Pool cleaner modular drivetrain

• US 10,155,538 B2
• Filed: 01/29/2018
• Issued: 12/18/2018
• Est. Priority Date: 05/11/2017
• Status: Active Grant

• Current Assignee: Hayward Industries, Inc.
• Original Assignee: Hayward Industries, Inc.
• Inventors: Marciano, Edward Lawrence, Teuscher, Scott, Hayes, Graham M.
• Primary Examiner(s): KARLS, SHAY LYNN
• Application Number:
  US15/882,508
• Publication Number:
  US 20180327026A1
• Time in Patent Office: 323 Days
• CPC Class Codes: B62D 11/04 by means of separate power sources
• CPC Class Codes: E04H 4/1654 Self-propelled cleaners
• CPC Class Codes: F16H 1/22 with a plurality of driving or driven shafts; with arrangements for dividing torque between two or more intermediate shafts
• CPC Class Codes: F16H 57/025 Support of gearboxes, e.g. torque arms, or attachment to other devices
• CPC Class Codes: F16H 57/031 characterised by covers or lids for gearboxes

Abstract

Exemplary embodiments are directed to pool cleaners that remove debris from water using a plurality of cyclonic flows, or that include a removable impeller subassembly, a check valve for a debris canister, a particle separator assembly having a handle that locks to the pool cleaner, a modular roller drive gear box, or a roller latch that secures a roller to the pool cleaner. Exemplary embodiments are also directed to the check valve and the roller latch themselves. Exemplary embodiments are directed to a filter medium for pool cleaners that includes embossments providing flow channels for water, and to roller assemblies for pool cleaners. Exemplary embodiments are directed to pool cleaners including alternative pump motor engagements. Exemplary embodiments are directed to pool cleaners power supplies that include a potted and contoured power board assembly, and to kickstands therefor. Exemplary embodiments are directed to a pool cleaner caddy, and removable wheels therefor.

Claims

1. A pool cleaner for cleaning a pool or spa and having removable modular assemblies for facilitating replacement or service, comprising:

a chassis;

a first roller set including at least one roller;

a second roller set including at least one roller;

a first roller drive gear train in mechanical communication with the first roller set;

a second roller drive gear train in mechanical communication with the second roller set;

a first roller drive gear box including a housing and a first gear stack secured within the housing, the first roller drive gear box removably fastened to the chassis and in mechanical communication with the first roller drive gear train;

a second roller drive gear box including a housing and a second gear stack secured within the housing, the second roller drive gear box removably fastened to the chassis and in mechanical communication with the second roller drive gear train; and

a motor system in mechanical communication with the first gear stack and the second gear stack;

wherein the motor system drives rotation of the first gear stack, the first gear stack drives rotation of the first roller drive gear train, and the first roller drive gear train drives rotation of the first roller set,

wherein the motor system drives rotation of the second gear stack, the second gear stack drives rotation of the second roller drive gear train, and the second roller drive gear train drives rotation of the second roller set,

wherein said pool cleaner creates a suction effect at an inlet opening receiving debris-laden water from the pool or spa, and

wherein the chassis includes a first drive gear box housing and a second drive gear box housing, the first roller drive gear box removably fastened within the first drive gear box housing and the second roller drive gear box removably fastened within the second drive gear box housing.

2. The pool cleaner of claim 1, wherein the first and second drive gear box housings include side walls, and the first and second roller drive gear boxes include sidewalls configured to match the sidewalls of the first and second drive gear box housings and align the first and second roller drive gear boxes when positioned within the first and second drive gear box housings.

3. The pool cleaner of claim 1, wherein the first and second drive gear box housings include a plurality of mounts, and the first and second roller drive gear boxes include a plurality of mounting tabs configured to align with the mounts to position the first and second roller drive gear boxes within the first and second drive gear box housings.

4. A pool cleaner for cleaning a pool or spa and having removable modular assemblies for facilitating replacement or service, comprising:

a chassis;

a first roller set including at least one roller;

a second roller set including at least one roller;

a first roller drive gear train in mechanical communication with the first roller set;

a second roller drive gear train in mechanical communication with the second roller set;

a first roller drive gear box including a housing and a first gear stack secured within the housing, the first roller drive gear box removably fastened to the chassis and in mechanical communication with the first roller drive gear train;

a second roller drive gear box including a housing and a second gear stack secured within the housing, the second roller drive gear box removably fastened to the chassis and in mechanical communication with the second roller drive gear train; and

a motor system in mechanical communication with the first gear stack and the second gear stack;

wherein the motor system drives rotation of the first gear stack, the first gear stack drives rotation of the first roller drive gear train, and the first roller drive gear train drives rotation of the first roller set,

wherein the motor system drives rotation of the second gear stack, the second gear stack drives rotation of the second roller drive gear train, and the second roller drive gear train drives rotation of the second roller set,

wherein said pool cleaner creates a suction effect at an inlet opening receiving debris-laden water from the pool or spa, and

wherein the first roller set includes a first front roller, a first middle roller, and a first rear roller;

the second roller set includes a second front roller, a second middle roller, and a second rear roller; and

the first and second front rollers are disposed adjacent to each other, the first and second middle rollers are disposed adjacent to each other, and the first and second rear rollers are disposed adjacent to each other.

5. The pool cleaner of claim 4, wherein the first and second roller drive gear boxes include a removable lid secured to the housing, and the first and gear stacks are accessible when the lid is removed from the housing.

6. The pool cleaner of claim 4, wherein a gear of the first gear stack extends out from an opening in the housing and drives rotation of a first drive gear of the first roller drive gear train, and a gear of the second gear stack extends out from an opening in the housing and drives rotation of a second drive gear of the second roller drive gear train.

7. The pool cleaner of claim 6, wherein a first axle is engaged and rotates with the first drive gear and the gear of the first gear stack is engaged with and drives rotation of the first axle, and a second axle is engaged and rotates with the second drive gear and the gear of the second gear stack is engaged with and drives rotation of the second axle.

8. The pool cleaner of claim 4, wherein the first roller set includes a first front roller, a first middle roller, and a first rear roller.

9. The pool cleaner of claim 8, wherein the motor system comprises a first drive motor that drives the first front roller, the first middle roller, and the first rear roller at the same rate.

10. The pool cleaner of claim 4, wherein the second roller set includes a second front roller, a second middle roller, and a second rear roller.

11. The pool cleaner of claim 10, wherein the motor system comprise a second drive motor that drives the second front roller, the second middle roller, and the second rear roller at the same rate.

12. The pool cleaner of claim 4, wherein the motor system drives the first front roller, the first middle roller, and the first rear roller at a first rate, and the motor system drives the second front roller, the second middle roller, and the second rear roller at a second rate that is different than the first rate to cause the pool cleaner to turn.

13. The pool cleaner of claim 12, wherein the motor system comprises a first motor drive that drives the first front roller, the first middle roller, and the first rear roller at a first rate, and the motor system comprises a second motor drive that drives the second front roller, the second middle roller, and the second rear roller at a second rate that is different than the first rate to cause the pool cleaner to turn.

14. The pool cleaner of claim 4, wherein the motor system drives the first front roller, the first middle roller, and the first rear roller in a first rotational direction, and the motor system drives the second front roller, the second middle roller, and the second rear roller in a second rotational direction that is different than the first rotational direction to cause the pool cleaner to turn.

15. The pool cleaner of claim 14, wherein the motor system comprises a first motor drive that drive the first front roller, the first middle roller, and the first rear roller in a first rotational direction, and the motor system comprises a second motor drive that drives the second front roller, the second middle roller, and the second rear roller in a second rotational direction that is different than the first rotational direction to cause the pool cleaner to turn.

16. The pool cleaner of claim 4, wherein said pool cleaner includes a bottom configured to be positioned adjacent a bottom wall of the pool or spa when said pool cleaner is driven along the bottom wall, the bottom including the inlet opening.

17. The pool cleaner of claim 4, wherein said pool cleaner includes filtration means for separating debris from the debris-laden water and further includes an outlet for expelling the water from said pool cleaner.

18. The pool cleaner of claim 17, wherein said filtration means is at least one of a cyclone chamber and a cyclone container.

19. The pool cleaner of claim 17, wherein said filtration means is a filter medium.

20. The pool cleaner of claim 4, wherein said pool cleaner is powered by an electric source.

21. The pool cleaner of claim 4, wherein said pool cleaner is a pressure cleaner or a suction cleaner.

22. The pool cleaner of claim 4, wherein the motor system comprises a first drive motor and a second drive motor, the first drive motor is in mechanical communication with the first gear stack and drives rotation of the first gear stack, and the second drive motor is in mechanical communication with the second gear stack and drives rotation of the second gear stack.

23. The pool cleaner of claim 4, wherein the first roller drive gear box can be unfastened and removed from the chassis, and a third roller drive gear box can be removably fastened to the chassis in place of the first roller drive gear box.

24. A pool cleaner for cleaning a pool or spa and having removable modular assemblies for facilitating replacement or service, comprising:

a chassis;

a first roller set including at least one roller;

a second roller set including at least one roller;

a first roller drive gear train in mechanical communication with the first roller set;

a second roller drive gear train in mechanical communication with the second roller set;

a first roller drive gear box including a housing and a first gear stack secured within the housing, the first roller drive gear box removably fastened to the chassis and in mechanical communication with the first roller drive gear train;

a second roller drive gear box including a housing and a second gear stack secured within the housing, the second roller drive gear box removably fastened to the chassis and in mechanical communication with the second roller drive gear train; and

a motor system in mechanical communication with the first gear stack and the second gear stack;

wherein the motor system drives rotation of the first gear stack, the first gear stack drives rotation of the first roller drive gear train, and the first roller drive gear train drives rotation of the first roller set,

wherein the motor system drives rotation of the second gear stack, the second gear stack drives rotation of the second roller drive gear train, and the second roller drive gear train drives rotation of the second roller set,

wherein said pool cleaner creates a suction effect at an inlet opening receiving debris-laden water from the pool or spa,

wherein said pool cleaner includes filtration means for separating debris from the debris-laden water and further includes an outlet for expelling the water from said pool cleaner, and

wherein said filtration means is at least one of a cyclone container and a cyclone chamber.

25. A pool cleaner for cleaning a pool or spa and having removable modular assemblies for facilitating replacement or service, comprising:

a chassis;

a first roller set including at least one roller;

a second roller set including at least one roller;

a first roller drive gear train in mechanical communication with the first roller set;

a second roller drive gear train in mechanical communication with the second roller set;

a first roller drive gear box including a housing and a first gear stack secured within the housing, the first roller drive gear box removably fastened to the chassis and in mechanical communication with the first roller drive gear train;

a second roller drive gear box including a housing and a second gear stack secured within the housing, the second roller drive gear box removably fastened to the chassis and in mechanical communication with the second roller drive gear train; and

a motor system in mechanical communication with the first gear stack and the second gear stack;

wherein the motor system drives rotation of the first gear stack, the first gear stack drives rotation of the first roller drive gear train, and the first roller drive gear train drives rotation of the first roller set,

wherein the motor system drives rotation of the second gear stack, the second gear stack drives rotation of the second roller drive gear train, and the second roller drive gear train drives rotation of the second roller set,

wherein said pool cleaner creates a suction effect at an inlet opening receiving debris-laden water from the pool or spa, and

wherein at least one of the first roller drive gear train and the second roller drive gear train includes a plurality of gears.