Note: Descriptions are shown in the official language in which they were submitted.
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METHOD OF ATTACHING A CABINET ASSEMBLY TO A HOT TUB
BACKGROUND OF THE INVENTION
This invention relates to an assembly of a spa or hot tub.
More specifically, this invention relates to attaching the
cabinet assembly around and to a hot tub.
Spas have been used for leisure activities for many years.
Specifically, a large tub is presented that holds heated water
and typically contains a plurality of jets to whirl water around
the tub as desired. Typically, a spa is held up by a frame that
is not aesthetically pleasing to a casual observer. As a
result, a cabinet assembly is placed around the frame to provide
a more aesthetically pleasing look.
This cabinet assembly is made by building a wooden or metal
frame and then securing to that frame a plurality of rigid
individually manufactured panels utilizing fastening members
such as screws. Then, if this cabinet assembly is built
separate from the spa, the spa still needs to be either placed
within the cabinet assembly or the cabinet assembly placed
around the spa.
While this wood frame used in combination with the
manufactured rigid panels covers up the spa frame thus providing
an aesthetically pleasing look, problems still remain.
Specifically, building the wood frame is not only time consuming
but additionally the individually manufactured pieces can be
very costly. In addition, the wood frame provides minimal
insulation for the hot tub or spa itself wherein often the water
within the spa is desired to be at an elevated temperature.
Thus, inefficiencies of the spa occur.
In addition, problems occur with cabinets used as a part of
spas because the environment in which spas are generally used is
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harsh and causes deterioration over time. This is because
conventionally many spas are merely placed on the open ground.
This often leads to the lower end of the spa cabinet being
continually exposed to a certain amount of moisture which causes
accelerated deterioration to the lower portion of a wood
cabinet. In addition, what complicates the matter is that
water, moisture, chemicals and heat are an intrinsic and
unavoidable part of spas. These conditions can accelerate and
further contribute to the deterioration of a spa's cabinet.
Therefore, a principal object of the invention is to
provide a method of attaching a cabinet assembly to a spa that
is both efficient and cost effective.
Another object of the invention is to provide a cabinet
assembly that resists deterioration over time.
Yet another object of the invention is to provide a system
wherein a single frame can be used with several configurations
while being simplistic in design.
Yet another object of the invention is to provide a spa
system wherein the panels are quickly and easily reversible.
These and other objects, features or advantages will become
apparent from the specification and claims.
BRIEF SUMMARY OF THE INVENTION
A method of attaching a cabinet assembly to a spa. The
steps include providing a frame that has a plurality of channels
that form a perimeter that is of size and shape to receive a
spa. This spa is then placed onto the frame such that a flange
or lip extends from the spa past the perimeter of the frame such
that the flange is positioned in parallel spaced relation to at
least one of the plurality of channels. Once the spa is in
place, insulating panels are inserted between the flange of the
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spa and the plurality of channels of the frame. A plurality of
flexible slats are then secured between the flange of the spa
and the channel to form a cabinet around the spa thus covering
the frame and insulating panels of the spa. The spa having a pan
and a toe kick secured adjacent its bottom end.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a perspective view of a cabinet assembly;
Fig. 2 is a perspective view of a spa within a frame of a
cabinet assembly;
Fig. 3 is a perspective view of a spa within a frame that
contains an insulating panel of a cabinet assembly; and
Fig. 4 shows a perspective view of a plurality of slats
that have been secured to the frame and spa of a cabinet
assembly.
Fig. 5 is a elevation view of a spa having a cabinet
assembly that includes a toe kick positioned around the
periphery of the spa with the channel connected to the top
surface of the toe kick and a pan covering the bottom surface of
the cabinet assembly, the view shows a slat and insulating panel
about to be assembled into the channel and held between the
channel and the flange of the spa.
Fig. 6 is a close-up elevation view of the spa of Fig. 5
focused on the toe kick in the periphery of the cabinet
assembly, the channel positioned on the toe kick and the pan
covering the bottom surface of the cabinet assembly.
Fig. 7 is an elevation view of a modified version of the
spa of Fig. 5, with the toe kick removed and the channel
connected to an upwardly extending lip of the pan.
Fig. 8 is a close-up elevation view of the spa of Fig. 7
focused on the periphery of the cabinet assembly, the channel
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=
positioned above the ground a distance to and the pan having an
upwardly extending lip to protect and covering the bottom and
exterior surface of the cabinet assembly.
Fig. 9 is an elevation view of a modified version of the
spa of Fig. 5 where the channel has been lowered to engage the
pan directly.
Fig. 10 is a close-up elevation view of the spa of Fig. 9
focused on the periphery of the cabinet assembly, the channel
positioned in engagement with the pan adjacent the ground.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The figures show a cabinet assembly 10 that includes a
frame 12. The frame 12 has channel 14 that is secured to a
plurality of posts 16 in order to form a perimeter that is of
size and shape to accommodate a spa or a hot tub. The posts 16
can be of single piece construction or be formed of three corner
brace sections. The three brace embodiment allows the corners
to be universal regardless of length. In a preferred
embodiment, the channel 14 is a U-shaped channel; however, an L-
shaped or J-shaped channel or the like could be used without
falling outside the scope of this disclosure. Extending between
individual channels 14 are a plurality of horizontal brace
members 18 that provide additional structural support to the
frame 12. Similarly, a plurality of brace members 20 are
secured to the channel 14 and extend diagonally and vertically
to form a king post truss to provide additional support and
strength.
Placed on top of the vertical brace members 20 and post 16
of the frame 12 is a spa or a hot tub 22. The spa or hot tub 22
is of any kind known in the art and typically has a fiberglass
body 24 that forms a cavity 26 that receives water and
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additionally has a plurality of openings 28 disposed therein for
receiving nozzles 30 and the like. Also, as known in the art,
the spa 22 has a flange or lip 32 at its top outer perimeter,
that in one arrangement extends outwardly and over the exterior
perimeter of frame 12. In order to form the cabinet assembly 10
of the invention the spa 22 is placed on the frame 12 such that
the flange 32 extends past the frame 12 and is positioned in
parallel spaced relation from the channel 14. In one embodiment
the frame 12 is a galvanized powder-coated steel frame.
Fig. 3 shows insulating panels 34 that are placed between
an individual channel 14 and the flange 32 of the spa 22 such
that the insulating panel 34 is secured therebetween.
Individual panels can be placed within any side of the frame to
provide additional insulation for the spa 22.
After a plurality of insulating panels 34 are in place
around the spa 22 a plurality of slats 36 are placed between the
individual channels 14 and the flange 32 of the spa 22.
Preferably the plurality of slats 36 are made of an elastic
material such as plastic such that the plurality of slats 36 can
individually be snapped into place between the channel 14 and
the flange 32 of the spa 22, however any other material is
hereby contemplated for use. When securing the plurality of
slats 36 between the flange 32 of the spa 22 and channel 14 to
form a cabinet around the spa 22, the flange 32, spa 22 and the
channel 14 place tension on the plurality of slats 36 in order
to secure the plurality of slats 36 in place.
In operation, in order to attach the cabinet assembly 10 to
the spa 22, the frame 12 having the channel 14 that form a
perimeter is provided. Next, the spa 22 is placed onto the
frame 12 such that a flange 32 extends from the spa 22 past the
perimeter of the frame 12 so that the flange is positioned in
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parallel spaced relation to the channel 14. The insulating
panels 34 are then inserted within and in between the flange 32
of the spa 22 and the channel 14. Once the insulating panels 34
are in place, a plurality of slats 36 are secured between the
flange 32 of the spa 22 and channel 14 to form a cabinet around
the spa 22.
By utilizing the cabinet assembly 10 there is no longer a
need for a wood frame and panelized system to produce a cabinet
assembly. Instead, by using the cabinet assembly 10 an
insulated metal frame can be quickly and easily assembled by
snapping in the plurality of slats 36. Thus, assembly time is
reduced as the individual assembling the cabinet no longer has
to use fastening materials such as screws to secure together a
wooden frame. In addition, by using the plastic slats for the
cabinet assembly, cost is greatly reduced. Thus, not only does
the cabinet assembly reduce costs but additionally the assembly
saves time during installation. In addition, the insulating
panel 34 provides an extra layer of insulation and thus at the
very least all of the stated objectives have been met.
In an alternative embodiment, with reference to Figs. 5 &
6, toe kick SO and a pan 52 is presented and used in association
with the cabinet assembly 10 described herein. Toe kick 50 is
formed of any suitable size, shape and design. In one
arrangement, as is shown, toe kick 50 is an elongated member
such as a board. Toe kick 50 is positioned at the bottom edge
of cabinet assembly 10 and extends around the entire perimeter
of frame 12. In one arrangement, toe kick SO is positioned just
outside of and connected to the exterior edge of cabinet
assembly 10 and frame 12 adjacent its bottom edge (as is shown
in Fig. 6). Alternatively, toe kick 50 is positioned below the
other components of cabinet assembly 10 and frame 12, or said
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another way, the cabinet assembly 10 and frame 12 are positioned
on top of toe kick 50. Toe kick 50 is secured to cabinet
assembly 10 and frame 12 by any conventional means such as
screwing, bolting, snap-fitting, tongue-and-groove, adhesives,
or the like.
In one arrangement toe kick 50 is formed of a single
continuous piece which is formed by any means. In one
arrangement, pan 52 is formed of a flexible material, such as a
sheet of flexible plastic. In an alternative arrangement, pan
52 is formed of a rigid material, such as a rigid plastic.
In
one arrangement, pan 52 is formed of a single unitary sheet of
polyethylene that is approximately of 90 gage thickness (90
thousandths of an inch).
Pan 52 is secured to the bottom surface of toe kick 50
frame 12 and the other components of cabinet assembly 10 by any
conventional means such as screwing, bolting, snap-fitting,
tongue-and-groove, adhesives, welding or the like. In one
arrangement, the entire periphery of pan 52 is adhesively
secured around the entire periphery of toe kick 50 thereby
sealing the entire bottom end of cabinet assembly 10. In one
arrangement, the exterior periphery of pan 52 is in alignment
with the exterior periphery of toe kick 52. In an alternative
arrangement, the exterior periphery of pan 52 is spaced inward
from the exterior periphery of toe kick 52 a distance, such as
1/4 inch, 1/3 inch, 1/2 inch or the like, so as to prevent
snagging the edge of pan 52 while moving or assembling the
cabinet assembly 10 as well as to prevent pan 52 from being seen
below toe kick 50. In an alternative arrangement, with reference
to Fig. 6, the pan extends upwardly between inward side of toe
kick 50 and the outward side of brace member 20, thereby being
pinched and held therebetween.
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In the arrangement shown in Figs. 5 and 6, channel 14 is
positioned on top of toe kick 50 and pan 52. In the arrangement
shown, the channel 14 is a J-shaped channel with the interior
lip extending upwardly a longer distance than the exterior lip.
The longer extension of the interior lip allows for easy
connection of the channel 14 to components of the cabinet
assembly 10, such as brace member 20 with a conventional
fastener such as a screw or bolt (as is shown in Figs. 5 and 6).
In the arrangement shown, the bottom surface of channel 14 is in
flush alignment with the upper surface of toe kick 50. In one
arrangement, toe kick 50 and channel 14 are separate pieces;
however in another arrangement toe kick 50 and channel 14 are
formed of a single unitary piece.
Also seen in Figs. 5 and 6 is the presence of insulating
panel 34 positioned behind slats 36. In this arrangement, the
lower end of slats 36 and insulating panel 34 are held within
the channel 14. The thicknesses of slats 36 and insulating
panel 34 are held within close tolerances such that the combined
thickness causes a tight frictional engagement of the lower end
of slats 36 and insulating panel 34 within the channel 14. In
this arrangement, the slats 36 are relatively incompressible
while the insulating panel 36 is somewhat compressible. As
such, when the lower end of slats 36 and insulating panel 34 are
inserted within the channel 14 the insulating panel 34 partially
compresses allowing slat 36 to fit therein while applying an
expansive force which helps to hold the slats 36 and insulating
panel 34 within channel 14. While this expansive force holds the
slats 36 and insulating panel 34 within the channel 14, the
slats 36 can still be easily removed by the user for repair,
replacement or access within the spa 10.
Another improvement of the arrangement is that slats 36 are
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reversible. That is, the slats 36 have two faces that are of
suitable aesthetic appearance. In this arrangement, in the
event that a slat or plurality of slats 36 get damaged, such as
scratched, dinged, stained or faded by the sun, the user can
quickly and easily remove the slats 36 (as is described herein),
flip them around, and Install them (as is described herein) with
the other side facing outward. This reduces the cost of repairs
for the owner and Improves the aesthetic appearance of the spa
10.
Yet another alternative embodiment is presented with
reference to Figs. 7 and 8 that is similar to the embodiment of
Figs. 5 and 6. In the arrangement of Figs. 7 and 8 the toe kick
50 has been removed and with the channel 14 positioned above the
bottom of cabinet assembly 10 a distance. That is, the channel
14 is connected to brace member 20 above the ground or bottom a
distance. This arrangement provided an amount of relief, or a
recess, around the bottom of the spa 10 which allows a user's
toes to occupy when they are standing next to the spa 10.
As is shown in Figs. 7 and 8, the outward edge of pan 52
terminates in an upwardly extending lip which is positioned
between the interior side of channel 14 and exterior side of
brace member 20. In this way, the pan 52 forms an upwardly
facing bowl, cavity or recess. At a minimum lip extends
upwardly at least the distance the bottom of channel 14 is
positioned above the ground. In this way, the pan 52 encloses
the open interior of the cabinet assembly 10 thereby keeping
contaminants out of the interior of spa assembly 10. In this
arrangement, the pan 52 having the upwardly extending flange or
lip is formed of a single molded piece such as through vacuum
molding, injection molding or the like. The single molded piece
is formed as either a rigid piece, a semi-rigid piece or a
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flexible piece.
By positioning the channel 14 above the ground and
eliminating the use of toe kick 50, this eliminates components
and reduces costs for the cabinet assembly 10. Also, by raising
the channel 14 above the ground, this shortens the slats 36,
which are relatively expensive components, thereby further
reducing the cost of the cabinet assembly 10.
Yet another alternative embodiment is presented with
reference to Figs. 9 and 10 that is similar to the embodiment of
Figs. 5 and 6. In the arrangement of Figs. 9 and 10 the toe
kick 50 has been removed and with the channel 14 positioned
directly on the top surface of the pan 52. This arrangement
eliminates the need for the additional component of toe kick 50.
The alternative embodiments of Figs 5-10 are just a few
examples which depict the versatility and array of arrangements
that are easily created using cabinet assembly 10. In
operation: The cabinet is assembled in the manner described
herein. The pan 52 is adhesively secured to the bottom surfaces
of cabinet assembly 10 which it comes into contact, such as the
entire periphery of frame 12 and/or toe kick 50. Toe kick 50 is
secured to the frame 12 and channel 14 is positioned on top of
toe kick 50 and secured to frame 12.
Once formed, pan 52 functions to keep the interior of
cabinet 10 clean, dry, warm and free of contaminants, insects
and rodents thereby improving the useful life of the spa. The
toe kick 50 engages the ground, but due to its composition,
resists deterioration thereby also extending the useful life of
the spa. In addition, because the toe kick 50 extends upwardly
from the bottom end of the cabinet assembly 10 the length of
slats 36 are shortened. This reduces the cost of the cabinet
assembly 10 as the toe kick 50 can be formed of a less expensive
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material than slats 36.
As is shown, a plurality of configurations are easily
created using the cabinet assembly 10, each having their own
benefits and each being suitable for different applications.
In view of the disclosure and figures, one of ordinary
skill in the art will appreciate that the spa and cabinet
assembly presented herein is an improvement over the state of
the art and that all objectives have been accomplished as are
stated herein. Namely, the spa presented is both efficient and
cost effective; it resists deterioration over time and it is
aesthetically pleasing.
It will be appreciated by those skilled in the art that
other various modifications could be made to the device without
departing from the spirit and scope of this invention. All such
modifications and changes fall within the scope of the claims
and are intended to be covered thereby.
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