This invention relates to methods and apparatus for propelling automated or robotic swimming pool and tank cleaners employing water jet propulsion.
A conventional pool cleaner comprises a base plate on which are mounted a pump, at least one motor for driving the pump and optionally a second motor for propelling the apparatus via wheels, rollers or endless track belts; a housing having a top and depending sidewalls and end walls that encloses the pump and motor(s) that are secured to the interior structure and/or the base plate; one or more types of filter media are positioned internally and/or externally with respect to the housing; and a separate external handle is optionally secured to the housing. Power is supplied by floating electrical cables attached to an external source, such as a transformer or a battery contained in a floating housing at the surface of the pool; pressurized water can also be provided via a hose for water turbine-powered cleaners. Tank and pool cleaners of the prior art also operate in conjunction with a remote pump and/or filter system which is located outside of the pool and in fluid communication with the cleaner via a hose.
Automated or robotic swimming pool cleaners of the prior art have traditionally been powered by one or more drive motors which, in some instances are reversible; a separate water pump motor is employed to draw debris-containing water through one or more openings in a base plate close to the surface to be cleaned. The water passes through one or more filters positioned in the pool cleaner housing and is typically discharged vertically through one or more ports in an upper surface of the housing to thereby create an opposite force vector in the direction of the surface being cleaned. This configuration of the apparatus and its method of operation permit the movement of the pool cleaner across the bottom wall and optionally, permit it to climb the vertical sidewalls of the pool, while maintaining a firm contact with the surface being cleaned.
An innovative use of water jets to propel a pool cleaner is described in U.S. Pat. No. 6,412,133, the entire disclosure of which is incorporated herein by reference. A single propeller is attached to the drive shaft projecting from the upper end of a vertically-mounted pump motor positioned in the interior of a pool cleaner housing. The water drawn through the base plate and filter(s) is diverted from a direction that is generally normal to the surface being cleaned by means of a directional flap valve and is discharged in alternating directions through a conduit that is positioned along the longitudinal axis of the pool cleaner in the direction of movement of the pool cleaner; the discharge conduit is generally parallel to the surface being cleaned. In one embodiment, the position of the directional flap valve changes when the water pump stops, or is slowed sufficiently, thereby allowing the water jet to be discharged in the opposite direction and causing the pool cleaner to reverse its direction of movement.
Although the water jet reversing propulsion system of U.S. Pat. No. 6,412,133 has been commercially successful, the size and power requirements of the pump motor must account for certain energy losses associated with changing the direction of the flowing water abruptly as it comes into contact with the directional flap valve and undergoes essentially a 90° change in direction.
It would therefore be desirable to provide an apparatus and method that reduced turbulent flow within the interior of the housing and facilitated the alternating directional discharge of the water jets used to propel the apparatus with a minimum loss in energy due to turbulence.
In the description that follows, it will be understood that the cleaner moves on supporting wheels, rollers or tracks, or a combination of these means that are aligned with the longitudinal axis of the cleaner body when it moves in a straight line. References to the front or forward end of the cleaner will be relative to its then-direction of movement.
The above objects and other advantages are obtained using the apparatus and method of the present invention which broadly comprehends positioning the pump motor horizontally within the pool cleaner housing, attaching a propeller to either end of the motor drive shaft which extends though and projects from opposing ends of the motor body, and providing opposing water jet discharge openings in the housing, each with a pressure-sensitive flap valve, in axial alignment with the motor's drive shaft and axis of rotation of the respective propellers. When the propellers rotate in one direction, the water is drawn through one or more openings in the base plate, passes through a filter or filters associated with the pool cleaner and is discharged through one of the discharge ports as a water jet of sufficient force to propel the pool cleaner along the surface being cleaned.
In one embodiment, each propeller is securely fixed or mounted to a respective end of the pump motor drive shaft. The water jet created by the propeller is aligned with the adjacent discharge port formed in the end wall of the housing. The force of the water jet is sufficient to open a valve that is positioned downstream of the propeller. The valve can be configured as a split flap valve that is hinged to fold outwardly from a normally closed position, and is designed to produce minimum resistance to the passage of the water jet as it moves toward the discharge port.
In this embodiment, a second flap valve is mounted in a second discharge port located at the opposite end of the housing. The second flap valve is pressed against a rim seal formed in the interior peripheral surface of a discharge duct to close the opposing (second) discharge port. The second flap valve is closed by a water pressure drop created adjacent the second valve in the interior of the housing as a result of the rapid flow of water entering an inlet port, passing through a filter device and flowing out of the open discharge port on the opposite end of the cleaner.
In one embodiment, the propeller adjacent the closed flap valve is also turning to enhance the flow of water towards the open flap valve at the opposite end of the housing. In order to minimize turbulent flow, the opposing ends of the motor body are provided with a curvilinear cap or cover having a streamlined surface configuration that enhances a more laminar flow of the pressurized water created by the rotating propeller. The movement of water across the motor housing at a velocity in the direction of the opposing propeller also enhances the water jet force as it is eventually discharged through the port to provide a force to move the pool cleaner in the opposite direction.
In another embodiment, the propellers are provided with a clutch mechanism so that they will turn in only one direction. In this embodiment, the propeller adjacent the discharge port with its flap valve in the closed position does not rotate; rather, the shaft of the motor spins within the clutch mechanism and applies no force to the propeller mounting. During a cleaning operation, when the motor stops and is reversed, the propeller that had been turning is no longer driven by the drive shaft and the clutch of the propeller on the opposite end is engaged and the propeller rotates, thereby applying a pressurized stream of water against the flap valve, which then opens and discharges a water jet through the discharge duct and out the discharge port, causing the pool cleaner to be propelled in the opposite direction. As previously noted, the valve at the opposite end is closed by the biasing force.
In a preferred embodiment, the end of the discharge conduit on the interior of the housing surrounds the propeller in order to increase the efficiency of the system in moving water through the conduit to the discharge port. The interior of the conduit is advantageously provided with a projecting seat that contacts the edge of the flap valve to form a seal and to limit the range of movement of the valve member(s). The interior surface of the seat can be angled or tapered to join the adjacent conduit surface to minimize turbulence.
The operation of the pump motor can be controlled in accordance with a predetermined program that interrupts and then reverses the polarity, or direction of the electrical current flowing to the pump motor in response to either a timed sequence, a sensor which detects movement, or lack of movement, or a sensor which is responsive to a vertical wall or other change in position of the pool cleaner, either in the generally horizontal or generally vertical position. Various apparatus, means and methods for controlling the stopping and starting of drive motors and/or pump motors are well-known in the art and form no specific part of the present invention. Similarly, other choices in addition to those specifically described and exemplified herein will be apparent to those of ordinary skill in the art without departing from the scope of the invention.
In one preferred embodiment of the invention, an auxiliary discharge port is positioned above the directional discharge port upstream of the flap valve and in the jet discharge conduit proximate the driving propeller. As used herein, the term “driving propeller” refers to the propeller adjacent the open flap which is producing a water jet that propels the pool cleaner. A reference to the “forward end” or “forward movement” will be understood as a reference to the end facing in the direction in which the pool cleaner is then moving.
The auxiliary discharge port is in fluid communication with a vertical discharge conduit which is generally of a smaller diameter than the conduit passing the propelling water jet, and has an outlet that is oriented vertically when the pool cleaner is positioned on a horizontal surface. Water exiting the vertical conduit produces a force vector that is generally normal to the surface being cleaned. When the pool cleaner is moving over the generally horizontal surface of the bottom wall of a pool or tank, the vertical discharge conduit has the effect of forcing the wheels or other supporting means of the pool cleaner onto contact with the surface. A vertical discharge conduit is positioned at either end of the pool cleaner. In one embodiment, a pressurized water jet exits vertically from only the end at which the water jet is discharged. In another embodiment, water can be discharged from both vertical conduits simultaneously. This relief of pressure by discharge of water through the vertical conduit adjacent the closed valve also serves the beneficial purpose of reducing turbulence. It will be understood that the direction of the “vertical discharge” is relative to the surface being cleaned. When the pool cleaner is ascending or descending a vertical wall, the discharge through the auxiliary discharge port produces an opposite force vector to maintain the pool cleaner in contact with the vertical surface.
The orientation of the discharged water jet can be varied to provide a downward component or force vector, lateral components, or a combination of such components or force vectors to complement the translational force produced by the exiting water jet. Other methods and apparatus can be adapted to achieve the desired combination of force vectors whose resultant provides a sufficient force to cause the pool cleaner to move along the surface being cleaned while also maintaining traction and to permit the unit to reliably ascend and descend vertical wall surfaces. Examples of suitable alternative configurations are also disclosed in U.S. Pat. No. 6,412,133, e.g., in FIGS. 8, 9, 12A, 15-17, 23 and 24 and the corresponding description in that patent's specification, which is incorporated herein by reference.
In one preferred embodiment of the pool cleaner of the present invention, the housing is supported by a pair of wheels mounted for rotation on a transverse axle secured at one end of the housing, and a third swivel-mounted wheel positioned at the opposite end of the housing and located substantially on the longitudinal center line of the cleaner. In the operation of this embodiment, movement of the pool cleaner in a direction in which the two wheels mounted on the transverse axle are at the leading end of the pool cleaner results in the swivel wheel at the opposite end of the housing typically following, and the pool cleaner moves in a generally straight line for cleaning. When the pump motor is stopped and reverses direction, the now-leading swivel-mounted wheel typically rotates to one side or the other, or back and forth between alternate positions, thereby causing the pool cleaner to assume a random or at least curvilinear path. This alternating straight-line or linear movement of the pool cleaner followed by curvilinear movement enables the pool cleaner to traverse most, if not all of the bottom surfaces of the pool during a cleaning cycle.
Another preferred aspect of the invention includes the use of at least one, but preferably, a pair of pleated filter units through which the pool water-containing debris is drawn and the debris retained as the water passes through the housing. In a particularly preferred embodiment, the pair of pleated filter paper cartridges extend longitudinally and their axes are parallel to the axis of the drive motor shaft. The use of these elongated pleated filters has the advantage of reducing the profile of the pool cleaner and thereby the energy required to move it through the water.
The pleated filters are preferably supported to prevent collapse and thereby to enhance their performance and useful life between cleanings and/or replacement. The supporting material can be a wire screen formed of a non-rusting material that is also able to withstand exposure to salt water and/or the treatment chemicals that may be present in the pool water. A particularly preferred support for the pleated filter is a Dutch weave stainless steel wire mesh or screen that is folded in the same configuration as the pleated paper or other natural or synthetic fibrous material that functions to filter the water and retain the debris. Porous plastic supporting materials can also be used.
In addition to using the pleated filter cartridge, the pool cleaner can also be provided with a conventional woven mesh or screen filter to remove larger debris from the incoming flow of water entering from the base plate. In a preferred embodiment, the flexible mesh filter is fitted into the lower region of the housing and positioned above the base plate. Water entering the body first passes through the mesh filter, which entrains larger pieces of debris, e.g. small twigs, leaves, and the like; the water leaving this first stage of filtration then passes into the interior or the pleated filter unit and the smaller debris is trapped on its interior as the filtered water passes through. The use of the primary mesh filter also serves the purpose of extending the life of the pleated filter medium, as well as reducing the frequency of maintenance. Assuming that the pleated filter medium is not punctured, the cartridge can be removed from the unit and back-flushed to permit its reuse.
From the above description, in its broadest construction, the invention comprehends a method of propelling a pool or tank cleaner by means of a water jet that is alternatively discharged in at least a first and second direction that results in movement in opposite translational directions. The direction of the water jet is controlled by the direction of rotation of a horizontally mounted pump motor and propellers mounted on either end of the pump's driveshaft. Opposing discharge conduits are axially aligned with the motor's drive shaft and the pressurized water controls the movement of one or more valves that operate in one or more discharge conduits to pass the water for discharge in alternating directions. During the change from one direction to the alternate opposing direction, the motor is stopped and its direction reversed. This interrupts the discharge of water from one discharge conduit, causing the valve to close and the pressure created by the opposing propeller causes the valve to open permitting the discharge of the water jet to propel the unit in the opposite direction.
The invention comprehends methods and apparatus for controlling the movement of robotic tank and swimming pool cleaners that can be characterized as systematic scanning patterns, scalloped or curvilinear patterns and controlled random motions with respect to the bottom surface of the pool or tank. For the purposes of this description, references to the front and rear of the cleaning apparatus or to its ends or end walls of its housing will be with respect to the direction of its movement.
In one embodiment of the invention described below with respect to the drawings, the pool cleaner is supported by, and moves on a plurality of wheels, which contact the surface being cleaned. In a presently preferred embodiment, wheels are attached to a transverse axle attached to one end of the pool cleaner assembly and a third swivel wheel is mounted at the opposite end of the unit at a position corresponding to the longitudinal axis of the pool cleaner. The turning range or angle of radial movement around the pivot point of the swivel wheel is limited by either fixed or adjustable control elements. This combination of fixed wheels and a pivoting, or swivel wheel produces essentially straight-line movement in the direction in which the third wheel is trailing and a curvilinear cleaning pattern when the third wheel is leading. Various mechanical and/or electro-mechanical means known to the art can be utilized to control and vary the directional position of the swivel wheel to thereby create different and varying patterns of curvilinear movement of the pool cleaner.
As will be understood by those of ordinary skill in the art, the pool cleaner can also be provided with a second pair of axle-mounted wheels in place of the single swivel-mounted wheel. The use of a set of wheels at opposing ends of the pool cleaner can be used to provide for more regular patterns of movement than the random movement associated with the swivel wheel. For example, one or both ends of one or both of the two axles can be positioned in fixed or adjustable slots that permit the respective portion(s) of the axle(s) to move in response to a change in direction.
While the illustrative figures which accompany this application, and to which reference is made herein, schematically illustrate various embodiments of the invention on robotic cleaners equipped with wheels, it will be understood by one of ordinary skill in the art that the invention is equally applicable to cleaners which move on transverse rollers and endless tracks or belts.
The invention will be described in further detail below and with reference to the attached drawings where the same or similar elements are referred to by the same number, and in which:
To facilitate an understanding of the invention, identical reference numerals are used when appropriate, to designate the same or similar elements that are common to the figures. Further, unless stated otherwise, the features shown in the figures are not drawn to scale, but are shown for illustrative purposes only.
In the description that follows, a pool or tank cleaner 10 has an exterior cover or housing 12 with a top wall 12A, an internal pump and drive motor 60 that draws water and debris through openings in a base plate that are entrained by one or more filters 88.
Referring to
With continuing reference to
The pool cleaner body is supported by a pair of wheels 30 mounted on axle 31, which is mounted or otherwise installed transversely to the longitudinal axis of the pool cleaner as defined by direction of movement. A third supporting wheel assembly 32 is mounted at the end opposite the transverse axle. For purposes of clarity in further describing the invention, the pair of wheels 30 are illustratively shown as being mounted proximate first end “A” of the cleaner 10 and the wheel assembly 32 is illustratively shown and labeled as being mounted at opposing second end “B” of the cleaner 10. In one embodiment, wheel assembly 32 includes a mounting bracket 34 with downward projecting flanges 36 that engage a wheel support member 38, which retains and controls the angular or radial range of movement of wheel 39. As will be apparent to those of ordinary skill in the art, the angular range of movement can be controlled by providing adjustable pins, which can be repositioned by the user. Further, the illustrative wheel assembly 32 shown in
With continuing reference to
Referring now to the top view of
Although the vertical discharge conduit section 71 and 70 are each illustratively configured with two right angle elbows, a person of ordinary skill in the art will appreciate that a straight or angled conduit can also be provided to extend from the outlet 43 positioned downstream of the propeller through the top surface of the upper cover portion 12A. For example, referring to
The positioning and functioning of split flap valves 90 are now described with reference to the side elevation view in cross-section of
Referring now to
Referring to
Preferably, the pleated paper or the woven mesh is supported by a larger mesh like structure or support member 110 that supports the inner circumference of the paper or woven mesh. In one embodiment, the support member 110 includes a plurality of spaced-apart concentric rings 112 that are aligned and secured together by a plurality of spaced-apart cross members 114. The support member 110 is sized to support the inner surface of the filter material 88 and the end caps 80. As shown in
As previously noted, upper cover portion 12A is removable to permit convenient access to the interior of the body, e.g., for maintenance of the filters 88. The filter assemblies are preferably supported and held in position by the upper and lower body portions 12A and 12B. Other configurations of filter supports and assemblies known in the prior art can be used with the invention.
As best shown in
In describing the method of operation of the pool cleaner of the invention, it will be understood that the direction of the rotation of the motor 60 is effected by changing the polarity of the power supply. This technique is well-known in the art and a particular means for accomplishing this change does not form part of the present invention. This reversal of polarity can be accomplished using a programmed controller 68 and other appropriate circuit elements well-known in the art. As previously noted; the change in direction of rotation of the motor can be the result of a predetermined program which is specifically designed to result in a random pattern of movement of the pool cleaner that will result in the cleaning of all or substantially all of the desired pool surface(s). Other changes can be the result of signals emanating from various types of optical, mechanical and/or radio frequency devices. Similarly, control signals can be generated by one or more sensors 120 which detect the motion of, or the absence of movement of the pool cleaner, e.g., when the pool cleaner's forward motion is stopped by encountering a wall or an obstacle such as a ladder.
Referring to
Preferably, the sensor 120 is a magnetic pickup switch 122 that is coupled to one or more wheels 30, as also illustratively shown in
Other magnetic sensors of the types described in U.S. Pat. No. 6,758,226 can be coupled to the pool cleaner's processor/controller to provide a periodic signal while the unit is moving, while a predetermined delay will result in a change in direction of the pump motor. In one embodiment, a reed switch is opened or closed to generate the signal. Other motion detecting systems known in the art can be adapted for use.
The pool cleaner 10 is placed on the bottom of the pool or tank to be cleaned and power supplied to the motor 60, which causes one or both of the propellers 64 to rotate with the motor's drive shaft 62. In accordance with the directional references indicated in
As will be understood by one of ordinary skill in the art, the water jet discharge conduits 40 can alternatively be positioned at an angle other than horizontal to the surface being traversed by the pool cleaning apparatus. For example, a downward thrust or force vector can be provided to assist in maintaining the apparatus in contact with the surface over which it is traveling by positioning the respective discharge conduits 40 at an acute angle to the horizontal. Similarly, an upward thrust or vertical force vector can be provided by declining the exhaust tube below the horizontal. The end of the discharge conduit 40 can be divided so that the exiting water jet stream is split into a horizontal vector and an upward (or downward) discharge stream. A further method for controlling the directional discharge is by use of a plate or rudder, either fixed or adjustable by the user that is positioned in the end of the discharge conduit.
In the embodiment in which both propellers 64 rotate simultaneously, the propeller shown on the right end of the pool cleaner in
Referring to
During operation, when a main discharge flap valve 90, e.g., flap valve on the left side of
In an alternative embodiment, the invention comprehends the use of two separate motors (not shown) whose axes of shaft rotation are coincident, instead of a single motor 60. Preferably, a programmable processor controller regulates the rotations of the shafts of the two axially aligned motors. In this embodiment, a first motor is provided with power to turn the propeller that produces the motive jet stream and the adjacent and opposing (second) motor is stopped to reduce turbulence inside the housing 12. When the directional movement of the cleaner is reversed, the power to the rotating motor is interrupted and the second motor is activated. The flap valves 90 and 96 operate in a similar manner as described above with respect to the embodiment shown with a single motor 60.
In addition to, or in place of the discharge of a vertical stream, pressurized water can also be delivered via a tube or tubes to the underside of the pool cleaner for the purpose of lifting debris into suspension for capture by the water flowing into the inlet ports 18 formed in the baseplate 16. Various examples of arrangements for creating a pressurized stream and various modes of delivering it to the underside of the baseplate 16 for this purpose are shown and described in U.S. Pat. No. 6,412,133, as well as in U.S. Pat. Nos. 6,971,136 and 6,742,613, the disclosures of which are incorporated herein in their entirety.
Referring to
The pool cleaner 10 can include a ballast member 142 at a position on the base plate 16 towards the opposing second end B of the cleaner that is opposite the flotation device 140 and proximate the single wheel assembly 32. The ballast member 142 can be fabricated from a material that is resistant to water and salt, such as stainless steel, ceramic materials, and the like, and is preferably in the form of a plate. The ballast member 142 is preferably mounted to the interior surface of the base plate 16, so that it does not interfere with the flow of water through the inlet ports 18 and filters 88, although the shape and positioning of the ballast 142 is not to be considered limiting. The ballast 142 can be used to provide stability to the cleaner as it traverses the pool surfaces. The ballast 142 also serves as a counter-weight to the floatation device 140, such that when end A of the cleaner 10 floats upward, the opposite end B with the ballast will not float upwards and the single wheel assembly 32 maintains contact with the surface of the pool. Accordingly, the weight of the ballast 142 is selected to prevent end B of the cleaner from floating upward, but does not prevent the cleaner 10 from climbing a sidewall of the pool when the propulsion system is activated, as described below in further detail with respect to the flow diagram of
Referring again to
Referring now to
A signal is sent from the processor/controller in step 1008 to interrupt the vertical discharge of pressurized water through the auxiliary discharge port thereby eliminating the downward force vector at the forward end of the pool cleaner. Optionally, the power to the pump motor can also be terminated for a predetermined period of time, or until a signal is received from an orientation sensing device.
Since the forward end of the pool cleaner housing includes a flotation device, the forward end will float up under its effect in step 1010 to form an angle ranging from 45° to 60° with the horizontal.
When the pool cleaner body has achieved an angle of at least 45°, a tilt sensor transmits a signal to the processor/controller in step 1012 and a further signal is generated to reinstitute the discharge of water through the auxiliary discharge port and thereby provide an opposing force vector to direct the pool cleaner towards the side wall in a vertical orientation. In an optional embodiment of step 1012, a timer clock is activated when the vertical discharge of water is interrupted in step 1008 and after a predetermined period of time, the discharge is resumed. The time required for the unit to achieve the desired angular orientation of the forward end can be readily determined by those of ordinary skill in the art using simple experimentation for use in programming the processor/controller. As noted above in conjunction with the description of step 1008, the pump motor can remain activated so that the unit may be moved closer to the wall as the flotation lifts the forward end; if the pump has been interrupted, then it will be reactivated by a signal from the processor/controller at the same time that the discharge of water from the auxiliary discharge port resumes. With the pump motor running, the pool cleaner ascends the side wall of the pool.
When the pool cleaner reaches the water line in step 1014, a signal is sent either by an optional sensor or a time clock that initiated the count of a predetermined period of time after the reactivation of the vertical discharge of water in step 1012.
In accordance with step 1016, the interruption of power to the pump motor is continued for a predetermined period of time as measured by the timer clock, or until a sensor signal is generated indicating that the pool cleaner has again assumed a generally horizontal position on the bottom of the pool. Thereafter, the pump motor is activated in step 1018, in one embodiment with the opposite polarity to propel the pool cleaner in a new direction with the swivel wheel in the forward position. The pool cleaner continues moving in accordance with a pattern determined by the setting of the swivel wheel, which direction may also be affected by encounters with arcuate curve surfaces joining the bottom and side walls of the pool which do not interrupt the movement of the unit and/or encounters with other objects/obstacles in the pool which may deflect the movement of the unit, but do not cause it to come to a complete stop. In accordance with step 1020, a signal is generated to interrupt power to the pump motor when a motion sensor detects that the pool cleaner has stopped moving. Thereafter, the processor/controller reverses the polarity and activates the pump motor in step 1022 to propel the unit in a new direction with the axle-mounted wheels defining the forward end. As indicated in step 1024, the sequence of steps of this process are repeated as in step 1006 when the forward end is proximate a side wall.
Referring to
In
From the above description, it will be understood that when operating in a rectangular pool or tank, the embodiments shown in
As shown in
In
The use of this method and apparatus are known in the art and are also described in detail in U.S. Pat. No. 6,412,133 referred to above. The optional predetermined movement of the end(s) of the axle(s) will provide patterned movement of the pool cleaner that afford the user the opportunity to make the selection in order to customize the unit to maximize the efficient cleaning of round, oval, rectangular and kidney-shaped pools of varying sizes.
The invention has been described and illustrated in detail and various modifications and enhancements will become apparent to those of ordinary skill in the art from this disclosure. The scope of the invention and its protection are therefore to be determined with references to the following claims.
This patent application claims priority to U.S. application Ser. No. 13/578,432, filed Aug. 10, 2012, which claims priority to International Application No. PCT/US2011/000261, filed on Feb. 11, 2011, which claims the benefit of U.S. Provisional Application Ser. No. 61/337,940, filed Feb. 11, 2010, the contents of which are incorporated by reference herein in their entireties.
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Number | Date | Country | |
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Parent | 13578432 | US | |
Child | 14714862 | US |