System and Method to Convert Spa Cover Lifts to Electric

Description

FIELD OF THE INVENTION

The present invention relates generally to spa cover lifts. Particularly, the present invention comprises a system and method of producing and providing mounting brackets, paired with electric actuators, sized and matched to spa cover lifts to convert any common over-the-counter spa cover lift to an electric operated spa cover lift.

BACKGROUND OF THE INVENTION

Spa covers for hot tubs and spas can be heavy and cumbersome to open or close. Spa covers can be so heavy that it is unsafe and prohibitive for many people to the extent that they stop using their spa not being able to open or close the spa cover. A typical spa or hot tub cover lift is used to help make the opening and closing of a spa cover easier and safer for users. Spa cover lifts also provide a place to store the cover when in the open position. A quality spa cover lift can extend the life of the spa cover.

There are many different types of spa cover lifts available. Spa cover lifts can be manual, electric-assisted, or have gas springs or shocks to hydraulically assist. Some spa cover lifts lift the cover straight up vertically, while most other spa cover lifts swing the cover back to store vertically or horizontally behind the spa during use.

An objective of the present invention is to provide a system to convert or retrofit all of the most common styles of cover lift apparatuses available today to being electrically operated with the user's choice of a toggle switch, push button switch, keyed switch, or radio-controlled remote controller that can be handheld like a key fob, or wall mounted remotely and wirelessly. The present invention comprises a retrofit kit that converts most common styles of existing lifts being sold today to being electric assisted so that with the push of a button, a manual spa cover lift can operate automatically and electrically.

Another objective of the present invention is to adapt most styles of spa cover lifts. Different mounting brackets allow the present invention to work with the majority of spa cover lifts sold. Said mounting brackets are used to connect and install electric actuators between the spa itself and the existing cover lift apparatus. A different mounting bracket may be used for one brand of spa lift cover versus another. The electric actuators of the present invention are also sized and specified according to the brand, type and style of spa cover lift.

Another objective of the present invention is to provide safety to the user and spa owners. The components of the present invention are designed to always meet or exceed all required ASTM safety requirements. Using the present invention, users may lift a heavy spa cover more easily without risk of injury. Use of the present invention also provides additional safety by assisting to keep unwanted users out of the spa by locking out access to the electric switch that opens and closes the cover and will also extend the life of the cover lift and the cover itself by reducing stresses and strains caused by other lifts or manually handling of the cover.

SUMMARY OF THE INVENTION

The present invention is a system and method to convert any common over-the-counter spa cover lift to an electric operated spa cover lift. The present invention comprises a retrofit kit and a method of applying said retrofit kit to common spa cover lifts. The retrofit kit further comprises a power supply, a plurality of mounting brackets, a control system, and a plurality of electric actuators. The control system of the present invention further comprises a switch and a wireless remote controller. In some embodiments of the present invention, the retrofit kit further comprises a backing which provides additional support and rigidity for the mounting brackets.

The method of applying said retrofit kit to common spa cover lifts accounts for different brands, types, and styles of spa cover lifts. A user can apply said method to most any spa cover lift using the appropriately sized and matching components.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of parts and components of the present invention.

FIG. 2 is a perspective view of a spa with a closed spa cover.

FIG. 3 is a perspective view of a typical center coupler, cover support arms, and upper actuator brackets.

FIG. 4 is a perspective view of a typical pivot arm assembly of one of the most popular styles of lifts available today with a mounting bracket attached.

FIG. 5 is a perspective view of a typical pivot arm assembly of one of the most popular styles of lifts available today with a mounting bracket attached.

FIG. 6 is a perspective view of a typical pivot arm assembly of one of the most popular styles of lifts available today with a mounting bracket attached.

FIG. 7 is a perspective view of a pivot arm and support arm assembly.

FIG. 8 is a perspective view of a center coupler attached to a spa cover.

FIG. 9 is a perspective view of a mounting bracket attached to a spa vertically.

FIG. 10 is a perspective view of a mounting bracket attached to a spa horizontally.

FIG. 11 is a perspective view of a backing installed to a spa beneath the skirting.

FIG. 12 is a perspective view of an upper actuator bracket attached to the cover support arm.

FIG. 13 is a perspective view of mounting brackets facing each other when mounted to the bottom of each actuator.

FIG. 14 is a perspective view of an actuator assembly with a mounting bracket attached.

FIG. 15 is a perspective view of an actuator assembly with a mounting bracket above a spa.

FIG. 16 is a perspective view of a cover support arm not aligned in parallel to the spa cover.

FIG. 17 is a perspective view of a support arm, support arm screws, and screw head covers.

FIG. 18 is a perspective view of an actuator assembly and an approximate location of a drill hole for wiring.

FIG. 19 is a perspective view of a plurality of embodiments of mounting brackets in the present invention.

FIG. 20 is a perspective view of a switch found in the present invention.

FIG. 21 is a wire diagram depicting an example of electrical connections of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

All illustrations of the drawings are for the purpose of describing selected versions of the present invention and are not intended to limit the scope of the present invention. The present invention is to be described in detail and is provided in a manner that establishes a thorough understanding of the present invention. There may be aspects of the present invention that may be practiced or utilized without the implementation of some features as they are described. It should be understood that some details have not been described in detail in order to not unnecessarily obscure focus of the invention. References herein to “the preferred embodiment”, “one embodiment”, “some embodiments”, or “alternative embodiments” should be considered to be illustrating aspects of the present invention that may potentially vary in some instances, and should not be considered to be limiting to the scope of the present invention as a whole.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well as the singular forms, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising”, when used herein, specify the presence of stated features, steps, operations, elements, various embodiments, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, various embodiments, components, and/or groups thereof.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one having ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those used in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

In describing the invention, it will be understood that a number of techniques, embodiments and/or steps are disclosed. Each of these has individual benefit and each can also be used in conjunction with one or more, or in some cases all, of the other disclosed techniques, embodiments and/or steps. Accordingly, for the sake of clarity, this description will refrain from repeating every possible combination of the individual steps, techniques or embodiments in an unnecessary fashion. Nevertheless, the specification and claims should be read with the understanding that such combinations are entirely within the scope of the invention and the claims.

Referring to FIG. 1-21, the present invention is a system and method to convert any common over-the-counter spa cover lift to an electric operated spa cover lift. The present invention comprises a retrofit kit and a method of applying said retrofit kit to common spa cover lifts. The retrofit kit further comprises a power supply 114, a plurality of mounting brackets 104, a control system, and a plurality of electric actuators 111. The control system of the present invention further comprises a switch 121 and a wireless remote controller 115, 116. As shown in FIG. 19, in some embodiments of the present invention, some or all of the mounting brackets 104, 120 may be supplied in a different style, size, shape, or configuration paired to fit any particular style of cover lift that the retrofit kit is being matched to fit with. In some embodiments of the present invention, the retrofit kit further comprises a backing 1101 which provides additional support and rigidity for the mounting brackets.

As shown in FIG. 1, one preferred embodiment of the present invention comprises a center coupler 101; cover support arms 102; pivot arms 103; a plurality of mounting brackets 104, 120; a plurality of bushings 105; a plurality of ⅜″ flat washers 106; a plurality of ⅜″ lock nuts 107; a plurality of ⅜″×3″ hex bolts 108; a plurality of #10×1.5″ mounting screws 109; a plurality of upper actuator brackets 110; a plurality of actuator motors 111; a plurality of ⅜″×1″ hex bolts 112; a plurality of #10×⅝″ self tapping screws 113; a power supply 114; a remote control module 115; a remote controller 116; a switch 121; a plurality of screw head covers 117; a plurality of bolt head covers 118; and a plurality of ⅜″ nuts 119.

The power supply 114 provides electricity to the electric actuators 111 to function and operate. In the preferred embodiment of the present invention, the power supply 114 accepts GFCI-protected 120V AC input and outputs 12V DC. Said power supply 114 distributes electricity through the control system to the electric actuators 111. Said power supply 114 can be connected into any power outlet or connected into the spa itself. Said power supply 114 may further comprise extra plugins or can be hotwired to the terminal block of the spa.

One preferred embodiment of the present invention include a plurality of mounting brackets 104, 120 used to connect the existing spa cover lift to the spa to allow room to install the electric actuators 111. Said mounting brackets 104, 120 are sized and specified according to the brand, style, and type of existing spa cover lift that is being converted to electric. In some cases, the mounting brackets 104, 120 are a replacement of the existing brackets on the lift mechanism, while other brands, styles, and types of lifts may need a different style of mounting bracket 104, 120. In some cases, existing mounting brackets may have a hold-open safety feature. The hold-open safety feature becomes redundant after the present invention is installed, as the electric actuators 111 will prevent the spa cover lift from falling closed. In some cases, the hold-open safety feature may impede the movement of the present invention. Therefore, some brands of existing spa cover lifts require complete replacement of existing mounting brackets. Other brands of existing spa cover lifts will not require replacement of existing mounting brackets. Said plurality of mounting brackets 104, 120 may comprise either four or six mounting brackets depending on the brand of existing spa cover lift. Said mounting brackets 104, 120 are designed to accommodate the size and shape of the electric actuators 111. Said mounting brackets 104, 120 are designed as an open U-shape bracket. Said mounting brackets 104, 120 must be strong enough to support 200 lbs or more to consistently accommodate the spa cover weight. In some embodiments, said mounting brackets 104, 120 are powder coated in black to prevent rusting of components. In preferred embodiments, said mounting brackets 104, 120 are made of aluminum or steel.

As shown in FIG. 19, mounting brackets 104 and/or 120 may be substituted for other types and styles of brackets as shown and specified for the brand, style, and type of lift that is getting retrofitted with the current embodiment. A plurality of mounting brackets of different styles, shapes, and sizes are employed in the present invention. As labeled, Bracket A fits spa cover lift models such as, but not limited to, the Covermate 1, the Pivot 1, the RegMics 101, and the SpaEase 100. In these examples, a pair of brackets are used to modify the existing lift apparatuses to allow clearances for the actuators to move and pivot, while another pair of brackets are used to mount the bottom pivot points of the actuators to the skirting wall of the spa. Bracket E is a taller variation of Bracket A to offer more clearance that is needed on other brands of lifts. Bracket B fits spa cover lift models such as, but not limited to, the ProMax Lift, the Covermate Easy and ECO, the PuriTech Elevate, and the ShockPro lifts. In these examples, only one pair of brackets is necessary for installation. Bracket C fits spa cover lift models such as, but not limited to, the Covermate 3, the Cover Valet CV400, and the CoverGuy Hydraulic lifts. In these examples, only one pair of brackets is necessary for installation. The majority of existing spa cover lifts require installation of a pair of said upper actuator brackets 110. However, some models of existing spa cover lifts do not require these upper actuator brackets 110, such as the Vanish XL by Leisure Concepts. Other embodiments of mounting brackets such as Brackets D, F, and G are shown.

The control system of the present invention further comprises a switch 121 and/or a wireless remote controller 116. FIG. 20 shows a switch 121 found in the present invention. In the preferred embodiment of the present invention, said switch 121 is a single pole double throw switch. Said single pole double throw switch 121 has three positions wherein the top position is open, the bottom position is closed, and the middle position is off. Said switch 121 may be either a momentary switch or a latching switch, wherein a momentary switch requires continuous compression to operate and a latching switch does not require continuous compression to operate. A latching switch may be convenient for users as the spa can be opened or closed without requiring the user to be present. Alternatively, some safety benefits may exist for a momentary switch in the present invention, requiring the user to be present by the spa while closing the spa cover in case a person or object is left in the spa. Said switch 121 can be mounted on the side of the spa or mounted remotely within sight of the spa. In the preferred embodiment of the present invention, said switch 121 is weatherproof. Said switch 121 may be a keyed switch for added safety and security.

In the preferred embodiment of the present invention, said wireless remote controller 116 comprises a wireless receiver 115 with an antenna and may also include a single pole double throw remote switch 121. FIG. 20 shows a switch 121 found in the present invention. Said remote switch 121 has three positions wherein the top position is open, the bottom position is closed, and the middle position is off. Said remote switch 121 may be either a momentary switch or a latching switch, wherein a momentary switch requires continuous compression to operate and a latching switch does not require continuous compression to operate. Said antenna may extend the effective range between the wireless remote controller and the wireless receiver. Said wireless receiver 115 connects with the wireless remote controller to control the electric actuators 111. Said wireless receiver 115 is connected to said power supply 114 to receive electricity. Said wireless receiver 115 is installed under the skirting of the spa. In the preferred embodiment of the present invention, said wireless receiver 115 is mounted vertically to improve wireless range.

The electric actuators 111 of the present invention allow the spa cover lift to be opened and closed with electric assistance. In the preferred embodiment of the present invention, said plurality of electric actuators 111 comprises two electric actuators. The top pivot point of the electric actuators 111 mounts to the side arm of the existing spa lift. In some embodiments, the bottom pivot point of the electric actuators 111 can be mounted onto the side of the spa. In other embodiments, the bottom pivot point of the electric actuators 111 can be mounting directly to the spa cover lift itself. Existing spa lifts commonly include gas springs. Said gas springs must be removed to install the electric actuators of the present invention. In the preferred embodiment of the present invention, said electric actuators 111 are powered by said power supply 114 at a low voltage, approximately 12V DC, to comply with electrical safety requirements. In the preferred embodiment of the present invention, said electric actuators 111 are 100% waterproof with an IP67 or better safety rating. The speed at which the present invention opens and closes the spa cover lift depends on the electric actuator 111 installed. In the preferred embodiment of the present invention, said electric actuator 111 moves the spa cover lift approximately 1 inch per second. In the preferred embodiment of the present invention, said electric actuator 111 can lift over 150 lbs each. Said electric actuator 111 should be able to lift no less than 90 lbs each. In the preferred embodiment of the present invention, said electric actuators 111 have a 12 inch stroke distance between fully retracted and fully extended. Actual stroke distance is specified for each style of lift being retrofitted. Some styles of lifts may need an 8″ stroke, while other styles of lifts may need a 24″ stroke. In the preferred embodiment of the present invention, said electric actuators 111 are colored black and silver to match commonly found spa cover lifts.

In some embodiments, the present invention further comprises a backing component 1101. In some cases, the plastic skirting of the spa is not strong enough to accommodate the installation of the present invention. As a result, said backing 1101 must be installed behind the plastic skirting of the spa to provide rigid support. Said backing 1101 may be made of wood or metal.

The present invention comprises a method of pairing and installing said retrofit kit with an existing spa cover lift, converting a common spa cover lift into an electric lift. Said method further comprises the following steps for one preferred embodiment as an example, as other types and styles of lifts may require a different assembly procedure:

Step 1. Position the spa cover in the closed position centered on the spa, making sure that all four corners and edges are properly positioned and square on the spa with equal overhang on all four sides. Ensure that the cover remains in this position, centered on the spa, throughout the assembly and installation process.

• • Step 2. Insert the long arms of the support arms 102 into the ends of the center coupler 101 as shown in FIG. 3. For narrow covers, flip the support arms 102 and insert the short side of the support arm 102 into the center coupler 101.

Step 3. Slide one upper actuator bracket 110 onto the end of each support arm 102 with the hole in the bracket flange on the end closest to the elbow of the pivot arm 103 as shown in FIG. 3.

Step 4. Attach one mounting bracket 104 to the end of the pivot arm 103 using one ⅜″×3″ hex bolt 108, two ⅜″ flat washers 106, two bushings 105, and one ⅜″ lock nut 107 as shown in FIG. 4. Repeat this process for the other side with the mounting bracket 104 on the opposite side of the pivot arm 103 as shown in FIG. 5. Both mounting brackets 104 face inwards towards each other. Tighten the lock nut 107 firmly, then loosen ½ turn so that the mounting bracket 104 rotates freely by hand as shown in FIG. 6.

Step 5. Slide each pivot arm assembly 103 onto the end of the cover support arms 102 so that the mounting brackets 104 face each other as shown in FIG. 7.

Step 6. Lay the lifter assembly on the spa cover. Position the center coupler 101 and the support arms 102 so that the center coupler assembly is lying parallel to and resting directly over the spa cover hinge. Adjust and extend the length of the center coupler assembly 101 so that the ends of the pivot arms 103 extend out over the edges of the cover hang freely over each side as shown in FIG. 8.

Step 7. Attach the mounting brackets 104 to the sides of the spa as shown in FIG. 9-10. Measure down from the top of the acrylic curb of the spa 9″ and from the back flat surface of the spa 10″ and make a mark. Use six #10×1½″ mounting screws 109 to secure the bracket 104 to the spa. It is very important that these 6 mounting screws 109 get anchored to an internal wood or metal stud located behand the skirting of the spa. Remove the skirting of the spa and inspect to see if sufficient backing is provided. If not, install either a 2″×4″ stud, metal stud, or plywood backing 1101 to attach these screws to. The mounting bracket can be mounted vertically or horizontally to better align with available backing as shown in FIG. 9-10. FIG. 11 illustrates an example of a wood backing 1101 that can be installed to attach the mounting brackets 104 to. If no backing is found in the proper location as outlined in Step 7 and FIG. 9-10, a new backing 1101 will need to be installed before reinstalling the skirting of your spa. The skirting on most brands of spas is not sufficiently strong enough to hold the weight of the cover and cover lift assembly. Severe injuries may result to the occupants of the spa if proper backing 1101 is not installed. A thorough inspection for sufficient backing is always required.

Step 8. Slide each upper actuator bracket 110 all the way down the pipe of the cover support arm 102 so that the end is touching the end of the pivot arm 103 with the flange pointed down as shown in FIG. 12.

Step 9. Mount the mounting brackets 104 to the bottom end of each actuator motor 111. The bottom end is the thicker end with the wire hanging out. With the actuator motor 111 being held so that the wire points down, a mounting bracket 104 is mounted on the left side of the actuator 111, as shown in FIG. 13. Another mounting bracket 104 is mounted on the right side of the actuator 111, as shown in FIG. 13. For each side, using one ⅜″×3″ hex bolt 108, two ⅜″ flat washers 106, one ⅜″ nut 119, one mounting bracket 104 and one ⅜″ lock nut 107, assemble the mounting bracket 104 as shown in FIG. 13-14.

Step 10. Using one ⅜″×1″ hex bolt 108, two ⅜″ flat washers 106, and one ⅜″ lock nut 107, attach each actuator 111 to the upper actuator bracket 110 and allow it to hang freely. The lock nut 107 should be tightened far enough to engage the nylon threads so that the mounting bracket 104 does not come loose. One actuator motor 111 mounts on the left side and one on the right side. The mounting brackets 104 should be facing in towards the spa wall as shown in FIG. 15.

Step 11. Mark the locations for the bottom actuator motor mounting brackets 104 by measuring down 11″ from the top of the acrylic lip of the spa and over 20.5″ from the back side of the spa, similar to how the locations of the pivot arms 103 were measured and marked. Use a square to measure from the back wall for the 20.5″ to be accurate.

Step 12. Make final adjustments to the lengths of the center coupler 101, both cover support arms 102, and both pivot arms 103. Before doing this, make certain that the cover is still centered and square on the spa as outlined in Step 1. The center coupler 101 should be parallel to the hinge of the cover and located just behind the center of the hinge as shown in FIG. 8. The two cover support arms 102 and the two pivot arms 103 should also be parallel to the edges of the cover. FIG. 16 shows a pivot arm 103 and support arm 102 that are not parallel to the cover. Slide the pipes in and out until each arm is aligned properly.

Step 13. Cover all screw heads, bolts and nuts with the screw head covers 117 and bolt head covers 118 as shown in FIG. 17.

Step 14. There are various ways that the electrical wiring can be connected to the present invention. FIG. 21 is a wire diagram depicting an example of electrical connections of the present invention.

Step 15. The switch can be mounted in many possible locations. In the preferred embodiment of the present invention, the switch is installed near one of the front corners of the spa under the acrylic lip. Remove the skirting panel of the spa to make sure there is room behind the panel for the switch. Cut a hole in the side wall of your spa skirting the same size as the switch that you have and insert the switch into that hole. Attach wires according to FIG. 21.

Step 16. Run wires from the actuators 111 to the remote control module 115. Drill one 5/16″ diameter hole 1801 approximately 3″ down below the bottom of each actuator wire and feed the wire into this hole leaving a little slack as shown in FIG. 18.

Step 17. Snake the actuator cables through the spa cabinet over to the remote-control module 115. It is best to mount the remote control module 115 in an area that is protected from water and away from other electrical equipment to reduce interference signals for the remote controller. Extend the antenna for better signal strength. Wire according to FIG. 21.

Step 18. Install the power supply 114 in an area that is protected from water. Mount the power supply 114 close enough for the original wire to reach or add an extension wire according to all electrical code requirements.

Step 19. Turn power off and make all electrical connections per code.

Step 20. Secure all electrical components from sliding around if the spa gets moved in the future. Secure in a location where it will stay dry. Plenty of wire may be included to provide for most spa sizes. If the spa is larger, if power is run from a house, or if mounting any component such as the remote-control module 115 or switch outside of the spa cabinet, additional wire may be required. Use only wire of the proper size to meet all electrical code requirements.

Although the invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made to retrofit most any brand, style, and type of spa cover lift available, without departing from the spirit and scope of the invention.