Hot tub cover including modular core

Abstract

A hot tub cover including at least one core module including a jacket and at least one core module within the jacket. Each core module is fabricated from a plurality of rigidly interconnected core elements. In the disclosed embodiment, the core elements are extruded and include dovetail elements at their edges enabling the core elements to slide together.

1 . A hot tub cover comprising:
 at least one core module including a plurality of rigidly interconnected core elements, each core element being a single unitary piece including connector means for connecting the core element to at least one adjacent core element; and   a jacket enclosing said core.   
   
   
       2 . The hot tub cover of  claim 1  wherein each element includes upper and lower surfaces spaced from one another. 
   
   
       3 . The hot tub cover of  claim 1  further comprising:
 at least two of said core modules; and   a hinge interconnecting said core modules.   
   
   
       4 . The hot tub cover in  claim 3  wherein each core module includes a hinged edge and a peripheral edge, said upper surfaces collectively sloping downwardly from said hinged edge to said peripheral edge. 
   
   
       5 . The hot tub cover of  claim 1  wherein said core elements are slidably interconnected by male and female dovetails. 
   
   
       6 . The hot tub cover of  claim 2  wherein each core element further includes a plurality of spaced ribs extending between said upper and lower surfaces of said element, said spaced ribs defining a plurality of openings between said upper and lower surfaces. 
   
   
       7 . The hot tub cover of  claim 6  further comprising an insulating material between said ribs. 
   
   
       8 . A hot tub cover core module comprising a plurality of rigidly interconnected core elements. 
   
   
       9 . The hot tub cover core module of  claim 8  wherein each of said core elements is a single unitary piece including connector means for connecting said core element to at least one adjacent core element. 
   
   
       10 . The hot tub cover core module of  claim 9  wherein each connector means comprises a dovetail component. 
   
   
       11 . The hot tub cover core module of  claim 8  wherein each core element includes upper and lower surfaces spaced from one another. 
   
   
       12 . The hot tub cover core module in  claim 11  wherein each core element includes a plurality of spaced ribs extending between said upper and lower surfaces of said element said spaced ribs defining a plurality of openings between said upper and lower surfaces. 
   
   
       13 . The hot tub cover core module in  claim 12  further comprising an insulating material between said upper and lower surfaces. 
   
   
       14 . The hot tub cover core module in  claim 11  wherein said upper and lower surfaces of each core element are non-parallel. 
   
   
       15 . A hot tub cover kit comprising:
 a plurality of core elements adapted to be rigidly interconnected to form a core module; and   a water resistant jacket.   
   
   
       16 . The hot tub cover kit of  claim 15  wherein:
 said elements have non-parallel upper and lower surfaces; and   said elements are arranged into a substantially straight stack with said elements alternating.   
   
   
       17 . A method of manufacturing a hot tub cover comprising the steps of:
 providing a plurality of core elements adapted to be rigidly interconnected;   rigidly interconnecting the core elements to provide a core module; and   enclosing the core module within a jacket.   
   
   
       18 . The method of  claim 17  wherein each of the core elements is a single piece. 
   
   
       19 . The method of  claim 18  wherein said providing step includes extruding each of the core elements. 
   
   
       20 . The method of  claim 17  wherein the interconnecting step includes:
 aligning a male dovetail of a first element with a female dovetail of a second element; and   sliding the male and female dovetails relative one another.   
   
   
       21 . A method of shipping a hot tub cover comprising the steps of:
 providing a hot tub having an interior;   placing a plurality of core elements within the interior of the hot tub, the elements adapted to be rigidly interconnected to form a core module that cannot lit within the interior of the hot tub;   shipping said hot tub with the core elements within the hot tub, whereupon the elements can be subsequently removed from the hot tub and rigidly interconnected into a core capable of covering the hot tub.   
   
   
       22 . The method of shipping of  claim 21  wherein:
 the hot tub is rectangular; and   said placing step includes placing the plurality of elements diagonally within the hot tub.   
   
   
       23 . The method of shipping of  claim 21  wherein:
 each core element includes non-parallel upper and lower surfaces; and   said placing step includes alternating the orientation of the elements so that they form a substantially straight stack.   
   
   
       24 . The method of  claim 21  further comprising the step of:
 packaging said plurality of core elements.   
   
   
       25 . The method of  claim 21  wherein each core element includes at least one dovetail element adapted to interfit with a dovetail element on another core element. 
   
   
       26 . A method of shipping a hot tub cover comprising the steps of:
 providing a plurality of core elements each having planar, non-parallel upper and lower surfaces;   stacking the plurality of core elements in alternating fashion to form a substantially straight stack despite the non-parallel upper and lower surfaces;   packaging the stack;   shipping the stack.   
   
   
       27 . The method of  claim 26  wherein said providing step includes providing each core element with at least one dovetail element adapted to interfit with a dovetail element on another core element.