Cover body of hydrotherapy bathtub and method for manufacturing cover body of hydrotherapy bathtub

Abstract

A method for manufacturing a hydrotherapy bathtub article, the method comprising laminating a decorative film to a substrate; laminating an acrylic film to the decorative film, the substrate, the decorative film, and the acrylic film forming a laminated assembly; and forming the laminated assembly.

Description

[0001] Divisional application This application is a divisional application of the invention application filed on February 15, 2019, with application number 201980023541.7 and titled "Cover of a Spa Bathtub and Method of Manufacturing the Cover of a Spa Bathtub". Cross-references to related applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 62 / 630,887, filed February 15, 2018, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present invention relates generally to spa bathtubs, and more specifically, to the cover of a spa bathtub, and related methods for manufacturing a cover for a spa bathtub or hot tub. Background Technology

[0004] Spa bathtubs, also commonly known as hot tubs, are a popular feature in many homes. They typically consist of a vacuum-formed tub with a smooth acrylic lining, filled with hot water for soaking and relaxation. Spa bathtubs often include water jets for massage.

[0005] Typically, acrylic liners are made in various shapes to provide multiple seating arrangements within the bathtub. Each seat is usually equipped with spa jets that direct pressurized water streams to multiple parts of the user's body. The water streams can be aerated for additional effects, and some or all of the jets may also move or rotate automatically, thus changing the water pressure on the body to provide a massage-like effect.

[0006] Because many spa / hot tubs are located outdoors, they are typically equipped with covers to close the tub when not in use. These covers help prevent dust, leaves, and other debris from entering the water and provide safety features to prevent children and animals from falling in. Additionally, spa tub covers are usually insulated for energy efficiency and readiness purposes, limiting heat loss from the water when the spa tub is not in use.

[0007] Both soft and hard covers are known in the art. Typical hard covers usually consist of a hollow plastic shell that can be filled with insulating foam. These covers typically include internal ribs or posts (also known as "kiss offs") extending between the upper and lower shell members of the cover to provide structural rigidity and support for the cover. While providing rigidity, these kiss offs also provide a means of heat conduction from the spa tub into the atmosphere, thus reducing the overall insulation effect of the cover.

[0008] In summary, various molding methods, such as rotational molding and blow molding, can be used to form general hard covers for spa baths. However, these molding methods require very expensive custom molds, meaning that new molds are needed if a new size or shape of cover is required. Therefore, this cost hinders the widespread adoption of hard covers in the spa bath industry, especially considering the large number of spa baths of different sizes and shapes produced by numerous manufacturers. Furthermore, existing molding methods do not allow for a wide range of color variations in the produced covers.

[0009] In view of the above, there is still a need for spa bath covers with improved thermal insulation and structural integrity, as well as related methods for producing covers of any size and shape at a reduced cost. Summary of the Invention

[0010] The purpose of this invention is to provide a cover for a spa bath and a related method for manufacturing the cover of the spa bath.

[0011] Another object of the present invention is to provide a method for manufacturing a cover for a spa bath, the method producing a cover with improved thermal insulation properties compared to existing covers.

[0012] Another object of the present invention is to provide a cover for a spa bath that does not require the use of "kiss-offs" connecting the upper and lower sides of the cover.

[0013] Another object of the present invention is to provide a method for manufacturing a cover for a spa bath, the cover of which has improved strength and rigidity compared with existing covers.

[0014] Another object of the present invention is to provide a method for manufacturing a spa bath cover with a high-quality or "furniture-quality" finish.

[0015] Another object of the present invention is to provide a method for manufacturing an easily customizable cover for a spa bath.

[0016] Another object of the present invention is to provide a method for manufacturing a cover for a spa bath, which allows for the rapid production of covers of different sizes and shapes in a cost-effective manner.

[0017] Another object of the present invention is to provide a method for manufacturing a customizable spa bathtub cover.

[0018] These and other objectives are achieved through this invention.

[0019] According to an embodiment of the present invention, a method for manufacturing spa bath products includes: laminating a decorative film onto a substrate; laminating an acrylic film onto the decorative film, wherein the substrate, the decorative film, and the acrylic film form a laminated assembly; and shaping the laminated assembly.

[0020] According to another embodiment of the present invention, a cover for a spa bath includes: a first shell member having a base layer; a decorative film laminated to the base layer; an acrylic film laminated to the decorative film; a second outer shell member nested with the first shell member and defining an internal space therebetween; and foam located in the internal space and bonded to the first shell member and the second shell member.

[0021] According to another embodiment of the present invention, a method for manufacturing a cover for a spa bath includes forming a first shell component, comprising: laminating a decorative film onto a base sheet, laminating an acrylic film onto the decorative film, the base sheet, the decorative film, and the acrylic film forming a first laminated assembly, and vacuum-forming the first laminated assembly. The method further includes vacuum-forming a second shell component, positioning a high-density closed-cell foam within at least one of the first and second shell components, such that the first and second shell components are nested to enclose the foam between the first and second shell components, and bonding the foam to the first and second shell components to form an integral structure. Attached Figure Description

[0022] The invention will be better understood by referring to the following description of non-limiting embodiments, in which: Figure 1 This is a top perspective view showing the upper and lower halves of a spa bathtub cover according to an embodiment of the present invention; Figure 2 It is shown Figure 1 A bottom perspective view of the upper and lower halves of the spa bathtub cover; Figure 3 It is a perspective view showing the upper and lower halves moving in alignment with each other; Figure 4 This is another perspective view, showing the upper and lower halves being moved closer together to align with each other; Figure 5 It is a perspective view showing the upper and lower halves arranged nested within each other to form a hollow shell; Figure 6 This is an exploded perspective view of the cover for a spa bathtub, showing the upper cover component, the lower cover component, and the internal foam material; Figure 7 This is a partial three-dimensional sectional view of the lid in its assembled state, showing the foam inside the lid; Figure 8 It is an enlarged detail of all parts of the lid, showing the foam inside the lid; Figure 9 It is a perspective view of the cover, showing the lifting holes or channels formed therein; Figure 10 yes Figure 9 A perspective view of the cover, showing the tube extending through the lifting channel in the cover; Figure 11 yes Figure 10 An enlarged perspective view of the cover; Figure 12 It is a perspective view of a cover assembly having two cover component halves; Figure 13 yes Figure 12 An enlarged perspective view of the cover assembly, showing its sealing and lifting channels; Figure 14 It is an enlarged perspective view of the sealing and lifting channels; Figure 15 The diagram shows detailed cross-sectional views of the upper and lower halves of the cover, illustrating its locking features; Figure 16 This is an enlarged view of the first locking feature of the cover; Figure 17 This is an enlarged view of the second locking feature of the cover; Figure 18 This is a cross-sectional view of the cover, showing the outer wall in the locked position; Figure 19 This is an enlarged cross-sectional view of a portion of the cover, showing the joining of the two halves of the cover; Figure 20-22 An upper shell member and a lower shell member of a cover member according to an embodiment of the present invention are shown; Figure 23 and 24 An accessory for a spa bathtub according to an embodiment of the present invention is shown; Figure 25 yes Figure 20-22 A cross-sectional view of the cover structure, showing its individual layers. Detailed Implementation

[0023] refer to Figures 1 to 8 The image shows a cover assembly 10 for a spa bath. (Example) Figure 1 and Figure 2As shown, the cover assembly 10 includes an upper housing member 12 and a lower housing member 14. Each of the housing members 12, 14 is generally rectangular in shape and includes an outer surface (e.g., outer surfaces 13, 15) and peripheral sidewalls (e.g., peripheral sidewalls 17, 19) extending from the outer surface, with an internal space 16 defined between these peripheral sidewalls. In one embodiment, the housing members 12, 14 are manufactured using a vacuum molding process (or pressure molding process). In a preferred embodiment, the housing members 12, 14 are made of an acrylic material. For example, in a preferred embodiment, the housing members 12, 14 may be made of a material selected from acrylonitrile-butadiene-styrene (ABS) and polyvinyl chloride (PVC). In other embodiments, without departing from a broader aspect of the invention, the housing members 12, 14 may be made of other materials such as polyethylene (PE).

[0024] As in Figure 3-5 As best illustrated, once the respective housing components 12, 14 are made by a vacuum molding process, they are nested and aligned to form a hollow cavity between them. For example, housing component 12 may be housed within housing component 14. Housing components 12, 14 may then be joined together to form a waterproof seal using one or more of mechanical joints, adhesives, or welding, as will be discussed in detail below.

[0025] refer to Figure 6-8 Once the housing members 12 and 14 are joined together, foam 18 is injected or otherwise filled into the hollow cavity, for example through injection ports or similar openings (not shown) in the outer surfaces or peripheral sidewalls of the housing members 12 and 14. In a preferred embodiment, foam 18 is polyurethane foam. In other embodiments, the foam may be expanded polystyrene foam. In some embodiments, foams made of other materials may also be used without departing from the broader aspects of the invention.

[0026] Importantly, foam 18 is bonded to the vacuum-formed shell components 12 and 14. As a result, shell components 12 and 14 and foam 18 form a single, structural component. As will be readily understood, this bonding of foam 18 to shell components 12 and 14 provides increased structural stiffness and strength to the cover assembly 10 as a whole, eliminating the need for kiss-offs, ribs, or other structural components within the cover, which are typically more expensive, time-consuming to manufacture, and reduce the cover's thermal efficiency. This also contrasts with existing covers utilizing free-floating foam within the cover (i.e., which does not bond to the inner surface of the shell components), where free-floating foam does not increase the cover's structural stiffness or strength.

[0027] In one embodiment, foam 18 can be a high-density foam, meaning a foam with a density exceeding 1.7 lb / ft³. Even if one of the shell components 12, 14 ruptures, this high-density foam (defined as closed-cell foam) will not absorb water. As a result, the present invention avoids the water absorption that plagues existing polystyrene caps, as well as the subsequent loss of strength and insulation performance, mold growth, etc.

[0028] Although the above embodiments disclose filling the chamber with foam after aligning the housing members 12, 14 with each other, the present invention also contemplates that foam may be deposited or positioned in one of the housing members 12, 14 before placing the housing members 12, 14 together and sealing them with each other. For example, in one embodiment, foam may be deposited in the lower housing member 14, and then the upper housing member 12 may be aligned with the lower housing member 14 and the foam sealed therein along the edges, as discussed above.

[0029] Importantly, the use of vacuum molding to manufacture the corresponding shell components 12, 14 allows for the rapid, easy, and inexpensive production of covers of various shapes, sizes, colors, etc. In particular, vacuum molding can be manufactured and adjusted inexpensively compared to rotary molds and blow molds commonly used in industry. This provides the ability to produce covers of any size to fit any size spa bath. Furthermore, vacuum molding allows for the rapid production of such covers, enabling aftermarket cover production without the need to produce hundreds of different stock units (skus) or stock thousands of covers. In effect, the method of this invention allows for on-demand production of rigid covers for spa baths, as a form of aftermarket manufacturing (i.e., just-in-time manufacturing).

[0030] In addition, the vacuum molding process using acrylic allows for the subsequent injection of polyurethane foam, which bonds to the two halves of the surrounding acrylic shell to form a monolithic structural component. This cannot be achieved using rotational molding and other molding methods that cannot use acrylic. Importantly, the combination of acrylic, the vacuum-formed shell, and polyurethane, high-density foam, or similar foams allows the foam to bond to the shell, thereby forming a monolithic, structural component capable of withstanding significant loads.

[0031] Now for reference Figure 9-12 In one embodiment, the cover assembly 10 may also include various specific configurations that facilitate the opening and closing of the cover. For example, in one embodiment, the cover assembly 10 may be manufactured without any holes or channels for receiving a lifting mechanism or handle. In another embodiment, such as Figure 9As shown, in one embodiment, the cover assembly 10 may have a hole or channel 20 formed on its side, through which a lifting rod (not shown) may be inserted. Figure 10 and 11 As shown, the cover assembly 10 may alternatively be formed with a hole 20 and a tube 22 (e.g., a PVC pipe) extending therethrough. In this embodiment, the tube 22 is preferably sealed to the cover to prevent water ingress, and the tube 22 is configured to accommodate a lifting rod of a lifting mechanism passing through it.

[0032] Reference Figure 12 The cover assembly 100 may alternatively include a central seal 110 connecting two opposing cover halves 10. The seal 110 also serves as a lift hole 112 for the lift rod of the lifting mechanism. Figure 12 As shown, two cover assemblies 10 may be joined together by a seal 110 to form a cover 100 covering the entire spa bathtub. In one embodiment, the seal 110 may be joined to the cover half by adhesive, welding, or other joining methods known in the art. Figure 13 As best shown in the diagram, the seal 110 forms a channel 112 extending along the width of the cover 100, through which a lifting rod can be inserted. During the unpacking operation, the cover 100 is folded onto itself and then lifted from the top of the spa tub by the lifting rod. Figure 14 A simplified diagram of the central seal 110 and the channel 112 is shown.

[0033] Turn now Figure 15-19 The figure illustrates how the two vacuum-formed halves 12, 14 of the cover assembly 10 may be joined together. As shown, each housing member 12, 14 (particularly the sidewalls 17, 19 of housing members 12, 14) may be formed with one or more mating locking features or joints, such as a first joint / locking feature 28 and a second joint / locking feature 30. Figure 16 and 17 As best illustrated, the first joint 28 and the second joint 30 may be formed as bends or protrusions within the housing members 12, 14. For example, as... Figure 16 and 17 As shown, the first joint 28 may be formed as mating bends 40, 42 (e.g., male and female) in the first housing member 12 and the second housing member 14, while the second joint may be formed as mating recesses or arched protrusions 44, 46 in the first housing member 12 and the second housing member 14. The bends / protrusions 28, 30 are preferably formed in the housing members 12, 14 as part of the vacuum molding process.

[0034] Importantly, the slight elasticity of the shell members 12 and 14 allows them to subsequently slide fairly easily into their nested structure. When foam 18 is injected into the hollow cavity after the shell members 12 and 14 have joined together, the foam expands, causing the joint / locking features 28 and 30 in the respective shell members 12 and 14 to lock together, thereby mechanically preventing the shells from sliding apart. Specifically, the mating locking features 28 and 30 (i.e., male protrusions or recesses accommodated in the corresponding female grooves) prevent the shell members 12 and 14 from... Figure 15 The arrows indicate sliding or movement relative to each other (and in any direction). This feature, combined with adhesive or welding along the joint interface, forms a durable and impermeable seal that is waterproof.

[0035] refer to Figure 19 The hollow cavity 32 of the cover assembly 10 can also be formed by nesting two shell members 12, 14 together, as shown in the figure. Then, the halves 12, 14 can be easily glued or thermally bonded at the joint 34. Additionally, as... Figure 19 As shown, this process allows for the molding or shaping of the joined ends (i.e., at 34) to form a skirt that closes the shell or sides of the spa bathtub. This potentially eliminates the need for separate vinyl or plastic skirts around the perimeter of the spa bathtub, reducing overall costs and improving the overall aesthetics of the spa bathtub.

[0036] In addition to the advantages mentioned above, compared to existing methods, the color of the cover assembly 10 can be easily changed by using the vacuum-formed shell components 12 and 14 made of the aforementioned materials; many different patterns are possible, and the resulting finish and gloss are much better. Relatedly, the method of the present invention and the resulting cover assembly allow images to be adhered to the cover assembly (which has been impossible until now due to the rough surface of existing hard covers). In some embodiments, the surface treatment provided by the vacuum molding process also allows the molded cover to be painted to provide even more personalized appearances. Moreover, by utilizing the vacuum molding process, raised or recessed embossing can be molded into the cover assembly to create unique designs, words, phrases, etc.

[0037] While the above embodiments envision polyurethane foam being injected into the hollow cavity after the two halves are joined together, pre-formed or pre-cut foam inserts may also be used. Specifically, in one embodiment, a pre-formed foam insert that closely matches the internal shape and dimensions of the housing component may be placed within the hollow cavity, and the insert is bonded to the respective housing half with an adhesive when the two halves are closed to seal the insert. In other embodiments, liquid polyurethane may be poured into the hollow cavity, or polystyrene foam particles may be blown into the hollow cavity to form the foam interior.

[0038] Now for reference Figure 20-24 This illustrates a spa bath product that may be formed using a manufacturing method according to another embodiment of the invention. For example, Figure 20-22 A cover member 100 for a spa bathtub is shown, manufactured using the methods discussed below. In one embodiment, an ABS sheet is used as the base of the cover member 100, wherein the cover member 100 includes an upper cover member / shell 112, a lower cover member / shell 114, and insulating foam 110 sandwiched between the upper cover member 112 and the lower cover member 114, as will be described below. For example, special ABS sheets of 48”×96” and 52”×100” sizes may be used, such as those manufactured by Positron.

[0039] Reference Figure 25 In one embodiment, a decorative film 104 is then laminated onto an ABS sheet 102. In one embodiment, the decorative film 140 may be a polymer film with wood grain, carbon fiber, white pearl, or any desired color or surface finish. After laminating the decorative film 104 onto the ABS sheet 102, an acrylic film 106 with a UV protectant is then laminated over the decorative film 104, and a protective plastic film 108 is then adhered over the acrylic film 106 to protect the laminated assembly before vacuum stretching, as will be discussed in detail below. Figure 25 As shown, therefore, prior to vacuum forming, the components forming the cover member 112 or 114 include an ABS substrate 102, a decorative film 104 above the substrate, an acrylic layer 106 above the decorative film 104, and a removable protective film above the acrylic layer 106. The protective film must first be removed before vacuum stretching or forming by other methods.

[0040] Importantly, the decorative film 104 allows the lid components to be manufactured to resemble any type of material, such as wood, plastic, marble, etc. In particular, the decorative film 104 allows the lid components to achieve a "furniture-quality" wood appearance. This type of surface treatment has been impossible in the spa bath and lid manufacturing industry until now.

[0041] To form the cover component 100, the laminated sheet / assembly is heated to approximately 350 degrees Fahrenheit in a ceramic heater oven. The heated sheet is then vacuum-formed on several male / female molds specifically designed to keep the ABS film-laminated side out of contact with the mold surface. Thermal cycling is then performed to a specific temperature, and the acrylic layer is stretched and fused to the ABS / laminated sheet.

[0042] In one embodiment, the four corners of the cover component are simultaneously formed from a single sheet in a single vacuum stretching operation. For example... Figure 20 and21 As shown, the upper / shell of the cover member 100 is made of a single sheet, and the lower / shell of the cover is also made of a single sheet. As will be readily understood, and as discussed above, the cover member 100 is formed from separate upper and lower shell members joined together. After molding each shell member, the shell member is cooled to approximately 130 degrees Fahrenheit, and a protective film is applied to the film-side surfaces (i.e., the outward-exposed surfaces). This protective film remains on the shell member throughout the manufacturing process.

[0043] Next, the four formed corners are placed on specially designed vacuum holders, which are designed to hold them in place and support them from falling off due to the vacuum holding pressure. The corners are then cut from the vacuum-formed rough edges using a built-in air router tool, which slides along guide channels within the corner. In this way, external holders are unnecessary and could otherwise obstruct the cut and pose a risk of contacting and scratching the film's side surfaces. The corners are now cut to the appropriate size and are ready to be drilled and installed on the spa tub.

[0044] After trimming the edges, one of the housing components is placed in a nested vacuum clamping device, which uses vacuum suction to hold it in place. Then, a slitting insert / end mill is used to trim away the vacuum-formed burrs from the inside of the housing.

[0045] Next, the cover components are cut to a predetermined bonding height in a single operation. Specifically, the cover components are cut such that there is sufficient surface area between the upper and lower cover components to form a joint at least 1 inch wide.

[0046] The lower cover component is then mounted on a base holder that holds it in place. The burrs are then manually removed from the lower cover component using a Dremmel tool or similar tool. This step is performed in this way because grooves are created in the burr area for cutting, and cutting in this way is much faster than using a milling machine, and this type of cutting does not require precision.

[0047] refer to Figure 20 Then, the expanded polystyrene (EPS) pieces are cut into any chambers or recesses that fit within the upper cover member 112 and the lower cover member 114. The main EPS block, spanning most of the cover's thickness, is then cut. Smaller chamber / recess pieces are glued to their appropriate positions within the upper and lower cover members, and then the main EPS block, spanning from top to bottom, is glued to the lower cover member 114. The glue / adhesive is then allowed to dry and cure.

[0048] Next, a 1 1 / 4" black PVC pipe is cut to a suitable length and inserted into the upper cover member 112 of the cover 100. Two holes are drilled on opposite sides (long dimension) of the upper cover member 112 of the cover to allow the PVC pipe to pass through and be inserted. The PVC pipe is then glued in place from the inside of the cover using retaining rings, which secure and seal the pipe in place. This pipe is then used for the insertion of the crossbar of the lifting mechanism. The glue is allowed to harden and dry. The holes are sized and positioned such that the assembled and foam-filled cover, in the open position, tilts when lifted and standing vertically along the side of the spa tub.

[0049] To assemble the upper cover component 112 to the lower cover component to form the cover 100, the lower cover component 114, with EPS blocks 110 bonded in place, is placed on an adhesive base. Both the upper and lower EPS are coated with adhesive. In one embodiment, the adhesive is a high-temperature EPS-compatible glue that will withstand temperatures of at least approximately 140 to 150 degrees Fahrenheit that the upper cover component 112 might experience under direct sunlight. The adhesive is then applied to increase tack. Methyl methacrylate adhesive is then applied to one side of the ABS to the ABS bonding point (between the upper and lower cover components), and the upper and lower cover components are then assembled together. Weight is then applied to the upper part to press the entire assembly together, and a special adhesive fastener (with an inflatable bladder that matches the outer contour of the cover) is clamped in place, pressing the two bonded sides (upper and lower) together with sufficient pressure and holding them there for one hour.

[0050] One hour later, the pressure is released from the clamping airbag and the fixing device is removed, and the fully bonded cover 100 is placed to one side to cure overnight. After a curing time of approximately 15 hours or longer, the fully bonded cover assembly 100 is inserted into the vacuum nesting fixing device, and the bonded flange is trimmed to the final size using a cutting saw in a milling machine.

[0051] Next, remove the cover assembly from the vacuum clamp and place it on the inspection table. Then visually inspect the total length of the bonded interface. If any gaps are detected, fill them with glue and clamp. Then allow the assembly to cure for at least one hour. Any areas where glue has been repaired should be sanded and polished. The cover is now ready to be fitted to its other half and installed on the spa tub. Finally, before installation, check the cover for repairable scratches and repair any scratches using a commercially available scratch repair agent.

[0052] refer to Figure 23 and 24It may also form other spa bath components and accessories, such as decorative corner component 200, in the manner described herein.

[0053] Although the invention has been described above in connection with the manufacture of a spa bath cover, it is not limited thereto. In particular, it is foreseeable that the above-described method may also be used to provide various other manufactured articles in which internal strength and rigidity may be provided to the hollow article by utilizing the bonding of foam to the inner surface of the hollow article. For example, various other spa bath components, including but not limited to spa bath bases, spa bath doors, etc., can be manufactured using the methods described herein.

[0054] Although the invention has been shown and described with reference to detailed embodiments thereof, those skilled in the art will understand that various changes may be made and elements may be substituted with equivalents without departing from the scope of the invention. Furthermore, modifications may be made to adapt particular situations or materials to the teachings of the invention without departing from the essential scope of the invention. Therefore, the invention is not intended to be limited to the specific embodiments disclosed in the above detailed description, but rather the invention will include all embodiments falling within the scope of this disclosure.

Claims

1. A method for manufacturing a spa bath product, comprising the following steps: Laminate the decorative film onto the substrate; An acrylic film is laminated onto the decorative film, and the substrate, the decorative film, and the acrylic film are formed into a laminated assembly; and The stacked components are shaped.

2. The method according to claim 1, wherein: The substrate is a sheet made of one of the following materials: acrylonitrile-butadiene-styrene (ABS) and polyvinyl chloride (PVC).

3. The method according to claim 2, wherein: The acrylic film includes an ultraviolet protectant.

4. The method according to claim 1, further comprising the following steps: The protective film is adhered to the acrylic film.

5. The method according to claim 4, wherein: The protective film can be removed from the acrylic film.

6. The method according to claim 1, wherein: The step of forming the laminated assembly includes vacuum forming the laminated assembly.

7. The method according to claim 6, further comprising the following step: The laminated assembly is heated before vacuum forming.

8. The method according to claim 7, wherein: The stacked assembly is heated to approximately 350 degrees Fahrenheit.

9. The method according to claim 1, wherein: The decorative film is a polymer film with a wood grain or carbon fiber appearance.

10. The method according to claim 1, wherein: The decorative film is a colored polymer film.

11. A cover for a spa bathtub, comprising: The first housing component has a base layer, a decorative film laminated to the base layer, and an acrylic film layer laminated to the decorative film layer; The second housing member is nested with the first housing member and defines an internal space between the first housing member and the second housing member; as well as Foam, located in the internal space, is bonded to the first shell component and the second shell component.

12. The cover according to claim 11, wherein: The decorative film is a polymer film with a wood grain or carbon fiber appearance.

13. The cover according to claim 11, wherein: The decorative film is a colored polymer film.

14. The cover according to claim 11, wherein: The base layer is made of one of the following materials: acrylonitrile-butadiene-styrene (ABS) and polyvinyl chloride (PVC).

15. The cover according to claim 11, wherein: The acrylic film includes an ultraviolet protectant.

16. A method for manufacturing a cover for a spa bath, comprising the following steps: The first shell component is fabricated, comprising: The decorative film is laminated onto the base sheet; An acrylic film is laminated onto the decorative film, and the substrate, the decorative film, and the acrylic film form a first laminated assembly; and The first stacked component is vacuum-formed; The second shell component was formed using vacuum forming. High-density closed-cell foam is positioned in at least one of the first shell component and the second shell component; The first and second shell members are nested together to enclose the foam between them; and The foam is bonded to the first component and the second shell component to form an integral structure.

17. The method of claim 16, further comprising the step of: The protective film is removably applied to the acrylic film; The first shell component and the second shell component are pressed tightly against the foam.

18. The method of claim 16, wherein: The substrate material includes one of acrylonitrile-butadiene-styrene (ABS) and polyvinyl chloride (PVC); and The acrylic film includes an ultraviolet protectant.

19. The method of claim 16, wherein: The decorative film is a polymer film with a wood grain or carbon fiber appearance.

20. The method of claim 16, wherein: The decorative film is a colored polymer film.

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