TECHNICAL FIELD
The present disclosure relates to pool and spa cleaners. More particularly, the present disclosure relates to a base for a pool and/or spa cleaner.
BACKGROUND
Swimming pools and spas are usually cleaned by traditional pool cleaners having an outer cover positioned at a bottom of the cleaner. The outer cover holds one or more components of the cleaner. Such one or more components may be hydraulic power generation systems (e.g., a Pelton wheel or drive system), one or more water flow management paths, one or more venturis to generate flow to remove debris off a bottom and into a bag, and/or power transmission systems that route power around the cleaner to drive the wheels. However, the known pool cleaners require the removal of the outer cover for any service, repair, or replacement of these components. The removal of the outer cover takes time and thus, is a tedious task.
Further, known pool cleaners have plumbing (e.g., tubing or holes) to route water flow through the interior of the cleaner body. This tubing is usually retained to a nipple with a clip or other mechanical fastener. However, such tubing in the existing cleaner makes the overall structure of the existing cleaner complex.
Therefore, the art recognizes a need for an improved cleaner of a swimming pool with easy service, repair, or replacement of one or more components without requiring the removal of an outer cover. The art also recognizes the need for an improved cleaner that eliminates/reduces the need for plumbing/tubing to route the water flow through the cleaner.
SUMMARY
A pool cleaner, a base for a pool cleaner, and a drive system for a pool cleaner are disclosed. In one aspect, a pool cleaner is provided. The pool cleaner includes a base. The base includes one or more jet ports disposed about a bottom of the base and a fluid conduit system enclosed within the base having one or more flow paths. The pool cleaner also includes an elongated connector coupled to the base and configured to intake fluid into the fluid conduit system. The pool cleaner further includes a plenum coupled to the base for discharging fluid and a drive system having one or more drive units coupled to the base and configured to move the pool cleaner via the fluid.
In an embodiment, each jet port of the one or more jet ports includes a venturi port for directing fluid toward the plenum.
In an embodiment, each of the drive units of the one or more drive units of the drive system includes a wheel, a gear assembly mechanically connected to the wheel, and an impeller operatively connected to the gear assembly and configured to be drive the wheel via fluid received from the fluid conduit system.
In another embodiment, the base includes one or more connection surfaces for coupling the one or more drive units to the base.
In an embodiment, each flow path of the one or more flow paths diverges into a drive unit flow path and a venturi flow path. The drive unit flow path is coupled to a corresponding drive unit of the drive system. The venturi flow path is coupled to a corresponding jet port of the base.
In another aspect, a base for a pool cleaner is provided. The base includes a top housing having an opening, a bottom housing having an outlet cavity, and a fluid conduit system disposed between the top housing and the bottom housing. The fluid conduit system including a duct and an inlet for receiving a fluid into the base.
In an embodiment, the opening of the top housing, the duct of the fluid conduit system, and the outlet cavity of the bottom housing are substantially aligned to receive a plenum that is positioned on the base.
In another embodiment, the fluid conduit system includes one or more flow paths. The inlet and the one or more flow paths of the fluid conduit system are coupled to the duct and in fluid communication therewith. The bottom housing includes one or more jet ports coupled to the one or more flow paths. Each of the one or more jet ports includes a venturi port and a guide portion that are positioned to direct fluid to a plenum positioned in the base. The one or more jet ports surround the outlet cavity.
In another aspect, a drive system for a pool cleaner is provided. The drive system includes a wheel coupled to a drive shaft assembly and a drive system member operatively coupled to the drive shaft assembly. The drive system member includes a passageway. The drive system also includes a housing coupled to the drive system member. The housing includes an inlet jet port for receiving a fluid. The drive system further includes a gear assembly rotatably coupled to the drive shaft assembly and an impeller rotatably coupled to the gear assembly. The passageway directs fluid from the inlet jet port to the impeller to drive the wheel.
In an embodiment, the wheel and the housing enclose the drive shaft assembly, the drive system member, the gear assembly, and the impeller.
In another embodiment, the housing includes a connection surface for mounting the drive system to a base of the pool cleaner.
In an embodiment, the drive shaft assembly includes at least one drive shaft.
In an embodiment, the impeller is a Pelton wheel.
In another embodiment, the housing includes one or more vents for discharging fluid.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front, top, and right side isometric view of a pool cleaner including a base and a drive system, according to an example embodiment;
FIG. 2 is an exploded rear, top, and left side isometric view of the pool cleaner of FIG. 1;
FIG. 3 is a front, top, and right side isometric view of the base of the pool cleaner of FIG. 1;
FIG. 4 is a front, bottom, and left side isometric view of the base of FIG. 3;
FIG. 5 is an exploded front, top, and right side isometric view of the base of FIG. 3;
FIG. 6A is a front and right side isometric view of a drive unit of the drive system of the pool cleaner of FIG. 1;
FIG. 6B is a rear and left side isometric view of the drive unit of FIG. 6A;
FIG. 7 is a front isometric exploded view of the drive unit of FIG. 6A;
FIG. 8 is a front elevational view of the pool cleaner of FIG. 1;
FIG. 9 is a front cross-section view of the pool cleaner of FIG. 1 taken along lines 9-9 of FIG. 1;
FIG. 10 is a left side elevational view of the pool cleaner of FIG. 1;
FIG. 11 is a left side cross-section view of the pool cleaner of FIG. 1 taken along lines 11-11 of FIG. 1;
FIG. 12 is a top view of the pool cleaner of FIG. 1;
FIG. 13 is a bottom view of the pool cleaner of FIG. 1;
FIG. 14 is a rear, top, and left side cross-section isometric view of the pool cleaner of FIG. 1 taken along lines 14-14 of FIG. 10; and
FIG. 15 is a flowchart of an example method of manufacturing the base of FIG. 3.
DETAILED DESCRIPTION
The following discussion is presented to enable a person skilled in the art to make and use embodiments of the invention. Various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the generic principles herein can be applied to other embodiments and applications without departing from embodiments of the invention. Thus, embodiments of the invention are not intended to be limited to embodiments shown but are to be accorded the widest scope consistent with the principles and features disclosed herein. The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of embodiments of the invention. Skilled artisans will recognize the examples provided herein have many useful alternatives and fall within the scope of embodiments of the invention.
It is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. For example, 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. As used herein, unless otherwise specified or limited, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, unless otherwise specified or limited, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.
As used herein, unless otherwise specified or limited, “at least one of A, B, and C,” and similar other phrases, are meant to indicate A, or B, or C, or any combination of A, B, and/or C. As such, this phrase, and similar other phrases can include single or multiple instances of A, B, and/or C, and, in the case that any of A, B, and/or C indicates a category of elements, single or multiple instances of any of the elements of the categories A, B, and/or C.
Referring now to FIGS. 1 and 2, FIGS. 1 and 2 illustrate an embodiment of a pool cleaner 100 for a swimming pool or spa. The pool cleaner 100 may be used to clean a swimming pool or spa (not shown). In some embodiments, the pool cleaner 100 may be provided in the form of a robotic pool cleaner, a motor driven cleaner, or other swimming pool cleaners known in the art. According to the example embodiment shown, the pool cleaner 100 may include a base 104, a plenum 110, an elongated connector 112, and a drive system 504.
In the embodiment shown in FIGS. 1 and 2, the base 104 of the pool cleaner 100 may be provided in a substantially rectangular shape having one or more corners 106. For example, the base 104 may include a first corner 106a, a second corner 106b, a third corner 106c, and a fourth corner 106d (as best shown in FIG. 3). In other embodiments, the base 104 may have a different shape and may include more or less than four corners, or no corners at all. The base 104 may include one or more layers, housings, or components. In the embodiment shown in FIG. 1, the base 104 may include a top housing 204, a bottom housing 304, and a fluid conduit system 404 (see FIG. 5).
Additionally, the pool cleaner 100 may include an elongated connector 112 and a plenum 110, which may both be positioned on the base 104. In some embodiments, the elongated connector 112 may be provided in the form of a substantially tubular or cylindrical member positioned perpendicular to the base 104 and extending outwardly therefrom. The elongated connector 112 may include a top portion 122 and a bottom portion 124. The plenum 110 may be provided in the form of a substantially cylindrical or frustoconical member positioned perpendicular to the base 104 and extending outwardly therefrom. The plenum 110 of the base 104 may include a plenum internal surface 116 and a plenum external surface 118. Additionally, the plenum 110 may include a plenum base 120 located at a bottom area of the plenum 110.
In some embodiments, the plenum 110 and the elongated connector 112 may be coupled to one another at the plenum base 120 to form one unit (e.g., the bottom portion 124 of the elongated connector 112 may be attached or otherwise coupled to the plenum base 120). In other embodiments, the plenum 110 and the elongated connector 112 may be separate components. In the embodiment shown in FIG. 1, the plenum 110 and the elongated connector 112 may be positioned on the top housing 204 of the base 104 near a center portion of the pool cleaner 100. In other embodiments, the plenum 110 and the elongated connector 112 may be located in any position or orientation relative to the pool cleaner 100. In some embodiments, the elongated connector 112 may be connected to a water or fluid supply hose by a removable clamp (not shown). The plenum 110 may include outlet jet ports (not shown) on the plenum internal surface 116. Positioned near the plenum 110 and the elongated connector 112, the pool cleaner 100, in some embodiments, may include a loop 114 capable of connecting additional embodiments such as a mesh filter or debris screen. In some embodiments, the mesh filter may be coupled to the plenum 110 or elongated connector 112 of the pool cleaner 100.
The drive system 504 of the pool cleaner 100 may include one or more drive units 506 coupled to the base 104. For example, as shown in FIG. 1, in some embodiments, the one or more drive units 506 may be located at each corner 106 of the base 104. The one or more drive units 506 of the drive system 504 may include a first drive unit 506a, a second drive unit 506b, a third drive unit 506c, and a fourth drive unit 506d. In some embodiments, the one or more drive units 506 may each include a wheel 508, a rear housing 510, and a drive system enclosure 512 or member 512. For example, as shown in FIG. 2, the first drive unit 506a may include a first wheel 508a, a first rear housing 510a, and a first drive system enclosure 512a. The second drive unit 506b may include a second wheel 508b, a second rear housing 510b, and a second drive system enclosure 512b. The third drive unit 506c may include a third wheel 508c, a third rear housing 510c, and a third drive system enclosure 512c. And, the fourth drive unit 506d may include a fourth wheel 508d, a fourth rear housing 510d, and a fourth drive system enclosure 512d.
Turning to FIGS. 3 and 4, the base 104 is shown in an assembled configuration. As best shown in FIG. 3, the top housing 204 may include a top housing inner surface 206, a top housing outer surface 208, and a plenum opening 210 for receiving the plenum base 120. In some embodiments, the plenum opening 210 may have a size and shape that mirrors the size and shape of the plenum base 120. The top housing 204 may also include one or more drive assembly surfaces 214 for coupling the drive units 506 to the base 104. For example, the top housing 204 may include a first drive assembly surface 214a, a second drive assembly surface 214b, a third drive assembly surface 214c, and a fourth drive assembly surface 214d. In some embodiments, the one or more drive assembly surfaces 214 may be located about the outer surface 208 of the top housing 204. For example, as shown in FIGS. 3 and 4, the first drive assembly surface 214a may be positioned near or adjacent to the first corner 106a, the second drive assembly surface 214b may be positioned near or adjacent to the second corner 106b, the third drive assembly surface 214c may be positioned near or adjacent to the third corner 106c, and the fourth drive assembly surface 214d may be positioned near or adjacent to the fourth corner 106d.
Further, each of the drive assembly surfaces 214 may include one or more apertures 216. In some embodiments, the one or more apertures 216 may be substantially circular and extend through the drive assembly surfaces 214 of the top housing 204 as shown in FIG. 3. In other embodiments, the one or more apertures 216 may be in the form of other shapes and/or profiles. In some embodiments, the one or more apertures 216 may include a first aperture 216a, a second aperture 216b, a third aperture 216c, and a fourth aperture 216d. In the example embodiments shown in FIGS. 2 and 3, the first aperture 216a may be disposed on the first drive assembly surface 214a, the second aperture 216b may be disposed the second drive assembly surface 214b, the third aperture 216c may be disposed on the third drive assembly surface 214c, and the fourth aperture 216d may be positioned on the fourth drive assembly surface 214d. Although FIG. 3 illustrates four apertures 216, a person skilled in the art would understand that the base 104 may have any number of apertures 216. The drive assembly surfaces 214 may also include a cutout 218. In some embodiments, the cutout 218 may be substantially circular in shape and positioned on each of the drive assembly surfaces 214. While four cut-outs 218a, 218b, 218c, and 218d are shown disposed on the drive assembly surfaces 214a, 214b, 214c, 214d, respectively, in FIG. 3, it should be understood that the base 104 may have any number of cutouts 218.
As shown in FIG. 4, like the top housing 204, the bottom housing 304 of the base 104 may include a bottom housing inner surface 306 and a bottom housing outer surface 308. The bottom housing 304 also may include an outlet cavity 310 located about a center of the bottom housing 304. In some embodiments, the outlet cavity 310 may be coupled to the plenum base 120 when the pool cleaner 100 is an assembled configuration (as shown in FIG. 1) and may have a substantially circular shape. The bottom housing 304 may include one or more wheel recesses 318 positioned about each corner 106 of the base 104 for engaging the one or more drive units 506. In some embodiments, the one or more wheel recesses 318 may be semicircular shaped and configured to reside within the one or more wheels 508. In the embodiment shown in FIG. 4, the bottom housing 304 may include a first wheel recess 318a for engaging the first drive unit 506a, a second wheel recess 318b for engaging the second drive unit 506b, a third wheel recess 318c for engaging the third drive unit 506c, and a fourth wheel recess 318d for engaging the fourth drive unit 506d when the pool cleaner 100 is in the assembled configuration of FIG. 1.
The bottom housing 304 may further include one or more jet ports 312 including a first jet port 312a, a second jet port 312b, a third jet port 312c, and a fourth jet port 312d (see also FIG. 13). The one or more jet ports 312 may be positioned about the outer surface 308 of the bottom housing 304. In some embodiments, the one or more jet ports 312 may be positioned near the corners 106 of the base 104 and may encircle or surround the outlet cavity 310. The one or more jet ports 312, in some embodiments, may protrude outward from the outer surface 308 of the bottom housing 304 and may be provided in the form of a substantially frustoconical member having a substantially flat surface that is perpendicular to the outer surface 308. In other embodiments, the one or more jet ports 312 may protrude inward from the outer surface 308 and have any suitable size or shape. The one or more jet ports 312 may include one or more venturi ports 314. The one or more venturi ports 314 may include a first venturi port 314a, a second venturi port 314b, a third venturi port 314c, and a fourth venturi port 314d. The venturi ports 314a, 314b, 314c, 314d may be positioned about the flat surface of the jet ports 312a, 312b, 312c, 312d, respectively, and may be capable of directing fluid toward the outlet cavity 310 of the bottom housing 304. To help with the direction of fluid flow, the bottom housing 304 may contain one or more guide portions 316 aligned with the jet ports 312. In some embodiments, a first guide portion 316a may be positioned in front of the first jet port 312a, a second guide portion 316b may be positioned in front of the second jet port 312b, a third guide portion 316c may be positioned in front of the third jet port 312c, and a fourth guide portion 316d may be positioned in front of the fourth jet port 312d. As best shown in FIGS. 4 and 13, each of the one or more guide portions 316 may be provided in the form of a rounded channel that protrudes inward from the outer surface 308 of the bottom housing 304.
The base 104 also may include the fluid conduit system 404 as best shown in the exploded view of FIG. 5. The fluid conduit system 404 may be positioned between the top housing 204 and the bottom housing 304 of the base 104. In some embodiments, the fluid conduit system 404 may be provided in the form of a substantially circular conduit. In other embodiments, the fluid conduit system 404 may be provided in the form of any shaped conduit or piping system. The fluid conduit system 404 may include an inlet connector 406 that is configured to be coupled to the bottom portion 124 of the elongated connector 112 and a plenum cavity duct 408 positioned about a center of the fluid conduit system 404. In some embodiments, the plenum cavity duct 408 may mirror the size and shape of the outlet cavity 310.
Within the fluid conduit system 404, one or more flow paths 410 to direct fluid may be provided. The one or more flow paths 410 may be provided in the form of a pipe or other conduit. In some embodiments, the one or more flow paths may be coupled to and in fluid connection or communication with the inlet connector 406 and the plenum cavity duct 408. The fluid conduit system 404 may also include one or more drive unit flow paths 412, one or more venture flow paths 414, one or more drive connection ports 416, and one or more venturi connection ports 418. For example, the fluid conduit system 404 may include a first flow path 410a diverging into a first drive unit flow path 412a and a first venturi flow path 414a. The first flow path 410a may also include a first drive connection port 416a and a first venturi connection port 418a. About the opposite end of the first flow path 410a of the first drive unit flow path 412a, the first drive connection port 416 may be positioned. Similarly, about the opposite end of the first flow path 410a of the first venturi flow path 414a, the first venturi connection port 418a may be positioned. Additionally, the fluid conduit system 404 may include a second flow path 410b diverging into a second drive unit flow path 412b and a second venturi flow path 414b. The second flow path 410b may also include a second drive connection port 416b and a second venturi connection port 418b. About the opposite end of the second flow path 410b of the second drive unit flow path 412b, the second drive connection port 416b may be positioned. Similarly, about the opposite end of the second flow path 410b of the second venturi flow path 414b, the second venturi connection port 418b may be positioned. The fluid conduit system 404 may include a third flow path 410c diverging into a third drive unit flow path 412c and a third venturi flow path 414c. The third flow path 410c may also include a third drive connection port 416c and a third venturi connection port 418c. About the opposite end of the third flow path 410c of the third drive unit flow path 412c, the third drive connection port 416c may be positioned. Similarly, about the opposite end of the third flow path 410c of the third venturi flow path 414c, the third venturi connection port 418c may be positioned. The fluid conduit system 404 may further include a fourth flow path 410d diverging into a fourth drive unit flow path 412d and a fourth venturi flow path 414d. The fourth flow path 410d may include a fourth drive connection port 416d and a fourth venturi connection port 418d. About the opposite end of the fourth flow path 410d of the fourth drive unit flow path 412d, the fourth drive connection port 416d may be positioned. Similarly, about the opposite end of the fourth flow path 410d of the fourth venturi flow path 414d, the fourth venturi connection port 418d may be positioned.
When the base 104 is in the assembled configuration of FIGS. 3 and 4, the top housing 204 and the bottom housing 304 of the base 104 may fully or partially enclose the fluid conduit system 404. For example, the top and bottom housing inner surfaces 206, 306 may connect or otherwise couple to each other to partially enclose the fluid conduit system 404 with the plenum opening 210, the outlet cavity 310, and the plenum cavity duct 408 axially aligned about the center of the pool cleaner 100. When the base 104 is assembled, the one or more drive unit connection ports 416 may align with the one or more apertures 216 of the top housing 204 about the top housing inner surface 206. Additionally, the one or more venturi connection ports 418 may align with the one or more venturi ports 314 of the bottom housing 304.
FIGS. 6A and 6B illustrate an embodiment of the drive unit 506 of the drive system 504 of the pool cleaner 100. The drive unit 506 may include a wheel 508, a wheel plate 530, and a rear housing 510. The wheel 508 of the drive unit 506 may be provided in the form of a circular body designed to receive one or more axles of a drive shaft mechanism. A surface of the wheel 508 may include treads or a traction mechanism and may be provided in the form of a durable material such as plastic, rubber, polyurethane, or the like. The pool cleaner 100 may include one or more wheels 508 located about each corner 106 of the pool cleaner 100. Although the embodiments shown in FIGS. 1 and 2 illustrate four wheels 508 (e.g., 508a, 508b, 508c, and 508d), a person skilled in the art would understand that the pool cleaner 100 may have less than four wheels or more than four wheels.
FIG. 7 illustrates an exploded view of the drive unit 506 of the drive system 504.
Located within the wheel 508 and the rear housing 510, the drive unit 506 may include a drive system enclosure 512 including a water passage 514, an impeller 516, a gear assembly 518, and a drive shaft assembly 520. In some embodiments, the wheel 508 may be concentric with the rear housing 510 and configured to enclose the drive system enclosure 512 along with the water passage 514, the impeller 516, the gear assembly 518, and the drive shaft assembly 520.
The rear housing 510 may include an internal cavity 526 having a connection surface 528, one or more inlet jet ports 522, and one or more outlet vents 524 (See FIG. 6A). In some embodiments, the one or more inlet jet ports 522 may be located on the connection surface 528 within the internal cavity 526. The one or more outlet vents 524 may be located about an internal cavity wall 532. The rear housing 510 may be provided in the form of a durable material such as plastic, or polyurethane capable of withstanding the pool cleaner's 100 environment.
The drive system enclosure 512 may be provided in the form of a structural housing configured to reside within the internal cavity 526 of the rear housing 510 and be coupled to the connection surface 528. The water passage 514 of the drive system enclosure 512 may be provided in the form of a through hole in the drive system enclosure 512 structural housing. The impeller 516 of the drive system enclosure 512 may include a plurality of blades 534 protruding concentrically from a hub 536. In the embodiment shown in FIG. 7, the plurality of blades 534 may be substantially perpendicular to the hub 536. In other embodiments, the plurality of blades 534 may include a pitch or angled portion. The impeller 516 may also include an impeller driving axle 538 coupled to the hub 536, located at the center of the plurality of blades 534.
In some embodiments, the impeller 516 may include a Pelton wheel system having a Pelton wheel. The Pelton wheel may include a plurality of blades having a bucket profile blade or an impulse blade which include substantially concave blade profiles. The Pelton wheel may include a disk where the plurality of blades are coupled concentrically about a main hub.
Additionally, the drive system enclosure 512 may include one or more drive system hub components 540 for attaching one or more axles about the structural housing of the drive system enclosure 512. In some embodiments, the gear assembly 518 may include a gear train having a pinion gear, bull gear, or the like. The gear assembly 518 may be coupled to the drive system enclosure 512 via the one or more drive system hub components 540. Additionally, the gear assembly 518 may include one or more driving axles mechanically coupled to a plurality of gears located within the drive unit 506. For example, the gear assembly 518 may be operatively coupled to the impeller driving axle 538 of the impeller 516 via the drive system enclosure 512. The drive system enclosure 512 may also include a drive shaft assembly 520 operatively coupled within the drive system enclosure 512. The drive shaft assembly 520 may be axially aligned with the one more axles of the drive system enclosure 512. The drive shaft assembly 520 may be coupled to the wheel 508, the drive system enclosure 512, and the gear assembly 518. The gear assembly 518 may use the gear train to rotate the drive shaft assembly 520, which in turn rotates the wheel 508 of the pool cleaner 100 (see FIG. 9).
Turning to FIGS. 8-13, the pool cleaner 100 and aspects thereof are shown in further detail.
FIG. 8 illustrates a front view of the pool cleaner 100 according to an embodiment. As can be seen in FIG. 8, the plenum 110 and the elongated connector 112 may be aligned with the central axis A of the pool cleaner 100. In addition, the plenum opening 210 of the top housing 204, the plenum cavity duct 408 of the fluid conduit system 404, and the outlet cavity 310 of the bottom housing 304 may be substantially aligned such that the plenum base 120 may be positioned within the plenum opening 210, the plenum cavity duct 408, and the outlet cavity 310. In some embodiments, the plenum 110 and the elongated connector 112 may be coupled to the top housing 204, the bottom housing 304, or the fluid conduit system 404 by removable fasteners such as screws, bolts, and the like. In some embodiments, the elongated connector 112 and the plenum 110 may be coupled to the base 104 by adhesives, or other permanent or semi-permanent attachment means. In some embodiments, the elongated connector 112 may be coupled to an external pump with a hose (not shown) to supply fluid to the pool cleaner 100. The pump may be removably coupled to the elongated connector 112 by a clamp or locking device. The hose may be coupled over an end lip portion of the top portion 122 of the elongated connector 112. In additional embodiments, the plenum 110 may also include outlet ports or outlet jet ports for fluid to exit the pool cleaner 100. For example, fluid from the swimming pool or spa may flow through the plenum 110 pushed along by the one or more outlet jet ports in the plenum 110. In some embodiments, the fluid from the elongated connector 112 may flow directly to the one or more outlet jet ports of the plenum 110. For example, once fluid travels down the elongated connector 112, the fluid may be distributed to one or more outlet jet ports in the plenum 110 via internal channels in the plenum base 120 or the fluid conduit system 404. Fluid not flowing to the one or more outlet jet ports of the plenum 110 may be directed to the flow conduit system 404 of the pool cleaner 100.
The drive system 504 components shown in FIG. 8 include the first drive unit 506a and the second drive unit 506b, which may mirror the first drive unit 506a on the other side of the base 104. The first drive unit 506a may be coupled to the first rear housing 510a via a first connection surface 528a (see FIG. 9) that is coupled to the first drive assembly surface 214a on the front portion of the pool cleaner 100. The second drive unit 506b may be coupled to the second rear housing 510b via a second connection surface 528b (see FIG. 9) that is coupled to the second drive assembly surface 214b on the front portion of the pool cleaner 100. While not shown in FIG. 8, the third drive unit 506c may be coupled to the third rear housing 510c via a third connection surface 528c that is coupled to the third drive assembly surface 214c on the rear portion of the pool cleaner 100. Further, the fourth drive unit 506d may be coupled to the fourth rear housing 510d via a fourth connection surface 528d that is coupled to the fourth drive assembly surface 214d on the rear portion of the pool cleaner 100.
FIG. 9 is a section view taken along lines 9-9 of FIG. 1 depicting the drive system 504 and the fluid conduit system 404 in an example configuration. The fluid conduit system 404 may be located within the base 104 between the top housing 204 and bottom housing 304. In one embodiment, the fluid conduit system 404 may receive fluid from the inlet connector 406 via the elongated connector 112. The inlet connector 406 may be in fluid connection or communication with the one or more flow paths 410 and the plenum cavity duct 408. When fluid is received by the inlet connector 406 via the elongated connector 112, the first flow path 410a, the second flow path 410b, the third flow path 410c, and the fourth flow path 410d may concurrently fill with fluid.
Turning to the area of the first drive unit 506a shown in FIG. 9, the first flow path 410a may channel fluid to the first drive unit 506a. The first flow path 410a may diverge into the first drive unit flow path 412a and the first venturi flow path 414a (see FIG. 5). The first drive unit flow path 412a may be coupled to the first drive connection port 416a located at an end of the fluid conduit system 404. The first drive connection port 416a may protrude though the first aperture 216a of the top housing 204 and couple to a first inlet jet port 522a of the first rear housing 510a. When the base 104 is assembled, a sealed fluid passageway may be formed from the first flow path 410a to the first inlet jet port 522a by way of the first drive unit flow path 412a, the first drive connection port 416a, the first aperture 216a, and the first rear housing 510a. Additionally, the first venturi flow path 414a, which diverges from the first flow path 410a, may be connected to the first venturi connection port 418a. The first venturi connection port 418a may be coupled to the first venturi port 314a of the bottom housing 304. When the base 104 is assembled, a sealed passageway may be formed from the first flow path 410a to the first venturi port 314a by way of the first venturi flow path 414a, the first venturi connection port 418a, and the first venturi port 314a.
Similar to the first flow path 410a, the second flow path 410b, the third flow path 410c, and the fourth flow path 410d may channel fluid to the second drive unit 506b, the third drive unit 506c, and the fourth drive unit 506d, respectively, using the same or similar mechanisms discussed with respect to the first flow path 410a. Thus, when the base 104 is assembled, a sealed fluid passageway may be formed from each of the flow paths 410b, 410c, 410d to its respective inlet jet ports 522b, 522c, 522d by way of the drive unit flow paths 412b, 412c, 412d, the respective drive connection ports 416b, 416c, 416d, the respective apertures 216b, 216c, 216d, and the respective rear housings 510b, 510c, 510d. Further, venturi flow paths 414b, 414c, 414d may be connected to the venturi connection ports 418b, 418c, 418d, respectively. Thus, when the base 104 is assembled, a sealed passageway may be formed from the flow paths 410b, 410c, 410d to the respective venturi ports 314b, 314c, 314d by way of the respective venturi flow paths 414b, 414c, 414d, the respective venturi connection ports 418b, 418c, 418d, and the respective venturi ports 314b, 314c, 314d. It should be noted that the mechanisms illustrated above with respect to the first flow paths 410a, the first drive unit 506a, and the coupled components located about the first corner 106a, may be mirrored or reproduced in the additional areas or corners of the pool cleaner 100 including the second, third, and fourth corners 106b, 106c, 106d.
FIGS. 10 and 11 describe additional features around the function of the drive system 504 and base 104. FIG. 10 illustrates a left side of the pool cleaner 100 according to an embodiment. In the example of FIG. 10, shown on the left side of the pool cleaner 100 are two drive units (e.g., second drive unit 506b and fourth drive unit 506d) positioned on the base 104. On the right side of the pool cleaner 100 (as best seen in FIGS. 1 and 2), for example, two drive units (e.g., first drive unit 506a and third drive unit 506c) are positioned on the base 104.
FIG. 11 illustrates a cross section view taken along lines 10-10 of FIG. 1. Here, the internal cavities 526 of the drive units 506 and base 104 are shown. After fluid enters the rear housing 510 via the inlet jet port 522, the fluid may be received by the drive system 504, the drive system enclosure 512, the impeller 516, and/or the water passage 514. The inlet jet port 522 may create a stream of high velocity fluid capable of using force to drive components within the drive system 504. After fluid has entered the internal cavity 526 through the inlet jet ports 522 from the fluid conduit system 404 (described above), the fluid may be directed into the drive system enclosure 512. The fluid exiting the inlet jet port 522 may create a high velocity stream before it enters the drive system enclosure 512. The high velocity fluid may be directed to hit the plurality of blades 534 of the impeller 516 within the drive system enclosure 512. The impeller 516 is capable of rotating in a counterclockwise or clockwise direction when a high velocity fluid acts against the plurality of blades 534. After the fluid enters the drive system enclosure 512, the fluid is directed out of the drive system enclosure 512 by the water passage 514. After fluid leaves the drive system enclosure 512, the fluid may reside within the internal cavity 526 or exit the rear housing 510 though the one or more outlet vents 524 located in the rear housing 510 or any other opening in the rear housing 510. In some embodiments, the water passage 514 allows fluid to exit the drive system enclosure 512, which may improve efficiency of the power generated by the drive system 504. In other embodiments, the water passage 514 serves to flush debris out of the one or more drive unit flow paths 412 or the one or more drive units 506, which may reduce debris buildup in the fluid conduit system 404 or the drive system 504 over time.
The impeller 516 within the drive system enclosure 512 may be mechanically or operatively coupled to the gear assembly 518 and capable of rotating the gear assembly 518 concurrently with the impeller 516. The inlet jet ports 522 may feed hydraulic power via fluid pressure to the impellers 516a, 516b, 516c, 516d of the drive units 506a, 506b, 506c, 506d, respectively, which provide torque to the respective one or more wheels 508a, 508b, 508c, 508d via the respective one or more gear assemblies 518a, 518b, 518c, 518, 518d to navigate the pool cleaner 100 through water or other fluid.
In some embodiments, the impeller 516 may include a Pelton wheel including a plurality of bucket profile blades having a substantially concave profile. The one or more inlet jet ports 522 may feed hydraulic power via fluid pressure to a Pelton wheel within the one or more drive units 506, which may provide torque to the respective one or more wheels 508 via the respective one or more gear assemblies 518 to navigate the pool cleaner 100 through water or other fluid. Fluid exiting the Pelton wheel may flow through the drive system enclosure 512 and exit the drive unit 506 through one or more outlet vents 524.
Turning to FIG. 12 of the current disclosure, the pool cleaner 100 is shown from a top view. In this embodiment, the plenum opening 210 on the base 104 is shown in additional detail. In some embodiments, the plenum 110 may contain a plurality of outlet jet ports where fluid is directed from the fluid conduit system 404 into the plenum 110 thereby directing fluid through the plenum 110 from the base 104 of the pool cleaner 100 about the bottom housing 304 to the top housing 204. Additionally, FIG. 12 illustrates the drive units 506a, 506b, 506c, 506d located about each of the respective drive assembly surfaces 214a, 214b, 214c, 214d via the connection surfaces 528a, 528b, 528c, 528d of the drive units 506 (see FIGS. 9 and 11). Although the one or more drive units 506 are positioned on each corner 106 of the base 104, a person skilled in the art would understand that the one or more drive units 506 may be positioned about any orientation of the base 104 to move the pool cleaner 100.
FIG. 13. illustrates the pool cleaner 100 from a bottom view. Located on the outer surface 308 of the bottom housing 304, may be the one or more jet ports 312, the one or more venturi ports 314, and the one or more guide portions 316. Each of the one or more jet ports 312 may create a virtual fence action that can use fluid to lift debris off the bottom of the swimming pool. This enables debris to be easily sucked into the plenum 110 through the outlet cavity 310, thereby allowing the pool cleaner 100 to pick up and/or collect debris. Fluid (e.g., water) and entrained debris flowing through the plenum 110 may enter into a collection bag or a canister attached to the pool cleaner 100.
In some embodiments, each of the venturi ports 314 are inseparable parts of their respective jet port 312. In other embodiments, each of the one or more venturi ports 314 are a separate part of their respective jet ports 312. In addition, each of the venturi ports 314 may include a small opening that generates a high-velocity flow of fluid which lifts debris off the bottom of the swimming pool and thus, creates a virtual fence. The pool cleaner 100 may include removable venturi ports with different-sized venturi port openings for an option for a user, a technician, a distributor, or a dealer to create a customized cleaner that cleans debris off the bottom, where the cleaner is optimized for different debris types (such as sand, small leaves, large leaves, etc.) that are found in local or regional areas. Such removable ports may be cleaned or replaced when clogged or worn.
Turning to FIG. 14, a partial section view of the pool cleaner 100 taken along the lines 14-14 of FIG. 10 is provided. Here, the first flow path 410a, the second flow path 410b, the third flow path 410c, and the fourth flow path 410d are shown. Additionally, the connecting flow paths including the drive unit flow paths 412a, 412b, 412c, 412d and venturi flow paths 414a, 414b, 414c, 414d are shown. An example directional flow path 450 for a fluid is also shown.
In one embodiment, fluid enters the pool cleaner 100 through the elongated connector 112 (see. e.g., FIG. 1) and exits the bottom portion 124 of the elongated connector 112 into the fluid conduit system 404 via the inlet connector 406. The fluid may then fill the plenum cavity duct 408 distributing fluid evenly throughout the flow paths 410a, 410b, 410c, 410d. In the example embodiment of FIG. 14, the first flow path 410a and the second flow path 410b are shown at a front portion of the pool cleaner 100. The first flow path 410a may extend from the plenum cavity duct 408 about the first corner 106a of the pool cleaner 100. At an end opposite the plenum cavity duct 408, the first flow path 410a may diverge into the first drive unit flow path 412a and the first venturi flow path 414a. As previously described, the first drive unit flow path 412a may connect to the first drive connection port 416 about an end opposite the first flow path 410a. Additionally, the first venturi flow path 414a may connect to the first venturi connection port 418a about an end opposite the first flow path 410a.
The second flow path 410b may extend from the plenum cavity duct 408 about the second corner 106b of the pool cleaner 100. About an end of the second flow path 410b opposite the plenum cavity duct 408, the second flow path 410b may diverge into the second drive unit flow path 412b and the second venturi flow path 414b. As described previously, the second drive unit flow path 412b may connect to the second drive connection port 416 about an end opposite of the second flow path 410b. Additionally, the second venturi flow path 414b may connect to the second venturi connection port 418b about an end opposite the second flow path 410b.
In the example embodiment of FIG. 14, the third flow path 410c and the fourth flow path 410d are shown at a rear portion of the pool cleaner 100. The third flow path 410c may extend from the plenum cavity duct 408 about the third corner 106c of the pool cleaner 100. About an end of the third flow path 410c opposite the plenum cavity duct 408, the third flow path 410c may diverge into the third drive unit flow path 412c and the third venturi flow path 414c. The third drive unit flow path 412c may connect to the third drive connection port 416c about an end opposite of the third flow path 410c. Additionally, the third venturi flow path 414c may connect to the third venturi connection port 418c about an end opposite the third flow path 410c.
The fourth flow path 410d may extend from the plenum cavity duct 408 about the fourth corner 106d of the pool cleaner 100. About an end of the fourth flow path 410d opposite the plenum cavity duct 408, the fourth flow path 410d may diverge into the fourth drive unit flow path 412d and the fourth venturi flow path 414d. The fourth drive unit flow path 412d may connect to the fourth drive connection port 416 about an end opposite of the fourth flow path 410d. Additionally, the fourth venturi flow path 414d may connect to the fourth venturi connection port 418d about an end opposite the fourth flow path 410d.
Turning to FIG. 15, an embodiment of a method for manufacturing a base (e.g., base 104) of a pool cleaner (e.g., pool cleaner 100) is provided.
At 602, a first part (e.g., top housing 204) may be manufactured for the base. In an example embodiment, the first part is manufactured as a single unit by the process of molding.
At 604, a second part (e.g., bottom housing 304) may be manufactured for the base. In an exemplary embodiment, the second part is manufactured as a single unit by the process of molding.
At 606, a third part (e.g., fluid conduit system 404) may be manufactured for the base. In some embodiments, the third part may be manufactured by molding a plurality of parts separately and then, joining the plurality of parts to form the third part. For example, a first flow path (e.g., first flow path 410a), a second flow path (e.g., second flow path 410b), a third flow path (e.g., third flow path 410c), a fourth flow path (e.g., fourth flow path 410d) may be molded separately and joined together by laser welding or the like. In other embodiments, the first flow path, the second flow path, the third flow path, and the fourth flow path may be molded together first. Further, one or more fluid jet ports (e.g., jet ports 312, venturi port 314, and guide portion 316) and one or more wheel ports (e.g., drive assembly surface 214 and wheel recesses 318) may be molded separately and joined together with the flow paths by laser welding or the like.
At 608, the first part, the second part, and the third part may be joined together to form the base as a single, unitary, and inseparable unit. In some embodiments, the first part, the second part, and the third part may be joined or coupled together by laser welding or the like.
In some embodiments, the base may be a manifold integrated with a frame of the pool cleaner.
In some embodiments, the base may be manufactured using materials such as acrylonitrile butadiene styrene (ABS) glass-filled ABS material or Acrylonitrile Styrene Acrylate (ASA) material. The present disclosure also encompasses any other material for manufacturing the base.
By providing the base 104 as a single, unitary, and inseparable unit for the pool cleaner 100, performing any kind of service such as maintenance or replacement service of any component becomes easier as the base 104 holds or connects all the components of the pool cleaner 100 together. The present disclosure also eliminates the need to remove an outer cover of the pool cleaner 100 for performing the maintenance or replacement service. The present disclosure also reduces the need for plumbing or tubing to route the fluid flow around the pool cleaner 100 by providing the one or more flow paths.
Patent Application
20250198189
