Patent Publication Number: US-2022220761-A1

Title: Battery powered automatic swimming pool cleaners and associated components

Description:
REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Patent Application No. 63/137,386, filed on Jan. 14, 2021 and entitled BATTERY POWERED AUTOMATIC SWIMMING POOL CLEANERS AND ASSOCIATED COMPONENTS, the content of which is hereby incorporated by reference in its entirety. 
    
    
     FIELD OF THE INVENTION 
     This application relates to cleaning devices for water-containing vessels such as swimming pools and spas and more particularly, although not necessarily exclusively, to constructions and components of autonomous swimming pool cleaners powered by batteries. 
     BACKGROUND 
     Automatic swimming pool cleaners (APCs) are well known. These cleaners often are categorized as either “hydraulic” or “robotic” (or “electric”), depending on the source of their motive power. Hydraulic cleaners, for example, typically use pressurized (or depressurized) water to effect their autonomous movement within pools, whereas robotic cleaners typically utilize an electric motor to cause their movement. Moreover, hydraulic cleaners frequently are subcategorized as either “pressure-side” or “suction-side” devices, with pressure-side cleaners receiving pressurized water output from an associated water-circulation pump and suction-side cleaners, by contrast, being connected to an inlet of the pump. 
     Some APCs may use a battery as a source of power; however, traditionally, such batteries are housed within the body of the APC. For example, one of numerous types of APCs is described in commonly-owned U.S. Patent Application Publication No. 2020/0056391 of Lancry. Disclosed in the Lancry application is an “electric” cleaner as well as a docking station or base. The cleaner may be cordless, containing instead within its body “one or more on-board batteries for electrical power.” See Lancry, p. 1, ¶ 0011. As noted in the Lancry application, the battery advantageously is rechargeable when the cleaner is docked at the base. See id., p. 3, ¶ 0038. 
     U.S. Patent Application Publication No. 2007/0067930 to Garti illustrates another type of robotic cleaner. Tethered to the body of the cleaner is a head designed to float within a swimming pool, while contained within the body is a rechargeable battery pack. See Garti, p. 2, ¶ 0026; p. 1, ¶ 0023. Charging of the batteries occurs using an external charging cable attachable between the body and the head. See id., p. 3, ¶ 0034. 
     Yet another battery-powered electric cleaner is described in U.S. Patent Application Publication No. 2014/0263087 of Renaud, et al. According to the Renaud application, a rechargeable battery may be included “within” or “outside of” a housing of the cleaner. See Renaud, pp. 2-3, ¶ 0025. An electric cable positioned between a docking station and a power source facilitates recharging the battery when the cleaner is connected to the docking station. See id., p. 3, ¶ 0028. 
     SUMMARY 
     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 some embodiments, a modular battery block is configured for attachment to a component of an automatic swimming pool cleaner. 
     According to various embodiments, an automatic swimming pool cleaner (i) comprises a chassis and (ii) is powered by at least one battery attached to the chassis and accessible from externally of the chassis. 
     According to certain embodiments, an automatic swimming pool cleaner includes (i) at least one battery and (ii) an arrangement for venting gas produced by the at least one battery. 
     According to various embodiments, a method of supplying electrical power to an automatic swimming pool cleaner having a chassis and a motor includes (i) attaching a modular battery block to the chassis so as to form an integrated device, and (ii) causing an electrical connection within the integrated device between the motor and at least one battery of the modular battery block. 
     According to some embodiments, an automatic swimming pool cleaner includes a chassis defining an interior cavity, and a modular battery block connected to the chassis and at least partially external to the interior cavity, the modular battery block comprising at least one source of electrical power. 
     Various implementations described herein may 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. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The specification makes reference to the following appended figures, in which use of like reference numerals in different figures is intended to illustrate like or analogous components. 
         FIG. 1  illustrates a battery block for an APC according to embodiments. 
         FIG. 2  illustrates the battery block of  FIG. 1  installed on an APC according to embodiments. 
         FIGS. 3A-D  illustrate steps for connecting the battery block of  FIG. 1  with the APC according to embodiments. 
         FIG. 4  illustrates a charging system for the APC of  FIG. 2  according to embodiments. 
         FIG. 5  illustrates the APC of  FIG. 2  with the charging system of  FIG. 4  according to embodiments. 
         FIG. 6  is another view of the APC with the charging system of  FIG. 4 . 
         FIG. 7  illustrates a portion of the charging system of  FIG. 4 . 
         FIG. 8  illustrates a portion of the battery block of  FIG. 1  with a venting system according to embodiments. 
         FIG. 9  illustrates a sealing device of the venting system of  FIG. 8 . 
         FIG. 10  illustrates the battery block of  FIG. 1  with a sensor. 
         FIG. 11  illustrates the sensor of  FIG. 10  and a controller of the battery block of  FIG. 1 . 
         FIG. 12  is another view of the battery block of  FIG. 1  with the sensor of  FIG. 10 . 
     
    
    
     DETAILED DESCRIPTION 
     The subject matter of embodiments is described herein with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described. Directional references such as “up,” “down,” “top,” “bottom,” “left,” “right,” “front,” and “back,” among others, are intended to refer to the orientation as illustrated and described in the figure (or figures) to which the components and directions are referencing; however, such direction references or identifies should not be considered limiting. 
     Disclosed herein are modular battery blocks configured to attach primarily to exteriors of cleaner bodies. In certain embodiments, the battery blocks provided herein are attachable to a chassis of an APC. Additionally, disclosed herein are modular battery blocks with an electronic management system for the batteries. Also disclosed herein are venting systems for the battery blocks. 
       FIG. 1  illustrates an exemplary modular battery block  10 . In certain embodiments, battery block  10  generally includes a housing  15  having a first wall  61  and a second wall  63  opposite from the first wall  61 . Sides  121  may optionally extend between the first wall  61  and the second wall  63 . In certain embodiments, the first wall  61  may form an outer surface  16  of an APC when the battery block  10  is assembled with the APC. In some embodiments, and as illustrated in  FIG. 2 , the outer surface  16  optionally includes a non-linear curvature and/or various curvatures as desired. The first wall  61  and the second wall  63  together define a housing cavity, and various components of the battery block  10  may be provided within the housing cavity. In some embodiments, the first wall  61  and the second wall  63  are secured such that the housing cavity is waterproof and/or otherwise minimizes or prevents water from entering the housing cavity. In the embodiment illustrated, one or more stores of electricity  12  and a controller  18  are housed within the housing cavity. 
     As mentioned, the housing  15  may house one or stores of electricity  12  as desired, and in the embodiment illustrated, the one or more stores of electricity  12  are one or more batteries  14 . The particular batteries  14  illustrated and the arrangement of the batteries  14  should not be considered limiting. 
     In addition to the stores of electricity  12 , the battery block  10  optionally includes part or all of an electronic battery management system  11 . In some embodiments, the battery management system  11  includes the controller  18 , which may be various devices or mechanisms including but not limited to a printed circuit board (PCB) or card. In general, because the battery block  10  is intended for use within a water-containing vessel such as a swimming pool or spa, part or all of the battery block  10  advantageously is sealed so as to isolate the stores of electricity  12  (e.g., the batteries  14 ) and at least a portion of the battery management system  11  (e.g., the controller  18 ) from contact with the water. 
     In some optional embodiments, and as illustrated in  FIG. 2 , the battery block  10  includes a powering or “start” button or switch  122  as part of battery block  10 . When included, the switch  122  may reduce the risk of having a non-start cycle or operation, and/or the switch  122  may improve safety of the APC  24  and/or the battery block  10 . 
     Optionally, and as illustrated in  FIG. 2  for example, the battery block  10  may include visual and/or other indicators of characteristics of the stores of electricity  12  and/or of an APC  24  as desired. The visual indicators may be various types of visual indicators as desired. Optionally where a plurality of visual indicators are included, at least one characteristic (e.g., color, pattern, intensity, etc.) of one visual indicator may be different from a characteristic of another visual indicator, although it need not be in other embodiments. In some non-limiting examples, one or more visual indicators may be light emitting diodes (LEDs), although in other embodiments they need not be LEDs. In the embodiment illustrated in  FIG. 2 , the battery block  10  includes four visual indicators  26 ,  30 ,  34 , and  38 . In this optional embodiment, the visual indicator  26  is a charging indicator providing an indication of battery charging status, the visual indicator  30  is a communication indicator providing an indication of whether the APC  24  is electronically connected to any other device for purposes of sending or receiving data or information, the visual indicator  34  is a power indicator that may indicate whether the APC  24  is, or is not, being powered by the batteries  14  or other store of electricity  12 , and the visual indicator  38  is an operational mode indicator which may indicate whether the APC  24  is configured primarily for floor travel along a pool bottom or instead for both floor travel and wall climbing. Persons skilled in the relevant art will understand that these indicators are optional and, if present, visual indicators need not be identical to those depicted in  FIG. 2 . 
     Optionally, and as best illustrated in  FIG. 3D , the battery block  10  may include one or more electrically conductive portions  111  that may be used to charge and/or recharge the stores of electricity  12  as desired. In the embodiment illustrated, the electrically conductive portions  111  are conductive pads  114  that may be used to selectively engage conductive elements of a charging system. The location, number, and type of the conductive portions  111  should not be considered limiting, and in other embodiments they may be omitted as desired. 
       FIG. 2  shows the battery block  10  attached to an APC  24  having a chassis  22  and a housing  25 . In  FIG. 2 , the battery block  10  is attached to the chassis  22  of the APC  24  and is provided between motive elements (e.g., tracks  58  in  FIG. 2 ). In some embodiments, attachment of the battery block  10  to the chassis  22  may allow for various housings to be provided with the chassis  22  without requiring removal and/or disconnection of the battery block  10 . The battery block  10  attached to the chassis  22  forms an integrated device as discussed in detail below. The housing  25  of the APC  24  may house various components of the APC  24  such as a filter, a pump, and/or various other components as desired. Optionally, a cover may be attached to the housing  25  to provide access to components within the housing  25 . 
     As best illustrated in  FIGS. 3A-B , the chassis  22  of the APC  24  defines an interior cavity or region  42  (see  FIGS. 3A-D ) that may house a motor block  46  comprising at least motor  50  and impeller  54 . The housing  25  may be attached to the chassis  22  using various mechanisms or devices as desired. In certain embodiments, attachment of the housing  25  to the chassis  22  may cover the interior cavity  42 . Optionally, a portion of the motor block  46  and/or other component housed in the interior cavity  42  may at least partially extend into the housing  25 . The APC  24  also includes a rotatable brush  66  as well as tracks  62  that may be utilized to facilitate movement of the APC  24  along a surface. However, the particular APC  24  illustrated should not be considered limiting, and in other embodiments, the APC  24  may be other types of APCs and/or include additional or alternative features as desired. As some non-limiting examples, the battery block  10  may be attachable to an APC with a cover that selectively provides access to the interior region  42 , other motive elements (e.g., wheels), pumps, sensors, filters or filter baskets, communication modules (e.g., antennas), combinations thereof, and/or other features or combinations of features as desired. 
     The attachment of the battery block  10  to the chassis  22  may be direct or indirect as desired. In certain embodiments and beneficially, some or all of battery block  10  remains external to chassis  22 , rendering the battery block  10  easily removable from, and re-attachable to, APC  24  as desired. As an example, and as illustrated in  FIG. 2 , a portion of the housing  15  may form an outer surface  16  of the APC  24 . The battery block  10  may be attached to the chassis  22  using various suitable mechanisms or devices as desired, including but not limited to snap-fit connections, clips, clasps, male and female connections, threaded fasteners, pins, combinations thereof, and/or other devices or mechanisms as desired. Non-limiting examples of such attachment is discussed in detail below with reference to  FIGS. 3A-D . The number, type, and location of the connecting mechanisms should not be considered limiting. 
       FIGS. 3A-D  depict the ease with which the battery block  10  may be connected to (or disconnected from) the APC  24 . In various embodiments, the connection between the battery block  10  and the APC  24  may be “selective” or “removable,” meaning that the battery block  10  may be connected to or disconnected from the APC  24  as desired. 
     Illustrated in  FIG. 3A  are portions of chassis  22 , with any cover (e.g., the housing  25 ) having been removed so as to show the interior region  42  of the chassis  22 . As previously mentioned, in certain embodiments, the motor block  46  with at least the motor  50  and the impeller  54  may be included within interior region  42 . In some embodiments, and as illustrated in  FIG. 3A , the motor block  46  optionally may include a connector  70  that is configured to selectively engage (e.g., mate with) a complementary connector  74  of the battery block  10  (see, e.g.,  FIG. 3C ). In some embodiments, the mating of the connectors  70 ,  74  may allow for electrical power from the battery block  10  to be conveyed to motor block  46  to operate motor  50  without material ingress of water into either of the battery block  10  or motor block  46 . In the embodiment illustrated and as best shown in  FIG. 3A , the connector  74  optionally may be the terminus of a cord  78  extending from the battery block  10  through a sealing grommet  82 . Interconnection of the battery block  10  and the motor block  46  need not be as shown, however; instead, as a non-limiting example, the cord  78  could be omitted, and the connectors  70 ,  74  may be configured to connect directly. Other mechanisms or devices may be used to selectively connect the battery block  10  with the APC  24 . In some optional embodiments, the battery block  10  advantageously may be connected to chassis  22  at the nominal rear end  17  of APC  24  (i.e. the end of chassis  22  opposite brush  66 ). However, in other embodiments, the battery block  10  may be connected to the chassis  22  at other portions of the chassis  22  as desired. 
     Optionally, and as best illustrated in  FIGS. 3B-C , the chassis  22  may include a recess  19  into which battery block  10  is fitted. As mentioned, attachment of battery block  10  to chassis  22  may occur in any suitable manner. In the embodiment illustrated and as best shown in  FIGS. 3C-D , the battery block  10  is connected to the chassis  22  via a frictional “snap fit” via engagement of hooks  21  on the battery block  10  (see  FIG. 1 ) with recesses or apertures  23  on the chassis  22  (see  FIG. 3C ). The hooks  21  are omitted in  FIGS. 3A-D  for clarity of the figure. In the embodiment, the connection is further secured by screw  86  or other fastener penetrating both the battery block  10  and a bottom  91  of the chassis  22 . 
     If the optional cord  78  is present, it optionally may be passed through a rear opening  94  (see  FIG. 3B ) of the chassis  22  if needed to allow connector  74  to engage connector  70 . If cord  78  is not present, the battery block  10  may be connected to, and disconnected from, the chassis  22  without any need to access the interior region  42  of the chassis  22 . In either circumstance, the battery block  10  is easily attached as part of the APC  24  and accessible, in whole or in part, externally of the chassis  22 . 
       FIGS. 4-7  conceptually illustrate a non-limiting example of a charging system  90  for selectively charging (or recharging) batteries  14  of the APC  24 . In this example, the charging system  90  includes a base or dock  98  which may be connected to a source  106  of electrical power via a cord  102  or other suitable mechanism or device. If available, the dock  98  may be located in any suitable area relative to the swimming pool. The dock  98  further may, but need not, include feet  101  such that the dock  98  may be freestanding as shown in  FIGS. 4-6 . Optionally, and as depicted in  FIGS. 4 and 7 , the dock  98  may include electrically conductive portions  103 . In the embodiment illustrated, the electrically conductive portion  103  are springs  110 , and when APC  24  is positioned correctly on the dock  98 , the springs  110  contact the conductive pads  114  of the battery block  10 . In this embodiment, such contact between the springs  110  and the conductive pads  114  allows electricity to flow from dock  98  to the batteries  14  within the battery block  10 . 
     In addition to the conductive portions  104 , the dock  98  may include one or more supports  105  for selectively supporting the APC  24  on the dock  98 . In certain embodiments, the supports  105  may facilitate positioning of the APC  24  on the dock  98 . 
     As best illustrated in  FIGS. 5 and 6 , during charging or recharging of the batteries  14 , the battery block  10  may remain attached to chassis  22 , and the entirety of APC  24  is driven or otherwise positioned onto a base or dock  98  of the charging system  90 , which in turn is connected (e.g., via the cord  102 ) to the source  106  of electrical power. Electricity from source  106  may be carried through the cord  102  to the batteries  14  of the battery block  10  for charging. 
     In some embodiments of the battery block  10 , the batteries  14  optionally can be of the lithium-ion type. In these versions, gases produced by batteries  14  may require, or at least benefit from, being vented from battery block  10 .  FIGS. 8 and 9  show an exemplary venting system  118  for selectively venting these gases (and/or otherwise included as desired) while allowing the battery block  10  otherwise to remain sealed. In such embodiments, a portion of the battery block  10  (e.g., a side  121  of the housing  15  as illustrated in  FIG. 8 ) may include one or more venting apertures  123 . Optionally, and depending on the type of sealing device of the venting system  118 , the side  121  includes a seal support  127  and a side wall  135 . 
     The venting system  118  may be various devices or mechanisms for selectively venting the battery block  10 . In the embodiment illustrated, the venting system  118  includes a sealing device  125  and spring structure (not illustrated) biasing the sealing device  125  to cover and/or otherwise seal the venting apertures  123 . In the embodiment illustrated, and as best illustrated in  FIG. 9 , the sealing device  125  is a lip seal  129  with a spring-receiving cavity  131  and a central aperture  133 . When assembled, the lip seal  129  is positioned on the seal support  127  and within the side wall  135  such that the seal support  127  is received within the central aperture  133 . The spring device may be positioned within the spring-receiving cavity  131  and bias the lip seal  129  into contact with the seal support  127 , thereby sealing the venting apertures  123 . As overpressure builds within battery block  10 , it overcomes the biasing force of the spring device and displaces the lip seal (e.g., a gap is formed between the seal support  127  and the sealing device  125 ), thus allowing gas to escape from battery block  10  and through the sealing device  125  (represented by arrow  151  in  FIG. 9 ). As the overpressure diminishes, the spring structure returns to its normal position, no longer displacing the lip seal. 
     Referring to  FIGS. 10-12 , in some embodiments, the battery block  10  optionally includes one or more sensors  126  for detecting various characteristics or features about the battery block  10  and/or the APC  24 . In certain aspects, the one or more sensors  126  may be communicatively coupled to the controller  18 , and the controller  18  may control an operation of the battery block  10  and/or the APC  24  based on information detected by the one or more sensors  126 . As one non-limiting example, the one or more sensors  126  is a humidity sensor for detecting whether water has intruded into the battery block  10 , and the controller  18  may cease charging of the batteries  14  should water be detected by the sensor  126 . As another non-limiting example, the one or more sensors  126  is a temperature sensor so as to monitor potential heat build-ups within the battery block  10  and/or the one or more sensors  126  is an exterior water sensor so as to prevent operation of APC  24  when no water is present (e.g. when APC  24  is remote from the swimming pool). In  FIGS. 10-12 , a single sensor  126  is illustrated, and the sensor  126  is a humidity sensor  141 . The number, type, or location of sensors should not be considered limiting on the disclosure. 
     Exemplary concepts and combinations of features of the invention may include:
         A. A modular battery block configured for attachment to a component of an automatic swimming pool cleaner.   B. The modular battery block according to statement A., wherein the modular battery block is configured to form an external surface when assembled with the automatic swimming pool cleaner.   C. The modular battery block according to statement A. or B., further comprising a housing and at least one source of electrical power within the housing.   D. The modular battery block according to any one of statements A.-C., further comprising at least one snap fit connector for selectively connecting the modular battery block with the automatic swimming pool cleaner.   E. An automatic swimming pool cleaner (i) comprising a chassis and (ii) powered by at least one battery attached to the chassis and accessible from externally of the chassis.   F. The automatic swimming pool cleaner according to statement E., wherein the chassis defines an interior cavity and a recess external to the interior cavity, and wherein the battery is attached to at least the recess.   G. The automatic swimming pool cleaner according to statement E. or F., further comprising a battery block housing the at least one battery, wherein the battery block is attached to the recess.   H. The automatic swimming pool cleaner according to any one of statements E.-G., further comprising a battery block housing the at least one battery, wherein the battery block is at least partially external to the chassis and defines an external surface of the automatic swimming pool cleaner.   I. The automatic swimming pool cleaner according to any one of statements E.-H., wherein the chassis defines an interior cavity, and wherein the battery block is external from the interior cavity.   J. The automatic swimming pool cleaner according to any one of statements E.-I., wherein the battery block further comprises a controller and at least one sensor communicatively coupled to the controller, and wherein the controller is configured to control the battery block based on information detected by the at least one sensor.   K. The automatic swimming pool cleaner according to any one of statements E.-J., wherein the battery block is indirectly connected to the chassis.   L. The automatic swimming pool cleaner according to any one of statements E.-K., further comprising a venting system for selectively venting the battery block.   M. An automatic swimming pool cleaner comprising (i) at least one battery and (ii) an arrangement for venting gas produced by the at least one battery.   N. The automatic swimming pool cleaner according to statement M., further comprising a battery module housing the at least one battery, wherein the battery module comprises at least one venting aperture, and wherein the venting system is configured to control a flow of the gas through the venting aperture.   O. The automatic swimming pool cleaner according to statement M. or N., wherein the venting system comprising a sealing device and a spring device biasing the sealing device.   P. The automatic swimming pool cleaner according to any one of statements M.-O., wherein the sealing device comprises a lip seal.   Q. The automatic swimming pool cleaner according to any one of statements M.-P., further comprising a chassis defining an interior cavity, wherein the at least one battery is accessible from externally of the chassis.   R. A method of supplying electrical power to an automatic swimming pool cleaner having a chassis and a motor, comprising: (i) attaching a modular battery block to the chassis so as to form an integrated device, and (ii) causing an electrical connection within the integrated device between the motor and at least one battery of the modular battery block.   S. The method according to statement R., wherein attaching the modular battery block comprises connecting the modular battery block at least partially externally to an interior cavity defined by the chassis.   T. The method according to statement R. or S., wherein attaching the modular battery block comprises connecting the modular battery block such that the modular battery block forms an external surface of the integrated device.   U. The method according to any one of statements R.-T., further comprising receiving information from at least one sensor on the battery block, and controlling the supply of electrical power based on the information received from the at least one sensor.   V. An automatic swimming pool cleaner comprising: a chassis defining an interior cavity; and a modular battery block connected to the chassis and at least partially external to the interior cavity, the modular battery block comprising at least one source of electrical power.   W. The automatic swimming pool cleaner according to statement V., further comprising a venting system configured to selectively vent the modular battery block.   X. The automatic swimming pool cleaner according to statement V. or W., wherein the modular battery block further comprises at least one electrically conductive pad for selectively engaging a charging system.       

     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. 
     The foregoing is provided for purposes of illustrating, explaining, and describing embodiments of the present invention. Modifications and adaptations to these embodiments will be apparent to those skilled in the art and may be made without departing from the scope or spirit of the invention. Additionally, the word “pool” and phrase “swimming pool” as used herein may include vessels such as spas and hot tubs within their definitions. Finally, the entire contents of all of the Lancry, Garti, and Renaud applications are incorporated herein by this reference.