WO2014022843A1

WO2014022843A1 - Spa cover

Info

Publication number: WO2014022843A1
Application number: PCT/US2013/053530
Authority: WO
Inventors: Marvin H. HOWELL; David J. Ludlow; Nate Alder
Original assignee: Howell Marvin H; Ludlow David J; Nate Alder
Priority date: 2012-08-03
Filing date: 2013-08-03
Publication date: 2014-02-06

Abstract

Spa covers may have at least two layers that are sealed or fastened together at their edges and be filled with pressurized gas. Embodiments further include an open cell foam core and at least one valve to provide additional advantages.

Description

SPA COVER BACKGROUND

[001] Spas are commonly owned and used to obtain the relaxing benefit of heated circulating water. Sufficient power is required to achieve spa temperatures that may be as high as one hundred and four degrees Fahrenheit or more. To make efficient use of power needed to achieve and maintain such temperatures, spa covers are used to cover a spa. Providing an insulative effect, spa covers effectively reduce conductive, convective, and evaporative heat loss.

[002] A common drawback of a spa cover, however, is that it may be heavy,

exceeding 50 lbs (-23 kg) to ship or warehouse. The weight, along with the size, can make it awkward for an individual to install and remove. Consequently, a spa cover lift may be required to remove the spa cover from the spa, which may be expensive and further include associated costs for shipping and storing.

[003] Another drawback of spa covers is that they may be susceptible to hot pressure and moisture from within the spa. Pressure may cause the pores of a spa cover to open, which allows moisture to enter the pores. As moisture accumulates, the spa cover becomes less thermally efficient and less insulative. Thus, moisture and pressure may be problematic to a spa cover.

[004] Another drawback of a spa cover is that it may be rigid and made from closed cell foam, which makes it susceptible to bending and breaking when excessive and even moderate force is applied. Forces may come from a variety of sources, including weight from a person that sits or stands on the spa cover, or from forces exerted by snow accumulation. [005] The following provides advantages that address the common drawbacks described, as well as advantages that may be readily apparent to those skilled in the art.

SUMMARY

[006] A spa cover may comprise at least two air-tight layers, configured to provide a hollow interior encased between each air-tight layer with outer edges of the air-tight layers sealed together and low or high pressure gas contained in the hollow interior with pressurized gas preventing spa moisture from entering the spa cover, providing heat insulation for a spa, and exerting enough pressure to be in equilibrium with pressure exerted by heat from a spa. Embodiments include an open cell foam core within the air-tight layers.

BRIEF DESCRIPTION OF THE DRAWINGS

[007] Figure 1 is a side cross-sectional view of a spa cover in a closed position.

[008] Figure 2 is a side cross-sectional view of a spa cover in an open position.

[009] Figure 3 is a side cross-sectional view of a single panel of a spa cover.

[0010] Figure 4 is a perspective view of a spa cover that includes perforated open cell foam cores.

[0011] Figure 5 is a perspective view of a spa cover that includes perforated open cell foam cores.

[0012] Figure 6a is a perspective view of valves attached to spa panels.

[0013] Figure 6b is a front view of a mouth-inflating valve attached to spa panels.

[0014] Figure 6c is a perspective view of a mouth-inflating valve attached to spa panels. [0015] Figure 7a is a perspective view of inflating valves attached to spa panels.

[0016] Figure 7b is a perspective view of inflating valves attached to spa panels.

[0017] Figure 8a is a perspective view of a female side of a valve used for gas

insulation.

[0018] Figure 8b is a perspective view of a male side of a valve that attached to a tank of gas and plugs into the female side shown in Figure 8a.

[0019] Figure 8c is a side view of a self-inflating valve.

[0020] Figure 8d is a perspective view of a self-inflating valve.

[0021] Figure 9 is a perspective view a ruler measurement of perforated holes.

[0022] Figure 10 is a front view of a ruler measurement of the width of a divider.

[0023] Figure 11 is a perspective view of a ruler measurement of the width of a spa panel.

[0024] Figure 12 is a perspective view of a ruler measurement of the width of a spa panel.

[0025] Figure 13 is a perspective view of a ruler measurement of the distance from a corner of a spa panel to a valve.

[0026] Figure 14 is a perspective view of a ruler measurement of the distance from a corner of a spa panel to a valve.

[0027] Figure 15 is a perspective view of a ruler measurement of the distance from a corner of a spa panel to a valve.

[0028] Figure 16 is a perspective view of a ruler measurement of the distance from a corner of a spa panel to a valve.

[0029] Figure 17 is a perspective view of a divider between spa panels.

[0030] Figure 18 is a perspective view of a domed spa cover. DETAILED DESCRIPTION

[0031] Turning to FIG. 1, a side cross-sectional view of a spa cover 100 in a closed position is shown. In the figure, the spa cover 100 comprises outer encasement 116, and insulating panels 102 and 103, and hinge point 120. Insulating panels 102 and 103 abut each other or otherwise conform to each other along a horizontal plane.

Insulating panels 102 and 103 may be encased in outer encasement 116. Hinge point 120 indicates a pivot point at which panel 103 may be folded back over panel 102. Embodiments include multiple panels, however, only one panel without a hinge point 120 may be used if desired.

[0032] With multiple panels, positioning of the panels may include that the panels overlap each other along the horizontal plane. As shown, the sides of the panels 102 and 103 may be slanted such that the slanted side of one panel conforms to the slanted side of another panel. For example, if the top of one side of a first panel 102 extends outward, the bottom of one side of a second panel 103 extends outward. When the panels are laid next to each other, as in FIG. 1, their slanted sides lay flush with each other. In this manner, gaps and airways are prevented and thermal insulative effects are utilized.

[0033] Securing the slanted sides may be accomplished with a number of means, including fasteners, tethers, knots, anchors, loop and hook fasteners (Velcro), links, hinges, and more. Turning to FIG. 2, a side cross-sectional view of the spa cover 100 is shown in an open position with hinge point 120 between panels 102 and 103 indicating where a securement may be attached. As shown, panel 103 is raised or otherwise lifted at its end around the pivot point at the hinge point 120 shown.

Closing the spa cover 100 may be accomplished by lowering panel 118 around the same hinge point 120.

[0034] With multiple panels laying together in a flat side-by-side arrangement,

encasement 116 configured as a sleeve that encases panels 102 and 103, serves to both protect and hold the shape of the panels 102 and 103. Although not shown, multiple panels may be layered, or in other words, vertically stacked on top of each other, in addition to being laid in a side-by-side arrangement. In this manner, a variety of layering configurations may be achieved. For materials, encasement 116 may comprise water impervious material. Suitable materials include outdoor or marine fabrics or canvas, made from natural or synthetic fibers, such as, for example, one or more of nylon, acrylic, and cotton. A suitable material includes fabrics marketed under the name "Sunbrella™ fabric. Other materials and properties are anticipated. Note that embodiments include that each panel may have its own encasement, rather than one all-encompassing encasement. Embodiments further include that multiple encasements be provided to allow groupings of one or more panels to each have their own encasement.

[0035] Within encasement 116, panels 102 and 103 may be comprised of membrane layers 112 and 114. Each membrane layer 112 and 114 may have airtight properties. Using two membrane layers that are bonded, sealed, or otherwise attached at their outer edges, a hollow interior, cavity, or continuous bladder, may be formed. Also, multiple membrane layers with edges sealed may be used to form the interior cavity. One continuous membrane layer may also be used to form the hollow cavity. For example, a single membrane layer could be made to wrap around a hollow cavity with a lengthwise seam and seams at each of the remaining ends.

[0036] As shown, membrane layers 112 and 114 may be configured around insulating foam core panels 102 and 103. The membrane layer may be glued or otherwise sealed to the foam core panels 102 and 103. A tight or loose fit may be used.

[0037] Into the cavity formed by membrane layers 112 and 114 that houses foam core panels 102 and 103, respectively, a non-pressurized or pressurized noble gas may be added within the cavity. Embodiments include that gas be contained within the foam core and not the cavity, however. Gases may include, for example xenon, argon, krypton, SF6, or simply air... Indeed, any noble gas heavier than helium on the Periodic Table may be considered as an option. Combinations of gases, including combinations of gases that include elements that are not noble gases, may also be used. The gas (air, argon, etc.) may be beneficial in providing insulation due to its low thermal conductivity. Also, the outer air-tight membrane layers 112 and 114 prevent evaporative heat loss and contain the gas and foam to create a very thermal efficient layer.

[0038] Embodiments further include that pressurized air, gas, or a combination

thereof, be used to achieve a pressurized spa cover. This creates rigidity of the spa cover to stay on top of a spa and exert pressure against heat and pressure from the spa, which could otherwise force moisture into the spa cover. Being pressurized, the gas helps to keep the panel in a rigid state which helps it to stay on top of the spa and not sink into the spa water. Also, the pressurized gas counters the pressure exerted from hot water in the spa to achieve a state of equilibrium and thus prevent water accumulation inside the panel. [0039] Embodiments may include a foam core panel that has an open cell foam structure. Turning to FIG. 3, spa cover 300 includes an open cell foam core 105 within the cavity of the two membrane layers is depicted. An open cell foam core structure promotes rigidity, reduces convection, and allows pressurized gas within the open cells to exert pressure against the pressures from hot water in the spa, as well as providing other advantages.

[0040] Embodiments may further include perforations in the open cell foam core.

Adding perforations is helpful to allow air gaps, which in turn may be filled with pressurized gas. Using perforations is beneficial because it allows the foam core to be more lightweight, making the spa panels easier to maneuver, particularly for covering and uncovering a spa. A weight of 15 pounds (~7 kg) or less may be achieved for a spa cover, as opposed to typical spa covers that may range upwards from 60 pounds (-27 kg) or more. The use of perforations also allows the panel to be compressed or rolled tightly for storage. Furthermore, perforations create more space within a panel for holding insulative gas. As previously described, insulative gas helps the spa maintain heat and thus improves thermal efficiency. Other advantages may be readily observed.

[0041] Turning to FIGS. 4 and 5, perspective views of perforated open cell foam cores 104 are 106 shown. Perforations 130 may comprise rounded or circular holes that extend vertically from one side to the other side of open cell foam cores 104 and 106. Perforations 130 are made by puncturing the cores 104 and 106 with methods that include drilling, punching, or using other known means. Other shapes of holes may be used as desired. Also, instead of perforations, rounded wells, pits, indentations, hollows or other types of surface disruptions that do not actually amount to complete perforations may be used. Of course, combinations of perforations and non-penetrative surface disruptions may be used in tandem.

[0042] Hole size may be optimized to reduce conduction or convection. For example, a hole diameter less than or equal to 3.5 inches (~9 cm) may be desirable for this purpose. Also, a desirable hole diameter may vary depending on the thickness of the core layer 104 and 106. While batting may be used as a core layer, it may be undesirable because it creates a much larger possible cell size that results when pressurized gas or air is added to the panel. Batting also makes for a much larger possible cell size that results when water inadvertently makes its way into the panel. A large cell size is susceptible to heat loss in the form of conduction and convection, both for gases and water. Regarding entry of water, a large cell size allows more space for water, and consequently more water weight in the panel. This is undesirable because it makes the panel heavier to lift for purposes of both covering the spa, uncovering the spa, and for transporting the spa cover. More water weight distribution also makes the panel more apt to weaken structurally. Finally, a water increase due to a large cell size may cause an increase of bacterial growth within the panel. Other detrimental effects may be recognized. Therefore, it is believed that an open cell core, and a perforated open cell core with attention to perforation size and core thickness, may greatly benefit the structural capability and insulative properties of the panels.

[0043] In selecting an open cell foam, it may be desirable to find one that is

hydrophobic. This is beneficial to prevent bacterial growth and encourage water drainage. Although the open cell foam may be rigid, it may be desirable to find a foam that is flexible, and perhaps even self-expanding, such as a type of memory foam. This is beneficial to help restore shape after storing the foam, particularly if it is rolled up tightly. Otherwise, memory foam is helpful generally in maintaining overall shape.

[0044] Placement of perforations 130 along the surface of core layers 104 and 106 may include a series or grouping of perforations in isolated regions of the core. For example, a series or grouping of perforations may occur in a checkerboard pattern, such that the series or grouping of perforations alternate with regions of the original open cell foam structure. Other patterns and configurations are also envisioned. As shown, embodiments include that perforations be spaced evenly apart along both the length and width of core layer 104 and 106. A cover that contains multiple panels may have one or more panels that include such a series or grouping of perforations in a pattern form or other configuration.

[0045] Note that perforations may extend in a horizontal direction rather than a

vertical direction in the open core. Such a fashion may be beneficial in reducing convection because the heat is more easily trapped within a horizontal space and does not have an easy vertical escape that would otherwise be provided by perforations that extend in a vertical direction. Structural form of the perforations may truly vary, taking forms such as abtuse angles, slanted angles, curved forms, or other forms.

[0046] The membrane layer on a foam core or an open cell foam core may be a

plastic surface layer. As shown in FIGS. 4 and 5, plastic surface layers 108 and 110 cover exterior sides of each of the perforated open cell foam cores 104 and 106, respectively. Although shown covering all sides, they may cover only one side, multiple sides, or all sides, according to desire. For a layer that encompasses one or more of the top, the bottom, and sides, the layer may be one solid piece. Alternatively, the layer may be comprised of sections. Although a plastic surface layer or multiple sections that make up a plastic surface layer may envelop or otherwise surround only one individual foam core, it is further anticipated that a plastic surface layer be used to envelope multiple core layers together.

[0047] Note that the plastic surface layers 108 and 110 may be attached in an airtight manner. With an airtight fit, foam cores 104 and 106 may be held more tightly to keep the intended shape and prevent the foam from bulging out into a sphere or other undesired shape. In addition to being airtight, material selection may be based on properties that include the following: waterproof or hydrophobic, resistant to harsh pool and hot tub chemicals, resistant to hot tub temperatures of 110 °F (or 43.3 °C), having an exterior with an ability to bond to foam core, an encasement, each other, etc., (possibly using spray adhesive), etc.. Examples of materials used for the layers include polyurethane (PU), thermoplastic polyurethane (TPU), polyvinyl chloride (PVC) and other durable materials. Note that the plastic surface layer may be clear or transparent to make it easy to check the foam core on occasion or for specific purposes, such as bacterial growth, without having to remove the plastic surface layer.

[0048] In covering open cell foam cores 104 and 106, and other foam cores generally speaking, the plastic surface layer 108 and 110 may completely surround the foam cores in one piece or by sections. For an example of sections, a given foam core may be covered by one piece on top and one piece on bottom with ends of both the top piece and the bottom piece seamed together. Alternatively, a surface layer that is specific to the sides of the core may be used, shown as gusseting 132 and 134.

Gusseting 132 and 134 comprises a plastic surface film strip on the sides of open cell foam cores 104 and 106, respectively. With top and bottom surface layer-sections, edges of gusseting 132 and 134 connect or otherwise attach to edges of top and bottom plastic surface layer sections of 108 and 110, respectively. Gusseting 132 and 134 may adhere to foam core facing with glue or by other fastening means. It may not, however. It may be somewhat loose to provide give for easier maneuvering of the panels and flexibility for rolling and storing the panels.

[0049] Note that the membrane layers 112 and 114, plastic surface layers 108 and 110, and gusseting 132 and 134 may be bonded, laminated, or otherwise adhered to the foam core 102 and 103 and perforated open cell foam cores 104 and 106.

[0050] For adding pressurized gas to the spa cover, one or more valves may be used.

Turning to FIG. 6a, a perspective view of valves 122 and 124 are shown attached to plastic surface layers 108 and 110, respectively, and located on open cell foam core panels 102a and 102b, respectively. Valves 122 and 124 may be used to allow gas to enter and exit spa panels 102a and 102b, respectively. Alternatively, each of valves 122 and 124 may be used to allow gas to enter panels 102a and panels 102b while another set of valves (not shown) allow gas to exit panels 102a and panels 102b. If another set of valves are used to allow gas to exit, they may be located on the opposite side of the panels 102a and 102b. This encourages passage of air, or gas, to travel from one side to another side of the panels 102a and 102b and thus fully exit.

[0051] Embodiments include that one valve may be a one-way valve, allowing gas to enter, while another valve is a two-way valve, allowing gas to both enter and exit. A combination of multiple valves may be used. When a valve is opened, air and gas may freely enter through the valve and into the hollow interior or open cells, allowing the spa cover to self-inflate. If a user lacks access to a gas, like the ones listed above, or if a user prefers air, the self-inflating technique is useful as a substitute for gas. Self- inflation capability is also useful as a temporary method to keep using the spa cover until gas can be used.

[0052] To purge or clean out the hollow interior or the open cells of the foam core and remove or purge air or foreign gas, a gas may enter through a first valve and exit through the second valve for a desired time period. After a period of time, the second valve may be closed, such that pressurized gas may be built up in the hollow interior or open cells. When the gas has reached a desired pressure, the first valve may be closed. In this manner, the spa cover may be pressurized with gas.

[0053] To release the gas, one or more valves may be opened. Pressure on the exterior may be applied to the spa cover to squeeze gas out of the hollow interior or open cells and push gas out through the one or more valves. Also, pressure may be exerted on the spa cover by rolling the spa cover. Steps of applying pressure and rolling may be used interchangeably to effectively remove gas while making the spa cover compact for storage purposes. A vacuum on the valves may be used as well to extract air/gas.

[0054] Note that embodiments may include all standard means of inflation and

deflation techniques.

[0055] Typical rigid foam spa covers are highly susceptible to becoming moisture- saturated, which makes them heavy and more difficult to handle, and thus more likely to break. When spa covers do become moisture- saturated, a drastic reduction in thermal efficiency results. Although the spa cover is designed to prevent any moisture from ever entering, embodiments that include at least two valves enable any moisture or other foreign gasses that actually could enter to then be pumped out. This is accomplished by pumping air or other gasses through at least one valve, through the hollow interior or open cells, and then out through at least one other valve. This makes the spa cover reusable and sustainable over a long-term period.

[0056] Turning to FIGS. 6b and 6c, mouth-inflating valve 125 is shown. A mouth- inflation valve like that shown in FIGS. 6b and 6c is advantageous when gas is not required, when a temporary source of inflation is needed, or for other reasons.

[0057] Turning to FIGS. 7a and 7b, inflating valves 126 and 127 are shown.

[0058] Turning to FIGS. 8a-8d, different types of self-inflating valves are shown.

[0059] Note that the various types of valves described may be included such that more than one source of air or gas, or more than one means of inflating and deflating may be used.

[0060] As for dimensions, the panel may be designed to fit across the length of a spa, the well of a spa, or at another length desired for a spa, pool, or body of water.

Embodiments include that multiple panels of the same length and one or more widths be laid in parallel to form a complete spa cover. Alternatively, a single panel may cover the entire width, well width, or other desired width of the spa or other body of water. The height of the panel may be anywhere from approximately one inch to eight inches (-20 cm) or more, depending on the materials and the pressure exerted within the panel.

[0061] FIGS. 9 through 16 present a host of possible measurements that may be used to achieve thermal efficiency, lightweight attributes, etc... The measurements are exemplary and in no way meant to be binding. Note that the perforations, holes, or cells may be less than 2.5" in (~6 cm) diameter, or potentially reach 10-12" in (-25- 30 cm) diameter. [0062] Embodiments may include an extension wing that extends from at least one side of each panel. The extension wing may include the same material as the membrane layer or the protective layer. Other materials may be used as well. To connect the panels together, the extension wing from one panel may overlay the extension wing of another panel. Securing the extension wings may be accomplished with a number of means, including the means previously listed for the slanted sides.

[0063] Instead of extension wings, a divider may be used to connect multiple panels together. Turning to FIG. 17, an extruded perspective view of a spa cover 200 that includes a divider 210, panels 204 and 206, support bar 212, support bar 214, opening 216, and insert 218. Although a connection is not shown, the divider 210 may be connected to the panels 204 and 206 by means such as a material fabric that attaches to the panels 204, 206, and the divider 210. The encasement 116 may also be used to attach the divider. The encasement 116 may have extra material that provides a gap or space between the panels for a divider. The divider may be attached or sewn to the encasement 116. Various means of attachment may be used, such as straps, hinges, etc.

[0064] The sides of divider 210 have the same lines and curvature as the sides of the panels 204 and 206 so that the divider 201 aligns, sides flush, with the sides of panels 204 and 206. As shown, the divider 210 has straight sides and panels 204 and 206 have straight sides. Embodiments include that if panels 204 and 206 have slanted sides, then the divider 201 may have slanted sides. With sides that match up, a continuous layer of insulative protection for the spa may be achieved.

[0065] The divider 210 may be comprised of similar fabric as panels 204 and 206.

The interior of the divider 210 may further have a similar makeup as panels 204 and 206 in the form of an insert 218, including an open cell foam or an open cell foam with perforations. Other types of material, however, may also be used to provide the insulative padding. For example, other types of foam, polycarbonate and other plastics, or rubberized materials may be used.

[0066] Opening 216 may be a slit or some other type of opening that allows insert 218 to be removably received within divider 210. Although shown on the side of divider 210, an opening may be located on any side of the divider 210, including top, bottom, or opposing side. Additionally, opening 216 may be located at corners of divider 210. The opening 216 may further include a closure, a flap, zipper, snaps, or other type of closure that maintains the insert 218 within the divider 210.

[0067] Embodiments may include a support bar 215, a member that extends between the ends of divider 210 and that fits within opening 216. Alternatively, support bar 215 may be attached to the exterior of divider 210 by means such as straps, snaps, etc. Also, the support bar 215 may be magnetized and be held in place to the divider 215 by magnetic attraction. Support bar 215 may be used in conjunction with or separate from insert 218. Instead of opening 216, a separate opening for the support bar may be used.

[0068] Support bar 215 may be comprised of a rigid or somewhat flexible material.

Materials include any non-rusting, moisture resistant, rigid or semirigid, materials that can be fabricated into a bar for support, as described. Suitable materials include natural and synthetic materials, and include for example, polycarbonate, nylon, polyurethane, polypropylene, polyethylene and other plastics, treated wood products, glass fiber or carbon fiber composites rubberized or rubber coated materials, and non- ferrous metals such as aluminum. It may be optimal for the support bar 215 to be rigid. Located at a midway point of spa cover 200, the support bar 215 may extend on to or over the edges of a spa container, thereby providing support for spa panels 204 and 206. Such a measure helps to maintain the spa panels 204 and 206 in a level position, maintaining spa cover shape and avoiding potential sagging. Also, support bar 215 helps the spa cover 200 resist forces from nature, such as rain, snow, wind, etc. Similarly, the support bar 215 protects against unnatural forces, such as those caused by people standing on the spa cover 200 or by foreign objects placed or dropped on the spa cover 200.

[0069] Note that the support bar does not have to be located at a midway point of the spa cover 200. Multiple support bars may be used with the spa cover and they may be located at any place on the panels 204, 206, and divider 210. For instance, they may be located on the bottom, top, at ends, span opposite corners, etc... Using support bars provides stability, support, and strength, and does not have to add much weight to the spa cover 200.

[0070] Instead of being sheathed or secured within the divider 210, the support bar 212 may extend outside the ends of the divider 210 and be secured to edges of a spa container. Alternatively, the support bar 212 may be attached to the outer sides of a spa container. Attachments to the edges or outer sides of a spa container may include means such as straps, fasteners, tethers, anchors, clips, and other means commonly known. In this manner, the support bar 12 may be prevented from sliding or moving around relative to a spa container.

[0071] Instead of a rectangular panel as shown, the support bar 212 may be a T-shape or I-shape bar or hollow tube, according to desire. Using a T-shape or I-shape, or any other shape, the divider may have openings that allow the T-shape or I-shape to be contained but not all the way. So, for example, the cross on the T may extend out of the divider, supporting the divider from underneath. The cross of the T may further provide support to end portions of the panels 204 and 206. The T-shape and I-shape support bars may not be housed within the divider opening, but rather be attached to the outer surface of the divider. Moreover, the T-shape and I-shape may be attached to one or both of the spa panels 302 and 304.

[0072] Embodiments further include that the spa cover 200 include a brace 214. As shown, brace 214 may be housed within spa panel 204. It may also be housed within spa panel 206 (not visible within Fig. 17). Brace 214 may encompass one side of spa panel 204, multiple sides, or all sides of spa panel 204. This is true for panel 206. If more than two panels make up spa cover 200, braces may be used for each panel. Alternatively, a brace may be used to surround the outer sides of the spa cover 200, encasing the panels together as a unit, rather than each panel individually.

[0073] Turning to FIG. 18, a domed spa cover 200 with curved panels 302 and 403, curved open cell foam 306 and 308, divider 310, brace 312, and tethers 316 and 318 are shown. Embodiments include that the panels have curvature to enable water, snow, debris, and other materials to run off the spa cover 200 more easily. Curvature may only be found from one end to the opposite end of a curved panel. So, for example, a curve may extend from each spa panel 302 and 304 starting at the end located near the divider 310, midline of the spa cover 300, or contact point of another spa panel and extending to the opposite end of the spa panel 302 and 304. Also, there may be curvature between the remaining ends of spa panels 302 and 304. In such a manner, a dome-like effect may be created, with the apex of the dome at the center of the spa cover 300. If there is curvature only extended from the midline, and not the other two sides, an arch or rainbow shape may still be achieved. Embodiments include all features previously addressed.

[0074]

[0075] Once the spa cover 300 is placed on a spa container, the spa cover 300 may be attached or tethered to the spa container with means that include ties, fasteners, tethers, knots, anchors, Velcro, links, and more. Exemplary means are indicated by tethers 316 and 318.

[0076] One of the advantages of using embodiments presented herein concern

transportation and storage issues. First, using perforated foam makes for lightweight transportation and storage. Compared to a conventional spa cover, the weight of embodiments herein may be approximately 60% less or more.

[0077] Using panels that may be separated makes for easy handling and transporting.

It is anticipated that the spa cover components may be placed within a spa container during times of transporting and then assembled to form a spa cover. This eliminates the need for a separate space or compartment area for spa covers when transporting a set of spa units. For original equipment manufacturer (OEM) shipping purposes, fitting components of the spa cover inside the spa container helps eliminate spa cover shipping costs.

[0078] In storing the spa cover, a reduced size, nearly 20% the size of conventional spa covers, eases the storage burden for manufacturer, Spa OEM, and retailer.

[0079] Furthermore, a small compacted size allows inventory to hold spa panels separate from encasements (the outer protective coverings). Segregating these two items allows for the storage of multiple colors of encasements with a minimum number of foam core panels. For example, if a seller were to offer four colors of encasements, he or she would ordinarily need four encasements and four sets of spa panels. Using removable foam core panels, however, a seller would need only have four sets of encasements and one set of foam core panels. Not only does this help the seller, but it also helps the buyer who may need a replacement foam core panel or who wants a new encasement and does not want to replace the entire spa cover itself. Thus, the buyer-seller market is mutually benefitted.

[0080] Another advantage is found from the use of the support bar. Spanning a spa container, the support bar may be incorporated as part of a hinge of the spa cover and kept erect by being pressed together by at least two adjacent spa panels. This provides added strength, support and stability to a spa cover. Other advantages may be readily apparent.

[0081] While this invention has been described with reference to certain specific embodiments and examples, it will be recognized by those skilled in the art that many variations are possible without departing from the scope and spirit of this invention, and that the invention, as described by the claims, is intended to cover all changes and modifications of the invention which do not depart from the spirit of the invention

Claims

CLAIMS We claim:

1. A self-supporting spa cover comprising:

at least one generally horizontally disposed planar panel with lateral edges that comprises at least one membrane layer that surrounds a space containing an open cell foam core in an airtight manner, the space containing the foam core further containing pressurized gas; and an outer protective covering that surrounds an outer surface of the at least one membrane layer,

the at least one panel being sufficiently rigid to be self-supporting between the lateral edges of the panel.

2. The spa panel as in Claim 1 wherein pressure of the pressurized gas is selected to impart at least a portion of self-supporting rigidity to the panel.

3. The spa panel as in Claim 1 wherein the lateral edges are dimensioned and adapted to be supported by edges surrounding a spa water containment.

4. The spa panel as in Claim 1 wherein the gas is argon.

The spa panel as in Claim 1 wherein the gas is a noble

6. The spa cover as in Claim 1, wherein the foam core is perforated.

7. The spa cover as in Claim 2, wherein perforations are spaced evenly apart.

8. The spa cover as in Claim 1, wherein the spa cover comprises a water impervious

material.

9. The spa cover as in Claim 1, further comprising at least one valve attached to the at least one membrane layer and that allows air and gas to enter and exit the space surrounded by the membrane layer.

10. The spa cover as in Claim 1, further comprising at least one valve attached to the at least one membrane layer and that allows air and gas to enter the space surrounded by the membrane layer; and at least one valve attached to the at least one membrane layer and that allows air and gas to exit the space surrounded by the membrane layer.

11. The spa cover as in Claim 10, wherein the valves are located on opposite sides of the foam core.

12. The spa cover as in Claim 10, wherein the valves are mouth-inflating valves.

13. The spa cover as in Claim 10, wherein the valves are self-inflating gas valves.

14. The spa cover as in Claim 1, wherein the membrane layer is a plastic surface layer.

15. The spa cover as in Claim 1, wherein the membrane layer is laminated to the foam core.

16. The spa cover as in Claim 1, wherein the membrane layer is transparent.

17. The spa cover as in Claim 10, wherein the laminated surface layer is bonded to the

exterior of the foam core.

18. The spa cover as in Claim 1, wherein the at least one membrane layer further comprises gusseting around the sides of the foam core.

19. The spa cover as in Claim 1, wherein the spa cover includes at least two membrane layers and a divider, the divider located between the two membrane layers, the sides of the divider able to lay flush with the sides of the two membrane layers and thus provide a generally continuous covering over the spa containment.

20. The spa cover as in Claim 19, wherein the divider is an extension of or secured to the outer protective covering.

21. The spa cover as in Claim 19, wherein the divider includes an opening that encases at least one member such as an insert, or a support bar.

22. The spa cover as in Claim 19, wherein a support bar may be attached to the divider or to a side of one of the two membrane layers.

23. The spa cover as in Claim 19, wherein a T-shape brace fits within an opening on the divider, with ends of the T-shape brace resting on ends of a spa container, thus providing strength and stability to the spa cover.

24. The spa cover as in Claim 19, wherein a T-shape brace is attached to the divider, with ends of the T-shape brace resting on ends of a spa container, thus providing strength and stability to the spa cover.

25. The spa cover as in Claim 19, wherein an I-shape brace fits within an opening on the divider, with ends of the I-shape brace resting on ends of a spa container, thus providing strength and stability to the spa cover.

26. The spa cover as in Claim 19, wherein an I-shape brace is attached to the divider, with ends of the I-shape brace resting on ends of a spa container, thus providing strength and stability to the spa cover.

27. The spa cover as in Claim 19, wherein the at least two membrane layers are curved to form a dome-shaped spa cover with the apex of the dome located at the center of the spa cover.

28. The spa cover as in Claiml, wherein the space containing the foam core and surrounded by the membrane layer is removably received within the outer covering, allowing the foam core to be removed for ease of storage and shipping, as well as allowing for a generic inventory of foam cores as opposed to multiple colors of encasements with inserted foam cores.

29. A means for covering a spa including:

inserting foam cores into individual outer protective coverings, the outer protective coverings connected or otherwise attached to a divider;

inserting a support bar into an opening in the divider;

placing the foam cores, the outer protective coverings, and the divider over a spa containment.

30. A self-supporting spa cover comprising:

at least one generally horizontally disposed planar panel with lateral edges that comprises at least one membrane layer that surrounds an insulative space containing pressurized gas; and an outer protective covering that surrounds an outer surface of the at least one membrane layer,

31. The spa cover as in Claim30, wherein the space surrounded by the membrane layer is removably received within the outer covering, allowing the foam core to be removed for ease of storage and shipping, as well as allowing for a generic inventory of foam cores as opposed to multiple colors of encasements with inserted foam cores.