Cover attachment for lawnmower cutter housing

A lawnmower includes a belt cover attached to a cutter housing via one or more interlocking tabs and pockets. The lawnmower may include a cutter mounted to a shaft oriented in a vertical direction. The lawnmower may include a rear axle oriented in a horizontal direction. The lawnmower may include a cutter housing defining a lower opening below the cutter, a belt opening between the shaft and the rear axle, and at least one discharge opening. The lawnmower may include a belt cover including a ring portion at least partially surrounding the shaft above the cutter and a guard portion extending toward the belt opening. The belt cover may include at least one tab that engages a corresponding pocket on the cutter housing adjacent the belt opening.

TECHNICAL FIELD

Aspects of the present disclosure relate to power equipment and methods of assembly thereof, and in particular to systems, devices and methods of assembling a lawnmower.

BACKGROUND

Lawnmowers offer various options for handling clippings of the cut grass. A mulching option restricts the clippings from leaving a cutter housing such that the cutter repeatedly cuts the clippings and reduces their size. The small clippings eventually exit the cutter housing via a lower opening. A bagging option utilizes a discharge chute, typically located at a rear of the cutter housing.

A self-propelled lawnmower may include a single engine that rotationally drives a shaft. A cutter may be releasably engaged to the shaft to rotate the cutter for cutting grass. A transmission may be coupled to the shaft via a belt to rotate an axle or one or more drive wheels. The belt is typically located above the cutter. To reduce damage and wear to the belt and transmission, the belt is typically shielded from the cutter and grass clippings by a belt cover. Conventional belt covers may be integrated with a cutter housing. While secure, such integrated belt covers make service of the belt inconvenient.

In view of the foregoing, there is a need for improved self-propelled lawnmower systems. Further advantages will become apparent from the disclosure provided below.

SUMMARY

In an aspect, the disclosure provides a lawnmower. The lawnmower may include a cutter mounted to a shaft oriented in a vertical direction. The lawnmower may include a rear axle oriented in a horizontal direction. The lawnmower may include a cutter housing defining a lower opening below the cutter, a belt opening between the shaft and the rear axle, and at least one discharge opening. The lawnmower may include a belt cover including a ring portion at least partially surrounding the shaft above the cutter and a guard portion extending toward the belt opening. The belt cover may include at least one tab that engages a corresponding pocket on the cutter housing adjacent the belt opening.

In another aspect, the disclosure provides a belt cover for a self-propelled lawnmower. The belt cover may include a ring portion at least partially surrounding a cutter shaft above a cutter. The belt cover may include a guard portion extending rearward toward a belt opening in a rear wall of a cutter housing, wherein the belt cover includes at least one tab extending rearward that engages a corresponding pocket on the rear wall of the cutter housing.

In another aspect, the disclosure provides a method of assembling a lawnmower. The method may include mounting a motor having a motor shaft on top of a cutter housing, the cutter housing defining a lower opening, a belt opening between the motor shaft and a rear axle, and at least one discharge opening. The method may include mounting a belt on the motor shaft and on a transmission coupled to the rear axle. The method may include providing a belt cover including a ring portion at least partially surrounding the motor shaft, the belt cover including a guard portion extending rearward toward the belt opening below the belt, wherein the guard portion includes at least one tab extending from a rearward edge. The method may include inserting the at least one tab into a corresponding pocket on the cutter housing adjacent the belt opening. The method may include securing the ring portion to a bottom surface of the cutter housing with a plurality of fasteners.

DETAILED DESCRIPTION

The following includes definitions of selected terms employed herein. The definitions include various examples and/or forms of components that fall within the scope of a term and that may be used for implementation. The examples are not intended to be limiting.

It should be understood that the description and drawings herein are merely illustrative and that various modifications and changes can be made in the structures disclosed without departing from the present disclosure. In general, the figures of the example lawnmower are not to scale. As used herein, lateral directions are transverse across the lawnmower, i.e., left and right directions. Likewise, longitudinal directions refer to forward and rearward directions of lawnmower travel, and the vertical directions relate to elevation, i.e., upward and downward directions. It will also be appreciated that the various identified components of the example vehicle door system disclosed herein are merely terms of art that may vary from one manufacturer to another and should not be deemed to limit the present disclosure.

Generally described, the present disclosure provides for a lawnmower including a belt cover that is releasably coupled to a cutter housing using at least one tab that engages a respective pocket on the cutter housing. The engagement of the tab and the respective pocket prevents the belt cover from moving horizontally, axially, and vertically. In an aspect, the belt cover includes a ring portion that at least partially surrounds a cutter shaft and a guard portion that extends toward the belt opening to shield the belt from the cutter.

Turning to the figures, where like reference numbers refer to like components,FIG. 1illustrates an example lawnmower100. In an aspect, the lawnmower100may include some components of a conventional lawnmower. For example, the lawnmower100may include a motor110, a cutter housing120, front wheels122, and rear wheels124. The cutter housing120may be generally dome-shaped, defining a volume underneath for cutting grass. The cutter housing120may be supported on the front wheels122and rear wheels124such that a bottom edge is elevated and defines a lower opening126through which grass may enter the cutter housing. The cutter housing120may also be described an annular shape that includes a central opening, where the motor110is mounted. It should be appreciated that various shapes of lawnmower cutter housings known in the art may be adapted to accommodate a belt cover as discussed in further detail below.

The lawnmower100may also include a handle150including controls154and a dead-man switch152(or operator presence control). The controls154may control motor speed and/or transmission direction. The dead-man switch152may stop the motor, cutter, or transmission of the lawnmower100when not held by an operator. The lawnmower100may include a rear cover140that may be raised to permit the use of a bagging attachment and lowered when the bagging attachment is not in use. It should be appreciated that although depicted in an example arrangement, the conventional lawnmower components may be arranged or substituted according to other known designs or modified as appropriate for a particular goal. For example, the motor110may be an electric motor or a gasoline engine.

FIG. 2illustrates a longitudinal cross-sectional view of the example lawnmower100along the line2-2. The motor110includes a shaft210that is rotationally driven by the motor110. The shaft210may be oriented vertically and extend downward from the motor110. The shaft210, in turn, may rotate a cutter212mounted on the shaft210. The cutter212may be, for example, a blade or a line. In an aspect, the dead-man switch152may rotationally couple the cutter212to the shaft210when the dead-man switch152is activated and rotationally decouple the cutter212from the shaft210when the dead-man switch152is released.

A pulley230may be mounted on the shaft210and rotationally driven by the motor110. A belt240may be mounted on the pulley230and connect the pulley230to a transmission250. The transmission250may releasably couple the belt to one or more rear wheels124(e.g., via a rear axle252), to drive the lawnmower100in a forward or reverse direction. The controls154may control the transmission250to provide forward, reverse or neutral drive of the rear wheels124via the transmission250.

In an aspect, a belt cover220may be positioned between the belt240and the cutter212. The belt cover220may be generally flat and extend horizontally from an area surrounding the shaft210toward the transmission250. The belt cover220may divide a volume under the cutter housing120into a cutting volume including the cutter212and a belt volume including the belt240. The belt cover220may perform several functions. The belt cover220may protect the belt240and transmissions250from the cutter212and from debris (e.g., grass clippings) moving within the cutter volume. Without a belt cover220, the debris may contact the belt240or transmission250and cause additional wear. Additionally or alternatively, the debris may stick to the belt240or transmission250and either lubricate the belt240, thereby causing slippage, or clog the transmission250. The belt cover220may reduce the amount of debris contacting the belt240and transmission250. Additionally, the belt cover220may define a shape and aerodynamic properties of the cutting volume. The belt cover220may direct the movement of the debris within the cutting volume. In an aspect, the belt cover220may direct the debris toward a discharge port or chute, for example, for bagging. In another aspect, the belt cover220may block discharge to encourage recirculation of the debris within the cutting volume to reduce debris size for mulching. In an aspect, the present disclosure provides for a separate belt cover220that is removably coupled to the rear assembly via a plurality of tabs that engage pockets on the rear assembly. The disclosed separate belt cover220may allow easier access to the belt240while providing an effective shield against debris.

FIGS. 3-7illustrate an example belt cover220and an example rear assembly300.FIG. 3is a perspective view of the example belt cover220mounted to the rear assembly300.FIG. 4is an additional perspective view of the example belt cover220and rear assembly300.FIG. 5is a top view of the example belt cover220and rear assembly300.FIG. 6is a perspective view of the example rear assembly in isolation.FIG. 7is a perspective view of the example belt cover220in isolation. The rear assembly300may form a rear portion of the cutter housing120. For example, the rear assembly300may be mounted to a metal dome portion of the cutter housing120. The belt cover220and the rear assembly300may be separately molded from a high-strength plastic such as, for example, polypropylene, polypropylene high impact copolymers, high-density polyethylene (HDPE), low-density polyethylene (LDPE), acrylonitrile butadiene styrene (ABS), ultra high molecular weight polyethylene (UHMWPE), polycarbonate (PC), polyoxymethylene (POM), Nylon, or a combination thereof.

The rear assembly300may form a rear wall302of the cutting volume. The rear wall302may include a lower portion304that is located below the cutter212and an upper portion306located above the cutter212. The rear assembly300may also support the transmission250, rear wheels124, and handle150at various locations behind the rear wall302. The rear assembly300may include a belt opening310that allows the belt240to pass through the rear wall to the transmission250. The belt opening310may be located above the lower portion304.

The rear assembly300may include a discharge chute340extending through the rear wall302. The discharge chute340may be located, for example, above the lower portion304. The discharge chute340may share a common wall308with the belt opening310. The discharge chute340may include a lower surface342that inclines upwardly from the lower portion304to a rearward edge of the discharge chute340.

In an aspect, the cutter212may rotate in a clockwise direction316when viewed from the top. The discharge chute340may be located before the belt opening310in the clockwise direction316.

A top surface312of the lower portion304may include a plurality of pockets314. For example, in the illustrated example, the top surface312may include three pockets314.

The belt cover220may include a ring portion320and a guard portion330. The ring portion320may surround the shaft (not shown). The ring portion320may include mounting holes322for mounting the belt cover220to the cutter housing120via fasteners (not shown). In an aspect, the fasteners may be inserted from the top through the cutter housing120such that the fasteners do not fall into the cutting volume if they become loose.

The guard portion330may have a relatively flat bottom surface332that is located above the cutter212at approximately the same height at the top surface312of the lower portion304. The bottom surface332may prevent debris from rising upward to contact the belt240. The bottom surface332may include an incline portion338that is located past the belt240in the clockwise direction316. The incline portion338may extend upward to a bottom surface of the cutter housing. The incline portion338may allow debris to move upwards (toward the discharge chute340) as the debris travels in the clockwise direction316. The guard portion330may also include a vertical wall334forming a leading edge of the guard portion330in the clockwise direction316. The vertical wall334may prevent debris that is above the cutter212and passes the discharge chute340from contacting the belt240. The vertical wall334may direct such debris into the discharge chute340or downward below the bottom surface332. The vertical wall334may contact the common wall308of the rear assembly300to form a continuous wall.

In an aspect, the belt cover220may include an optional adjustment portion350. The adjustment portion350may be mounted to the ring portion320, for example, via curved arms that engage and slide along an inner top edge of the ring portion320. The adjustment portion350may rotate with respect to the ring portion320to alter the shape of the belt cover220. In an aspect, for example, the adjustment portion350may be positioned in a first position that blocks a discharge chute or a second position that opens the discharge chute.

FIG. 8illustrates an interface between the belt cover220and the rear assembly300. The belt cover220may include a plurality of tabs360extending rearwardly from a rearward edge of the guard portion330. Each tab360may have a rounded leading edge. In an aspect, each tab360may be approximately one inch long and one-half inch wide, although other dimensions are possible. A top surface312of the lower portion304may include a plurality of pockets314. For example, in the illustrated example, the top surface312may include three pockets314. Each tab360may engage a corresponding pocket314as illustrated inFIG. 9. For example, each tab360may slide into the pocket314and form an interference fit with the top surface312and the pocket314. A portion of each tab360may extend out a rear edge of the corresponding pocket314.

FIG. 10illustrates assembly of the belt cover220with the cutter housing120and rear assembly300. The tabs360may be inserted into a corresponding pocket314. Insertion of a tab360into a pocket may not require any tool. In an aspect where the adjustment portion350is included, an adjustment lever352may be inserted through a slot354in the cutter housing120. Each of the mounting holes322may be aligned with a corresponding opening324in the cutter housing120. A fastener may be inserted through each opening324and corresponding mounting hole322to secure the belt cover220to the cutter housing120. For example, a bolt may be inserted from the outside of the cutter housing120such that the bold will not fall into the cutting volume if the bolt becomes loosened by vibration of the motor110.

The tabs360may prevent horizontal, vertical, and rotational movement of the guard portion330. In particular, when the tabs360extend through the pockets314in the rearward direction, the sides of the tabs contact the sides of the pocket to oppose forces exerted in the clockwise direction316(e.g., by debris contacting the vertical wall334). Additionally, the top surface of the tabs360may contact a bottom surface of the pocket314to oppose upward forces (e.g., from debris contacting the bottom surface332). The mounting holes322of the ring portion320being secured to the cutter housing120may prevent the belt cover220from moving in a forward direction, thereby preventing the tabs360from pulling out of the pockets314.

FIG. 11is a flow diagram of an example method400for assembling the lawnmower100including the belt cover220. The method400may be performed by a technician or assembly robot.

At block410, the method400may include mounting a motor having a motor shaft on top of a cutter housing, the cutter housing defining a lower opening, a belt opening between the motor shaft and a rear axle, and at least one discharge opening. In an aspect, for example, the technician or assembly robot may mount the motor110having the motor shaft210on top of the cutter housing120. The cutter housing120may define a lower opening126, belt opening310between the motor shaft210and a rear axle252, and at least one discharge chute340.

At block420, the method400may include mounting a belt on the motor shaft and on a transmission coupled to the rear axle. In an aspect, for example the technician or assembly robot may mount the belt240on the motor shaft210and on the transmission250, which is coupled to the rear axle252or at least one rear wheel124.

At block430, the method400may include positioning a belt cover including a ring portion to at least partially surround the motor shaft, the belt cover including a guard portion extending rearward toward the belt opening below the belt, wherein the guard portion includes at least one tab extending from a rearward edge. In an aspect, for example, the technician or assembly robot may position the belt cover220including a ring portion320to at least partially surround the motor shaft210. The belt cover220may include a guard portion330extending rearward toward the belt opening310below the belt240. The guard portion330may include at least one tab360extending from a rearward edge.

At block440, the method400may include inserting the at least one tab into a corresponding pocket on the cutter housing adjacent the belt opening. In an aspect, for example, the technician or assembly robot may insert the at least one tab360into a corresponding pocket314on the cutter housing120adjacent the belt opening310. In an aspect, the cutter housing120includes a rear assembly300defining the belt opening310and the corresponding pockets314.

In block450, the method400may include securing the ring portion to a bottom surface of the cutter housing with a plurality of fasteners. In an aspect, for example, the technician or assembly robot may secure the ring portion320to the bottom surface of the cutter housing120with a plurality of fasteners.

In block460, the method400may include mounting a cutter at an end of the motor shaft below the belt cover. In an aspect, for example, the technician or assembly robot may mount the cutter212at the end of the motor shaft210below the belt cover220.

Also, as used herein, including in the claims, “or” as used in a list of items prefaced by “at least one of” indicates a disjunctive list such that, for example, a list of “at least one of A, B, or C” means A or B or C or AB or AC or BC or ABC (i.e., A and B and C).