Note: Descriptions are shown in the official language in which they were submitted.
89622410 (89003-210D1)
TITLE: WATER-COOLED PUMP ASSEMBLY FOR BATHING UNIT SYSTEM
AND PUMP ASSEMBLY FOR BATHING UNIT SYSTEM WITH MOUNTING
BRACKETS
TECHNICAL FIELD
The disclosure relates generally to the field of bathing unit systems and,
more specifically, to
pump assemblies for use in bathing unit systems, such as therapeutic pools,
fitness pools,
spas, hot tubs, baths and the like.
BACKGROUND
For some time, consumers have enjoyed the recreational and hydro-therapeutic
benefits of
spas, pools, hot tubs, whirlpools, and jetted baths, generally referred to
"bathing unit
systems". Bathing unit systems can serve as a retreat for relaxation or
socialization. They
can also provide therapeutic benefits by making use of circulating heated
water to treat
muscles and/or joints to improve physical well-being. Swim-in-place bathing
unit systems,
such as for example swim-in-place pools and spas, are also becoming
increasingly popular
and allow a swimmer to engage in swimming without the need for a full-sized
pool.
Such systems are equipped with water circulation systems that use pump
assemblies to
circulate water to and from a water receptacle. Such pump assemblies can be
used with other
components in the bathing unit system to achieve various objectives such as,
for example,
filtration and heating as well as a broad range of propulsion effects. A pump
assembly
typically includes a motor for driving a propeller structure that causes water
to flow through
tubing between a water intake and a water outlet of the pump assembly. While
some
conventional systems often make use of pump assemblies with constant (single)
speed
motors, and thereby release a water flow at an essentially constant force when
activated,
modern systems increasingly allow setting the force (or velocity) of the water
released by the
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pump assemblies to different levels by using pump assemblies equipped with
variable speed
motors. Such variable speed motors may be continuously variable speed motors
or motors
configured for achieving distinct discrete motor speeds. Pumps assemblies with
variable
speed motors are typically equipped with circuit board mounted controllers
that are
configured to regulate the manner in which the motor operates by controlling
an amount of
electrical power supplied to the motor.
In a typical pump assembly, the motor and the circuit board mounted controller
(when one is
present) generate a certain amount of heat that must be dissipated to prevent
components of
the pump assembly from overheating, which may lead to damage and/or premature
ageing of
the components. Conventionally, a fan is provided in the pump assembly to
dissipate heat
generated by the motor and large air-cooled heat sinks are used for cooling
the circuit board
mounted controller.
There are several deficiencies with heat pump assemblies of the type described
above. For
example, it is noted that certain bathing unit systems, such as spas,
generally have limited
space for accommodating devices and one or more pump assemblies must generally
fit
underneath the spa skirt and share such confined space with other components.
The fan to
cool the motor and the air-cooled heat sink for the circuit board mounted
controller each add
significantly to the size and weight of the pump assembly, which is
undesirable in a context
where space is limited. Another deficiency associated with the use of a fan is
the noise that it
generates, which can be perceived negatively by the users of the bathing unit.
Yet another
deficiency associated with a pump assembly of the type described above is that
it is lacking
in terms of energy-efficiency. For example, in conventional pump assemblies
the heat of the
motor and circuit board is essentially dissipated into air without otherwise
producing any
useful output and energy is used to operate the fan for the sole purpose of
cooling
components.
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Some approaches have been proposed to attempt to alleviate some of the above
deficiencies.
For example, instead of using a fan to cool the motor, some pump assemblies
use a fluid and
are equipped with pipes and/or channels that surround an outer surface of the
motor
housing. As the fluid circulates in the pipes and/or channels, heat from the
water is
transferred from the motor to the fluid. For examples of fluid-cooled pump
assemblies of
the types described above, the reader is invited to refer to U.S. 7,347,674
issued March 25,
2008 and to U.S. 6,200,108 issued March 13, 2001.
Replacing the fan with a fluid circulating through pipes and/or channels
allows reducing
some of the noise associated to operating the pump assembly as well as
provides an
opportunity to reduce the amount of space required for the pump assembly. In
addition, in
some implementations, the water from the spa may be used as the fluid that is
circulated
through the pipes or channels, which has an added advantage of recycling the
heat absorbed
from the motor in the form of heat for the spa water, which improves the
energy efficiency
of the bathing unit.
While fluid-cooled pumps assemblies of the type described above present some
advantages
over the conventional fan-cooled assemblies, other deficiencies are associated
with such
assemblies. One deficiency is that there is a risk that liquid may leak into
the motor body as
fluid is circulated through the pipes and/or channels over the motor housing,
for example
through a breach or inadequately sealed joint of the motor housing. To address
this,
increased care needs to be exercised during manufacturing to ensure that the
units are
properly sealed, which in turn increases the associated manufacturing costs of
the pump
assemblies. In addition, the fluid circulated through the pipes or channels
may contain
corrosive substances, such as for example salts, that may over time corrode
the pipes or
channels. In addition, particles/debris may be present in the fluid (for
example hair or dirt
may be present in spa water) and may become lodged in the pipes or channels
thereby
obstructing the flow of fluid through the pipes and/or channels.
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Another challenge associated with bathing unit systems and pump assemblies is
related to the
limited space. As mentioned above, a pump assembly must generally fit
underneath the spa
skirt and must share such confined space with other components. To address
such space
constraints, pump assemblies are typically manufactured in different
configurations, each
with a water intake and a water outlet positioned in different orientations. A
particular pump
assembly is selected by a bathing unit manufacturer in part by taking into
account the
orientation of its intake and outlet. To meet their needs, manufacturers must
often keep in
inventory multiple types of pump motors having intake and outlet oriented in
different
manners.
In order to avoid storing pump motors having water intakes and outlets
oriented in different
manners, some pump assemblies are configured so that the front end (the wet
end) of the
pump assembly can be disassembled from the back end (the dry end or motor end)
of the
pump assembly. For such pump assemblies, to change the orientation of the
intake and
outlet, the pump assembly typically needs to be manually disassembled, usually
by
unscrewing the front end (the wet end) of the pump assembly. The front end is
then rotated
relative to the body of the pump assembly and re-fastened to it. A deficiency
with such an
approach is that the water seal between the front end and the motor can be
damaged during
these manipulations and it requires more time from technicians performing the
disassembling
and reassembling of the pump.
Against the background described above, there remains a need in the industry
to provide a
pump assembly that alleviates at least part the deficiencies associated with
existing pump
assemblies.
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SUMMARY
In accordance with a first aspect, a pump assembly for a bathing unit system
is provided, the
pump assembly comprising:
a. a motor housing holding an electric motor, the motor housing having a front
end, a
back end and a rotor shaft extending through the front end;
b. a wet-end housing having:
i. an impeller connected to the rotor shaft extending through the front end
of the
motor housing thereby allowing the impeller to be rotatable by the electric
motor via the rotor shaft;
ii. a water inlet port and a water outlet port in fluid communication with the
water inlet port for circulating water through the wet-end housing in response
to rotation of the impeller;
and
c. a heat transfer interface positioned between the front end of the motor
housing and
the wet-end housing, wherein the heat transfer interface is configured for
establishing
a thermal conduction path between the motor housing and the wet-end housing so
that, in use, a portion of heat generated by the motor is absorbed by the heat
transfer
interface and is dissipated in water circulating through the wet-end housing.
Advantageously, embodiments of the above-proposed pump assembly leverage the
temperature differential between the water in the bathing unit system and the
motor to
transfer heat from the pump motor to the water flowing through the pump. As a
result, heat
dissipated from the motor may be put to use in heating water in the bathing
unit rather than
being dissipated into the air, thereby leading to improved energy efficiency
of the bathing
unit system. In addition in pump assemblies of the type described above,
through the use of
heat transfer interface positioned between the front end of the motor housing
and the wet-end
housing, the water flow may be essentially limited to the wet-end housing of
the pump
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assembly. This allows concurrently allowing heat to be transferred from the
pump motor to
the water flowing through the pump while reducing risks of water infiltrating
into the motor
body relative to systems in which piping surrounding the motor housing.
In some implementations, the heat transfer interface may be engaged with the
front end of the
motor housing to establish the thermal conduction path between the motor
housing and the
wet-end housing. The heat transfer interface may include a first surface
engaged with the
front end of the motor housing and a second surface opposed to the first
surface, wherein
when the pump assembly is in use, at least a portion of the second surface is
exposed to water
flowing through the wet-end housing.
In some implementations, the wet-end housing may further include an active
heating element
powered by a source of electrical power and configured for selectively
actively heating water
flowing through the wet-end housing. The active heating element may be made
using
different technologies such as, but without being limited to thick film, a
tubular heating
element and ceramic heating element.
In some practical implementations, the heat transfer interface may be coupled
to the front end
of the motor at least in part via an induction heat shrinking process, via a
welding process,
via a brazing process, through the use of an adhesive and/or using one or more
mechanical
fasteners, such as but not limiting to clamps, screws and the like.
In practical implementations, the motor housing may be made of a material
comprised at
least in part of aluminum.
In specific implementations, the heat transfer interface may be made of
different types of
materials. In some implementations, the heat transfer interface may be made of
a thermally
conductive material, such as but not limited to, a material that includes
copper and/or
aluminum. While such materials can provide useful thermal conduction
properties, since the
heat transfer interface is in contact with water from the bathing unit, and
since such water
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may contain corrosive materials (such as salts), the heat transfer interface
may need to be
replaced more frequently due to wear.
In alternative implementations, the heat transfer interface may be made of a
material
generally resistant to corrosion even if heat conduction properties may be
lower than
materials such as copper and/or aluminum. For example, materials may include,
without
being limited to, titanium and/or stainless steel. While such materials are
not considered to
have good thermal conduction properties, it has been found that their
respective levels of
conduction can be sufficiently suitable to establish a thermal conduction path
between the
motor housing and the wet-end housing. In addition, materials such a stainless
steel and
titanium are generally resistant to corrosion and thus, since the heat
transfer interface is at
least partially in contact with water containing corrosive materials, the use
of such materials
may extend the useful life of the pump assembly and/or may reduce the
frequency of
required repairs and maintenance.
In some practical implementations, a thermal interface material may fill at
least some voids
between the first surface of the heat transfer interface and the front end of
the motor housing,
wherein the thermal interface material is characterized by a higher thermal
conductivity than
air, thereby improving the thermal conductivity between the motor housing, the
heat transfer
interface and the front end of the motor housing. Various types of suitable
thermal interface
materials may be used to improve the thermal conductivity. For example, the
thermal
interface material may include a thermal gap filler material, including but
not limited to a
thermal paste or thermal pad.
In some implementations, the thermal conduction path established by the heat
transfer
interface between the motor housing and the wet-end housing is a first thermal
conductive
path. The pump assembly may comprise a controller module for controlling the
operation of
the electrical motor and the heat transfer interface may be further configured
to establish a
second thermal conduction path between the controller module and the wet-end
housing so
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that, in use, a portion of heat generated by the controller module is absorbed
by the heat
transfer interface and is dissipated in water circulating through the wet-end
housing. In some
implementations, a thermal insulation layer may be located between the
controller module
and the motor housing to reduce an amount of heat transfer between the
controller module
and the motor housing. The thermal insulation layer may comprise one or more
air gaps
between the controller module and the motor housing and/or it may comprise a
thermal
insulating material between the controller module and the motor housing.
Specific examples
of suitable thermal insulating material may include, but are not limited to,
plastic, KevlarTM,
mylar, fiberglass are good insulation materials.
In some implementations, the motor housing may comprise a flange member
forming a rim
about the front end of the motor housing, the heat transfer interface being
configured to
engage the flange member. The rim formed by the flange member may include a
first partial
rim member and a second partial rim member distinct from the first partial rim
member. In
some implantations, the first partial rim member cooperates with the heat
transfer interface to
establish the first thermal conduction path between the motor housing and the
wet-end
housing and the second partial rim member cooperates with the heat transfer
interface to
establish the second thermal conduction path between the controller module and
the wet-end
housing, wherein the second partial rim member at least partially thermally
insulates the
controller module from the motor housing.
The second partial rim member may include a thermal insulation layer
positioned between
the controller module and the motor housing for at least partially thermally
insulating the
controller module from the motor housing. In addition, or alternatively, the
second partial rim
member may include a heat sink portion, the heat sink portion being configured
to establish a
thermal coupling with the controller module. More specifically, the heat sink
portion may
comprise a controller-facing side configured to establish the thermal coupling
with the
controller module, and a motor-housing-facing side shaped to conform to an
outer surface of
the motor housing.
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In some specific implementation, the pump assembly includes components to
facilitate
mounting the pump assembly to a supporting structure. In this regard, the pump
assembly
may comprise an external casing having:
- a first pump
mounting bracket for fastening the pump assembly to a surface
mounting bracket, the first pump mounting bracket being positioned at a first
radial location on the external casing; and
- a second pump mounting bracket for fastening the pump assembly to the
surface mounting bracket, the second pump mounting bracket being
positioned at a second radial location on the external casing, the first
radial
location being distinct from the second radial location there by permitting
the
pump assembly to be fastened to the surface mounting at two different angles
corresponding to the first radial location and second radial location.
In accordance with another aspect, a pump assembly for a bathing unit system
is provided,
the pump assembly comprising:
- an external casing having an outer surface and a central axis, said external
casing
including at least two pump mounting brackets protruding from the outer
surface of
the external casing, wherein a first one of said at least two pump mounting
brackets is
positioned at a first radial location on the external casing and a second one
of said at
least two pump mounting brackets is positioned at a second radial location on
the
external casing; and
- a surface mounting bracket configured to be mounted to a supporting
structure in the
bathing unit system;
- wherein the surface mounting bracket is configured to engage a selected one
of the at
least two pump mounting brackets thereby positioning the pump assembly at an
angle
corresponding to one of the first radial location and second radial location,
the
selected one of the at least two pump mounting brackets being selected by
rotating the
external casing about the central axis relative to the to surface mounting
bracket to
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align the selected one of the at least two pump mounting brackets with the
surface
mounting bracket.
Advantageously, embodiments of the above-proposed pump may allow for
conveniently
adjusting the radial orientation of the pump assembly without compromising the
integrity of
the pump assembly by disassembling components of the assembly.
In some practical implementations, the first pump mounting bracket is
configured to be
fastened to the surface mounting bracket using one or more mechanical
fasteners, the one or
more mechanical fasteners engaging the first pump mounting bracket and the
surface
mounting bracket along an axis that extend longitudinally along at least part
of the
supporting structure. Such configuration facilitates the installation of the
pump assembly by
positioning the fasteners in a manner that renders them accessible by a
technician and
reduces their interference with the external casing.
In accordance with another aspect, a pump assembly is provided for a bathing
unit system,
the pump assembly comprising:
a. a motor housing holding an electric motor, the motor housing having a front
end, a
back end and an outer lateral surface between the front end and the back end;
b. a wet-end housing positioned adjacent the front end of the motor housing,
the wet-
end housing having a water inlet port and a water outlet port in fluid
communication
with the water inlet port for circulating water through the wet-end housing,
the water
inlet port and the water outlet port being configured to connect to
circulation piping
in the bathing unit system;
c. a controller module including a circuit board mounting controller for
controlling the
operation of the electrical motor, the controller module being positioned upon
the
outer lateral surface of the motor housing, a thermal insulation layer at
least partially
separating the outer lateral surface of the motor housing from the controller
module
to reduce an amount of heat transfer between the controller module and the
motor
housing; and
Date Recue/Date Received 2023-09-08
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d. a heat transfer interface positioned between the controller module and the
wet-end
housing, wherein the heat transfer interface is configured for establishing a
thermal
conduction path between the controller module and the wet-end housing so that,
in
use, a portion of heat generated by the controller module is absorbed by the
heat
transfer interface and is dissipated in water circulating through the wet-end
housing.
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Advantageously, embodiments of the above-proposed pump assembly leverage the
temperature differential between the water in the bathing unit system and the
controller
module to transfer heat from the controller module to the water flowing
through the pump.
As a result, heat dissipated from the controller module may be put to use in
heating water in
the bathing unit rather than being dissipated into the air, thereby leading to
improved energy
efficiency of the bathing unit system. In addition, this configuration may
allow reducing the
overall size of the pump assembly by replacing what would typically be
relatively large fin-
based heat sinks with a more compact configuration using a heat transfer
interface and water
flow.
In some implementations, the pump assembly includes a thermal insulation layer
located
between the controller module and the motor housing to reduce an amount of
heat transfer
between the controller module and the motor housing. Different types of the
thermal
insulation layers may be considered in practical implementations. In a first
non-limiting
example, the thermal insulation layer may comprise one or more air gaps
between the
controller module and the motor housing. Alternatively, in another non-
limiting example,
the thermal insulation layer may comprise a thermal insulating material
between the
controller module and the motor housing.
In some implementations, the motor housing may comprise a flange member
forming a rim
about the front end of the motor housing and the heat transfer interface may
be shaped to
engage the flange member in a complementary manner.
In some implementations, the thermal conduction path established by the heat
transfer
interface between the controller module and the wet-end housing is a second
thermal
conductive path. The rim formed by the flange member includes a first partial
rim member
and a second partial rim member distinct from the first partial rim member,
wherein:
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- the first partial rim member cooperates with the heat transfer interface
to establish a
first thermal conduction path between the motor housing and the wet-end
housing;
and wherein
- the second partial rim member cooperates with the heat transfer interface
to establish
the second thermal conduction path between the controller module and the wet-
end
housing, said second partial rim member at least partially thermally
insulating the
controller module from the motor housing.
The second partial rim member may include a thermal insulation layer
positioned between
the controller module and the motor housing for at least partially thermally
insulating the
controller module from the motor housing. The thermal insulation layer may
comprise one or
more air gaps and/or a layer of thermal insulating material.
In some implementations, the second partial rim member may include a heat sink
portion, the
heat sink portion being configured to establish a thermal coupling with the
controller module.
The heat sink portion includes a controller-facing side configured to
establish the thermal
coupling with the controller module and a motor-housing-facing side shaped to
conform to
an outer surface of the motor housing. The motor-housing-facing side may be
machined to
create a thermal separation gap between the motor-housing-facing side and the
outer surface
of the motor housing, thereby providing some thermal insulation between the
motor housing
and the controller module.
These and other aspects of the disclosure will now become apparent to those of
ordinary skill
in the art upon review of the following description of embodiments of the
disclosure in
conjunction with the accompanying drawings.
All features of exemplary embodiments which are described in this disclosure
and are not
mutually exclusive can be combined with one another. Elements of one
embodiment or
aspect can be utilized in the other embodiments/aspects without further
mention. Other
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aspects and features of the present invention will become apparent to those
ordinarily skilled
in the art upon review of the following description of specific embodiments in
conjunction
with the accompanying Figures.
BRIEF DESCRIPTION OF THE DRAWINGS
A detailed description of embodiments of the disclosure is provided below, by
way of
example only, with reference to the accompanying drawings, in which:
FIG. 1 shows a block diagram of a bathing unit system including one or more
pump
assemblies in accordance with a non-limiting embodiment of the invention;
FIG. 2 shows a perspective view of a pump assembly in accordance with a non-
limiting
embodiment of the invention used in the bathing unit system of FIG. 1;
FIG. 3 shows a partial exploded view of the pump assembly of FIG. 2;
FIG. 4 shows a cutaway view of the pump assembly of FIG. 2;
FIG. 5 shows a perspective view of the pump assembly of FIG. 2 in which an
external casing
has been removed to reveal some internal components of the pump assembly;
FIG. 6 shows a partial exploded view of the pump assembly components shown in
FIG. 5;
FIGS. 7A and 7B show front and side views of a heat transfer interface used in
the pump
assembly of FIG. 2;
FIGS. 8A and 8B show perspective views of a (second) partial rim member of the
motor
housing of the pump assembly of FIG. 2, wherein the (second) partial rim
member includes a
heat sink portion;
FIGS. 9A and 9B show bottom plan views of the (second) partial rim member
depicted in
Figures 8A and 8B accordance to two different embodiments;
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FIG. 10 shows an exploded view of the pump assembly of FIG. 2 including a
thermal
insulation layer in accordance with a specific embodiment;
FIGS. 11A and 11B show computer software-generated heat map images of the
motor
housing of a pump assembly in accordance with two different configurations;
FIG. 12 shows a rear isometric view of the pump assembly of FIG. 2 with two
pump
mounting brackets positioned at different radial orientations about the
surface of the casing
of the pump assembly;
FIG. 13A and 13B show perspective rear views of the of the pump assembly of
FIG. 2 with
the external casing removed, wherein the perspective rear views show the pump
assembly in
two different radial orientations;
HG. 14 shows a surface mounting bracket configured for receiving the pump
mounting
brackets depicted in the pump assembly shown in FIG. 12, 13A and 13B.
In the drawings, the embodiments of the disclosure are illustrated by way of
examples. It is to
be expressly understood that the description and drawings are only for the
purpose of
illustration and are an aid for understanding. They are not intended to be a
definition of the
limits of the disclosure.
DETAILED DESCRIPTION
Specific examples of implementation of the disclosure will now be described
with reference
to the Figures.
The description below is directed to a specific implementation of a pump
assembly in the
context of a bathing unit system. It is to be understood that the terms
"bathing system" or
"bathing unit system", as used for the purposes of the present description,
are used
interchangeably and refer to spas, whirlpools, hot tubs, bathtubs, therapeutic
baths,
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swimming pools and any other type of bathing unit that can be equipped with a
pump
assembly for circulating water to and from a water receptacle.
A bathing unit system typically includes a tub or basin that is suitable to
contain a fluid such
as water. In some embodiments the bathing unit system may include one or more
stations that
may each be occupied by one or more persons. In at least one station, one or
more jets may
be selectively located. As used herein, a "jet" refers to an orifice or nozzle
through which a
fluid may be pumped, discharged or dispensed into the tub. Jets may be
provided in various
shapes and sizes as commonly known in the art.
Bathing unit system overview
FIG. 1 is a block diagram of a bathing unit system 10 in accordance with an
embodiment of
the present disclosure. The bathing unit system 10 includes a water receptacle
18 for holding
water, a plurality of jets 20, a set of drains 22 and a controller, which in
the embodiment
shown in a network-enabled controller 24. In the illustrative example shown in
Fig. 1, the
bathing unit system 10 includes a set of bathing unit components including a
heating module
30, two water pumps 11 and 13, a filter 26 and an air blower 28. The bathing
unit system 10
can include more or fewer bathing unit components. For example, although not
shown in
Fig.1, the bathing unit system 10 could include an ozonator, a lighting system
for lighting up
the water in the water receptacle 18, multimedia devices such as an MP3
player, a CD/DVD
player as well as other suitable devices.
In the non-limiting embodiment shown, the network-enabled controller 24
includes a spa
functionality controller 34 for controlling the set of bathing unit components
11, 13, 26, 28,
30 and a network processing unit 40 for coordinating interactions between the
spa controller
and any external devices. Although Fig. 1 shows that the spa functionality
controller 34 and
the network processing unit 40 are two distinct components of the network-
enabled controller
24, they can be implemented by a same physical processor and be part of the
same physical
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device. The spa functionality controller 34 communicates with a user control
panel 31,
which enables a user to enter user commands for the spa functionality
controller 34. In a
specific embodiment, the user control panel 31 includes a display screen and a
user input
device (which can also be referred to as a user operable input). The user
input device can
include a trackball, mouse, gyroscope remote (which senses movement of the
device in the
air so as to move a cursor), a keypad, a touch sensitive screen, turn-dials,
turn-and-push dials
(such as idrive from BMW), a stylus pen or a microphone, among other
possibilities. The
user input device can include one or a combination of any or all of the above
input devices.
The user control panel 31 provides an interface that allows a user to enter
commands for
causing the spa functionality controller 34 to control the various operational
settings of the
bathing unit components 11, 13, 26, 28, 30. Some non-limiting examples of
operational
settings include temperature control settings, jet control settings, and
lighting settings, among
other possibilities. In a non-limiting embodiment where the bathing unit is
connected to
entertainment and/or multimedia modules, the operational settings of the
bathing unit may
also include audio settings and video settings, amongst others. The expression
"operational
settings", for the purpose of the present disclosure, is intended to cover
operational settings
for any suitable bathing unit component or components that can be operated by
a user of the
bathing system.
In normal operation, water flows from the water receptacle 18, through the
drains 22 and is
pumped by water pump 13 through the heating module 30 where the water is
heated. The
heated water then leaves the heating module 30 and re-enters the water
receptacle 18 through
the jets 20. In addition, water flows from the water receptacle 18, through
different drains 22
and is pumped by the water pump 11 through the filter 26. The filtered water
then re-enters
the water receptacle 18 through different jets 20. Water can flow through
these two cycles
continuously while the bathing unit system 10 is in operation. Optionally,
water can also
flow from the water receptacle 18 through one or more drains 22 to the air
blower 28 that is
16
Date Recue/Date Received 2022-03-30
89622410 (89003-210D1)
operative for delivering air bubbles to water that re-enters the water
receptacle 18 through
jets 20.
The network-enabled controller 24 receives electrical power from a power
source 36 that is
connected thereto via service wiring 51, e.g., an electric power source. The
power source 36
supplies the network-enabled controller 24 with any conventional power service
suitable for
residential or commercial use.
The spa functionality controller 34 is configured for controlling the
distribution of power
supplied to the various bathing unit components 11, 13, 26, 28, 30 to cause
desired
operational settings to be implemented on the basis of program instructions
and signals
received from the user control panel 31 or from a device external to the
bathing unit system
10 through the network processing unit 40. The spa functionality controller 34
may also
receive control signals from various sensors 71 to cause the desired
operational settings to be
implemented. Manners in which the spa functionality controller 34 can be used
to control the
individual bathing unit components of the bathing system, such as for example
the jets 20,
the drains 22, the heating module 30, the water pumps 11 and 13, the filter
26, the air blower
28, a valve jet sequencer for massage, a variable speed pump with a pre-
programmed
massage setting, a water fall, an aroma therapy device and an atomizer, as
well as any
lighting and multimedia components, are known in the art and as such will not
be described
in further detail here.
The network-enabled controller 24 includes a network processing unit 40 for
coordinating
interactions between the spa functionality controller 34 and external devices.
The network
processing unit 40 is in communication with a memory unit 42 and a network
interface 68.
The network interface 68 may be of any suitable type known in the art
including a wireless
interface and wired interface. In a non-limiting implementation, the network
interface 68
includes a wireless antennae suitable transmitting signal in a Wi-Fi network.
Any suitable
network interface, including, for example, a cellular interface, power line
transmission and
17
Date Recue/Date Received 2022-03-30
89622410 (89003-210D1)
low power long range transmission (ex: LoRa, Sigfox), may be used in alternate
embodiments. The memory unit 42 stores program instructions for execution by
the network
processing unit 40 for coordinating interactions between spa functionality
controller 34 and
any external devices. The network-enabled controller 24 is in communication
with a router
202.
The memory unit 42 stores program instructions and data for use by the network
processing
unit 40. The data stored in the memory unit 42 includes, amongst others,
information
conveying operational settings associated with components in the bathing unit.
For example,
the operational settings may include temperature control settings, jet control
settings, and
lighting settings, among other possibilities. The memory unit 42 may also
store water
temperature information conveying water temperature measurements for water in
the bathing
system. The program instructions stored in the memory unit 42 when executed by
the
network processing unit 40 provide network related functionality which will be
described in
greater detail in the present application.
Pump hardware
FIG. 2 shows a pump assembly 110 in accordance with a specific embodiment of
the
invention. For example, the pump assembly 110 can be the water pump 11 or the
water
pump 13 shown in FIG. 1. The pump assembly 110 has an external casing 112 that
surrounds internal components of the pump assembly 110, including an electric
motor 132
(shown in FIG. 4). The external casing 112 has a casing top portion 116 and a
casing bottom
portion 118 that together surround and define a pump dry section 114 of the
pump assembly
110. The external casing 112 also includes a front casing 122 that surrounds
and defines a
wet-end housing 120 of the pump assembly 110. The wet-end housing 120 includes
a water
inlet port 124 and a water outlet port 126. Water is configured to flow
through the wet-end
housing 120 from the water inlet port 124 and out through the water outlet
port 126. In some
18
Date Recue/Date Received 2022-03-30
89622410 (89003-210D1)
embodiments, the external casing 112 is made of a durable plastic material and
acts as a
protective barrier for the components of the pump assembly 110.
FIG. 3 shows an exploded view of some of the pump components of the pump
assembly 110
that are inside the external casing 112. Referring as well to FIG. 4, a motor
housing =130
surrounds an electric motor 132, which includes a rotor 146 and stator 148. In
the
embodiment depicted, the motor housing 130 is generally cylindrical in shape
with a curved
housing lateral surface 134 separating a motor housing front end 136 and a
motor housing
back end 138. In some embodiments the motor housing 130 is made of aluminum
although
other suitable materials may be used in alternate implementations. The motor
housing 130 is
located within the pump dry section 114 and sealed from contact by the casing
top portion
116 and the casing bottom portion 118 together with appropriate seals as is
known in the art.
In some embodiments the motor housing 130 is made of aluminum.
A rotor shaft 142 extends through the motor housing front end 136 of the motor
housing 130.
The rotor 146 of the electric motor 132 is mounted to the rotor shaft 142 that
operationally
connects with an impeller 140 positioned outside of the motor housing 130 and
extends into
the wet-end housing 120. The rotor 146 is caused to rotate by electricity
being supplied to
the stator 148. When rotated, the impeller 140 centrifugally forces water
brought into the
wet-end housing 120 through the water inlet port 124 out through the water
outlet port 126.
A heat transfer interface 150 is provided on the motor housing 130 at the
motor housing front
end 136. The heat transfer interface 150, which in the embodiment depicted has
a generally
circular/disc shape, is positioned between a rear surface of the impeller 140
and the front
surface of the motor housing front end 136. A central aperture 152 in the heat
transfer
interface 150 (better shown in FIG. 7A) allows the rotor shaft 142 of the
electric motor 132
to extend therethrough.
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Date Recue/Date Received 2022-03-30
89622410 (89003-210D1)
Optionally, in some embodiments, the motor housing front end 136may include an
active
heating element 201 for heating water that flows through the pump assembly
110. The
heating element 201 can be made using different technologies such as, but
without being
limited to thick film, tubular heating element, ceramic heating element. In a
specific
example of implementation, the heating element 210 is mounted to the dry side
of the heat
transfer interface 150. The element can be welded, brazed, glued or laminated
to the heat
transfer interface. It is appreciated that the active heating element may be
positioned
elsewhere than on the heat transfer interface 150 within the motor housing
front end 136
provided it is positioned such as to avoid interfering with the movement of
propeller 140 of
the pump assembly 110.
In some practical implementations, the controller component 190 of the pump
assembly 110
may be configured for selectively operating the active heating element 201 in
dependence on
a status of operation of the electric motor 132. For example, when the pump
assembly 110 is
a variable speed pump, the controller component 190 of the pump assembly 110
may be
programmed to selectively provide electrical power to the active heating
element 201 to
actively heat water circulating only when the electric motor 132 operates at
an intensity level
below a threshold intensity level. As another example, the controller
component 190 of the
pump assembly 110 may be programmed to selectively provide electrical power to
the active
heating element 201 to actively heat water circulating only when the motor
housing 130 has a
temperature below a threshold temperature. The temperature the motor housing
130 may be
measured by a temperature probe (not shown in the Figures) in proximity to the
motor
housing 130 and in communication with the controller component 190.
In use, recirculating water from the bathing unit system 10 enters the wet-end
housing 120 of
the pump assembly 110. However, it is undesirable for that water to move into
the motor
housing 130 and contact the electric motor 132. Therefore, various seals whose
function is to
prevent the passage of water into the motor housing 130 are distributed at
various locations.
For example, the rotor shaft 142 is surrounded by spring seal components 144
and 145 whose
Date Recue/Date Received 2022-03-30
89622410 (89003-210D1)
function is to prevent the conducting of water into the motor housing 130. The
rotor shaft
142 is also equipped with bearings that facilitate its rotation.
A partial rim member 160 is attached to the motor housing 130 at the motor
housing lateral
surface 134 and extends between a circuit board-mounted controller 190 and the
motor
housing 130. The partial rim member 160 is shaped so that it generally fits
the contours of
the motor housing lateral surface 134 of the motor housing 130 on a first
surface and
supports the circuit board-mounted controller 190 on the other. The circuit
board-mounted
controller 190 is in communication with the electric motor 132 within the
motor housing 130
to supply electric current to operate the electronic motor 132. The circuit
board as well as the
electric motor 132 generate heat during operation.
Mounting brackets 220A 220B are also attached to the motor housing 130 on the
motor
housing lateral surface 134. The pump mounting brackets 220A 220B function to
fixedly
secure the pump assembly 110 at its desired installed location within a spa by
a series of
mechanical fasteners (shown in FIG. 13).
Pump cooling features
The motor housing 130 is located in what is referred to as the pump dry
section 114,
indicating that water from the bathing unit system 10 is prevented from making
contact with
the electric motor 132 within.
FIG. 5 and FIG. 6 show perspective assembled and exploded views, respectively,
of some of
the components of the pump assembly 110 that are involved in the heat exchange
process to
transfer heat away from the motor housing 130 and the circuit board mounted
controller 190
towards water circulating through the pump assembly. A typical installation
would be, as
previously mentioned, in conjunction with a hot tub, spa or therapy pool.
Typically, the
water within these types of tubs is constantly being recirculated. The
movement of the water
through the recirculating system is accomplished by a pump with the pump
assembly 110
21
Date Recue/Date Received 2022-03-30
89622410 (89003-210D1)
being such a pump. Electrical power is supplied to the stator 148 and rotor
146 of the
electric motor 132 which results in the rotor 146 and the rotor shaft 142
rotating. This
rotation causes rotation of the impeller 140 which results in water being
pumped from the
water inlet port 124 to the water outlet port 126 in the wet-end housing 120
of the pump
assembly 110.
The operation of the electric motor 132 generates heat within the motor
housing 130. This
heat is transferred from within the motor housing 130 to the water travelling
through the wet-
end housing 120 along a first thermal conductive path. This heat transfer
takes place across
the heat transfer interface 150 that is positioned at the motor housing front
end 136.
The motor housing 130 has a flange member forming a rim 128 160 about the
front end 136
of the motor housing 120. When the heat transfer interface 150 is assembled
with the motor
housing 130, the heat transfer interface 150 fits around and is supported by
the flange
member. While in some embodiments, the rim formed by the flange member may be
constructed as a single unitary piece, in the specific example depicted, the
rim formed by the
flange member includes a first partial rim member 128 and a second partial rim
member 160
distinct from the first partial rim member 128 so that there is a
discontinuity between the first
partial rim member 128 and the second partial rim member 160 when they are
positioned
next to one another to form the rim.
As best shown in FIG. 6, in the embodiment depicted, the first partial rim
member 128 is
formed as a unitary piece of the motor housing body and has a missing arc
where portion is
flat with the rest of the surface of the motor housing 130. This missing arc
is filled by the
second partial rim member 160, which is a separately machined or die-casted
component of
the motor housing 120 so that when the second partial rim member 160 and the
motor
housing 130 are assembled, the first partial rim member 128 and the second
partial rim
member 160 form a near complete arc around the perimeter of the motor housing
front end
136, as seen in FIG. 5.
22
Date Recue/Date Received 2022-03-30
89622410 (89003-210D1)
FIGS. 7A and 7B show front and side views of the heat transfer interface 150.
The heat
transfer interface 150 has a heat transfer interface body 154 that is
generally circular in shape
in the embodiment shown. The heat transfer interface body 154 is sized and
shaped to fit
over and to cover the motor housing front end 136, acting as an end cap that
covers the
water-facing end of the motor housing 130.
The heat transfer interface 150 includes a first surface engaged with the
front end of the
motor housing and a second surface opposed to the first surface, wherein when
the pump
assembly is in use, at least a portion of the second surface is exposed to
water flowing
through the wet-end housing.
The central aperture 152 of the heat transfer interface 150 permits the rotor
shaft 142 of the
electric motor 132 to extend through the heat transfer interface body 154 and
mate with a rear
surface of the impeller 140. The heat transfer interface 150 also includes a
protrusion 159
that is sized and shaped to accommodate the positioning and movement of the
spring seal
144 and 145 on the rotor shaft 142. In the example depicted, the heat transfer
interface 150
also includes a side ground connector ring 158 for facilitating grounding the
heat transfer
interface 150.
When assembled with the motor housing 130, the heat transfer interface 150 is
fixed to the
motor housing 130 on its back surface, with the rotor shaft 142 of the
electric motor 132
passing through the central aperture 152. The impeller 140 is positioned for
rotation near the
front surface of the heat transfer interface 150. As best seen in FIG. 4, the
impeller 140 is not
flush with the front surface of the heat transfer interface 150. Instead,
there is a gap 156
between the front surface of the heat transfer interface 150 and the rear
surface of the
impeller 140, that allows the water circulating in the wet-end housing 120 to
contact the front
surface of the heat transfer interface 150. This contact facilitates heat
transfer between the
23
Date Recue/Date Received 2022-03-30
89622410 (89003-210D1)
electric motor 132 and the recirculating water as heat flows from the electric
motor 132 to the
water along a first thermal conductive path.
The heat transfer interface 150 may be coupled to the front end of the motor
housing using
any suitable fastening technique including, without being limited to, an
induction heat
shrinking process, a welding process, a brazing process, through the use of an
adhesive
and/or using one or more mechanical fasteners, such as clamps, screws and the
like.
In specific implementations, the heat transfer interface 150 may be made of
different types of
materials. In some implementations, the heat transfer interface 150 may be
made of a
thermally conductive material, such as but not limited to, a material that
includes copper
and/or aluminum. While such materials can provide useful thermal conduction
properties,
since the heat transfer interface 150 is in contact with water from the
bathing unit, and since
such water may contain corrosive materials (such as salts and chemicals), the
heat transfer
interface 150 may need to be replaced more frequently due to wear.
As such, in practical implementations, it may be desirable that the material
of the heat
transfer interface 150 not corrode and is chemical-resistant to prolong the
life of the heat
transfer interface 150 in operation even if the thermal conductivity of the
material used may
be lower than materials such as copper and/or aluminum. For example, the heat
transfer
interface 150 can be made of a material such as stainless steel, or titanium.
While such
materials are not typically considered to have good thermal conduction
properties, it has been
found that their respective levels of conduction can be sufficiently suitable
to establish a
thermal conduction path between the motor housing 130 and the wet-end housing
120. In
addition, materials such a stainless steel and titanium are generally
resistant to corrosion and
thus, since the heat transfer interface 150 is at least partially in contact
with water containing
corrosive materials, the use of such materials may extend the useful life of
the pump
assembly 110 and/or may reduce the frequency of required repairs and
maintenance.
24
Date Recue/Date Received 2022-03-30
89622410 (89003-210D1)
The thickness of the heat transfer interface 150 may vary between
implementations however
it has been found that thinner designs have improved heat transfer properties
in particular
where the material used to make the heat transfer interface 150 has a lower
thermal
conductivity. In specific examples of implementation, the heat transfer
interface 150 is made
of aluminum and has an average thickness of less than 2 mm thick; e.g., less
than 1.5 mm;
less than 1 mm; less than 0.5 mm. In a non-limiting example of implementation,
the average
thickness of the heat transfer interface 150 is selected to be about 1.016mm
(which
corresponds to approximately 0.040") and the material is selected to be
stainless steel.
A thermal interface material with a higher thermal conductivity than that of
air may be used
to fill at least some voids between the first surface of the heat transfer
interface 150 and the
motor housing front end 136, to improve the thermal conductivity between the
heat transfer
interface 150 and the motor housing front end 136. This improvement occurs as
the material
fills any voids created by surface roughness effects, defects and misalignment
between the
transfer interface 150 and the motor housing front end 136. This filling
allows heat transfer to
occur due to conduction across the actual (solid) contact area rather than by
conduction (or
natural convection) and radiation across the gaps. Properly applied thermal
interface
materials displace the air that is present in the gaps between the two objects
with a material
that has a much higher thermal conductivity (e.g., 0.3 W/m=K and higher
compared has a
thermal conductivity of 0.022 Wim=K for air).
Various types of suitable thermal interface materials may be used such as a
thermal gap filler
material, including but not limited to thermal pastes and thermal pads.
Thermal paste is also
called thermal compound, thermal grease, thermal interface material, thermal
gel, heat
paste, heat sink compound, or heat sink paste. Generally, selection of a
thermal interface
material is based on the interface gap which the material must fill, the
contact pressure, and
the electrical resistivity of the thermal interface material. In some
embodiments, such pastes
can include particles of different sizes and different thermal conductivities,
which may be
Date Recue/Date Received 2022-03-30
89622410 (89003-210D1)
suspended in a suitable binder such as, but without being limited to, a
silicone binder or a
ceramic binder.
Specific non-limiting examples of thermal pastes for use between the first
surface of the heat
transfer interface 150 and the motor housing front end 136 include silicone
based thermal
pastes, ceramic-based thermal pastes, metal-based pastes, carbon-based pastes,
diamond
carbon pastes and liquid metal-based thermal paste.
It is noted that, while in the embodiments described with reference to the
Figures, the heat
transfer interface 150 is a component distinct from the motor housing 130, in
alternate
embodiments the heat transfer interface 150 may form an integral physical part
of the motor
housing 130. For example, the heat transfer interface 150 may be permanently
attached to
the motor housing 130, for example using welding, brazing of lamination
process.
Alternatively, the motor housing 130 itself may be made from a material
resistant to
corrosion and therefore the front portion of the motor housing 130 itself may
behave as a heat
transfer interface.
Referring back to FIGS. 5 and 6 heat is also generated by the circuit board
mounted
controller 190 that is exterior to the motor housing 130. The heat generated
by the circuit
board mounted controller 190 must be dissipated to prevent damage and/or
premature failure
of the electronic components. Rather than using conventional large fin-based
heat sinks to
dissipate heat in the air, the heat generated by the circuit board mounted
controller 190 is
transmitted through the heat transfer interface 150 to the water flowing
through the wet-end
housing 120 and thereby used as a source heat for the water in the bathing
unit system.
In the embodiment depicted in the figures, the thermal conductive path between
the circuit
board mounted controller 190 and the wet-end housing 120 is distinct from the
thermal
conductive path between the motor housing 130 and the wet-end housing 120.
26
Date Recue/Date Received 2022-03-30
89622410 (89003-210D1)
Referring as well to FIGS. 8A and 8B, the separate the first partial rim
member 128 and the
second partial rim member 160 acts to partially thermally insulate the circuit
board-mounted
controller 190 and the motor housing 130 from each other by creating a
discontinuity in the
thermal conductivity between the circuit board mounted controller 190 and the
motor
housing.
In the embodiment depicted, the second partial rim member 160 has a heat sink
portion with
a (top) a controller-facing side 162, a (bottom) motor-housing-facing side
164, and a
forward-facing edge or lip 166. The controller-facing side 162 includes
various surface
features 168 shaped and sized to mate with and support components of the
circuit board-
mounted controller 190. A wire access hole 170 is provided through the body of
the second
partial rim member 160 from the motor-housing-facing side 164 to the
controller-facing side
162 to permit wires (not shown) to pass therethrough. These wires enable
electric power to
flow between the electric motor 132 inside the motor housing 130 and the
elements of the
circuit board-mounted controller 190. In some embodiments the second partial
rim member
160 may be made of the same material as the motor housing 130. In some
embodiments the
second partial rim member 160 is made of aluminum.
As best shown in FIG. 8B, the motor-housing-facing side 164 of the second
partial rim
member 160 is curved. The curvature of the motor-housing-facing side 164 is
chosen to
generally match the curvature of the motor housing lateral surface 134 such
that the motor-
housing-facing side 164 contours to the motor-housing-facing side 134.
In some embodiments, the second partial rim member 160 is separate from the
motor housing
130, as shown in FIGS. 3 and 6. In such embodiments, the second partial rim
member 160
can be attached to the motor housing, e.g., by mechanical fasteners such as
screws.
The lip 166 of the second partial rim member 160 is in the shape of an arc on
the forward-
facing front surface of the second partial rim member 160. As best seen in
FIGS. 5 and 6,
27
Date Recue/Date Received 2022-03-30
89622410 (89003-210D1)
when the second partial rim member 160 is assembled with the motor housing
130, the lip
166 fits into the missing portion of first partial rim member 128 of the motor
housing front
end 136. The lip 166 is an arc that fills the mission portion of the first
partial rim member
128 such that when assembled, second partial rim member 160 and the first
partial rim
member 128 together form a rim around the perimeter of the motor housing front
end 136.
As mentioned above, the second partial rim member 160 is configured to
thermally insulate
the circuit board-mounted controller 190 and the motor housing 130 from each
other. This
thermal insulation is accomplished in various manners. In the embodiment
shown, the
second partial rim member 160 is a separate part from the motor housing 130.
When
assembled, the second partial rim member 160 and the motor housing 130 are
physically
attached; however, the second partial rim member 160 being a separate part
from the motor
housing 130 causes a thermal discontinuity at the points where the two parts
touch. This
discontinuity results in at least a partial decoupling of the heat conduction
between the motor
housing 130 and the circuit board-mounted controller 190.
Other embodiments of the second partial rim member 130 thermally insulate the
circuit
board-mounted controller 190 from the motor housing 130 are also possible.
For example, a thermal insulation layer may be provided between the circuit
board-mounted
controller 190 and the motor housing 130, for example on a lower surface of
the second
partial rim member 160, to reduce an amount of heat transfer between the
circuit board-
mounted controller 190 and the motor housing130. The thermal insulation layer
may
comprise one or more air gaps between the circuit board-mounted controller 190
and the
motor housing 130 and/or it may comprise a thermal insulating material between
the
controller module and the motor housing.
For example, FIG. 9A shows an embodiment of the second partial rim member 160,
namely
second partial rim member 160B that is similar to the partial rim member 160,
with
28
Date Recue/Date Received 2022-03-30
89622410 (89003-210D1)
additional heat insulation features on a motor-housing-facing side 164B. The
heat insulation
features as shown include a thermal separation gap 174. The thermal separation
gap 174 is
a blind hole that thins the body of the second partial rim member 160B such
that there is an
air gap between that portion of the motor-housing-facing side 164B of the
second partial rim
member 160B and the motor housing lateral surface 134. This air gap enhances
the thermal
insulation of the two parts.
The additional heat insulation features on a rear side of the second partial
rim member 160
can take other forms. For example, FIG. 9B shows another embodiment of the
second partial
rim member 160, namely second partial rim member 160C that is similar to the
partial rim
member 160, where the additional heat insulation features on a motor-housing-
facing side
164C include of a thermal separation groove 176. The thermal separation groove
176 is a
blind hole that thins the body of the second partial rim member 160C such that
there is an air
gap between that portion of the motor-housing-facing side 164C and the motor
housing
lateral surface 134. Other arrangements are also possible. For example, the
additional heat
insulation features can be circular, rather than generally rectangular as
shown, or any other
shape such an octagon-based prism, or can be a series of prongs, etc.
Referring to FIG. 10, in some embodiments a thermal insulation layer 180
comprising a
thermal insulating material is provided to enhance the thermal insulation of
the partial rim
member 160 and the attached circuit board-mounted controller 190. The thermal
insulation
layer 180 can be made of any suitable thermally insulating material such as
plastic, mylar,
KevlarTM, fiberglass, adhesives or any materials. The thickness of the thermal
insulation
layer 180 can vary between implementations and depending on the type of
material used as
well as the desired amount of insulation to be achieved. In a specific
practical
implementation, a thermal insulation layer made of a plastic material and
having a thickness
between 0.5 mm and 2 mm is used.
29
Date Recue/Date Received 2022-03-30
89622410 (89003-210D1)
When assembled as shown in FIG. 5, the heat transfer interface 150 is in
contact with the
flange 128 of the motor housing 130 and with the lip 166 of the partial rim
member 160. The
recirculating water is supplied into water inlet port 124 into the pump
assembly 110 and then
out via the water outlet port 126 under force of the impeller 140 in the wet-
end housing 120.
Heat generated from the circuit board-mounted controller 190 and from the
electric motor
132 within the motor housing 130 is transferred via the heat transfer
interface 150 to the
water flowing past its front face in the second thermal conduction path.
FIGS. 11A and 11B illustrate the effectiveness of use of the second partial
rim member 160.
FIG. 11A is a computer software-generated thermal heat map of a motor housing
130 where
the second partial rim member 160 and the first partial rim member 128 are
constructed as a
unitary piece (thus eliminating the discontinuity in thermal conductivity) and
where there is
very little or no thermal insulation between the circuit board-mounted
controller 190 and the
motor housing 130. FIG. 11B is a thermal heat map of the motor housing 130
with the
second partial rim member 160 described with reference to FIGs. 8A to 10. As
can be
observed, the overall temperature distribution is much wider for the
traditional motor casing
of FIG. 11A with temperatures ranging from approximately 310K(Kelvin) to
approximately
365K. By contrast, the simulation results of the second partial rim member 160
assembled
with the motor housing 130 shown in FIG. 11B show a temperature range of
between
approximately 310K and 350K. The temperature range in the region of the second
partial rim
member 160 is also generally lower in FIG. 11B, roughly 2-3K lower than the
equivalent
region in FIG. 11A.
While the pump assembly 110 is being operated, there is a constant steady flow
of water
through the front casing 122. For a typical bathing unit system, the amount of
heat generated
from the pump assembly 110 may complement dedicated heaters in the system and
help
maintain the water temperature at a desired temperature level while reducing
the energy
requirement for operating additional heaters in the bathing unit system.
Date Recue/Date Received 2022-03-30
89622410 (89003-210D1)
Pump mounting brackets 220A 220B
FIG. 12 shows a rear isometric view of the pump assembly 110 of FIG. 2 and
FIG. 13 shows
a similar view of the pump assembly 110 with the external casing 112 removed.
Visible in
FIG. 12 is a surface mounting bracket 210 and a pump mounting bracket 220B.
Referring to FIGS. 13A and 13B, in the embodiment shown, the pump assembly 110
includes two pump mounting brackets 220A, 220B. The two pump mounting brackets
220A,
220B are positioned at different angles along the circumference of the motor
housing 130 and
are configured for mounting the pump assembly 110 to the bathing unit system
at a desired
location and orientation. That is, the pump assembly 110 is mounted to a
desired supporting
structure, for example to a structure underneath the spa skirt, so that the
water outlet port
126 is directed differently, e.g., so that water exits from the water outlet
port 126 upwards in
FIG. 13A and to the right in FIG. 13B. Each of the pump mounting brackets
220A, 220B is
positioned at a different radial location on the motor housing 130 (and
protrudes through the
external casing 112 at a different radial location), the first radial location
of the first pump
mounting bracket 220A being distinct from the second radial location of the
second pump
mounting brackets 220B. This arrangement permits the pump assembly 110 to be
fastened to
the surface mounting bracket 210 at two different angles corresponding to the
first radial
location and second radial location.
Although two pump mounting brackets 220A, 220B are shown at 90 degrees from
each
other, differing numbers of mount portions positioned at different radial
locations along the
motor housing 130 are also possible in alternative implementations in order to
provide
varying levels of flexibility in the orientation of the water outlet port 126.
For example, three
pump mounting brackets can be positioned at 90 degrees from each other or pump
mounting
brackets can be positioned at 45 degrees from each other. Alternatively, the
pump mounting
brackets can be unevenly spaced and may be positioned at varying angles, e.g.,
pump
mounting brackets can be positioned at 90 degrees and a third pump mounting
bracket can be
positioned at 45 degrees, at 30 degrees or at any suitable radial location
about the
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89622410 (89003-210D1)
circumference of the motor housing 130. Four or more pump mounting brackets
are also
possible.
Each pump mounting bracket 220 extends from the motor housing lateral surface
134
through the external casing 112 and is configured to mate with the surface
mounting bracket
210. Referring as well to FIG. 14, the pump mounting bracket 220 engages with
a slot 214
of the surface mounting bracket 210. When so fitted, screw holes 222 in the
body of the
pump mounting bracket 220 align with screw holes 212 of the wall mount
portion, and
mechanical fasteners 240 affix the portions of the mounting bracket together.
The
mechanical fasteners 240 can be screws or any other suitable fasteners. Wall
fastener slots
216 permit the pump assembly 110 to be attached to a supporting structure at
the desired
orientation, such as to a wall or to a wooden frame in the spa.
As seen in FIGS. 13A and 13B, the mechanical fasteners 240 are oriented so
that they
connect the surface mounting bracket 210 and pump mounting bracket 220 at an
angle
orthogonal to the circumference of the motor housing 130. That is, the
mechanical fasteners
240 are not oriented normal to or "into" the supporting structure (as
fasteners fastened in
slots 216 would be), but rather along an axis that extend longitudinally along
at least part of
the supporting structure. This orientation of the mechanical fasteners 240
beneficially
reduces transmission of vibrations from the pump assembly 110 to the
supporting structure to
which is mounted the pump assembly 110 and may therefore reduce vibrations
that would be
felt by a user using the bathing unit system 10 (shown in FIG. 1).
In the embodiment shown in FIG. 14, a rubber pad 230 is affixed to the surface
mounting
bracket 210. The rubber pad 230 covers a generally arcuate top surface 224 of
the mounting
bracket 210 and, optionally, at least a part of the surface within the slot
214. The rubber pad
230 thus separates the surface mounting bracket 210 from the pump mounting
bracket 220
when the two are joined. This separation aids in vibrational insulation of the
pump assembly
110, as the rubber pad 230 functions to absorb vibrations generated by the
motor.
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89622410 (89003-210D1)
Additionally, the rubber pad 230 aids the installer of the pump assembly,
allowing some
freedom of movement when mounting the pump assembly 110. In some embodiments,
the
rubber pad 230 is made of rubber.
In addition, although the embodiments discussed make use of a generally
cylindrical outer
surface for the motor body and corresponding circulate shape for the arcuate
member of the
mounting bracket, other suitable surfaces shapes, such as for example but
without being
limited to octagonal or pentagonal shapes may be used in alternate
embodiments. In such
embodiments, the rotation of the mounting bracket about the circumference of
the motor
body may require that the mounting bracket be disengaged from the motor body,
rotated and
then re-engaged at the desired angle.
Certain additional elements that may be needed for operation of some
embodiments have not
been described or illustrated as they are assumed to be within the purview of
those of
ordinary skill in the art. Moreover, certain embodiments may be free of, may
lack and/or may
function without certain elements disclosed herein.
All references cited throughout the specification are hereby incorporated by
reference in their
entirety for all purposes.
It will be understood by those of skill in the art that throughout the present
specification, the
term "a" used before a term encompasses embodiments containing one or more to
what the
term refers. It will also be understood by those of skill in the art that
throughout the present
specification, the term "comprising", which is synonymous with "including,"
"containing,"
or "characterized by," is inclusive or open-ended and does not exclude
additional, un-recited
elements or method steps.
Unless otherwise defined, all technical and scientific terms used herein have
the same
meaning as commonly understood by one of ordinary skill in the art to which
this invention
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Date Recue/Date Received 2022-03-30
89622410 (89003-210D1)
pertains. In the case of conflict, the present document, including definitions
will control. As
used in the present disclosure, the terms "around", "about" or "approximately"
shall
generally mean within the error margin generally accepted in the art. Hence,
numerical
quantities given herein generally include such error margin such that the
terms "around",
"about" or "approximately" can be inferred if not expressly stated.
Although the present invention has been described in considerable detail with
reference to
certain embodiments thereof, variations and refinements are possible and will
become
apparent to the person skilled in the art in view of the present description.
The invention is
defined more particularly by the attached claims.
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Date Recue/Date Received 2022-03-30
