Cover for a spa and method of fabricating a cover for a spa

1. A method of manufacturing an article for a spa, comprising the steps of:

laminating a cosmetic film to a base substrate;

laminating an acrylic film to the cosmetic film, the base substrate, cosmetic film and the acrylic film forming a layered assembly; and

forming the layered assembly to shape.

2. The method according to claim 1 , further comprising the step of:

adhering a protective film to the acrylic film.

3. A method of manufacturing an article for a spa, comprising the steps of:

laminating a cosmetic film to a base substrate;

laminating an acrylic film to the cosmetic film;

adhering a protective film to the acrylic film, the base substrate, cosmetic film and the acrylic film forming a layered assembly; and

forming the layered assembly to shape;

wherein the protective film is removable from the acrylic film.

4. The method according to claim 3 , wherein:

the base substrate is a sheet formed from one of acrylonitrile butadiene styrene (ABS) and polyvinyl chloride (PVC).

5. The method according to claim 4 , wherein:

the acrylic film includes a UV protectorant.

6. The method according to claim 3 , wherein:

the step of forming the layered assembly to shape includes vacuum forming the layered assembly.

7. The method according to claim 6 , further comprising the step of:

heating the layered assembly prior to vacuum forming.

8. The method according to claim 7 , wherein:

the layered assembly is heated to approximately 350 degrees Fahrenheit.

9. The method according to claim 3 wherein:

the cosmetic film is a polymer film having a wood grain or carbon fiber finish look.

10. The method according to claim 3 , wherein:

the cosmetic film is a colored polymer film.

11. A cover for a spa, comprising:

a first shell member having a base layer, a cosmetic film laminated to the base layer, and an acrylic film laminated to the cosmetic film; a

a second shell member nested with the first shell member and defining an interior space therebetween; and

a foam within the interior space and bonded with the first shell member and the second shell member.

12. The cover of claim 11 , wherein:

the cosmetic film is a polymer film having a wood grain or carbon fiber finish look.

13. The cover of claim 11 , wherein:

the cosmetic film is a colored polymer film.

14. The cover of claim 11 , wherein:

the base layer is formed from one of acrylonitrile butadiene styrene (ABS) and polyvinyl chloride (PVC).

15. The cover of claim 11 , wherein:

the acrylic film includes a UV protectorant.

16. The cover of claim 11 , further comprising:

a protective film removably affixed to the acrylic film.

17. A method of manufacturing a cover for a spa, comprising the steps of:

forming a first shell member, including:

laminating a cosmetic film to a base sheet;

laminating an acrylic film to the cosmetic film;

removably applying a protective film to the acrylic film, the base sheet, the cosmetic film and the acrylic film forming a first layered assembly; and

vacuum forming the first layered assembly to shape;

vacuum forming a second shell member to shape;

locating a high density, closed-cell foam within at least one of the first shell member and the second shell member;

bringing the first shell member and the second shell member into nesting relationship to enclose the foam between the first shell member and the second shell member;

compressing the first shell member and the second shell member against the foam; and

bonding the foam to the first member and the second shell member to create an integral structure.

18. The method according to claim 17 wherein:

the base sheet comprises one of acrylonitrile butadiene styrene (ABS) and

polyvinyl chloride (PVC); and

wherein the acrylic film includes a UV protectorant.

19. The method according to claim 17 wherein:

the cosmetic film is a polymer film having a wood grain or carbon fiber finish look.

20. The method according to claim 17 , wherein:

the cosmetic film is a colored polymer film.