Integrated interchangeable jet modules for a SPA and / or bathing system

Abstract

An interchangeable jet module includes at least one jet and a casing having an open front and a back manifold, with the back manifold having a mounting surface for mounting a base portion of the at least one jet. The interchangeable jet module may also include a jet plate for closing the open front of the casing, with the jet plate having a mounting surface for mounting a top portion of the at least one jet. The at least one jet may extend from the mounting surface of the jet plate to the mounting surface of the back manifold of the casing, where a side wall of the casing hides the at least one jet from view. The jet play may sit flush with the casing, such that the interchangeable jet module appears to be one solid unit.

Description

[0001] Attorney Docket 8039-3033USU1

[0002] TITLE INTEGRATED INTERCHANGEABLE JET MODULES FORA SPA AND / OR BATHING SYSTEM

[0003] CLAIM FOR PRIORITY

[0004] A claim for priority to the November 15, 2024 filing date of U.S. Provisional Application No. 63 / 721,311 titled “INTEGRATED INTERCHANGEABLE JET MODULES FOR A SPA AND / OR BATHING SYSTEM,” (the “’311 Provisional Application”) is hereby made pursuant to 35 U.S.C. §119(e). The entire disclosure of the ’311 Provisional Application is herein incorporated by reference

[0005] TECHNICAL FIELD

[0006] This disclosure relates generally to unitary and integrated interchangeable jet modules for a spa and / or bathing system. More specifically, this disclosure relates to interchangeable jet modules with built-in jet and headrest components.

[0007] SUMMARY

[0008] Disclosed are systems, devices, and / or methods of use thereof regarding unitary and integrated interchangeable jet modules for a spa and / or bathing system. In various aspects, an interchangeable jet module includes at least one jet and a casing having an open front and a back manifold, with the back manifold having a mounting surface for mounting a base portion of the at least one jet. The interchangeable jet module may also include a jet plate for closing the open front of the casing, with the jet plate having a mounting surface for mounting a top portion of the at least one jet. The at least one jet may extend from the mounting surface of the jet plate to the mounting surface of the back manifold of the casing, where a side wall of the casing hides the at least one jet from view. The jet plate may sit flush with the casing, such that the interchangeable jet module appears to be one solid unit.

[0009] In various aspects, an interchangeable jet module includes a casing having an open front and a back manifold. The interchangeable jet module may also include at least one air chamber arranged in front of the back manifold and at least one water chamber arranged adjacent to the at least one air chamber. The interchangeable jet module may further include a jet plate for closing the open front of the casing. The jet plate may have a mounting surface 1

[0010] SL 8527674.1 Attorney Docket 8039-3033USU1

[0011] with at least one in-molded jet, with a top portion of the at least one in-molded jet being flush with the mounting surface. The at least one in-molded jet may extend from the mounting surface of the jet plate to a mounting surface of the back manifold of the casing, such that a base portion of the at least one in-molded jet is in fluid communication with the at least one air chamber and the at least one water chamber. A side wall of the casing may hide the at least one jet from view and the jet plate may sit flush with the casing, such that the interchangeable jet module appears to be one solid unit.

[0012] In various aspects, a method of manufacturing an interchangeable jet module includes forming a hollow structure from a thermoplastic material, with the hollow structure having a front and a back, and molding jet structures into an exterior surface of the front of the hollow structure. The method may also include forming at least one air chamber and at least one water chamber within the hollow structure, with the jet structures in connection with the at least one air chamber and the at least one water chamber. Further, the method may include inserting a jet nozzle into the jet structures, the jet nozzles extending from the exterior surface of the front of the hollow structure to the at least one air chamber and the at least one water chamber.

[0013] In various aspects, a method of manufacturing an interchangeable jet module includes forming a hollow structure from a thermoplastic material, with the hollow structure having a front and a back, and molding jet structures into an exterior surface of the front of the hollow structure. The method may also include internally forming dividing walls between the front and the back of the hollow structure and tacking off the dividing walls to form at least two chambers within the hollow structure. The at least two chambers may include an air chamber and a water chamber, with the jet structures extending from the exterior surface to and through the at least two chambers.

[0014] In various aspects, a method of manufacturing an interchangeable jet module includes forming a casing having a back manifold, a side wall extending from the back manifold, and an open front defined by the side wall. The method may also include forming a jet plate to close the open front of the casing and positioning at least one jet between the jet plate and the back manifold, with a top portion of the jet mounted on the jet plate. Further, the method may include forming a first chamber and a second chamber within the back manifold, where the first chamber and the second chamber are arranged front-to-back.

[0015] 2

[0016] SL 8527674.1 Attorney Docket 8039-3033USU1

[0017] In various aspects, a method of manufacturing an interchangeable jet module includes forming a hollow structure from a thermoplastic material, with the hollow structure having a front and a back manifold. The method may also include forming an air chamber and a water chamber within the back manifold, and forming a cavity at a top of an exterior surface of the front. Further, the method may include positioning a headrest module within the cavity of the front of the hollow structure, where the headrest module is in fluid communication with the air chamber and the water chamber of the back manifold.

[0018] Other aspects of the disclosed subject matter, as well as features and advantages of various aspects of the disclosed subject matter, should be apparent to those of ordinary skill in the art through consideration of the ensuing description, the accompanying drawings, and the appended claims.

[0019] BRIEF DESCRIPTION OF THE DRAWINGS

[0020] In the drawings:

[0021] FIGS. 1A and IB illustrate interchangeable jet module configurations of the prior art;

[0022] FIG. 2 A illustrates a perspective view of an interchangeable jet module according to the present disclosure;

[0023] FIG. 2B illustrates a side view and FIG. 2C illustrates a top view of the interchangeable jet module of FIG. 2 A;

[0024] FIG. 3 illustrates an exploded view of the interchangeable jet module of FIGS. 2A through 2B;

[0025] FIG. 4A illustrates an exploded, perspective view of another embodiment of an interchangeable jet module;

[0026] FIG. 4B illustrates a side cross-sectional view of FIG. 4 A;

[0027] FIG. 4C illustrates a jet insert for use with the interchangeable jet module of either FIG. 2A or FIG. 4A;

[0028] FIG. 5 illustrates a top, side, perspective view of another embodiment of an interchangeable jet module;

[0029] FIG. 6 illustrates a front view of the interchangeable jet module of FIG. 5 installed within a spa or bathing system;

[0030] 3

[0031] SL 8527674.1 Attorney Docket 8039-3033USU1

[0032] FIG. 7 A illustrates a partially exploded view of the interchangeable jet module of FIG. 5 with another embodiment of a pillow or headrest;

[0033] FIG. 7B schematically illustrates a user utilizing the interchangeable jet module and pillow of FIG. 7A;

[0034] FIG. 8 A illustrates a perspective view of any of the interchangeable jet module of FIGS. 2, 4 A, or 5 with another embodiment of a pillow or headrest;

[0035] FIG. 8B schematically illustrates a user utilizing the pillow or headrest of FIG. 8 A; FIGS. 9 A through 9C illustrate various embodiments of a bulkhead fitting and water inlets that may be incorporated into any of the interchangeable jet modules of FIGS. 2, 4 A, or 5 and flows or air and water through the bulkhead fitting;

[0036] FIG. 9D illustrates a flow of air and / or water through chambers of any of the interchangeable jet modules of FIGS. 2, 4A, or 5;

[0037] FIG. 9E shows a cross-sectional view of a chamber of another configuration of an interchangeable jet module;

[0038] FIG. 10A illustrates a pump and blower system for routing or delivering air and water to the bulkhead fitting of FIGS. 9A through 9C and any of the interchangeable jet modules of FIGS. 2, 4 A, or 5;

[0039] FIG. 10B illustrates a water inlet for any of the interchangeable jet modules of FIGS. 2, 4 A, or 5;

[0040] FIG. 11 A illustrates an actuatable valve positioned between air and water chambers of any of the interchangeable jet modules of FIGS. 2, 4A, or 5;

[0041] FIGS. 11B and 11C illustrate additional embodiments for actuating the valve of FIG. 11 A; and

[0042] FIG. 12 is flowchart of one example method of manufacturing an interchangeable jet module;

[0043] FIG. 13 is a flowchart of one example method of manufacturing an interchangeable jet module;

[0044] FIG. 14 is a flowchart of another example method of manufacturing an interchangeable jet module; and

[0045] FIG. 15 is a flowchart of another example method of manufacturing an interchangeable jet module.

[0046] 4

[0047] SL 8527674.1 Attorney Docket 8039-3033USU1

[0048] DETAILED DESCRIPTION FIGS. 1A and IB illustrate jet module configurations 900 of the prior art. The jet modules 900 have a substantial gap 905 between a front 915 and a back 920. The gap 905 is to accommodate the plurality of jets 910 that extend between the front 915 and the back 920. This configuration, while accommodating for the jets 910, gives the jet modules 900 a bulky and modular appearance.

[0049] Additionally, as seen in FIG. IB, the jet modules 900 may receive a pillow 925 at a top of the jet modules 900. Jets or other water structures 930 may be located underneath the pillow 925 to massage the neck of a user using the jet module 900. However, the pillow 925 itself has no water or jet functionality. Additionally, the pillow 925 must sit on top of the jet module 900 and is not seamlessly integrated into the jet module 900. To hold the pillow 925 in place, there must be a snap or connection mechanism at the top of the jet modules 900.

[0050] FIGS. 2A through 2C illustrate a unitary and integrated interchangeable jet module 100 according to the present disclosure. The interchangeable jet module 100 (also referred to as the “jet module 100”) may be selectively installed within a spa shell, such as within a hollow or impression defined in the spa shell. The jet module 100 includes a jet plate 20 having an exterior surface 21 with a plurality of jet mounting locations 22. The jet plate 20 is connected to a casing 10. Specifically, the jet plate 20 is connected to a sidewall 12 of the casing 10, where the sidewall 12 extends from a back manifold 11 of the casing 10. The jet plate 20 attaches to the casing 10 such that the jet module 100 is a unitary or singular unit (see, for example, FIG. 2B). A headrest module 40 is incorporated near the top 24 of the jet plate 20. The headrest module 40 may be integral with, connected to, or removable from the jet module 100. In some configurations, a cavity 25 is defined at the top 24 of the jet plate for receiving the headrest module 40 (FIG. 3). The cavity 25 is configured to place the headrest module 40 in fluid communication with the jet module 100 and / or the spa within which the jet module 100 is installed.

[0051] Referring briefly to FIG. 3, the casing 10 has an open front 13, which may be defined by the sidewall 12. The jet plate 20 connects to the casing 10, and the sidewall 12, to close the open front 13. The back manifold 11 may include or define one or more chambers 30 (see FIG. 4B). The chambers 30 may be in fluid communication with the jets 50 that are disposed between the jet plate 20 and the back manifold 11.

[0052] 5

[0053] SL 8527674.1 Attorney Docket 8039-3033USU1

[0054] For example, referring also to FIGS. 4A through 4C, a plurality of jets 50 may be installed within the plurality of jet mounting locations 22. As seen in the cross-sectional view of FIG. 4B, chambers 30 may be formed between the jet plate 20 and the back manifold 11, and the jets 50 may be in fluid communication with the chambers 30. The jet mounting locations 22 may be molded into the jet plate 20. The entirety of the jet structure (e.g., a nozzle, mixing chamber, etc.) may be molded into the jet plate 20 at the jet mounting locations 22. Alternatively, the jet mounting locations 22 may be impressions or holes to receive a jet insert 54.

[0055] Specifically, a top portion 51 of the jets 50 (see FIG. 4C, illustrating a jet insert 54) may be mounted on the exterior surface 21 of the jet plate 20. The bottom portion 52 of the jets 50 may extend into the one or more chambers 30 (e.g., through mounting locations 22 into the one or more chambers 30). In some embodiments, the jet mounting locations 22 are threaded, and the bottom portion 52 of the jets 50 includes threadings 55 to mate with and engage the jet mounting locations 22. Alternatively, the jets 50 may be pressed, snapped, or otherwise connected into the jet mounting locations 22.

[0056] However the jets 50 are incorporated into the jet mounting locations 22 (e.g., molded, inserted, snapped, etc.), the jets 50 are in fluid communication with the chambers 30. Referring to FIGS. 4A and 4B, the chambers 30 may include two chambers arranged front-to-back. As seen in the exploded view of FIG. 4 A, a first chamber 30a may be located in front of a second chamber 30b. The casing 10 may include two (2) sidewalls 12 to help define the chambers 30. The back manifold 11 may include both the chambers 30a, 30b. In some embodiments, the first chamber 30a may correspond to or share space with the open front 13 of the casing 10. The first chamber 30a may be a water chamber and the second chamber 30b may be an air chamber. Alternatively, the first chamber 30a may be an air chamber and the second chamber 30b may be a water chamber. A drain 14 at the bottom of the jet module 100 may be in communication with both chambers 30.

[0057] FIG. 5 illustrates a side, perspective view of the interchangeable jet module 100. As clearly shown, the jet module 100 has the appearance of a unitary or singular unit. That is, the jet plate 20 has seamlessly closed the open front 13 of the casing 10. The jet plate 20 is flush with the sidewall 12 of the casing 10, such that the jet plate 20 and the casing 10 appear to be one piece. The headrest module 40 is situated within the cavity 25 at the top

[0058] 6

[0059] SL 8527674.1 Attorney Docket 8039-3033USU1

[0060] 24 of the jet plate 20. The headrest module 40 is positioned such that it is substantially flush with the top 24 of the jet plate 20.

[0061] The jet plate 20 may be formed from acrylic or other appropriate thermoplastic material and may match any paneling of the spa within which the jet module 100 is positioned. For example, as seen in FIG. 6, when the jet module 100 is positioned within the spa 80, the jet plate 20 sits flush within the spa 80 or walls of the spa 80. The jet module 100 is positioned within a hollow 85 of the spa 80, such that the jet plate 20 appears to be another segment of the spa 80. The jet module 100 includes controls 60, which may be electronic controls 65, disposed at the top 24 of the jet plate 20. The controls 60 may control a jet emission from the jet module 100. Alternatively, the controls 60 may control lights or other features of the jet module 100.

[0062] FIG. 7 A illustrates a partially exploded view of the interchangeable jet module 100 with another embodiment of a pillow or headrest module 40. The headrest module 40 is a jet headrest 42, having a jet plate 44 and a casing 43, which may house components (e.g., a manifold) for placing the headrest module 40 in fluid communication with the jet module 100. As seen in FIG. 7A, the jet headrest 42 is attachable to the jet plate 20 through the cavity 25. The cavity 25 may include a bulkhead or other fitting (see FIG. 9B) to place the jet headrest 42 in fluid communication with the jet module 100 and / or the spa within which the modules 100, 42 are placed.

[0063] Each of the casing 43 and the jet plate 44 of the jet headrest 42 may be shaped to accommodate a neck and shoulder region of a user (see FIG. 7B). Similar to the jet plate 20, the jet plate 44 of the jet headrest 42 includes a plurality of jet mounting locations 46. As with the jet mounting locations 22, the jet mounting locations 46 may include molded jet structures or may be capable of receiving jet inserts 54. When the jet headrest 42 is connected to the jet plate 20, the jet headrest 42 appears to be a unitary component of the jet module 100.

[0064] In some configurations, the headrest module 40, whether a pillow 41 or a jet headrest 42, may be hingedly attached to the jet plate 20. FIGS. 8A and 8B illustrate the jet headrest module 42 in multiple positions and in use by a user. For example, the jet headrest 42 may hinge about a pivot point 47. As seen in FIG. 8A, the jet headrest 42 may simply pivot from a horizontal position to a vertical position. This may accommodate taller users. As seen in FIG. 8B, the jet headrest 42 may pivot between a substantially horizontal 7

[0065] SL 8527674.1 Attorney Docket 8039-3033USU1

[0066] position A, a vertical position B, and an extended horizontal position C. These positions may provide different therapeutic effects to a user, while also accommodating for taller users or users with longer torsos.

[0067] FIGS. 9 A through 9C illustrate a fluid port 15 that may be incorporated into any of the interchangeable jet modules 100 of FIGS. 2, 4A, or 5. Also illustrated are flows air and / or water through the fluid port 15. FIG. 9D illustrates a flow of air and / or water through chambers 30 of any of the interchangeable jet modules 100 of FIGS. 2, 4A, or 5. The fluid port 15 may engage a bulkhead fitting to place the jet modules 100 in fluid communication with the air and fluid system of the spa 80 within which the module 100 are installed (see FIG. 10A).

[0068] The fluid port 15 may include a water channel 16 and an air channel 17. The water channel 16 may deliver water to the water chamber 32 and the air channel 17 may deliver air to the air chamber 31 (see FIG. 9D). As seen in FIG. 9B, the fluid port 15 may be inserted into the bulkhead fitting 86 of the spa. The fluid port 15 may be press-fit into the bulkhead fitting 86 and may include gaskets or seals to help seal the connection between the fluid port 15 and the bulkhead fitting 86. Alternatively, the fluid port 15 may snap or clip into the bulkhead fitting 86. As shown in FIG. 9C, the bulkhead fitting 86 may have corresponding air and water channels 16, 17 that connect and feed into the air and water channels 16, 17 of the fluid port 15.

[0069] In some configurations, such as that shown in FIG. 9E, the air and water may mix in a single chamber 30 behind the jet plate 20. The jets 50 may be, in one example an inmolded jet, such as a jet molded into the jet plate 20 at a jet mounting location 22. With an in-molded jet, the outer housing of a typical jet is incorporated into the body of the jet plate 20 such that they are integral or a single part. The jet insert, a typically separate item that threads or presses into the outer housing of the jet, would typically be kept separate to allow movement or spinning action of the jet insert. If the jet is fixed and does not require movement, then it may also be possible to incorporate the jet insert, as well as the outer housing, into the jet plate 20 such that the entire jet and the jet plate 20 are one integral unit. Thus, an in-molded jet may be a jet where any portion of the jet, or the entire jet, is molded with the jet plate 20.

[0070] The molded jets 50 may extend from the jet plate 20, where a mixture of water and air will be dispersed into a spa or bathing system, to the chamber 30. In this way, the jets 8

[0071] SL 8527674.1 Attorney Docket 8039-3033USU1

[0072] 50 may be in fluid communication with the chamber 30, such that the jet 50 may deliver a mixture of water and air to the spa or bathing system. By molding the jets 50 directly into the jet plate 20, fewer components are utilized to construct the interchangeable jet modules 100. This decreases the likelihood of any one component breaking or failing. This also streamlines the overall interchangeable jet modules 100.

[0073] The mixture of air and water may be delivered to the chamber 30 through the water channel 26 located at the bottom of the casing 10 and / or the bottom of the jet plate 20. The water channel 26 may be secured to a bulkhead fitting 86 that supplies both the air and water to the chamber 30. That is, the air may come from the same bulkhead fitting 86 as the water comes from. This allows air to be pulled from multiple areas within the spa, such as pulling hot air out of the equipment area which is typically below the spa shell (e.g., a pump system 70 such as illustrated in FIG. 10A). By having both air and water mix behind the jet (rather than within the jet), different air / water consistencies can be applied for a desired therapeutic effect.

[0074] FIG. 10A illustrates a pump and blower system 70 for routing or delivering air and water to the fluid port 15 and the bulkhead fitting 86 of FIGS. 9 A through 9C and, thus, jet modules 100. The system 70 includes a fan or blower 71 and a pump 72. The fan 71 cools the pump 72 as the pump 72 moves air and water through the spa. The pump 72 may deliver air and water to each hollow 85, in which an interchangeable jet module 100 may be installed. Referring to FIG. 10B, in some embodiments, the interchangeable jet modules 100 may include a water channel 26 near a bottom of the jet plate 20.

[0075] It is possible that the pump system 70 can supercharge the air flow instead of relying on a Venturi system to pull the air in to the jet modules 100. Compared to systems that rely on Venturi effect to pull air near a user’s head above the water line of the spa, this may reduce noise being generated right behind the head of the user. The air can be injected into the water right at the bulkhead fitting 86 (see FIG. 9A) or it could be ducted up into the jet modules 100 and released at each jet. This design allows the typical venturi flow to be used to pull the air at each jet.

[0076] Just as the air may be routed into the jet modules 100, the water may also be pulled directly into the jet modules 100. Specifically, the water channel 26 pulls water into the jet modules 100 and the back manifolds 11. It is critical that the water flowing around the jet plates 20 into the back manifolds 11 is sufficient to keep up with the suction line of the spa 9

[0077] SL 8527674.1 Attorney Docket 8039-3033USU1

[0078] or water will drain out this area and cause the suction to cavitate and draw air into the pump 72. Currently, the gap 905 between the jet plate 915 and the back 920 (see FIG. 1A) is relied upon to be the source of water flow. This is not always the most efficient way of getting water flow and can cause cavitation. Introducing purposeful water recessing (such as a channel 26 in the jet plate 20) in the jet modules 100 and creating inserted recessing features 27 improve the flow of water to the suction.

[0079] FIG. 11A illustrates an actuatable valve 67 positioned between air and water chambers 31, 32 of the interchangeable jet modules 100 and FIGS. 11B and 11C illustrate additional embodiments for actuating the valve of FIG. 11 A. The valve 67 may selectively close off either the air or water chambers 31, 32 or may change a flow of air / water to the air or water chambers 31, 32, respectively. The valve 67 may be actuated by a lever 61. Some prior art systems use a rotational knob disposed behind the headrest module 40 to actuate the valve 67. However, rotational knobs may be difficult to actuate with wet fingers and positioning the knob behind the head of the user may make it difficult for a user to grasp and turn.

[0080] FIG. 1 IB illustrates the incorporation of valves 67 at the top and the bottom of the jet module 100. The bottom valve 67 may regulate a flow of air and water to the jet plate 20, while the top valve 67 may regulate a flow of air and water to the headrest module 40. FIG. 11C illustrates a slider 64 to actuate the valve(s) 67. The slider 64 may provide haptic or other feedback to the user to indicate a change in flow. The jet modules 100 may include a switch, toggle, buttons, or other appropriate actuator to actuate the valve(s) 67.

[0081] FIGS. 12 through 15 are flowcharts of example methods according to the present disclosure. FIG. 12 is a method 300 of manufacturing an interchangeable jet module 100. The method 300 includes forming a hollow structure from a thermoplastic material, with the hollow structure having a front and a back, at 305, and molding jet structures into an exterior surface of the front of the hollow structure, at 310. The front may be a jet plate, such as jet plate 20, and the back may be a back manifold, such as back manifold 11. The molded jet structures may be fully functional jets. Alternatively, the molded jet structures may receive a jet insert.

[0082] The method 300 may also include forming at least one air chamber and at least one water chamber within the hollow structure, with the jet structures in connection with the at least one air chamber and the at least one water chamber, at 315. Further, the method 300

[0083] 10

[0084] SL 8527674.1 Attorney Docket 8039-3033USU1

[0085] may include inserting a jet nozzle into the jet structures, the jet nozzles extending from the exterior surface of the front of the hollow structure to the at least one air chamber and the at least one water chamber, at 320. The jet nozzles may be included as a jet insert, or may be the only portion of the jet that is not molded into the front of the hollow structure. The jet module may be formed from a blow-molding or injection molding process.

[0086] FIG. 13 is a method 400 of manufacturing an interchangeable jet module, such as the jet module 100. The method 400 may include forming a hollow structure from a thermoplastic material, with the hollow structure having a front and a back, at 405, and molding jet structures into an exterior surface of the front of the hollow structure, at 410. The method 400 may also include internally forming dividing walls between the front and the back of the hollow structure, at 415, and tacking off the dividing walls to form at least two chambers within the hollow structure, at 420. The at least two chambers may include an air chamber and a water chamber, with the jet structures extending from the exterior surface to and through the at least two chambers. The molded jet structures may include all of the functioning elements of a jet (e.g., body, nozzle, fluid communication for air and water, etc.), such that no jet inserts are required. The jet module may be formed from a blow-molding or injection molding process.

[0087] FIG. 14 is a method 500 of manufacturing an interchangeable jet module, such as jet module 100. The method 500 may include forming a casing having a back manifold, a side wall extending from the back manifold, and an open front defined by the side wall, at 505. The method 500 may also include forming a jet plate to close the open front of the casing, at 510, and positioning at least one jet between the jet plate and the back manifold, at 515, with a top portion of the jet mounted on the jet plate. Further, the method 500 may include forming a first chamber and a second chamber within the back manifold, where the first chamber and the second chamber are arranged front-to-back, at 520. The first chamber may be an air chamber and the second chamber may be a water chamber, or vice-versa. The jet module may be formed from a blow-molding or injection molding process.

[0088] FIG. 15 is a method 600 of manufacturing an interchangeable jet module, which may be the jet module 100. The method 600 may include forming a hollow structure from a thermoplastic material, with the hollow structure having a front and a back manifold, at 605. The method may also include forming an air chamber and a water chamber within the back manifold, at 610, and forming a cavity at a top of an exterior surface of the front, at 11

[0089] SL 8527674.1 Attorney Docket 8039-3033USU1

[0090] 615. Further, the method 600 may include positioning a headrest module within the cavity of the front of the hollow structure, where the headrest module is in fluid communication with the air chamber and the water chamber of the back manifold, at 620. The headrest module may be a jet headrest 42. The jet module may be formed from a blow-molding or injection molding process.

[0091] SL 8527674.1 Attorney Docket 8039-3033USU1

[0092] Embodiments

[0093] Embodiment 1. An interchangeable jet module comprising:

[0094] at least one jet;

[0095] a casing comprising an open front and a back manifold, the back manifold having a mounting surface for mounting a base portion of the at least one jet;

[0096] a jet plate for closing the open front of the casing, the jet plate having a mounting surface for mounting a top portion of the at least one jet,

[0097] the at least one jet extending from the mounting surface of the jet plate to the mounting surface of the back manifold of the casing,

[0098] a side wall of the casing hiding the at least one jet from view, and

[0099] the jet plate sitting flush with the casing, such that the interchangeable jet module appears to be one solid unit.

[0100] Embodiment 2. The interchangeable jet module of Embodiment 1, wherein the back manifold of the casing comprises at least one air chamber and at least one water chamber.

[0101] Embodiment 3. The interchangeable jet module of Embodiment 1 or 2, wherein the at least one jet is in fluid communication with both the at least one air chamber and the at least one water chamber.

[0102] Embodiment 4. The interchangeable jet module of Embodiment 2 or 3, wherein the at least one air chamber is arranged in front of the at least one water chamber.

[0103] Embodiment 5. The interchangeable jet module of Embodiment 2, 3, or 4, wherein the at least one water chamber is arranged in front of the at least one air chamber.

[0104] Embodiment 6. The interchangeable jet module of any one of Embodiments 1 through 5, wherein the jet plate defines a cavity near a top end of the jet plate, the cavity for receiving a headrest module.

[0105] Embodiment 7. The interchangeable jet module of Embodiment 6, wherein the headrest module comprises a pillow.

[0106] Embodiment 8. The interchangeable jet module of Embodiment 6 or 7, wherein the headrest module is hingedly attached to the cavity, such that the headrest module is moveable between a first horizontal position and a second position vertical position.

[0107] Embodiment 9. The interchangeable jet module of Embodiment 6, 7, or 8, further comprising a first bulkhead fitting disposed within the cavity, the bulkhead fitting for

[0108] 13

[0109] SL 8527674.1 Attorney Docket 8039-3033USU1

[0110] placing the headrest module in fluid communication with a water flow and an air flow of a spa in which the interchangeable jet module is installed.

[0111] Embodiment 10. The interchangeable jet module of any one of Embodiments 6 through 9, wherein the headrest module comprises a neck and shoulder jet module.

[0112] Embodiment 11. The interchangeable jet module of any one of Embodiments 6 through 10, wherein the headrest module comprises a neck and shoulder jet module comprising:

[0113] at least one jet;

[0114] a casing having a mounting surface for mounting a base portion of the at least one jet; and

[0115] a jet plate having a mounting surface for mounting a top portion of the at least one jet,

[0116] the at least one jet extending from the mounting surface of the jet plate to the mounting surface of the casing,

[0117] the casing being in fluid communication with the back manifold of the interchangeable jet module.

[0118] Embodiment 12. The interchangeable jet module of any one of Embodiments 10 through 11, wherein the jet plate is shaped to accommodate a neck and shoulder area of a user of the headrest module.

[0119] Embodiment 13. An interchangeable jet module comprising:

[0120] a casing comprising an open front and a back manifold;

[0121] at least one air chamber arranged in front of the back manifold;

[0122] at least one water chamber arranged adjacent to the at least one air chamber; and a jet plate for closing the open front of the casing, the jet plate having a mounting surface with at least one in-molded jet, a top portion of the at least one in-molded jet being flush with the mounting surface,

[0123] the at least one in-molded jet extending from the mounting surface of the jet plate to a mounting surface of the back manifold of the casing, such that a base portion of the at least one in-molded jet is in fluid communication with the at least one air chamber and the at least one water chamber,

[0124] a side wall of the casing hiding the at least one jet from view, and

[0125] 14

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[0127] the jet plate sitting flush with the casing, such that the interchangeable jet module appears to be one solid unit.

[0128] Embodiment 14. A method of manufacturing an interchangeable jet module, the method comprising:

[0129] forming a hollow structure from a thermoplastic material, the hollow structure having a front and a back;

[0130] molding jet structures into an exterior surface of the front of the hollow structure; forming at least one air chamber and at least one water chamber within the hollow structure, the jet structures in connection with the at least one air chamber and the at least one water chamber; and

[0131] inserting a jet nozzle into the jet structures, the jet nozzles extending from the exterior surface of the front of the hollow structure to the at least one air chamber and the at least one water chamber.

[0132] Embodiment 15. A method of manufacturing an interchangeable jet module, the method comprising:

[0133] forming a hollow structure from a thermoplastic material, the hollow structure having a front and a back;

[0134] molding jet structures into an exterior surface of the front of the hollow structure; internally forming dividing walls between the front and the back of the hollow structure; and

[0135] tacking off the dividing walls to form at least two chambers within the hollow structure, the at least two chambers including an air chamber and a water chamber, the jet structures extending from the exterior surface to and through the at least two chambers.

[0136] Embodiment 16. A method of manufacturing an interchangeable jet module, the method comprising:

[0137] forming a casing having a back manifold, a side wall extending from the back manifold, and an open front defined by the side wall;

[0138] forming a jet plate to close the open front of the casing;

[0139] positioning at least one jet between the jet plate and the back manifold, a top portion of the jet mounted on the jet plate; and

[0140] forming a first chamber and a second chamber within the back manifold, the first chamber and the second chamber arranged front-to-back.

[0141] 15

[0142] SL 8527674.1 Attorney Docket 8039-3033USU1

[0143] Embodiment 17. A method of manufacturing an interchangeable jet module, the method comprising:

[0144] forming a hollow structure from a thermoplastic material, the hollow structure having a front and a back manifold;

[0145] forming an air chamber and a water chamber within the back manifold; forming a cavity at a top of an exterior surface of the front; and

[0146] positioning a headrest module within the cavity of the front of the hollow structure, the headrest module in fluid communication with the air chamber and the water chamber of the back manifold.

[0147] Embodiment 18. An interchangeable jet module comprising:

[0148] a casing comprising an open front and a back manifold;

[0149] at least one air chamber arranged in front of the back manifold;

[0150] at least one water chamber arranged adjacent to the at least one air chamber; and a jet plate for closing the open front of the casing, the jet plate having a mounting surface with at least one in-molded jet, a top portion of the at least one in-molded jet being flush with the mounting surface,

[0151] the at least one in-molded jet extending from the mounting surface of the jet plate to a mounting surface of the back manifold of the casing, such that a base portion of the at least one in-molded jet is in fluid communication with the at least one air chamber and the at least one water chamber,

[0152] a side wall of the casing hiding the at least one jet from view, and

[0153] the jet plate sitting flush with the casing, such that the interchangeable jet module appears to be one solid unit.

[0154] Additional Terms and Definitions

[0155] While particular embodiments have been illustrated and described herein, it should be understood that various other changes and modifications may be made without departing from the spirit and scope of the claimed subject matter. Moreover, although various aspects of the claimed subject matter have been described herein, such aspects need not be utilized in combination. It should also be noted that some of the embodiments disclosed herein may have been disclosed in relation to a particular water-containing vessel (e.g., a spa); however, other vessels (e.g., pools, tubs, swim spas, etc.) are also contemplated. A spa is 16

[0156] SL 8527674.1 Attorney Docket 8039-3033USU1

[0157] also known in the industry as a hot tub and is generally formed of a concave shell to receive and contain water. Structures, such as a jet, can extend through the concave shell to move water from a surface outside the spa to a surface inside the spa or shell. Surfaces inside the shell are referred to as more “proximal” while surfaces that extend through the shell are referred to as “distal.” A proximal side of a jet faces the spa shell where the user relaxes, and the jet can provide hydrotherapy to the user in the spa.

[0158] In one embodiment, the terms “about” and “approximately” refer to numerical parameters within 10% of the indicated range. The terms “a,” “an,” “the,” and similar referents used in the context of describing the embodiments of the present disclosure (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein is intended merely to better illuminate the embodiments of the present disclosure and does not pose a limitation on the scope of the present disclosure. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the embodiments of the present disclosure.

[0159] Groupings of alternative elements or embodiments disclosed herein are not to be construed as limitations. Each group member may be referred to and claimed individually or in any combination with other members of the group or other elements found herein. It is anticipated that one or more members of a group may be included in, or deleted from, a group for reasons of convenience and / or patentability. When any such inclusion or deletion occurs, the specification is deemed to contain the group as modified thus fulfilling the written description of all Markush groups used in the appended claims.

[0160] Certain embodiments are described herein, including the best mode known to the author(s) of this disclosure for carrying out the embodiments disclosed herein. Of course, variations on these described embodiments will become apparent to those of ordinary skill in the art upon reading the foregoing description. The author(s) expects skilled artisans to 17

[0161] SL 8527674.1 Attorney Docket 8039-3033USU1

[0162] employ such variations as appropriate, and the author(s) intends for the embodiments of the present disclosure to be practiced otherwise than specifically described herein. Accordingly, this disclosure includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the present disclosure unless otherwise indicated herein or otherwise clearly contradicted by context.

[0163] Specific embodiments disclosed herein may be further limited in the claims using consisting of or consisting essentially of language. When used in the claims, whether as filed or added per amendment, the transition term “consisting of’ excludes any element, step, or ingredient not specified in the claims. The transition term “consisting essentially of’ limits the scope of a claim to the specified materials or steps and those that do not materially affect the basic and novel characteristic(s). Embodiments of this disclosure so claimed are inherently or expressly described and enabled herein.

[0164] Although this disclosure provides many specifics, these should not be construed as limiting the scope of any of the claims that follow, but merely as providing illustrations of some embodiments of elements and features of the disclosed subject matter. Other embodiments of the disclosed subject matter, and of their elements and features, may be devised which do not depart from the spirit or scope of any of the claims. Features from different embodiments may be employed in combination. Accordingly, the scope of each claim is limited only by its plain language and the legal equivalents thereto.

[0165] 18

[0166] SL 8527674.1

Claims

Attorney Docket 8039-3033USU1CLAIMSWhat is claimed:

1. An interchangeable jet module comprising:at least one jet;a casing comprising an open front and a back manifold, the back manifold having a mounting surface for mounting a base portion of the at least one jet; anda jet plate for closing the open front of the casing, the jet plate having a mounting surface for mounting a top portion of the at least one jet,the at least one jet extending from the mounting surface of the jet plate to the mounting surface of the back manifold of the casing,a side wall of the casing hiding the at least one jet from view, andthe jet plate sitting flush with the casing, such that the interchangeable jet module appears to be one solid unit.

2. The interchangeable jet module of claim 1, wherein the back manifold of the casing comprises at least one air chamber and at least one water chamber.

3. The interchangeable j et module of claim 2, wherein the at least one j et is in fluid communication with both the at least one air chamber and the at least one water chamber.

4. The interchangeable jet module of claim 2, wherein the at least one air chamber is arranged in front of the at least one water chamber.

5. The interchangeable jet module of claim 2, wherein the at least one water chamber is arranged in front of the at least one air chamber.

6. The interchangeable jet module of claim 1, wherein the jet plate defines a cavity near a top end of the jet plate, the cavity for receiving a headrest module.

7. The interchangeable jet module of claim 6, wherein the headrest module comprises a pillow.19SL 8527674.1Attorney Docket 8039-3033USU18. The interchangeable jet module of claim 6, wherein the headrest module is hingedly attached to the cavity, such that the headrest module is moveable between a first horizontal position and a second position vertical position.

9. The interchangeable jet module of claim 6, further comprising a first bulkhead fitting disposed within the cavity, the bulkhead fitting for placing the headrest module in fluid communication with a water flow and an air flow of a spa in which the interchangeable jet module is installed.

10. The interchangeable jet module of claim 6, wherein the headrest module comprises a neck and shoulder jet module.

11. The interchangeable jet module of claim 6, wherein the headrest module comprises:at least one jet;a casing having a mounting surface for mounting a base portion of the at least one jet; anda jet plate having a mounting surface for mounting a top portion of the at least one jet,the at least one jet extending from the mounting surface of the jet plate to the mounting surface of the casing,the casing being in fluid communication with the back manifold of the interchangeable jet module.

12. The interchangeable jet module of claim 11, wherein the jet plate is shaped to accommodate a neck and shoulder area of a user of the headrest module.

13. An interchangeable jet module comprising:a casing having an open front and a back manifold;at least one air chamber arranged in front of the back manifold;at least one water chamber arranged adjacent to the at least one air chamber; and 20SL 8527674.1Attorney Docket 8039-3033USU1a jet plate for closing the open front of the casing, the jet plate having a mounting surface with at least one in-molded jet, a top portion of the at least one in-molded jet being flush with the mounting surface,the at least one in-molded jet extending from the mounting surface of the jet plate to a mounting surface of the back manifold of the casing, such that a base portion of the at least one in-molded jet is in fluid communication with the at least one air chamber and the at least one water chamber,a side wall of the casing hiding the at least one in-molded jet from view, and the jet plate sitting flush with the casing, such that the interchangeable jet module appears to be one solid unit.

14. The interchangeable jet module of claim 13, further comprising controls disposed near a top of the jet plate, the controls for controlling a jet emission from the interchangeable jet module.

15. The interchangeable jet module of claim 13, further comprising a headrest module in connection with a cavity defined by a top of the jet plate, the headrest module in fluid communication with the casing of the interchangeable jet module.

16. The interchangeable jet module of claim 15, further comprising a bulkhead fitting disposed within the cavity to establish fluid communication with the casing of the interchangeable jet module17. A method of manufacturing an interchangeable jet module, the method comprising:forming a hollow structure from a thermoplastic material, the hollow structure having a front and a back;molding jet structures into an exterior surface of the front of the hollow structure; forming at least one air chamber and at least one water chamber within the hollow structure, the jet structures in connection with the at least one air chamber and the at least one water chamber; and21SL 8527674.1Attorney Docket 8039-3033USU1inserting a jet nozzle into the jet structures, the jet nozzles extending from the exterior surface of the front of the hollow structure to the at least one air chamber and the at least one water chamber.

18. The method of claim 17, wherein forming a hollow structure from the thermoplastic material comprises blow-molding the hollow structure.

19. The method of claim 17, wherein forming the at least one air chamber and the at least one water chamber within the hollow structure comprises:internally forming dividing walls between the front and the back of the hollow structure; andtacking off the dividing walls to form at least two chambers within the hollow structure, the at least two chambers including an air chamber and a water chamber, the jet structures extending from the exterior surface to and through the at least two chambers.

20. The method of claim 17, wherein inserting a jet nozzle into the jet structure comprises threading the jet nozzle into the jet structure.22SL 8527674.1

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