Abstract:
The present invention is a mulch plate assembly in a rotary lawnmower having a deck member featuring a discharge aperture wherein grass clippings and the like are discharged during use of the lawnmower, the mulch plate assembly comprising a rigid plate member, attachment means whereby the rigid plate is attached to the deck member in position to obstruct the discharge aperture, the attachment means capable of disengagement by a single unidirectional application of force by a user.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]    This application claims the benefit of priority to U.S. Provisional Application No. 61/801,151 filed Mar. 15, 2013. The content of U.S. Provisional Application No. 61/801,151 is incorporated by reference herein in its entirety. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT  
       [0002]    Not Applicable. 
       THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT  
       [0003]    Not Applicable. 
       INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC  
       [0004]    Not Applicable. 
       BACKGROUND OF THE INVENTION 
       [0005]    (a) Field of the Invention 
         [0006]    The present invention is in the technical field of devices designed for use in the field of lawn care. More particularly, the present invention is in the technical field of lawnmowers, generally. Still more particularly, the present invention is in the technical field of lawnmower mulch plate assemblies. 
         [0007]    (b) Background Art 
         [0008]    In a rotary power lawnmower of the pushing or riding type, a deck member is typically fabricated from steel or aluminum and has a downwardly projecting skirt portion to define a downwardly facing cavity or chamber. The deck member is supported for ground traversing movement by a set of four wheels which are adjustable for changing the height of the deck member relative to the ground. In the case of a rotary power lawnmower of the pushing type, a gasoline engine is commonly mounted on the deck member and includes a vertical shaft which projects downwardly through the deck member into the chamber, the vertical shaft supporting a grass cutting blade having sharpened outer edge portions and the cutting blade being suspended from the vertical shaft in a roughly horizontal plane within the downwardly facing cavity or chamber defined by the deck member. In the case of a rotary power lawnmower of the riding type, the analog gasoline engine, vertical shaft, and cutting blade assembly exists, however, the gasoline engine is typically mounted behind a seat assembly that is mounted on the deck member. 
         [0009]    Common in the prior art is a discharge outlet aperture in the downwardly projecting deck member skirt allowing the for the distribution of grass clippings propelled by the cutting blade back onto the ground. Frequently, this discharge outlet aperture is coupled with a deflector that extends down and outward from the deck member skirt, the deflector serving the purpose of deflecting the grass clippings expelled through the discharge outlet aperture down and outwardly from the lawnmower. Also known in the art is a duct-like component that couples to the discharge outlet aperture, forming an extension for the discharge outlet aperture and directing grass clippings discharged into a bag component that is attached to the duct-like component. 
         [0010]    Further known in the art is the principle that fresh grass clippings are rich in nutrients and, therefore, serve as an excellent natural fertilizer for the lawn being cut. From time to time, a power lawnmower user will want the grass clippings to be spread over the lawn being cut to decay and fertilize the lawn. Likewise, the user will at other times want the grass clippings to be bagged or otherwise blown free from the lawn being cut. That said, the tendency in the prior art is mowers that expel grass clippings through a discharge outlet aperture either into a collection bag or in a such way as to leave the clippings in a concentrated and unnatural pattern that fails to evenly distribute the clippings across the lawn being cut. Further, because the function of the mower is to cut each blade of grass and then expel the grass clipping from the deck member cavity as soon as possible, the clippings expelled from mowers known in the prior art tend to be larger clippings as compared to clippings retained inside the deck member cavity for longer periods of time—clippings retained in the deck member cavity for longer periods of time are usually cut and diced multiple times and thus leave the cavity in smaller and multiple pieces. For the purposes of the present application, the finer cut grass clippings will be referred to as “mulch” and the act of dispersing the finer cut grass clippings for the purposes of decay and fertilization of the lawn will be referred to as “mulching”. 
         [0011]    As identified above the prior art thoroughly addresses the problem of how to manage, discharge and dispose of grass clippings created during use of the power lawnmower. However, the prior art does not effectively address the problem of how to effectively retain and re-use grass clippings created during use of the power lawnmower. Accordingly, a need exists for a power lawnmower assembly specifically designed for the purpose of retaining grass clippings in the deck member cavity for as long as possible during use of the lawnmower, thus yielding finer cut grass clippings evenly dispersed over the area of lawn mowed at the election of a user. Accompanying this stated need in the prior art for a power lawnmower assembly specifically designed to better facilitate mulching, is the need for a power lawnmower assembly that is readily configurable by a user to either better facilitate mulching or to function as would a standard mower known in the prior art. Of specific importance to the configurable aspects of the mower would be the ease with which a user may configure the same. Omitting altogether or otherwise limiting the need for a user to utilize tools to configure the mower is deemed a preeminent need in the art, particularly in the circumstance of for-hire mowing companies for whom “time is money” and the delay occasioned by a complicated and tool-based configuration of the lawnmower assembly can negatively affect the company&#39;s bottom line. 
       BRIEF SUMMARY OF THE INVENTION  
       [0012]    Stated as broadly as possible, the present invention is a mulch plate assembly, in a power rotary lawnmower having a deck member cavity and a discharge outlet aperture in the otherwise enclosed deck member cavity, comprising a rigid plate, means whereby the rigid plate may interchangeably be configured to completely block the discharge outlet aperture or be configured such that the discharge outlet aperture is completely unobstructed, and means whereby the rigid plate may be interchangeably attached or detached from the deck member. 
         [0013]    Further and as noted above, ease of use is considered a primary need in the prior art and, therefore, it is expressly contemplated that the now disclosed mulch plate assembly be designed in such way as to make its configuration and attachment or detachment to the deck member as efficient and quick of process as may be possible without compromising safety in the use of the lawnmower or the effectiveness of the lawnmower at accomplishing its primary task—cutting the grass. It is contemplated that the now disclosed mulch plate assembly should be easily configured while attached to the lawnmower and should be able to be easily removed from the lawnmower as needed. Therefore, in more detail, the broadest articulation of the invention as recited above may further comprise means by which the rigid plate may be completely released from the deck member of the lawnmower without the use of tools and by way of a single unidirectional application of force by the hand of a user, as well as simple and straightforward means to securely lock the rigid plate in a first “closed” orientation to the discharge outlet aperture, and simple and straightforward means to securely restrain the rigid plate in a second “open” orientation to the discharge outlet aperture. 
         [0014]    The means whereby the rigid plate may be attached to the deck member is contemplated to be a hinging means, the means to feature all the hallmarks of commonly known hinge assemblies. By virtue of the hinging means, the rigid plate may pivot about a hinge axis thereby being easily manipulated by a user and being easily positioned in a down “closed” orientation or an up “open” orientation vis-a-vis the discharge outlet aperture in the deck member. As suggested above, it is deemed desirable that the hinge assembly be designed to enable disengagement and dismantling of the hinge assembly through a single unidirectional application of force by the hand or hands of a user. This enablement allows the full configuration of the mulch plate assembly by a user easily, efficiently, quickly and without the need for tools. In what is considered a best mode of the now disclosed invention, a user may dismantle the hinging means by removing a hinge pivot pin through a single application of a pulling or pushing force upon the hinge pivot pin, thereby releasing the rigid plate from the deck member. So as to avoid loss of any of the components of the assembly, it is further contemplated that both the hinge pivot pin and the rigid plate itself may be tethered directly to the deck member so that neither component is ever lost during use. 
         [0015]    Further contemplated with regard to the now disclosed mulch plate assembly is a locking means whereby the rigid plate may be securely locked in a first “closed” position completely obstructing the discharge outlet aperture of the deck member cavity. Likewise, also contemplated is a restraint means whereby the rigid plate may be securely restrained in a second “open” position leaving the discharge outlet aperture of the deck member cavity completely unobstructed. The preferred embodiment of the now disclosed invention supposes that the restraint means would be a biased restraint comprising either a shock cord or a compression spring joined at a first end to the rigid plate and joined at a second end to the deck member such that when both ends are joined as provided, the rigid plate is restrained in an “open” position leaving the discharge outlet aperture completely unobstructed. 
         [0016]    Specifically, the preferred embodiment supposes that the locking means will be a slide lock apparatus comprising two spaced protrusions from the deck member, each deck member protrusion having a perforation and both protrusion perforations being in a single vertical axis, at least one protrusion from the rigid plate having a perforation, and a pin having a cylindrical shaft of smaller diameter than the perforations in the deck member protrusions and the rigid plate protrusion and a head of larger diameter than the perforations in the deck member protrusions and the rigid plate protrusion. When the perforations in the deck member protrusions are in common vertical axis with the perforations of any rigid plate members, the pin may be inserted through all relevant perforations, thus locking the rigid plate and the deck member together. For the purposes of this application the locking means identified and explained in detail in this paragraph will be simply referred to as a “slide lock assembly”. 
         [0017]    It is a primary object of the now disclosed invention to provide a power rotary lawnmower that is equally capable of standard mowing and disposal or collection of grass clippings during mowing or mulching at the election of a user. 
         [0018]    It is a primary object of the now disclosed invention to provide a mulch plate assembly for installation on a power rotary lawnmower that enables the lawnmower to alternatively serve the functions of standard mowing and disposal or collection of grass clippings during mowing or mulching at the election of a user. 
         [0019]    It is a primary object of the now disclosed invention to provide a power rotary lawnmower that may be easily and efficiently transitioned between the functions of standard mowing and disposal or collection of grass clippings during mowing to mulching at the election of a user and without need for the use of outside tools. 
         [0020]    It is a primary object of the now disclosed invention to provide a mulch plate assembly for installation on a power rotary lawnmower that enables the lawnmower to be easily and efficiently transitioned between the functions of standard mowing and disposal or collection of grass clippings during mowing to mulching at the election of a user and without need for the use of outside tools. 
         [0021]    It is a further object of the now disclosed invention to provide a mulch plate assembly for a power rotary lawnmower that may be conveniently engaged or disengaged without need of the assistance of tools and without fear of the loss of any components of the assembly. 
         [0022]    It is a further object of the now disclosed invention to provide a mulch plate assembly for installation on a power rotary lawnmower that enables the lawnmower to conveniently transition between a standard mowing use and a mulching use without sacrificing the effectiveness of the lawnmower in either its standard mowing use or its mulching use. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)  
         [0023]      FIG. 1  is a top view of a preferred embodiment of the presented inventive mulch plate assembly; 
           [0024]      FIG. 2  is a side view of a preferred embodiment of the presented inventive mulch plate assembly; 
           [0025]      FIG. 3  is a perspective view of a securing means mechanism of a preferred embodiment of the presented inventive mulch plate assembly; and 
           [0026]      FIG. 4  is a side view of a preferred embodiment of the presented inventive mulch plate assembly, the view of  FIG. 4  being an alternative configuration to that shown in  FIG. 2 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0027]    Referring now to the invention in more detail, in  FIG. 1  there is shown a mulch plate assembly in a rotary lawnmower, the rotary lawnmower having the attributes of a typical rotary lawnmower including a deck member  10 , front right wheel  13 , and rear right wheel  21 . Though not intrinsic to the presently claimed invention nor the particular embodiment depicted in  FIG. 1 , the deck member  10 , front right wheel  13 , and rear right wheel  21  are now disclosed to provide a context and frame of reference for one of ordinary skill in the art to understand the placement of the now disclosed mulch plate assembly with regard to the standard rotary lawnmower. Integrated with the deck member  10  is a left hinge knuckle  20  and a right hinge knuckle  17  through which a hinge pin shaft  12  is run, said hinge pin shaft  12  also running through a second left hinge knuckle  19  and second right hinge knuckle  11 , the second left hinge knuckle  19  and second right hinge knuckle  11  being integrated with a rigid plate  18  depicted in a “closed” orientation and being at a near perpendicular orientation to the top of the deck member  10 . Further depicted in  FIG. 1  is a partial view of a mechanism whereby the rigid plate  18  is secured in the “closed” position, the visible portion of the mechanism comprising a locking pin  16  run through the axial perforation of a first member  15  integrated with the face of the rigid plate  18 , and a pin leash  14  affixed at one end to the locking pin  16  and at a second end to the hinge pin shaft  12 . The hinge pin as depicted comprises a shaft  12  and a flattened head  22 . 
         [0028]    Referring now to the invention in more detail, in  FIG. 2  there is shown a mulch plate assembly in a rotary lawnmower, the rotary lawnmower having the attributes of a typical rotary lawnmower including a deck member  10 , front right wheel  13 , and rear right wheel  21 . Though not intrinsic to the presently claimed invention nor the particular embodiment depicted in  FIG. 2 , the deck member  10 , front right wheel  13 , and rear right wheel  21  are now disclosed to provide a context and frame of reference for one of ordinary skill in the art to understand the placement of the now disclosed mulch plate assembly with regard to the host rotary lawnmower. Integrated with the deck member  10  is a left hinge knuckle  20  and a right hinge knuckle  17  through which a hinge pin shaft  12  is run, said hinge pin shaft  12  also running through a second left hinge knuckle  19  and second right hinge knuckle  11 , the second left hinge knuckle  19  and second right hinge knuckle  11  being integrated with a rigid plate  18  depicted in a “closed” orientation and being at a near perpendicular orientation to the top of the deck member  10 . The hinge pin as depicted comprises a shaft  12  and a flattened head  22 . Further depicted in  FIG. 2  is a full view of a mechanism whereby the rigid plate  18  is secured in the “closed” position, the mechanism comprising a locking pin  16 , a first member  15  integrated with the face of the rigid plate  18 , a second member  23  integrated with the side of the deck member  10 , a third member  24  integrated with the side of the deck member  10 , and a pin leash  14  affixed at one end to the locking pin  16  and at a second end to the hinge pin shaft  12 . The mechanism whereby the rigid plate  18  is secured in the “closed” position works by insertion of the locking pin  16  into coaxial perforations in the first member  15  integrated with the face of the rigid plate  18 , the second member  23  integrated with the side of the deck member  10 , and the third member  24  integrated with the side of the deck member  10 . 
         [0029]    Referring now to the invention in more detail, in  FIG. 3  there is shown a mulch plate assembly in a rotary lawnmower, the rotary lawnmower having the attributes of a typical rotary lawnmower including a deck member  10  and a front right wheel  13 . Though not intrinsic to the presently claimed invention nor the particular embodiment depicted in  FIG. 3 , the deck member  10  and front right wheel  13  are now disclosed to provide a context and frame of reference for one of ordinary skill in the art to understand the placement of the now disclosed mulch plate assembly with regard to the host rotary lawnmower.  FIG. 3  is a perspective view of the same preferred embodiment depicted in  FIG. 1  and  FIG. 2 , the perspective being an up-close detailed view of the mechanism whereby the rigid plate  18  is secured in the “closed” position. Referring now to  FIG. 3  in more detail, integrated with the deck member  10  is a right hinge knuckle  17  through which a hinge pin shaft  12  is run, said hinge pin shaft  12  also running through a second right hinge knuckle  11 , the second right hinge knuckle  11  being integrated with a rigid plate  18  depicted in a “closed” orientation and being at a near perpendicular orientation to the top of the deck member  10 . The hinge pin as depicted comprises a shaft  12  and a flattened head  22 . As noted above, the reason for inclusion of  FIG. 3  is to present a more detailed full view of the mechanism whereby the rigid plate  18  is secured in the “closed” position, the mechanism comprising a locking pin  16 , a first member  15  integrated with the face of the rigid plate  18 , a second member  23  integrated with the side of the deck member  10 , a third member  24  integrated with the side of the deck member  10 , and a pin leash  14  affixed at one end to the locking pin  16  and at a second end to the hinge pin shaft  12 . The mechanism whereby the rigid plate  18  is secured in the “closed” position works by insertion of the locking pin  16  into coaxial perforations in the first member  15  integrated with the face of the rigid plate  18 , the second member  23  integrated with the side of the deck member  10 , and the third member  24  integrated with the side of the deck member  10 . 
         [0030]    Referring now to the invention in more detail, in  FIG. 4  there is shown a mulch plate assembly in a rotary lawnmower, the rotary lawnmower having the attributes of a typical rotary lawnmower including a deck member  10 , front right wheel  13 , and rear right wheel  21 . Though not intrinsic to the presently claimed invention nor the particular embodiment depicted in  FIG. 4 , the deck member  10 , front right wheel  13 , and rear right wheel  21  are now disclosed to provide a context and frame of reference for one of ordinary skill in the art to understand the placement of the now disclosed mulch plate assembly with regard to the host rotary lawnmower. Integrated with the deck member  10  is a left hinge knuckle  20  and a right hinge knuckle  17  through which a hinge pin shaft  12  is run, said hinge pin shaft  12  also running through a second left hinge knuckle  19  and second right hinge knuckle  11 , the second left hinge knuckle  19  and second right hinge knuckle  11  being integrated with a rigid plate  18  depicted in an “open” orientation exposing a lawnmower discharge  25  as well as the interior wall  26  of the deck member  10 . The hinge pin as depicted comprises a shaft  12  and a flattened head  22 . Further depicted in  FIG. 4  is a partial view of a mechanism whereby the rigid plate  18  may be secured in the “closed” position, the partial view of the mechanism comprising a locking pin  16 , a second member  23  integrated with the side of the deck member  10 , a third member  24  integrated with the side of the deck member  10 , and a pin leash  14  affixed at one end to the locking pin  16  and at a second end to the hinge pin shaft  12 . The mechanism whereby the rigid plate  18  may be secured in the “closed” position works by insertion of the locking pin  16  into coaxial perforations in a first member (not viewable in the present  FIG. 4 ) integrated with the face of the rigid plate  18 , the second member  23  integrated with the side of the deck member  10 , and the third member  24  integrated with the side of the deck member  10 . It will be noted that because the rigid plate  18  is depicted in its “open”, the mechanism whereby the rigid plate  18  may be secured in the “closed” position is depicted as it would look when not engaged, the rigid plate  18  being open and exposing the lawnmower discharge  25  and interior wall  26  of the deck member  10 . 
         [0031]    In more detail, still referring to the invention of  FIG. 1 ,  FIG. 2 ,  FIG. 3  and  FIG. 4 , the preferred embodiment as shown in the varying views include two paramount inventive mechanisms the inventor believes critical in distinguishing the present invention from the prior art—the first being a releasable hinging mechanism whereby the proposed mulch plate is affixed to the rotary lawnmower and the second being a mechanism whereby a mulch plate may be locked in a “closed” or “mulching” configuration obstructing the lawnmower discharge  25 . Specifically, it is contemplated that the mulch plate assembly as depicted in the aforementioned figures is quickly and easily removable from the lawnmower by a single unidirectional application of force by a user pulling on the hinge pin flattened head  22  and in a single motion sliding the hinge pin shaft  12  out of the cavities of the first left hinge knuckle  20  and first right hinge knuckle  17  integrated with the deck member and out of the second left hinge knuckle  19  and second right hinge knuckle  11  integrated with the rigid plate  18 , thus releasing the rigid plate  18  from the deck member  10 . Release of the rigid plate  18  from the deck member  10  results in a fixed configuration of the lawnmower in which the lawnmower discharge  25  and interior wall  26  of the deck member  10  are exposed and, thus, vegetation cut while utilizing the lawnmower is ejected from beneath the deck member  10  rather than maintained therein and converted to mulch as is the case when the rigid plate  18  is secured in a “closed” or “mulching” orientation obstructing the lawnmower discharge  25 . When the rigid plate  18  is secured in its “closed” or “mulching” configuration, the second inventive mechanism is utilized, the locking pin  16  being dropped through the coaxial perforations in the first member  15  integrated with the rigid plate  18 , the second member  23  integrated with the side of the deck member, and the third member  24  integrated with the side of the deck member. The locking pin  16  has a pin leash  14  securing the locking pin  16  to the hinge pin  12  at all times to prevent loss of the locking pin  16 . A further inventive mechanism is believed to be the restraint of the rigid plate  18  in its “open” configuration as depicted in  FIG. 4 , the restraint accomplished by biased restraint means, preferably a length of elastic material or a biased spring mechanism that is hooked to the rigid plate  18  when in the “open” configuration, thus securing the rigid plate  18  to the deck member  10  or other fixed component of the lawnmower and allowing use of the lawnmower while the rigid plate  18  is in the “open” configuration without need for total removal of the rigid plate  18  via release of the hinge pin shaft  12  by pulling the hinge pin head  22  as described above. 
         [0032]    In further detail, still referring to the invention of  FIG. 1 ,  FIG. 2 ,  FIG. 3 , and  FIG. 4 , the rigid plate  18  is contemplated to be made of any strong and rigid material including, but not limited to steel, stainless steel, iron, wrought iron, carbon composite, or ceramic. Further, all hinge components including but not limited to the first left hinge knuckle  20 , the first right hinge knuckle  17 , the second left hinge knuckle  19 , the second right hinge knuckle  11 , and the hinge pin shaft  12  and head  22  are contemplated to be made of a strong and rigid material comparable to the composition of the rigid plate  18 , the aforesaid hinge knuckles being affixed to the rigid plate  18  or deck member  10 , as appropriate, by strong attachment means and preferably by weld. Likewise, all components of mechanism securing the rigid plate  18  in the “closed” or “mulching” configuration including but not limited to the locking pin  16 , first member  15  integrated with the rigid plate  18 , second member  23  integrated with the side of the deck member  10 , and third member  24  integrated with the side of the deck member  10  are contemplated to be made of a strong and rigid material comparable to the composition of the rigid plate  18 , the aforesaid members being affixed to the rigid plate  18  or deck member  10 , as appropriate, by strong attachment means and preferably by weld. The locking pin leash  14  is contemplated to be composed of any durable but flexible material including without limitation wire, small gauge wire rope, or small gauge steel cable.