Self-propelled lawn mower and sulky device

A self-propelled lawn mower and sulky device. The self-propelled lawn mower comprises handle bars and an operator console that are positioned between the front end and rear end of the lawn mower. A securing bar and a placement bar are designed and situated an a angle to one another to appropriately position the handle bars and operator console. The sulky device comprises an operator platform, a pair of sulky arms, a pair of caster wheels, and a hitch bar. When the sulky device is mounted to the self-propelled lawn mower, a first hinge means is used for attaching the operator platform to the hitch bar, a second hinge means is used for attaching the hitch bar to the lawn mower, and a third hinge means is used for attaching the caster wheels to the sulky arms.

I. CROSS-REFERENCE TO RELATED APPLICATION

Not applicable.

II. FIELD OF THE INVENTION

The present invention relates to self-propelled lawn mowers and sulky devices and, more particularly, to a self-propelled lawn mower and a sulky device that are uniquely designed and mounted to one another to improve the mobility, stability, and trimming capabilities of the lawn mower when in use.

III. DESCRIPTION OF THE PRIOR ART

Sulky devices have been used in conjunction with power mowers for many years and are, thus, well known in the prior art. Sulkies were originally used with mowers in a general trailer type fashion without the use of pivots. For example, U.S. Pat. No. 2,218,064 to G. A. Amsbury entitled “Riding Trailer” discloses a riding trailer which can be hitched to the rear of a lawn mower by two side bars. The riding trailer has a seat situated above a supporting wheel and the user is provided with foot controls to guide the movements of the lawn mower.

Later, sulkies were designed to incorporate the use of a vertical pivot point at the attachment of the sulky to the mower. For example, U.S. Pat. No. 5,118,123 to Betrock entitled “Standing/Sitting Lawn Mower Trailer” discloses a system in which a trailer hitches to a self-propelled lawn mower. The trailer has an elongated towbar which is adjusted and locked to the lawn mower. Similarly, U.S. Pat. No. 5,388,850 to Simone entitled “Convertible Sulky” discloses an H-shaped support wheelbase frame member with a T-shaped mower attachment frame.

To accommodate increased maneuverability, sulkies have been designed with vertical pivot points along the attachment arms to enable the lawn mower to maneuver through a narrow or small turning radius or as desired by the user. For example, U.S. Pat. No. 5,004,251 to Velke et al. entitled “Sulky Apparatus Attachable To A Self-Propelled Power Mower” discloses a sulky apparatus that is attachable to a self-propelled power mower to transport an operator in the standing position. The sulky provides a first arm connected to the lawn mower through a horizontal pivot point and a second arm connected to the operator platform. The first arm and the second arm are connected through a vertical pivot point permits movement of the operator platform about the vertical pivot point. In this fashion, the lawn mower can better navigate tight turns.

Likewise, U.S. Pat. Nos. 5,810,371 and 5,882,020 to Velke entitled “Sulky Device With Triple Pivot Attachment To Mower” disclose the sulky in U.S. Pat. No. 5,004,251 with a third pivot point located at the connection of the second arm to the operator platform and an additional wheel to form a two-wheeled sulky. The third pivot point operates along the horizontal axis and theoretically provides a storage position for the operator platform with respect to the lawn mower.

Although these sulkies permit operation in small areas, they do not leverage the forces and loads on the vertical pivot point as applied by the weight of the operator and torque of the mower. Therefore, the vertical pivot point was susceptible to uncontrollable bending or structural failure of the vertical pivot point. Also, the uncontrollable bending or structural failure requires that the weight of the operator must be limited to reduce the counterbalancing forces on the vertical pivot point. Another shortcoming of these sulkies is that the vertical pivot point permits 360° rotation about the first arm. The inherent danger with the free rotation is that a user is vulnerable to injury if positioned on the operator platform as the second arm rotates the operator platform to cross under the first arm. Therefore, these sulkies are not practical for all consumers.

These problems were overcome by U.S. Pat. No. 6,375,201 to Havener, entitled “Walk Behind Mower Sulky Apparatus With Improved Operator Platform Attachment Means” which discloses an operator platform attached to a hitch arm through the interconnection of a vertical pivot tube and an essentially C-shaped clevis. The clevis counter balances and leverages the forces and loads that are applied to the vertical pivot pin while the sulky is in operation and, thereby, prevents the unnecessary anomalies and structural failures of the vertical pivot pin. The design further limited the angle of rotation to prevent operator injury from the platform sweeping under the hitch arm.

Now, Applicant has improved upon all of these earlier devices with its self-propelled lawn mower and a sulky device that are uniquely designed and mounted to one another to further improve the mobility, stability, and trimming capabilities of the lawn mower when in use. Thus, there is a need and there has never been disclosed Applicant's self-propelled lawn mower and a sulky device.

IV. SUMMARY OF THE INVENTION

The present invention is a self-propelled lawn mower and sulky device. The self-propelled lawn mower comprises handle bars and an operator console that are positioned between the front end and rear end of the lawn mower. A securing bar and a placement bar are designed and situated an a angle to one another to appropriately position the handle bars and operator console. The sulky device comprises an operator platform, a pair of sulky arms, a pair of caster wheels, and a hitch bar. When the sulky device is mounted to the self-propelled lawn mower, a first hinge means is used for attaching the operator platform to the hitch bar, a second hinge means is used for attaching the hitch bar to the lawn mower, and a third hinge means is used for attaching the caster wheels to the sulky arms.

VI. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Turning first toFIG. 1, there is illustrated a self-propelled lawn mower20and a sulky device (“sulky”)22. For purposes of this patent application, the self-propelled lawn mower20may be any type of and, operate in the same manner as any, self-propelled lawn mower that is known to one skilled in the art. To accomplish Applicant's invention, and as further described in more detail below, the self-propelled lawn mower20is provided with an operator console23and handle bars24in which the position of these components have been altered.

The self-propelled lawn mower20has a front end26and a rear end28. In the preferred embodiment, the rear end28of the lawn mower20defines a vertical plane30.

The handle bars24are separated into and/or comprise a securing bar32and a placement bar34. The securing bar32is provided with securing holes35for use with threaded bolts36to fixedly secure the securing bar32to the lawn mower20. Alternatively, any other means known to one skilled in the art for securing the securing bar32to the lawn mower20may be used. Upon securing the securing bar32to the lawn mower20, the securing bar32extends, a securing bar length44, forwardly toward the front end26of the lawn mower20and upwardly for attachment to or connection with the placement bar34. Preferably, the securing bar32is integrally molded to the placement bar34. Alternatively, any other means for attaching the securing bar32to the placement bar34known to one skilled in the art may be used. The placement bar34then extends, a placement bar length46, rearwardly toward the rear end28of the lawn mower20and upwardly to adjacent the operator console23and terminating in a gear handle38. In this manner, the securing bar32and the placement bar34are positioned at an angle42to one another.

In the preferred embodiment, the handle bars24(i.e., securing bar32, placement bar34, and gear handles38) and operator console23are situated and/or positioned: (a) between the front end26and rear end28of the lawn mower20and forward of the vertical plane30; and (b) at the appropriate height for ease of use of the operator console23and the gear handles38by an operator40(seeFIG. 3) when in use with the sulky22. As such, to accomplish this, Applicant has designed the securing bar length44to be preferably longer than the placement bar length46and the angle42between the securing bar32and the placement bar34to be formed an obtuse angle. Alternatively, either or both of the securing bar length44of the securing bar32and the placement bar length46of the placement bar34may be altered to be longer or shorter and/or the angle42may be altered to be an acute angle, or any all possible combinations thereof; provided that, the above conditions are provided for.

The sulky22comprises an operator platform48, a pair of sulky arms50, a pair of caster wheels52, and a hitch bar54. In the preferred embodiment, a first hinge means56is used for attaching the operator platform48to the hitch bar54; a second hinge means58is used for attaching the hitch bar54to the lawn mower20; and a third hinge means60is used for attaching the caster wheels52to the sulky arms50.

In the preferred embodiment, as illustrated inFIG. 2, the first hinge means56permits the operator platform48to rotate or pivot about a first axis of rotation A in relation to the hitch bar54(see alsoFIG. 6). In this manner, when in use and the self-propelled lawn mower20is pulling the sulky22, if the self-propelled lawn mower20encounters uneven terrain which will cause the self-propelled lawn mower20to traverse in a horizontal direction (either left or right) which is different than the terrain which is currently being traversed by the sulky22, the first hinge means56permits the operator platform48to rotate or pivot about the first axis of rotation A (or a first horizontal axis) in relation to the hitch bar54, and likewise the self-propelled lawn mower20, to thereby permit the independent movement of both the self-propelled lawn mower20and sulky22to accommodate this uneven terrain.

The second hinge means58permits the hitch bar54and, likewise the operator platform48, to rotate or pivot about a second axis of rotation B in relation to the self-propelled lawn mower20(see alsoFIG. 5). In this manner, when in use and the self-propelled lawn mower20is pulling the sulky22, if the self-propelled lawn mower20encounters uneven terrain which will cause the self-propelled lawn mower20to traverse in a vertical direction (either upwardly or downwardly) which is different than the terrain which is currently being traversed by the sulky22, the second hinge means58permits the hitch bar54and, likewise the operator platform48, to rotate or pivot about the second axis of rotation B (or a second horizontal axis which is perpendicular to the first horizontal axis) in relation to the self-propelled lawn mower20, to thereby permit the independent movement of both the self-propelled lawn mower20and sulky22to accommodate this uneven terrain.

The third hinge means60permits the caster wheels52to rotate or pivot about a third axis of rotation C in relation to the sulky arms50. In this manner, when in use and the self-propelled lawn mower20is pulling the sulky22, if the self-propelled lawn mower20and sulky22are encountering uneven terrain and each is traversing in the horizontal direction (either left or right) or in the vertical direction (either upwardly or downwardly), the third hinge means60permits the caster wheels52to rotate or pivot about the third axis of rotation C (or a vertical axis) in relation to the sulky arms50, to thereby permit the independent movement of the caster wheels52to accommodate this uneven terrain and facilitate the continued movement of the sulky22behind the self-propelled lawn mower20.

The first hinge means56is more clearly illustrated inFIG. 7. In the preferred embodiment, the first hinge means56comprises a shaft62having a shaft hole64, a tube66, a retaining means67, and a first pin securing means68.

The shaft62is preferably rigid having opposed ends72and74. Opposed end72is fixedly secured to the hitch bar54. The shaft62extends outwardly from the hitch bar54to opposed end74where the shaft hole64is located.

The tube66is positioned adjacent to a flange76on the operator platform48. The tube66contains a bearing (not illustrated) that extends through the tube66and a bore70that extends through the center of the bearing. In the preferred embodiment, the bore70is situated in alignment with the shaft62. The tube66is illustrated as being cylindrical in shape, however, the tube66may alternatively be any other shape desired provided that the tube66accomplishes the invention as disclosed.

To create the first hinge means56, the opposed end74of the shaft62is inserted into and through the bore70of the tube66until the shaft hole64of the shaft62exits the bore70of the tube66. The retaining means67fixedly secures the tube66to the flange76of the operator platform48(see alsoFIG. 9andFIG. 10).

In the preferred embodiment, the retaining means67comprises a cover77and two opposed retaining walls78and80. As further illustrated inFIG. 9andFIG. 10, the tube66is situated or enclosed between the cover77and the flange76. Each retaining wall78and80is fixedly secured, at one end, to the flange76of the operator platform48and, at the other end, to the cover77. In the preferred embodiment, the retaining wall78and80are fixedly secured to the flange76of the operator platform48and the cover77using solder or any other type of weld. Alternatively, the retaining wall78and80may be fixedly secured to the flange76and/or cover77using any other means known to one skilled in the art. Retaining wall78is also provided with a hole90.

In the preferred embodiment, and as illustrated inFIG. 10, the first pin securing means68then releaseably secures the shaft62to the tube66. The first pin securing means68is a linchpin which comprises a pin124, a wheel126, and a fastening member128. The pin124is attached at one end to the fastening member128and has a free end130. The wheel126is rotatably attached, at both ends, to the fastening member128. In use, the free end130of the pin124is inserted into and through the shaft hole64until the fastening member128engages the shaft62, and then, the wheel126is rotated through rotation A to lock on to the shaft62. In this manner, the first pin securing means68secures the shaft62to the tube66. Alternatively, the first pin securing means68may be accomplished using any other means known to one skilled in the art.

The second hinge means58is more clearly illustrated inFIG. 7andFIG. 8. As illustrated, the hinge bar54comprises a pair of opposed hinge arms84, each hinge arm84having a hinge hole82. In the preferred embodiment, the second hinge means58comprises the hinge arms84having the hinge holes82, a mounting bracket86, an interconnecting bracket85, and a second pin securing means88.

The mounting bracket86provides two opposed sidewalls92and94, a back wall96, and further defining an opening98between them. Each sidewall92and94provides a sidewall hole100and102and which are positioned in the sidewall92and94to be in direct alignment across from one another.

The interconnecting bracket85is substantially flat in shape and having two opposed surfaces104and106and bracket holes108and110. In the preferred embodiment, threaded bolts112are inserted through each bracket hole108and110of the interconnecting bracket85and into a corresponding hole (not illustrated) in the lawn mower20. Bolts or other means (not illustrated) are used to tighten the interconnecting bracket85to, and the surface104against, the lawn mower20. Alternatively, the interconnecting bracket85may be fixedly secured to the lawn mower20using solder, weld, integrally molded to, or any other means known to one skilled in the art. A wedge114is preferably integrally molded to the surface106of the interconnecting bracket85and to the sidewall94of the mounting bracket86. The wedge114creates a spacing120between the interconnecting bracket85and the mounting bracket86. Alternatively, any other means known to one skilled in the art may be used to fixedly secure the interconnecting bracket85to the mounting bracket86. In this manner, the interconnecting bracket85fixedly secures or interconnects the lawn mower20to the mounting bracket86.

To attach the hinge bar54to the mounting bracket86, the hinge arm84is inserted into the opening98of the mounting bracket86between the opposed sidewalls92and94until the hinge hole82in the hinge arm84is aligned between the sidewall holes100and102. The second pin securing means88then secures the hinge bar54to the mounting bracket86. In the preferred embodiment, the second pin securing means88comprises a pivot pin116having a pinhole118and a pin122. The pivot pin116is inserted through the sidewall hole100of sidewall92, through the hinge hole82of the hinge arm84, and through the sidewall hole102of sidewall94, until the pinhole118is exposed in the spacing120between the mounting bracket86and the interconnecting bracket85. When this occurs, the pin122is inserted into and through the pinhole118to releaseably secure the pivot pin116to the mounting bracket86and hinge arm84. The pin122is preferably a cotter pin, however, any pin known to one skilled in the art for securing a pivot pin116as described herein may be used.

The third hinge means60is more clearly illustrated inFIG. 2. In the preferred embodiment, the third hinge means60comprises a tube132and a yoke134having a yoke shaft138.

The tube132contains a bearing (not illustrated) that is provided with a receiving chamber136(not illustrated). In the preferred embodiment, the receiving chamber136is situated in alignment with the yoke shaft138. The tube132is illustrated as being cylindrical in shape, however, the tube132may alternatively be any other shape desired provided that the tube132accomplishes the invention as disclosed. To create the third hinge means60, the yoke shaft138is inserted into the receiving chamber136of the bearing and retained by the tube132. In the preferred embodiment, as the yoke134supports the caster wheels52and the yoke shaft138is freely rotatable within the tube132by the bearings, the caster wheels52can rotate three hundred and sixty degrees (360°), if desired, when the sulky22is in use with the self-propelled lawn mower20.

As described in detail above and based on these disclosures, Applicant's unique inventive law mower and sulky device design provides several advantages including but not limited to: providing a mower that is shorter and more maneuverable; providing a mower that is more stable and, particularly, when traversing or moving across steep terrain or slopes; providing a mower that can accomplish shorter turns; providing a mower that enables greater vision for the operator over the front of the mowing deck; providing a mower that has increased trimming capabilities; providing a mower that improved rear or drive wheel traction as the location of the sulky in relation to the lawn mower and position of the operator standing on the operator platform transfers the operator's weight to the rear or drive wheels; and providing a sulky with sulky arms and castering wheels that avoids turning issues and assists in facilitating the transfer and use of the operator's weight with the lawn mower.

Thus, there has been provided Applicant's unique inventive self-propelled lawn mower and sulky device. While the invention has been described in conjunction with a specific embodiment, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it in intended to embrace all such alternatives, modifications and variations as fall within the spirit and scope of the appended claims.