Abstract:
A multi-use lawn mower capable of operating as a mulching, side-discharge, or a bagging mower. The lawn mower ( 10 ) includes; a mower deck ( 14 ) having an opening ( 58 ) therein forming a passageway through which grass clippings exit the cutting chamber during select modes of operation. The lawn mower also includes a grass-collecting hopper ( 40 ) removably mounted on the mower deck ( 14 ), the grass-collecting hopper ( 40 ) having a basket portion ( 42 ) for receiving grass clippings cut by the cutting blade ( 36 ) and a multi-station mounting portion ( 60 ) configured to interface with the opening ( 58 ) in the mower deck in a plurality of orientations. The mounting portion includes a mulching station ( 64 ) that configures the lawn mower to function as a mulching mower, a bagging station ( 66 ) that configures the lawn mower to function as a bagging mower, and a side-discharge station ( 68 ) that configures the lawn mower to function as a side-discharge mower. When the multi-station mounting portion mounts the grass-collecting hopper on the mower deck, a single one of the stations interfaces with the opening in the mower deck to configure the lawn mower for desired mode of operation.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the priority benefit of U.S. Provisional Patent Application Ser. No. 60/681,730 filed May 17, 2005. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of Invention 
         [0003]    This invention relates to mowing machines, and more specifically, to a lawn mower that can selectively function as a bagging mower, a mulching mower and a discharge mower. 
         [0004]    2. Description of Related Art 
         [0005]    Lawn mowers for cutting grass, weeds and leaves with a rotating cutting blade housed in a downward-opening mower deck are well known in the art. Generally, lawn mowers are classified in one of three classes, specifically: (1) bagging mowers that collect the grass cut by the cutting blade in a grass receptacle such as a hopper or bag; (2) side-discharge mowers that discharge the cut grass through an opening in the side of the mower deck in order to leave the grass clippings on the lawn; and (3) mulching mowers that that chop the grass clippings more finely within the cutting chamber formed by the mower deck and discharge the clippings downward of the deck. 
         [0006]    Bagging-type lawn mowers collect grass clippings in the grass receptacle in order to remove all of the clippings from the lawn, thereby providing a professional quality appearance. However, the grass clippings collected in the grass receptacle must be carried to and dumped at a disposal site. The side-discharge and mulching-mode lawn mowers eliminate the need for dumping the grass clippings by returning grass clippings to the lawn. Mulching mowers chop the grass clippings into finer pieces so that they decompose more rapidly and give the lawn a good finished quality. However, if the grass is exceptionally tall or thick, mulching mowers tend to bog down with the excess grass clippings, leaving unsightly clumps and causing the mower to frequently stall. In such situations, discharging the grass clippings through a discharge chute in the mower deck as found on a side-discharge mower is the preferred option. It is commonly the case that a lawn caretaker may desire to use each of these different modes at different times, even on the same plot of grass. 
         [0007]    In recent years, lawn mowers have been developed that can be selectively configured to operate in more than just a single mode of operation, e.g., the mower may be configured to operate as a mulching mower and a bagging mower, or even as a mulching mower, a side-discharge mower and a bagging mower. It is, however, inconvenient to reconfigure these lawn mowers between the different operational modes. Converting the lawn mower to a different operational mode typically involves the manual installation and/or removal of parts to the lawn mower requiring time consuming work. For example, mulching operations typically require the installation of a discharge cover or plug which a user must install in the discharge opening of the mower deck. If the user wants to switch back to the bagging mode of operation, the user must remove the mulch plug and reinstall the grass-collecting hopper. Tools are typically required to install or remove the mulching plug. The awkward, inconvenient and relatively time consuming process of installing and uninstalling the discharge plug also requires the installer to reach into the discharge opening with his/her hand, which can be difficult and messy. Additionally, the components not being used in the selected mode of operation, such as the mulch plug or the grass collection receptacle, must be stored separate from the lawn mower. Often, these parts become lost or misplaced or are otherwise not readily available when needed. 
         [0008]    Therefore, there is a need for an improved lawn mower that can be easily reconfigured between a bagging mode, a mulching mode and a discharge mode by simple operation. 
       SUMMARY OF THE INVENTION 
       [0009]    One aspect of the invention is a multi-use lawn mower that can be configured to operate in either a mulching mode, a discharge mode, or a bagging mode of operation, wherein the selection of the mode of operation is performed without the need to remove or add additional components to the lawn mower. The lawn mower includes a power source, a pair of front ground engaging wheels, a pair of rear ground engaging wheels, and a cutting blade connected to the power source. The lawn mower also includes a mower deck having a top panel surrounded by a downward extending skirt forming a cutting chamber in the underside the mower deck. The cutting chamber houses the cutting blade. The mower deck has an opening therein forming a passageway through which grass clippings exit the cutting chamber during select modes of operation. The lawn mower also includes a grass-collecting hopper removably mounted on the mower deck, the grass-collecting hopper having a basket portion for receiving grass clippings cut by the cutting blade and a multi-station mounting portion configured to interface with the opening in the mower deck in a number of different orientations. The mounting portion includes a mulching station that configures the lawn mower to operate in a mulching mode, a bagging station that configures the lawn mower to operate in a bagging mode, and a discharge station that configures the lawn mower to operate in a discharge mode. When the grass-collecting hopper is mounted on the mower deck, one of the stations interfaces with the opening in the mower deck to configure the lawn mower for the desired mode of operation. 
         [0010]    Another aspect of the invention is a multi-use lawn mower capable of selectively bagging grass clippings or returning the grass clippings on the lawn. The lawn mower includes a power source, a cutting blade connected to the power source, and a mower deck forming a cutting chamber in the underside the mower deck. The cutting chamber houses the cutting blade. The mower deck has an opening therein forming a passageway through which grass clippings exit the cutting chamber during select modes of operation. The lawn mower also includes a grass-collecting hopper removably mounted on the mower deck. The grass-collecting hopper has a basket portion for receiving grass clippings cut by the cutting blade and a multi-station mounting portion configured to interface with the opening in the mower deck in a plurality of orientations. The mounting portion includes a bagging station that configures the lawn mower to operate in a bagging mode, and at least one other station that configures the lawn mower to operate in a mode that returns the grass clippings to the lawn. When the grass-collecting hopper is mounted on the mower deck, one of the plurality of stations interfaces with the opening in the mower deck to configure the lawn mower for the desired mode of operation. 
         [0011]    In another aspect, the invention is directed to a multi-use lawn mower capable of selectively operating in a mulching mode of operation, a side-discharge mode of operation, or a bagging mode of operation. The lawn mower includes a power source, a pair of front ground engaging wheels, a pair of rear ground engaging wheels, and a cutting blade connected to the power source. The lawn mower further includes a mower deck that forms a cutting chamber in the underside the mower deck, the cutting chamber housing the cutting blade. The mower deck has an opening therein that forms a passageway through which grass clippings exit the cutting chamber during select modes of operation. The lawn mower also includes a grass-collecting hopper removably mounted above and generally over the center of the mower deck such that substantially the entire hopper is positioned between the front and rear ground engaging wheels. The grass-collecting hopper has a basket portion for receiving grass clippings cut by the cutting blade and a multi-station mounting portion configured to interface with the opening in the mower deck in a plurality of orientations. The basket portion and mounting portion are molded together and components that comprise the different stations of the mounting portion are molded into the mounting portion so that the grass-collecting hopper is a single unitary part. The mounting portion includes a mulching station that configures the lawn mower to function as a mulching mower, a bagging station that configures the lawn mower to function as a bagging mower, and a side-discharge station that configures the lawn mower to function as a side-discharge mower. When the multi-station mounting portion mounts the grass-collecting hopper on the mower deck, a single one of the stations interfaces with the opening in the mower deck to configure the lawn mower for the selected mode of operation. 
         [0012]    These and other features and advantages of this invention are described in, or are apparent from, the following detailed description of various exemplary embodiments of the systems and methods according to this invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]    The above mentioned and other features of this invention 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: 
           [0014]      FIG. 1  is perspective view of a lawn mower according to one embodiment of the invention; 
           [0015]      FIG. 2  is a partially exploded perspective view of the lawn mower of  FIG. 1  illustrating a grass-collecting hopper; 
           [0016]      FIG. 3  is a partially exploded and cutaway perspective view of the mower deck and grass-collecting hopper of the lawnmower  FIG. 1 ; 
           [0017]      FIG. 4  is a bottom perspective view of a mounting portion of the grass-collecting hopper of  FIG. 2 ; 
           [0018]      FIG. 5A  is an enlarged perspective view of a mulching station on the grass-collecting hopper of  FIG. 4 ; 
           [0019]      FIG. 5B  is a view of the grass-collecting hopper and mower deck illustrating the flow of grass clippings when the mower is in a mulching mode of operation; 
           [0020]      FIG. 6A  is an enlarged perspective view of a discharge station on the grass-collecting hopper of  FIG. 4 ; 
           [0021]      FIG. 6B  is a view of the grass-collecting hopper and mower deck illustrating the flow of grass clippings when the mower is in a discharge mode of operation; 
           [0022]      FIG. 7A  is an enlarged perspective view of a bagging station on the grass-collecting hopper of  FIG. 4 ; and 
           [0023]      FIG. 7B  is a view of the grass-collecting hopper and mower deck illustrating the flow of grass clippings when the mower is in a bagging mode of operation. 
       
    
    
       [0024]    Corresponding reference characters indicate corresponding parts throughout the views of the drawings. 
       DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
       [0025]    The invention will now be described in the following detailed description with reference to the drawings, wherein preferred embodiments are described in detail to enable practice of the invention. Although the invention is described with reference to these specific preferred embodiments, it will be understood that the invention is not limited to these preferred embodiments. But to the contrary, the invention includes numerous alternatives, modifications and equivalents as will become apparent from consideration of the following detailed description. 
         [0026]    Referring now to the Figures, one embodiment of a lawn mower according to the invention is shown generally at  10  in  FIGS. 1 and 2 . The lawn mower  10  has mower body  12  comprising a mower deck  14  at least partially covered by a housing  16 . Front ground engaging wheels  18  are provided at the front of the mower body  12  and rear ground engaging wheels  20  are provided at the rear of the mower body  12 . Desirably, the rear wheels  20  constitute drive wheels for the lawn mower  10 , although the front wheels  18  may also be used as the drive wheels or the lawn mower may be manually propelled without departing from the scope of the invention. A handle  22  extends rearward from the mower body  12  to permit an operator to maneuver the lawn mower  10 . The handle  22  has a conventional operator presence bail  24  and a speed control rod  26  as is known in the art. Although the invention is described herein as part of a walk-behind mower, one skilled in the art will understand that the invention may also be used on a riding lawnmower without departing from the scope of the invention. 
         [0027]    As best seen in  FIG. 3 , in one embodiment the mower deck  14  is fabricated with a generally horizontal top panel  30  surrounded by a downward extending skirt  32  to form a cutting chamber  34  in the underside the mower deck  14 . However, other shapes for the mower deck can be selected using sound engineering judgment provided the mower deck forms a suitable cutting chamber. As is understood in the art, a grass cutting blade  36  is provided in the cutting chamber  34  of the mower deck  14 . A power source, such as a gasoline powered engine  38  is mounted on the mower body  12  for rotating the cutting blade  36  and desirably driving the rear wheels  20 . However, it is understood that the power source  38  may be an electric motor without departing from the scope of the invention. The power source  38  has an output shaft (not shown) that is operatively connected to the drive wheels and the cutting blade  36  through transmission means well understood in the art. Therefore, further description of the transmission means need not be provided herein. 
         [0028]    A grass-collecting hopper  40  is removably mounted on the mower deck  14 . The grass-collecting hopper  40  comprises a bottom portion  41  and a basket portion  42  configured to receive and hold the grass clippings. Referring also now to  FIG. 4 , the basket portion  42  has an upper rim  44  containing a plurality of lift handles  46  molded therein for lifting and carrying the hopper  40 . The basket portion  42  desirably contains mesh openings (not shown) to aid with air flow out of the basket portion  42  so that the grass clippings can be effectively deposited in the hopper  40 . In one embodiment, the grass-collecting hopper  40  is molded as a single integral piece of polypropylene such that the hopper is somewhat stiff so that it retains it shape to aid in placement onto the mower deck  14  when empty. However, it is noted that other like materials that enable the manufacture of a long-lasting, durable part may be used. It is further to be understood that the grass-collecting hopper  40  may comprise several different components that are glued, snapped or welded together or otherwise fastened together with screws, rivets or other fasteners without departing from the scope of the invention. 
         [0029]    As best seen in  FIG. 2 , the housing  16  defines a cavity  50  configured to receive the grass-collecting hopper  40  so that the hopper can mount above the top panel  30  of the mower deck  14 . In the embodiment illustrated, the grass-collecting hopper  40  is mounted above and generally over the center of the mower deck  14  such that substantially all of the grass-collecting hopper  40  is positioned between the front and rear wheels  18 ,  20  when in its operational position. While the position of the hopper  40  in the illustrated embodiment is desirable, one skilled in the art will understand that other embodiments are contemplated that may position the hopper  40  in other locations on the mower body  12  such that a substantial portion of the hopper is behind the rear wheels  20  or to the side of the mower deck  14  without departing from the scope of the invention. 
         [0030]    The housing  16  contains a flap  52  that covers the grass-collecting hopper  40  when it is mounted in the cavity  50 . Desirably, the flap  52  is attached to the housing  16  with a hinge  54  so that the flap  52  can be pivoted to enable access to the grass-collecting hopper  40  for easy insertion and removal of the hopper into and out of the cavity  50 . Thus, with the flap  52  in the open position, the user can lift the grass-collecting hopper  40  out of the cavity  50  and carry the hopper to a suitable grass disposal location to dump and dispose of the grass clippings collected in the hopper. Alternately, the flap  52  may be made part of the grass-collecting hopper  40  without departing from the scope of the invention. In the illustrated embodiment, the mower deck  14  has a circumferential ridge  56  extending generally around the outer circumference of the top panel  30 . The ridge  56  engages the grass-collecting hopper  40  to secure the hopper in the cavity  50 . 
         [0031]    As best seen in  FIG. 3 , an opening  58  is formed in the mower deck  14  to permit grass clippings cut by the cutting blade  36  to exit the cutting chamber  34 . Desirably, the opening  58  is in the top panel  30  of the mower deck  14  and is located to the rear and toward one side of the deck as illustrated in  FIG. 3 . However, the opening  58  may be located in other positions in the mower deck  14  using sound engineering judgment without departing from the scope of the invention. According to the invention, the grass-collecting hopper  40  selectively interfaces with the opening  58  in the mower deck  14  to determine the mode of operation of the lawn mower  10  as will now be discussed. 
         [0032]    Turning now to  FIG. 4 , a mounting portion  60  of the grass-collecting hopper  40  comprises a plurality of stations configured to interface with the mower deck  14  of the lawn mower  10 . In one embodiment, the mounting portion  60  is the bottom portion  41  of the grass-collecting hopper  40  and comprises three separate stations. The three stations will be described below as a mulching station  64 , a bagging station  66  and a discharge station  68 , because when the particular station interfaces with the opening  58  in the mower deck  14 , the designated station ( 64 ,  66  or  68 ) causes the lawn mower  10  to operate as a mulching mower, a bagging mower and a side-discharge mower, respectively. Desirably, the mounting portion  60  contains the three stations illustrated in  FIG. 4 . However, one skilled in the art will understand that the mounting portion  60  may contain only two stations without departing from the scope of the invention. In such embodiment, it is preferable that the mounting portion  60  have a bagging station and a station that returns the grass clippings to the lawn, such as either a mulching station or a discharge station. Desirably, the components comprising the stations  64 ,  66 ,  68  are molded into the mounting portion  60  such that the grass-collecting hopper  40  is made as a single unitary part. However, the components comprising the stations  64 ,  66 ,  68  may be glued, welded, attached with fasteners or otherwise affixed to the hopper  40  without departing from the scope of the invention. 
         [0033]    To aid in the convenience of using the lawn mower  10 , it is desirable that the grass-collecting hopper  40  be the only component necessary to configure the lawn mower  10  for the particular mode of operation desired. Therefore, it is not necessary to install or remove additional components from the lawn mower in order to reconfigure the mower  10  between the bagging, discharge and mulching operational modes. In the illustrated embodiment, the grass-collecting hopper  40  has a generally triangular layout with each station  64 ,  66 ,  68  forming one corner of the triangle so that the stations are spaced about 120 degrees apart around the circumference of the bottom portion  41  of the hopper  40 . To select the mode of operation, the operator simply positions the grass-collecting hopper  40  such that the desired station ( 64 ,  66  or  68 ) interfaces with the opening  58  in the mower deck  14 . To switch modes of operation, the operator simply needs to remove the grass-collecting hopper  40  and reposition it (as illustrated by the arrows in  FIG. 2 ) so that the station ( 64 ,  66  or  68 ) corresponding to the desired mode of operation interfaces with the opening  58  in the mower deck  14 . 
         [0034]    As illustrated in  FIGS. 4 ,  5 A and  5 B, the mulching station  64  comprises a plug  70  extending downward from the bottom portion  41  of the grass-collecting hopper  40 . The plug  70  has a shape corresponding to the shape of the opening  58  in the mower deck  14 , and when the grass-collecting hopper  40  is mounted on the mower deck  14  such that the plug  70  interfaces with the opening  58 , the plug  70  substantially fills the opening  58  such that grass clippings are prevented from passing through the opening  58 . Thus, the plug  70  substantially seals the opening  58  causing the grass clippings to remain in the cutting chamber  34  as illustrated by the pathway  76  in  FIG. 5B  so that the cuttings are repeatedly chopped into smaller clippings as in a conventional mulching mower. 
         [0035]    As best seen in  FIGS. 4 ,  6 A and  6 B, the discharge station  68  comprises a skirt  80  extending from the bottom portion of the hopper that engages the opening  58  in the mower deck  14  such that at least a portion of the skirt is received about the outer circumference of the opening. The skirt  80  directs the grass clippings so that they pass out of the cutting chamber  34  through the opening  58  in the mower deck  14  and through a discharge passageway  82  formed by a chute  84  ( FIG. 3 ) mounted on the mower deck  14  such that they are discharged outwardly on the ground to the side of the lawn mower  10  as illustrated by the pathway  86  in  FIG. 6B . As best seen in  FIGS. 3 and 4 , the skirt  80  forms a wall having the general shape of the opening  58  with the side adjacent the chute  84  being left open so that grass clippings are free to pass through the chute. 
         [0036]    As best seen in  FIGS. 4 ,  7 A and  7 B, the bagging station  66  comprises a ramp  90  leading to an aperture  92  in the bottom portion  41  of the grass-collecting hopper  40 . An end wall  94  effectively blocks the chute  84  to prevent the grass clippings from being discharged to the side of the mower  10 . The ramp  90  guides the grass clippings from the opening  58  in the mower deck  14  through the aperture  92  in the bottom portion  41  and up into the grass-collecting hopper  40  so that the clippings are collected in the hopper  40 . Thus, when the grass-collecting hopper  40  is mounted such that the bagging station  66  interfaces with the opening  58  in the mower deck  14 , the grass cut by the cutting blade  36  is received and collected in the basket portion  42  of the hopper  40  as illustrated by the pathway  96  illustrated in  FIG. 7B . Desirably, the ramp  90  extends into the basket portion  42  of the hopper  40  to maintain a pathway for the grass clippings as they enter the basket portion so that they do not fall and clump near the aperture  92  and impede the collection of additional grass clippings at least until the basket is substantially full. 
         [0037]    As briefly set forth above, the plug  70 , skirt  80  and ramp  90  are desirably molded as part of the bottom portion  41  of the hopper  40 . Therefore, when the operator desires to select a certain mode of operation for the lawn mower  10 , the operator simply positions the grass-collecting hopper  40  so that the station  64 ,  66 ,  68  corresponding to the desired mode of operation interfaces with the opening  58  in the mower deck  14 . Suitable markings (not shown) can be placed on the upper rim  44  of the grass-collecting hopper  40  to visually aid the operator in correctly positioning the hopper  40  in the proper orientation. Accordingly, the operator does not need to add or remove any components to the lawn mower  10  in order to change modes of operations, but must only re-position the grass-collecting hopper  40  to the selected position. Desirably, each station  64 ,  66 ,  68  has a shape corresponding to the opening  58  in the mower deck  14  such that when correctly positioned in the cavity  50 , the hopper  40  snaps or locks in place to help securely mount and discourage misplacement of the hopper. Additionally, as best seen in  FIG. 3 , the top panel  30  of the mower deck  14  may have features that receive the stations ( 64 ,  66 ,  68 ) not engaged with the opening  58  to aid in securely affixing the hopper  40  to the mower deck. Additionally, the stations  64 ,  66 ,  68  permit a gap between the central surface of the bottom portion  41  of the hopper  40  and the mower deck  14  so that suitable connecting means (not shown) can connect the cutting blade  36  with the power source  38 . 
         [0038]    While this invention has been described in conjunction with the specific embodiments described above, it is evident that many alternatives, combinations, modifications and variations are apparent to those skilled in the art. Accordingly, the preferred embodiments of this invention, as set forth above are intended to be illustrative only, and not in a limiting sense. Various changes can be made without departing from the spirit and scope of this invention.