BOOSTER PUMP DRIVE ATTACHMENT

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to U.S. Provisional Application No. 63/717,394, filed on Nov. 7, 2024, entitled “BOOSTER PUMP DRIVE ATTACHMENT,” and U.S. Provisional Application No. 63/728,826, filed on Dec. 6, 2024, entitled “BOOSTER PUMP DRIVE ATTACHMENT,” and U.S. Provisional Application No. 63/871,917, filed on Aug. 28, 2025, entitled “BOOSTER PUMP DRIVE ATTACHMENT,” the entire contents of which being expressly incorporated herein by reference.

FIELD OF THE DISCLOSURE

The present disclosure pertains to booster pumps, and more specifically to a configuration for mounting a drive box to a booster pump.

BACKGROUND

Residential water pressure may vary from place to place and time to time for a variety of reasons. Low water pressure, for example pressure below approximately 40 psi, may be frustrating for users of water delivery mechanisms such as shower heads, faucets, etc. Some low water pressure instances are a result of blockages or leaks in the plumbing of the residential structure. Other instances occur because the residential water source provides low water pressure. In these instances, one solution for the problem of low water pressure is a residential water pressure booster.

Generally speaking, water pressure boosters are installed in the home or garage and plumbed to the incoming main water source. The boosters include a pump that increases the pressure of the incoming water and one or more outlets that route the higher-pressure water to one or more water delivery mechanisms. Many such boosters can control the higher-pressure water to a substantially constant pressure, regardless of variations in the pressure of the main water source or variations in demand by the water delivery mechanisms.

The operation of water pressure boosters is generally controlled by control electronics in a drive box of the booster, which may receive input from a user through an interface of the booster. The drive box electronics generally provide power to, control the functions of, and receive signals from the interface, the pump and other electronic components of the booster. This generates heat within the drive box which, if not sufficiently dissipated, may damage the drive box and/or degrade its performance. Accordingly, it is desirable to provide an approach for attaching a drive box to a water pressure booster that provides for heat transfer away from the drive box.

SUMMARY

According to one embodiment, the present disclosure provides a system for mounting a drive box to a water pressure booster pump having a cylindrical pump shell, comprising: a housing including a rear wall; at least one adhesive pad extending from the rear wall of the housing and including a rearward surface having a radius of curvature that substantially corresponds to a curvature of an outer surface of the cylindrical pump shell; and adhesive applied to the rearward surface of the at least one adhesive pad and configured to connect the housing to the cylindrical pump shell and facilitate heat transfer from the drive box to the cylindrical pump shell. In one aspect of this embodiment, the at least one adhesive pad includes a first adhesive pad and a second adhesive pad each extending from the rear wall of the housing and including a rearward surface having a radius of curvature that substantially corresponds to the curvature of the outer surface of the cylindrical pump shell. In a variant of this aspect, the first and second adhesive pads are substantially aligned along a central portion of the rear wall of the housing. In another aspect, the at least one adhesive pad includes at least one spacer that extends beyond the rearward surface of the at least one adhesive pad, the at least one spacer being configured to engage the cylindrical pump shell to control a thickness of the adhesive between the at least one adhesive pad and the cylindrical pump shell. In another variant, the at least one adhesive pad includes a third adhesive pad extending from the rear wall of the housing between the first and second adhesive pads. In another aspect, the housing further includes a plurality of projections extending from the rear wall beyond the rearward surface of the at least one adhesive pad and terminating in a first plane that is substantially parallel to a second plane including the rear wall of the housing. In another aspect, the system further comprises: a plurality of flexible clips including a first flexible clip and a second flexible clip, the first and second flexible clips each including an attachment segment; wherein the housing further includes a plurality of tabs including a first tab and a second tab each extending from the rear wall of the housing; wherein the attachment segment of the first flexible clip is coupled to the first tab to connect the first flexible clip to the first tab, and the attachment segment of the second flexible clip is coupled to the second tab to connect the second flexible clip to the second tab. In a variant, the system further comprises: a plurality of clip fasteners including a first clip fastener and a second clip fastener; wherein the attachment segments of the first and second flexible clips each include a first opening; wherein the first and second tabs each include a second opening; and wherein the first clip fastener is configured to extend through the first opening of the attachment segment of the first flexible clip and into the second opening of the first tab to connect the first flexible clip to the first tab, and the second clip fastener is configured to extend through the first opening of the attachment segment of the second flexible clip and into the second opening of the second tab to connect the second flexible clip to the second tab. In a further variant, each of the second openings of the first and second tabs is threaded to receive a threaded shaft of one of the plurality of clip fasteners. In a further variant, each of the first and second clip fasteners includes a head and a threaded shaft extending from the head, and wherein the first and second flexible clips transition from an unflexed state to a flexed state when the first and second clip fasteners are threaded into the first and second tabs, respectively, as a result of the heads of the first and second clip fasteners drawing the attachment segments of the first and second flexible clips into engagement with the first and second tabs, respectively. In another variant, the first and second flexible clips each include a hook segment coupled to the attachment segment and positioned, when the first and second flexible clips are coupled to the first and second tabs, to capture a respective rod extending between a base and a discharge cover of the pump and apply a holding force to draw the housing of the drive box into engagement with the cylindrical pump shell. In another variant, each of the plurality of flexible clips includes an extension segment connected to the attachment segment of the flexible clip by a first transition segment, the extension segment being positioned in a substantially perpendicular orientation relative to the attachment segment. In another variant, each of the plurality of flexible clips includes a return segment connected to the extension segment by a second transition segment, the return segment being positioned at an obtuse angle relative to the extension segment. In another variant, the hook segment of each of the plurality of flexible clips is connected to the return segment by a third transition segment, the hook segment being positioned in a substantially perpendicular orientation relative to the return segment. In another variant, the first tab extends outwardly from a first side of the drive box and the second tab extends outwardly from a second side of the drive box that is opposite the first side. In another variant, the first and second flexible clips transition from an unflexed state to a flexed state when the first and second flexible clips are coupled to the first and second tabs, respectively. In another variant, the housing further includes: a plurality of upper tabs including a first upper tab and a second upper tab, each of the first and second upper tabs being coupled to a discharge cover of the pump, thereby securing the drive box to the discharge cover of the pump. In another variant, the housing further includes: a plurality of upper tabs including a first upper tab extending outwardly from a first side of the housing and a second upper tab extending outwardly from a second side of the housing opposite the first side of the housing, each of the first and second upper tabs including a threaded opening; and a plurality of discharge cover fasteners including a first discharge cover fastener and a second discharge cover fastener, the first discharge cover fastener being configured to extend through a first flange of a discharge cover of the pump into the threaded opening of the first upper tab and the second discharge cover fastener being configured to extend through a second flange of the discharge cover of the pump into the threaded opening of the second upper tab, thereby securing the drive box to the discharge cover of the pump.

In another embodiment, the present disclosure provides a water pressure booster pump, comprising: a base having an inlet configured to receive incoming water, an outlet configured to deliver outgoing water, and a shell collar configured to receive a lower end of a cylindrical pump shell; a pump/motor assembly (“PMA”) positioned within the cylindrical pump shell and including a motor that drives a plurality of impellers to pressurize the incoming water, wherein the incoming water flows around a portion of the PMA in a gap between the PMA and the cylindrical pump shell; a discharge cover configured to receive an upper end of the cylindrical pump shell and route the pressurized incoming water from the PMA to a sensor pipe in flow communication with the outlet of the base; a plurality of rods extending between the base and the discharge cover to clamp the base and the discharge cover to the cylindrical pump shell; a drive box for controlling operation of the PMA, the drive box including an outer cover attached to a housing, the housing including a rear wall; a plurality of adhesive pads including a first adhesive pad and a second adhesive pad each extending from the rear wall of the housing and including a rearward surface having a radius of curvature that substantially corresponds to a curvature of an outer surface of the cylindrical pump shell; and adhesive applied to the rearward surfaces of the first and second adhesive pads and configured to connect the housing to the cylindrical pump shell and facilitate heat transfer from the drive box to the cylindrical pump shell. In one aspect of this embodiment, the first and second adhesive pads are substantially aligned along a central portion of the rear wall of the housing. In another aspect, the first and second adhesive pads each include at least one spacer that extends beyond the rearward surfaces of the first and second adhesive pads, the at least one spacer being configured to engage the cylindrical pump shell to control a thickness of the adhesive between the first and second adhesive pads and the cylindrical pump shell. In another aspect, the plurality of adhesive pads includes a third adhesive pad extending from the rear wall of the housing between the first and second adhesive pads. In another aspect, the pump further comprises: a first flexible clip and a second flexible clip, each of the first and second flexible clips having an attachment segment; wherein the housing further includes a first tab and a second tab, each of the first and second tabs extending from the rear wall of the housing; wherein the attachment segment of the first flexible clip is coupled to the first tab to connect the first flexible clip to the first tab, and the attachment segment of the second flexible clip is coupled to the second tab to connect the second flexible clip to the second tab. In a variant of this aspect, the first and second flexible clips each include a hook segment coupled to the attachment segment and positioned, when the first and second flexible clips are coupled to the first and second tabs, to capture a respective one of the plurality of rods extending between the base and the discharge cover and apply a holding force to draw the mount of the drive box into engagement with the cylindrical pump shell. In another variant, each of the first and second flexible clips includes an extension segment connected to the attachment segment of the flexible clip by a first transition segment, the extension segment being positioned in a substantially perpendicular orientation relative to the attachment segment. In another variant, each of the first and second flexible clips includes a return segment connected to the extension segment by a second transition segment, the return segment being positioned at an obtuse angle relative to the extension segment. In another variant, the hook segment of each of the first and second flexible clips is connected to the return segment by a third transition segment, the hook segment being positioned in a substantially perpendicular orientation relative to the return segment. In another variant, the pump further comprises: a plurality of clip fasteners including a first clip fastener and a second clip fastener; wherein the attachment segments of the first and second flexible clips each include a first opening; wherein the first and second tabs each include a second opening; and wherein the first clip fastener is configured to extend through the first opening of the attachment segment of the first flexible clip and into the second opening of the first tab to connect the first flexible clip to the first tab, and the second clip fastener is configured to extend through the first opening of the attachment segment of the second flexible clip and into the second opening of the second tab to connect the second flexible clip to the second tab. In a further variant, each of the second openings of the first and second tabs is threaded to receive a threaded shaft of one of the first and second clip fasteners. In a further variant, each of the first and second clip fasteners includes a head and a threaded shaft extending from the head, and wherein the first and second flexible clips transition from an unflexed state to a flexed state when the first and second clip fasteners are threaded into the first and second tabs, respectively, as a result of the heads of the first and second clip fasteners drawing the attachment segments of the first and second flexible clips into engagement with the first and second tabs, respectively. In a further variant, the first tab extends outwardly from a first side of the drive box and the second tab extends outwardly from a second side of the drive box that is opposite the first side. In a further variant, the first and second flexible clips transition from an unflexed state to a flexed state when the first and second flexible clips are coupled to the first and second tabs, respectively. In a further variant, the housing further includes: a plurality of upper tabs including a first upper tab and a second upper tab, each of the first and second upper tabs being coupled to the discharge cover of the pump, thereby securing the drive box to the discharge cover of the pump. In a further variant, the housing further includes: a plurality of upper tabs including a first upper tab extending outwardly from a first side of the housing and a second upper tab extending outwardly from a second side of the housing opposite the first side of the housing, each of the first and second upper tabs including a threaded opening; and a plurality of discharge cover fasteners including a first discharge cover fastener and a second discharge cover fastener, the first discharge cover fastener being configured to extend through a first flange of the discharge cover of the pump into the threaded opening of the first upper tab and the second discharge cover fastener being configured to extend through a second flange of the discharge cover of the pump into the threaded opening of the second upper tab, thereby securing the drive box to the discharge cover of the pump.

In another embodiment, the present disclosure provides a method for mounting a drive box to a water pressure booster pump, comprising: applying an adhesive to at least one adhesive pad extending from a rear wall of a housing of the drive box; connecting a plurality of flexible clips to a corresponding plurality of tabs extending from the housing of the drive box by passing a plurality of clip fasteners through first openings in the plurality of flexible clips and threading the plurality of clip fasteners into second openings in the plurality of tabs; placing the at least one adhesive pad on an outer surface of a cylindrical pump shell of the pump and aligning a plurality of upper tabs extending from sides of the housing with a corresponding plurality of flanges of a discharge cover coupled to the cylindrical pump shell; clipping the plurality of flexible clips over a corresponding plurality of rods extending between the discharge cover and a base of the pump; connecting the housing to the discharge cover by passing a plurality of discharge cover fasteners though third openings in the plurality of flanges and threading the plurality of discharge cover fasteners into fourth openings in the plurality of upper tabs; and further threading the plurality of clip fasteners into the second openings of the plurality of tabs to draw the plurality of flexible clips into contact with the plurality of tabs, thereby deforming the plurality of flexible clips and applying a holding force to maintain the at least one adhesive pad in contact with the outer surface of the cylindrical pump.

In yet another aspect, the present disclosure provides a water pressure booster pump, comprising: a base having an inlet configured to receive incoming water, an outlet configured to deliver outgoing water, and a shell collar configured to receive a lower end of a cylindrical pump shell; a pump/motor assembly (“PMA”) positioned within the cylindrical pump shell and including a motor that drives at least one impeller to pressurize the incoming water, wherein the incoming water flows around a portion of the PMA in a gap between the PMA and the cylindrical pump shell; a discharge cover configured to receive an upper end of the cylindrical pump shell and route the pressurized incoming water from the PMA to a sensor pipe in flow communication with the outlet of the base; a plurality of rods extending between the base and the discharge cover to clamp the base and the discharge cover to the cylindrical pump shell; a drive box for controlling operation of the PMA, the drive box including an outer cover attached to a housing, the housing including a rear wall and a lower lug extending downwardly from the housing; at least one adhesive pad extending from the rear wall of the housing and including a rearward surface having a radius of curvature that substantially corresponds to a curvature of an outer surface of the cylindrical pump shell; and a strap configured to surround the lower lug and the shell collar to compress the housing against the cylindrical pump shell. In one aspect of this embodiment, at least one of the at least adhesive pad includes at least one spacer that extends beyond the rearward surface of the at least one adhesive pad, the at least one spacer being configured to engage the cylindrical pump shell to control one of a thickness of an adhesive or a compression of a solid thermal transfer pad between the at least one adhesive pad and the cylindrical pump shell. In another aspect, the pump further comprises an adhesive applied to the rearward surface of the at least one adhesive pad and configured to affix the at least one adhesive pad to the housing. In another aspect, the strap includes a body having a free end and a coupling, the coupling being configured to receive and retain the free end of the body to secure the strap around the lower lug and the shell collar. In another aspect, the pump further comprises: a first flexible clip and a second flexible clip, each of the first and second flexible clips having an attachment segment; wherein the housing further includes a first tab and a second tab, each of the first and second tabs extending from the rear wall of the housing; wherein the attachment segment of the first flexible clip is coupled to the first tab to connect the first flexible clip to the first tab, and the attachment segment of the second flexible clip is coupled to the second tab to connect the second flexible clip to the second tab. In a variant of this aspect, the first and second flexible clips each include a hook segment coupled to the attachment segment and positioned, when the first and second flexible clips are coupled to the first and second tabs, to capture a respective one of the plurality of rods extending between the base and the discharge cover and apply a holding force to draw the housing of the drive box into engagement with the cylindrical pump shell. In another variant, each of the first and second flexible clips includes an extension segment connected to the attachment segment of the flexible clip by a first transition segment, the extension segment being positioned in a substantially perpendicular orientation relative to the attachment segment. In another variant, each of the first and second flexible clips includes a return segment connected to the extension segment by a second transition segment, the return segment being positioned at an obtuse angle relative to the extension segment. In another variant, the hook segment of each of the first and second flexible clips is connected to the return segment by a third transition segment, the hook segment being positioned in a substantially perpendicular orientation relative to the return segment. In another variant, the pump further comprises: a plurality of clip fasteners including a first clip fastener and a second clip fastener; wherein the attachment segments of the first and second flexible clips each include a first opening; wherein the first and second tabs each include a second opening; and wherein the first clip fastener is configured to extend through the first opening of the attachment segment of the first flexible clip and into the second opening of the first tab to connect the first flexible clip to the first tab, and the second clip fastener is configured to extend through the first opening of the attachment segment of the second flexible clip and into the second opening of the second tab to connect the second flexible clip to the second tab. In another variant, each of the second openings of the first and second tabs is threaded to receive a threaded shaft of one of the first and second clip fasteners. In another variant, each of the first and second clip fasteners includes a head and a threaded shaft extending from the head, and wherein the first and second flexible clips transition from an unflexed state to a flexed state when the first and second clip fasteners are threaded into the first and second tabs, respectively, as a result of the heads of the first and second clip fasteners drawing the attachment segments of the first and second flexible clips into engagement with the first and second tabs, respectively. In another variant, the first tab extends outwardly from a first side of the drive box and the second tab extends outwardly from a second side of the drive box that is opposite the first side. In another aspect, the first and second flexible clips transition from an unflexed state to a flexed state when the first and second flexible clips are coupled to the first and second tabs, respectively. In another aspect, the housing further includes:

• • a plurality of upper tabs including a first upper tab and a second upper tab, each of the first and second upper tabs being coupled to the discharge cover of the pump, thereby securing the drive box to the discharge cover of the pump. In another aspect, the housing further includes: a plurality of upper tabs including a first upper tab extending outwardly from a first side of the housing and a second upper tab extending outwardly from a second side of the housing opposite the first side of the housing, each of the first and second upper tabs including a threaded opening; and a plurality of discharge cover fasteners including a first discharge cover fastener and a second discharge cover fastener, the first discharge cover fastener being configured to extend through a first flange of the discharge cover of the pump into the threaded opening of the first upper tab and the second discharge cover fastener being configured to extend through a second flange of the discharge cover of the pump into the threaded opening of the second upper tab, thereby securing the drive box to the discharge cover of the pump.

In yet another embodiment, the present disclosure provides a water pressure booster pump, comprising: a base having an inlet configured to receive incoming water, an outlet configured to deliver outgoing water, and a shell collar configured to receive a lower end of a cylindrical pump shell; a pump/motor assembly (“PMA”) positioned within the cylindrical pump shell and including a motor that drives at least one impeller to pressurize the incoming water, wherein the incoming water flows around a portion of the PMA in a gap between the PMA and the cylindrical pump shell; a discharge cover configured to receive an upper end of the cylindrical pump shell and route the pressurized incoming water from the PMA to a sensor pipe in flow communication with the outlet of the base; a plurality of rods extending between the base and the discharge cover to clamp the base and the discharge cover to the cylindrical pump shell; a drive box for controlling operation of the PMA, the drive box including an outer cover attached to a housing, the housing including a rear wall and a lower lug extending downwardly from the housing; at least one thermal transfer pad extending from the rear wall of the housing and including a rearward surface having a radius of curvature that substantially corresponds to a curvature of an outer surface of the cylindrical pump shell; and a strap configured to surround the lower lug and the shell collar to compress the at least one thermal transfer pad between the housing and the cylindrical pump shell.

In still another embodiment, the present disclosure provides a water pressure booster pump, comprising: a base having an inlet configured to receive incoming water, an outlet configured to deliver outgoing water, and a shell collar configured to receive a lower end of a cylindrical pump shell; a pump/motor assembly (“PMA”) positioned within the cylindrical pump shell and including at least one impeller to pressurize the incoming water, wherein the incoming water flows around a portion of the PMA in a gap between the PMA and the cylindrical pump shell; a discharge cover configured to receive an upper end of the cylindrical pump shell and route the pressurized incoming water from the PMA to a sensor pipe in flow communication with the outlet of the base; a plurality of rods extending between the base and the discharge cover to clamp the base and the discharge cover to the cylindrical pump shell; a drive box for controlling operation of the PMA, the drive box including an outer cover attached to a housing; and at least one clamp configured to substantially surround an outer surface of the cylindrical pump shell and couple to the housing of the drive box, thereby securing the drive box to the cylindrical pump shell to facilitate heat transfer from the drive box to the cylindrical pump shell. In one aspect of this embodiment, the at least one clamp includes a generally circular body, a pair of clamping ends and an attachment lug. In a variant of this aspect, the body includes a central opening with a diameter that is substantially the same as a diameter of the outer surface of the cylindrical pump shell. In another variant, the body includes a reinforcement rib that extends radially outwardly from an outer surface of the body along a perimeter of the body between the pair of clamping ends. In a further variant, the reinforcement rib includes a plurality of alignment segments configured to align the at least one clamp with the plurality of rods. In a further variant, each of the plurality of alignment segments includes a pair of protrusions that extend farther radially outwardly than a remainder of the reinforcement rib to define a notch. In a further variant, the notches of the plurality of alignment segments are spaced apart on the at least one clamp to correspond to a spacing of the plurality of rods. In another variant, each clamping end of the pair of clamping ends includes a connecting plate that extends radially outwardly from the body, at least one of the connecting plates including at least one through hole, the at least one through hole being configured to receive a fastener to draw the pair of clamping ends toward one another. In a further variant, when the pair of clamping ends are drawn toward one another, the diameter of the central opening of the body is reduced such that an inner surface of the at least one clamp comes substantially into contact with the outer surface of the cylindrical pump shell to position the drive box. In another aspect, the attachment lug of the at least one clamp includes an upper portion that extends above the body and a lug that extends radially outwardly from the body. In a variant of this aspect, the upper portion of the attachment lug includes a fastener that engages the outer surface of the cylindrical pump shell to locate the at least one clamp axially along the cylindrical pump shell. In another variant, the cylindrical pump shell includes at least one reinforcement groove, the fastener engages the at least one reinforcement groove. In another aspect, the housing of the drive box further includes an upper bracket and a lower bracket and the at least one clamp includes an upper clamp and a lower clamp. In a variant of this aspect, the attachment lug of the upper clamp includes a threaded hole configured to receive an upper fastener that connects the upper clamp to the upper bracket of the housing of the drive box. In further variant, the attachment lug of the lower clamp includes a threaded hole configured to receive a lower fastener that connects the lower clamp to the lower bracket of the housing of the drive box. In another aspect, the housing further comprises at least one heatsink pad extending from a rear wall of the housing and including a curved surface having a radius of curvature that substantially corresponds to a curvature of the outer surface of the cylindrical pump shell. In a variant of this aspect, the pump further comprises an adhesive applied to the curved surface to adhere the drive box to the cylindrical pump shell. In another aspect, the at least one clamp is formed from a resilient wire. In a variant of this aspect, the at least one clamp includes a generally circular body, a pair of clamping ends and an attachment loop. In a further variant, the body defines a central opening with a diameter that is substantially the same as a diameter of the outer surface of the cylindrical pump shell. In a further variant, each clamping end of the pair of clamping ends includes a connecting segment that extends radially outwardly from the body. In a further variant, each connecting segment includes a loop formed at an end of the connecting segment and defining an opening. In a further variant, the loops of the connecting segments are aligned and sized to receive a fastener to draw the connecting segments toward one another, thereby reducing the diameter of the central opening such that the at least one clamp engages the outer surface of the cylindrical pump shell to secure the drive box to the cylindrical pump shell. In another variant, the attachment loop of the at least one clamp includes a pair of extension segments and a catch segment that extends between the extension segments to form the attachment loop. In a further variant, the housing includes at least one bracket having a notch sized to receive the attachment loop. In another aspect of this embodiment, the at least one clamp includes a generally semi-circular body with a pair of L-shaped ends, the body including an inner surface that defines a central opening and an outer surface. In a variant of this aspect, the inner surface has a diameter that is substantially the same as the diameter of the outer surface of the cylindrical pump shell. In another variant, the body extends more than 180 degrees, but less than 360 degrees around the cylindrical pump shell. In another variant, each of the pair of L-shaped ends includes a stand-off segment that extends from the body substantially perpendicularly from the housing of the drive box when the at least one clamp is coupled to the housing. In a further variant, each of the pair of L-shaped ends includes a connecting segment that extends from and is substantially perpendicular to the stand-off segment, the connecting segment including at least one through hole configured to receive a fastener to connect the connecting segment to the housing. In a further variant, the housing includes a plurality of lateral tabs that extend from side walls of the housing, each of the lateral tabs including an opening configured to receive the fastener to connect the connecting segment to the lateral tab. In another variant, the housing further comprises at least one heatsink pad extending from a rear wall of the housing and including a curved surface having a radius of curvature that substantially corresponds to a curvature of the outer surface of the cylindrical pump shell. In a further variant, the pump further comprises an adhesive applied to the curved surface to adhere the drive box to the cylindrical pump shell. In another aspect of this embodiment, the at least one clamp includes a band having a strap that extends partially around and in contact with the cylindrical pump shell, over but not in contact with the plurality of rods, and around and in contact with the drive box. In a variant of this aspect, the band includes a pair of ends and a clip that connects one end of the pair of ends to another end of the pair of ends. In another variant, the at least one clamp further includes a spring element including a pair of engagement arms coupled to a biasing ridge, and wherein the strap is resiliently stretchable along a length of the strap. In a further variant, the spring element is configured to engage the outer surface of the cylindrical pump shell and be compressed against the cylindrical pump shell by the strap, which is stretched around the spring element. In another variant, the housing further comprises at least one heatsink pad extending from a rear wall of the housing and including a curved surface having a radius of curvature that substantially corresponds to a curvature of the outer surface of the cylindrical pump shell. In a further variant, the pump further comprises an adhesive applied to the curved surface to adhere the drive box to the cylindrical pump shell.

In still another embodiment, the present disclosure provides a water pressure booster pump, comprising: a base having an inlet configured to receive incoming water, an outlet configured to deliver outgoing water, and a shell collar configured to receive a lower end of a cylindrical pump shell; a pump/motor assembly (“PMA”) positioned within the cylindrical pump shell and including at least one impeller to pressurize the incoming water, wherein the incoming water flows around a portion of the PMA in a gap between the PMA and the cylindrical pump shell; a discharge cover configured to receive an upper end of the cylindrical pump shell and route the pressurized incoming water from the PMA to a sensor pipe in flow communication with the outlet of the base; a plurality of rods extending between the base and the discharge cover to clamp the base and the discharge cover to the cylindrical pump shell; a drive box for controlling operation of the PMA, the drive box including an outer cover attached to a housing; and at least one clamp configured to substantially surround an outer surface of the cylindrical pump shell and the drive box, thereby securing the drive box to the cylindrical pump shell; wherein the at least one clamp includes a cable-tie having a flexible strap and a self-locking head. In one aspect of this embodiment, the housing of the drive box further includes an upper bracket and a lower lug. In another aspect, the housing further comprises at least one heatsink pad extending from a rear wall of the housing and including a curved surface having a radius of curvature that substantially corresponds to a curvature of the outer surface of the cylindrical pump shell. In a variant of this aspect, the pump further comprises an adhesive applied to the curved surface to adhere the drive box to the cylindrical pump shell. In another aspect, the upper bracket is configured to connect to the discharge cover, the at least one clamp further comprising a strap configured to substantially surround the shell collar and the lower lug of the housing to compress the housing against the cylindrical pump shell. In another aspect, the pump further comprises: a first flexible clip and a second flexible clip, each of the first and second flexible clips having an attachment segment; wherein the housing further includes a first tab and a second tab, each of the first and second tabs extending from the rear wall of the housing; wherein the attachment segment of the first flexible clip is coupled to the first tab to connect the first flexible clip to the first tab, and the attachment segment of the second flexible clip is coupled to the second tab to connect the second flexible clip to the second tab. In a variant of this aspect, the first and second flexible clips each include a hook segment coupled to the attachment segment and positioned, when the first and second flexible clips are coupled to the first and second tabs, to capture a respective one of the plurality of rods extending between the base and the discharge cover and apply a holding force to draw the mount of the drive box into engagement with the cylindrical pump shell. In a further variant, each of the first and second flexible clips includes an extension segment connected to the attachment segment of the flexible clip by a first transition segment, the extension segment being positioned in a substantially perpendicular orientation relative to the attachment segment. In a further variant, each of the first and second flexible clips includes a return segment connected to the extension segment by a second transition segment, the return segment being positioned at an obtuse angle relative to the extension segment. In a further variant, the hook segment of each of the first and second flexible clips is connected to the return segment by a third transition segment, the hook segment being positioned in a substantially perpendicular orientation relative to the return segment. In another variant the pump further comprises: a plurality of clip fasteners including a first clip fastener and a second clip fastener; wherein the attachment segments of the first and second flexible clips each include a first opening; wherein the first and second tabs each include a second opening; and wherein the first clip fastener is configured to extend through the first opening of the attachment segment of the first flexible clip and into the second opening of the first tab to connect the first flexible clip to the first tab, and the second clip fastener is configured to extend through the first opening of the attachment segment of the second flexible clip and into the second opening of the second tab to connect the second flexible clip to the second tab. In a further variant, each of the second openings of the first and second tabs is threaded to receive a threaded shaft of one of the first and second clip fasteners. In a further variant, each of the first and second clip fasteners includes a head and a threaded shaft extending from the head, and wherein the first and second flexible clips transition from an unflexed state to a flexed state when the first and second clip fasteners are threaded into the first and second tabs, respectively, as a result of the heads of the first and second clip fasteners drawing the attachment segments of the first and second flexible clips into engagement with the first and second tabs, respectively.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other advantages and objects of this invention, and the manner of attaining them, will become more apparent, and the invention itself will be better understood, by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a perspective view of a fully assembled water pressure booster according to one embodiment of the present disclosure;

FIG. 2 is a perspective view of the water pressure booster of FIG. 1 with the outer housing and cover removed;

FIG. 3 is a bottom view of the base of FIG. 2;

FIG. 4 is a perspective view of the water pressure booster of FIG. 2 with the pressure tank removed;

FIG. 5 is a side view of the water pressure booster of FIG. 4;

FIG. 6 is a top view of the water pressure booster of FIG. 4;

FIG. 7 is a front view of the water pressure booster of FIG. 4;

FIG. 8 is a top cross-sectional view of the water pressure booster of FIG. 7 taken along line A-A;

FIG. 9 is an enlarged, top cross-sectional view of the portion of the water pressure booster labelled C in FIG. 8;

FIG. 10 is an enlarged, top cross-sectional view of the portion of the water pressure booster labelled D in FIG. 8;

FIG. 11 is a side cross-sectional view of the water pressure booster of FIG. 7 taken along line B-B;

FIG. 12 is an enlarged, side cross-sectional view of the portion of the water pressure booster labelled E in FIG. 11;

FIG. 13 is a drive box according to one embodiment of the present disclosure;

FIGS. 14A and 14B are top views of a flexible clip in both an unflexed state (FIG. 14A) and a flexed state (FIG. 14B) according to one embodiment of the present disclosure;

FIG. 15 is a perspective view of the clip shown in FIGS. 14A and 14B;

FIG. 16 illustrates a drive box attached to a cylindrical pump housing using circumferential clamps according to one embodiment of the present disclosure;

FIG. 17 is a perspective view of a circumferential clamp of FIG. 16;

FIG. 18 is a enlarged side view of a portion of FIG. 16;

FIG. 19 is a perspective view of a drive box of FIG. 16;

FIG. 20 is a perspective view of an alternative embodiment of a circumferential clamp according to one embodiment of the present disclosure;

FIG. 21 is a perspective view of a water pressure booster with a drive box attached using omega clamps according to another embodiment of the present disclosure;

FIG. 22 is a perspective, cross-sectional view taken along line A-A of FIG. 21;

FIG. 23 is a close-up perspective view of an end of an omega clamp of FIG. 21;

FIG. 24 is a side view of an alternative embodiment of a cylindrical pump shell for use with one or more of the drive box attachment mechanisms described herein;

FIGS. 25 and 26 are perspective views of a water pressure booster with a drive box attached using band clamps according to another embodiment of the present disclosure;

FIG. 27 is a perspective view of an alternative embodiment of a drive box;

FIG. 28 is a perspective view of a water pressure booster with the drive box of FIG. 27 attached;

FIG. 29 is a perspective view of another embodiment of a water pressure booster with the outer housing and cover removed;

FIG. 30 is a perspective view of another embodiment of a drive box according to the present disclosure; and

FIG. 31 is a perspective view of another embodiment of a drive box according to the present disclosure.

Corresponding reference characters indicate corresponding parts throughout the several views. Although the drawings represent embodiments of the present disclosure, the drawings are not necessarily to scale, and certain features may be exaggerated or omitted in some of the drawings in order to better illustrate and explain the present disclosure.

DETAILED DESCRIPTION

Referring now to FIG. 1, a water pressure booster pump 10 according to one embodiment of the present disclosure is shown. Pump 10 generally includes a base 12, an outer housing 14, a cover 16, as well as a plurality of internal components that will be described below. Further description of the pump 10 is provided in co-pending provisional application Ser. No. 63/717,374, attorney docket no. FEC0370-01-US, entitled “WATER PRESSURE BOOSTER,” filed on Nov. 7, 2024, the entire disclosure of which being expressly incorporated herein by reference. The base 12 includes a body 18 having two inlets 20A, 20B (only 20B is shown in FIG. 1) and two outlets 22A, 22B. A plurality of adjustable feet 24 are threaded into a bottom wall 27 of the body 18 adjacent each of its corners. A power cord 28 is shown extending from the base 12 between a gap formed by the adjustable feet 24 between the bottom wall 27 of the body 18 and the installation surface 26. The cord 28 includes a conductor cable 30 connected on one end to the pump 10, and a plug 32 on the other end configured to connect to an outlet supplying main power.

In embodiments, the outer housing 14 generally includes two housing halves 34A, 34B which mate with one another. Together, the housing halves 34A, 34B form a generally rectangular enclosure that is opened at the top facing the cover 16 and at the bottom facing the base 12.

The cover 16 is generally configured to connect to the top of the outer housing 14 and enclose the components (described below) within the outer housing 14. The cover 16 includes a top surface 42 with a pair of priming ports 50A, 50B and a front surface 46 that carries an interface 60 which functions as a human-to-machine interface.

With reference to FIGS. 2-8, other components of the pump 10 will now be described in more detail. The base 12 connects several of the various components of the pump 10 together and directs the flow of incoming and outgoing water, depending upon which of the inlets 20A, 20B and the outlets 22A, 22B are connected to the plumbing at the installation site. The outer housing halves 34A, 34B connect to the base 12 along an upper edge 72 of the body 18 of the base 12 using screws and/or other fasteners. In general, the base 12 functions as a manifold for the inlets 20A, 20B and the outlets 22A, 22B as is further described herein.

Referring now to FIG. 3, the base 12 further includes a power opening 110 for receiving the cable 30 of the power cord 28 and motor power openings 111A and 111B for receiving a motor cable 31 (not shown). The cable 30 is routed through the base 12 and exits the base 12 at a conductor holder 112 shown in FIG. 4. The motor cable 31 is routed through the base 12 and exits the base 12 at a motor conductor holder 113 shown in FIG. 4. The motor ground wire exits base 12 at a ground holder 114 shown in FIG. 2. Cables (not shown) extend between the base 12 and the drive box 62 carrying the power, motor and ground signals from the power cord 28, motor cable 31 and ground wire 115.

As shown in FIG. 2, the base 12 further includes a tank fitting 116 configured to mate with a tank pipe 118 extending from the pressure tank 70, which provides constant pressure of the water provided by the pump 10 even as the supply of and/or the demand for water fluctuates. The tank fitting 116 provides fluid communication between the pressure tank 70 and the outlets 22A, 22B, which are also in fluid communication with a sensor pipe 68. The base 12 further includes a shell collar 122 that extends upwardly from the base 12. The shell collar 122 is a cylindrical wall that is sized to have an inner diameter that substantially corresponds to a diameter of an outer surface 65 of a cylindrical pump shell 64 such that the cylindrical pump shell 64 is received within the shell collar 122. In certain embodiments, the cylindrical pump shell 64, which encloses a pump motor assembly (“PMA 104”), is made of stainless steel. As best shown in FIG. 4, the sensor pipe 68 is connected to a discharge opening 140 of the discharge cover 66 using a discharge fitting 146 and to a sensor pipe inlet of the base 12 using a sensor pipe fitting 131.

The drive box 62 generally includes an outer cover 100 and a housing 102. In one embodiment, the drive box 62 is formed by die-casting ADC-12 aluminum. In certain embodiments, the outer cover 100 is connected to the housing 102 using fasteners 105 such as screws. When connected together, the outer cover 100 and the housing 102 form an enclosed volume in which is mounted a printed circuit board (“PCB 107; FIGS. 11 and 12) carrying electronic components that receive power from the power cord 28, receive signals from a pressure sensor (not shown) and a flow sensor (not shown) connected to the sensor pipe 68, control the functions of the PMA 104 (FIG. 11) enclosed by the cylindrical pump shell 64, and communicate with the interface 60.

Referring now to FIG. 11, the bottom or end bell of the PMA 104 is received by a recess 132 in a PMA mounting section 86 of the base 12. The cylindrical pump shell 64 is fitted over the PMA 104 and into the shell collar 122 of the base 12. An annular recess 138 of the discharge cover 66 is fitted over the upper end of the cylindrical pump shell 64.

Referring now to FIGS. 2-8, the discharge cover 66, the cylindrical pump shell 64 and the base 12 are clamped together by a plurality of rods 182A-C to prevent water pressurized by the PMA 104 from leaking through the connections between the discharge cover 66 and the cylindrical pump shell 64 and the base 12 and the cylindrical pump shell 64. As best shown in FIGS. 2, 4 and 5, the rod 182A is positioned adjacent the side of the pump 10 having the inlet 20A, the rod 182B is positioned adjacent the pressure tank 70, and the rod 182C is positioned adjacent the side of the pump 10 opposite the side having the inlet 20B and the outlet 22A. In this manner, the rods 182A-C are positioned at relatively evenly spaced intervals around the cylindrical pump shell 64 as shown in FIG. 8 to apply a relatively evenly distributed clamping force to the discharge cover 66, the cylindrical pump shell 64 and the base 12 as is further described herein.

Each of the rods 182A-C includes a lower end that extends through the base 12 and receives a lower nut 184 as shown in FIG. 3. The upper ends of the rods 182A-C extend through rod receivers 186 formed in the discharge cover 66 as shown in FIGS. 2, 4 and 5. The upper ends also receive an upper nut 188 (or are formed to include a bolt head). Upon tightening the upper nut 188 on the upper end of each rod 182A-C, pressure is applied by the lower nut 184 to the base 12 and by the upper nut 188 to the rod receivers 186, thereby tensioning the rod 182A-C and compressing the discharge cover 66 and the base 12 against the PMA 104.

Referring now primarily to FIG. 11, the PMA 104 generally includes a motor section 190 substantially enclosed by a cylindrical housing 192 and a mechanical section 194. The motor section 190 generally includes a stator 198 fixed within the cylindrical housing 192 and a rotor 200 situated within the stator 198 and configured to rotate about a central, vertical axis of the PMA 104. The rotor 200 is coupled to a drive shaft 202. When the rotor 200 rotates as a result of electricity flow through windings of the stator 198 (as is known in the art), the drive shaft 202 also rotates. The upper end of the drive shaft 202 includes a coupling 208 which couples with and transfers the rotation of the drive shaft 202 to the mechanical section 194 as is further described below.

The mechanical section 194 of the PMA 104 includes an impeller assembly 210 having a driven shaft 212 supported at a lower end by the coupling 208 of the drive shaft 202. In embodiments, a plurality of impellers 216 are coupled to the driven shaft 212 and are configured to drive the flow of water radially and upwardly from a lower portion of the mechanical section 194 toward the discharge cover 66. The mechanical section 194 also includes a plurality of diffusers 218, each above a respective impeller 216. The diffusers 218 convert the kinetic energy of the water driven by the impellers 216 into static pressure in a manner known in the art.

Openings 196 formed within the mechanical section 194 provide a flow path of water from the inlets 20A, 20B of the base 12, through the annular gap 90 of the PMA mounting section 86 and a gap 222 formed between the cylindrical pump shell 64 and the cylindrical housing 192 of the motor section 190, into the mechanical section 194. As shown in FIG. 11, the gap 222 also extends upwardly around the mechanical section 194 as is further described below.

Referring now to FIGS. 1 and 11, when the cover 16 is connected to the outer housing 14, depending upon the orientation of the cover 16, either the priming port 50A or the priming port 50B is aligned with a priming opening 226 of the discharge cover 66. In the configuration of FIG. 1, the user primes the pump 10 by pouring water directly through the priming port 50A of the cover 16 into a central cavity 238 of the discharge cover 66 through the priming opening 226 of the discharge cover 66. The priming opening 226 may then be sealed by threading a cap 52 (FIG. 1) into the priming opening 226.

The operation of the pump 10 is described below with primary reference to FIG. 11 and assuming that the inlet 20A and the outlet 22B are selected during installation (i.e., inlet 20A is connected to a water supply line and the outlet 22B is connected to water delivery mechanisms), while the inlet 20B and the outlet 22A are closed with plugs 74. After making the plumbing connections to the inlet 20A and the outlet 22B, the user primes the pump 10 by pouring water into the priming port 50A, which fills the mechanical section 194 of the PMA 104 as well as the gap 222 surrounding the PMA 104 and the annular gap 90 of the base 12. After the power cord 28 is plugged into an electrical outlet and the drive box 62 is powered on, the pump 10 is ready for use.

Incoming water enters inlet 20A and flows into the annular gap 90 of the base 12. The water flows up through the gap 222 around the PMA 104 as a result of suction generated by the impellers 216 of the impeller assembly 210. As the water flows through the gap 222, heat from the motor section 190 is transferred through the cylindrical housing 192 to the water, thereby cooling the motor section 190 of the PMA 104. The flow of water through the gap 222 also absorbs heat from the drive box 62 which is mounted in contact with the outer surface 65 of the cylindrical pump shell 64 as is further described below. The water then flows through the PMA 104 where it is pressurized. The pressurized water flows from the mechanical section 194 of the PMA 104 into the central cavity 238 of the discharge cover 66 and out of the discharge cover 66 through the discharge opening 140. The pressurized water flows through the sensor pipe 68 where its pressure and flow rate are sensed. The water then flows out of the sensor pipe 68 into the base 12. The pressurized water also flows through the tank fitting 116 of the base 12 and the tank pipe 118 of the pressure tank 70 to fill the pressure tank 70. In this example, the outlet 22A is closed with a plug 74 so the pressurized water flows out of the pump 10 through the outlet 22B to provide water having a substantially constant, increased pressure (relative to the water supply) to the water delivery mechanisms connected to the pump 10.

As shown in FIGS. 2, 4, 5 and 8-10, the housing 102 of the drive box 62 may be coupled to two of the rods 182A, 182B using a pair of flexible clips 300A, 300B. The clips 300A, 300B are attached to tabs 302A, 302B of the housing 102 of the drive box 62, respectively. As best shown in FIG. 13, the tabs 302A, 302B extend laterally from the side walls of the housing 102. The housing 102 may also be coupled to the discharge cover 66 using fasteners 304 or other mechanisms as is further described below. Finally, the housing 102 of the drive box 62 may be adhered to the outer surface 65 of the cylindrical pump shell 64 using at least one adhesion pads 306A-C as is further described below. Using this system of connection features, the drive box 62 is securely fixed in place such that the housing 102 is in contact with the cylindrical pump shell 64 to permit heat transfer from the drive box 62, through the cylindrical pump shell 64 and into the water flowing through the gap 222 formed between the cylindrical pump shell 64 and the cylindrical housing 192 of the motor section 190 of the PMA 104 and the mechanical section 194 of the PMA 104. It should be understood that the adhesive pads 306A-C may be used without the tabs 302A, 302B and the clips 300A, 300B, and without coupling the housing 102 to the discharge cover 66 using fasteners 304. Alternatively, the adhesive pads 306A-C may be used with one or the other or both of these coupling features (i.e., tabs 302A, 302B and clips 300A, 300B and/or fasteners 304). While three adhesive pads 306A-C are shown in FIG. 13, it should be understood that more or fewer than three pads may be used.

The system for coupling the drive box 62 to the cylindrical pump shell 64, whether using the rods 182A, 182B and/or the discharge cover 66 or not, provides secure positioning of the drive box 62 without requiring any structure on the outer surface 65 of the cylindrical pump shell 64 and without causing deformation of the cylindrical pump shell 64, which could impair the seal between the cylindrical pump shell 64 and the discharge cover 66 provided by the O-ring 191 (FIG. 11) and the seal between the cylindrical pump shell 64 and the shell collar 122 of the base 12 provided by the O-ring 193 (FIG. 11). Each of the features of the drive box attachment mechanisms is described in more detail below.

Referring again to FIG. 13, in certain embodiments, the housing 102 of the drive box 62 includes a pair of upper tabs 308 extending outwardly from the sides of the housing 102 adjacent an upper wall 310 of the housing 102. Each upper tab 308 may include a threaded opening 312 for receiving the discharge cover fasteners 304 which are passed through a corresponding pair of flanges 314 (FIGS. 2 and 4) formed on the discharge cover 66. As shown in FIG. 13, in certain embodiments, the tabs 302A, 302B for receiving the clips 300A, 300B extend from a rear wall 316 of the housing 102 and outwardly from the sides of the housing 102. Each tab 302A, 302B may include a threaded opening 318 for receiving a clip fastener 320 to secure the clips 300 to the housing 102 as is further described below. The housing 102 may also include a lower tab 322 with a threaded hole 324 for connecting the motor ground wire 115.

Additionally, the housing 102 may include an upper bracket 326 with an opening 328 extending upwardly from the upper wall 310 of the housing 102 and a lower bracket 330 with an opening 332 extending downwardly from a lower wall 334 of the housing 102. In alternative embodiments, the brackets 326, 330 may be used to mount the drive box 62. The housing 102 may further includes a plurality of projections 336 extending from the rear wall 316 of the housing 102. In embodiments, the projections 336 extend farther from the rear wall 316 than the adhesive pads 306A-C described below and terminate in substantially the same plane, which is substantially parallel to a plane of the rear wall 316 of the housing 102. The projections 336 support the housing 102 when the housing 102 is placed on a flat surface in substantially parallel relationship to the flat surface. In this manner, the projections 336 function as feet that prevent the housing 102 from rocking to one side or another on the adhesive pads 306A-C, for example, during assembly. In the example shown, four projections 336 are provided, each positioned adjacent a corner of the rear wall 316 of the housing 102. In other embodiments, more or few projections 336 may be used, and they may be positioned in other locations.

The adhesive pads 306A-C protrude from the rear wall 316 of the housing 102 and, in certain embodiments, are spaced apart from one another in substantial vertical alignment along a central portion of the rear wall 316 as best shown in FIG. 13. The number, size and shape of the pads 306A-C may be selected to transfer a maximum amount of heat from the drive box 62 to the water flowing through the cylindrical pump shell 64 while minimizing the possibility of condensation forming on the inside of the drive box 62 as a result of cold water in the cylindrical pump shell 64. In certain embodiments, the adhesive pads 306A-C may be combined into a single adhesive pad or split into a number of adhesive pads that is greater than three. The adhesive pad 306A includes a curved rearward surface 338 to which adhesive is applied for adhering the adhesive pad 306A (and therefore the drive box 62) to the cylindrical pump shell 64. In certain embodiments, the adhesive pads 306A-C have a thermal conductivity of approximately 1.6 W/mK.

In certain embodiments, the adhesive may be a single or two component material which may or may not include fillers to improve heat transfer. In certain embodiments, the adhesive is a 1-part silicone adhesive with fillers to improve heat transfer. The fillers may be aluminum, silver or other materials that promote heat transfer. Such an adhesive may provide a cost advantage and improve the manufacturing process because 2-part adhesives can require expensive dispensing equipment such as pails and mixers, while 1-part adhesives may be dispensed using a simple cartridge. Additionally, silicone adhesive may be preferable because it remains flexible and can withstand the thermal expansion and contraction of the drive box 62 and the shell 64 over time without thermal separation of the surfaces of those components. In some operating conditions, the adhesive is capable of withstanding thermal extremes of −5° C. in operation and −40° C. in storage on the low end and 60° C. in storage and 80° C. in operation on the high end. Silicone may also provide better adhesion than certain 2-part adhesives. In one embodiment, the adhesive is DOWSIL™ SE-4486 adhesive, manufactured by Dow®.

In certain embodiments, the rearward surface 338 of the adhesive pad 306A has a radius of curvature that substantially corresponds to the curvature of the outer surface 65 of the cylindrical pump shell 64. In one embodiment, the radius of curvature is configured to fit onto a 114.3 mm shell 64. In embodiments, a pair of cast spacers 340 extend from the adhesive pad 306A beyond the rearward surface 338 of the adhesive pad 306A to control the thickness of the adhesive applied to the adhesive pad 306A as is further described below. As best shown in FIG. 12, the cast spacers 340 engage the outer surface 65 of the cylindrical pump shell 64 and form a gap 341 between the outer surface 65 of the cylindrical pump shell 64 and the rearward surface 338 of the adhesive pad 306A. The gap 341 defines the thickness of the adhesive applied to the rearward surface 338 of the adhesive pad 306A. It should be understood that more or fewer than two cast spacers 340 may be used, and the location(s) of the cast spacers 34 may vary from that shown in FIG. 13.

The adhesive pad 306B similarly includes a curved rearward surface 342 which receives adhesive and has a radius of curvature that substantially corresponds to the curvature of the outer surface 65 of the cylindrical pump shell 64. Finally, the adhesive pad 306C also includes a curved rearward surface 344 to which adhesive is applied for adhering the adhesive pad 306C (and therefore the drive box 62) to the cylindrical pump shell 64. In certain embodiments, the rearward surface 344 of the adhesive pad 306C has a radius of curvature that substantially corresponds to the curvature of the outer surface 65 of the cylindrical pump shell 64. A pair of cast spacers 346 extend from the adhesive pad 306C beyond the rearward surface 344 of the adhesive pad 306C to control the thickness of the adhesive applied to the adhesive pad 306C in the manner described above with reference to adhesive pad 306A.

Referring now to FIGS. 9 and 10, the flexible clips 300A, 300B according to one embodiment of the present disclosure are shown. The clips 300A, 300B include generally the same features but in certain instances the dimensions of the features may differ between the two clips 300A, 300B. In certain embodiments, the clips 300A, 300B are formed from steel such as galvanized steel or stainless steel. Referring to FIGS. 9 and 15, the clip 300A generally includes an attachment segment 348, an extension segment 350, a return segment 352 and a hook segment 354. The attachment segment 348 is configured to facilitate coupling of the clip 300A to the tab 302A of the housing 102 of the drive box 62. As shown in FIG. 8, when the drive box 62 is coupled to the pump 10, the tab 302A is positioned adjacent the side of the pump 10 on which the inlet 20A is located.

In certain embodiments, the attachment segment 348 may include an opening 356 adjacent a free end 358 of the attachment segment 348. The opening 356 may be sized to receive a clip fastener 320 (FIG. 9), which includes a head 360 that engages an outer surface of the attachment segment 348 and a threaded shaft 362 which is configured to thread into the threaded opening 318 of the tab 302A. The attachment segment 348, in its natural, unflexed state as shown in FIG. 9, is substantially planar and, before the clip fastener 320 is fully threaded into the threaded opening 318 of the tab 302A, is substantially parallel to the rear wall 316 of the housing 102 of the drive box 62.

The attachment segment 348 is connected to the extension segment 350 by a first transition segment 364. In certain embodiments, the first transition segment 364 is a right-angle bend in the clip 300A which causes the extension segment 350 to be positioned in a substantially perpendicular orientation relative to the attachment segment 348, thereby extending the clip 300A away from the rear wall 316 of the housing 102 of the drive box 62. In certain embodiments, the extension segment 350 is substantially planar.

The extension segment 350 is connected to the return segment 352 by a second transition segment 366. In certain embodiments, the second transition segment 366 is an obtuse-angle bend in the clip 300A which causes the return segment 352 to be positioned at an obtuse angle relative to the extension segment 350. In certain embodiments, the return segment 352 is substantially planar. As shown in FIG. 9, the lengths of the attachment segment 348, the extension segment 350 and the return segment 352 are such that when the clip 300A is connected to the tab 302A in its natural, unflexed state, the second transition segment 366 is adjacent the cylindrical pump shell 64 and the return segment 352 extends between the cylindrical pump shell 64 and the rod 182A.

The return segment 352 is connected to the hook segment 354 by a third transition segment 368. In certain embodiments, the third transition segment 368 is a right-angle bend in the clip 300A which causes the hook segment 354 to be positioned in a substantially perpendicular orientation relative to the return segment 352. In certain embodiments, the hook segment 354 is substantially planar. As shown in FIG. 9, the length of the hook segment 354 from the third transition segment 368 to a free end 370 of the hook segment 354 is sufficient to substantially overlap the rod 182A such that the return segment 352 and the hook segment 354 engage and capture the rod 182A.

Referring to FIG. 10, the clip 300B generally includes an attachment segment 348, an extension segment 350, a return segment 352 and a hook segment 354. The attachment segment 348 is configured to facilitate coupling of the clip 300B to the tab 302B of the housing 102 of the drive box 62. As shown in FIG. 8, when the drive box 62 is coupled to the pump 10, the tab 302B is positioned adjacent the pressure tank 70.

In certain embodiments, the attachment segment 348 may include an opening 356 (not shown) adjacent a free end 358 of the attachment segment 348. The opening 356 is sized to receive a clip fastener 320, which includes a head 360 that engages an outer surface of the attachment segment 348 and a threaded shaft 362 which is configured to thread into the threaded opening 318 of the tab 302B. The attachment segment 348, in its natural, unflexed state as shown in FIG. 10, is substantially planar and, before the clip fastener 320 is fully threaded into the threaded opening 318 of the tab 302B, is substantially parallel to the rear wall 316 of the housing 102 of the drive box 62.

The attachment segment 348 is connected to the extension segment 350 by a first transition segment 364. In certain embodiments, the first transition segment 364 is a right-angle bend in the clip 300B which causes the extension segment 350 to be positioned in a substantially perpendicular orientation relative to the attachment segment 348, thereby extending the clip 300B away from the rear wall 316 of the housing 102 of the drive box 62. In certain embodiments, the extension segment 350 is substantially planar. In certain embodiments, the extension segment 350 of the clip 300B is shorter than the extension segment 350 of the clip 300A because of the relative distances between the rods 182A, 182B and the rear wall 316 when the drive box 62 is mounted to the pump 10 as best shown in FIG. 8.

The extension segment 350 is connected to the return segment 352 by a second transition segment 366. In certain embodiments, the second transition segment 366 is an obtuse-angle bend in the clip 300B which causes the return segment 352 to be positioned at an obtuse angle relative to the extension segment 350. In certain embodiments, the return segment 352 is substantially planar. As shown in FIG. 10, the lengths of the attachment segment 348, the extension segment 350 and the return segment 352 are such that when the clip 300B is connected to the tab 302B in its natural, unflexed state, the second transition segment 366 is adjacent the cylindrical pump shell 64 and the return segment 352 extends between the cylindrical pump shell 64 and the rod 182B.

The return segment 352 is connected to the hook segment 354 by a third transition segment 368. In certain embodiments, the third transition segment 368 is a right-angle bend in the clip 300B which causes the hook segment 354 to be positioned in a substantially perpendicular orientation relative to the return segment 352. In certain embodiments, the hook segment 354 is substantially planar. As shown in FIG. 10, the length of the hook segment 354 from the third transition segment 368 to a free end 370 of the hook segment 354 is sufficient to substantially overlap the rod 182B such that the return segment 352 and the hook segment 354 engage and capture the rod 182B.

Referring now to FIGS. 14A and 14B, in FIG. 14A the clip 300A is shown in its unflexed state loosely attached to the housing 102 (identical to FIG. 9) and in FIG. 14B the clip 300A is shown in its flexed state firmly attached to the housing 102. FIG. 15 also shows the clip 300A in its flexed state. While only the clip 300A is shown in its flexed state in FIGS. 14B and 15, it should be understood that the clip 300B is similarly flexed and the description below also applies to the clip 300B. When the clip fasteners 320 are further threaded into the threaded openings 318 of the tabs 302A, 302B, the heads 360 of the clip fasteners 320 draw portions of the attachment segments 348 adjacent the free ends 358 into engagement with the tabs 302A, 302B of the housing 102 of the drive box 62. This causes the attachment segments 348 and the extension segments 350 to deform, and generally causes the clips 300A, 300B to flex out of their natural, unflexed state as the free ends 358 of the attachment segments 348 are moved away from the free ends 370 of the hook segments 354. When the clips 300A, 300B are in this flexed state, they apply a holding force which draws the adhesive pads 306A-C of the housing 102 (and the adhesive applied thereto) into engagement with the outer surface 65 of the cylindrical pump shell 64.

The drive box 62 may be coupled to the pump 10 in the following manner. Adhesive may be applied to the rearward surfaces 338, 342 and 344 of the adhesive pads 306A, 306B and 306C, respectively. The clips 300A, 300B may be loosely coupled to the tabs 302A, 302B of the housing 102 of the drive box 62 using the clip fasteners 320. The drive box 62 may then be placed such that the adhesive applied to the adhesive pads 306A-C is in contact with the outer surface 65 of the cylindrical pump shell 64 and the drive box 62 is at a location that aligns the upper tabs 308 of the housing 102 of the drive box 62 with the flanges 314 of the discharge cover 66 (FIG. 4). The clips 300A, 300B may be positioned around the rods 182A, 182B, respectively. The discharge cover fasteners 304 may be passed through openings in the flanges 314 of the discharge cover 66 and threaded loosely into the threaded openings 312 of the upper tabs 308 of the housing 102 to couple the drive box 62 to the discharge cover 66. The clip fasteners 320 may be threaded further into the threaded openings 318 of the tabs 302A, 302B to draw the attachment segments 348 of the clips 300A, 300B against the tabs 302A, 302B, respectively, thereby flexing the clips 300A, 300B as described above to apply a holding force which draws the adhesive pads 306A-C (and the adhesive applied thereto) into engagement with the outer surface 65 of the cylindrical pump shell 64. Finally, the discharge cover fasteners 304 may be tightened to draw the upper tabs 308 of the housing 102 into secure engagement with the flanges 314 of the discharge cover 66 to couple the drive box 62 to the discharge cover 66.

As indicated above, by drawing the attachment segments 348 against the tabs 302A, 302B of the housing 102, the clip fasteners 320 cause a deformation of the clips 300A, 300B (as described above and shown in FIGS. 14B and 15) from their natural, unflexed state which draws the drive box 62 relatively tightly against the outer surface 65 of the cylindrical pump shell 64. The combination of the connection between the flanges 314 of the discharge cover 66 and the upper tabs 308 of the housing 102 and the holding force provided by the clips 300A, 300B retains the drive box 62 in place as the assembled pump 10 is moved and boxed for shipping while the adhesive cures, which in some embodiments may take many days or even weeks. As indicated above, when the adhesive cures, it not only retains the drive box 62 in place and in contact with the outer surface 65 of the cylindrical pump shell 64, it also facilitates heat transfer from the drive box 62 to the cylindrical pump shell 64, which is cooled by water flowing through the pump 10 in the manner described above.

360 Degree Clamps

Referring now to FIG. 16, another embodiment of a mechanism for attaching the drive box 62 such that it engages the outer surface 65 of the cylindrical pump shell 64 to facilitate heat transfer as described herein is shown in the form of two substantially circumferential clamps 400. While two clamps 400 are shown, it should be understood that in alternative embodiments a single clamp 400 may be used or more than two clamps 400 may be used. As shown, the clamps 400 extend substantially around the circumference of the cylindrical pump shell 64, one clamp 400 adjacent the discharge cover 66 and another clamp 400 adjacent the base 12. The clamps 400 are connected to the housing 102 of the drive box 62 as is further described below with reference to FIGS. 17 and 18.

The clamps 400 are identical so only one clamp 400 is described in detail herein. The clamp 400 generally includes a generally circular body 402 with a pair of clamping ends 404 and an attachment lug 406. The body 402 has an inner surface 410 that defines a central opening 412 and an outer surface 414. The body 402 is sized such that the diameter of the central opening 412 is substantially the same as the diameter of the outer surface 65 of the cylindrical pump shell 64.

A reinforcement rib 416 extends radially outwardly from the outer surface 414 of the body 402 along the perimeter of the body 402 between the clamping ends 404, interrupted only by the attachment lug 406. The reinforcement rib 416 forms three alignment segments 418 configured to position the clamp 400 in a desired orientation relative to the rods 182A-C extending between the discharge cover 66 and the base 12. Each alignment segment 418 includes a pair of protrusions 420 that extend farther radially outwardly than the remainder of the reinforcement rib 416 and define a notch 422. The notches 422 are spaced apart on the clamp 400 to correspond to the spacing of the rods 182A-C when the clamp 400 is attached to the cylindrical pump shell 64.

The clamping ends 404 each include a connecting plate 424 that extends radially outwardly from the body 402. The connecting plates 424 include through holes 426 that extend through the plates 424 and are aligned with one another. The clamp 400 is attached to the cylindrical pump shell 64 by placing the body 402 around the shell 64 such that the rods 182A-C are received in the notches 422 of the alignment segments 418 and a fastener (not shown) such as a bolt is passed through the through holes 426. A nut (not shown) is then threaded onto the fastener and tightened such that the head of the fastener and the nut draw the clamping ends 404 toward one another until the diameter of the central opening 412 is reduced such that the inner surface 410 of the clamp 400 comes substantially into contact with the outer surface 65 of the cylindrical pump shell 64. The screw and nut (not shown) are torqued such that the clamp load and the friction between the outer surface 65 of the pump shell 64 and the inner surface 410 of the clamp 400 are sufficient to maintain the position of the drive box 62 during operation and shipping. In an alternative embodiment, only one connecting plate 424 includes a through hole 426 and the other connecting plate 424 includes a tapped area which is aligned with the through hole 426. In such an embodiment, a screw may be passed through the through hole 426, threaded into the tapped area of the opposed connecting plate 424 and tightened to draw the connecting plates together in the manner described above. When the clamp 400 is attached to the cylindrical pump shell 64 in this manner, the attachment lug 406 is positioned between the rods 182A and 182B as shown in FIG. 16.

The attachment lug 406 includes an upper portion 430 that extends above the body 406 and a lug 432 that extends radially outwardly from the body 402 of the clamp 400. The upper portion 430 of the attachment lug 406 can include a fastener, such as a screw (not shown) that engages outer surface 65 of pump shell 64 such that it locates the clamp 400 axially along the cylindrical pump shell 64. In the embodiment of the pump shell 64 shown in FIG. 24, the fastener (not shown) could engage one of the reinforcement grooves 546, 548, 550 or 552 described below. The lug 432 includes a threaded hole 434 that extends into the lug 432 and receives a fastener (not shown) that connects an upper bracket of the housing 102 of the drive box 62 to the clamp 400 as is described below.

Referring primarily to FIG. 19, in this embodiment, the housing 102 of the drive box 62 includes an upper bracket 436 and a lower bracket 438 for attaching the drive box 62 to the upper clamp 400 and the lower clamp 400, respectively. More specifically, the housing 102 includes an upper wall 440 and a lower wall 442. The upper bracket 436 includes a pair of side walls 444 and an attachment wall 446 that extends between the side walls 444. The side walls 344 and the attachment wall 446 extend upwardly from the upper wall 440 of the housing 102. A through hole 448 or slot extends through the attachment wall 446. Similarly, the lower bracket 438 includes a pair of side walls 450 and an attachment wall 452 that extends between the side walls 450. The side walls 450 and the attachment wall 452 extend downwardly from the lower wall 442 of the housing 102. A through hole 454 or slot extends through the attachment wall 452.

In certain embodiments, the housing 102 further includes heatsink pads 532A-C which each have curved surfaces 534, 712, 714, respectively, that engage the outer surface 65 of the cylindrical pump shell 64 when the drive box 62 is clamped to the cylindrical pump shell 64. In certain embodiments, adhesive may be applied to the curved surfaces 534, 712, 714 to adhere the drive box 62 to the cylindrical pump shell 64 in the manner described herein. The curved surfaces 534, 712, 714 may have a radius of curvature that is substantially the same as the radius of curvature of the cylindrical pump shell 64.

As shown in FIGS. 18 and 19, the housing 102 of the drive box 62 is connected to the attachment lugs 406 of the clamps 400 by passing a fastener (not shown) through the through hole 448 of the attachment wall 446 of the upper bracket 436 and a fastener (not shown) through the through hole 454 of the attachment wall 452 of the lower bracket 438 and threading the fasteners into the threaded holes 434 of the attachment lugs 406 of the upper clamp 400 and the lower clamp 400, respectively. It should be understood that the radial thickness of the lugs 432 of the attachment lugs 406 and the position of the attachment walls 446, 452 of the upper bracket 436 and the lower bracket 438 are such that when the brackets 436, 438 are fastened to the lugs 432 as described above, the curved surfaces 534, 712, 714 of the heatsink pads 532A-C extending from a rear wall 456 of the housing 102 are in contact with the outer surface 65 of the cylindrical pump shell 64 to facilitate heat transfer away from the drive box 62.

A variation of this embodiment is depicted in FIG. 20. In this variation, the clamp 400A is formed from a resilient wire which functions in part as a spring clamp. The clamp 400A generally includes a generally circular body 402A with a pair of clamping ends 404A and an attachment loop 406A. The body 402A defines a central opening 412A. The body 402A is sized such that the diameter of the central opening 412A is substantially the same as the diameter of the outer surface 65 of the cylindrical pump shell 64.

The clamping ends 404A each include a connecting segment 424A that extends radially outwardly from the body 402A. A loop 426A is formed at the end of each connecting segment 424A and defines an opening 427A. The openings 427A are substantially aligned with one another. The attachment loop 406A includes a pair of extension segments 430A, 432A and a catch segment 433A that extends between the extension segments 430A, 432A to form the loop 406A. In this embodiment, the side walls 444, 450 of the upper bracket 436 and the lower bracket 438, respectively, include notches sized to receive the attachment loop 406A of the clamp 400A to clamp the housing 102 of the drive box 62 as is described below.

The clamp 400A is attached to the cylindrical pump shell 64 by flexing the body 402A such that the clamping ends 404A flex away from one another and placing the body 402A around the pump shell 64. As the body 402A is placed around the pump shell 64, the attachment loop 406A is positioned between the rods 182A and 182B as shown in FIG. 16. Additionally, the attachment loop 406A is fitted into the notches (not shown) in the side walls 444, 450 of one of the upper bracket 436 or the lower bracket 438 to connect the clamp 400A to the housing 102 of the drive box 62. Another clamp 400A is similarly connected to the other of the upper bracket 436 or the lower bracket 438. The body 402A is then released. The body 402A unflexes partially such that it clamps around the shell 64. In this partially unflexed state, a fastener (not shown) such as a bolt is passed through the openings 427A. A nut (not shown) is then threaded onto the fastener and tightened such that the head of the fastener and the nut draw the clamping ends 404A toward one another, thereby reducing the diameter of the central opening 412A of the clamp 400A such that it fits snugly around the cylindrical pump shell 64. In this manner, the clamps 400A are secured to the pump shell 64 and the drive box 62 is secured to the clamps 400A.

Omega Clamps

Referring now to FIG. 21, another embodiment of a mechanism for attaching the drive box 62 such that it engages the outer surface 65 of the cylindrical pump shell 64 to facilitate heat transfer as described herein is shown in the form of two omega clamps 500. While two clamps 500 are shown, it should be understood that in alternative embodiments a single clamp 500 may be used or more than two clamps 500 may be used. As shown, the clamps 500 extend partially around the circumference of the cylindrical pump shell 64. The clamps 500 are connected to the housing 102 of the drive box 62 as is further described below with reference to FIGS. 22 and 23.

The clamps 500 are identical so only one clamp 500 is described in detail herein. The clamp 500 includes a generally semi-circular body 502 with a pair of L-shaped ends 504. The body 502 includes an inner surface 510 that defines a central opening 512 (not shown) and an outer surface 514. The body 502 is sized such that the diameter of the inner surface 510 is substantially the same as the diameter of the outer surface 65 of the cylindrical pump shell 64. As best shown in FIG. 22, in one embodiment the body 502 may extend substantially more than 180 degrees around the cylindrical pump shell 64, but substantially less than 360 degrees. In certain other embodiments, the body 502 extends approximately 180 degrees around the cylindrical pump shell 64. In other embodiments, the body 502 extends less than 180 degrees around the cylindrical pump shell 64, for example, 170 degrees, 160 degrees or less. A reinforcement rib 516 extends radially outwardly from the outer surface 514 of the body 502 along the length of the body 502.

The L-shaped ends 504 each include a stand-off segment 518 that extends from the body 502 substantially perpendicular to the housing 102 of the drive box 62 when the drive box 62 is connected to the clamp 500. The L-shaped ends 504 also include a connecting segment 520 that extends from and is substantially perpendicular to the stand-off segment 518. The reinforcement rib 516 continues from the body 502 on the stand-off segment 518 and the connecting segment 520. The reinforcement rib 516 terminates adjacent a free end 522 of the connecting segment 520. The connecting segment 520 include a through hole (not shown) adjacent the free-end 522 configured to receive a fastener 526 such as a screw for connecting the connecting segment 520 to the housing 102 of the drive box 62 as is further described below.

In this embodiment, the housing 102 of the drive box 62 includes a plurality of lateral tabs 528 that extend substantially perpendicular to and outwardly from side walls 530 of the housing 102. Each of the tabs 528 includes a threaded opening (not shown) configured to receive one of the fasteners 526 to connect a connecting segment 520 of a clamp 500 to the tab 528. Also, as best shown in FIG. 22, in certain embodiments at least one heatsink pad 532 with or without thermal adhesive is used to make a thermal connection between the rear wall 556 of the housing 102 and the pump shell 64. In other embodiments, thermal adhesive is used instead of the heatsink pad 532. The heatsink pad 532 includes a curved contact wall 534. The curved contact wall 534 has a radius of curvature that is substantially the same as the radius of curvature of the outer surface 65 of the cylindrical pump shell 64.

The clamps 500 may be used to support the drive box 62 in contact with the cylindrical pump shell 64 by first flexing the body 502 of the clamp 500 and placing the body around the cylindrical pump shell 64. When the body 502 is released, it partially returns to its natural unflexed state and the inner surface 510 of the clamp 500 engages the outer surface 65 of the cylindrical pump shell 64. When the clamps 500 are placed on the cylindrical pump shell 64 in this manner, the L-shaped ends 504 are positioned to extend away from the cylindrical pump shell 64 such that the connecting segments 520 are substantially parallel to the side of the base 12 including the inlet 20B and the outlet 22A.

In embodiments using the at least one heatsink pad 532 with thermal adhesive, the pad 532 is attached to the rear wall 456 of the housing 102 of the drive box 62 (e.g., using adhesive). The drive box 62 is then positioned such that the pad 532 engages the outer surface 65 of the cylindrical pump shell 64 and the threaded openings (not shown) of the lateral tabs 528 of the housing 102 align with the through holes (not shown) at the free ends 522 of the connecting segments 520 of the L-shaped ends 504 of the clamps 500. Finally, the fasteners 526 are placed through the through holes (not shown) and threaded into the threaded openings to secure the housing 102 of the drive box 62 to the clamps 500.

In certain embodiments, the clamps 500 may be formed such that when they are attached to the drive box 62 as described above, the body 502 of the clamp 500 is compressed securely against the cylindrical pump shell 64 and adhesive is not necessary to prevent the drive box 62 from moving relative to the cylindrical pump shell 64 during shipping or during use. However, such tight compression of the clamps 500 may cause slight deformation of the cylindrical pump shell 64. Such deformation may affect the seals described above between the cylindrical pump shell 64 and the discharge cover 66 and the cylindrical pump shell 64 and the base 12. In certain embodiments, the cylindrical pump shell 64 may be formed of material with sufficient rigidity to prevent such deformation. In other embodiments, the cylindrical pump shell 64 may be formed with reinforcement grooves as depicted in FIG. 24 and described below.

As shown in FIG. 24, the cylindrical pump shell 64A is formed to include a central cylindrical section 536, an upper cylindrical section 538 and a lower cylindrical section 540. An upper intermediate section 542 is disposed between the central cylindrical section 536 and the upper cylindrical section 538. More specifically, a first upper reinforcement groove 546 is formed between the central cylindrical section 536 and the upper intermediate section 542 and a second upper reinforcement groove 548 is formed between the upper cylindrical section 538 and the upper intermediate section 542. Similarly, a lower intermediate section 544 is disposed between the central cylindrical section 536 and the lower cylindrical section 540. More specifically, a first lower reinforcement groove 550 is formed between the central cylindrical section 536 and the lower intermediate section 544 and a second lower reinforcement groove 552 is formed between the lower cylindrical section 540 and the lower intermediate section 544. If the central cylindrical section 536 is deformed such as by the use of clamps 500, the upper reinforcement grooves 546, 548 and the upper intermediate section 542 prevent such deformation from affecting the cylindrical shape of the upper cylindrical section 538, thereby avoiding the risk of degrading the seal between the upper cylindrical section 538 and the discharge cover 66. Similarly, deformation of the central cylindrical section 536 is prevented from affecting the cylindrical shape of the lower cylindrical section 540 by the lower reinforcement grooves 550, 552 and the lower intermediate section 544. Thus, the risk of degrading the seal between the lower cylindrical section 540 and the base 12 is avoided.

Banding

Referring now to FIGS. 25 and 26, another embodiment of a mechanism for attaching the drive box 62 such that it engages the outer surface 65 of the cylindrical pump shell 64 to facilitate heat transfer as described herein is shown in the form of a banded attachment. While one band 500A is shown in the figures, it should be understood that in alternative embodiments more than one band 500A may be used. As shown, the band 500A extends partially around and in contact with the circumference of the cylindrical pump shell 64, over but not in contact with the rods 182A, 182B and around and in contact with the drive box 62.

The band 500A includes a strap 502A and a clip 504A that connects one end of the strap 502A to another end as is further described below. In certain embodiments, one or more spring elements 506A are used with the band 500A. The spring element 506A includes a pair of engagement arms 508A, 510A that are each connected to or integral with a biasing ridge 512A.

In certain embodiments, where the strap 502A is resiliently stretchable along its length, the band 500A may be used to secure the drive box 62 in engagement with the outer surface 65 of the cylindrical pump shell 64 by wrapping the strap 502A around the cylindrical pump shell 64 and threading a free end of the strap 502A through the clip 504A, which is attached to the other end of the strap 502A. The free end may be pulled through the clip 504A such that the strap 502A stretches along its length, thereby applying a compression force to the drive box 62 and the cylindrical pump shell 64. The free end of the strap 502A may then be cut adjacent the clip 504A. The clip 504A may be configured such that the strap 502A may be pulled through the clip 504A in one direction but not withdrawn from the clip 504A in the opposite direction. For example, the clip 504A may have a ratchet mechanism, flexible retaining ridges such as a cable-tie, or be deformable to retain the stretched strap 502A within the clip 504A.

In other embodiments, the band 500A may be replaced with a cable-tie having a flexible strap and a self-locking head (also known as a zip-tie). The cable-tie may be formed of plastic and a tool may be used to adjust the tension on the cable-tie to ensure that the cable-tie does not deform the cylindrical pump shell 64. One example of such a cable-tie may be an all-weather band such as the PLT8H locking cable tie sold by Panduit. In certain embodiments, the cable-tie may be used in addition to the strap 904 depicted in FIG. 29. In such an embodiment, the drive box 62 may be secured to the cylindrical pump shell 64 by first applying adhesive to one of the variations of pads (e.g., the adhesive pads 306A-C of FIG. 13 and/or the heatsink pads 532A-C of FIGS. 19 and 27), affixed to the rear wall 316 of the housing 102, attaching the upper bracket 326 (FIG. 13) of the housing 102 to the discharge cover 66, attaching the cable-tie around the cylindrical pump shell 64 and the drive box 62, and allowing the adhesive to cure or at least partially cure for a dwell time (e.g., approximately 45 minutes). After the dwell time, the clips 300A, 300B (FIG. 15) described herein may be used to attach the drive box 62 to the rods 182A, 182B (FIGS. 9 and 10) and the strap 904 may be attached to the drive box 62 and the shell collar 122 as described herein.

In other embodiments, one or more heatsink pads 532 (FIG. 22) with thermal adhesive as described above may be used in conjunction with one or more bands 500A with stretchable straps 502A to provide an additional mechanism for securing the drive box 62 in contact with the cylindrical pump shell 64.

In other embodiments, one or more bands 502A (with straps 502A that are either stretchable or not stretchable) are used with a corresponding one or more spring elements 506A. In such an embodiment, the spring element 506A is placed in contact with the outer surface 65 of the cylindrical pump shell 64 and the strap 502A is wrapped around the cylindrical pump shell 64 over the outer surface 514A of the spring element 506A and over the drive box 62. The free end of the strap 502A is then threaded through the clip 504A and pulled tight (e.g., using a tensioning tool) to draw the biasing ridge 512A of the spring element 506A closer to the outer surface 65 of the cylindrical pump shell 64. This causes the biasing ridge 512A to flex, moving the engagement arms 508A away from one another (i.e., the spring element 506A is flexed and compressed against the cylindrical pump shell 64 by the strap 502A). As the spring element 506A is configured to return to its natural, unflexed state, the compression of the spring element 506A against the cylindrical pump shell 64 results in a tensioning of the strap 502A, which secures the drive box 62 to the cylindrical pump shell 64. After the strap 502A is drawn through the clip 504A, it may be cut and secured in place by the clip 504A in the manner described above. One or more heatsink pads 532 (with or without thermal adhesive) may be used with the band 500A and spring element 506A in the manner described above. Additionally, the cylindrical pump shell 64A with reinforcement grooves as depicted in FIG. 24 may be used with the embodiments described above to prevent deformation of the cylindrical pump shell 64A from affecting the sealed connections of the cylindrical pump shell 64A with the discharge cover 66 and the base 12.

Base/Discharge

Referring now to FIGS. 27 and 28, another embodiment of a mechanism for attaching the drive box 62 such that it engages the outer surface 65 of the cylindrical pump shell 64 to facilitate heat transfer as described herein includes use of a modified drive box 62A. In this embodiment, the drive box 62A is attached to the discharge cover 66 and the base 12 such that the drive box 62A is secured in contact with the cylindrical pump shell 64. The housing 102 of the drive box 62A includes a pair of upper tabs 800 extending outwardly from the sides of the housing 102 adjacent the upper wall 440 of the housing 102. The upper tabs 800 include threaded openings 802 for receiving fasteners 804 passed through holes or slots formed on a corresponding pair of flanges 806 (FIG. 28) of the discharge cover 66.

The housing 102 also includes a lower bracket 818 that extends downwardly from the lower wall 442 of the housing 102 and includes a lower wall 820. A through hole 822 is formed in the lower wall 820 and is configured to receive a fastener 824 (FIG. 28) which extends into a threaded opening (not shown) in the base 12 to secure the lower bracket 818 (and therefore the drive box 62A) to base 12.

In this embodiment, the drive box 62A is axially attached to both the discharge cover 66 and the base 12. In other words, the fasteners 804 and 824 extend vertically, along the longitudinal axis of the cylindrical pump shell 64. In such an embodiment, it may be desirable to use thermal adhesive or heatsink pads (with or without thermal adhesive) as described herein to provide improved radial thermal contact between the drive box 62A and the cylindrical pump shell 64. In alternative embodiments, the threaded openings 802 through the upper tabs 800 are replaced with slots, each slot having a longitudinal axis that is perpendicular to the rear wall 456 of the housing 102. The through hole 822 in the lower wall 820 of the lower bracket 818 may also be formed as a slot having a longitudinal axis that is perpendicular to the rear wall 456 of the housing 102. Such slotted openings permit the housing 102 (and the drive box 62A) to be moved toward and away from the cylindrical pump shell 64. As such, after the fasteners 804 are passed through the slotted openings 802 in the upper tabs 800 and loosely threaded into nuts (not shown) positioned below the upper tabs 800 and the fastener 824 is passed through the slotted opening 822 in the lower wall 820 of the lower bracket 818 and loosely threaded into the corresponding threaded opening (not shown) in the base 12, the drive box 62A may be urged toward and into engagement with the cylindrical pump shell 64. Then, the fasteners 804 may be further threaded into the nuts and the fastener 824 may be further threaded into the threaded opening to fix the drive box 62A in place in a position of firm engagement with the cylindrical pump shell 64. Heatsink pads (with or without thermal adhesive) may or may not be used in this alternative embodiment.

As explained above, in certain embodiments where the housing 102 of the drive box 62 is adhered to the outer surface 65 of the cylindrical pump shell 64, a plurality of heatsink pads 532A-C may be used. Using this system of connection features, the drive box 62 is securely fixed in place such that the housing 102 is in contact with the cylindrical pump shell 64 to permit heat transfer from the drive box 62, through the cylindrical pump shell 64 and into the water flowing through the gap 222 formed between the cylindrical pump shell 64 and the cylindrical housing 192 of the motor section 190 of the PMA 104 and the mechanical section 194 of the PMA 104. It should be understood that the pads 532A-C may be used without coupling the housing 102 to the discharge cover 66 using fasteners 804 or coupling the housing 102 to the base 12 using the fastener 824.

In certain embodiments, the heatsink pads 532A-C protrude from the rear wall 456 of the housing 102 and are spaced apart from one another in substantial vertical alignment along a central portion of the rear wall 456 as shown in FIG. 27. The number, size and shape of the pads 532A-C may be selected to transfer a maximum amount of heat from the drive box 62A to the water flowing through the cylindrical pump shell 64 while minimizing the possibility of condensation forming on the inside of the drive box 62A as a result of cold water in the cylindrical pump shell 64. In certain embodiments, the pads 532A-C may be combined into a single pad or split into a number of pads that is greater than three. As indicated above, the pad 532A includes a curved rearward surface 534 to which adhesive may be applied for adhering the pad 532A (and therefore the drive box 62A) to the cylindrical pump shell 64. In certain embodiments, the pads 532A-C have a thermal conductivity of approximately 1.6 W/mK.

In certain embodiments, the adhesive may be a single or two component material which may or may not include fillers to improve heat transfer. In certain embodiments, the adhesive is a 1-part silicone adhesive with fillers to improve heat transfer. The fillers may be aluminum, silver or other materials that promote heat transfer. Such an adhesive may provide a cost advantage and improve the manufacturing process because 2-part adhesives can require expensive dispensing equipment such as pails and mixers, while 1-part adhesives may be dispensed using a simple cartridge. Additionally, silicone adhesive may be preferable because it remains flexible and can withstand the thermal expansion and contraction of the drive box 62A and the shell 64 over time without thermal separation of the surfaces of those components. In some operating conditions, the adhesive is capable of withstanding thermal extremes of −5° C. in operation and −40° C. in storage on the low end and 60° C. in storage and 80° C. in operation on the high end. Silicone may also provide better adhesion than certain 2-part adhesives. In one embodiment, the adhesive is DOWSIL™ SE-4486 adhesive, manufactured by Dow®.

In certain embodiments, the rearward surface 534 of the pad 532A has a radius of curvature that substantially corresponds to the curvature of the outer surface 65 of the cylindrical pump shell 64. In one embodiment, the radius of curvature is configured to fit onto a 114.3 mm shell 64. In the depicted embodiment, a pair of cast spacers 810 extend from the pad 532A beyond the rearward surface 534 of the pad 532A to control the thickness of the adhesive applied to the pad 532A. The cast spacers 810 engage the outer surface 65 of the cylindrical pump shell 64 and form a gap between the outer surface 65 of the cylindrical pump shell 64 and the rearward surface 434 of the pad 532A. The gap defines the thickness of the adhesive applied to the rearward surface 434 of the pad 532A. It should be understood that more or fewer than two cast spacers 810 may be used, and the location(s) of the cast spacers 810 may vary from that shown in FIG. 27.

The pad 532B similarly includes a curved rearward surface 712 which receives adhesive and has a radius of curvature that substantially corresponds to the curvature of the outer surface 65 of the cylindrical pump shell 64. Finally, the pad 532C also includes a curved rearward surface 714 to which adhesive is applied for adhering the pad 532C (and therefore the drive box 62A) to the cylindrical pump shell 64. In certain embodiments, the rearward surface 714 of the pad 532C has a radius of curvature that substantially corresponds to the curvature of the outer surface 65 of the cylindrical pump shell 64. A pair of cast spacers 816 extend from the pad 532C beyond the rearward surface 714 of the pad 532C to control the thickness of the adhesive applied to the pad 532C in the manner described above with reference to pad 532A.

In certain embodiments, the housing 102 may further include a plurality of projections 808 extending from the rear wall 456 of the housing 102. The projections 808 extend farther from the rear wall 456 than the pads 532A-C and terminate in substantially the same plane, which is substantially parallel to a plane of the rear wall 556 of the housing 102. The projections 808 support the housing 102 when placed on a flat surface in substantially parallel relationship to the flat surface. In this manner, the projections 808 function as feet that prevent the housing 102 from rocking to one side or another on the pads 532A-C, for example, during assembly. In the example shown, four projections 808 are provided, each positioned adjacent a corner of the rear wall 456 of the housing 102. In other embodiments, more or fewer projections 808 may be used, and they may be positioned in other locations.

Finally, it should be understood that thermal adhesive alone or heatsink pad(s) alone (or with thermal adhesive) may be used with any of the various approaches described above for attaching the drive box 62 to the booster pump 10.

Referring now to FIG. 29, another embodiment of a water pressure booster pump 900 according to the present disclosure. The pump 900 is similar to the pump 10 depicted, for example, in FIG. 2. As such, the components of the pump 900 that are the same as the components of the pump 10 retain the same reference designations. The pump 900 differs from the pump 10 primarily in the structure for securing the drive box 62 to the cylindrical pump shell 64. Like the pump 10, the upper tabs 308 (FIG. 13) of the drive box 62 are used to connect the drive box 62 to the flanges 314 of the discharge cover 66 and the tabs 302A, 302B and the clips 300A, 300B are used to connect the drive box 62 to the rods 182A, 182B. In this embodiment, however, the drive box 62 includes a lower lug 902 extending from the lower wall 334. The pump 900 also includes a strap 904 that secures the drive box 62 to shell collar 122. The strap 904, in certain embodiments, may be similar to a cable-tie, and includes a flexible body 906 and a coupling 908 at one end of the flexible body 906 configured to receive and retain the opposite or free end of the flexible body 906. As shown, the strap 904 is placed over the lower lug 902 of the drive box 62 and wrapped under the rods 182A, 182B and over the shell collar 122. Then, the free end of the flexible body 906 is inserted into the coupling 908 and pulled to compress the drive box 62 against the cylindrical pump shell 64. In certain embodiments, the free end of the flexible body 906 may be retained in this tightened configuration by cooperating ratcheting surfaces on the flexible body 906 and the inside surface of the coupling 908.

Referring now primarily to FIG. 30, another embodiment of a housing 910 of the drive box 62 is shown. The housing 910 is similar to the housing 102 depicted in FIG. 13 and the components of the housing 910 that are the same as the components of the housing 102 retain the same reference designations. The housing 910 differs from the housing 102 in that it includes the lower lug 902 depicted in FIG. 29 and a solid thermal transfer pad 912A on the curved rearward surfaces 338, 342, 344 of the adhesive pads 306A-C. In certain embodiments, the thermal transfer pad 912A may be formed of a tacky material such that it stays affixed to the curved rearward surfaces 338, 342, 344 while the drive box 62 is being secured to the cylindrical pump shell 64, after which the strap 904, the connection between the upper tabs 308 and the flanges 314, and the tabs 302A, 302B and the clips 300A compress the thermal transfer pad 412 between the cylindrical pump shell 64 and the curved rearward surfaces 338, 342, 344 of the adhesive pads. In other embodiments, the thermal transfer pad 912A may be attached to the curved rearward surfaces 338, 342, 344 using an adhesive. In still other embodiments, the thermal transfer pad 912A may be omitted and an adhesive may be applied to the heat transfer pads 338, 342, 344 before securing the drive box 62 to the cylindrical pump shell 64.

FIG. 31 shows another embodiment of an attachment mechanism for a housing 910. In this embodiment, the adhesive pads 306A-C are omitted and a thick compliant thermal transfer pad 912 is used. It should be understood that in other embodiments, the adhesive pads 306A-C, the thermal transfer pad 912 and the spacers 340, 346 may be omitted and pads such as the adhesive pads 306A-C may be applied directly to the cylindrical pump shell 64 at a location corresponding to the housing 410.

Some embodiments may be described using the expression “coupled” and “connected” along with their derivatives. For example, some embodiments may be described using the term “coupled” to indicate that two or more elements are in direct physical or electrical contact. The term “coupled,” however, may also mean that two or more elements are not in direct contact with each other, but yet still co-operate or interact with each other. The embodiments are not limited in this context.

As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.

As used herein, the modifier “about” used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (for example, it includes at least the degree of error associated with the measurement of the particular quantity). When used in the context of a range, the modifier “about” should also be considered as disclosing the range defined by the absolute values of the two endpoints. For example, the range “from about 2 to about 4” also discloses the range “from 2 to 4.”

It should be understood that the connecting lines shown in the various figures contained herein are intended to represent exemplary functional relationships and/or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in a practical system. However, the benefits, advantages, solutions to problems, and any elements that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as critical, required, or essential features or elements. The scope is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” Moreover, where a phrase similar to “at least one of A, B, or C” is used in the claims, it is intended that the phrase be interpreted to mean that A alone may be present in an embodiment, B alone may be present in an embodiment, C alone may be present in an embodiment, or that any combination of the elements A, B or C may be present in a single embodiment; for example, A and B, A and C, B and C, or A and B and C.

In the detailed description herein, references to “one embodiment,” “an embodiment,” “an example embodiment,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art with the benefit of the present disclosure to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. After reading the description, it will be apparent to one skilled in the relevant art(s) how to implement the disclosure in alternative embodiments. As used herein the term “substantially” means “to a large degree or amount.” In some cases, the term “substantially” may mean “more than 50%.”

Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S. C. 112(f), unless the element is expressly recited using the phrase “means for.” As used herein, the terms “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.

Various modifications and additions can be made to the exemplary embodiments discussed without departing from the scope of the present disclosure. For example, while the embodiments described above refer to particular features, the scope of this disclosure also includes embodiments having different combinations of features and embodiments that do not include all of the described features. Accordingly, the scope of the present disclosure is intended to embrace all such alternatives, modifications, and variations as fall within the scope of the claims, together with all equivalents thereof.