Pool cleaner power coupling

• US 9,885,196 B2
• Filed: 05/11/2017
• Issued: 02/06/2018
• Est. Priority Date: 01/26/2015
• Status: Active Grant

• Current Assignee: Hayward Industries, Inc.
• Original Assignee: Hayward Industries, Inc.
• Inventors: Hayes, Graham M., Teuscher, Scott
• Primary Examiner(s): Prince, Fred
• Application Number:
  US15/592,398
• Publication Number:
  US 20170247896A1
• Time in Patent Office: 271 Days
• Field of Search: 21016716, 21016717, 15 17
• CPC Class Codes: B01D 21/267 by using a cyclone
• CPC Class Codes: B04C 2009/002 with external filters
• CPC Class Codes: B04C 2009/005 with external rotors, e.g. impeller, ventilator, fan, blower, pump
• CPC Class Codes: B04C 5/185 Dust collectors
• CPC Class Codes: B04C 5/24 Multiple arrangement thereof combination types according to other /00 groups, B04C7/00
• CPC Class Codes: B04C 5/28 for parallel flow
• CPC Class Codes: B04C 9/00 Combinations with other devices, e.g. fans, expansion chambers, diffusors, water lockswith filters B01D50/00
• CPC Class Codes: C02F 1/385 by centrifuging suspensions centrifuges B04B
• CPC Class Codes: E04H 4/1636 Suction cleaners
• CPC Class Codes: E04H 4/1654 Self-propelled cleaners
• CPC Class Codes: E04H 4/169 Pool nozzles

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, comprising:

a chassis having a motor box housing;

a motor box mounted within the motor box housing;

a pump motor positioned within the motor box, the pump motor having a rotor including a first coupling member that extends out from the motor box; and

a debris container assembly including as one or more components thereof a rotatable shaft having a first end and a second end, and an impeller mounted to the first end of the rotatable shaft, the second end of the rotatable shaft including a second coupling member configured to receive the first coupling member;

wherein, when the debris container assembly is mounted on the chassis with the first coupling member engaged with the second coupling member, the pump motor drives rotation of the rotatable shaft through engagement of the first coupling member with the second coupling member, the first coupling member being disengaged from the second coupling member when the debris container assembly is removed.

2. The pool cleaner of claim 1, wherein the first coupling member is an external spline member and the second coupling member is an internal spline member.

3. The pool cleaner of claim 1, wherein the first coupling member is a first blender coupler and the second coupling member is a second blender coupler.

4. The pool cleaner of claim 1, wherein the debris container assembly further comprises a sleeve surrounding the rotatable shaft, and the pump motor further comprises a guide fillet, the sleeve configured to engage the guide fillet to center the rotatable shaft with the pump motor.

5. The pool cleaner of claim 1, wherein the pump motor is a brushless DC outer rotor motor.

6. The pool cleaner of claim 1, wherein when the debris container assembly is mounted on the chassis the first coupling member extends into an interior of the debris container assembly.

7. The pool cleaner of claim 1, wherein the impeller is rotatable with the rotatable shaft, and when the pump motor drives rotation of the rotatable shaft the impeller rotates with the rotatable shaft and expels fluid from the debris container assembly.

8. The pool cleaner of claim 7, wherein the fluid being expelled from the debris container assembly generates an opposing force on the pool cleaner when the debris container assembly is mounted on the chassis.

9. The pool cleaner of claim 1, wherein the debris container assembly includes an outlet in a first side and an opening in a second side that is opposite the first side, the impeller positioned adjacent the outlet and the second coupling member positioned adjacent the opening.

10. The pool cleaner of claim 9, wherein the first side is a top of the debris container assembly and the second side is a bottom of the debris container assembly.

11. The pool cleaner of claim 10, wherein when the debris container assembly is mounted on the chassis the first coupling member extends through the opening and engages the second coupling member.

12. The pool cleaner of claim 11, wherein when the debris container assembly is mounted on the chassis the motor box is outside of the debris container assembly and adjacent the second side of the debris container assembly.

13. The pool cleaner of claim 10, wherein the impeller is rotatable with the rotatable shaft, and when the pump motor drives rotation of the rotatable shaft the impeller rotates with the rotatable shaft and expels fluid from the outlet.

14. The pool cleaner of claim 13, wherein the fluid being expelled from the outlet generates an opposing force on the pool cleaner when the debris container assembly is mounted on the chassis.

15. The pool cleaner of claim 1, wherein the debris container assembly includes a body defining an inner chamber, the shaft being positioned at least partially within the inner chamber, and the impeller being positioned outside of the inner chamber.

16. The pool cleaner of claim 15, wherein when the debris container assembly is mounted on the chassis the pump motor is positioned outside of the inner chamber.

17. The pool cleaner of claim 15, wherein the debris container assembly includes a filtering medium positioned in the inner chamber surrounding the shaft, the filtering medium being positioned between the impeller and the first coupling member.

18. The pool cleaner of claim 15, wherein the inner chamber includes at least a first chamber surrounding the shaft and fluid flows in the first chamber in a cyclonic flow path.

19. The pool cleaner of claim 18, wherein the inner chamber includes a second chamber, the first chamber being separated from the second chamber at least in part by a filtering medium, the first chamber and the second chamber surrounding the shaft.

20. The pool cleaner of claim 19, wherein the debris container assembly includes a cyclone block positioned within the second chamber surrounding the shaft, the cyclone block including a plurality of cyclone containers.

21. The pool cleaner of claim 20, wherein the debris container assembly can be mounted on the chassis with a downward motion and can be removed from the chassis with an upward motion.