Automatic Swimming Pool Cleaner Systems with Brush Holder Removal

This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63/657,278, filed on Jun. 7, 2024, and entitled AUTOMATIC SWIMMING POOL CLEANER SYSTEMS WITH BRUSH HOLDER REMOVAL, the content of which is hereby incorporated by reference in its entirety.

The invention relates to self-propelled swimming pool cleaners for cleaning water-containing vessels such as swimming pools and spas and more particularly, although not necessarily exclusively, to brush holders for such swimming pool cleaners.

Numerous cleaning devices capable of self-propelled (e.g., autonomous or semi-autonomous) movement within swimming pools and spas currently exist. The most common of these devices are self-propelled pool cleaners, which often are either hydraulic or robotic in type. Hydraulic cleaners vary water flow for movement, while robotic cleaners typically employ electric motors to cause motion. Hydraulic self-propelled pool cleaners, furthermore, subdivide into “pressure-side” and “suction-side” cleaners, with pressure-side cleaners being fluidly connected to outputs of pumps of pool water circulation systems and suction-side cleaners being fluidly connected to inputs of such pumps.

Pool cleaners commonly include one or more cleaning devices (e.g., brushes, pressurized jets, etc.) for dislodging debris from pool surfaces so that the dislodged debris may be removed from the water (e.g., by being drawn into a filter). Brushes are effective cleaning devices, but during a cleaning cycle, elongated debris such as hairs, straw, branches, rope, string, and the like may accumulate on gears and bearings of the brush. Such accumulation increases the motor current, slows the surface brushing speed of the brush, and decreases the cleaner displacement speed. Traditionally, to remove such entangled hairs and/or other debris from the gears and bearings of the brush, relatively significant disassembly of the self-propelled pool cleaner is required. In particular, to remove the brush, wheels of the self-propelled pool cleaner overlapping and covering the brush must first be removed and additional screws must be unscrewed.

Embodiments covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various embodiments and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings, and each claim.

According to certain embodiments, a self-propelled pool cleaner includes a brush assembly and a plurality of wheels. The brush assembly is removable from the self-propelled pool cleaner without removing the plurality of wheels.

According to some embodiments, a self-propelled pool cleaner includes a brush holder for supporting a brush, a brush support, and a brush coupler secured to the brush support. The brush coupler may connect the brush holder with the brush support, and the brush holder is detachable from the brush coupler.

According to certain embodiments, a self-propelled pool cleaner includes a brush holder for supporting a brush, a brush support, and a brush coupler connecting the brush holder and the brush support. In various embodiments, the brush coupler is supported by the brush holder and is configured to selectively engage and disengage the brush support such that the brush holder and the brush coupler are detachable from the brush support.

According to certain embodiments, a self-propelled pool cleaner includes a brush holder for supporting a brush, a brush support, a mechanical fastener securing the brush holder to the brush gear, and a wheel for moving the self-propelled pool cleaner along a surface. The wheel may include a removal aperture configured to align with the mechanical fastener such that the mechanical fastener is accessible through the wheel.

According to some embodiments, a self-propelled pool cleaner includes a brush holder for supporting a brush and a brush coupler configured to couple the brush holder with a brush support. In various embodiments, the brush holder is attachable to and detachable from the brush coupler in a radial direction relative to an axis of rotation of the brush holder.

According to various embodiments, a self-propelled pool cleaner includes a brush assembly, a brush support on the cleaner configured to enable rotation of the brush assembly, and at least one wheel for moving the self-propelled pool cleaner along a surface, where the brush assembly is removable from the brush support without removing the at least one wheel.

A method includes removing a brush assembly from a self-propelled pool cleaner without removing a wheel from the self-propelled pool cleaner.

Various implementations described herein can include additional systems, methods, features, and advantages, which cannot necessarily be expressly disclosed herein but will be apparent to one of ordinary skill in the art upon examination of the following detailed description and accompanying drawings. It is intended that all such systems, methods, features, and advantages be included within the present disclosure and protected by the accompanying claims.

Described herein are systems and methods for improved brush holder assembly and removal compared to traditional approaches. In certain embodiments, the systems and methods described herein enable removal of the brush of the self-propelled pool cleaner without requiring removal of a wheel and/or a screw of the self-propelled pool cleaner. The systems and methods described herein may allow for easy removal of hairs and/or other debris accumulated on brush gears and/or brush bearings without requiring the disassembly of many parts of the self-propelled pool cleaner as required with traditional approaches.

In certain embodiments, the brush holder assemblies described herein include one or more couplers allowing for removal of brush assemblies from the pool cleaner. Couplers may include, but are not limited to, spring clips, sliding couplers, dovetailed couplers, other clip couplers, friction fit couplers, snap-fit couplers, combinations thereof, and/or as otherwise desired.

In some embodiments, the systems and methods described herein include a brush coupler connected to a brush support (collectively referring to a brush gear assembly, brush bearing, and/or other structure or device on the self-propelled pool cleaner) and from which the brush holder may be released without removing a wheel of the self-propelled pool cleaner. In certain embodiments the brush holder may selectively engage the brush coupler in a radial direction relative to an axis of rotation. Optionally, the brush holder and the brush coupler include one or more locking features for controlling (e.g., allowing or preventing) radial movement of the brush holder relative to the brush coupler. Locking features include but are not limited to a dovetail, a radial fastener, a clip, combinations thereof, and/or as otherwise desired.

Additionally, or alternatively, the systems and methods described herein include a removal aperture defined in the wheel and aligned with a screw or mechanical fastener connecting the brush support with the brush holder. In such embodiments, a tool such as but not limited to a screwdriver may access the mechanical fastener through the removal aperture, thereby allowing for the removal of the brush support from the brush holder without requiring removal of the wheel.

Additionally, or alternatively, the systems and methods described herein include the brush coupler supported on the brush holder. The brush coupler may be movable relative to the brush holder between a retracted configuration and an extended configuration. The brush coupler in the retracted configuration may allow for detachment of the brush holder and brush coupler from the brush support. Optionally, the brush coupler may be biased into the extended configuration by a biasing member applying a biasing force, such as but not limited to a spring.

The systems and methods described herein may improve the efficiency of assembling and/or disassembling of the brush holder from the self-propelled pool cleaner compared to traditional approaches. Optionally, the improved assembly and/or disassembly may be realized without requiring additional components. Various other benefits and advantages may be realized with the systems, devices, and methods provided herein, and the aforementioned advantages should not be considered limiting.

illustrates an example of a self-propelled pool cleaneraccording to embodiments. The self-propelled pool cleanermay be a robotic cleaner using electrical power for movement and cleaning. However, in other embodiment, the pool cleanermay be a hydraulic pool cleaner and/or as otherwise as desired. The pool cleanergenerally includes a housinghaving a nominal front endand back endin a direction of travel, one or more motive elements(e.g., wheels, tracks, combinations thereof, etc.) enabling movement of the pool cleaneralong a surface, and one or more cleaning devices(including but not limited to one or more brush assemblies). A motor, pump, filter, controller, and/or various other features or combinations of features may be provided on or within the self-propelled pool cleaneras desired. In certain embodiments, the self-propelled pool cleanerincludes an on-board power source, such as but not limited to one or more on-board batteries. Non-limiting examples of self-propelled pool cleanersmay include those described in U.S. Pat. Nos. 10,316,534, 9,488,154, 8,578,538, and U.S. Patent Publication No. 2014/0303810, all of which are hereby incorporated by reference in their entireties.

As illustrated in, each brush assemblymay include a brushsupported on a brush holder. While two brush assembliesare illustrated in, in other embodiments, a single brush assemblymay be utilized with a pool cleanerand/or a plurality of brush assembliesmay be utilized with a pool cleaner.

The brush supportsmay be various devices suitable for supporting the brush assemblyon and/or relative to the pool cleaner, such as on the housingof the pool cleaner. In some embodiments, the brush supportsmay include one or more brush gear assemblies(see, e.g.,) and/or one or more brush bearings supported on the housingof the self-propelled pool cleaner.

Traditionally, a mechanical fastener such as a screw, connects each end of the brush holderto a brush support. As an example, one end of the brush holdermay be connected the brush gear assemblyand an opposite end of the brush holdermay be connected to the brush bearing. However, as illustrated in, one or more of the wheels(or other motive elements) may overlap the brush assembliesin a lateral direction. Thus, to access the mechanical fastener connecting the brush holderto the brush supports, traditional approaches require removal of the wheelsbefore the brush assembliescan be removed from the self-propelled pool cleaner. Compared to traditional approaches, and as described in detail below with reference to, the self-propelled pool cleanersdescribed herein allow for selective removal of the brush assembliesfrom the self-propelled pool cleanerwithout requiring removal of the wheels.

In some embodiments, and as illustrated in, the self-propelled pool cleanersinclude a brush couplerconnecting the brush holderto the brush support. The brush couplersmay allow for attachment of the brush assembly to the pool cleanerand removal of the brush assembly from the pool cleanerwithout requiring the removal of a wheel. Brush couplersmay include, but are not limited to, spring clips, sliding couplers, dovetailed couplers, other clip couplers, friction fit couplers, snap-fit couplers, combinations thereof, and/or as otherwise desired.illustrate examples of brush couplers, but the particular brush couplersshould not be considered limiting and a pool cleanermay include various devices or mechanisms (or combinations thereof) as the brush couplers. In one non-limiting example, the brush couplersmay include spring clips, such as generally U-shaped spring clips. Other couplers may be utilized as desired.

In some embodiments, and as illustrated in, the brush couplermay be secured to the brush support, and the brush holderis attachable to and detachable from the brush coupler. In such embodiments, the brush holdermay be releasable from the brush support.

In some embodiments, and as best illustrated infor example, the brush couplermay be secured to the brush supportor a component thereof (e.g., the brush gear assemblyor brush bearing) using a mechanical fastenerand/or other suitable mechanism or device as desired. In these embodiments, the brush couplerand the brush holdermay include complementary engagement features,allowing for selective engagement and disengagement between the brush couplerand the brush holder. As a non-limiting example, one engagement feature (e.g., engagement featureon the brush holder) may include a grooveand the other engagement feature (e.g., engagement featureon the brush coupler) may include a rib, ridge, or other suitable features. In other embodiments, the groovemay be provided on the brush couplerand the ribmay be provided on the brush holder. Other engagement features may be utilized as desired.

In various embodiments, the engagement features,may be configured to sliding and/or linear engagement. In certain embodiments, and as illustrated in, the engagement features,may be radial engagement features. As used herein, radial engagement features refer to the engagement features,being movable into or out of engagement via radial movement relative to a rotation axisof the brush support. In various embodiments, radial engagement features may allow for release of the brush holderfrom the brush coupler(and thus the brush support) without requiring access and/or movement along the axis. In another non-limiting example, radial engagement features may include a spring clip as one engagement feature,and a complimentary feature as the other engagement feature,, and the engagement features,may be moved into and out of engagement with each other. Other radial engagement features may be utilized as desired.

Optionally, and as illustrated in, one or more locking featuresmay be included to control radial movement of the brush holderrelative to the brush coupler. In some non-limiting examples, the locking featuresmay control radial movement of the brush holderby preventing and/or limiting radial movement, providing resistance to radial movement in one or more directions, combinations thereof, and/or as otherwise desired.

As one non-limiting example,illustrates a dovetail locking featurewhere a dovetail portionmay be received by a dovetail slot or groove. In this embodiment, engagement between the dovetail portionand the dovetail slot or groovemay provide resistance to radial movement. The shape, number, location, and type of the components of the dovetail locking featureshould not be considered limiting. Moreover, the particular components including the dovetail portionand the dovetail slot or grooveshould not be considered limiting. As a non-limiting example, while the dovetail portionis illustrated on the brush couplerand the dovetail slot or grooveis illustrated on the brush holder, in other embodiments, the dovetail portionmay be on the brush holderand the dovetail slot or groovemay be on the brush coupler.

As another non-limiting example,illustrates a fastener locking featurewhere a mechanical fastenerselectively engages apertures,(or other suitable features) of the engagement features,in a radial direction. In this embodiment, the mechanical fasteneroptionally may prevent radial movement and/or secure the engagement until the mechanical fasteneris unscrewed or otherwise disengaged.

As another non-limiting example,illustrates a clipping locking featurewhere a clipmay engage groovesand/or other features or components. In this embodiment, engagement between the clipand the groovesmay provide resistance to radial movement. In a non-limiting example, a spring clip may be utilized as the clip, although it need not be a spring clip in other embodiments. The particular components including the clipand the groovesshould not be considered limiting. As a non-limiting example, while the groovesand/or other engagement feature is illustrated on the brush couplerand the clipis illustrated on the brush holder, in other embodiments, the groovesand/or other engagement feature may be on the brush holderand the clipmay be on the brush coupler.

Whileillustrate the brush couplersecured to the brush support, in other embodiments the brush couplermay be supported on the brush holder. As a non-limiting example,illustrate the brush coupleroptionally supported on the brush holder. In these embodiments, the brush couplermay selectively engage or disengage the brush supportsuch that the brush holderand brush couplerare releasable from the brush support.

As best illustrated in, in some embodiments the brush couplermay be supported on the brush holder. Optionally, the brush coupleris supported on the brush holdersuch that the brush couplerand brush holderdefine ends,of the brush assembly.

In certain embodiments, the brush coupleris slidable and/or linearly movable relative to the brush holderbetween an extended configuration and a retracted configuration.illustrate the brush couplerin the extended configuration. A distance between the ends,when the brush coupleris in the extended configuration may be greater than a distance between the ends,when the brush coupleris in the retracted configuration. In certain embodiments, in the extended configuration, the brush couplermay be engaged with the brush support, and in the retracted configuration, the brush couplermay be disengaged from the brush support, thereby allowing removal of the brush couplerand the brush holder.

Optionally, a biasing membermay be provided between a portion of the brush couplerand a portion of the brush holderfor applying a force or pressure to the brush couplerand the brush holderand controlling movement and/or maintaining a specific positioning of the brush couplerrelative to the brush holderin the absence of an external force. Various devices or mechanisms may be utilized as the biasing member, such as but not limited to a spring, compression member, pneumatic cylinders, elastic material, combinations thereof, and/or as otherwise desired. In embodiments with the biasing member, the biasing membermay bias the brush couplertoward the extended configuration (e.g., by applying a force or pressure). In addition to facilitating removal of the brush assemblyfrom the self-propelled pool cleaner, the sliding brush couplerwith the biasing membermay further facilitate installation of the brush assembly. As a non-limiting example, and as illustrated in, the brush couplersmay be compressed into the retracted configuration (represented by arrows) (e.g., by a user and/or by engagement of the couplerswith portions of the bodyof the pool cleaneror as otherwise desired) and then positioned within the self-propelled pool cleaner(represented by arrow), after which the biasing membersbias the brush couplersinto the extended configuration and into engagement with the brush supports(e.g., due to the absence of an external force or pressure provided by the user and/or disengagement of the couplerswith the portion of the pool cleanerpreviously compressing the couplers).

The brush couplersillustrated inmay facilitate removal of the brush assemblyfrom the self-propelled pool cleanerwithout requiring removal of the wheels.

In other embodiments, and as illustrated in, a separate brush couplermay not be required to allow for removal of the brush assemblywithout requiring removal of the wheels.

Referring to, in certain embodiments, a mechanical fastenermay connect the brush supportand the brush holder. In these embodiments, one or more removal aperturesare defined in the wheeland axially align with the mechanical fastener. The removal aperturesmay be defined in various parts of the wheelas desired and suitable for alignment with the mechanical faster(or a location on the brush holderfor the mechanical fastener), such as but not limited to a hubof the wheel. In certain embodiments, the one or more removal aperturesmay be offset from an axis of rotation of the wheel.

The wheelwith the one or more removal aperturesthus allows a removal toolto access the mechanical fastenerthrough the removal aperturewithout requiring removal of the wheel. As a non-limiting example, as illustrated in, the removal toolmay access the mechanical fastenerthrough the removal apertureto cause disengagement of the mechanical fastenerfrom the brush holder(step). In certain embodiments, where the brush holderand brush supportare optionally nested (e.g., as illustrated in), disengagement of the mechanical fastenerfrom the brush holdermay cause axial movement of the brush support(step), which may further result in disengagement of the brush holderfrom the brush support(step). The brush supportdecoupled and detached from the brush holderallows for removal of the brush holder(step).

As illustrated in, the self-propelled pool cleanersdescribed herein allow for removal of brush assemblieswithout requiring removal of wheelsof the self-propelled pool cleaner. In certain embodiments, a single type of mechanism or technique may be utilized to facilitate removal of the brush assemblies. As non-limiting examples, couplers allowing for removal of brush assembliesmay include, but are not limited to, spring clips, sliding couplers, dovetailed couplers, other clip couplers, friction fit couplers, snap-fit couplers, combinations thereof, and/or as otherwise desired. As a non-limiting example, opposing ends of a brush assemblyboth utilize the sliding brush coupleras illustrated in. As a further non-limiting example, opposing ends of a brush assemblyboth utilize the brush couplerssecured to the brush supportsand with the dovetail locking featureas illustrated in. In other embodiments, a combination of mechanisms or techniques may be utilized for removal of the brush assemblyfrom the self-propelled pool cleaner. As a non-limiting example, one end of the brush assemblymay include the sliding brush coupleras illustrated in, and the opposite end of the brush assemblymay include the mechanical fasteneraccessible through a removal aperturein the wheel. As a further non-limiting example, opposing ends of a brush assemblyboth utilize the brush couplerssecured to the brush supports, but one end includes the clipping locking featureas illustrated inand the other end includes the fastener locking featureas illustrated in. Various other combinations of features may be utilized as desired, and the aforementioned examples should not be considered limiting.

Exemplary concepts or combinations of features of the invention may include:

These examples are not intended to be mutually exclusive, exhaustive, or restrictive in any way, and the invention is not limited to these example embodiments but rather encompasses all possible modifications and variations within the scope of any claims ultimately drafted and issued in connection with the invention (and their equivalents). For avoidance of doubt, any combination of features not physically impossible or expressly identified as non-combinable herein may be within the scope of the invention. Further, although applicant has described devices and techniques for use principally with self-propelled pool cleaners, persons skilled in the relevant field will recognize that the present invention conceivably could be employed in connection with other objects and in other manners. Finally, references to “pools” and “swimming pools” herein may also refer to spas or other water containing vessels used for recreation, training, or therapy and for which cleaning of debris is needed or desired.