Modular inflatable SPA cover
Patent Information
- Application Number
- PCT/US2026/016682
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2025-02-28
- Filing Date
- 2026-02-25
- Publication Date
- 2026-09-03
Smart Images
Figure US2026016682_03092026_PF_FP_ABST
Abstract
Description
MODULAR INFLATABLE SPA COVERCROSS-REFERENCE TO RELATED APPLICATION
[0001] This international application claims priority to, and the benefit of, U.S. Provisional Application No.: 63 / 765417 filed February 28, 2025; the contents of which are incorporated by reference herein in their entirety for all purposes.BACKGROUND
[0002] Spa covers play a critical role in maintaining water cleanliness, retaining heat, reducing evaporative water loss, and ensuring safety when the spa is not in use. These covers are typically used for spas, hot tubs, jacuzzis, lap pools, and / or any other indoor / outdoor heated water structures to help prevent debris, such as leaves and dirt, from contaminating the water, reducing the need for frequent cleaning and excessive chemical treatments. Additionally, a well-designed cover can significantly improve energy efficiency of the temperature control system by minimizing heat loss and reducing water evaporation, leading to lower heating and maintenance costs.
[0003] Conventional spa covers are typically made from foam-insulated vinyl or other weather-resistant materials. While these covers provide varying degrees of insulation and debris ingress protection, they often present several challenges. One common issue is excessive weight and bulkiness, which can make conventional spa covers difficult to remove and replace for spa use, particularly for individuals with limited strength or mobility. Additionally, prolonged exposure to thermal stress from the heated spa water, internal and external moisture, inclement weather, and external UV rays can lead to deterioration, such as mold growth, sagging, cracking, or waterlogging, reducing the effectiveness and lifespan of the spa cover.
[0004] Another challenge with conventional spa covers is their vulnerability to heat loss and environmental damage. Many covers lack a secure seal, allowing heat to escape, reducing thermodynamic performance of the spa and increasing operating costs. Inadequate sealing additionally permits external contaminants to enter, requiring increased cleaning and chemical treatments. In colder climates, the reduced thermodynamic performance exacerbates higher energy consumption as the spa heater must work harder to maintain the desired water temperature. Furthermore, weak or poorly designed covers maynot provide sufficient safety protection, posing a risk for children, pets, or wildlife that may accidentally fall into the spa.
[0005] Several innovations have attempted to address these issues, including folding covers, motorized or mechanically assisted lifting systems, and reinforced insulation layers. However, many of these solutions either increase costs and weight, require complex installation, or fail to provide a long-term, durable solution that balances convenience, efficiency, and safety.DESCRIPTION OF THE DRAWINGS
[0006] The foregoing aspects and many of the attendant advantages of the claimed subject matter will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
[0007] FIGURE l is a perspective view of an embodiment of a modular inflatable spa cover assembly, shown covering a spa, in accordance with aspects of the present disclosure;
[0008] FIGURES 2A and 2B are side and front elevation views, respectively, of the modular inflatable spa cover assembly of FIGURE 1, in accordance with aspects of the present disclosure;
[0009] FIGURES 2C and 2D are top and bottom plan views of the modular inflatable spa cover assembly of FIGURE 1;
[0010] FIGURES 3A-3C are top plan, side elevation, and front elevation views, respectively, of a modular inflatable insert panel for use with the modular inflatable spa cover assembly of FIGURE 1;
[0011] FIGURES 4A and 4B are exploded and assembled views, respectively, of an augmented modular inflatable spa cover, including the modular inflatable insert panel of FIGURES 3A-3C positioned between first and second panels of the modular inflatable spa cover assembly of FIGURE 1 ; and
[0012] FIGURES 5A-5E are exemplary components for use with the modular inflatable spa cover of FIGURE 1, including a handle (FIGURE 5A), an inflation / deflation valve (FIGURE 5B), a securement strap and clasp (FIGURE 5C), a zippered interconnect (FIGURE 5D), and a pressure relief valve (FIGURE 5E).DETAILED DESCRIPTION
[0013] The detailed description set forth above in connection with the appended drawings, where like numerals reference like elements, are intended as a description of various embodiments of the present disclosure and are not intended to represent the only embodiments. Each embodiment described in this disclosure is provided merely as an example or illustration and should not be construed as preferred or advantageous over other embodiments. The illustrative examples provided herein are not intended to be exhaustive or to limit the disclosure to the precise forms disclosed.
[0014] The present disclosure relates to the field of modular inflatable covers for human-occupied heated water enclosures (e.g., spas, hot tubs, jacuzzis, lap pools, hydrotherapy tanks, etc.). The modular inflatable covers may be referred to herein generally as "spa covers"; however, covers suitable for any heated water enclosure are within the scope of the present disclosure. The spa covers disclosed herein are modular and inflatable, and are expected to be light weight, easy to use, durable, and capable of providing superior insulation and human safety in comparison to conventional spa covers. The spa covers of the present disclosure incorporate advanced materials for longevity, a robust sealing mechanism to prevent heat loss and contaminant ingress, and a user-friendly design that allows for low-effort removal and replacement. The materials of the spa covers disclosed herein can be waterproof or water-resistant, can include UV protection, and can provide structural support to improve performance and lifespan.
[0015] Embodiments of the spa covers disclosed herein can include interconnectable panels to provide modularity in the shape and size of the spa cover. The modularity can permit the spa cover to align with the edges of the spa unit to interface closely with the spa sides, improving the sealing characteristics. Each of the panels of the modular spa cover can be constructed using drop stitch technology, which can include insulated drop stitch technology, for lightweight, durable, packable, and heat retaining properties. Drop stitch material is a high-performance fabric construction used in inflatable products, such as paddleboards, water platforms, inflatable boats, air mattresses, camping pads, gym mats, and inflatable aircraft structures. Drop stitch material is engineered to maintain a rigid and stable shape when inflated, while allowing for compact storage / shipping (e.g., folding, rolling, etc.) when deflated. The construction of drop stitch material consists of several main components: the top and bottom fabric layers, a plurality of internal threads extending between the top and bottom fabric layers, side panels, and anairtight sealing material. In some embodiments, an insulating layer is included in the drop stitch construction and can be constructed with any suitable insulating material. Further, different types of top sheets can be adhered to the top fabric layer, such as a rubber grip sheet, etc.
[0016] The outer layers of drop stitch construction used on the embodiments of the spa covers of the present disclosure can be made from high-strength woven polyester or nylon fabric, which provides durability and puncture resistance. These layers serve as the outer surfaces of the inflatable structure and are coated with an airtight material, typically PVC (polyvinyl chloride) or TPU (thermoplastic polyurethane), to ensure the outer surfaces can hold air pressure without leaking. Drop stitch construction includes a high quantity of polyester or nylon threads connecting the top and bottom fabric layers. These threads are spaced apart and woven into the fabric during the manufacturing process. When the drop stitch structure is inflated, the threads spanning across the layers prevent the layers from expanding beyond a predetermined distance (the length of the threads), maintaining a uniform and flat shape instead of ballooning outward, or requiring multiple chambers, such as a standard, non-drop stitch inflatable mattresses or pool accessories. The drop stitch construction of the spa covers disclosed herein results in a highly rigid panel when the material is pressurized to the recommended pressure range.
[0017] In some embodiments, the sides of the spa cover can connect the top and bottom sheets with side panels to create an airtight chamber therebetween. As the material used for the top and bottom fabric layers be porous and air permeable, the top and bottom sheets and the internal threads are coated with an airtight material, as noted above, such as PVC or TPU, which enhances durability and prevents air from escaping the pressure chamber therebetween. Additional reinforcement layers, such as welded seams or extra coatings, can be added to improve strength, resistance to abrasion, and waterproofing. In embodiments of the present disclosure, one or more insulating layers can be included within the drop stitch construction to limit heat transfer from the contents within the spa enclosure to the surrounding atmosphere, which increases efficiency of the spa. In examples using the modular spa cover of the present disclosure with a hot tub, the insulating layers can increase efficiency of the heating system, reducing the cost to keep the hot tub at the desired temperature, particularly when the atmosphere surrounding the spa is significantly colder than the desired spa temperature.
[0018] Drop stitch construction produces panels with high rigidity that can withstand significantly higher air pressure than conventional inflatable items (with drop stitch construction typically being designed to withstand between 10-25 PSI). These relatively high air pressures provide a rigid, board-like feel. Since air pressure and construction provide rigidity to the spa covers, the drop stitch panels of the present disclosure are relatively lightweight when compared to conventional spa covers constructed with foam-insulated vinyl and the like. When the spa covers are deflated, the drop stitch construction permits the spa cover to be packed into a relatively small package for easy transport, storage, and / or retail display. The outer layers / coatings can include additional durability provisions for UV resistance, puncture resistance, anti-microbial properties, and other environmental exposure durability coatings.
[0019] Although embodiments of the present disclosure may be described with reference to panels having drop stitch construction suitable for modular spa covers, one skilled in the relevant art will appreciate that the disclosed embodiments are illustrative in nature and therefore should not be construed as limited to such an application. It should therefore be apparent that the disclosed technologies and methodologies have wide application, and therefore may be suitable for use with other types of cover architecture, including different types of spas, heated or cooled containers, cover sizes, insulation and debris ingress performance levels, and the like. Accordingly, the following descriptions and illustrations herein should not limit the scope of the claimed subject matter.
[0020] As will be described in more detail below, the present disclosure provides examples of modular inflatable spa cover assemblies that have one or more panels arranged to cover the top opening of a spa enclosure (e.g., a heated water enclosure). In an exemplary embodiment illustrated in a portion of the FIGURES, the spa cover has two rectangular panels that are interconnected and can be folded with respect to each other. The two rectangular panel arrangement of the illustrated embodiment is expected to permit individual panel packaging arrangements, making each panel lighter weight and easier to handle. The panels can also be separately inflatable, as will be discussed in greater detail below. In these embodiments, the two panels are interconnected with a mechanical coupling, such as a zipper, hook and loop fasteners, snaps, buttons, bead and channel, etc. The mechanical coupling can have a web portion coupled to each panel, for example, with adhesive, for operable coupling of the web portion during use of the spa cover. A first panel of the spa cover can have one portion of the mechanical coupling while thecomplementary mechanical coupling portion is located on the second panel (e.g., male and female fasteners, zipper halves, etc.). The embodiments disclosed herein can also include a side skirt configured to cover the interface gap between a top surface of the spa perimeter and the bottom surface of the spa cover to limit heat transfer out of the fluid in the spa enclosure. The side skirts can be modular in any suitable configuration and coupled to the panels with a mechanical coupling interconnect, such as a zipper, hook and loop fasteners, snaps, buttons, bead and channel, etc.
[0021] The modular spa cover assemblies of the present disclosure can include expanding panels to expand the size of the spa cover to accommodate larger sizes of spas. In an example, an insert panel can be arranged between two main panels, interconnecting therebetween, to expand the overall size of the cover by the width of the insert panel. In these embodiments, an insert side skirt can be arranged to extend along the edges of the insert panel such that the skirt covers the entire perimeter of the cover, when assembled. The skirts can have multiple pieces, such as one or more pieces per panel edge, multiple edges can be covered by one skirt portion, or the side skirt can be a single piece surrounding the entire perimeter. In some embodiments, a first skirt can surround three outer perimeter edges of the first main panel, and a second skirt can surround three outer perimeter edges of the second main panel, with the two side skirts together forming a gap-covering skirt around the entire perimeter of the assembled spa cover. In other embodiments, greater or fewer skirt portions can be used to provide insulating and contamination protecting coverage of the gap between the spa and the spa cover.
[0022] The modular covers described herein can have other features that will be described with reference to the FIGURES. For example, the spa cover can have tethering straps coupled to the panels to permit operable coupling of the panels to the spa, such as with receiving portions of the tethering straps on the spa. The tethering straps can include any type of suitable removable coupling configuration, such as releasable clasps, clips, snaps, webbing, t-handles, etc. Any of the panels can include one or more handles to aid in installation / removal of the cover, or to fold the cover for partial spa use. In some embodiments, the panels have drop stitch construction that requires inflation with air to provide the panel rigidity. In this regard, the panels can each include a valve for inflation and deflation, which can be an H3-type (Halkey-Roberts) valve or any other suitable valve. The inflatable panels can further include a pressure relief valve to selectively permit releaseof pressurized gas within the panel, such as when the panel is over-inflated, increasing temperature causes over-pressurization, etc.
[0023] As described above, the cover assembly can include modularity using different panel sizes (e.g., widths, heights, and thicknesses) and configurations (e.g., insulated, side skirts, tethering straps, handles, etc.), and can be customizable during the specification process. The embodiments disclosed herein show exemplary configurations of the spa cover assemblies, and are not intended to be exhaustive of all potential configurations of the spa covers. Further, the spa covers disclosed herein can have various materials suitable for use with the spa environment.
[0024] In some embodiments, the components of the modular spa cover assemblies can include any length, size, or profile. Although rectangular panels are shown in the illustrated embodiments of the FIGURES, other embodiments may include any suitable shape of panel, such as rounded, L-shaped, triangular, etc. Further embodiments can include any number of panels, with assemblies scaled in size and including any suitable material. In some embodiments, the assemblies can have any suitable coupling scheme, e.g., zippers, snap together components, fasteners, locking features, bead and channel, etc. The embodiments shown in the FIGURES are intended as exemplary, and other configurations of the modular inflatable spa covers are also withing the scope of the present disclosure.
[0025] FIGURE l is a perspective view of an embodiment of a modular inflatable spa cover assembly 100 (hereinafter "assembly 100"), shown covering a spa S, in accordance with aspects of the present disclosure. The assembly 100 shown covering the spa S is an example of an environmental use of the assembly 100.
[0026] FIGURES 2A and 2B are side and front elevation views, respectively, of the assembly 100. The assembly 100 can include a first panel 120a and a second panel 120b operably coupled to the first panel by an interconnect 122. The first and second panels 120a and 120b can be inflatable and constructed using drop stitch technology, which can include insulated drop stitch technology. The interconnect 122 can be a zippered flange as shown in the illustrated embodiments, or hook and loop fasteners, snaps, buttons, beaded channel, or any other suitable coupling as described above. The interconnect 122 can permit a hinged motion between the first and second panels 120a and 120b, such that the first panel 120a can be rotated about the interconnect 122 to rest atop the second panel 120b, or vice-versa.
[0027] Each of the first and second panels 120a and 120b can include an inflation / deflation valve 124, such as an H3-type (Halkey-Roberts) valve for inflation / deflation of the first and second panels 120a and 120b. Although the inflation / deflation valve 124 is shown in FIGURE 2B as a valve 124a on a side surface of the first panel 120a, other illustrated embodiments (FIGURE 2D) show the inflation / deflation valve on an upper surface of the first and second panels 120a and 120b. In this regard, the inflation valves can be positioned in any suitable location on the panels 120 that is accessible for inflating and deflating the panels 120. The assembly 100 can further include one or more handles 126a and 126b integrated into the first and second panels 120a and 120b, respectively, for carrying and manipulation of the first and second panels and / or assembly by the user. In this regard, the handle 126a can be used for rotation of the first panel 120a with respect to the second panel 120b, or vice-versa, and / or for carrying the assembly 100 on and off of the spa S. As shown, the panels 120 can include any number of handles 126, including any placement along the side of the panels 120, or the top surface of the panels 120, and can include any number of handles per panel. In the illustrated embodiment of FIGURES 2 A and 2B, the first panel 120a includes a first handle 126a near the interconnect 122 (see FIGURE 2A), and a second handle 126a central to the front side of the panel 120a (see FIGURE 2B).
[0028] The panels 120a and 120b of the assembly 100 can further include side skirt portions 130a and 130b, respectively, configured to cover the interface gap between a top surface of a perimeter of the spa S and a lower surface of the panels 120. The side skirt portions 130 can be integrated into the panels (e.g., by adhesive, stitching, etc.) or can be removably attached, such as with a flange connector 131 (e.g., a zipper flange, bead and channel, etc.). As described above, the assembly 100 can have any number of tethering straps 132 that operably couple the assembly 100 to the spa S, e.g., to secure the assembly 100 to the spa S in the wind, prevent animals from removing the assembly 100 from the spa S, and / or to prevent inadvertent shifting of the assembly 100 with respect to the spa S.
[0029] FIGURES 2C and 2D are top and bottom plan views, respectively, of the assembly 100. Referring first to FIGURE 2C, the assembly 100 can further include corner forms 123a and 123b that have a wedge shape and are positioned between the panels 120a and 120b adjacent to the interconnect 122. The corner forms 123a and 123b can be included to fill a gap between the interconnect 122 and the rounded corners of the panels 120a and 120b such that an edge of the assembly 100 is generally linear along the cornerforms 123a and 123b. In other embodiments, the corner form is a single piece spanning across the gap of the rounded corners of the panels 120a and 120b. In the embodiments disclosed herein, the inflatable panel corners are rounded for air pressure retention. The first and second panels 120a and 120b can further include first and second pressure relief valves 134a and 134b, which are generally positioned aligned with inflation / deflation valves 124a' and 124b' of the first and second panels 120a and 120b (see FIGURE 2D). In other embodiments, the first and second pressure relief valves 134a and 134b can be placed at any location on the surface of the panels 120.
[0030] The illustrated embodiment in FIGURE 2D shows the zipper flange (represented by a dotted line) of the interconnect 122. The interconnect 122 can be arranged between the first and second panels 120a and 120b and can be operably coupled to the first panel 120a by a first web portion 121a, and to the second panel 120b by a second web portion 121b. As set forth above, the assembly 100 can include the inflation / deflation valves 124a' and 124b' on the top surfaces of the panels 120a and 120b, as shown in FIGURE 2D instead of the side surface as shown in FIGURE 2B. In embodiments with the inflation / deflation valves 124 included on the sides of the panels 120 (e.g., as shown in FIGURE 2B), the inflation / deflation valves 124a' and 124b' are omitted from the top surfaces, or vice-versa. Although the inflation / deflation valves 124a' and 124b' are shown generally axially aligned with the first and second pressure relief valves 134a and 134b, the inflation / deflation valves 124a' and 124b' can be positioned in any suitable location on the surface of the panels 120, and can be located independent of the location of the first and second pressure relief valves 134a and 134b.
[0031] FIGURES 3A-3C are top plan, side elevation, and front elevation views, respectively, of a modular inflatable insert panel 140 (hereinafter "insert panel 140") for use with the assembly 100. The insert panel 140 can include similar features to the first and second panels 120a and 120b described above, including a first interconnect 142a, a second interconnect 142b, side skirts 144, a flange connector 141 (e.g., a zipper flange, bead and channel, etc.) to operably couple the side skirts 144 to the insert panel 140, and an inflation / deflation valve 146.
[0032] FIGURES 4A and 4B are exploded and assembled views, respectively, of an augmented modular inflatable spa cover assembly 102 (hereinafter "assembly 102"), including the insert panel 140 positioned between the first and second panels 120a and 120b. The insert panel 140 can be arranged in the assembly 102 to expand the length ofthe assembly 102 when compared to the assembly 100, e.g., to cover larger spa configurations. Any number or shape of insert panels 140 can be used with the assembly 102, such as one, two, three, etc., with each interconnected to the panels 120. In the illustrated embodiment, the first interconnect 142a can be configured to interface with the interconnect 122 on the first panel 120a, and the second interconnect 142b can be configured to interface with the interconnect 122 on the second panel 120b, with each of the complementary interconnects shown separated in FIGURE 4A and operably coupled in FIGURE 4B. In the assembled configuration of FIGURE 4B, the side skirt 144 of the insert panel 140 can be arranged between the side skirts 130a and 130b to form a continuous skirt along the perimeter of the spa S. The side skirt 144 can be coupled to the insert panel 140 by the flange connector 141. Although not shown, in other embodiments, any of the panels can include insulating material to reduce heat transfer across the panels, e.g., so that a heated hot tub is more efficient. Any of the panels can further include a pressure relief valve 134, such as shown in FIGURE 5E, to release pressure over a maximum operating pressure of the panels 120 and 140.
[0033] FIGURES 5A-5E are exemplary components for use with the assemblies 100 and 102, and the panels 120 and insert panel 140, including the handle 126 (FIGURE 5A), the inflation / deflation valve 124 (FIGURE 5B), the securement strap 132 (FIGURE 5C), the interconnect 122 (shown as a zipper in FIGURE 5D), and the pressure relief valve 134 (FIGURE 5E). The handle 126, the valve 124, the safety strap 132, the interconnect 122 (showing the zipper flange embodiment), and the pressure relief valve 134 can be integrated into the assemblies 100 and / or 102, or the panels 120 and 140, by any suitable method, such as head-welding, adhesive, etc.
[0034] Although continuous side skirts 130 are shown in FIGURES 2A and 2B, the side skirts disclosed herein can have any number of individual segments, such as segments for each of the three skirted edges of the panels 120a and 120b, multiple side skirt segments on each edge, and so forth. The illustrated embodiments of FIGURES 1-2D are intended to show one exemplary configuration of the assembly 100, with two panels of approximately the same size and shape connected together. In other embodiments, the panels can be any size, shape, or configuration and can arranged to fit multiple spa sizes. In further embodiments, the modular spa cover assembly can have the inflation / deflation valves, tethering straps, handles, pressure relief valves, and other components in other locations than shown, or certain of the components can be omitted or increased in quantity.
[0035] In the foregoing description, specific details are set forth to provide a thorough understanding of exemplary embodiments of the present disclosure. It will be apparent to one skilled in the art, however, that the embodiments disclosed herein may be practiced without embodying all of the specific details. In some instances, well-known process steps have not been described in detail in order not to unnecessarily obscure various aspects of the present disclosure. Further, it will be appreciated that embodiments of the present disclosure may employ any combination of features described herein.
[0036] The present application may reference quantities and numbers. Unless specifically stated, such quantities and numbers are not to be considered restrictive, but exemplary of the possible quantities or numbers associated with the present application. Also in this regard, the present application may use the term "plurality" to reference a quantity or number. In this regard, the term "plurality" is meant to be any number that is more than one, for example, two, three, four, five, etc. The terms "about," "approximately," "near," etc., mean plus or minus 10% of the stated value. For the purposes of the present disclosure, the phrase "at least one of A and B" is equivalent to "A and / or B" or vice versa, namely "A" alone, "B" alone, or "A and B." Similarly, the phrase "at least one of A, B, and C," for example, means (A), (B), (C), (A and B), (A and C), (B and C), or (A, B, and C), including all further possible permutations when greater than three elements are listed.
[0037] It should be noted that for purposes of this disclosure, terminology such as "upper," "lower," "vertical," "horizontal," "fore," "aft," "inner," "outer," "front," "rear," etc., should be construed as descriptive and not limiting the scope of the claimed subject matter. Further, the use of "including," "comprising," or "having" and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms "connected," "coupled," and "mounted" and variations thereof herein are used broadly and encompass direct and indirect connections, couplings, and mountings.
[0038] Throughout this specification, terms of art may be used. These terms are to take on their ordinary meaning in the art from which they come, unless specifically defined herein or the context of their use would clearly suggest otherwise.
[0039] The principles, representative embodiments, and modes of operation of the present disclosure have been described in the foregoing description. However, aspects of the present disclosure, which are intended to be protected, are not to be construed as limited to the particular embodiments disclosed. Further, the embodiments described herein are tobe regarded as illustrative rather than restrictive. It will be appreciated that variations and changes may be made by others, and equivalents employed, without departing from the spirit of the present disclosure. Accordingly, it is expressly intended that all such variations, changes, and equivalents fall within the spirit and scope of the present disclosure as claimed.
Claims
CLAIMSThe embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:
1. A modular spa cover assembly for covering the opening of a spa enclosure, the spa cover assembly comprising:first and second inflatable panels each having:a top layer, a bottom layer, and a plurality of drop stitch threads extending between the top layer and bottom layer; anda side panel extending around a perimeter and operably coupling the top layer and the bottom layer, wherein the top layer, bottom layer, and side panel together form a continuous outer surface of the inflatable panel and retain pressurized air therein;an interconnect having:a first web portion extending from an edge of the first inflatable panel, the first web portion having a first portion of a mechanical coupling; anda second web portion extending from an edge of the second inflatable panel, the second web portion having a second portion of the mechanical coupling operable to couple the second web to the first web in an assembled configuration, thereby coupling the first inflatable panel to the second inflatable panel through the interconnect,wherein the interconnect is flexible such that the first and second inflatable panels can be rotated with respect to each other by bending the interconnect.
2. The spa cover assembly of Claim 1, wherein the interconnect further comprises a corner form positioned at each longitudinal end portion of the interconnect between rounded comers of the first and second inflatable panels.
3. The spa cover assembly of Claims 1 or 2, wherein the first inflatable panel further comprises a first side skirt extending downward along a portion of the perimeter of the first inflatable panel, and the second inflatable panel further comprises a second side skirt extending downward along a portion of the perimeter of the second inflatable panel, wherein the first side skirt and the second side skirt surround an assembled perimeter of the spa cover assembly in the assembled configuration to cover a gap between the spa cover assembly and a top surface of the spa.
4. The spa cover assembly of any of Claims 1-3, further comprising a first tethering strap operably coupled to the first inflatable panel and a second tethering strap operably coupled to the second inflatable panel, wherein the first and second tethering straps are operable to couple the spa cover assembly to the spa.
5. The spa cover assembly of any of Claims 1-4, further comprising a handle positioned in the side panel of one or both of the first and second inflatable panels, wherein the handle is configured to permit a user to rotate the first or second inflatable panel with respect to the spa.
6. The spa cover assembly of any of Claims 1-5, further comprising an inflation / deflation valve extending through the top layer, the bottom layer, or the side panel of each of the first and second inflatable panels, wherein each inflation / deflation valve is operable to inflate and / or deflate the corresponding first and second inflatable panels.
7. The spa cover assembly of any of Claims 1-6, further comprising a pressure relief valve extending through the top layer, the bottom layer, or the side panel of each of the first and second inflatable panels, wherein each pressure relief valve is operable to release pressure from the corresponding first and second inflatable panels.
8. The spa cover assembly of any of Claims 1-7, wherein the mechanical coupling of the interconnect comprises a zipper, a snap, a fastener, a locking feature, or a bead and channel.
9. The spa cover assembly of any of Claims 1-8, where in the first inflatable panel is mirror symmetrical to the second inflatable panel.
10. The spa cover assembly of any of Claims 1-9, further comprising an inflatable insert panel having:a top layer, a bottom layer, and a plurality of drop stitch threads extending between the top layer and bottom layer; anda side panel extending around a perimeter and operably coupling the top layer and the bottom layer, wherein the top layer, bottom layer, and side panel together form a continuous outer surface of the inflatable insert panel and retain pressurized air therein;a first insert web extending from a first edge of the inflatable insert panel, the first insert web having a portion of a first insert mechanical coupling operable to couple the first insert web to the first web of the first inflatable panel and form a first interconnect; and a second insert web extending from a second edge of the inflatable insert panel, the second insert web having a second portion of a second insert mechanical coupling operable to couple the second insert web to the second web of the second inflatable panel and form a second interconnect,wherein the first and second interconnects are operable to couple the first and second inflatable panels to the inflatable insert panel to form an augmented assembled configuration.
11. The spa cover assembly of Claim 10, wherein the first interconnect and the second interconnect are flexible such that the first and second inflatable panels can be rotated with respect to the inflatable insert panel by bending the first and second interconnects, respectively.
12. The spa cover assembly of Claims 10 or 11, wherein the first interconnect further comprises first and second corner forms positioned at each longitudinal end portion of the first interconnect between rounded corners of the first inflatable panel and the inflatable insert panel, and wherein the second interconnect further comprises third and fourth corner forms positioned at each longitudinal end portion of the second interconnect between rounded comers of the second inflatable panel and the inflatable insert panel.
13. The spa cover assembly of any of Claims 10-12, wherein the inflatable insert panel further comprises:a first side skirt extending downward along a first edge portion of the perimeter of the inflatable insert panel; anda second side skirt extending downward along a second edge portion of the perimeter of the inflatable insert panel, wherein the first side skirt, the second side skirt, a side skirt of the first inflatable panel, and a side skirt of the second inflatable panel surround an assembled perimeter of the spa cover assembly in the augmented assembled configuration to cover a gap between the spa cover assembly and a top surface of the spa.
14. The spa cover assembly of any of Claims 10-13, wherein a plurality of inflatable insert panels are connected between the first and second inflatable panels to form the augmented assembled configuration.
15. A modular spa cover for covering the opening of a spa enclosure, the modular spa cover comprising:a first inflatable panel having a first web portion extending from an edge, the first web portion having a portion of a first mechanical coupling;a second inflatable panel having a second web portion extending from an edge, the second web portion having a portion of a second mechanical coupling; andan insert panel having:a first insert web extending from a first edge of the inflatable insert panel, the first insert web having a portion of the first mechanical coupling operable to couple the first insert web to the first web of the first inflatable panel and form a first interconnect; anda second insert web extending from a second edge of the inflatable insert panel, the second insert web having a portion of the second mechanical coupling operable to couple the second insert web to the second web of the second inflatable panel and form a second interconnect,wherein, in a first assembled configuration, the first and second web portions are operably coupled to form an assembly of the first and second inflatable panels in the absence of the insert panel, andwherein, in a second assembled configuration, the first and second interconnects are operable to couple the first and second inflatable panels to the inflatable insert panel to form an augmented assembly.
16. The modular spa cover of Claim 15, wherein each of the first inflatable panel, the second inflatable panel, and the insert panel further comprise:a top layer, a bottom layer, and a plurality of drop stitch threads extending between the top layer and bottom layer; anda side panel extending around a perimeter and operably coupling the top layer and the bottom layer, wherein the top layer, bottom layer, and side panel together form a continuous outer surface of the inflatable panel and retain pressurized air therein.
17. The modular spa cover of Claims 15 or 16, wherein the first inflatable panel, the second inflatable panel, and the inflatable insert panel each comprise a side skirt extending downward along an outer edge around a perimeter of the augmented assembly to cover a gap between the spa cover assembly and a top surface of the spa.
18. The modular spa cover of any of Claims 15-17, wherein the first interconnect and the second interconnect are flexible such that the first and second inflatable panels can be rotated with respect to the inflatable insert panel by bending the first and second interconnects, respectively.
19. The modular spa cover of any of Claims 15-18, wherein each of the first inflatable panel, the second inflatable panel, and the insert panel further comprise:a tethering strap operable to couple the augmented assembly to the spa;a handle configured to permit a user to rotate the respective panel with respect to the spa;an inflation / deflation valve operable to inflate and / or deflate the corresponding panel; anda pressure relief valve operable to release pressure from the corresponding panel.
20. The modular spa cover of any of Claims 15-19, wherein the first and second mechanical couplings comprise a zipper, a snap, a fastener, a locking feature, or a bead and channel.