CORDLESS SNOW THROWER

A cordless electric snow thrower is disclosed having a separate and distinct battery housing containing a battery being positioned on a handle of the cordless snow thrower. The cordless snow thrower may include an electronic controller that allows a user to rotate a chute of the cordless snow thrower to alter a direction in which snow is thrown. The cordless snow thrower may also include a light that provides sufficient light to allow the user to use the cordless snow thrower at night to clear snow. The placement of the battery housing provides balance to the cordless snow thrower and allows power to be provided to all of the electronic devices and components of the cordless snow thrower.

FIELD

The present disclosure relates to devices for removing snow and other debris from driveways, sidewalks, decks, and other areas.

BACKGROUND

In general, during the winter months certain geographic areas experience colder temperatures and snowfall. During and after periods of snowfall, driveways, sidewalks, decks, and other areas may be coated or covered with varying amounts of snow and ice. Currently there are a number of snow throwers that can be used to remove snow and ice from surfaces. However, most snow throwers have a gasoline powered motor, which requires certain maintenance and procedures to be performed if the snow thrower is to be stored for long periods of time. For example, oil may need to be changed and/or drained, and any gasoline remaining in the gas tank of the snow thrower may need to be removed or stabilized prior to storage.

SUMMARY

This disclosure relates to a cordless electric snow thrower having a battery disposed in a battery housing, separate from a main housing, positioned on a handle of the cordless snow thrower. The cordless snow thrower may include an electronic controller that allows a user to rotate a chute of the cordless snow thrower to alter a direction in which snow is thrown. The cordless snow thrower may also include a light that provides sufficient light to allow the user to use the cordless snow thrower at night to clear snow. The placement of the battery and battery housing, separate from the main housing, provides balance to the cordless snow thrower and allows power to be provided to the electronic devices of the cordless snow thrower.

In an embodiment, a snow thrower is disclosed including a frame, a main housing coupled to the frame and having an inlet cavity, and a handle portion coupled to the frame opposite the main housing. An auger assembly is disposed in the main housing and extends across the inlet cavity for cutting through and directing snow through the snow thrower, for example out of a chute. An electric motor is disposed in the main housing and coupled to the auger assembly to rotate the auger assembly. A battery housing is coupled to the handle portion, and a battery is disposed in the battery housing and electrically connected to the electric motor to supply power or voltage to the electric motor. A switch may be electrically connected to the battery and the electric motor to activate and deactivate voltage flow from the battery to the electric motor.

The snow thrower also includes a wheel axle coupled to the frame between the main housing and the handle portion, and wheels coupled to ends of the wheel axle. In an embodiment, the battery housing and the main housing are positioned on opposite sides of a pivot point formed by the wheel axle. This provides balance to the snow thrower.

The chute may be coupled to the main housing over an outlet aperture in the main housing. The chute may be coupled to a chute motor that is disposed in the main housing and adapted to rotate the chute with respect to the main housing. A control member may also be electrically connected to the battery and the chute motor to activate and deactivate voltage flow from the battery to the chute motor to rotate the chute.

A light may be disposed on the handle portion and electrically connected to the battery. A light switch may also be electrically connected to the light and adapted to activate and deactivate voltage flow from the battery to the light.

The handle may have a gripping portion for an operator to grasp on an end opposite the frame. A control housing may be coupled to the handle portion proximal to the gripping portion, and house the switch for controlling the electric motor, the control member or joystick for controlling the chute motor, and the light switch for controlling the light.

In an embodiment, a method of assembling the show thrower is disclosed. In general, the method includes coupling a main housing having an inlet cavity to a frame, coupling a handle portion having a gripping portion to the frame opposite the main housing, disposing an auger assembly in the main housing and extending across the inlet cavity, coupling an electric motor to the auger assembly for rotating the auger assembly, and coupling a battery housing to the handle portion between the frame and the gripping portion. The coupling of the battery housing to the handle portion may include coupling the battery housing to the handle portion on an opposite side of a pivot point formed by a wheel axle coupled to the frame with respect to the main housing.

A chute motor may be coupled to the chute for rotating the chute with respect to the main housing. A control member may be coupled to the chute motor for activation and deactivation of voltage flow to the chute motor. Further, a light and light switch may be coupled to the snow thrower.

DETAILED DESCRIPTION

Detailed embodiments of cordless snow throwers for removing snow and other debris from driveways, sidewalks, decks, and other areas are disclosed herein, however, it is to be understood that the disclosed embodiments are merely exemplary of the device, which may be embodied in various forms. Therefore, specific functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present disclosure.

A cordless electric snow thrower is disclosed having a battery disposed in a battery housing, separate from a main housing, positioned on a handle of the cordless snow thrower. The cordless snow thrower may include an electronic controller that allows a user to rotate a chute of the cordless snow thrower to alter a direction in which snow is thrown. The cordless snow thrower may also include a light that provides sufficient light to allow the user to use the cordless snow thrower at night to clear snow. The placement of the battery and battery housing, separate from the main housing, provides balance to the cordless snow thrower and allows power to be provided to all of the electronic devices of the cordless snow thrower.

A cordless snow thrower100according to an illustrative embodiment is described with reference toFIGS. 1-7. As illustrated, the cordless snow thrower100includes a frame102having a wheel axle104(as illustrated inFIG. 3) coupled to the frame. The wheel axle104rotates with respect to the frame102and wheels106are coupled to opposite ends of the wheel axle104using means known in the art, for example, threaded nuts, cotter pins and other known means.

A main housing108is also coupled to the frame102. In an illustrative embodiment, the main housing108houses an electric motor and an rotor or auger assembly. The auger assembly may include a rotor shaft110that extends across the main housing108. The rotor shaft110is coupled at a first end to the electric motor and rotated by the electric motor. A second end of the rotor shaft110may be rotatably coupled to the main housing108or a bracket of the main housing108, by one or more bearings. One or more blades112are coupled to the rotor shaft110for cutting through and directing snow through the cordless snow thrower100. As illustrated there are four (4) blades112, however, more than four or less than four blades may be used.

The electric motor may be a brushless DC motor or other type of motor capable of rotating the rotor or auger assembly. The one or more blades112may be made of any suitable material, for example, steel or other metal, plastic or polymers, and other materials. In an illustrative embodiment, the one or more blades112may include a rubber-coating or other flexible material coating on tips of the blades112to reduce damage to a surface being cleared of snow or other debris.

As illustrated, the main housing108includes an inlet cavity114having an inlet opening116for receiving snow and other debris to be cleared. In one embodiment, the inlet opening116may be about 18 inches in length in a horizontal direction and about 10 inches in length in a vertical direction. In other embodiments, the dimensions of the inlet opening116may be large or smaller. The inlet cavity114is designed to direct snow and other debris toward an outlet chute118coupled to the housing. The one or more blades112of the auger assembly are located in the inlet cavity114and cut and throw the snow and other debris out of the chute118. In an illustrative embodiment, snow and other debris is thrown out of the chute118up to about 20 feet, however, the snow and other debris may be thrown more or less than 20 feet.

In an illustrative embodiment, the housing incudes an outlet opening120(as illustrated inFIG. 6) disposed on a top portion of the main housing108. The chute118is disposed over the outlet opening120and directs the snow and other debris being thrown out of the main housing108. As illustrated, the chute118includes a substantially cylindrical and hollow tube portion122that is coupled to the main housing108and a substantially semi-circular tube portion124that is coupled to the substantially cylindrical tube portion122at an end opposite the main housing108.

The substantially cylindrical tube portion122rotates with respect to the main housing108around a vertical axis extending through a center of the substantially cylindrical tube portion122. In an embodiment, the substantially cylindrical tube portion122rotates about 180 degrees, however, in other embodiments, the substantially cylindrical tube portion122may rotate more or less than 180 degrees. The substantially semi-circular tube portion124rotates with respect to the substantially cylindrical tube portion122around an axis substantially perpendicular to the vertical axis.

In an illustrative embodiment, the substantially semi-circular tube portion124includes one or more teeth that mate with corresponding teeth on the substantially cylindrical tube portion122at an attachment point126or point of coupling of the substantially semi-circular tube portion124with the substantially cylindrical tube portion122. The teeth allow the substantially semi-circular tube portion124to be positioned at varying angles with respect to the substantially cylindrical tube portion122by loosening and tightening fasteners128.

In an illustrative embodiment, a handle portion130is coupled to the frame portion102at an end opposite the main housing108and extends in a direction substantially away from the main housing108. As illustrated, the handle portion130includes a first member132and a second member134that are coupled to the frame portion102by fasteners136, which may be for example, nuts and bolts, cotter pins, screws, or other known fasteners. As illustrated, the fasteners136are substantially “J” shaped. This coupling of the handle portion130to the frame portion102may allow a user of the cordless snow thrower100to uncouple the handle portion130from the frame portion102or rotate the handle portion130for storing or transporting the cordless snow thrower100when not in use.

The handle portion130may also include first and second extension portions138and140, respectively. The first extension portion138is coupled to the first member132opposite the frame portion102, and the second extension portion140is coupled to the second member134opposite the frame portion102.

A gripping portion142may also be coupled to an end of the handle portion130opposite the frame portion102. As illustrated, the gripping portion142is coupled to ends of the first and second extension portions138and140, respectively, opposite the first and second members132and134, respectively. The gripping portion142extends between and connects the first and second extension portions138and140, respectively. The gripping portion142may be ergonomically shaped to provide a comfortable operating point for an operator or user of the cordless snow thrower100.

One or more angular adjustments144may also be positioned between the gripping portion142and the point of coupling of the handle portion130to the frame portion102to allow a user to adjust the angular position of the first and second extension portions138and140, respectively, and the gripping portion142.

In an illustrative embodiment, there are two angular adjustments144, one corresponding to the first member132of the handle portion130and another corresponding to the second member134of the handle portion130. Only one of the angular adjustments is described below, however it should be understood that the other angular adjustment is substantially similar and merely couples to the second member134.

As illustrated, the angular adjustment144includes a first portion146coupled to the first member132having first teeth148(as illustrated inFIG. 3), and a second portion150coupled to the first extension portion138having mating second teeth152(as illustrated inFIG. 3). The first and second teeth148and152of the first and second portions146and150, respectively, of the angular adjustment144mate with one another to allow adjustment of the position of the gripping portion142.

The angular adjustments144may also include a latch154. The latch154when positioned in a latching position (as illustrated inFIG. 1) compresses the first portion146and the second portion150of the angular adjustment144together. To adjust the angular position, the latch154is moved to an unlatched position, which allows the first portion146and the second portion150to rotate with respect to one another. Thus, to adjust the angular position, a user merely positions the latch154in the unlatched position, rotates the first portion146and the second portion150with respect one another to a desired position, and positions the latch144in the latched position causing the first and second teeth148and152of the first and second portions146and150to engage each other and hold the desired position.

In some embodiments, the handle portion130may be a single monolithically formed piece that includes the first member132, the second member134, the first extension portion138, the second extension portion140, and the gripping portion142.

A battery housing156, separate and distinct from the main housing108, is coupled to the handle portion130between the gripping portion142and the point of coupling of the handle portion130to the frame portion102. As illustrated, the battery housing156is coupled to the handle portion130between the point of coupling of the handle portion130to the frame portion102and the angular adjustment(s)144of the handle portion130. However, the battery housing156may be coupled to the handle portion130at varying locations along the handle portion130.

The battery housing156is disposed on an opposite side of a pivot point extending through the wheel axle104from the main housing108. This placement provides balance to the cordless snow thrower100, and reduces the risk of the cordless snow thrower100falling or tipping over during use and storage. The placement of the battery housing156may also provide ease of tilting and maneuverability of the cordless snow thrower100to clear snow and other debris from a surface during operation. The placement of the battery housing156also allows for the electrical connection of the various electrical devices of the cordless snow thrower100, which are located at different positions on the cordless snow thrower100, for example, the electrical motor(s), the start switch164(illustrated inFIG. 4), the control member168, the light switch174, etc.

In an illustrative embodiment, the battery housing156includes brackets158that couple the battery housing156to opposing parts, for example, the first and second members132and134of the handle portion130. The battery housing156may be constructed of any suitable material, for example, plastics, polymers, metals, and other materials. The battery housing156protects and shields the components housed in the battery housing156from damage and contact with water, snow, dust and other environmental related factors.

In an illustrative embodiment, the battery housing156houses one or more batteries capable of powering the cordless snow thrower100. In one embodiment, the battery is a forty volt (40 V) rechargeable Lithium Ion battery having about 2.2to about 4.4 ampere hour (Ah). However, it should be appreciated that other batteries may be used that are sufficient to power the cordless snow thrower100.

The battery housing156may house electrical components and circuitry for electrically connecting and providing power to the electrical devices of the cordless snow thrower100. For example, the battery housing156may include one or more switches, switchboards, actuators such as solenoids, resistors, capacitors, conductors, electrical busses, or other electrical components. The battery housing156may include a battery power indicator disposed on an outer surface of the battery housing156. For example, the battery housing156may include indicator lights, such as light-emitting diodes (LEDs), that indicate to the operator or user a level of power remaining in the battery. The battery housing156may also include one or more electrical connections for electrically connecting additional electrical devices to the cordless snow thrower100. For example, the battery housing156may include one or more electrical connections for electrically connecting a horn, additional lights, audio components, or other electrical devices.

In an embodiment, the battery housing156includes a power inlet port electrically connected to the battery. The power inlet port receives a corresponding wired power connector that electrically connects to an external power source, for example, a wall outlet, for charging the battery. In another embodiment, the battery is removable from the battery housing156and electrically connects to a wired power charging station that electrically connects to an external power source for charging the battery. In some embodiments, both charging options may be incorporated into the cordless snow thrower100. For example, the battery housing156may include the power inlet port and the battery may be removable from the battery housing156for charging. In one embodiment, the battery takes about 1.5 hours to fully charge when the battery is a 2.2 Ah battery, and about 3 hours to fully charge when the battery is a 4.4 Ah battery.

The battery provides power to the electric motor that operates the auger assembly. The electric motor is electrically connected to the battery through one or more electrical connections, for example, wiring160extending into the main housing108and to the electric motor. In an aspect, the wiring160may be included in or extend along at least a portion of an interior of the handle130.

A control housing162is coupled to the handle portion130proximal to the gripping portion142to allow an operator or user to easily access the control housing162during operation of the cordless snow thrower100. In an illustrative embodiment, the control housing162houses a start switch164(as illustrated inFIG. 4) that is accessible by the user through an aperture of the control housing162.

An activation member166is coupled to the start switch164and extends through the control housing162and along at least a portion of the gripping portion142. The start switch164and activation member166are electrically connected to the battery and the electric motor, for example, through wiring160extending from the control housing162. The start switch164and activation member166cooperate with one another to control the flow of power from the battery to the electric motor that controls the auger assembly. For example, a user may push the start switch164and hold the activation member166adjacent the gripping member142to cause power to be supplied to the electric motor and rotate the auger blade(s)112.

In an illustrative embodiment, the main housing108also houses an electric motor that rotates the substantially cylindrical tube portion122with respect to the main housing108. The electric motor may also rotate the substantially semi-circular tube portion124with respect to the substantially cylindrical tube portion122. The electric chute motor is electrically connected to the battery, for example through wiring160. In this embodiment, the control housing162also houses a control member168, for example, illustrated as a joystick, that extends from the control housing162. The control member168is electrically connected to the battery and the electric chute motor, for example, through wiring160. The control member168controls the rotation of the substantially cylindrical tube portion122with respect to the main housing108allowing a user to manipulate a direction snow is being thrown by the cordless snow thrower100. For example, movement of the control member168or joystick in a rightward direction may cause the substantially cylindrical tube portion122to rotate in a rightward direction with respect to the main housing108, and movement of the control member168in a leftward direction may cause the substantially cylindrical tube portion122to rotate in a leftward direction with respect to the main housing108.

A motor electrically connected to the battery may also be included in the housing108that rotates the substantially semi-circular tube portion124with respect to the substantially cylindrical tube portion122. The control member168or joystick may also be electrically connected to this motor to control the rotation of the substantially semi-circular tube portion124with respect to the substantially cylindrical tube portion122. For example, movement of the joystick in an upward direction may cause the substantially semi-circular tube portion124to rotate in an upward direction with respect to the substantially cylindrical tube portion122, and movement of the joystick in a downward direction may cause the substantially semi-circular tube portion124to rotate in a downward direction with respect to the substantially cylindrical tube portion122.

In an illustrative embodiment, a light170may be coupled to the handle portion130proximal to the gripping portion142. As illustrated, the light170is coupled to an opposing portion of the handle portion130with respect to the control housing162, however, the light170and the control housing162may be positioned in other locations on the handle portion130or on another portion of the cordless snow thrower100, such as the main housing108. The light170may also include a pivotable and/or rotatable joint172to allow the light170to pivot and/or rotate with respect to the handle portion130to allow the user or operator to position the light in a desired direction. The light170allows for the use and operation of the cordless snow thrower100when daylight or ambient light is low. The light170is electrically connected to the battery through wiring160extending from the light170. The light may be any suitable light source, for example, a halogen light or other type of light.

A light on/off switch174may be electrically connected to the light170. As illustrated, the light switch174is disposed on and housed by the control housing162and electrically connected to the light through wiring160. The wiring160electrically connects the light170, the light switch174, and the battery, to allow the user to turn the light170on and off. In this manner, the user can turn or leave the light170in an off position to conserve battery power when the cordless snow thrower100is being used in daylight.

In an illustrative embodiment, the main housing108may include a first handle176disposed on a top portion of the main housing108for carrying, lifting, and moving the cordless snow thrower100when it is not being operated or used. The substantially semi-circular tube portion124may include a second handle178for use by the operator or user in manually rotating the substantially semi-circular tube portion124with respect to the substantially cylindrical tube portion122.

A functional block diagram of electrical devices and components of the cordless snow thrower100is described with reference toFIG. 8. As illustrated, a battery180, which is disposed in the battery housing156, is electrically connected to the start switch164, the activation member166, the control member168, the light switch174, the light170, a first motor182, and optionally one or more additional motors184.

The first motor182is disposed in the main housing108and may control the rotor or auger assembly by rotating the rotor shaft110. The start switch164and the activation member166may control activation of power being supplied to the first motor182. For example, upon an operator activating the start switch164and the activation member166, voltage may be supplied from the battery180to the first motor182. Similarly, upon release of the activation member166by the operator, voltage supplied from the battery180to the first motor182may be deactivated or turned off.

The first motor182may also control the rotation of the substantially cylindrical tube portion122with respect to the main housing108and/or the rotation of the substantially semi-circular tube portion124with respect to the substantially cylindrical tube portion122. Alternatively, one or more additional motors184may be disposed in the main housing108and control the rotation of the substantially cylindrical tube portion122with respect to the main housing108and/or the rotation of the substantially semi-circular tube portion124with respect to the substantially cylindrical tube portion122.

The control member168may control activation of power being supplied to the first motor182or the one or more additional motors184to move the chute. For example, in response to the operator moving the control member168, voltage may be supplied from the battery180to the first motor182or the one or more additional motors184and the substantially cylindrical tube portion122or the substantially semi-circular tube portion124may rotate.

The light170may be controlled by the light switch174. For example, in response to the operator placing the light switch174in an on position, voltage may be supplied from the battery180to the light170. Similarly, in response to the operator placing the light switch174in an off position, voltage supplied from the battery180to the light170may be deactivated or turned off.

As described above, one or more electrical components, for example, switches, switchboards, actuators such as solenoids, resistors, capacitors, conductors, electrical busses, or other electrical components may be included in the battery housing156or the main housing108and electrically connected to the battery180and/or one or more of the electrical devices of the cordless snow thrower100.

The electrical devices and other electrical components may be electrically connected or wired in a number of different ways known to those having ordinary skill in the art. For example, the electrical devices may be electrically connected through one or more electrical busses disposed in the battery housing156. In one embodiment, the start switch164and the activation member166may be electrically connected to the battery180and electric motor182through an actuator, for example a solenoid.

Although the device has been described and illustrated in connection with certain embodiments, many variations and modifications will be evident to those skilled in the art and may be made without departing from the spirit and scope of the disclosure.

For example, as illustrated and described, the cordless snow thrower is a single-stage snow thrower, meaning that the snow thrower is a push drive device. However, it should be appreciated that the cordless snow thrower may be a multi-stage snow thrower and include a drive motor electrically connected to the battery to rotate the wheels.

The disclosure is thus not to be limited to the precise details of methodology or construction set forth herein as such variations and modification are intended to be included within the scope of the disclosure. Moreover, unless specifically stated any use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are merely used to distinguish one element from another.