SPA cover with metalized moisture barrier and method of manufacture

Abstract

A moisture barrier for a rigid insulating panel of a spa cover is a laminate bag of at least two layers. A first layer of polyethylene plastic film is bonded with at least a second and inner layer of metalized plastic film to form the laminate bag. A third layer of polyester is optionally provided and which is enveloped within second layer as an additional moisture barrier. The laminate bag has at least an open end which is adapted for receiving the panel and which is sealed. The sealed laminate bag can be evacuated for additional insulating characteristics.

1 . A moisture barrier for a rigid thermally insulating spa cover panel comprising: 
 a first envelope of polyethylene having at least one open periphery for accepting the panel therein; and    a second envelope of metalized plastic film, enveloped within the first envelope and having at least one open periphery adapted for accepting the panel therein,    wherein 
 the first and second envelopes are bonded together, and  
 the at least one open periphery is sealed to form a bag with the panel therein for forming a barrier against the transfer of moisture through the first envelope to within the second envelope.  
   
   
   
       2 . The moisture barrier of  claim 1  wherein the first and second envelopes are bonded together with adhesive.  
   
   
       3 . The moisture barrier of  claim 1  further comprising: 
 a third envelope of polyester enveloped within the second envelope and having at least one open periphery for accepting the panel therein and wherein the second and third envelopes are bonded together.    
   
   
       4 . The moisture barrier of  claim 3  wherein the second and third envelopes are bonded together with adhesive.  
   
   
       5 . The moisture barrier of  claim 1  further comprising: 
 a puncture resistant envelope of biax nylon sandwiched between the first and second envelopes having at least one open periphery for accepting the panel therein and wherein the puncture resistant envelope is bonded to the first and second envelopes are bonded together.    
   
   
       6 . The moisture barrier of claims  5  wherein the first, the biax nylon and second envelopes are bonded together with adhesive.  
   
   
       7 . The moisture barrier of  claim 6  further comprising: 
 a third envelope of polyester enveloped within the second envelope and having at least one open periphery for accepting the panel therein and wherein the second and third envelopes are bonded together.    
   
   
       8 . The moisture barrier of claims  7  wherein the second and third envelopes are bonded together with adhesive.  
   
   
       9 . The moisture barrier of claims  8  wherein the first and second envelopes are bonded together with adhesive.  
   
   
       10 . A cover for spa comprising the moisture barrier of  claim 1  wherein, 
 the panel further comprises a foam insert.    
   
   
       11 . The spa cover of  claim 10  wherein the foam insert is expanded polystyrene.  
   
   
       12 . The spa cover of  claim 10  wherein the foam insert is polyurethane.  
   
   
       13 . The spa cover of  claim 10  wherein the foam insert further comprises polyurethane encapsulating a core of expanded polystyrene.  
   
   
       14 . The moisture barrier of  claim 1  wherein the bag is evacuated.