IMPROVED SELF DRIVE ASSEMBLY FOR LAWN MOWER

Abstract: A self drive assembly (21) for a walk behind lawn mower including a motor for driving a cutting deck, front and rear wheels, a housing (20) with a rear opening (22) for the passage of cut grass into a detachable grass catcher; the self drive assembly (21) including: a gear box (27) having an input connected to the motor; an output assembly for driving a wheel axle (28); and means for engaging and disengaging the drive assembly (21) such that when the drive assembly (21) is engaged the mower is self propelled and when the drive assembly is disengaged the mower can be manually propelled; wherein the gear box (27) is located relative to the wheel axle (28) to maximise the area of the rear opening (22).

Description: IMPROVED SELF DRIVE ASSEMBLY FOR LAWN MOWER BACKGROUND The present invention relates to self drive lawn mowers and more particularly relates to an improved self drive assembly for attachment to mowers of the walk behind push variety and which are capable of conversion between a self drive state and a manual state. PRIOR ART There are in existence a wide variety of self drive lawn mowers which require manual engagement and disengagement of a drive assembly by an operator walking behind the mower. The known self drive assemblies operate by taking power from the engine and transferring drive to the rear wheels of the mower. By way of example, a known mower self drive assembly comprises a gear box mounted on an axle, an input arm on said gear box which takes power from a drive motor via a drive belt, an output connected to the gear box which engages a cog wheel mounted on a wheel hub, such that when the motor of the mower is running, the drive belt transfers engine power to the gear box via the input whereupon the gear box transfers drive to an output which turns the rear wheels of the mower via interengaging cogs. Although the known self drive mowers operate adequately to drive the mower, they suffer from a number of attendant disadvantages arising from the configuration of the drive assembly and its location relative to the opening to the grass catcher. In the known arrangements the gear box and drive arrangements partially obstruct the passage of grass delivered from the cutting blades to the grass catcher. This can cause clogging of the opening to the catcher and in serious cases particularly where the grass is wet, eventual stalling of the motor. Due to the physical size of conventional push type mowers and the limited space available in the cutting deck housing, designs thus far have not overcome the problem of obstruction of the grass catcher by the self drive assembly. INVENTION The present invention seeks to ameliorate the problems associated with the known self drive assemblies by providing an alternative assembly which provides efficient self drive but without obstruction of the chute opening to the grass catcher and unwanted clogging of the grass catcher chute opening. In its broadest form the present invention comprises: A self drive assembly for a walk behind lawn mower of the type including a motor for driving a cutting deck, front and rear wheels supporting a housing for said cutter deck, the housing including a rear opening which allows passage therethrough of grass delivered from said cutting deck into a grass catcher which detachably engages said housing and opposes said opening; the self drive assembly including; a gear box including an input connected to an output of said motor; an output assembly connected to said gear box which drives a wheel axle of said mower, means for engaging and disengaging said drive assembly such that when the drive assembly is engaged said mower is self propelled and when the assembly is disengaged said mower is manually operable; wherein the self drive assembly is mounted on the mower such that said gear box is located relative to said wheel axle to maximise the area defined by said rear opening available to receive grass from said cutting deck to said grass catcher. In another broad form the present invention comprises; a self drive assembly for a walk behind lawn mower of the type including a motor for operating a cutting deck, front and rear wheels for supporting a housing for said cutter deck, the housing including a rear opening which allows passage therethrough of grass delivered from said cutting deck into a grass catcher which detachably engages said housing and opposes said opening; said self drive assembly including; a gear box including an input connected to said motor; an output assembly connected to said gear box which drives a wheel axle of said mower, means for engaging and disengaging said drive assembly such that when the drive assembly is engaged said mower is self propelled and when the assembly is disengaged said mower is manually operable; wherein the self drive assembly is mounted on the mower such that only said drive to said wheel axle is within the area defined by said opening thereby maximising the area of said opening available to receive grass delivered from said cutter deck. According to a preferred embodiment the self drive output assembly is located at the side of the opening such that the width of the opening available to allow grass passage is increased due to the absence from the opening area of the remainder of the self drive assembly. According to a preferred embodiment, the self drive assembly includes a belt which transfers power from said motor to said input. The belt is mounted on a drive pulley at the drive motor and on an input pulley at the gear box. Preferably said connection between said output and said wheel is via a chain connected at said output to an output clutch and at said axle to a sprocket. Preferably, said drive assembly is mounted above the axle such that the input pulley is adjacent to but above said axle. Preferably, the assembly is eccentric to the centre line of the mower and is disposed such that the input pulley and drive sprocket are beneath the cutter deck housing and the output pulley is above the cutter deck housing. In another broad form the present invention comprises: a self drive assembly for a walk behind lawn mower of the type including a motor for operating a cutting deck, front and rear wheels for supporting a housing for said cutter deck, the housing including an opening which allows passage therethrough of grass delivered from said cutting deck into a grass catcher which engages detachably engages said housing; the self drive assembly including; a gear box mounted on said housing and including an input connected wither directly or indirectly to said motor; an output from said gear box directly or indirectly connected to a wheel axle, means for engaging and disengaging said drive assembly such that when the drive assembly is engaged said mower is self propelled and when the assembly is disengaged said mower is manually operable; wherein the self drive assembly includes a drive belt which transfers power from the motor to said input to said gear box; the connection between the output and the wheel axle provided by a drive chain; wherein the assembly is mounted such that the gear box does not obstruct said opening to said grass catcher. In another broad form the present invention comprises; a walk behind lawn mower of the type including a motor for operating a cutting deck, front and rear wheels for supporting a housing for said cutter deck, the housing including a rear opening which allows passage therethrough of grass delivered from said cutting deck into a grass catcher which detachably engages said housing and opposes said opening; the mower further comprising a self drive assembly including; a gear box including an input connected to said motor; an output assembly connected to said gear box which drives a wheel axle of said mower, means for engaging and disengaging said drive assembly such that when the drive assembly is engaged said mower is self propelled and when the assembly is disengaged said mower is manually operable; wherein the self drive assembly is mounted on the mower such that said gear box is located above said axle to maximise the area of said opening available to receive grass from said grass catcher. In another broad form the present invention comprises; A lawn mower of the type including a motor for driving a cutting deck, front and rear wheels supporting a housing for said cutter deck, the housing including a rear opening which allows passage therethrough of grass delivered from said cutting deck into a grass catcher which detachably engages said housing and opposes said opening; the mower further including a self drive assembly, wherein the self drive assembly includes; a gear box including an input operably connected to an output of said motor; an output assembly connected to said gear box which drives a wheel axle of said mower, means for engaging and disengaging said drive assembly such that when the drive assembly is engaged said mower is self propelled and when the assembly is disengaged said mower is manually operable; wherein the self drive assembly is mounted on the mower such that said gear box is located relative to said wheel axle to maximise the area defined by said rear opening available to receive grass from said cutting deck to said grass catcher. In another broad form of the method aspect the present invention comprises; A method of a constructing of a drive assembly for a self drive lawn mower, of the type including a motor for driving a cutting deck, front and rear wheels supporting a housing for said cutter deck, the housing including a rear opening which allows passage therethrough of grass delivered from said cutting deck into a grass catcher which detachably engages said housing and opposes said opening; the method comprising the steps of ; a) taking a gear box having an input and an output; b) attaching a clutch to said output of said gear box; c) attaching a pulley to said input of said gear box ; d) providing a link between said pulley and said drive motor; e) providing a link between said clutch and an axle of said mower; f) providing means for engaging and disengaging said drive assembly such that when the drive assembly is engaged said mower is self propelled and when the assembly is disengaged said mower is manually operable; g) locating said drive assembly on said mower such that said gear box is located relative to said wheel axle to maximise the area defined by said rear opening available to receive grass from said cutting deck to said grass catcher. Preferably, said gear box and clutch are located above said wheel axle with sufficient clearance to maximize the area of said rear opening which will allow grass to pass after cutting by said cutting deck. DETAILED DESCRIPTION The present invention will now be described in more detail according to a preferred but non limiting embodiment and with reference to the accompanying illustrations wherein: Figure 1 shows a perspective rear view of a mower housing and self drive assembly according to a prior art arrangement. Figure 2 shows a perspective view of a self drive assembly according to a preferred embodiment of the invention; and Figure 3 shows the drive assembly of figure 2 adapted to a mower and incorporated in a housing. Figure 4 shows a perspective view of a gear box of a self drive assembly according to a preferred embodiment of the invention. Figure 5 shows a perspective view of the gear box arrangement of figure 4 incorporated with drive assembly protective housings. Figure 6 shows the assembly of figure 5 with a clutch and sprocket protected by cover component . Figure 7 shows the self drive assembly fully assembled and installed on a mower housing from a front perspective view. Traditional walk behind self drive lawn mowers comprise a motor which drives a cutting deck. The cutting deck is protected by a housing which defines an underside space in which grass is cut and which exits the housing under energy imparted by cutting blades through a rear opening. Prior art self drive lawn mowers include a self drive assembly which unfortunately due to its configuration and location has caused obstruction to the rear opening in the housing compromising efficient discharge of cut grass tlirough the rear discharge opening. Referring to figure 1 there is shown a rear perspective view of a prior art mower housing 1 including a rear opening 2 which allows passage of grass delivered from a cutter deck within housing 1 to a grass catcher (not shown) having a corresponding entry opening which opposes opening 2. Housing 1 further comprises a self drive assembly 3 mounted on rear wheel axle 4. Self drive assembly 2 engages a motor which would normally be located in the region indicated by arrow 5 and by indirect transmission to axle 4 imparts self drive to the mower when axle 4 is caused to rotate. Ground engaging wheels normally located ( but not shown) at ends 6 and 7 of axle 4 and driven by axle 4 self drive the mower. Self drive assembly 3 includes gear box 8 directly connected to axle 4 so that direct self drive is imparted to the wheels. The location of gear box 8 significantly reduces the area of opening 2 available to deliver grass from the cutter deck to the grass catcher. Thus, opening 2 bounded and defined by walls 9 and 10 and roof 11 represents the potential opening area available to receive grass from the cutter deck into the grass catcher but this is significantly reduced in area by the location and configuration of self drive assembly 3. The configuration of the known self drive assemblies have traditionally involved a compromise between the advantages of including the self drive feature and the resultant restriction to the remaining opening space available to receive cut grass. The inclusion of the self drive arrangement as shown in figure 1 necessitates a substantial reduction of up to 30-40% of the area of opening 2 and a resultant decrease in the rate and efficiency of grass catching for a mower of a given size cutter deck. This results in an available opening defined by roof 11 wall 10 and partition 12. There has been a long felt want in the mower industry to provide a self drive mower of the walk behind type which includes a self drive assembly installed without compromise to the maximum available opening area in a housing through which cut grass may pass. The higher the area of the grass discharge opening the more efficient the mower. Gear box 8 of drive assembly 3 unavoidably takes up the space defined by roof 11 wall 9 and partition 12 as there is direct drive between gear box 8 and axle 4 which dictates gear box proximity to axle 4. Figure 2 shows a cutter deck housing 20 of a walk behind mower with self drive assembly 21 connected thereto according to one embodiment of the invention. Housing 20 includes opening 22 which allows passage of grass delivered from a cutter deck within housing 20 to a grass catcher (not shown) having an entry opening which opposes opening 22. Drive assembly 21 engages a motor which communicates with engine pulley 29 and further includes gear box 27 which is located at a predetermined clearance above axle 28 so that direct self drive is imparted to the wheels which would be fitted to ends 28a and 28b. The location of the gear box 27 significantly increases the available area of opening 22 available to receive grass from a grass catcher which opposes opening 22. Opening 22 which is bounded and defined by walls 23 and 24 and roof 25 represents the potential opening area available to receive grass from a grass catcher. Opening 22 is substantially free of obstruction and is significantly increased in area of grass delivery to a grass catcher compared to the available area remaining after subtracting the area taken up by self drive assembly 3 illustrated in Figure 1. The configuration of that assembly would if the prior art self drive assembly was used cause a substantial reduction of up to 30-40% of the area of opening 22 and a resultant decrease in the rate and efficiency of grass catching for a mower of a given size. With self drive assembly 21 installed on housing 20 the area of opening 22 available to receive grass from a grass catcher is increased to an extent that almost all opening 22 is available to allow passage of cut grass. The only obstruction of opening 22 is casing 26 which comprises a drive belt or chain transmitting drive from gear box 27 to axle 28. Axle 28 receives wheels ( not shown ) on ends 28a and 28b. Casing 26 takes up only a small portion of opening 22 leaving opening 22 substantially free of obstruction so all available area in opening 22 is dedicated to allowing passage of grass. This has the advantage that an increased volume of grass can be delivered through opening 22 by a cutter deck for the same size mower. Compared to the known self drive assemblies, the alternative configuration of self drive assembly 21 renders the opening substantially free of obstruction thereby minimising the risk of unwanted clogging of opening 22 with grass clippings. Casing 26 may be integral with wall 23 or a separate component attached thereto. Casing 26 also prevents fouling of output assembly components to be described below. Referring to figure 3 there is shown a perspective view of a self drive assembly 30 according to a preferred embodiment for attachment to a mower of the walk behind type. Assembly 30 which has been exploded from a mower housing ( not shown for clarity) is viewed from a side frontal direction. Assembly 30 includes a gear box 31 which transmits drive from a motor via a clutch to a drive axle. Power from a drive motor is transferred to drive pulley 32 which drives belt 33. Belt 33 also engages input pulley 34 which is connected to input shaft 35 which teπninates at gear box 31. Gear box 31 is operably linked to output clutch 36 disposed in a generally vertical plane and which receives drive belt or chain 37. Output clutch 36 is directly connected to gear box 31 via output shaft 38 and includes sprocket 39 which receives drive chain 37. Drive chain 37 is connected to axle 40 via sprocket 41 such that rotation of output clutch 36 responsive to drive imparted from a motor via input pulley 34 and input shaft 35 to gear box 31 causes axle 40 to rotate thereby imparting drive to wheels ( not shown) mounted on ends 40a and 40b of axle 40 of the lawn mower to which the drive assembly is attached. Self drive assembly 30 as shown, is located above axle 40 at a height which comfortably clears axle 40 and minimises or eliminates obstruction by gear box 31 of an opening in a mower housing which in the arrangement shown in figure 3 would be on the left side of gear box 31 and allows passage of grass cut by the mower for delivery to a grass catcher. Various alternatives may be employed in the self drive assembly 30 including substitution of a belt for chain 37 and replacement of sprockets 39 and 41 with pulleys. Referring to figure 4 there is shown a detailed view of the configuration of a gear box 42 from a self drive assembly according to a preferred embodiment of the invention. Gear box 42 includes output shaft 43 and input shaft 44. Input shaft 44 receives input pulley 45 which is driven by a motor on a lawn mower. Shaft 43 receives a sprocket which receives a chain which transfers drive from shaft 43 to a wheel axle in the same manner as that described with reference to figure 3. Gear box 42 as with the other gear boxes described in this specification receives input drive from a motor via a downwardly depending shaft such as shaft 44 as shown in figure 4. Figure 5 shows the self drive assembly of figure 4 including housings 47 and 48. Housing 48 accommodates the output assembly which includes output clutch 49 and sprocket 50. In use, clutch 49 is covered and this also protects the drive belt or chain driven by the sprocket. Figure 6 shows the assembly of figure 5 with clutch 49 and sprocket 50 protected by cover component 51. Figure 7 shows the self drive assembly fully assembled and installed on mower housing 52. It can be seen from the front perspective view in figure 7 that assembly 53 is arranged such that all components of the assembly 53 except for the transmission belt 37 ( see figure 3) and casing 26 (see figure 2) are above shaft 54 and above cutter deck cowling 55. This allows almost unobstructed passage of grass tlirough an opening in the rear of housing 52 to a grass catcher or in the event of non use of a grass catcher to the outside of housing 52. It will be recognised by persons skilled in the art that numerous variations and modifications may be made to the invention as broadly described herein without departing from the overall spirit and scope of the invention.

Claims: THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS: 1 A self drive assembly for a walk behind lawn mower of the type including a motor for driving a cutting deck, front and rear wheels supporting a housing for said cutter deck, the housing including a rear opening which allows passage therethrough of grass delivered from said cutting deck into a grass catcher which detachably engages said housing and opposes said opening; the self drive assembly including; a gear box including an input connected to an output of said motor; an output assembly connected to said gear box which drives a wheel axle of said mower, means for engaging and disengaging said drive assembly such that when the drive assembly is engaged said mower is self propelled and when the assembly is disengaged said mower is manually operable; wherein the self drive assembly is mounted on the mower such that said gear box is located relative to said wheel axle to maximise the area defined by said rear opening available to receive grass from said cutting deck to said grass catcher. 2 An assembly according to claim 1 wherein, said gear box is elevated above said wheel axle to minimize the area of said rear opening obstructed by said self drive assembly. 3 An assembly according to claim 2 wherein a drive pulley and belt or chain drives said rear axle when said self drive assembly is actuated. 4 An assembly according to claim 3 wherein said self drive assembly is configured to allow clear passage of said grass through up to 95% of the area of said rear opening. 5 An assembly according to claim 4 wherein said rear opening is defined by side walls and a roof of said housing. 6 An assembly according to claim 5 wherein said drive pulley which engages said drive shaft and said belt or chain is contained in a casing which lies adjacent one said side wall. 7 An assembly according to claim 6 wherein said casing is integral with said side wall. 8 An assembly according to claim 1 wherein drive to said axle is imparted remote from said gear box via a drive chain which engages a sprocket on said shaft. 9 An assembly according to claim 1 wherein drive to said axle is imparted remote from said gear box via a drive belt which engages a pulley on said shaft. 10 An assembly according to claim 8 or 9 wherein said drive belt or chain engages via a first end a clutch operably linked to said gear box, the clutch including a sprocket or pulley which imparts drive via said belt or chain to said axle. 11 A lawn mower of the type including a motor for driving a cutting deck, front and rear wheels supporting a housing for said cutter deck, the housing including a rear opening which allows passage therethrough of grass delivered from said cutting deck into a grass catcher which detachably engages said housing and opposes said opening; the mower further including a self drive assembly, wherein the self drive assembly includes; a gear box including an input operably connected to an output of said motor; an output assembly connected to said gear box which drives a wheel axle of said mower, means for engaging and disengaging said drive assembly such that when the drive assembly is engaged said mower is self propelled and when the assembly is disengaged said mower is manually operable; wherein the self drive assembly is mounted on the mower such that said gear box is located relative to said wheel axle to maximise the area defined by said rear opening available to receive grass from said cutting deck to said grass catcher. 12 A mower according to claim 1 wherein, said gear box is elevated above said wheel axle to minimize the area of said rear opening obstructed by said self drive assembly. 13 A mower according to claim 12 wherein a drive pulley and belt or chain drives said rear axle when said self drive assembly is actuated. 14 A mower according to claim 13 wherein said self drive assembly is configured to allow clear passage of said grass through up to 95% of the area of said rear opening. 15 A mower according to claim 14 wherein said rear opening is defined by side walls and a roof of said housing. 16 A mower according to claim 15 wherein said drive pulley or sprocket which engages said drive shaft and said belt or chain is contained in a casing which lies adjacent one said side wall. 17 An assembly according to claim 16 wherein said casing is integral with said side wall. 18 A mower according to claim 11 wherein drive to said axle is imparted remote from said gear box via a drive chain which engages a sprocket on said shaft. 19 A mower according to claim 1 1 wherein drive to said axle is imparted remote from said gear box via a drive belt which engages a pulley on said shaft. 20 A mower according to claim 18 or 19 wherein said drive belt or chain engages via a first end a clutch operably linked to said gear box, the clutch including a sprocket which imparts drive via said chain to said axle. 21 A self drive assembly for a walk behind lawn mower of the type including a motor for driving a cutting deck, front and rear wheels supporting a housing for said cutter deck, the housing including a rear opening which allows passage therethrough of grass delivered from said cutting deck into a grass catcher which detachably engages said housing and opposes said opening; the self drive assembly including; a gear box including an input connected to an output of said motor; an output assembly connected to said gear box which drives a wheel axle of said mower, means for engaging and disengaging said drive assembly such that when the drive assembly is engaged said mower is self propelled and when the assembly is disengaged said mower is manually operable; wherein the output of said gear box includes a clutch which receives a belt or chain to impart drive to said wheel axle when said self drive assembly is engaged. 22 An assembly according to claim 21 wherein said gear box and said clutch are remote from said axle. 23 An assembly according to claim 22 wherein the self drive assembly is mounted on the mower such that said gear box is located above said wheel axle to provide a clearance between said gear box and said axle to thereby maximise the area defined by said rear opening available to receive grass from said cutting deck to said grass catcher. 24 An assembly according to claim 23 wherein said belt or chain engages a sprocket or pulley on said axle to impart drive to said axle when said self drive assembly is actuated. 25 A method of a constructing of a drive assembly for a self drive lawn mower, of the type including a motor for driving a cutting deck, front and rear wheels supporting a housing for said cutter deck, the housing including a rear opening which allows passage therethrough of grass delivered from said cutting deck into a grass catcher which detachably engages said housing and opposes said opening; the method comprising the steps of ; a) taking a gear box having an input and an output; b) attaching a clutch to said output of said gear box; c) attaching a pulley to said input of said gear box ; d) providing a link between said pulley and said drive motor; e) providing a link between said clutch and an axle of said mower; f) providing means for engaging and disengaging said drive assembly such that when the drive assembly is engaged said mower is self propelled and when the assembly is disengaged said mower is manually operable; g) locating said drive assembly on said mower such that said gear box is located relative to said wheel axle to maximise the area defined by said rear opening available to receive grass from said cutting deck to said grass catcher. 26 A method according to claim 25 wherein said gear box and clutch are located above said wheel axle with sufficient clearance to maximize the area of said rear opening which will allow grass to pass after cutting by said cutting deck. 27 A method of a constructing a self drive lawn mower, of the type including a motor for driving a cutting deck, front and rear wheels supporting a housing for said cutter deck, the housing including a rear opening which allows passage tlierethrough of grass delivered from said cutting deck into a grass catcher which detachably engages said housing and opposes said opening; and a self drive assembly; the method comprising the steps of ; a) taking a lawn mower body; a) taking a gear box having an input and an output; b) attaching a clutch to said output of said gear box; c) attaching a pulley to said input of said gear box ; d) providing a link between said pulley and said drive motor; e) providing a link between said clutch and an axle of said mower; f) providing on said mower means for engaging and disengaging said drive assembly such that when the drive assembly is engaged said mower is self propelled and when the assembly is disengaged said mower is manually operable; g) locating said drive assembly on said mower such that said gear box is located relative to said wheel axle to maximise the area defined by said rear opening available to receive grass from said cutting deck to said grass catcher. 28 A method of construction of a lawn mower according to claim 27 wherein said gear box and clutch are located above said wheel axle with sufficient clearance to maximize the area of said rear opening which will allow grass to pass after cutting by said cutting deck.

Inventors: DALL OSTO GAVEN RAY, JACKSON STEPHEN LEONARD, MIATT STEVEN RICHARD, DALL'OSTO, GAVEN, RAY, JACKSON, STEPHEN, LEONARD, MIATT, STEVEN, RICHARD
Applicants: DALL OSTO GAVEN RAY, JACKSON STEPHEN LEONARD, MIATT STEVEN RICHARD, ROVER MOWERS LTD, DALL'OSTO, GAVEN, RAY, JACKSON, STEPHEN, LEONARD, MIATT, STEVEN, RICHARD, ROVER MOWERS LIMITED
Application year: 2001
Main classification: A01D34
IPC codes: A01D34