Leaf shredder attachment for a mower bagging system

A shredder attachment for use with lawn machines having vacuum or fan movement of shreddable material. The attachment comprises a frame suitably sized and shaped to be substantially mounted inside a conduit of a lawn machine. The attachment further comprises a cutter for cutting material passing through the conduit and a motor for driving the cutter. The attachment can be used in such lawn machines as a discharge conduit for a riding mower bagging system, an auxiliary cutter for a walk behind mower or a hand-held leaf vacuum.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
The present invention relates to lawn and garden machines and, more 
particularly, to a shredder attachment for use with motorized lawn and 
garden machines having vacuum or fan movement of shreddable material. 
2. Prior Art 
Various different lawn and garden machines or tools have been used in the 
art to perform multiple functions. One of these multiple functions is the 
collection of leaves, cut grass, or other material. A riding mower, for 
instance, can generally cut grass with either a side discharge or rear 
bagging of cut material. A riding mower can also use its rear bagging 
system to, at least partially, cut leaves and collect the leaves in its 
bagging system. Similarly, mobile vacuum systems have been used with 
riding tractors to collect leaves and hand held blower/vacuums have been 
used to collect and bag leaves. 
A problem exists with the various different lawn and garden machines or 
tools used in the prior art in that, although the tools can collect leaves 
or other matter and bag or store the leaves for disposal, because of the 
relatively irregular shape of leaves, their relative rigidity, and their 
relatively large size, relative to the storage container, the storage 
container must be emptied relatively often because leaves do not lend 
themselves to compact storage. This is because of the leaves somewhat 
irregular shape and rigidity which produce relatively large air voids 
therebetween. 
Another problem is that although leaf collectors, such as mowers, can 
partially cut leaves before they are moved to the leaf storage area or 
collecting container, lawn mowers with relatively large single blades do 
not shred leaves into sufficiently small pieces for compact storage. 
Therefore, the relatively large leaves or leaf portions that are delivered 
to a storage container allow for relatively large air voids therebetween 
and thus the storage container fills relatively rapidly requiring emptying 
of the storage container at relatively frequent intervals. 
Another problem is that prior art leaf collectors do not sufficiently cut 
or shred leaves into small pieces which results in the above mentioned 
storage problems. 
It is therefore an objective of the present invention to provide a shredder 
attachment for use with lawn and garden machines that can at least 
partially shred material, such as leaves, prior to storage in a collecting 
container. 
It is another objective of the present invention to provide a shredder 
attachment for use with a leaf collector that can substantially shred 
leaves into relatively small pieces. 
It is another objective of the present invention to provide a shredder 
attachment for use with a lawn or garden machine for collecting material, 
such as leaves, in a collecting container that can substantially diminish 
the size of air voids in collected material and thereby allow for 
collection of a larger amount of material in a container. 
It is another objective of the present invention to provide a leaf shredder 
attachment for use in a riding mower bagging system that can allow for 
fewer stops for emptying of a container of the system thereby reducing the 
time it takes to complete the riding of the mower over a given area. 
It is another objective of the present invention to provide a leaf shredder 
and collector that can shred leaves into relatively small pieces, thus 
reducing the volume of collected leaves for easier and less expensive 
disposal. 
SUMMARY OF THE INVENTION 
The foregoing problems are overcome and other advantages are provided by a 
shredder for use with a motorized lawn or garden machine for collecting 
material such as leaves and a method of manufacturing the same. 
In accordance with one embodiment of the invention, a shredder for use in a 
discharge conduit that provides a substantially closed path between a 
primary cutting area and a cut material catcher of a riding mower is 
provided. The shredder generally comprises frame means, drive means and 
means for cutting shreddable material. The frame means is suitably sized 
and shaped to be substantially mounted inside a discharge conduit. The 
drive means is fixedly connected to the frame means and has a drive shaft 
axially rotatable relative to the frame means. The means for cutting 
shreddable material can cut material passing through the discharge conduit 
from a primary cutting area to a cut material catcher. The cutting means 
comprises a cutter and means for connecting the cutter to the drive shaft 
of the drive means. The cutting means is suitably sized and shaped for 
rotation within a discharge conduit such that the cutter can shred 
shreddable material passing through a discharge conduit into relatively 
small pieces allowing for a denser storage of material in a cut material 
catcher with smaller air voids in the material whereby a relatively large 
amount of material can be collected in a catcher. 
In accordance with another embodiment of the present invention a discharge 
tube for use with a mower having a primary cutting area and being capable 
of exiting cut material from the primary cutting area through the 
discharge tube is provided. The discharge tube comprises frame means, 
means for connecting the frame means to a mower, and means for cutting 
material passing through the frame means. The frame means forms a 
substantially rigid conduit having a first open end and a second open end. 
The connecting means allows for connecting the first end of the frame 
means to a mower for receiving cut material from a primary cutting area of 
the mower. The means for cutting material passing through the frame means 
can cut material passing through the frame means conduit such that 
material exiting the conduit through the second end has been cut into 
relatively small pieces by the cutting means. 
In accordance with another embodiment of the present invention, a leaf 
collector is provided comprising frame means, means for transporting 
leaves, and means for substantially shredding leaves passing through the 
frame means. The frame means has means for storing collected leaves and 
means for conduiting leaves to the storing means. The conduiting means has 
a second end connected to the storing means and a first end. The means for 
transporting leaves can transport leaves through the conduiting means from 
the first end of the frame means out the second end of the fame means. The 
means for substantially shredding the leaves can shred leaves passing 
through the conduiting means and comprises a leaf cutter mounted in the 
conduiting means and drive means for moving the leaf cutter such that 
leaves entering the conduiting means first end are cut while passing 
through the conduiting means to exit the conduiting means second end in 
relatively small pieces whereby a large amount of leaves can be collected 
in the storing means. 
In accordance with one method of the present invention, a method of 
manufacturing a leaf cutting attachment for use with a leaf collecting 
device is provided. The method comprises the steps of connecting a cutter 
to a shaft; connecting the shaft to a frame member, the shaft being 
rotatably movable relative to the frame member; and connecting the frame 
member to a conduit tube for conduiting leaves, the frame member being 
fixedly connected to the tube such that the cutter is positioned inside 
the tube and can rotate therein such that the leaf cutting attachment can 
be connected to a mower for channeling leaves through the cutting 
attachment and cutting leaves as they pass therethrough.

DETAILED DESCRIPTION OF THE INVENTION 
Referring to FIG. 1, there is shown a perspective view of a riding lawn 
mower 10 having a mower bagging system 12 incorporating features of the 
present invention. It should be understood that although the features of 
the present invention will be primarily described with reference to use 
with lawn mowers, the present invention can be used in connection with any 
suitable type of lawn, yard, or garden collecting device or machine 
wherein the material being collected is of a shreddable nature. It should 
also be understood that the present invention can be embodied in many 
alternate forms and is not necessarily limited to the embodiments shown in 
the figures and may include any suitable size, shape, or type of materials 
without departing from the spirit of the invention. 
The riding mower 10 generally comprises an engine 13, such as an internal 
combustion engine, and a mower deck 14 surrounding a primary cutting area 
16 wherein a primary mower blade or blades (not shown) are rotated by the 
engine 13 both to cut grass and provide a strong vacuum or fan action to 
stand grass straight up for clean cutting, and to pick up grass cuttings, 
leaves, and other debris and discharge the vacuumed material from the 
primary cutting area 16 into the mower bagger system 12. In the embodiment 
shown, the mower bagger system 12 generally comprises a mower deck 
discharge tube 18, a center discharge tube 20, an elbow discharge tube 22 
and a collection container 24 generally comprising a container body 28 and 
hood assembly 26. In the embodiment shown, the three discharge tubes 18, 
20, 22 are provided as separate members which are removably connected to 
each other. However, in an alternate embodiment of the present invention, 
the three tubes 18, 20, and 22 may be provided as a single member. The 
mower deck discharge tube 18 generally provides a path from the primary 
cutting area 16 into the center discharge tube 20. The center discharge 
tube 20 has a center conduit 36 (See FIG. 2A) passing therethrough with a 
first end 30 removably connected to the mower deck discharge tube 18 and a 
second end 32 removably connected to the elbow discharge tube 22. The 
elbow discharge tube 22 generally provides a conduit or path into the 
container 24 wherein grass clippings, leaves and other debris can be 
deposited. 
Referring also to FIG. 2A, a partial perspective view of the center 
discharge tube 20 proximate its first end 30 is shown. As can be seen, the 
center tube 20 has a relatively thin structural wall 34 which forms a 
center conduit 36 between the first end 30 and second end 32. In the 
embodiment shown, located inside the center tube 20 in the conduit 36 
proximate the tube's first end 30 is a shredding device 38. Referring also 
to FIG. 2B, a plan side view of the shredding device 38 of FIG. 2A is 
shown. In the embodiment shown, the shredding device 38 generally 
comprises a frame 40, a shredder or cutter 42 and a drive motor 44. The 
frame 40 is generally comprised of any suitable material such as metal and 
generally comprises a center portion 45 and three legs 46, 47, and 48. 
Each leg 46, 47 and 48 generally comprises a branch portion 49 extending 
away from the center portion 45 at substantially equal angles and end 
portions 50 of the legs which are substantially perpendicular to the 
branch portions 49 at the ends of the legs. The end portions 50 may be 
provided as substantially flat, however, they may also be suitably shaped 
to mate with the curved inner side of the center tube wall 34 when 
inserted into the inner conduit 36. In the embodiment shown, each of the 
end portions 50 comprise a mounting aperture 52 passing therethrough for 
passage of a fastener (not shown), such as a screw or bolt therethrough. 
In the embodiment shown, the wall 34 of the center tube 20 is generally 
provided with three mounting apertures 54 suitably spaced relative to each 
other such that when the shredding device 38 is inserted into the center 
conduit 36 the frame mounting apertures 52 can be aligned with the tube 
mounting apertures 54 with suitable fasteners passing therethrough to 
fixedly, but removably, connect the shredding device 38 to the center 
discharge tube 20. However, any suitable means may be provided for 
connecting the shredding device 38 to the center tube 20 including means 
which would not allow for the removability of the shredding device from 
the tube. In addition, any suitable number of legs may be provided or any 
suitable type of frame may be provided for fixedly mounting the drive 
motor 44 and cutter 42 inside the discharge tube 20. In the embodiment 
shown, the frame 40 comprises an aperture 56 passing through the center 
portion 45. The drive motor 44 is suitably connected to a first side 58 of 
the frame 40 proximate the aperture 56. A shaft 60 generally extends from 
the drive motor 44 up through the aperture 56 extending outward from a 
second side 59 of the frame. A cutter connecting device 62 is fixedly 
connected to the shaft 60 and provides a means for fixedly, but removably 
connecting the cutter 42 to the shaft 60. The drive motor 44, in the 
embodiment shown, is generally comprised of an electric motor which can 
axially rotate the shaft 60. Suitable means 63 are provided for providing 
electricity from the engine 13 to the drive motor 44 such as a small 
generator (not shown) connected to the engine 13 which can produce 
electricity and deliver the electricity to the drive motor 44 via suitable 
conductor wires. However, any suitable type of means may be provided to 
drive the cutter and need not be an electric motor. 
In the embodiment shown, the cutter or shredder 42 is comprised of four 
string-like members 64. The string-like members 64 each have an inner end 
66 and an outer end 68. Each of the inner ends 66 are suitably connected 
to the cutter connecting device 62 such that when the drive motor 44 
rotates the shaft 60, the string-like members 64 are rotated about the 
center axis of the center discharge tube 20 with their outer ends 68 
slightly spaced from the inner surface of the wall 34. In a preferred 
embodiment of the present invention, the cutter connecting device 62 is 
suitably adapted to allow for relatively easy removal and replacement of 
the string-like members if they become worn or damager during shredding. 
Each string-like member 64 is generally comprised of a plastic or polymer 
material and is somewhat rigid, but flexible. However, any suitable type 
of material or combination of materials can be used such as a metal wire 
coated with a polymer coating or cover. The string-like members 64 may 
have any suitable size thickness and can also be provided as tubular 
members if so desired. Although four string-like members 64 have been 
described above, any suitable number of string-like members may be 
provided including 1, 2, 3 or more. In addition, the string-like members 
may be provided such that their centers are attached to the connector 62 
with their two ends extending therefrom. 
Referring also to FIG. 3, there is shown an alternate embodiment of a 
cutter or shredder 42. In the embodiment shown, the cutter 42 is generally 
comprised of a relatively rigid blade member 43 having three legs 70, 71 
and 72. An aperture 73 is provided for mounting the blade 43 to the 
connector 62 or alternatively, to the shaft directly. In the embodiment 
shown, the blade 43 is generally provided with relatively sharp edges 74 
on both sides of each leg 70, 71 and 72. The blade 43 is preferably made 
with a suitable material such as hardened steel and when rotated by the 
drive motor 44 and shaft 60 can cut through or shred material passing 
through the center conduit 36 of the tube 20. Each leg 70, 71 and 72 has 
both of its edges 74 as cutting edges such that in the event one of the 
edges on each side of the legs become dull or damaged, the blade 43 can be 
removed from the shaft 60, reversed, and mounted back onto the shaft 60 
such that the opposite edge of each leg can now be used for cutting 
purposes. This blade reversibility feature thus gives a new set of cutting 
edges to provide a longer and harder working life for the blade 43. 
Although a string-like cutter and a blade like cutter have been described 
above, any suitable type of cutter or shredder may be provided with the 
shredding device 38. The blade 43 may have any suitable shape for cutting 
or shredding purposes, but may also be shaped to help provide a fan-like 
action, similar to the mower blade (not shown), to propel material through 
the mower bagging system 12. 
For the embodiment shown in FIGS. 1, 2A and 2B, an operator can use the 
riding lawn mower 10 for both cutting grass and collecting leaves and 
other debris and for storing the material in the collecting container 24. 
Generally, the mower blade (not shown) located under the mower deck 14 
cooperates with the mower deck and the mower deck discharge tube 18 to cut 
material located in the primary cutting area 16 and exit the cut material 
through the mower deck discharge tube 18 via a lifting vacuum or fan 
action created by the mower blade (not shown) as it rotates. The cut 
grass, leaves, and other material are pushed through the discharge tubes 
18, 20 and 22 by the fan-like action of the mower blade (not shown). As 
the material enters the center discharge tube 20 it passes into the 
cutting area of the cutter 42 and its string-like members 64. Because the 
shaft 60 is being axially rotated by the drive motor 44, the string-like 
members 64 revolve about the center axis of the shaft 60 and the center 
axis of the tube 20 at a relatively high speed such that shreddable 
material, such as leaves or grass clippings, being pushed past the cutter 
42 by the fan-like action of the mower blade (not shown) are impacted upon 
by the string-like members 64 which effectively cut or shred the material 
passing through the cutting area of the shredding device 38. Because the 
string-like members 64 are rotating at a relatively high speed, they 
substantially prevent any material from being clogged on the frame 40. The 
shreddable material, once shred, can continue along the path of the 
discharge tubes 20 and 22 and be deposited in the collecting container 24. 
It should be understood that the term shred and variations thereof as used 
herein is generally intended to mean the tearing, cutting or shearing of 
material into relatively small pieces. 
Obviously, as the shreddable material passes through the cutting area of 
the shredding device 38 it is cut or shredded into smaller pieces. Because 
the shreddable material has been cut or shredded into smaller pieces 
various advantages are gained. First, because the shreddable material is 
in smaller pieces, the pieces are relatively easier to be moved by the 
flow of air from the fan-like action of the mower blade (not shown). Thus, 
the relatively small pieces can be more easily and quickly transported to 
the container 24, reducing the risk of clogging of shreddable material in 
the discharge tubes. Second, when the shreddable material is exited from 
the elbow discharge tube 22 into the container 24 it settles in the 
container 24. Because the shreddable material has been shred into 
relatively small pieces, the settling of the shredded material occurs in a 
denser manner, having relatively small air voids between collected 
material, thus allowing for collection of a larger amount of material in a 
more compact density in the container 24. Third, because collected 
material in the container 24 is being stored in the container in a 
relatively denser and more compact manner, it takes longer for the 
container to become full. This allows for fewer stops of the mower 10 by 
an operator for the purpose of emptying the container 24 when it becomes 
full Thus, this can reduce the time it takes to complete the operation of 
the mower 10 over a given area. Fourth, because collectible material can 
be collected in a relatively denser and more compact manner, disposal of 
the collected material is relatively easier and can be less expensive, 
such as by using less trash bags to eventually dispose of the material. As 
is evident from the above description, the present invention may be 
embodied in various forms or alternatives. Obviously, any suitable type of 
conduiting system may be provided. Any suitable type of vacuum or fan 
action for moving the shreddable material through the conduiting system 
may be provided. Any suitable type of container may also be provided. 
Preferably, the shredding device 3B is removably mounted in the center tube 
20 and can be removed such as in the springtime when cutting of dense, 
heavy and tall grass is necessary wherein even the slightest obstruction 
to the passage of grass clippings through the tubes may result in clogging 
of the tubes. Thus, the means for fastening the shredding device 38 to the 
center tube 20 may be comprised of means for relatively readily, easily 
and quickly mounting and dismounting the shredding device 38 with the tube 
20. Although the present invention has been described as having the 
shredding device 38 located proximate the first end 30 of the center tube 
20, it can be located anywhere in the three tubes 18, 20 and 22. In 
addition, the mower bagger system 12 may comprise a plurality of shredding 
devices 38 in series or in parallel arrangement. The shredding device 38 
may also be at least partially located outside the discharge tube 20. In 
addition, any suitable control may be provided on the riding mower 10 to 
activate, deactivate or modulate the drive motor 44. 
Referring now to FIG. 4, an alternate embodiment of the present invention 
is shown. In the embodiment shown, a yard tractor 76 is provided with a 
vacuum cart 78 having a conduit system 80. Obviously, the conduit system 
80 may be provided with a shredding device such as shown in FIG. 2B 
anywhere along its length or at a plurality of locations along its length. 
Referring also to FIG. 5, an alternate embodiment of the present invention 
is shown wherein a yard tractor 76 is provided with a trailer 82 having a 
bagging system 84 connected to a mower deck 88 via a conduit system 6. A 
shredding device such as that shown in FIG. 2B may be positioned in the 
conduit system 86 at any suitable location or at a plurality of locations. 
The bagging system 84 may be comprised of any suitable bagging system such 
as a SUPER BAGGER, a trademark of Textron, Inc. of Providence, R.I. 
Referring now to FIG. 6, an alternate embodiment of the present invention 
is shown. In the embodiment shown, a walk behind mower 90 is shown having 
a side discharge tube 92. The mower 90 generally has an engine 106, a 
frame 91 substantially defining a primary cutting area 16, and a primary 
cutting blade 108. Located inside the side discharge tube 92 is a 
shredding device 38 substantially similar to the shredding device shown in 
FIG. 2B. In the embodiment shown, although the shreddable material is not 
being collected, but rather is being discharged back onto a lawn, the 
combination of the primary mower blade (not shown) and the shredding 
device 38 allow for the shredding of material into a relatively fine 
mulch-like discharge as relatively small pieces. Because the grass 
clipping and other shreddable material are being side discharged, this 
substantially prevents the clogging of grass clippings under the mower 
deck of the mower 90 as is common with mowers producing mulch from grass 
clippings. 
Referring now to FIG. 7, there is shown an alternate embodiment of the 
present invention wherein a shredding device 38 is provided with a 
hand-held blower/vacuum 94. The blower/vacuum 94 in the embodiment shown 
is arranged for a vacuum configuration having a bag 96 connected to its 
discharge 98 for bagging collected leaves. The blower/vacuum 94 generally 
comprises a vacuum motor 100 and a main tube 102. In the embodiment shown, 
the shredding device 38 is located in the main tube 102 and supplied with 
electricity generated from the vacuum motor 100. The motor 100 can 
generally create a vacuum in the main tube 102 such that shreddable 
material such as leaves can be sucked into an entrance 104 of the main 
tube 102 and exited from the vacuum motor 100 via the discharge tube 98 
into the bag 96. As shreddable material passes through the cutting area of 
the shredding device 38 it can be shred into relatively small pieces for 
better collection and storage of the shreddable material in the bag 96. In 
an alternate embodiment of the present invention, the shredding device 38 
need not be provided in the main tube 102, but rather may be provided in 
the discharge tube 98. In another alternate embodiment of the present 
invention, the shredding device 38 need not be provided with an electrical 
drive motor, but rather may be provided with a mechanical drive means 
connected to the vacuum motor 102 such as a cable or flexible shaft which 
can drive the cutter or shredder of the shredding device 38. 
It should be understood that the foregoing description is only illustrative 
of the invention. Various alternatives and modifications can be devised by 
those skilled in the art without departing from the spirit of the 
invention. Accordingly, the present invention is intended to embrace all 
such alternatives, modifications and variances which fall within the scope 
of the appended claims.