Spa with integrally molded working components and method for making same

Abstract

A spa with spa working components integrally molded into a foam spa body. Certain working components, including the water circulation lines, electrical lines, air jet lines and a pump / heater housing are pre-assembled over a female mold. The working components are maintained in spaced relation from the female mold by spacer means. A male mold is placed over the female mold, defining a foam cavity between opposing sides of the female mold and the male mold and fully enclosing the spa components therein. Expandable foam is introduced into the foam cavity, integrally forming the spa body and encasing the enclosed working components. The female and male molds are removed from the spa body, and a flexible liner is installed over inner and outer sides of the wall of the spa body. The pump / heater unit is installed within its housing and attached to the electrical and water lines therein.

Description

BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The invention relates generally to free-standing spas containing a body of hot water, used for therapy and relaxation. More particularly, the invention pertains to an integrally molded spa, in which certain working components of the spa are encased in a foam spa body at the time the spa is manufactured. A waterproof liner is then installed over the inner and outer sidewalls of the spa body to form a waterproof containment system. [0003] 2. Description of the Prior Art [0004] Above-ground, free-standing spas, are well known in the prior art. One of the early designs was constructed from a plurality of redwood planks. Some of the planks were arranged in vertical relation and bound together with circumferential metal bands or rods to form the spa wall. Other planks were assembled in horizontal relation to form the spa floor. Known as redwood “hot tubs”, these spas typically included a water circulation and filtration s...

AI Technical Summary

Benefits of technology

[0014] A waterproof liner is installed over the floor and the inner and outer portions of the peripheral wall of the spa body. The liner, which is preferably flexible for economy and ease of assembly, forms a hydraulically impervious seal within the floor and inner portion of the peripheral wall, so it can retain the spa water. The liner also protects the foam spa body from wear and possible damage. Input and output fittings as well as any desired lighting fixtures are installed over the liner in the predetermined locations and connected to water, air or electrical lines extending to or abutting the inner portion of the peripheral wall. Air switches, for control of the pump and the lighting fixture, are also mounted at this time. The air switches are mounted within switch cavities formed when special spacer means supporting the pump / heater housing are withdrawn from the spa body.

Problems solved by technology

This arrangement, of course, requires ground excavation, and would not be considered portable.

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