U.S. patent application number 14/927715 was filed with the patent office on 2016-02-18 for brush assembly for self-propelled pool and tank cleaner.
The applicant listed for this patent is Aqua Products, Inc.. Invention is credited to Aleksandr KLEBANOV, William LONDONO.
Application Number | 20160047135 14/927715 |
Document ID | / |
Family ID | 55301762 |
Filed Date | 2016-02-18 |
United States Patent
Application |
20160047135 |
Kind Code |
A1 |
KLEBANOV; Aleksandr ; et
al. |
February 18, 2016 |
BRUSH ASSEMBLY FOR SELF-PROPELLED POOL AND TANK CLEANER
Abstract
A rotatable brush assembly for a cleaning apparatus includes a
cylindrical roller formed by first and second arcuate members. Each
arcuate member has an inner longitudinal portion and an opposing
longitudinal free end, the inner longitudinal portions being
adjacently hinged together. The longitudinal free ends are
positioned adjacently when the hinge is in a closed position. A web
includes spaced-apart cleaning members extending outward from its
external surface. Opposing longitudinal ends substantially conform
to the opposing longitudinal free ends of the roller and its width
is dimensioned such that an inner surface of the web wraps around
and directly covers an outer surface of the cylindrical roller.
Each longitudinal end of the web terminates in a U-shaped flange
which defines a channel that conforms to and interfaces with one of
the longitudinal free ends of the roller. Opposing end caps are
disposed over opposing ends of the elongated cylindrical
roller.
Inventors: |
KLEBANOV; Aleksandr;
(Bloomfield, NJ) ; LONDONO; William; (Wayne,
NJ) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Aqua Products, Inc. |
Cedar Grove |
NJ |
US |
|
|
Family ID: |
55301762 |
Appl. No.: |
14/927715 |
Filed: |
October 30, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13681899 |
Nov 20, 2012 |
|
|
|
14927715 |
|
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62073346 |
Oct 31, 2014 |
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Current U.S.
Class: |
15/1.7 |
Current CPC
Class: |
A46B 13/001 20130101;
E04H 4/1654 20130101; A46B 13/02 20130101 |
International
Class: |
E04H 4/16 20060101
E04H004/16; A46B 13/00 20060101 A46B013/00; A46B 13/02 20060101
A46B013/02 |
Claims
1. A rotatable brush assembly for a self-propelled robotic cleaning
apparatus for cleaning a submerged surface of a pool or tank
comprising: an elongated cylindrical roller formed by a first
arcuate member and a second arcuate member, each arcuate member
having an inner longitudinal portion and an opposing longitudinal
free end, the inner longitudinal portions being positioned
adjacently and hinged together, the longitudinal free ends being
positioned adjacently when the hinge is in a closed position to
form the elongated cylindrical roller; a web material having
spaced-apart cleaning members extending outwardly on an external
surface of the web material, opposing longitudinal ends that
substantially conform to the opposing longitudinal free ends of the
cylindrical roller, and a width dimensioned such that an inner
surface of the web material wraps around and directly covers an
outer surface of the elongated cylindrical roller, each
longitudinal end of the web material terminating in a U-shaped
flange which defines a channel that conforms to and interfaces with
one of the longitudinal free ends of the roller; and end caps
disposed over the opposing ends of the elongated cylindrical
roller.
2. The rotatable brush assembly of claim 1, wherein the arc lengths
of the first and second arcuate members are equal.
3. The rotatable brush assembly of claim 1, wherein the arc length
of the first arcuate member is greater than the arc length of the
second arcuate member.
4. The rotatable brush assembly of claim 1, wherein the inner
longitudinal portions are positioned adjacently and joined by an
integral living hinge.
5. The rotatable brush assembly of claim 4, wherein the living
hinge extends the entire length along the adjacent inner
longitudinal portions.
6. The rotatable brush assembly of claim 1, wherein the first and
second arcuate members include an inward shoulder portion formed at
each opposing end thereof.
7. The rotatable brush assembly of claim 6, wherein the inward
shoulder portions include an outwardly extending ridge formed
proximate the longitudinal free ends of the roller and collectively
define a pair of adjacent ridges on each end of the roller when the
arcuate members are in abutting relation.
8. The rotatable brush assembly of claim 7, wherein the endcaps
include a circular flange having a cutout sized to conform to the
pair of adjacently positioned ridges.
9. The rotatable brush assembly of claim 8, wherein each endcap is
positioned about a corresponding end of the roller such that the
pair of adjacent ridges extends through the corresponding cutout in
the circular flange of the endcap.
10. The rotatable brush assembly of claim 7, wherein the circular
flange of the endcap is positioned between the inward shoulder
portion and the inner surface of the web material.
11. The rotatable brush assembly of claim 1, wherein each endcap
includes a mounting hub extending coaxially in a direction along
the longitudinal axis of the roller for enabling installation of
the brush assembly into the self-propelled robotic cleaning
apparatus.
12. The rotatable brush assembly of claim 11, wherein at least one
of the endcap mounting hubs is resiliently mounted to facilitate
mounting and removal of the brush assembly from the cleaning
apparatus.
13. A self-propelled cleaning apparatus for cleaning a submerged
surface of a pool or tank comprising: a housing defining an
interior chamber, a water inlet positioned over the submerged
surface of the pool or tank, and an outlet for discharging filtered
water; drive means for moving the cleaning apparatus over the
submerged surface; filtering means mounted in said interior chamber
and configured to retain debris in the water entering the interior
chamber via the water inlet and discharge filtered water from the
interior chamber through the water discharge outlet; and at least
one rotatable brush assembly comprising: an elongated cylindrical
roller formed by a first arcuate member and a second arcuate
member, each arcuate member having an inner longitudinal portion
and an opposing longitudinal free end, the inner longitudinal
portions being positioned adjacently and hinged together, the
longitudinal free ends being positioned adjacently when the hinge
is in a closed position to form the elongated cylindrical roller; a
web material having spaced-apart cleaning members extending
outwardly on an external surface of the web material, opposing
longitudinal ends that substantially conform to the opposing
longitudinal free ends of the cylindrical roller, and a width
dimensioned such that an inner surface of the web material wraps
around and directly covers an outer surface of the elongated
cylindrical roller, each longitudinal end of the web material
terminating in a U-shaped flange which defines a channel that
conforms to and interfaces with one of the longitudinal free ends
of the roller; and end caps disposed over opposing ends of the
elongated cylindrical roller and configured to enable rotation of
the brush assembly during movement of the cleaning apparatus over
the submerged surface of the pool or tank.
14. The self-propelled cleaning apparatus of claim 13, wherein the
drive means includes an electric drive motor mounted in the
interior chamber and having a driveshaft, a propeller mounted on at
least one end of the driveshaft, rotatable mounted supports
rotatably mounted to the housing, and a drive mechanism for
rotating at least a portion of the rotatable mounted supports.
15. The self-propelled cleaning apparatus of claim 13, wherein the
drive means includes a water turbine mounted in the interior
chamber, the discharge outlet configured for attachment to a hose
to receive a pressurized stream of water from an external source to
rotate the water turbine, rotatable mounted supports rotatably
mounted to the housing, and a drive mechanism for rotating at least
a portion of the rotatable mounted supports.
16. The cleaning apparatus of claim 13, wherein the inner
longitudinal portions are positioned adjacently and joined by an
integral living hinge.
17. The cleaning apparatus of claim 16, wherein the living hinge
extends the entire length along the adjacent inner longitudinal
portions.
18. The cleaning apparatus of claim 13, wherein the first and
second arcuate members include an inward shoulder portion formed at
each opposing end thereof.
19. The cleaning apparatus of claim 18, wherein the inward shoulder
portions include an outwardly extending ridge formed proximate the
longitudinal ends of the roller and collectively define a pair of
adjacent ridges on each end of the roller when the arcuate members
are in abutting relation.
20. The cleaning apparatus of claim 19, wherein the endcaps include
a circular flange having a cutout sized to conform to the pair of
adjacently positioned ridges.
21. The cleaning apparatus of claim 20, wherein each endcap is
positioned about a corresponding end of the roller such that the
pair of adjacent ridges extends through a corresponding cutout in
the circular flange of the endcap.
22. The cleaning apparatus of claim 20, wherein the circular flange
of the endcap is positioned between the inward shoulder portion and
the inner surface of the web material.
23. The cleaning apparatus of claim 13, wherein each endcap
includes a mounting hub extending coaxially in a direction along
the longitudinal axis of the roller for enabling installation of
the brush assembly into the self-propelled robotic cleaning
apparatus.
24. The cleaning apparatus of claim 13, wherein at least one of the
endcap mounting hubs is resiliently mounted to facilitate mounting
and removal of the brush assembly from the cleaning apparatus.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This patent application is a continuation-in-part of U.S.
application Ser. No. 13/681,899, filed Nov. 20, 2013, and this
application also claims the benefit of U.S. provisional Application
No. 62/073,346, filed Oct. 31, 2014, the contents of which are
incorporated by reference herein in their entireties.
FIELD OF THE INVENTION
[0002] The present invention relates to a submersible robotic pool
and tank cleaning apparatus, and more specifically to a motor
driven rotatable brush assembly for stirring up and cleaning
undesirable contaminants and debris from a surface of a pool or
tank environment.
BACKGROUND OF THE INVENTION
[0003] Robotic pool cleaning devices are mounted on rotatable
supports, such as wheels, brushes and/or tracks, and are propelled
or otherwise travel along submerged surfaces of a pool, tank or the
like and, through the use of suction, thereby "vacuum" the pool
surfaces over which they pass. The pool cleaning devices can be
propelled over the surfaces of the pool by a directional or random
water jet propulsion system, or by one or more drive motors that
are coupled to (e.g., to the wheel axles) and cause the rotation of
the rotatable supports.
[0004] The cleaning devices configured with an internal filtering
system have an interior chamber with one or more filters mounted
therein. The internal filtering systems are effective to capture
and isolate contaminants and/or debris from portions of the
interior chamber where it is highly desirable that contamination
not encroach. The filtered water is then discharged back into the
pool or tank as a pressurized stream.
[0005] To stir up and/or remove debris from the surface beneath the
cleaner, a rotatable brush can be provided which extends
substantially normal to the longitudinal axis of and direction in
movement of the cleaner. The brush assembly can be non-powered and
rotate due to the frictional forces from the surface of the pool.
Alternatively, the brush assembly is powered by a water turbine or
electric motor through a mechanical arrangement of belts, tracks,
gears and/or a combination thereof. The powered rotatable brush
assembly can also be used to provide locomotion to the cleaner
either alone or in conjunction with another power source, such as a
jet drive system.
[0006] Cleaning brushes can be made of a foamed polymer or plastic
sponge material, in which case they are subject to wear and tear
due to their continuous rotating contact with the bottom and side
wall surfaces of the pool. As a result, foamed polymer cleaning
brushes must be periodically removed and replaced. Various types of
brushes have been used with pool cleaning machines of the prior
art. Brushes in the form of elongated cylinders produced from
molded polyvinyl acetate (PVA) having a relatively fine pore size
are designed to cover the entire length of the rotatable shaft in a
single piece. The molded PVA is relatively rigid when dry, but
becomes softer and more pliable when wet with water which
facilitates fitting it to the shaft.
[0007] Other types of brushes are formed as generally rectangular
elements having a flat surface on the back which can be wrapped
around and tightly fitted to the rotatable shaft. Interlocking tabs
and openings at the mating ends of the flexible mat permit its
secure assembly to the shaft in a generally cylindrical
configuration. For example, the rotatable shaft often has indents
or openings into which corresponding tabs of the mat are
inserted.
[0008] U.S. Pat. No. 6,564,417 to Porat provides a technique to
address these drawbacks by providing a flexible web having first
and second opposing edges, the first edge having at least one first
element extending in the direction of the first edge, and the
second edge having at least one second element extending in the
direction of the second edge. The web is deformable about the
rotatable shaft to bring the first and second edges into contact,
with the first element being in spaced relation to the second
element such that the first element is aligned with the second
element. A technician provides a positive locking structure such as
a pin to hold the first and second elements together in a secure,
locking fit. Although the pin secures the first and second elements
together, aligning and interleaving the first and second elements
while inserting the pin can be time consuming.
[0009] Elements of various configurations projecting from the
exterior surface of the mat contact the pool surface with a
scrubbing action to loosen debris and allow it to be drawn into the
pool cleaner's filter system. The flat brushes can be produced as
an integrally molded element using a synthetic rubber or polymer
compound. The flat brushes can also be fabricated by drawing
elongated rectangular pieces of cellular foamed plastic through
openings in an open-weave backing material.
[0010] While each type of cleaning brush possesses certain
advantages, and is intended for use under specific conditions,
these prior art brushes face a drawback in the effort associated
with removing a worn brush and installing a replacement cleaning
brush. In the case of the cylindrical PVA foam brush, the old
element can most easily be removed by cutting it away from the
shaft. However, considerable effort is required to pull and
properly fit the replacement brush on the shaft.
[0011] The dismounting of the prior art flat molded brushes is
likewise facilitated by cutting the neck portion of the tabs where
the mating ends overlap. Installing the new brush requires some
strength since the interlocking elements have limited resiliency,
which characteristic is required to enhance their ability to resist
disengagement once assembled in the correct interlocking position.
Therefore, after the tabs and slots of the overlying ends are
brought into mating alignment, it can be difficult, especially for
residential pool owners, to install the new brushes. Moreover,
unless the interlocking elements of these brushes are fully
positioned in their precise interlocking configuration, the
possibility of disengagement is appreciable, in which case the
brush can become loose or detached from the rotating shaft, so that
it does not rotate properly and no cleaning of the pool surface is
affected.
[0012] It is also known, in the case of the molded brushes having a
flat backing surface, that mildew and dirt can be formed during
periods of non-use and storage between the mounting shaft and the
back, causing the elements to stick together and necessitating
removal of the dirt, mold and mildew before a new brush can be
installed.
[0013] In view of the above limitations and difficulties associated
with the cleaning brushes of the prior art, it would be desirable
to provide a cleaning brush for pool cleaners as original equipment
or as a replacement for worn or damaged cleaning brushes that is
easy to install securely and to remove.
SUMMARY OF THE INVENTION
[0014] The above problems and disadvantages are solved and avoided
by the embodiments of an apparatus and method of the present
invention that are described below. In the description that
follows, it will be understood that the cleaner moves on supporting
wheels, brushes, rollers or tracks 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.
[0015] The present invention is directed to various embodiments of
a rotatable brush assembly installed along the bottom or base of an
automated pool or tank cleaner. As described in greater detail
below, a pool cleaner brush includes a cylindrical roller and a
resilient or semi-resilient brush covering that wraps around and
completely covers the roller. The roller includes a living hinge
formed between two halves of the cylindrical roller which, when
folded together, forms the cylindrical roller. The brush covering
wraps around the cylindrical roller.
[0016] Each opposing longitudinal edge of the brush covering
includes a U-shaped flange that is oriented inwardly. Each U-shaped
flange fits over a corresponding longitudinal edge of the
cylindrical roller, and the brush and two halves of the roller are
folded towards each other at the living hinge to form a cylindrical
tube and thereby secure the opposing longitudinal edges of the
brush to the corresponding longitudinal edges of the roller. End
caps are further provided at opposing ends of the cylindrical
roller and at least one of which can be spring-loaded to secure (i)
the brush to the roller and (ii) the roller/brush assembly to the
robotic cleaner.
[0017] More specifically, each opposing end secures a corresponding
end of the wrapped brush around the cylindrical roller. The end
caps cover a shoulder area of the roller and a channel formed in
each end cap aligns with the corresponding pair of raised edges of
the shoulder of the roller. The channel edges of the end caps lock
the U-shaped grooves of the brush together.
[0018] In one embodiment, a rotatable brush assembly for a
self-propelled robotic cleaning apparatus for cleaning a submerged
surface of a pool or tank comprises an elongated cylindrical roller
formed by a first arcuate member and a second arcuate member, each
arcuate member having an inner longitudinal portion and an opposing
longitudinal free end, the inner longitudinal portions being
positioned adjacently and hinged together, the longitudinal free
ends being positioned adjacently when the hinge is in a closed
position to form the elongated cylindrical roller; a web material
having spaced-apart cleaning members extends outwardly on an
external surface of the web material, opposing longitudinal ends
that substantially conform to the opposing longitudinal free ends
of the cylindrical roller, and a width dimensioned such that an
inner surface of the web material wraps around and directly covers
an outer surface of the elongated cylindrical roller, each
longitudinal end of the web material terminating in a U-shaped
flange which defines a channel that conforms to and interfaces with
one of the longitudinal free ends of the roller; and end caps
disposed over the opposing ends of the elongated cylindrical
roller.
[0019] In one aspect, the arc lengths of the first and second
arcuate members are equal. Alternatively, the arc length of the
first arcuate member is greater than the arc length of the second
arcuate member. In another aspect, inner longitudinal portions are
positioned adjacently and joined by an integral living hinge. The
living hinge can extend the entire length of the adjacent inner
longitudinal portions. Alternatively, the living hinge can be a
plurality of living hinges that are spaced apart along the length
of the inner longitudinal portions.
[0020] In yet another aspect, the first and second arcuate members
include an inward shoulder portion formed at each opposing end
thereof. Further, the inward shoulder portions can include an
outwardly extending ridge formed proximate the longitudinal free
ends of the roller and collectively define a pair of adjacent
ridges on each end of the roller when the arcuate members are in
abutting relation. In still another aspect, the endcaps include a
circular flange having a cutout sized to conform to the pair of
adjacently positioned ridges. Each endcap can be positioned about a
corresponding end of the roller such that the pair of adjacent
ridges extends through a corresponding cutout in the circular
flange of the endcap. In another aspect, the circular flange of the
endcap is positioned between the inward shoulder portion and the
inner surface of the web material.
[0021] In one aspect, each endcap includes a mounting hub extending
coaxially in a direction along the longitudinal axis of the roller
for enabling installation of the brush assembly into the robotic
cleaning apparatus. In another aspect, at least one of the endcap
mounting hubs is resiliently mounted to facilitate mounting
(installation) and removal of the brush assembly from the cleaning
apparatus.
[0022] In another embodiment, a self-propelled cleaning apparatus
for cleaning a submerged surface of a pool or tank comprises: a
housing defining an interior chamber, a water inlet positioned over
the submerged surface of the pool or tank, and an outlet for
discharging filtered water; drive means for moving the cleaning
apparatus over the submerged surface; filtering means mounted
within said interior chamber and configured to filter water and
debris entering the interior chamber via the water inlet and
discharge filtered water from the interior chamber through the
water discharge outlet; and at least one rotatable brush assembly
comprising: an elongated cylindrical roller formed by a first
arcuate member and a second arcuate member, each arcuate member
having an inner longitudinal portion and an opposing longitudinal
free end, the inner longitudinal portions being positioned
adjacently and hinged together, the longitudinal free ends being
positioned adjacently when the hinge is in a closed position to
form the elongated cylindrical roller; a web material having
spaced-apart cleaning members extending outwardly on an external
surface of the web material, opposing longitudinal ends that
substantially conform to the opposing longitudinal free ends of the
cylindrical roller, and a width dimensioned such that an inner
surface of the web material wraps around and directly covers an
outer surface of the elongated cylindrical roller, each
longitudinal end of the web material terminating in a U-shaped
flange which defines a channel that conforms to and interfaces with
one of the longitudinal free ends of the roller; and end caps
disposed over opposing ends of the elongated cylindrical roller and
configured to enable rotation of the brush assembly during movement
of the cleaning apparatus over the submerged surface of the pool or
tank.
[0023] In one aspect, the drive means includes an electric drive
motor mounted in the interior chamber and having a driveshaft, a
propeller mounted on at least one end of the driveshaft, rotatable
mounted supports (e.g., wheels, tracks, rollers and the like)
rotatably mounted to the housing, and a drive mechanism for
rotating at least a portion of the rotatable mounted supports. In
another aspect, the drive means includes a water turbine mounted in
the interior chamber, the discharge outlet configured for
attachment to a hose to receive a pressurized stream of water from
an external source to rotate the water turbine, rotatable mounted
supports rotatably mounted to the housing, and a drive mechanism
for rotating at least a portion of the rotatable mounted
supports.
[0024] In yet another aspect, the inner longitudinal portions are
positioned adjacently and are hinged together by an integral living
hinge. Further, the living hinge can extend an entire length of the
adjacent inner longitudinal portions. Alternatively, the living
hinge can be a plurality of living hinges that are spaced apart
along the length of the inner longitudinal portions.
[0025] In still another aspect, the first and second arcuate
members include an inward shoulder portion formed at each opposing
end thereof. In one aspect, the inward shoulder portions include an
outwardly extending ridge formed proximate the longitudinal ends of
the roller and collectively define a pair of adjacent ridges on
each end of the roller when the arcuate members are in abutting
relation.
[0026] In an aspect, the endcaps include a circular flange having
cutout sized to conform to the pair of adjacently positioned
ridges. Each endcap can be positioned about a corresponding end of
the roller such that the pair of adjacent ridges extends through a
corresponding cutout in the circular flange of the endcap. In
another aspect, the circular flange of the endcap is positioned
between the inward shoulder portion and the inner surface of the
web material. In still another aspect, each endcap includes a
mounting hub extending coaxially in a direction along the
longitudinal axis of the roller for enabling installation of the
brush assembly into the self-propelled robotic cleaning apparatus.
In still another aspect, at least one of the endcap mounting hubs
is resiliently mounted to facilitate mounting and removal of the
brush assembly from the cleaning apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The invention will be described in further detail below and
with reference to the attached drawings in which:
[0028] FIG. 1 is a top, rear, right side perspective view of a
cleaning vehicle;
[0029] FIG. 2 is a perspective view of the bottom of a cleaning
vehicle;
[0030] FIG. 3 is a perspective view of the interior drive train
elements of the powered roller brush of a cleaning vehicle;
[0031] FIG. 4 is a top, front right side perspective view of a
partial cut away of a cleaning vehicle with an extended telescoping
handle;
[0032] FIG. 5 is an exploded top, right side perspective view of a
brush assembly illustrating the arrangement of a cylindrical
roller, an outer web material having outwardly extending cleaning
members on a first surface, and opposing end caps in accordance
with the present invention;
[0033] FIG. 6 is a top, right side perspective view of the
assembled brush assembly of FIG. 5;
[0034] FIG. 7 is a top, right side perspective view of the brush
assembly of FIG. 5 including an expanded view of a living hinge
formed in the brush assembly;
[0035] FIG. 8 is a left side elevational view of the brush assembly
of FIG. 5;
[0036] FIG. 9 is a cross-sectional view of the brush assembly of
FIG. 5 taken along lines 9-9 of FIG. 8;
[0037] FIG. 10 is a cross-sectional view of the brush assembly of
FIG. 5 taken along lines 10-10 of FIG. 9;
[0038] FIG. 11 is a cross-sectional view of the brush assembly of
FIG. 5 taken along lines 11-11 of FIG. 9;
[0039] FIG. 12 is a front elevational view of the cylindrical
roller of FIG. 5 with the opposing end caps disposed thereon;
[0040] FIG. 13 is a bottom, left side perspective view of the
cylindrical roller and the left end cap of FIG. 12;
[0041] FIG. 14 is a front elevational view of the left end cap of
FIG. 12;
[0042] FIG. 15 is a top, front perspective view of the left end cap
of FIG. 12;
[0043] FIG. 16 is a bottom, right side perspective view of the
cylindrical roller and the right end cap of FIG. 12;
[0044] FIG. 17 is a front elevational view of the right end cap of
FIG. 12;
[0045] FIG. 18 is a top, front perspective view of the right end
cap of FIG. 12;
[0046] FIG. 19 is an exploded top, front perspective view of the
right end cap of FIG. 16 illustrating a spring-loaded retractable
mounting hub;
[0047] FIG. 20 is an exploded front elevational view of the
cylindrical roller and end caps of FIG. 12;
[0048] FIG. 21 is a perspective view illustrating the outer web
material being positioned over the cylindrical roller of FIG.
5;
[0049] FIG. 22 is a perspective view of a gear and clutch assembly
of the interior drive train suitable for rotating the roller brush
of a cleaning vehicle; and
[0050] FIG. 23 is a perspective view of the bottom of the cleaning
vehicle of FIG. 3 illustrating a second roller brush attached
thereto.
[0051] To facilitate an understanding of the invention, identical
reference numerals have been 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.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0052] For purposes of providing a better understanding the
invention, terms connoting direction and positioning of components
are defined as follows:
[0053] The terms "cleaning apparatus", "cleaning vehicle" and "pool
cleaner" as used herein are interchangeable and defined as a
self-propelled vehicle that is submersible in water and operable to
move and filter debris located along a surface of the pool.
[0054] longitudinal axis of the cleaner is defined as a single,
fixed axis extending centrally through the cleaner parallel to a
pool surface beneath the cleaner and in the general direction of
movement;
[0055] movement of the cleaner in a forward direction is the
direction that the cleaner is generally being propelled or driven
along its cleaning path;
[0056] movement of the cleaner in a reverse direction is a
direction that is generally opposite to the previous forward
direction along the cleaning path;
[0057] the front of the cleaner is defined as the portion of the
cleaner generally extending perpendicular to the longitudinal axis
in the forward direction of movement as the cleaner travels along
its cleaning path;
[0058] "base" or "base plate" is broadly interpreted as one or more
components forming or otherwise defining an underside or bottom
portion of the housing and which is positioned substantially
parallel to the surface of the pool or tank which is being cleaned;
and
[0059] "top", "bottom", "upper" and "lower" are adjectives that
denote different cleaner components, as well as define the relative
positioning of such components with respect to a central vertical
axis extending centrally through the housing cover and base of the
cleaner.
[0060] Referring to FIGS. 1-4, there is shown one embodiment of a
cleaning vehicle 10 having an electro-mechanically powered roller
brush 100. The cleaning vehicle 10 includes a housing 11 having a
base 13 or bottom portion and a housing cover 15 which together
define an interior chamber 12. In one embodiment, the housing cover
12 is removably fastened over the base 13 to define an interior
chamber 12. The housing cover 12 and base 13 are removably fastened
with one or more fasteners, such as a clasp, latch, spring clip,
bolt or other well-known and conventional fastener. A gasket or
other seal (not shown) can be inserted between the base 13 and
cover 12 to prevent water flowing therebetween into and out of the
interior chamber 12. The housing cover 12 and base 13 are
preferably made of a plastic-like material, such as
polyvinylchloride (PVC), polypropylene, among other well-known
thermoplastic materials, aluminum and/or alloys thereof, and/or
combinations thereof, and/or other water impermeable materials.
[0061] The roller brush 100 is suspended transversely with respect
to the longitudinal axis of the cleaner 10 proximately between a
pair of front wheels 30 and/or back wheels 40 (see, e.g., FIGS. 2
and 22) and at a height such that cleaning members 122 extending
from the roller brush 100 contact the surface on which the wheels
30 and 40 travel. In one embodiment, the distal ends of cleaning
members 122 just make contact with the surface on which the wheels
30 and 40 travel, to stir up debris from the surface and minimize
the load on the motor, as will be discussed below in further
detail. Alternatively, the cleaning members 122 can have a length
sufficient to provide additional frictional forces with the surface
beneath the cleaner and thereby contribute to the movement of the
cleaner 10 along the surface as the power driven roller brush 100
is rotated by the electric motor 80 and drive belt system 21 (FIG.
3).
[0062] Rotationally-mounted supports 18 are coupled to the housing
11 for moving the cleaner 10 over the submerged surface of a pool
or tank. As shown in FIGS. 1 and 4, the rotationally-mounted
supports 18 are wheels 30 and 40 mounted on axles 32.
Alternatively, the rotationally-mounted supports 18 can be or
include one or more tracks, rollers, casters, among other
well-known rotationally-mounted supports. As shown in FIG. 3, the
cleaner 10 is propelled by one or more drive motors 80 which engage
and rotate one or more of the wheels 18 through a mechanical
transmission system 86.
[0063] In one embodiment the cleaning vehicle 10 may be placed in
and removed from its use environment by a handle 50 (e.g., a
telescoping handle). The cleaner's internal electric motor 80
(shown in FIG. 3) receives power from power cord 60 which connects
to a remote power source (not shown). The vehicle is propelled by
the expulsion of the liquid from one of its outlet ports 70. The
vehicle 10 functions to clean the surfaces of a large liquid
reservoir, such as a swimming pool, which are covered by the liquid
stored in the reservoir.
[0064] Referring to FIG. 4, a telescoping handle 50 makes it easier
to place the pool cleaning vehicle 10 into and withdraw it from the
reservoir in which it is to operate. The handle comprises two side
arms 52 and a cross arm 54, which can be readily grasped. The side
arms 52 are accommodated in receiver shafts 56 which have ends 58.
The shafts 56 are long enough that the handle 50 may be fully
retracted so that it is flush with the vehicle as can be seen in
FIG. 1. The side arms 52 and the shafts 56 interact such that the
handle 50 can support the free air weight of the vehicle 10. This
is accomplished by providing one or the other or both with locking
mechanisms to limit the travel of the side arms 52 out of the
shafts 56.
[0065] The vehicle 10 is submerged in the stored liquid (water) and
is then propelled by taking in liquid through its inlet ports 72
formed in the base 13 or bottom of the housing 11 (visible in FIG.
2) and expelling it out one of its outlet ports 70 visible in FIGS.
1 and 4. The inlet ports 72 are illustratively formed through the
base 13 and outlets 70 are formed in the housing cover 15. The
water movement is effected by electric motor 80 visible in FIGS. 3
and 4 by turning its propellers 82 and 84 at opposing ends of the
motor drive shaft 81. The direction in which the vehicle 10 is
propelled is determined by the direction of rotation of the
electric motor 80 which is in turn is controlled by signals
received from the power supply via floating cable 60. Preferably,
the polarity of the motor is reversed to effect a change in
rotation of the motor drive shaft 81, transmission assembly 86, and
propeller 82 and 84. The propellers 82 and 84 are driven by the
motor 80 to expel liquid out of either the outlet port 70 above the
front wheels 30 (visible in FIG. 1) or the outlet port 70 (visible
in FIG. 4) above the back pair of wheels 40. In accordance with the
well-known physics concept of action and reaction, the vehicle 10
will be propelled in a direction opposite to that in which the
liquid is expelled.
[0066] More specifically, the expelled water is in the form of a
water jet that is discharged through one of the outlets 70, which
has a resultant force vector preferably directed towards the pool
surface beneath the cleaner. Preferably and as shown in the FIG. 1,
the outlets 70 are aligned generally along the longitudinal axis of
the cleaner and angled acutely with respect to the surface beneath
the cleaner such that the resultant force vector from the water jet
has a horizontal component and a vertical component and which
propels the cleaner in a forward direction and maintains the
cleaner along the surface being cleaned. Preferably, the resultant
force vector is directed directly beneath the vehicle 10 proximate
to and rearward of an axis of the front wheels 30 which is
generally transverse to the longitudinal axis of the cleaner.
However, the acute angles of the water jet and corresponding
resultant force vector are not considered limiting.
[0067] Referring again to FIG. 4, the design of the vehicle with
longitudinal filters 90 readily accommodates the shafts 56. The
vehicle 10 serves its cleaning function by drawing fluid containing
dirt and debris into its inlet ports 72 and subjecting this fluid
to a filtering action before expelling it out of its outlet ports
70. The positioning of the electric motor 80 and its propellers 82
and 84 longitudinally above the centerline of the vehicle allows
the placement of the filters 90 parallel to this centerline and in
one embodiment filters 90 are angled to accommodate the shafts 56.
The configuration of the filter assembly and it's positioning
within the interior chamber 12 or on the housing is not considered
limiting. For example, the filter assembly can be formed by one or
more shells or buckets comprising a frame and a mesh and/or web
covering, one or more pleated filter cartridges, a semi-deformable
wire or plastic mesh structure, a filter bag, among other
well-known filter assemblies. Moreover, the filter can be disposed
about the outlet 70 to provide filtering of debris captured
entrained with the water through the inlet 72 of the cleaner
10.
[0068] During operation, each motor-driven propeller 82, 84
functions as a water pump to create a low pressure environment in
the interior chamber 12, which causes water and debris from the
pool or tank to be drawn through the at least one water inlet 72
into the interior chamber 12, flow through the filter assembly 90,
and the filtered water is discharged through the water discharge
outlet 70. The expelled filtered water forms the water jet as
described above. The debris and/or other contaminants are separated
from the intake water and isolated within the interior chamber 12
by the filter assembly 90.
[0069] As can be seen in FIG. 3, the electric motor 80 is also used
to power the roller brush 100. The electric motor 80 is equipped
with a transmission assembly, e.g., gear box 86, which translates
the rotation of the electric motor 80 by 90.degree. or some other
angle and also reduces the number of rotations in some fixed ratio
such as 1:30 or any other ratio. A common way to effect these
changes is with a combination of a combination of a worm gear with
a spur gear. However other types of mechanical connections may be
used. The gear box has a takeoff spindle 88 which carries a first
pulley 89 which transmits force to a gear train or drive belt
system 21. The drive belt 21 in turn transmits this force to a
second pulley 22 on a drive transfer shaft 23. This drive transfer
shaft 23 is supported by an elongated bushing 24. This drive
transfer shaft 23 carries another pulley 25 at its other end which
transmits force to a second drive belt 26. The second drive belt 26
is looped over a fourth pulley 27 which is free to rotate. The
drive belt 26 frictionally engages the axle 28 of the roller brush
100. This facilitates slippage between the roller brush 100 and
ultimately the electric motor 80, should the roller brush encounter
some type of obstacle like a large piece of debris on the surface
being cleaned. This avoids the vehicle 10 becoming stalled by such
obstacles and allows the vehicle 10 to pass over them. Where a
series of gears, i.e., gear train 91 is used in place of one or
more drive belts, a clutch 92 may be positioned between the motor
80 and the roller brush 100, as shown in FIG. 22. The clutch 92
will allow the motor continue to rotate the propellers if the
roller brush 100 is obstructed from rotating by debris within the
pool.
[0070] Referring now to FIG. 23, a roller brush 100 is provided at
each opposing end (e.g., front brush 100.sub.1 and rear brush
100.sub.2) of the cleaner. In one embodiment, the second roller
brush 100.sub.2 is passively rotated by the frictional forces as
the cleaning members 122 or outer surface engages the surface of
the pool as the cleaner moves thereon. Alternatively, the second
roller brush 100.sub.2 can be actively rotated by the motor 80.
[0071] Referring to FIGS. 3 and 22, a person of ordinary skill in
the art will appreciate that a second gear box 86 can be provided
at the opposite end of the motor 80 in proximity towards propeller
84 to actively drive a second set of drive belts 26 or gear
train/clutch arrangement 91, 92. In other words, when there are two
brushes 100 installed, the motor 80 can include a gear box 86
affixed proximate each end opposing end of the drive shaft to drive
a corresponding roller brush 100. Advantageously, the second belt
system or second gear/clutch arrangement will also allow the motor
86 to continue to rotate the propellers if the second roller brush
100.sub.2 is obstructed from rotating by debris within the
pool.
[0072] The roller brush 100 and the front wheels 30 are both
mounted to the vehicle 10 via suspension brackets 34. This
arrangement allows the front wheels 30 to be mounted without a
transverse axle, thereby facilitating the mounting of the roller
brush 100 between the front wheels 30. The suction created through
the inlet ports 72 by the action of the propellers 82 and 84 holds
the vehicle to non-horizontal and even vertical side walls so long
as these side walls are submerged in liquid, while the expulsion of
liquid from an outlet port 70 propels the vehicle up the side
wall.
[0073] Referring now to FIGS. 5-21, an illustrative roller brush
100 is now described. The roller brush 100 comprises a cylindrical
roller 102, a web material 110 and a pair of opposing end caps 138,
as shown in FIGS. 5-10 and 21. Referring to FIGS. 5 and 21, the
roller 102 is formed by a first arcuate member 104 and a second
arcuate member 106, each arcuate member having an inner
longitudinal portion 103, 105 and an opposing free longitudinal end
107, 109 the inner longitudinal portions 103, 105 being positioned
adjacently and hinged 110 together, the longitudinal free ends 107,
109 being positioned adjacently when the hinge 110 is in a closed
position to form the elongated cylindrical roller 102.
[0074] In one embodiment, the arc lengths of the first and second
arcuate members 104 and 105 are equal. Alternatively, the arc
length of one of the portions, e.g., the first arcuate member 104
is greater than the arc length of the other (e.g., second 106)
arcuate member. In either embodiment, the two portions 104 and 106
collectively form a cylindrical roller 102.
[0075] Preferably, the inner longitudinal portions 103 and 105 are
hinged together by a living hinge 110 which extends the entire
length along the inner longitudinal portions 103 and 105.
Alternatively, the living hinge 110 can be formed as spaced-apart
segments along the inner longitudinal portions 103 and 105.
[0076] The roller 102 is preferably fabricated from polypropylene.
Alternatively, the roller 102 can be fabricated from acrylonitrile
butadiene styrene (ABS) or polyvinylchloride (PVC), among other
well-known rigid or semi-rigid materials.
[0077] Referring to FIGS. 5, 9, 11, 12 and 19, the first and second
arcuate members 104 and 106 include an inward shoulder portion 112
formed at each opposing end thereof. The inward shoulder portions
112 include an outwardly extending ridge 114 formed proximate the
longitudinal free ends 107, 109 of the roller and collectively
define a pair of adjacent ridges 114 on each end of the roller when
the hinge 110 is closed.
[0078] Referring to FIGS. 10 and 21, the web material 120 includes
a flat or substantially flat inner surface 121, and an outer
surface 123 having spaced-apart and outwardly extending protrusions
which serve as cleaning members 122. The web material 120 is
preferably fabricated from thermal plastic elastomer (TPE).
Alternatively, the web material 120 can be fabricated from
silicone, or vinyl, among other well-known flexible and/or
deformable materials.
[0079] The web material 120 is substantially rectangular in shape
and has opposing longitudinal ends 124 that substantially conform
to the opposing longitudinal free ends 107 and 109 of the
cylindrical roller 100, and a width 126 dimensioned such that an
inner surface 121 of the web material 120 wraps around and directly
covers an outer surface 101 of the elongated cylindrical roller
100. Each longitudinal end 124 of the web material 120 terminates
in a U-shaped flange 128 which defines a channel 129 that conforms
to and interfaces with one of the longitudinal free ends 107, 109
of the roller 102.
[0080] Referring to FIG. 21, inner surface 121 of the web material
120 is positioned adjacent to the outer surface 101 of the roller
102. Specifically, the longitudinal free end 107 of the first
portion 104 of the roller 102 is slidably inserted into the channel
129.sub.1 of the longitudinal end 128.sub.1. Similarly, the
longitudinal free end 109 of the second portion 106 of the roller
102 is slidably inserted into the channel 129.sub.2 of the
longitudinal end 128.sub.2. The longitudinal free ends 107 and 109
are rotated about the living hinge 110 adjacently together to
thereby tightly wrap the inner surface 121 of the web material 120
around the cylindrical roller 102. The width 126 of the web
material 120 is configured to conform to the outer circumference of
the cylindrical roller 102 to minimize slack therebetween.
Moreover, the longitudinal ends 128 of the web material 120 are
locked about the longitudinal free ends 107, 109 of the roller
102.
[0081] As discussed above, the cleaning members 122 can be a length
suitable to stir up debris without or with minimal or negligible
contribution towards the movement of the cleaner along the pool
surface. Alternatively, the cleaning members 122 can have an
extended length suitable to contribute to or cause in its entirety
the movement of the cleaner 10 over the surface of the pool.
[0082] As shown in FIGS. 5-11, the cleaning members can be a
plurality of cleaning members which extend as rows continuously and
equidistantly apart along the entire length of the roller. In one
embodiment, eighteen cleaning member 122 extend radially outward
equidistantly apart, where each one is tapered on opposing sides at
an angle of 3.5 degrees and extends a length of 0.45 mm. As shown
in FIGS. 1-4, each of the rows of cleaning members can be segmented
to and extend equidistantly apart along the entire length of the
roller. A person of ordinary skill in the art will appreciate that
the shape and the dimensions of cleaning members 122 discussed
herein are not considered limiting as other configurations can be
implemented.
[0083] Referring now to FIGS. 5-19, opposing end caps 138 are
disposed over opposing ends 130 of the elongated cylindrical roller
102. The opposing ends 130 are formed by each adjacent pair of
inward shoulder portions 112 of each of the first and second
portions 104 and 106 of the roller 102. Referring to FIGS. 13-17,
the end caps 138 comprise a circular-shaped wall 140 having an
exterior surface 141 and opposing interior surface 144. Each end
cap 138 further includes a circular flange 142 extending in a
direction that is normal from the interior surface 144 and having a
cutout 143 sized to conform to a corresponding pair of adjacently
positioned ridges 114.
[0084] The end caps 138 are preferably fabricated from
polycarbonate. Alternatively, the end caps 138 can be fabricated
from ABS or nylon, among other well-known suitable materials.
[0085] Each end cap 138 is positioned about a corresponding end of
the roller 102 such that the pair of adjacent ridges 114 extends
through a corresponding cutout 143 in the circular flange 142 of
the end cap 138, as shown in FIGS. 11, 12, 15 and 19. In this
manner, the web material is wrapped about the outer surface 101 of
the roller 102 and the circular flange 142 of each end cap 138 is
positioned and frictionally retained between the inward shoulder
portion 112 and the inner surface 121 of the web material 120.
Accordingly, the keying arrangement of the cutouts 143 with the
adjacent ridges 114 collectively lock the adjacent the first and
second portions 104 and 106 together in a closed position to form
the cylindrical roller 102, and the U or C-shaped flanges 128
retain the ends of the web material along the adjacent longitudinal
free ends 107 and 109 of the roller 102.
[0086] Referring to FIGS. 5 and 9, each end cap 138 includes a
central mounting hub (e.g., pin) 146 extending coaxially in a
direction along the longitudinal axis 116 (FIG. 5) of the roller
102 for enabling installation of the brush assembly 100 onto the
self-propelled robotic cleaning apparatus 10. In one embodiment,
the mounting hubs are molded integrally with the end caps 138 and
are fixed along the central longitudinal axis 145. The mounting
hubs 146 are configured to permit rotation of and removably
securing the roller brush assembly 100 to the cleaner 10.
[0087] Referring to FIGS. 11-19, at least one of the endcap
mounting hubs 146 can be a spring-loaded pin to further enable
installation and removal of the brush assembly from the cleaning
apparatus 10. Referring to FIGS. 18 and 19, the spring-loaded pin
146 includes a rear portion 149 that is slidably engagable with a
cylindrical rear housing 148 which is fastenable to the interior
wall 141 of the end cap 138. The rear housing 148 is tubular in
shape having closed rear end 152 and a channel 150 having a length
and circumference that is greater than the length and circumference
of the rear portion 149 of the mounting hub 146. A coil spring 147
is positioned in the channel 150 with one end abutting the closed
rear end 152 of the channel 150, and the opposing end adjacent the
rear portion 149 of the mounting hub 146. The rear portion 149 is
inserted over the free end of the coil spring and into the channel,
and the rear housing, spring and pin 146 are collectively fastened
to the interior wall 141 of the end cap 138 by aligning and
inserting the mounting hub 146 through an orifice 145, and
fastening the open end of the rear housing to the interior wall 144
using one or more fasteners, such as detents 151, threaded
fasteners, adhesives and/or the like.
[0088] In this manner, the mounting hub 146 extends outwardly in a
direction that is normal from the exterior wall 141 and is retained
by the interior wall 144 and rear housing 148. The coil spring 147
has a length sufficient to normally maintain the mounting hub 146
in a position extending through the orifice 145 of the end cap 138.
When an external force is applied longitudinally along the mounting
hub 146 towards the rear housing 148, the mounting hub 146 slides
in the channel 150 towards the closed rear end 152, thereby
compressing the spring 147. The mounting hub can be slidably moved
so that the tip is flush with the exterior wall 141 to thereby
readily enable installation into and removal from the cleaner 10.
When the external force is removed from the mounting hub 146, the
spring returns to its normal uncompressed state and slides the
mounting hub 146 along the channel 150 in the opposite direction
back to the normally extended position.
[0089] Although the roller brush 100 is illustrated and described
as being implemented in a cleaner driven by an internal electric
motor having opposing dual propellers, a person of ordinary skill
in the art will appreciate that other types of self-propelled
robotic pool cleaners can implement and benefit from the roller
brush 100 of the present invention. For example, suction type
cleaners 10 that implement an external pool pump system to drive an
internal water turbine, which in turn drives the cleaner can also
implement and benefit from the roller brush 100. For a better
understanding of suction type and other types of cleaners for which
the brush assembly of the present invention is suitable for
implementation, the reader is directed to U.S. Pat. No. 8,341,789
to Gard and US publication no. 20130031734 to Porat, the contents
of which are incorporated by reference herein in their entireties.
The types of cleaners which can implement the roller brush 100
include belt driven and/or wheel driven cleaners, and the cleaner
types are discussed for illustrative purposes only and are not
considered limiting.
[0090] The roller brush assembly 100 has numerous advantages not
seen in the prior art. One advantage is that a user can quickly and
easily detach the roller brush assembly 100 from the housing by
simply depressing the spring-loaded mounting hub 146 and lifting
the end with the spring-loaded mounting hub 146 so that the entire
roller brush assembly can slide out from beneath the cleaner 10.
Replacement of the brush assembly 100 merely requires the reverse
steps to insert the roller brush assembly back 100 on the cleaner.
Another advantage is that the living hinge 110 of the cylindrical
roller 102 enables the quick wrapping of the web material 120
around the roller 102. Further, the U or C-shaped flanges 128 and
corresponding channels 129 formed on the longitudinal edges of the
web material 120 advantageously secure the web material 120 about
the cylindrical roller 102. The end caps 138 are easily inserted
between the web material 120 and roller 102 at the opposing ends to
secure the web material to the roller 102 and prevent unravelling,
as well as enable the entire roller brush assembly 100 to be
transported as a single unit without undesirable component
separation and then readily installed on the cleaner 10. One or
both of the mounting hubs 146 can be keyed to enable positive
rotation of the roller brush assembly 100 by a power train, such as
an electric motor and gear drive arrangement or a water
turbine/gear drive arrangement. Alternatively, the mounting hubs
146 can be non-keyed (e.g., circular in shape) to enable free
spinning of the roller brush assembly 100 when installed in the
cleaner 10.
[0091] Advantageously, the core and web elements can be assembled
contemporaneously. As well, the core and web elements can be
manufactured contemporaneously. For example, the core and web
elements can be injected individually or over injected
together.
[0092] While the foregoing is directed to embodiments of the
present invention, other and further embodiments and advantages of
the invention can be devised by those of ordinary skill in the art
based on this description without departing from the basic scope of
the invention, which is determined by the claims that follow.
* * * * *