System and Method to Convert Spa Cover Lifts to Electric

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.

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.

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.

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, 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 switchand a wireless remote controller,. As shown in, in some embodiments of the present invention, some or all of the mounting brackets,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 backingwhich provides additional support and rigidity for the mounting brackets.

As shown in, one preferred embodiment of the present invention comprises a center coupler; cover support arms; pivot arms; a plurality of mounting brackets,; a plurality of bushings; a plurality of ⅜″ flat washers; a plurality of ⅜″ lock nuts; a plurality of ⅜″×3″ hex bolts; a plurality of #10×1.5″ mounting screws; a plurality of upper actuator brackets; a plurality of actuator motors; a plurality of ⅜″×1″ hex bolts; a plurality of #10×⅝″ self tapping screws; a power supply; a remote control module; a remote controller; a switch; a plurality of screw head covers; a plurality of bolt head covers; and a plurality of ⅜″ nuts.

The power supplyprovides electricity to the electric actuatorsto function and operate. In the preferred embodiment of the present invention, the power supplyaccepts GFCI-protected 120V AC input and outputs 12V DC. Said power supplydistributes electricity through the control system to the electric actuators. Said power supplycan be connected into any power outlet or connected into the spa itself. Said power supplymay 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,used to connect the existing spa cover lift to the spa to allow room to install the electric actuators. Said mounting brackets,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,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,. 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 actuatorswill 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,may comprise either four or six mounting brackets depending on the brand of existing spa cover lift. Said mounting brackets,are designed to accommodate the size and shape of the electric actuators. Said mounting brackets,are designed as an open U-shape bracket. Said mounting brackets,must be strong enough to support 200 lbs or more to consistently accommodate the spa cover weight. In some embodiments, said mounting brackets,are powder coated in black to prevent rusting of components. In preferred embodiments, said mounting brackets,are made of aluminum or steel.

As shown in, mounting bracketsand/ormay 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. However, some models of existing spa cover lifts do not require these upper actuator brackets, 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 switchand/or a wireless remote controller.shows a switchfound in the present invention. In the preferred embodiment of the present invention, said switchis a single pole double throw switch. Said single pole double throw switchhas three positions wherein the top position is open, the bottom position is closed, and the middle position is off. Said switchmay 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 switchcan 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 switchis weatherproof. Said switchmay be a keyed switch for added safety and security.

In the preferred embodiment of the present invention, said wireless remote controllercomprises a wireless receiverwith an antenna and may also include a single pole double throw remote switch.shows a switchfound in the present invention. Said remote switchhas three positions wherein the top position is open, the bottom position is closed, and the middle position is off. Said remote switchmay 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 receiverconnects with the wireless remote controller to control the electric actuators. Said wireless receiveris connected to said power supplyto receive electricity. Said wireless receiveris installed under the skirting of the spa. In the preferred embodiment of the present invention, said wireless receiveris mounted vertically to improve wireless range.

The electric actuatorsof 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 actuatorscomprises two electric actuators. The top pivot point of the electric actuatorsmounts to the side arm of the existing spa lift. In some embodiments, the bottom pivot point of the electric actuatorscan be mounted onto the side of the spa. In other embodiments, the bottom pivot point of the electric actuatorscan 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 actuatorsare powered by said power supplyat a low voltage, approximately 12V DC, to comply with electrical safety requirements. In the preferred embodiment of the present invention, said electric actuatorsare 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 actuatorinstalled. In the preferred embodiment of the present invention, said electric actuatormoves the spa cover lift approximately 1 inch per second. In the preferred embodiment of the present invention, said electric actuatorcan lift over 150 lbs each. Said electric actuatorshould be able to lift no less than 90 lbs each. In the preferred embodiment of the present invention, said electric actuatorshave 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 actuatorsare colored black and silver to match commonly found spa cover lifts.

In some embodiments, the present invention further comprises a backing component. 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 backingmust be installed behind the plastic skirting of the spa to provide rigid support. Said backingmay 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 3. Slide one upper actuator bracketonto the end of each support armwith the hole in the bracket flange on the end closest to the elbow of the pivot armas shown in.

Step 4. Attach one mounting bracketto the end of the pivot armusing one ⅜″×3″ hex bolt, two ⅜″ flat washers, two bushings, and one ⅜″ lock nutas shown in. Repeat this process for the other side with the mounting bracketon the opposite side of the pivot armas shown in. Both mounting bracketsface inwards towards each other. Tighten the lock nutfirmly, then loosen ½ turn so that the mounting bracketrotates freely by hand as shown in.

Step 5. Slide each pivot arm assemblyonto the end of the cover support armsso that the mounting bracketsface each other as shown in.

Step 6. Lay the lifter assembly on the spa cover. Position the center couplerand the support armsso 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 assemblyso that the ends of the pivot armsextend out over the edges of the cover hang freely over each side as shown in.

Step 7. Attach the mounting bracketsto the sides of the spa as shown in. 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 screwsto secure the bracketto the spa. It is very important that these 6 mounting screwsget 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 backingto attach these screws to. The mounting bracket can be mounted vertically or horizontally to better align with available backing as shown in.illustrates an example of a wood backingthat can be installed to attach the mounting bracketsto. If no backing is found in the proper location as outlined in Step 7 and, a new backingwill 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 backingis not installed. A thorough inspection for sufficient backing is always required.

Step 8. Slide each upper actuator bracketall the way down the pipe of the cover support armso that the end is touching the end of the pivot armwith the flange pointed down as shown in.

Step 9. Mount the mounting bracketsto the bottom end of each actuator motor. The bottom end is the thicker end with the wire hanging out. With the actuator motorbeing held so that the wire points down, a mounting bracketis mounted on the left side of the actuator, as shown in. Another mounting bracketis mounted on the right side of the actuator, as shown in. For each side, using one ⅜″×3″ hex bolt, two ⅜″ flat washers, one ⅜″ nut, one mounting bracketand one ⅜″ lock nut, assemble the mounting bracketas shown in.

Step 10. Using one ⅜″×1″ hex bolt, two ⅜″ flat washers, and one ⅜″ lock nut, attach each actuatorto the upper actuator bracketand allow it to hang freely. The lock nutshould be tightened far enough to engage the nylon threads so that the mounting bracketdoes not come loose. One actuator motormounts on the left side and one on the right side. The mounting bracketsshould be facing in towards the spa wall as shown in.

Step 11. Mark the locations for the bottom actuator motor mounting bracketsby 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 armswere 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, both cover support arms, and both pivot arms. Before doing this, make certain that the cover is still centered and square on the spa as outlined in Step 1. The center couplershould be parallel to the hinge of the cover and located just behind the center of the hinge as shown in. The two cover support armsand the two pivot armsshould also be parallel to the edges of the cover.shows a pivot armand support armthat 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 coversand bolt head coversas shown in.

Step 14. There are various ways that the electrical wiring can be connected to the present invention.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.

Step 16. Run wires from the actuatorsto the remote control module. Drill one 5/16″ diameter holeapproximately 3″ down below the bottom of each actuator wire and feed the wire into this hole leaving a little slack as shown in.

Step 17. Snake the actuator cables through the spa cabinet over to the remote-control module. It is best to mount the remote control modulein 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.

Step 18. Install the power supplyin an area that is protected from water. Mount the power supplyclose 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 moduleor 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.