Spa Tub Cover Lifter

Abstract

A spa tub cover lifter includes a first mount which is attached to a spa tub, and a second mount rotatable about a pivot axis on the first mount. A first support is connected to the second mount and is coupled to a first location on a first portion of the spa cover. A connector has a first assembly state in which the connector is movably displaceable relative to a portion of the first support and a second assembly state in which the connector is fixed relative to the portion of the first support. A second support is provided between the connector and a second location of the first spa cover portion. When the first support is rotated about the pivot axis, a lifting force is applied to the first cover portion to lift the first cover portion relative to an upper rim of the spa tub.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims benefit of U.S. Provisional No. 61/928,829, filed Jan. 17, 2014, which is hereby incorporated by reference herein in its entirety.

This application is related to U.S. Ser. No. 13/920,242, filed Jun. 18, 2013, which is a continuation-in-part of U.S. Ser. No. 13/300,774, filed Nov. 21, 2011, and now issued as U.S. Pat. No. 8,468,774, which is a continuation-in-part of U.S. Ser. Nos. 12/958,455 and 12/958,554, which were both filed on Dec. 2, 2010, and now issued as U.S. Pat. Nos. 8,516,626 and 8,516,625, respectively, and all of which are hereby incorporated by reference herein in their entireties.

BACKGROUND OF THE INVENTION

1. Field Of The Invention

This invention relates broadly to spa tubs. More particularly, this invention relates to covers for spa tubs and systems for lifting and replacing a spa tub cover relative to a portable spa tub.

2. State Of The Art

Spa tubs are frequently used for relaxation, physical therapy, personal enjoyment, and for social occasions. One of the appealing attributes of a spa tub is that the tub includes jets that direct warm pressurized water toward an interior portion of the tub. Water that exits the jets and contacts the user's skin can create a massaging effect that is pleasurable, and even rehabilitative.

Spa tubs come in two forms: permanent in-ground installations and ‘portable’ above-ground installations. Portable spa tubs include a frame that supports a molded tub shell, and a cabinet surrounding the frame. The tub shell has an upper boundary rim, a plurality of seating locations defined by seat bottoms and backs and reclining lounges, and a lower floor. At one or more of the seating locations hydrotherapy jets are installed and a suction fitting is provided near the floor. Between the spa shell and the cabinet a space is defined in which plumbing and manifolds are provided to connect the jets, as well as one or more water pumps that circulate the water and a heater that heats the water circulated by the water pumps.

Referring to prior art FIGS. 1 and 2, for purposes of energy efficiency and readiness of use, it is common to provide the spa 10 with an insulative cover 12 that limits heat loss from the water when the spa is not in use. Such a spa cover 12 includes first and second portions 14, 16 of equal size that together are sized to seat on and cover the upper rim 18 of the spa tub shell 20. Each of the first and second portions 14, 16 are constructed of insulative foam slabs provided within a water-resistant vinyl casing material. The second portion 16 is movable relative to the first portion 14 on a living hinge 22 that connects the first and second portions at their opposing inside upper corners 24, 26 so that the first portion 14 can be folded back over the second portion 16 (FIG. 2). The hinge 22 is constructed of the same vinyl material as the casing material. In order to prevent premature wear of the hinge 22 during folding, the hinge is sufficiently wide to prevent it from being subjected to excessive strain. This creates a gap 28 between the first and second portions when the cover is in the closed configuration. ‘Premium’ spa covers may include a spacer 30 to limit heat loss from the gap. However, such a spacer 30 does not entirely prevent heat loss at the gap. The spa cover 12 may also include a skirt 32 that further assists in preventing heat loss from around the perimeter of the spa tub. The skirt 32 also prevents heat damage to the tub shell 20, particularly at or near the rim 18, which can become heat-damaged if exposed to sunlight for long periods of time without protection.

To remove the spa cover 12, the second portion 16 is folded back onto the first portion 14. The first and second portions are then together lifted off the spa 10. Often a cover lifter 34 (FIG. 3) is provided for mechanical advantage to assist a user in lifting the cover and to temporarily hold the cover in a folded generally vertically orientation during spa use. The cover lifter seats on the cover and provides a bar which extends over the hinge and about which the second portion is folded back onto the first portion. The bar is then rotated to lift and support the cover at the hinge.

Once the spa cover 12 is lifted, it is appreciated that the upper surfaces 36, 38 of the first and second cover portions 14, 16, as designated in the flat (or closed) configuration of the cover, are now located in the middle and in contact, whereas the lower surfaces (underside water facing surfaces) 40, 42 are facing outwardly from each other. It is not uncommon for the lower surfaces 40, 42 to become discolored by fading or staining due to long-term placement over the spa tub water. As a result, when the folded cover 12 is raised for use of the spa (prior art FIG. 3), the unsightly discolored lower surface 40 of the first portion 14 faces the users in the tub 10.

Co-owned U.S. Pat. No. 8,468,617 describes a spa tub cover and lifter system that, among providing other advantages, overcomes this issue. The first and second cover portions are coupled together with a lower hinge that seats flush with the rim of the tub when the cover is in a flat (or closed) configuration so that it forms a seal about the rim. When the cover is moved into a folded (or open) configuration, the lower surfaces which face the water when in the closed configuration and can be unsightly, are moved into a position in which they face each other, whereas the upper surface of the second portion faces the users in the tub.

In an embodiment of this lifter, the lifter for the cover includes first and second U-shaped members that couple to at least one mount rotatable on a pivot axis. Where the rotatable mount is attached to the spa, it is positioned just below the spa rim. The first U-shaped member extends through a sleeve at the outer side of the first cover portion which is located adjacent the mount. The second U-shaped member extends from the rotatable mount below the lower surface of the first cover portion, along a lateral side of the cover, and to a top surface of the first cover portion. A handle for applying a lifting force to the lifter is coupled to the second U-shaped member. When the lifting force is applied, both the first and second cover portions lift upward, folding inward about the hinge in the manner discussed.

The upper portion of the spa tub defining the rim can have different heights on different spas. As such, for different spas, the cover which is seated in the closed position on the rim, and the rotatable mount which is located below the rim can be offset at various distances from each other. This then may require a custom installation for a spa cover and lifter that is being installed as an after-market accessory. Such installation may involve cutting the first U-shaped member to a size and shape adapted for the specific tub of the install. A custom installation requires additional labor. In addition, if the customization is performed improperly and needs to be re-done, it can lead to waste, added cost, and customer frustration.

SUMMARY OF THE INVENTION

A spa tub cover lifter for use with a portable spa tub and an insulative spa tub cover are provided. The spa tub includes a frame that supports a molded tub shell, and a cabinet surrounding the frame. The tub shell has a plurality of seating locations defined by seat bottoms and backs and reclining lounges, a lower floor. The spa is provided with the heating and plumbing systems required to heat and circulate water through hydrotherapy jet installed in the tub shell. One embodiment of the spa cover for use with the lifter has first and second cover portions that are coupled together with a lower living hinge, each of the cover portions having an upper surface, a lower surface, first and second lateral sides, an inner hinge side, and an opposite outer side. When the cover is in a flat (or closed) configuration, both the lower surface and hinge seat flush with the rim of the tub, preferably so that a seal is formed about the rim. The cover is adapted to be moved into a folded (or open) configuration in which the lower surfaces of the first and second spa cover portions that face the water when in the closed configuration are moved into a position in which they face each other, whereas the upper surface of the second portion faces the users in the tub.

The lifter includes a fixed mount which is locatable relative to the spa tub, and a rotatable mount rotatable on a pivot axis about the fixed mount. The lifter includes first and second supports. The first support extends from the rotatable mount to a first location on the first cover portion, preferably including the upper surface of the first cover portion. The second support extends from the first support to a second location on the first cover portion, preferably including the outer side of the first cover portion; i.e., opposite the inner hinge side. A connector is provided that is movably disposed relative to the first support during an assembly state. The connector includes a tubular portion and a bracket fixed to the tubular portion. The tubular portion is sized to extend over and move relative to the first support during assembly. This allows the first and second supports to be fixed in a custom relationship depending on a variable distance that may occur between the rotatable mount and outer surface of the first cover portion. In addition, the second support can be fixedly secured to the bracket, and the tubular portion can be fixedly secured to first support, and the structure is intended to operate in this fixed relation during use. This assembly allows a common set of lifter elements to be adapted without the standard costly, time consuming and potentially wasteful customization required for lifters for spa tubs of different dimensions. In addition, the assembly can be adjusted for other spa tubs after install, for example, if the lifter and cover are moved to a different spa tub.

Additional objects and advantages of the invention will become apparent to those skilled in the art upon reference to the detailed description taken in conjunction with the provided figures.

BRIEF DESCRIPTION OF THE DRAWINGS

Prior art FIG. 1 is a perspective view of a spa tub provided with a prior art insulative cover.

Prior art FIG. 2 is a side view of the spa tub and cover of FIG. 1, in which the cover is in a partially open configuration.

Prior art FIG. 3 is a side view of the spa tub and cover of FIG. 1, in which the cover is in a fully open configuration.

FIG. 4 is a partial side elevation of a spa tub and cover with cover lifter according to the invention.

FIG. 5 is a top view of the spa tub cover and lifter of FIG. 4.

FIG. 6 is a perspective view of the spa tub, cover and lifter, with the cover and lifter shown in a partially open configuration.

FIG. 7 is a side elevation view of the spa tub, cover and lifter, with the cover and lifter shown in a fully open configuration.

FIG. 8 is an enlarged broken view of a portion of the spa tub, cover and lifter shown in the configuration of FIG. 7.

FIG. 8A is an alternative clamping attachment for attaching the lifter to the cover.

FIG. 8B is a side perspective view showing the assembled clamping attachment of the lifter to the cover.

FIG. 9 is a side elevation of a spa tub and cover with cover lifter showing a lock configuration in which two adjacent sides of the spa cover are locked down relative to the spa tub.

FIG. 10 is a view similar to FIG. 8 illustrating a preferred stop configuration.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Turning now to FIG. 4-6, a portable spa tub 100 is provided with a spa tub cover 102 and a lifter 104 for raising the tub cover relative to the tub so that the tub may be used. The portable spa tub 100 includes a frame 106 that supports a molded tub shell 108, and a cabinet 110 surrounding the frame. The tub shell 108 has an upper boundary rim 112, a plurality of seating locations 114 defined by seat bottoms and backs and reclining lounges, and a lower floor. At one or more of the seating locations 114 hydrotherapy jets 116 are installed and a suction fitting (not shown) is provided near the floor. Between the spa shell 108 and the cabinet 110 a space 118 is defined in which manifolds and other plumbing 120 are provided to connect the jets 116, as well as one or more water pumps 124 that circulate the water, and a heater 126 that heats the water circulated by the water pumps.

The spa cover 102 includes first and second rectangular portions 130, 132 which together are sized to seat on and cover the upper rim 112 of the spa tub shell 108. The first and second portions 130, 132 are coupled together at a hinge 134, as described in more detail below. Each of the first and second portions 130, 132 is constructed of an insulative slab (e.g., a foam slab that has low transmission of heat energy, especially with respect to water heated to a temperature of between 75° and 110°) provided within an at least water-resistant, and more preferably waterproof, casing material such as vinyl.

The first portion 130 of the spa cover has a first lower surface 136 that faces the water in the spa tub 100 and an opposed first upper surface 138. Lateral sides 140, 142 extend between the first lower and first upper surfaces 136, 138. The lateral sides 140, 142 also extend transverse to the first lower surface 136 in a lengthwise dimension. The first portion 130 also includes an inner side 144 extending transverse to both the first lower surface 136 and the lateral sides 140, 142, as well as an outer side 146 extending parallel to and facing opposite the inner side 144. The inner side 144 extends in a widthwise dimension between the lateral sides 140, 142. A first length L1 is defined as the distance between the inner side 144 and the outer side 146. A first width W1 is defined as the distance between lateral sides 140, 142 along the inner side 144.

The second portion 132 of the cover includes corresponding surfaces to the first portion 130, with a second lower surface 148 that faces the tub water and an opposed second upper surface 150. Lateral sides 152, 154 extend between the second lower and upper surfaces 148, 150 in a lengthwise dimension. An inner side 156 extends transverse to the second lower surface 148 in a widthwise dimension between the lateral sides 152, 154. The inner side 156 of the second portion faces the inner side 144 of the first portion. The second portion 132 also includes an outer side 158 extending between the first and second lateral sides 152, 154 and facing opposite the inner side 144 of the first portion. A second length L2 is defined as the distance between the inner side 156 and the outer side 158. A second width W2 is defined as the distance between lateral sides along the inner side 156. In accord with one aspect of the invention, the first and second widths W1, W2 are the same, and the first length L1 is greater than the second length L2. The reasons that length L1 is greater than length L2 is described below.

The hinge 134 that couples the first and second portions 130, 132 has a pivot axis A1 that extends along the first and second portions in a direction parallel to the widthwise dimension defining W1 and W2. The hinge 134 is preferably a living hinge connected to the lower surfaces 136, 148 of the first and second portions. The hinge 134 is preferably comprised of a flexible nylon webbing. When the cover 102 is in a flat ‘closed’ configuration, the first and second lower surfaces 136, 148 are co-planar and seat adjacent one another on the upper rim 112 of the spa tub. Because the hinge is preferably provided as a living hinge of the same vinyl material of the first and second portions and because the hinge is provided at the lower surface, an unbroken, gapless seal (preferably air tight) is provided about the entirety of the rim, without the space for heat loss that results from prior art covers. Preferably, a flexible skirt 159 also extends about the perimeters of the first and second lower surfaces to further reduce the opportunity for heat loss and to protect the molded spa tub from the sun when not in use. For purposes of clarity, the skirt 159 is not shown in several of the figures; nevertheless it is preferably present in all embodiments. However, given that the hinge is at the lower surface, the methods of opening and removing a spa cover which are used in the prior art cannot be used with the cover of the invention, and another method is provided as described hereinafter. Referring to FIGS. 7 and 8, when the cover 102 is moved into a folded ‘open’ configuration, the lower surfaces 136, 148 which face the water when in the closed configuration and can be unsightly, are moved into a position in which they face each other, whereas the upper surface 150 of the second portion faces the users in the tub 100 and opposite upper surface 136. The lengths L1 and L2 are different to allow the spa cover to be folded and raised up; given the manner of folding and raising, if the lengths L1 , L2 were equal the second portion 132 would be too long to rotate into a vertical position with the relatively small profile lifter and about a pivot axis located on the spa cabinet and below the rim 112 of the tub. Given that the first and second portions 130, 132 have different lengths L1, L2 (maximum dimension transverse to the hinge pivot axis A1), when the cover 102 is in the open configuration, the first and second outer sides 146, 158 are longitudinally displaced from one another such that they are not coplanar.

The lifter 104 facilitates lifting the cover 102 from the closed configuration (FIGS. 4 and 5) to the open configuration (FIGS. 7 and 8). More particularly, the lifter 104 couples to the first portion 130 of the cover in a fixed relation; i.e., the first portion 130 cannot freely swing or otherwise move relative to the lifter. Referring specifically to FIG. 8, the lifter 104 is coupled to the spa tub with one or more supports or mounts 160 that are fixedly attached directly to the spa tub 100, such as at the frame and cabinet 110 as shown, or may be self-supporting on the ground (not shown), or which even may be movably mounted relative to the spa, such as in a recessable lifter system. In the embodiment of the lifter 104 shown in the figures, two fixed supports or mounts are provided on opposite sides of the spa tub, but only one fixed mount 160 is visible. It is appreciated that the second fixed mount is a mirror image of the first fixed mount. The second fixed mount is optional and a single first fixed mount of sufficient structure and stability can be used.

In one embodiment, a lifter frame 162 is coupled to each fixed mount 160 at a rotatable mount 164 integrated with each fixed mount 160 and rotatable about a common pivot axis A2. Preferably, a mirror image form of the following frame is provide on the opposite lateral sides of the cover where two fixed mounts are provided. However, it is within the scope that one lifter frame of suitable structural strength can be utilized.

The lifter frame 162 includes a first support (main swing arm) 168 extending from the rotatable mount 164 to a first location on the first cover portion 130. The first location preferably includes an aspect of the upper surface 138 of the first cover portion. In one embodiment, the first support 168 extends along one of the lateral sides 140 of the first portion 130 at an oblique angle relative to the lower surface 136 and then extends across the upper surface 138 of the first portion in proximity to the inner side 144 (FIGS. 4 and 8). Alternatively the first support 168 can extend along one the lateral side 140 and along none of, or only a small portion of the upper surface 138, as described below with respect to a clamping attachment. Referring to FIG. 8, in accord with a preferred aspect of the invention, a second support (rear support) 166 extends from the first support 168 to a second location on the first cover portion 130. The second location is preferably along an outer side 146 of the first cover portion 130, opposite the inner hinge side 144 of the first cover portion. A connector 165 is provided that is movably disposed relative to the first support 168 during an assembly configuration. The connector 165 includes a tubular portion 167 and a bracket 169 fixed to the tubular portion. The tubular portion 167 is sized to slidably extend over the first support 168 during assembly. The second support 166 has an end adapted to be fixedly secured to the bracket 169, and the tubular portion 167 of the connector can be fixedly secured to first support 168, and the support structure is intended to operate in this fixed relation during use. In addition, the second support 166 preferably is not directly connected to the rotatable mount 164, but is only coupled to the rotatable mount 164 through the first support 168. The same or similar structure may be located on the opposite lateral side of the spa, preferably coupled to another rotatable mount.

As described in detail below, the slidable relationship of the connector 165 to the first support 168 during assembly allows a common set of lifter components to be adapted without special parts or cutting to customize the install to a spa tub regardless of the offset between the rotatable mount 164 and the outer side 146 of the first portion 130 of the spa cover. More particularly, the slidable connector 165 is slidably mounted between the ends of the first support 168, and is preferably provided in this slidably mounted position as provided by the manufacturer for use by an installer. In assembly, the first support 168 is coupled between the rotatable mount 164 and the first location on the first cover portion, discussed below. The second support 166 is preferably L-shaped, with a first portion 166a and a second portion 166b which are preferably bent or otherwise configured in an orthogonal arrangement relative to each other. The first portion 166a of the second support is coupled at the outer side 146 of the first portion 130 of the cover, preferably through insertion of a sleeve provide in the cover. The second portion 166b of the second support is brought adjacent the first support 168. The connector 165 is displaced along the first support 168 until it meets up with the end 166c of the second portion 166b, and the end of the second portion and the bracket 169 are fixed together, preferably with fasteners 171. The end 166c and bracket 169 may both be in a flattened plate form to facilitate side-by-side connection. Other structures for assembly of the end portion 166c and the bracket 169 are within the scope of the invention. In addition, the tubular portion 167 is fixedly fastened to the first support 168 with fasteners 173 to prevent any further longitudinal displacement of the connector 165 relative to the first support 168. This assembly provides a rigid and stable supporting configuration for the lifter supports 166, 168 relative to the rotatable mount 164 without requiring any cutting or waste of such supports to provide a fit regardless of the offset of the spa tub rim 112 relative to the fixed and rotatable mounts 160, 164, and the particular height-wise location along the outer side 146 at which the first portion 166a of the second support 166 is attached. Further, the assembly can be adjusted for other spa tubs after install, for example, if the lifter and cover are moved to a different spa tub.

The lifter frame 162 also includes a handle member 170 that extends or is extendable laterally outward from the spa tub 100 to facilitate movement thereof and may be integrated with or distinct from the first support 168. The handle 170 may be connected to or integrated with the first support 168, fixed in position relative to the first support 168, or may movable relative to the upper member so that the handle does not protrude relative to the sides of the spa tub 100 when not in use. By way of example, the handle 170 may be coupled to a hinge 172 that permits it to fold relative to the frame (FIGS. 6 and 7) or may telescope into a recessed position.

Referring to FIG. 8, in order to couple the lifter 104 to the first portion 130 of the spa cover 102, the first portion 130 of the cover includes a plurality of sleeves, loops, pockets, ties, hook and loop straps, or other suitable structure at which the lifter can be coupled. For example, a first sleeve 174 may be provided to a lateral portion of the outer side 146 of the first portion and receives the second support 166 of the frame, a second sleeve 176 is provided along the upper surface 138 and receives the first support 168 of the frame, and a third sleeve 178 is provided adjacent the second sleeve 176 and receives the handle 170. In this manner, the first portion 130 of the cover is stably retained relative to the frame by being coupled thereto at two orthogonal sides (the upper surface 138 and the outer side 146).

Turning now to FIGS. 8A and 8B, additionally or alternatively, a compression clamp mechanism 250′ is provided to securely couple the first support 168 of the lifter 104 (FIG. 8) to the cover 102. The clamp mechanism 250′ includes a vertical bracket 252′, a first clamping element 254′, and a second clamping element 258′ adjustable relative to the first clamping element. The vertical bracket 252′ includes a hole 260′ through which the handle 170 or a handle carrier extends and is fixed. The first clamping element 254′ is fixed relative to the vertical bracket 252′ and extends parallel to and adjacent the upper surface 138 and preferably extends within the second sleeve 176 through which a portion of the first support 168 also extends. The second clamping element 258′ extends parallel to the first clamping element and in contact with the lower first surface 136. The cover 102 includes an elongate narrow slot opening 262′ within the first portion 130 of the spa cover 100 near the hinge 134 and at the level of the first lower surface 136 and the top of the skirt 159. The slot opening 262′ may be reinforced, for example with a sewn border 264′. The second clamping element 258′ extends through the slot opening 262′, and is adjusted relative to the first clamping element to securely grip the first cover portion 130, and is fixed in position thereabout. This may be accomplished with nut and bolt fasteners 266′, springs, or other suitable means. According to a preferred aspect of the embodiment, the second clamping element 258′ engages a peripheral portion of the lower surface 136 that is located external the rim 112 of the tub. In this manner, the second clamping element 258′ does not interrupt the seal formed between the lower surface 136 and the tub rim 112 when the cover is in a closed configuration. Again, the first portion 130 of the cover is stably retained relative to the frame by being coupled thereto at two relatively orthogonal sides (the upper surface 138 or lower surface 136 via the clamp 250′, and the outer side 146 via the second support 166).

Referring to FIG. 8, in either embodiment (described with respect to the first embodiment but similarly applicable to both), a pneumatic cylinder 180, piston, spring (e.g., metal or gas), or other form of lift assist, preferably extends between each support 160 and the first support 168 of the frame to limit the amount of human effort required to lift the cover. In a preferred embodiment, the cylinder stores potential energy in the closed compressed configuration and imparts force through kinetic energy when allowed to expand. The cylinder 180 assists in smoothly rotating the spa cover back and forth between the closed and open configurations. It is preferable that the expansion force of the cylinder be such that when the cover is in the closed configuration, the cylinder enables the cover to be rotated relatively easily about the pivot axis. More particularly, once the seal between the cover 102 and the rim 112 is broken (discussed below), if even a slight manual force is exerted on the cover toward an open configuration (e.g., an angular rotation of 5-25° about the axis A2), the expansion force of the cylinder 180 is sufficient to effect automatic opening from that point forward, even if the handle 170 or the cover 102 is not otherwise subject to additional force by the user. Further, the cylinder assists moving the spa cover from the open configuration into the closed configuration by preventing the cover from rotating too quickly which could otherwise occur, e.g., due to a lack of sufficient user strength to control such smooth closure or slippage of the handle from a user's grip. It is preferable that the cylinder 180 be coupled to the first support 168 and oriented such that once the cover 102 is rotated even a relatively small angular displacement about axis A2 (e.g., 10°-25°) from the open configuration toward the closed configuration, the cylinder 180 operates as a closure assist, with such closure compressing the cylinder gas and thereby gradually lowering the cover into the closed configuration. Moreover, because the cover is fixed in position relative to the cover at first and second supports 166, 168 and always referenced relative to the pivot axis A2, in distinction from other covers which can slide around relative to their manually activated lifting mechanisms, the cover is always referenced relative to the spa rim to automatically ensure a complete seal about the rim each time it is moved to the closed configuration.

Further, the cover 102 may be closed on the spa tub from either outside or inside the spa. From outside the spa, the user grabs the handle 170 and pulls the 102 cover toward the closed position. Once the cover 102 is partially closed, the handle 170 can be released, the fixed location of the pivot axis A2 to which the first portion 130 of the cover 102 is fixed, and cylinder 180 ensure that the cover smoothly closes in the same position each and every time. From inside the spa, the user grabs the outer side 158 of the second portion 132 (a handle may be provided for this purpose) and starts pulling and walks the cover closed as the user steps through the tub, away from the lift assist, and out of the spa. The cover will automatically close on its own after a certain amount of angular displacement toward the closed configuration.

Once the spa is in a closed configuration as shown back in FIG. 4, a single locking mechanism 181 extending between the second portion 132 of the cover 102 and the spa cabinet 110 can be used to secure the entirety of the cover 102 relative to the spa tub. The locking mechanism 181 can comprise a strap 181a and first mating element 181b on the second portion of the cover and a second mating element 181c fixed relative to the cabinet 110 and which is engageable with the first mating element 181b (as also seen in FIG. 6). The first and second mating elements 181b, 181c may include snap-locking elements, two elements that together receive a pad-lock, another locking structure, or a combination of suitable locks. The strap 181a and second mating element 181c are preferably attached at a location generally corresponding to the middle of width W2 of the second portion, preferably at or near the outer side 158. The single lock mechanism 181 effects lock-down of the entire cover 102 for the following reasons. The outer side 158 of the second portion 132 is locked down relative to the cabinet 110 with lock 181, the seal between the cover 102 and rim 112 inhibits lifting of the cover without lifting the outer side 158 of the second portion 132, and the first portion 130 of the cover is fixed to the first and second supports 166, 168 of the lift assist system and cannot be lifted when the second portion 132 of the cover is immobilized.

Turning to FIG. 9, an alternate locking system for the cover lifter is shown. The locking system includes locking mechanism 181 and additional locking mechanism 183. Locking mechanism 183 includes a strap hanger 300 which includes a hook portion 302 and a plate portion 304. Hook portion 302 removably attaches to the handle 170 at the end of the first support 168. Plate portion 304 includes a slot 306 at which an end of a first flexible strap 308 is coupled to the hanger 300. An end of a second flexible strap 310 is fixed relative to the cabinet 110. The opposite ends of the first and second flexible straps 308, 310 are lockable relative to each other at 312, via a pad-lock, another locking structure, or a combination of suitable locks. Thus, whereas locking mechanism 181 coupled the second portion 132 of the spa cover to the spa cabinet 110 and extends over the outer side 158 of the second cover portion, locking mechanism 183 couples the first portion 130 of the spa cover to the spa cabinet and extends over the lateral side 140 thereof, preferably by attaching to the lifter at the handle 170 which is fixed relative to the first portion of the cover. By locking two sides of the cover to the spa cabinet, a spa cover in the closed configuration relative to the spa with increased security. Further, by locking the end opposite the rotation point as well as a side at or near the hinge, the closed configuration is maintained secure. Moreover, to release the spa cover from the closed configuration, the user only needs to move between two adjacent sides of the spa; not walk to opposite sides of the spa. Once strap 308, 308 are released securement with each other, the hanger 300 can optionally be removed from other the handle 170.

Referring to FIGS. 6 and 8, when the locking mechanism 181 (and optional locking mechanism 183) is released and the handle 170 is raised, the lifter is rotated about axis A2. Because a seal is provided between the rim and cover, in order to lift the cover, it may be necessary to first break the seal at some location about the periphery of the cover. This can be done by applying an upward force with a user's hand, e.g., at the outer side 158 of the second portion 132 or at the handle 170. Once the seal is broken, a slight additional lifting force allows the cylinder 180 to assist in rotating the first portion 130 and consequently the second portion 132 into the open configuration. Further, the cylinder can be configured to substantially apply all the force to open the cover once the seal is broken. More particularly, when moving toward the open configuration, the second portion 132 is caused to rotate about hinge axis A1 toward the open configuration. Given that the hinge axis is defined by flexible material, the meaning of ‘hinge axis’ includes a perfectly straight axis as well as the natural ‘slop’ that may occur with such a flexible hinge. The second portion 132 may be entirely lifted from the spa rim 112 during such rotation or the corner 182 (defined at the intersection of the lower surface 148 and the outer side 158) may be drawn across and in contact with the rim 112. As the lifter rotates, the weight of the spa cover is preferably transferred to the second support 166 which at least partially supports the weight of the first and second portions 130, 132. Once the lifter 104 is fully rotated about axis A2, e.g., through approximately 90° of rotation, the second portion 132 is raised off the rim 112 and in an upright vertical configuration (i.e., oriented transverse to the rim 112).

Traditional spa covers may be inadvertently closed on a user, particularly on windy days. In order to prevent this occurrence, a stop 184, either integrated with the support 160 or distinct therefrom, limits the range of rotation of the lifter and assists in supporting the weight of the lifted cover. Stop 184, which is contacted by the first portion 166a of the second support 166, supports the back-shifted weight of the cover and lifter system to prevent inadvertent closure of the cover. Turning now to FIG. 10, more preferably, according to a preferred aspect of the invention, a stop 184′, preferably in the form of bolt or metal rod oriented parallel to the axis of rotation A2, is distinct from the pneumatic cylinder 180 and separate from the frame 106 (FIG. 4) or cabinet 110 of the spa. According to an even more preferred aspect of the invention, the stop 184′ is provided adjacent the circular rotatable mount 164′ and situated to be contacted by the first support 168 to limit rotation of the lifter 104 to a maximum permissible angle (by way of example only, 100°-110° relative to the spa rim 112) as the lifter rotates the first cover portion 130 into the open position.

In accord with a preferred aspect of the invention, when in the open configuration the first portion 130 is situated with its outer side 146 below the surface of the rim 112 of the tub and is situated vertically below the pivot axis A2, while the second portion 132 is preferably situated with its outer side 158 vertically even with or above the rim. As stated above, in this open configuration, the lower surfaces 136, 148 face one another, and the upper surfaces 138, 150 face opposite one another. The upper surface 150 of the second portion is oriented in a substantially vertical plane and faces toward the spa tub 100.

There have been described and illustrated herein several embodiments of a spa cover, a lifter in association of the spa cover, and a spa provided with the cover and lifter. In addition, methods of folding the spa cover are also provided. While particular embodiments of the invention have been described, it is not intended that the invention be limited thereto, as it is intended that the invention be as broad in scope as the art will allow and that the specification be read likewise. It will therefore be appreciated by those skilled in the art that yet other modifications could be made to the provided invention without deviating from its spirit and scope as claimed.

Claims

1. A spa tub cover lifter system for use in association with a spa tub and spa cover,

the spa tub having a tub shell defining an interior for holding water and an exterior, the tub shell having a plurality of seating locations and an upper rim having a perimeter, the perimeter having a first dimension and a transverse second dimension, and

the spa tub cover having a first spa cover portion having a first upper surface and a first lower surface, first and second opposite lateral sides, a first inner side, and a first outer side opposite the first inner side, a second spa cover portion having a second upper surface and a second lower surface, a second inner side facing the first inner side, and a second outer side opposite the first outer side, and a hinge extending between the first and second spa cover portions, the first and second spa cover portions rotatable relative to each other on the hinge about a hinge axis between a flat configuration and a folded configuration, the lifter system comprising:

a) a first mount stably locatable relative to the spa tub;

b) a second mount rotatably mounted to the first mount and defining a pivot axis;

c) a first support connected to the second mount and adapted to be coupled to a first location on the first spa cover portion;

d) a connector having a first assembly state in which the connector is movably displaceable relative to a portion of the first support and a second assembly state in which the connector is fixed relative to the portion of the first support; and

e) a second support connected between the connector and a second location of the first spa cover portion,

wherein when the first support is rotated about the pivot axis, a lifting force is applied to the first spa cover portion to lift the first and second spa cover portions relative to the upper rim of the spa tub.

2. A spa tub cover lifter according to 1, wherein:

the connector is slidably displaceable relative to the portion of the first support in the first assembly state.

3. A spa tub cover lifter according to 2, wherein:

the connector includes a tubular portion which is slidably disposable over the portion of the first support in the first assembly state.

4. A spa tub cover lifter according to 3, wherein:

the connector includes a bracket at which the second support is connected to the connector.

5. A spa tub cover lifter according to 1, wherein:

in the second assembly state, fasteners fixedly couple the first and second supports to the connector.

6. A spa tub cover lifter according to 1, wherein:

the first support includes an adjustable clamp by which the first support is adapted to be coupled to the first location on the first spa cover portion.

7. A spa tub cover lifter according to 1, wherein:

the first support and the second support are adapted to be coupled to orthogonal surfaces on the first spa cover portion.

8. A spa tub cover lifter system according to 7, wherein:

the first support is adapted to couple to the upper surface of the first spa cover portion, and the second support is adapted to couple to the outer surface of the first spa cover portion.

9. A spa tub cover lifter system according to 1, wherein:

the second support is not connected to the rotatable mount.

10. A spa tub cove lifter system according to 1, in combination with a spa tub, the spa tub having,

i) a tub shell defining an interior for holding water and an exterior, the tub shell having a plurality of seating locations and an upper rim having a perimeter, the perimeter having a first dimension and a transverse second dimension,

ii) a cabinet about the shell,

ii) hydrotherapy jets installed at one or more seating locations,

iii) a plumbing system to circulate water from the interior of the tub shell through the jets, and

iv) a heating system for heating the circulated water.

11. A spa tub cover and lifter system for use in association with a spa tub, the spa tub having a tub shell defining an interior for holding water and an exterior, the tub shell having a plurality of seating locations and an upper rim having a perimeter, the perimeter having a first dimension and a transverse second dimension, the cover and lifter system comprising:

a) a cover, including, i) a first spa cover portion having a first upper surface and a first lower surface, first and second opposite lateral sides, a first inner side, and a first outer side opposite the first inner side, ii) a second spa cover portion having a second upper surface and a second lower surface, a second inner side facing the first inner side, and a second outer side opposite the first outer side, and iii) a hinge extending between the first and second spa cover portions, the first and second spa cover portions rotatable relative to each other on the hinge about a hinge axis between a flat configuration and a folded configuration, wherein in the flat configuration the cover seats on the rim of the spa tub; and

b) a lifter system for lifting the cover from the rim of the spa tub, including, i) a first mount stably locatable relative to the spa tub, ii) a second mount rotatably mounted to the first mount and defining a pivot axis; iii) a first support connected to the second mount and adapted to be coupled to a first location on the first spa cover portion, iv) a connector having a first assembly state in which the connector is movably displaceable relative to a portion of the first support and a second assembly state in which the connector is fixed relative to the portion of the first support, and v) a second support connected between the connector and a second location of the first spa cover portion, wherein when the first support is rotated about the pivot axis, a lifting force is applied to the first spa cover portion to lift the first and second spa cover portions relative to the upper rim of the spa tub.

12. A spa tub cover lifter system according to 11, wherein:

the connector is slidably displaceable relative to the portion of the first support in the first assembly state.

13. A spa tub cover lifter system according to 12, wherein:

the connector includes a tubular portion which is slidably disposable over the portion of the first support in the first assembly state.

14. A spa tub cover lifter system according to 13, wherein:

the connector includes a bracket at which the second support is connected to the connector.

15. A spa tub cover lifter system according to 11, wherein:

in the second assembly state, fasteners fixedly couple the first and second supports to the connector.

16. A spa tub cover lifter system according to 11, wherein:

the first support includes an adjustable clamp by which the first support is adapted to be coupled to the first location on the first spa cover portion.

17. A spa tub cover lifter system according to 11, wherein:

the first support and the second support are adapted to be coupled to orthogonal surfaces on the first spa cover portion.

18. A spa tub cover lifter system according to 17, wherein:

the first support is adapted to couple to the upper surface of the first spa cover portion, and the second support is adapted to couple to the outer surface of the first spa cover portion.

19. A spa tub cover lifter system according to 11, wherein:

the second support is not connected to the rotatable mount.

20. A spa tub cover lifter system for use in association with a spa tub, the spa tub having a tub shell defining an interior for holding water and an exterior, the tub shell having a plurality of seating locations and an upper rim having a perimeter, the perimeter having a first dimension and a transverse second dimension, the cover and lifter system comprising:

a) a cover, including, i) a first spa cover portion having a first upper surface and a first lower surface, first and second opposite lateral sides, a first inner side, and a first outer side opposite the first inner side, ii) a second spa cover portion having a second upper surface and a second lower surface, a second inner side facing the first inner side, and a second outer side opposite the first outer side, and iii) a hinge extending between the first and second spa cover portions, the first and second spa cover portions rotatable relative to each other on the hinge about a hinge axis between a flat, closed configuration and a folded, open configuration, wherein in the closed configuration the cover is configured to seat on the rim of the spa tub; and

b) a lifter system for lifting the cover from the rim of the spa tub, including, i) a first mount stably locatable relative to the spa tub, a stop defined on the first mount, ii) a second mount rotatably mounted to the first mount and defining a pivot axis; iii) a first support connected to the second mount and adapted to be coupled to the upper surface on the first spa cover portion, and v) a second support connected between the connector and the first outer side of the first spa cover portion, wherein when the lifter system is rotated on the pivot axis, a lifting force is applied to the first spa cover portion to lift the first and second spa cover portions relative to the upper rim of the spa tub, and said stop is positioned relative to the first support so that during the rotation toward the open configuration the stop limits movement of the first support to a maximum permissible angle.

21. A spa tub cover lifter system for use in association with a spa tub, the spa tub having a tub shell defining an interior for holding water and an exterior, the tub shell having a plurality of seating locations and an upper rim having a perimeter, the perimeter having a first dimension and a transverse second dimension, the cover and lifter system comprising:

a) a cover, including, i) a first spa cover portion having a first upper surface and a first lower surface, first and second opposite lateral sides, a first inner side, and a first outer side opposite the first inner side, ii) a second spa cover portion having a second upper surface and a second lower surface, a second inner side facing the first inner side, and a second outer side opposite the first outer side, and iii) a hinge extending between the first and second spa cover portions, the first and second spa cover portions rotatable relative to each other on the hinge about a hinge axis between a flat, closed configuration and a folded, open configuration, wherein in the closed configuration the cover is configured to seat on the rim of the spa tub;

b) a lifter system for lifting the cover from the rim of the spa tub, including, i) a first mount stably locatable relative to the spa tub, a stop defined on the first mount, ii) a second mount rotatably mounted to the first mount and defining a pivot axis; iii) a first support connected to the second mount and adapted to be coupled to the upper surface on the first spa cover portion, and v) a second support connected between the connector and the first outer side of the first spa cover portion, wherein when the lifter system is rotated on the pivot axis, a lifting force is applied to the first spa cover portion to lift the first and second spa cover portions relative to the upper rim of the spa tub; and

c) a locking system for locking the cover in the closed configuration relative to the spa tub, the locking system consisting essentially of, i) a first locking mechanism for securing spa tub cover in the closed configuration, the first locking mechanism extending over the lateral side of the second portion of the spa tub cover, and ii) a second locking mechanism for securing spa tub cover in the closed configuration, the second locking mechanism extending over the outer side of the second portion of the spa tub cover.