Swimming pool cleaner with hydrocyclonic particle separator and/or six-roller drive system

• US 9,909,333 B2
• Filed: 01/26/2016
• Issued: 03/06/2018
• 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, Marciano, Edward Lawrence
• Primary Examiner(s): Prince, Fred
• Application Number:
  US15/006,869
• Publication Number:
  US 20160215516A1
• Time in Patent Office: 770 Days
• Field of Search: 21016716, 21016717, 2104161, 2104162, 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 5/24 Multiple arrangement thereof combination types according to other /00 groups, B04C7/00
• CPC Class Codes: B04C 5/26 for series flow
• 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: E04H 4/1654 Self-propelled cleaners

Abstract

Exemplary embodiments are directed to pool cleaners, generally including a canister body, a filtering medium assembly and a cyclone block. The canister body includes an inner chamber within inner walls of the canister body. The filtering medium assembly can be disposed within the inner chamber of the canister body. The cyclone block can be disposed within the inner chamber of the canister body and can be at least partially surrounded by the filtering medium assembly. The cyclone block includes a plurality of individual cyclone containers. A first cyclonic flow can be generated between the inner walls of the canister body and the filtering medium assembly. A second cyclonic flow can be generated within each of the plurality of cyclone containers.

Claims

1. A pool cleaner, comprising:

a canister body including an inner chamber within inner walls of the canister body;

a filtering medium assembly disposed within the inner chamber of the canister body;

a fine debris container disposed within the inner chamber of the canister body, the fine debris container including a dish and a central radial extension protruding from a bottom surface of the fine debris container; and

a cyclone block disposed within the inner chamber of the canister body and at least partially surrounded by the filtering medium assembly, the cyclone block including a plurality of cyclone containers;

wherein a first cyclonic flow is generated between the inner walls of the canister body and the filtering medium assembly; and

wherein a second cyclonic flow is generated within each of the plurality of cyclone containers.

2. The pool cleaner of claim 1, wherein the canister body defines a cylindrical configuration.

3. The pool cleaner of claim 1, wherein the canister body comprises a tangential inlet.

4. The pool cleaner of claim 1, wherein the filtering medium assembly comprises a filtering medium support and a filtering medium.

5. The pool cleaner of claim 1, wherein the filtering medium assembly is configured to separate large debris particles from a fluid flow during the first cyclonic flow.

6. The pool cleaner of claim 1, wherein each of the cyclone containers comprises a cylindrical cyclone chamber with a tangential inlet and a debris underflow nozzle.

7. The pool cleaner of claim 6, wherein the cyclone containers are radially disposed around a central axis.

8. The pool cleaner of claim 1, wherein each of the cyclone containers comprises a cylindrical top portion, a frustoconical bottom portion, and a debris underflow nozzle at a distal end of the cyclone container.

9. The pool cleaner of claim 1, wherein the plurality of cyclone containers comprises a first set of radially disposed cyclone containers and a second set of radially disposed cyclone containers positioned around the first set of radially disposed cyclone containers.

10. The pool cleaner of claim 1, wherein each of the plurality of cyclone containers is configured to separate small debris particles from a fluid flow during the second cyclonic flow.

11. The pool cleaner of claim 1, comprising a large debris container hingedly connected to a bottom edge of the canister body.

12. The pool cleaner of claim 11, wherein the large debris container comprises a dish including upwardly angled side walls.

13. The pool cleaner of claim 11, comprising a debris separator ring disposed between the filtering medium assembly and the large debris container.

14. The pool cleaner of claim 13, wherein the debris separator ring comprises a mesh ring configured to maintain large debris particles within the large debris container.

15. The pool cleaner of claim 1, wherein the fine debris container dish comprises a rounded dish including a central hub.

16. The pool cleaner of claim 1, wherein the central radial extension defines an inner chamber configured and dimensioned to maintain small debris particles separated from a fluid flow during the second cyclonic flow.

17. The pool cleaner of claim 16, wherein the central radial extension is disposed against a dish of a large debris container, the central radial extension maintaining a separation between the small debris particles within the inner chamber and large debris particles collected in the large debris container.

18. The pool cleaner of claim 17, comprising a gasket disposed between the dish of the large debris container and the central radial extension, the gasket maintaining separation between the small debris particles within the inner chamber and the large debris particles collected in the large debris container.

19. The pool cleaner of claim 18, wherein positioning the large debris container in an open position simultaneously empties the large debris container and the inner chamber of the fine debris container.

20. The pool cleaner of claim 1, comprising a ring of vortex finders, each of the vortex finders positioned within respective cyclone containers of the plurality of cyclone containers.

21. The pool cleaner of claim 20, wherein the ring of vortex finders comprises a central portion and a plurality of perimeter flaps, each of the perimeter flaps including a vortex finder.

22. The pool cleaner of claim 21, wherein a top surface of the central portion is recessed relative to surfaces of the plurality of perimeter flaps.

23. The pool cleaner of claim 21, wherein each of the plurality of perimeter flaps are hingedly connected to a polygonal perimeter of the central portion.

24. The pool cleaner of claim 1, comprising a top cap disposed over the canister body.

25. The pool cleaner of claim 24, wherein the top cap comprises a plurality of radially arched tubes defining a chamber extending to an outlet.

26. The pool cleaner of claim 24, wherein the top cap comprises a plurality of rounded lobes defining a chamber extending to an outlet.

27. The pool cleaner of claim 1, comprising a drive assembly comprising one front roller, one rear roller, and two middle rollers.

28. The pool cleaner of claim 1, comprising a drive assembly comprising two front rollers, two middle rollers, and two rear rollers.

29. A pool cleaner, comprising:

a drive assembly including one front roller, one rear roller, a first middle roller, and a second middle roller, the first and second middle rollers being disposed adjacent to each other;

a motor housing mounted relative to the drive assembly, the motor housing including a first drive motor and a second drive motor; and

a hydrocyclonic particle separator assembly mounted to the motor housing;

wherein the first drive motor drives rotation of the one front roller and the first middle roller; and

wherein the second drive motor drives rotation of the one rear roller and the second middle roller.

30. The pool cleaner of claim 29, wherein the first drive motor drives the one front roller and the first middle roller at the same rate.

31. The pool cleaner of claim 29, wherein the second drive motor drives the one rear roller and the second middle roller at the same rate.

32. A pool cleaner, comprising:

a drive assembly including a first front roller, a second front roller, a first middle roller, a second middle roller, a first rear roller, and a second rear roller, the first and second front rollers being disposed adjacent to each other, the first and second middle rollers being disposed adjacent to each other, and the first and second rear rollers being disposed adjacent to each other;

a motor housing mounted relative to the drive assembly, the motor housing including a first drive motor and a second drive motor; and

a hydrocyclonic particle separator assembly mounted to the motor housing;

wherein the first drive motor drives rotation of the first front roller, the first middle roller, and the first rear roller; and

wherein the second drive motor drives rotation of the second front roller, the second middle roller, and the second rear roller.

33. The pool cleaner of claim 32, wherein the first drive motor drives the first front roller, the first middle roller, and the first rear roller at the same rate.

34. The pool cleaner of claim 32, wherein the second drive motor drives the second front roller, the second middle roller, and the second rear roller at the same rate.

35. The pool cleaner of claim 32, comprising:

a canister body including an inner chamber within inner walls of the canister body;

a filtering medium assembly disposed within the inner chamber of the canister body; and

a cyclone block disposed within the inner chamber of the canister body and at least partially surrounded by the filtering medium assembly, the cyclone block including a plurality of cyclone containers;

wherein a first cyclonic flow is generated between the inner walls of the canister body and the filtering medium assembly; and

wherein a second cyclonic flow is generated within each of the plurality of cyclone containers.

36. The pool cleaner of claim 35, wherein the canister body defines a cylindrical configuration.

37. The pool cleaner of claim 35, wherein the canister body comprises a tangential inlet.

38. The pool cleaner of claim 35, wherein the filtering medium assembly comprises a filtering medium support and a filtering medium.

39. The pool cleaner of claim 35, wherein the filtering medium assembly is configured to separate large debris particles from a fluid flow during the first cyclonic flow.

40. The pool cleaner of claim 35, wherein each of the cyclone containers comprises a cylindrical cyclone chamber with a tangential inlet and a debris underflow nozzle.

41. The pool cleaner of claim 40, wherein the cyclone containers are radially disposed around a central axis.

42. The pool cleaner of claim 35, wherein each of the cyclone containers comprises a cylindrical top portion, a frustoconical bottom portion, and a debris underflow nozzle at a distal end of the cyclone container.

43. The pool cleaner of claim 35, wherein the plurality of cyclone containers comprises a first set of radially disposed cyclone containers and a second set of radially disposed cyclone containers positioned around the first set of radially disposed cyclone containers.

44. The pool cleaner of claim 35, wherein each of the plurality of cyclone containers is configured to separate small debris particles from a fluid flow during the second cyclonic flow.

45. The pool cleaner of claim 35, comprising a large debris container hingedly connected to a bottom edge of the canister body.

46. The pool cleaner of claim 45, wherein the large debris container comprises a dish including upwardly angled side walls.

47. The pool cleaner of claim 45, comprising a debris separator ring disposed between the filtering medium assembly and the large debris container.

48. The pool cleaner of claim 47, wherein the debris separator ring comprises a mesh ring configured to maintain large debris particles within the large debris container.

49. The pool cleaner of claim 35, comprising a fine debris container disposed within the inner chamber of the canister body.

50. The pool cleaner of claim 49, wherein the fine debris container comprises a rounded dish including a central hub.

51. The pool cleaner of claim 49, wherein the fine debris container comprises a dish and a central radial extension protruding from a bottom surface of the fine debris container.

52. The pool cleaner of claim 51, wherein the central radial extension defines an inner chamber configured and dimensioned to maintain small debris particles separated from a fluid flow during the second cyclonic flow.

53. The pool cleaner of claim 52, wherein the central radial extension is disposed against a dish of a large debris container, the central radial extension maintaining a separation between the small debris particles within the inner chamber and large debris particles collected in the large debris container.

54. The pool cleaner of claim 53, comprising a gasket disposed between the dish of the large debris container and the central radial extension, the gasket maintaining separation between the small debris particles within the inner chamber and the large debris particles collected in the large debris container.

55. The pool cleaner of claim 54, wherein positioning the large debris container in an open position simultaneously empties the large debris container and the inner chamber of the fine debris container.

56. The pool cleaner of claim 35, comprising a ring of vortex finders, each of the vortex finders positioned within respective cyclone containers of the plurality of cyclone containers.

57. The pool cleaner of claim 56, wherein the ring of vortex finders comprises a central portion and a plurality of perimeter flaps, each of the perimeter flaps including a vortex finder.

58. The pool cleaner of claim 57, wherein a top surface of the central portion is recessed relative to surfaces of the plurality of perimeter flaps.

59. The pool cleaner of claim 57, wherein each of the plurality of perimeter flaps are hingedly connected to a polygonal perimeter of the central portion.

60. The pool cleaner of claim 35, comprising a top cap disposed over the canister body.

61. The pool cleaner of claim 60, wherein the top cap comprises a plurality of radially arched tubes defining a chamber extending to an outlet.

62. The pool cleaner of claim 60, wherein the top cap comprises a plurality of rounded lobes defining a chamber extending to an outlet.

63. A pool cleaner, comprising:

a canister body including an inner chamber within inner walls of the canister body;

a filtering medium assembly disposed within the inner chamber of the canister body;

a cyclone block disposed within the inner chamber of the canister body and at least partially surrounded by the filtering medium assembly, the cyclone block including a plurality of cyclone containers; and

a ring of vortex finders, the ring of vortex finders including a central portion and a plurality of perimeter flaps, each of the perimeter flaps including a vortex finder, each of the vortex finders positioned within respective cyclone containers of the plurality of cyclone containers

wherein a first cyclonic flow is generated between the inner walls of the canister body and the filtering medium assembly; and

wherein a second cyclonic flow is generated within each of the plurality of cyclone containers.

64. The pool cleaner of claim 63, wherein the canister body defines a cylindrical configuration.

65. The pool cleaner of claim 63, wherein the canister body comprises a tangential inlet.

66. The pool cleaner of claim 63, wherein the filtering medium assembly comprises a filtering medium support and a filtering medium.

67. The pool cleaner of claim 63, wherein the filtering medium assembly is configured to separate large debris particles from a fluid flow during the first cyclonic flow.

68. The pool cleaner of claim 63, wherein each of the cyclone containers comprises a cylindrical cyclone chamber with a tangential inlet and a debris underflow nozzle.

69. The pool cleaner of claim 68, wherein the cyclone containers are radially disposed around a central axis.

70. The pool cleaner of claim 63, wherein each of the cyclone containers comprises a cylindrical top portion, a frustoconical bottom portion, and a debris underflow nozzle at a distal end of the cyclone container.

71. The pool cleaner of claim 63, wherein the plurality of cyclone containers comprises a first set of radially disposed cyclone containers and a second set of radially disposed cyclone containers positioned around the first set of radially disposed cyclone containers.

72. The pool cleaner of claim 63, wherein each of the plurality of cyclone containers is configured to separate small debris particles from a fluid flow during the second cyclonic flow.

73. The pool cleaner of claim 63, comprising a large debris container hingedly connected to a bottom edge of the canister body.

74. The pool cleaner of claim 73, wherein the large debris container comprises a dish including upwardly angled side walls.

75. The pool cleaner of claim 73, comprising a debris separator ring disposed between the filtering medium assembly and the large debris container.

76. The pool cleaner of claim 75, wherein the debris separator ring comprises a mesh ring configured to maintain large debris particles within the large debris container.

77. The pool cleaner of claim 63, comprising a fine debris container disposed within the inner chamber of the canister body.

78. The pool cleaner of claim 77, wherein the fine debris container comprises a rounded dish including a central hub.

79. The pool cleaner of claim 77, wherein the fine debris container comprises a dish and a central radial extension protruding from a bottom surface of the fine debris container.

80. The pool cleaner of claim 79, wherein the central radial extension defines an inner chamber configured and dimensioned to maintain small debris particles separated from a fluid flow during the second cyclonic flow.

81. The pool cleaner of claim 80, wherein the central radial extension is disposed against a dish of a large debris container, the central radial extension maintaining a separation between the small debris particles within the inner chamber and large debris particles collected in the large debris container.

82. The pool cleaner of claim 81, comprising a gasket disposed between the dish of the large debris container and the central radial extension, the gasket maintaining separation between the small debris particles within the inner chamber and the large debris particles collected in the large debris container.

83. The pool cleaner of claim 82, wherein positioning the large debris container in an open position simultaneously empties the large debris container and the inner chamber of the fine debris container.

84. The pool cleaner of claim 63, wherein a top surface of the central portion is recessed relative to surfaces of the plurality of perimeter flaps.

85. The pool cleaner of claim 63, wherein each of the plurality of perimeter flaps are hingedly connected to a polygonal perimeter of the central portion.

86. The pool cleaner of claim 63, comprising a top cap disposed over the canister body.

87. The pool cleaner of claim 86, wherein the top cap comprises a plurality of radially arched tubes defining a chamber extending to an outlet.

88. The pool cleaner of claim 86, wherein the top cap comprises a plurality of rounded lobes defining a chamber extending to an outlet.

89. The pool cleaner of claim 63, comprising a drive assembly comprising one front roller, one rear roller, and two middle rollers.

90. The pool cleaner of claim 63, comprising a drive assembly comprising two front rollers, two middle rollers, and two rear rollers.