Hot tub assembly

Abstract

A cover for a spa is configured to have an outer bag blended with a body of foam integrated with a reinforcing frame and an impact-resistant layer of material starched over the reinforcing frame and embedded in the body of foam.

What is claimed is:  
     
         1 . A cover for a reservoir adapted to store water at elevated temperatures, comprising a body of foam and a frame embedded in the body to reinforce the closure.  
     
     
         2 . The cover of  claim 1 , wherein the frame includes at least a pair of longitudinal hollow beams and at least one hollow cross beam extending between and coupled to the longitudinal hollow beams to define multiple pockets within the body of foam between the hollow beams.  
     
     
         3 . The cover of  claim 2 , wherein the hollow beams are made from aluminum and each having a polygonal or annular shape extending through the body of foam.  
     
     
         4 . The cover of  claim 2 , wherein the hollow beams are made from aluminum and each having an I cross-section configured to have a pair of longitudinal sides and a cross portion having a thickness varying within 4-6 mm range.  
     
     
         5 . The cover of  claim 2 , further comprising at least one impact-resistant layer made from mesh material stretched over and coupled to the hollow beams of the frame and blended with the body of foam to prevent concentration of force produced by an external impact upon the cover and to minimize the risk of forming a crack in the cover.  
     
     
         6 . The cover of  claim 5 , wherein the body of foam is made from polymeric material adapted to expand at elevated temperatures to form a rigid mass of foam, the hollow beams each having at least one opening configured to allow the expanding polymeric material to flow there through to provide the cover with an integrated structure.  
     
     
         7 . The cover of  claim 6 , wherein the body of foam is made from material selected from the group consisting of polypropylene, polyethylene, or PVC.  
     
     
         8 . The cover of  claim 6 , wherein the impact-resistant layer is made from a woven mesh material selected from metal wire, fabric or plastic.  
     
     
         9 . The cover of  claim 7  further comprising an outer bag configured to receive the body of foam reinforced with the embedded frame and impact resistant layer and configured to expand to the predetermined size and shape at elevated temperatures to accommodate the expanding polymeric material constituting the body of foam.  
     
     
         10 . The cover of  claim 9 , wherein the bag is made from reinforced PVC.  
     
     
         11 . A cover for a spa or hot tub, comprising: 
 a body of foam made from pellets expandable at elevated temperatures;    a reinforcing frame embedded within the body of foam;    at least one layer of mesh material embedded within the body of foam and stretched over and coupled to frame; and    an outer bag receiving the body of foam with the embedded reinforcing frame and the at least one layer of mesh material and configured to expand to a predetermined size and shape and blend with the pellets at the elevated temperatures to wrap around and blend with the body of foam.    
     
     
         12 . The cover of  claim 11 , wherein the body of foam is made from material selected from the group consisting of polypropylene, polyethylene, or PVC.  
     
     
         13 . The cover of  claim 11 , wherein the frame includes at least a pair of longitudinal hollow beams and at least one hollow cross beam extending between and coupled to the longitudinal hollow beams to define multiple pockets within the body of foam between the hollow beams, each of the hollow beams being provided with a respective opening to allow the pallet to flow through at the elevated temperatures to form an integral structure of the cover.  
     
     
         14 . The cover of  claim 1   1 , wherein the bag and the impact resistant layer are made from a woven mesh material selected from fabric or metal.  
     
     
         15 . A method of forming a cover for a spa, comprising the steps of: 
 forming an outer bag configured to have an interior;    providing a reinforcing frame including a plurality of beams;    stretching an impact-resistant layer of mesh material;    inserting the frame with the stretched impact resistant layer into the outer bag and filling the interior of the bag with pallets made from polymeric material capable of expanding at elevated temperatures to form a body of foam embedding the frame and the impact reinforcing layer and blending with the bag to form a rigid, light structure of the cover.