Pool cleaner roller assembly

• US 9,885,195 B1
• Filed: 05/11/2017
• Issued: 02/06/2018
• Est. Priority Date: 05/11/2017
• Status: Active Grant

• Current Assignee: Hayward Industries, Inc.
• Original Assignee: Hayward Industries, Inc.
• Inventors: Hayes, Graham M., Floyd, Greg, Marciano, Edward Lawrence, Ferrell, Garrett Jacob, Teuscher, Scott
• Primary Examiner(s): Karls, Shay
• Application Number:
  US15/592,392
• Time in Patent Office: 271 Days
• CPC Class Codes: A46B 13/001 Cylindrical or annular brush bodies
• CPC Class Codes: A46B 13/02 power-driven carriers
• CPC Class Codes: E04H 4/1654 Self-propelled cleaners

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 roller assembly for a pool cleaner, comprising:

a first cage half including a bottom portion defining a first mating surface, the bottom portion including (i) a first tab including a distal end and a proximal end, the distal end including a snap engaging end, and (ii) a protrusion extending from an inner surface of the first cage half; and

a second cage half including a bottom portion defining a second mating surface configured to mate against the first mating surface, the bottom portion including (i) a second tab including a distal end and a proximal end, the distal end including a snap engaging end;

wherein during assembly the snap engaging end of the first tab interlocks against the proximal end of the second tab, the snap engaging end of the second tab interlocks against the proximal end of the first tab, and the protrusion engages an inner surface of the second cage half.

2. The roller assembly of claim 1, wherein engagement of the protrusion with the inner surface of the second cage half limits disengagement of the first and second tabs during impact to the roller assembly.

3. The roller assembly of claim 1, wherein the snap engaging end of the first tab is oriented inwardly towards a central longitudinal axis of the first cage half and the snap engaging end of the second tab is oriented outwardly away from a central longitudinal axis of the second cage half.

4. The roller assembly of claim 1, wherein during assembly the first tab is positioned over and mates against the second tab.

5. The roller assembly of claim 1, wherein the first tab and the protrusion are disposed on a first connecting edge of the bottom portion of the first cage half, and the second tab is disposed on a complementary first connecting edge of the bottom portion of the second cage half.

6. The roller assembly of claim 5, wherein the first cage half comprises a second connecting edge including two spaced protrusions extending from the inner surface of the first cage half, and the second cage half comprises a complementary second connecting edge including a protrusion extending from the inner surface of the second cage half.

7. The roller assembly of claim 6, wherein during assembly the protrusion of the second cage half is received between the two spaced protrusions of the first cage half, the protrusion of the second cage half engages the inner surface of the first cage half, and the two spaced protrusions of the first cage half engage the inner surface of the second cage half.

8. The roller assembly of claim 1, wherein the first cage half and the second cage half each include first and second side surfaces, the first side surface of the second cage half including a third tab with a snap engaging end and the first side surface of the first cage half including a slot configured to receive at least a portion of the third tab of the second cage half.

9. The roller assembly of claim 8, wherein the snap engaging end of the third tab interlocks against an edge of the slot.

10. The roller assembly of claim 1, wherein the first cage half and the second cage half each include first and second side surfaces, the second side surfaces configured to receive a roller mount.

11. The roller assembly of claim 1 in combination with the pool cleaner.

12. A method of assembling a roller, comprising:

providing a first cage half including a bottom portion defining a first mating surface, the bottom portion including (i) a first tab including a distal end and a proximal end, the distal end including a snap engaging end, and (ii) a protrusion extending from an inner surface of the first cage half;

providing a second cage half including a bottom portion defining a second mating surface configured to mate against the first mating surface, the bottom portion including (i) a second tab including a distal end and a proximal end, the distal end including a snap engaging end;

interlocking the snap engaging end of the first tab against the proximal end of the second tab;

interlocking the snap engaging end of the second tab against the proximal end of the first tab; and

engaging an inner surface of the second cage half with the protrusion of the first cage half.

13. The method of claim 12, comprising positioning and mating the first tab against the second tab.

14. The method of claim 12, wherein the first tab and the protrusion are disposed on a first connecting edge of the bottom portion of the first cage half, and the second tab is disposed on a complementary first connecting edge of the bottom portion of the second cage half.

15. The method of claim 14, wherein the first cage half comprises a second connecting edge including two spaced protrusions extending from the inner surface of the first cage half, and the second cage half comprises a complementary second connecting edge including a protrusion extending from the inner surface of the second cage half, and

comprising positioning the protrusion of the second cage half between the two spaced protrusions of the first cage half.

16. The method of claim 15, comprising engaging the inner surface of the first cage half with the protrusion of the second cage half, and engaging the inner surface of the second cage half with the two spaced protrusions of the first cage half.

17. The method of claim 12, wherein the first cage half and the second cage half each include first and second side surfaces, the first side surface of the second cage half including a third tab with a snap engaging end and the first side surface of the first cage half including a slot configured to receive at least a portion of the third tab of the second cage half.

18. The method of claim 17, comprising interlocking the snap engaging end of the third tab against an edge of the slot.

19. The method of claim 12, wherein the first cage half and the second cage half each include first and second side surfaces, and

comprising mating the first side surfaces of the first and second cage halves to form a mounting boss.

20. The method of claim 12, comprising providing a roller cover including a first end and a second end, the first end including one or more openings configured to receive the first tab and the protrusion of the first cage half, and the second end including one or more openings configured to receive the second tab of the second cage half.

21. The method of claim 20, comprising passing the first tab and the protrusion of the first cage half through the one or more openings of the first end of the roller cover.

22. The method of claim 21, comprising passing the second tab of the second cage half through the one or more openings of the second end of the roller cover.

23. The method of claim 22, comprising rolling the first and second halves toward each other such that top surfaces of the first and second cage halves mate with the roller cover.

24. A roller assembly for a pool cleaner, comprising:

a first cage half including a bottom portion defining a first mating surface, the bottom portion including (i) a first tab including a distal end and a proximal end, the distal end including a snap engaging end, and (ii) a protrusion extending from an inner surface of the first cage half;

a second cage half including a bottom portion defining a second mating surface configured to mate against the first mating surface, the bottom portion including (i) a second tab including a distal end and a proximal end, the distal end including a snap engaging end; and

a roller cover including a first end and a second end, the first end including one or more openings configured to receive the first tab and the protrusion of the first cage half, and the second end including one or more openings configured to receive the second tab of the second cage half;

wherein during assembly (i) the first tab and the protrusion of the first cage half are passed through the one or more openings of the first end of the roller cover, (ii) the second tab of the second cage half is passed through the one or more openings of the second end of the roller cover, (iii) the first and second cage halves are rolled toward each other such that top surfaces of the first and second cage halves mate with the roller cover, (iv) the snap engaging end of the first tab interlocks against the proximal end of the second tab, (v) the snap engaging end of the second tab interlocks against the proximal end of the first tab, and (vi) the protrusion engages an inner surface of the second cage half.

25. The roller assembly of claim 24, wherein the roller cover defines a planar, flexible body extending between the first and second ends.

26. The roller assembly of claim 24, wherein the roller cover includes an outer surface and an inner surface.

27. The roller assembly of claim 26, wherein the inner surface is configured to mate against the top surfaces of the first and second cage halves.

28. The roller assembly of claim 27, wherein the outer surface includes a plurality of traction elements extending therefrom.

29. The roller assembly of claim 24 in combination with the pool cleaner.

30. A pool cleaner for cleaning a pool or spa, comprising:

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

a roller assembly, comprising;

a first cage half including a first connecting edge and a second connecting edge, the second connecting edge including two spaced protrusions extending from an inner surface of the first cage half; and

a second cage half including a first connecting edge and a second connecting edge, the second connecting edge including a protrusion extending from an inner surface of the second cage half;

wherein during assembly the protrusion of the second cage half is received between the two spaced protrusions of the first cage half, the protrusion of the second cage half engages the inner surface of the first cage half, the two spaced protrusions of the first cage half engage the inner surface of the second cage half, and the first connecting edge is scoured in the second connecting edge.