle is locked and cannot be opened without a key. This is advantageous for keeping children from releasing the buckle 16 and accessing the spa 70 through one of the segments. The buckle 16 may be made of any suitable material as desired. There may be as many buckles disposed on the cover 10 as desired, depending on the length of the cover 10. For example, the buckles may be as disclosed in U.S. Pat. Nos. 5,263,234; 6,463,640; or 6,704,977, which are hereby incorporated by reference.

The first segment 14 depicted in FIGS. 2 and 3, also has supporting structures in the form of reinforcing angled beams 90 contained within the foam core 20. The supporting structures 90 provide rigidity to the spa cover 10 to prevent it from bending or breaking. The supporting structures 90 are preferably made of aluminum because of aluminum's high strength-to-weight ratio, but the supporting structures 90 may be made of any other suitable material as known in the art, such as wood or plastic. In alternative embodiments, the foam core 20 may contain pipes, slats, I beams, or other supporting members to provide rigidity to the spa cover 10.

As shown in FIG. 2, the supporting structures 90 may be circular hollow rods or tubes 92. The tubes 92 may be aluminum, for example, or a similar material, such as a bicycle grade aluminum. Such material is preferably, hard, rigid and can be easily bent or bowed. Preferably, the tubes 92 are lightweight, resist rust or corrosion and may be encased or coated with a resin. Preferably, the tubes 92 are arched. The arch provides greater structural integrity and allows the tubes 92 to accommodate more weight than otherwise possible. Further, the arch in the tubes 92 will provide the spa cover 10 with a corresponding arch that will facilitate easy run-off of precipitation, such as rain. It may also be desired to bend or bow the tubes 92 adjacent the center of the cover 10 and leave tubes 92 flat or straight adjacent the edges. Thus, each segment may be configured separately and any combination may be utilized.

These tubes 92 may then be filled with a reinforcing element 94. The reinforcing element 94 may be a type of foam or the like that will lend additional rigidity and strength to the tubes 92. Further, it is preferable that the reinforcing element 94 is pourable or easily delivered and distributed throughout the tubes 92. For example, a high density polyurethane foam, or the like may be used. It may be poured through the tubes 92 and set, to reinforce the tubes 92. That the reinforcing element 94 is pourable is beneficial because the tubes 92 may be bowed.

Once the foam core 20 has set, a hole is bored into it to accommodate the supporting structures 90. Then, the particular supporting structure is slid into the hole and left there. The supporting structures 90 may have any shape or contour as desired. For example, the tubes 92 may be bowed or arched. Then the tubes may be inserted into the hole in the foam core 20. A contour in the tubes 92 translates into a contour in the core 20 and thus the cover 10. The foam core 20 will expand around and fit the tubes 92. Thus the foam core 20 will conform to any shape provided by the supporting structures 90. Further, no molds or other tedious techniques are required to shape the foam core 20. First and second layers 30, 40 may then be disposed on the core 20 once the supporting structures 90 are in place.

FIG. 5 depicts a segmented spa cover 500 as disposed on top of a spa 560. The spa cover 500 comprises a first segment 510 and a second segment 520. The two segments are joined together by at least one hinge 540. The hinge 540 may be a conventional hinge or a flexible strap of material such as a nylon strap or a geotextile fabric. The hinge 540 is shown as attached to the segments, 510 and 520, with an additional layer 550 of a protective coating used as a flexible waterproof adhesive and coating which bonds the hinge 540 to the segments 510, 520. The hinge 540 allows a user to lift one segment 510 or 520, of the spa cover 500 and fold it over the other segment, 520 or 510, of the spa cover 500 while the other segment remains stationary on the spa.

The hinge 540 may be joined to the segments 510 or 520, using any fasteners known in the art, such as screws, nails, or pegs. The hinge 540 may also be affixed to the segments 510 or 520 using an adhesive.

Although the spa cover 500 depicted in FIG. 5 is shown as attached with a hinge 540, other embodiments may have any number of hinge combinations, such as one continuous hinge covering a large portion of the spa cover 500 or a plurality of smaller hinges. In an alternative embodiment, the hinge 540 may be replaced by a zipper which releasably attaches the two segments 510, 520 together during use.

In yet other alternative embodiments, the spa cover segments 510 and 520, may not be joined at all, and may simply be added to the spa and taken off the spa in independent segments that may be releasably coupled using buckles as previously discussed. In these embodiments, the spa cover segments 510 and 520, may be joined together by a latch, clasp, zipper or other device as known in the art, to prevent the segments from separating while disposed on top of the spa 560. These embodiments may be particularly useful in situations where the spa 560 is excessively large and a single cover, even in segments, is difficult to handle.

FIG. 6 depicts another segment of a spa cover 10 adapted to mate with the spa cover 10 segment depicted in FIG. 3. The spa cover 10 has a foam core 20 that includes supporting structures 90 within the foam core 20. The spa cover 10 has a protective outer coating 60 over the entire surface of the spa cover 10. The first layer 30 is shown as wrapped over the top of the foam core 20. Additional layers, such as the second layer 40 are disposed on top of the spa cover 10 and on the sides of the spa cover 10 forming the skirt 73. The rubber cap 50 is shown on the sides of the spa cover 10. The rubber seal or gasket 80 is depicted underneath the spa cover 10 where the spa cover 10 will rest on the spa 70. The segment depicted in FIG. 6 has a second sidewall 83 which is adapted to abut the sidewall 82 of the segment depicted in FIG. 3. The segment depicted in FIG. 5 will abut the gasket 80 depicted in FIG. 3 at the location 80′ on the second sidewall 83 of the segment.

FIGS. 7 and 8 depict an alternate embodiment of a spa cover 100 according to the present invention as installed on a spa housed within a patio or concrete deck 160. This type of configuration is referred to as a coping type system. The spa cover 100 preferably has a foam core 110 which is surrounded by upper and lower layers 120, 130 respectively, preferably of a geotextile or neoprene. A bottom layer 140 of the cover 110 extends outwardly to form a skirt 142 encircling the core 110. Optionally, a reinforcement 143 such as a tape or scrim may be adhered between the juncture or connecting point of the upper and lower layers 120, 130.

The skirt 142 may be formed of regular marine grade vinyl or be reinforced with it. Additionally, the skirt 142 may be formed of a geotextile material or be a formed of a combination of the geotextile material and the vinyl. Any of a variety of combinations is imagined.

The bottom layer 140 is similar to outer coating 60 as previously described. An end 102 of the spa cover 100 may include a rubber cap 150, similar to cap 50, as previously described. The skirt 142 of the spa cover 100 preferably rests horizontally on the deck or concrete patio 160. A rubber gasket 180 may be attached to the spa cover 100 to provide a further seal between the outside environment and the water 170 within the spa. FIGS. 9 and 10 depict a larger view of a modified spa cover as depicted in FIGS. 7 and 8. In FIG. 10 an optional second layer 190 also preferably of a geotextile or neoprene, is shown disposed over the upper layer 120.

The bottom layer 140 is also shown disposed directly on the foam core 110 on an underside of the spa cover 100 in FIG. 10. In the embodiment shown in FIG. 10, the lower layer 130 which forms the skirt 142 does not extend over the entire bottom surface 112 of the foam core 110. In alternative embodiments, it may be desirable to completely encase the foam core 110 in a geotextile or neoprene.

The spa covers discussed herein, can also be adapted to float on the surface of the spa water known as a floating type system. FIG. 11 depicts a spa cover 10 configured to float atop water 170 in a spa 70. A floating system may be advantageous where it may be impractical to couple a cover 10 to a deck or patio 160.

The spa cover 10 is identical to a spa cover 10 used in a coping system, except that the foam core 20 may be thicker. The thicker core 20 allows the cover 10 to sit on the surface of the water 170 and be supported by the water 170. In essence, the cover 10 may be seen as being inverted, with the skirt 142 laying atop the deck 160 and the juncture 143 of the first and second layers, 30 and 40, forming on an underside of the skirt 142. FIG. 12 depicts a segmented spa cover 200 which is comprised of a first segment 300 and a second segment 400 joined by a hinge 210. The first segment 300 preferably has a first segment foam core 310. Adjacent the first segment foam core 310 is a first segment first layer 330 that may be made of a geotextile. The first segment 300 may be coated with a coating 320. The first segment coating 320 encapsulates the first segment core 310 and the first segment first layer 330. The first segment foam core 300 also has a first segment sidewall 342.

Similarly, the second segment 400 has a second segment foam core 410 with a second segment first layer 430 and a second segment coating 420. The second segment first layer 430 may be formed of a geotextile while the first and second segment coatings, 320 and 420, may be polyurea. The second segment 400 preferably has a small indentation 440 along second segment sidewall 442 which houses a rubber gasket 220 for insulation of the gap between the sidewalls 442, and 342. The hinge 210 that joins the two segments is preferably a flexible nylon hinge but may also be a series of straps or a flexible fabric. Alternatively, a conventional metal or plastic hinge may be used for this application. The hinge 210 is preferably adhered to the first and second segments, 300 and 400, respectively, by the protective coating 320, 420. Thus, when a segmented spa cover 200 is used to cover a large spa, the segments may fold over onto each other using the flexible hinge.

FIG. 13 depicts a cross-sectional view of another embodiment of two abutting segments 702, 704 of a spa cover 700. The first segment 702 comprises a first foam core 710 with a supporting angle 730 attached thereto. The supporting angle 730 may be formed of aluminum, steel, plastic, or any other supportive material. The supporting angle 730 is preferably adhered to the first foam core 710 using an adhesive or polycoating as known in the art, but may also be affixed with fasteners such as screws. The first supporting angle 730 serves to greatly reinforce the cover system at this point. A first layer of material 715, such as a geotextile or neoprene, is then disposed over the foam core 710 and the supporting angle 730. The exposed surfaces of the first layer 715, the first supporting angle 730, and the first foam core 710 are then coated with a first protective coating 740 such as a polyurea coating as discussed above.

The second segment 704 depicted in FIG. 13 is assembled in a similar manner. The segment 704 comprises a second foam core 720, a second supporting angle 735, and a second layer of material 725 such as a geotextile or neoprene. The entire second segment 704 is also coated with a second protective coating 745. The second segment 704 further comprises a rubber gasket 750 which is attached to the second segment 704 with an adhesive or fasteners. The rubber gasket 750 abuts against the edge of the first segment 702 and serves to provide a gasket-like seal between the first segment 702 and the second segment 704 when the spa cover 700 is in use.

The embodiment of the spa cover 700 depicted in FIG. 13 also has a hinge 760 which attaches the two segments 702, 704. The hinge is preferably attached to the two segments using an extra layer of the protective coating 770 which encases the hinge 760.

FIGS. 14 and 15 depict a cross-sectional view of another embodiment of a spa cover 800 according to an embodiment of the present invention. The spa cover 800 comprises a foam core 810. A first layer of material 820, such as a geotextile or neoprene, is disposed over the foam core 810 and may be adhered to the foam core 810 with an adhesive. A second layer of material 830, which is preferably also a geotextile or neoprene, may be affixed partially over the first layer 820 and forms a skirt 842 which abuts the edge of a spa 860. The second layer 830 may have a flexible cap 840 attached to the end of the second layer 830. The first layer 820 preferably terminates at a flexible molding 870. The flexible molding 870 separates the first layer 820 from a third layer 850 which is disposed over the top of the foam core 810. The flexible molding 870 may have ridges contained in the sides of the molding 870 in order to more securely hold the molding 870 into the spa cover 800, preferably within a notch or groove 872 within the core 810. The molding 870 is preferably adhered to the spa cover 800 with a waterproof adhesive or sealant as known in the art. The third layer 890, which is preferably also a geotextile or neoprene, is covered by a layer of finishing vinyl 880 which enhances the aesthetic appeal of the spa cover 800. The finishing coating 880 may also be of polyurea. The first layer 820 , the second layer 830, and a bottom 812 of the foam core 810 are coated with a protective coating 860 which is preferably a polyurea coating. The bottom 812 of the spa cover 800 may also comprise a rubber gasket 850 which provides a seal between the spa cover 800 and the spa 860.

The spa cover of the embodiments disclosed herein, preferably has a sufficiently high R-value, or thermal resistance, to insulate the heated water inside the spa in a way that prevents the water from losing heat.

In yet another embodiment of the present invention, when the spa cover 100 as shown in FIGS. 7-10 is coupled to a deck 160 or other supportive structure, as illustrated, the flange or skirt 142 may be releasably coupled to the deck 160.

Although any type of fasteners or couplers that are capable of releasably coupling the skirt 142 to the deck 160 are imagined and may be utilized, it is preferable to use a dzus type fastener 900, as illustrated in FIG. 16. A dzus fastener 900, having a head 901 and a stem 903, is configured at its stem 903 to provide a cam type action where it can be releasably coupled or uncoupled with a turn of the head 901.

In the particular configuration shown in FIG. 16, a socket 902 is bored into the deck 160 to accommodate the dzus fastener 900. A tubular insert 904 is inserted into the socket 902. The insert 904 has a rod 906 fixedly attached across its diameter. An opening 908 in the stem 903 is configured in a cam like fashion such that turning the fastener 900 in one direction allows the opening 908 to couple with the rod 904, while turning the fastener 900 in an opposite direction allows the opening 908 to release the rod 904.

A hole (not shown) may be formed in the skirt 142 to permit the fastener 900 through the skirt and into the tubular insert 904. Further, a plate or button 910 may be disposed immediately adjacent the head 901 of the fastener 900 to permit the cam like operation of the fastener 900. This plate 910 provides a spring like motion or movement. The plate 910 provides tension on the fastener 900 as it is coupled to the rod 906 and replaces a spring rod that normally couple to the fastener in conventional dzus fastener systems. Thus, the plate 910 acts a spring and may be flattened when the fastener 900 is turned in either direction. This flattening releases some of the tension between the fastener 900 and the rod 906, allowing the rod 906 to engage or disengage the opening 908. Once engaged, the plate 910 will rise and pull the fastener 900 in an upward direction, causing tension on the rod. There may also be a washer 912 disposed around the stem 903, below the skirt 142 to keep the fastener 900 in place.

An adhesive or epoxy may be utilized in the socket 902 to adhere the tubular insert 904 to the socket 902. Further, the head 901 may be configured with a shaped inset, for example, hexagonal or the like, for accommodating a key. This will ensure that the fastener 900 cannot be released without the key. A screw driver head with a magnetic head to attach to the key to lock and unlock (turn and unturn) the fastener 900 may be provided. This magnetic screw driver may be configured to releasably couple to one end of a pool stick such that a person can reach the fastener 900 from a longer distance.

Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.

Claims

1. A spa cover comprising:

a body comprising, a rigid foam center; a woven layer of polymer material substantially encasing the center; and a polymer layer substantially encasing the woven layer.

2. The spa cover of claim 1, wherein the center comprises a polymer selected from a group consisting of polyethylene, polystyrene, polypropylene, or polyurethane.

3. The spa cover of claim 1, wherein the woven layer comprises TERETEX HBG 16™.

4. The spa cover of claim 1, wherein the polymer layer is selected from a group consisting of an aliphatic polyurea, an aromatic polyurea, hypolon, polyvinyl chloride, polyethylene, or polyurethane.

5. The spa cover of claim 1, wherein the cover comprises a plurality of bodies.

6. The spa cover of claim 5, wherein the bodies are releasably coupled.

7. The spa cover of claim 1, wherein the body further comprises a flexible flange at an external perimeter of the body.

8. The spa cover of claim 1, wherein the flange is configured to releasably couple to a spa.

9. A spa cover comprising:

a body comprising, a rigid foam center; a layer substantially encasing the center; and a polyurea layer substantially encasing the layer.

10. The spa cover of claim 9, wherein the center comprises a polymer selected from a group consisting of polyethylene, polystyrene, polypropylene, or polyurethane.

11. The spa cover of claim 9, wherein the layer comprises a woven layer.

12. The spa cover of claim 11, wherein the woven layer comprises TERETEX HBG 16™.

13. The spa cover of claim 9, wherein the polyurea is an aliphatic polyurea.

14. The spa cover of claim 9, wherein the polyurea is an aromatic polyurea.

15. The spa cover of claim 9, further comprising a plurality of bodies.

16. The spa cover of claim 15, wherein the bodies further comprise a means for releasably coupling the bodies.

17. A spa cover comprising:

a body having an edge comprising, a rigid foam center having a top, a bottom and a plurality of sides; a first woven layer of polymer material substantially covering the top and plurality of sides; a flexible flange formed along the edge of the body adapted for coupling the body to a spa; and a polymer layer substantially encasing the first woven layer and the bottom of the foam center.

18. The spa cover of claim 17, wherein the first woven layer comprises a plurality of woven layers.

19. The spa cover of claim 17, wherein the first woven layer covers the bottom of the center.

20. The spa cover of claim 17, wherein the flange is formed of a second woven layer.