Abstract:
A spreader accessory mountable below the extension rack of an ATV. In another aspect, an improved spreader mechanism that automatically starts and stops the feed of material from a storage container in conjunction with the distribution of material therefrom.

Description:
This application is a divisional of U.S. patent application Ser. No. 11/363,739, filed on Feb. 28, 2006, and to be issued as U.S. Pat. No. 7,306,175, on Dec. 11, 2007, which is a continuation-in-part of U.S. patent application Ser. No. 10/941,208, filed on Sep. 15, 2004, now U.S. Pat. No. 7,607,595 herein incorporated by reference in their entireties. 

   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The invention relates generally to accessories that are mounted onto an all terrain vehicle (ATV) and the like, and more particularly to broadcast spreader mechanisms that that are mounted to ATVs and the like. 
   2. State of the Art 
   All terrain vehicles (ATVs) are popular as a mode of transportation, particularly for various types of off-road activities. Typically, an ATV is equipped with a factory installed (or other pre-existing) carrier rack. The carrier rack generally consists of a plurality of tubular members that are mounted to the frame of the ATV. The tubular members are arranged to form a horizontal support area and spaced apart in a manner that allows various items such as tents, guns, fishing poles, tackle boxes, other field equipment, to be removably attached thereto using rope, bungee cords and the like. 
   The rugged nature of the ATVs has also made it popular as a utility vehicle. For such purposes, it is cumbersome to repeatably lash items to the factory-installed carrier racks. Thus, it has become popular to mount accessory extension racks onto such factory-installed carrier racks. The extension rack provides a flat storage bed that is useful for carrying diverse items and animals, such as containers, bags, gear, tools, dogs, etc. An example of such an extension rack is illustrated in U.S. Pat. No. 6,502,728 to Savant. 
   It is also known to mount a broadcast spreader accessory to the top of an ATV carrier rack. For example, an ATV-mounted spreader accessory known as the “Bumper-Buddy” is sold commercially. It includes a conical hopper (20-gallon/50-lb. capacity) that is mounted behind and above the ATV rear rack by bolt mount clamps. A spreader mechanism that includes an aluminum flow control valve, spinner plate and motor are supported underneath the conical hopper. The broadcast spreader accessory provides for distribution of large quantities of seed, corn, granulated salt, fertilizer and other dry pellet material. 
   While the Bubby-Buddy spreader is useful, it suffers from several drawbacks. For example, because the spreader accessory is mounted on the ATV carrier rack, an extension rack cannot also be mounted onto the carrier rack due to interference between the two accessories. In the event that a user desires the functionality provided by both of these accessories, the user must independently demount and alternatively mount the respective accessories onto the ATV carrier rack, which is cumbersome and time consuming. In addition, because the Bumper Buddy spreader is mounted above the ATV carrier rack, it significantly obstructs rear vision, obstructs normal access and use of the rear rack, and also undesirably moves the center of gravity of the ATV so that the ATV is more prone to roll-over. 
   Moreover, commercially available broadcast spreaders typically employ a sliding gate mechanism to start and stop the feed of material for distribution. Such mechanisms are prone to leakage and/or jamming. Such failures cause material to spill wastefully and, in the case of fertilizers, pesticides, herbicides and the like, such excess amounts can cause crop and/or lawn damage. 
   Automatic feed and distribution mechanisms have been developed that are less prone to leakage and jamming. An example is described in U.S. Pat. No. 5,820,035 to Johnson, which employs a disc that is operably coupled via a rotating shaft to an electric motor. When the motor is powered on, the rotating shaft rotates, thereby driving rotation of the disc. The rotating shaft and disc incorporate a helical thread interface together with a return spring and stop mechanism. When the rotating shaft is not moving, the return spring biases the disc to remain in a closed position that prohibits distribution of material from a storage hopper. When the rotating shaft is initially rotated, the disc moves down the rotating shaft to an open position to allow for distribution of material from the storage hopper. In its open position, material exits the storage hopper and is distributed by rotation of the disc. This mechanism works well in automatically starting and stopping the feed of material from the storage hopper, but it is difficult to adjust the feed rate for a given size material and/or to adjust the feed rate for different size materials. Because of these limitations, the distribution mechanism is difficult to use with different size seeds or pellets and thus is used primarily for static feeding and distribution of feed for fish and game. 
   SUMMARY OF THE INVENTION 
   It is therefore an object of the invention to provide a spreader accessory mountable to an extension rack of an ATV and the like that provides a spreader mechanism suitable for storage and distribution of large quantities of dry pellet material (e.g., seeds, fertilizer, pellets or other granular material). 
   It is another object of the invention to provide such a spreader accessory for an ATV and the like that permits carrying a wide variety of diverse loads and simultaneously storing and distributing large quantities of dry pellet material, thus avoiding the need to switch between accessories. 
   It is a further object of the invention to provide such a spreader accessory for an ATV and the like that provides the operator with an unobstructed view while operating the ATV. 
   It is another object of the invention to provide such a spreader accessory for an ATV and the like that provides the operator with unobstructed normal access and use of an extension rack. 
   It is also an object of the invention to provide such a spreader accessory for an ATV that is easily adjustable for a wide range of dry pellet material and that is easily adjustable for a wide range of distribution rates. 
   It is yet another object of the invention to provide such a spreader accessory for an ATV and the like that need not be removed when not being used. 
   It is also an object of the invention to provide such a spreader accessory for an ATV and the like that lowers the center of gravity of the vehicle, thereby enhancing stability and making the vehicle more resistant to rollover. 
   In accord with these objects, which will be discussed in detail below, an accessory is provided that is mountable to the extension rack of an ATV and the like. The extension rack provides a substantially flat storage bed. The accessory is capable of storing and distributing granular material therefrom. The accessory is supported in a position below the extension rack. In the preferred embodiment, the accessory includes a hopper that extends rearward beyond the extension rack with a door that extends rearward beyond the extension rack for easy loading and cleaning. 
   It will be appreciated that the ATV accessory of the present invention is positioned completely out of the way of the user and can be left in place. This feature enables the operator to avoid the time required to switch between accessories. It also provides the operator with an unobstructed view while operating the ATV together with unobstructed normal access and use of the extension rack. In addition, supporting the accessory beneath the extension rack lowers the center of gravity of the vehicle, thereby enhancing stability and making the vehicle a bit more resistant to rollover. 
   In another aspect of the present invention, a broadcast spreader mechanism for distributing granulated material employs a container with an outlet port together with a housing having a first housing part and a second housing part. The first housing part is mounted beneath and aligned to the outlet port of the container. The second housing part supports a threaded shaft, a spinner plate mounted on the threaded shaft with a coupler provided with internal threads that interface to the threaded shaft, a power source that rotationally drives the threaded shaft causing the spinner plate to rotate and travel along the threaded shaft, and a return spring encircling the threaded shaft and disposed between the spinner plate and the power source. The spinner plate is disposed beneath and aligned to the outlet port of the container for distribution of granulated material therefrom. The second housing part is moveably fixed relative to said first housing part in order to adjust amount of travel of the spinner plate along the threaded shaft. In the preferred embodiment, the first housing part includes an opening and funnel section for receiving the outlet port of the container, and a spring stop is used that encircles the threaded shaft and engages the return spring together with means for fixably moving the spring stop along the threaded shaft. A clamp can be used to clamp the return spring to a user-selected portion of the spring stop. 
   It will be appreciated that the broadcast spreader mechanism of the present invention enabled the user to quickly and easily select an appropriate feed rate over a wide range of feed rates and thus allow the spreader mechanism to be used effectively for a broad range of products with varying size and weight. 
   According to the preferred embodiment, the first housing part (or the second housing part or both) employ slots and wing nut connections therethrough that provide for fixable movement of the second housing part relative to the first housing part. 
   Additional objects and advantages of the invention will become apparent to those skilled in the art upon reference to the detailed-description taken in conjunction with the provided figures. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is an isometric view of an illustrative embodiment of a multipurpose accessory for an ATV in accordance with the present invention. 
       FIG. 2  is an exploded view of the multipurpose accessory of  FIG. 1  in accordance with the present invention. 
       FIG. 3  is an exploded view of a spreader accessory for an ATV in accordance with the present invention. 
       FIG. 4  is an isometric view of the dispensing mechanism employed by the spreader accessory of  FIG. 3 . 
       FIG. 5  is a schematic rear view of the dispensing mechanism of  FIG. 4 . 
       FIG. 6  is a schematic side view of the dispensing mechanism of  FIG. 4 . 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   Turning now to  FIG. 1 , there is shown an ATV accessory  10  in accordance with the present invention. The ATV has a factory-installed (or other pre-existing) carrier rack that is affixed to its frame. The carrier rack, which is also referred to as a rear rack herein, includes a plurality of tubular members that provide a horizontal support area above the rear fenders of the ATV as is conventional. The rear rack is hidden in  FIG. 1  and thus not shown. An extension rack  12  is mounted to the rear rack. The extension rack  12  provides a flat storage bed that is useful for carrying diverse items and animals, such as containers, bags, gear, tools, dogs, etc. The extension rack  12  includes a base frame  16  and a side frame  18  both constructed from tubular members. The base frame substantially extends in the horizontal plane and is attached to the pre-existing rear rack utilizing bolted-collars, spring-clips, brackets, or other suitable fastening mechanisms. The side rail frame  18  is vertically displaced from the base frame  16  and preferably includes a rail  18 A, vertical supports  18 B, metal mesh sections  19 A,  19 B,  19 C and metal sheet sections  21 A,  21 B. Similarly, the base frame  16  is preferably covered with metal mesh sections  23 A,  23 B,  23 C and metal sheet section  25 . In this manner, the covered base frame and side rail frame provide a flat storage bed that is suitable for carrying a wide range of diverse items. 
   In accordance with the present invention, a spreader assembly  14  is provided that is affixed in position below the extension rack  12 . A door  27  is provided through the metal sheet  25  towards the rear of the extension rack  12  as shown in  FIGS. 1 and 2 . The door  27  provides a passageway to the spreader assembly  14  that is disposed below the extension rack  12 . 
   The spreader assembly  14  includes a gravity-feed hopper  31  and a dispensing mechanism  33  mounted thereunder. The hopper  31  is filled by loading material (e.g., seed, fertilizer, granulated lime, granulated salt, etc) through the door  27  and empties via outlet  35 . The dispensing mechanism  33  includes a spring-loaded gate  36  that slides relative to the outlet  35  to selectively control the flow rate of material exiting the outlet  35 . The position of the gate  36  is preferably controlled by pulling a wire/cable (not shown) to thereby open and close the gate. The dispensing system  33  also includes a spinner plate  37  that is operably coupled via rotating shaft  38  to an electric motor  39 . When the motor  39  is powered on, the rotating shaft  38  rotates, thereby driving rotation of the spinner plate  37 . When the spinner plate  37  rotates, material that exits the outlet  35  is distributed over a large area behind the spreader. Push button control can be used to selectively power the electrical motor on and off and thereby provide user control over distribution by the spinner plate. Alternatively, the dispensing mechanism  33  may include a motor-driven closure mechanism as described below or possibly the motor-driven closure mechanism described in U.S. Pat. No. 5,820,035, herein incorporated by reference in its entirety. 
   The hopper  31  may include slots  41  in its structure that conform to the geometry of the base frame structure  16  of the extension rack  12  as shown in  FIG. 2 . These slots enable the top of the hopper  31  to mount flushly to the underside of the extension rack  12 . The spreader assembly  14  is preferably mounted below the extension rack  12  by L-shaped brackets  43  (one shown) and bolts that join the hopper  31  to the base frame structure  16  as shown in  FIG. 2 . Alternatively, the hopper  31  (and spreader assembly  14 ) may be permanently affixed to the extension rack  12  by welding or other means. 
   An alternate embodiment of a spreader assembly  14 ′ in accordance with the present invention is shown in  FIG. 3 . In this alternate embodiment, the front portion of the hopper  31 ′ is affixed to the underside of the extension rack  12  by bolts, brackets, or other suitable fastening mechanisms (not shown). The rear portion of the hopper  31 ′ is realized by sidewalls that extend rearward beyond the rear of the extension rack  12 . In the illustrative embodiment shown, the rear portion of the hopper  31 ′ includes three angled sidewalls (two shown in the view of  FIG. 3  as  31 A′,  31 B′) that extend rearward beyond the rear of the extension rack  12 . A door  47  is disposed on the top of the hopper  31 ′. The door  47  extends rearward beyond the rear of the extension rack  12 . Preferably, the hinged portion of the door  47  extends along the major dimension of the hopper  31 ′, and the opposite edge of the door  47  interfaces to the rim  48  formed by the rearward projecting angled sidewalls of the hopper  31 ′ as shown. The door  47  is opened (depicted by arrow  49 ) to gain access into the interior of the hopper  31 ′. Material that is to be distributed by operation of the spreader assembly  14 ′ is loaded through the open door  47  (depicted by arrow  50 ). A dispensing mechanism  33 ′ is mounted below the hopper  31 ′ preferably by four bolts as depicted by the dotted lines of the exploded view. The embodiment of  FIG. 3  is advantageous because it can readily be mounted onto an existing rack  12  without significant modification (e.g., cutting an access door through the floor of the extension rack  12 ). 
   As shown in  FIGS. 4-6 , the dispensing mechanism  33 ′ includes a housing  51  with two parts ( 51 A,  51 B) that are mounted below the hopper  31 ′. The first housing part  51 A is mounted to the bottom side of the hopper  31 ′ preferably by four bolts  52  that pass through four corresponding thru-holes  53  in its top wall  54 . The top wall  54  also has an opening  55  that leads to a funnel section  56 , which are adapted to receive the outlet  35 ′ of the hopper  31 ′ as best shown in  FIG. 5 . The second housing part  51 B is mounted to the first housing part  51 A in a manner that allows the second housing part  51 B to be fixably moved vertically relative to the first housing part  51 A. 
   An electric motor  39 ′ is mounted below the bottom wall  57  of the second housing part  51 B preferably by bolts  58 . The electric motor  39 ′ drives a rotating shaft  38 ′ when powered on. The shaft  38 ′ has a helical thread (not shown). A spinner plate  37 ′ has a central opening with an internal threaded coupling  59  that mates with the helical thread of the shaft  38 ′. A return spring  60  surrounds the rotating shaft  38 ′ and is disposed between the spinner plate  37 ′ and the electric motor  39 ′. Preferably, a washer  61  or other suitable friction reducing member such as a bearing or like means is disposed between the top end of the return spring  60  and the bottom side of the coupling  59  of the spinner plate  37 ′. The lower end of the return spring  60  is positioned along the rotating shaft  38 ′ by a spring stop  62 . The user can manually adjust the position of the spring stop  62  along the rotating shaft  38 ′ by unscrewing and screwing one or more set screws (not shown) that engage the rotating shaft  38 ′ as is well known in the mechanical arts. In this manner, the user can adjust the position of the lower end of the return spring  60  along the rotating shaft  38 ′. 
   A hose clamp  63  or other like member encircles the return spring  60  over a portion of the spring stop  62 . The return spring  60  and/or hose clamp  63  can be moved up or down the spring stop  62  and the hose clamp  63  tightened by the user such that the return spring  60  is clamped to a user-selected portion of the spring stop  62 . In this manner, the user can i) adjust the position of the lower end of the return spring  60  along the rotating shaft  38 ′, ii) adjust the effective length of the return spring  60 , and iii) adjust the spring force applied by the return spring  60 . In the preferred embodiment, the spring stop  62  extends along the helical thread of the rotating shaft  38 ′ over a total length of 1-2 inches. The return spring  60  and/or hose clamp  63  can be moved up or down this 1-2 inch length of spring stop and the hose clamp  63  tightened such that the return spring  60  is clamped thereto. This configuration advantageously provides a wide range of adjustability for i) the position of the lower end of the return spring  60  along the rotating shaft  38 ′, ii) the effective length of the return spring  60 , and iii) the spring force applied by the return spring  60 . 
   The top surface of the spinner plate  37 ′ preferably includes a set of projections  64  at its periphery that throw material from the spinner plate  37 ′ as it rotates. When the shaft  38 ′ is not rotating, the return spring  60  biases the spinner plate  37 ′ in a closed position against the funnel section  56 , thereby preventing material from flowing out of the outlet  35 ′ of the hopper  31 ′ onto the spinner plate  37 ′. As the shaft  38 ′ is initially rotated by powering up the electric motor  39 ′, the spinner plate  37 ′ rotates and moves down the helical thread of the rotating shaft. The downward movement of the spinner plate  37 ′ continues to a stopping point where the spinner plate  37 ′ rotates at the rotational speed of the shaft  38 ′. When the shaft  38 ′ slows down and stops rotating by powering down the electric motor  39 ′, the centrifugal force of the rotating spinner plate  37 ′ and the return spring  60  cause the spinner plate  37 ′ to move back up the rotating shaft  38 ′ to its initial closed position against the funnel section  56 , In this closed position, the return spring  60  biases the spinner plate  37 ′ against the funnel section  56 , thereby preventing material from flowing out of the outlet  35 ′ of the hopper  31 ′ onto the spinner plate  37 ′. Push button control can be used to selectively power the electrical motor  39 ′ on and off and thereby provide user control over distribution by the spinner plate  37 ′. 
   The stopping point of the downward travel of the spinner plate  37 ′ dictates the open position of the spinner plate  37 ′. The offset distance of the spinner plate  37 ′ between its initial closed position and its open position controls the feed rate of the material that flows out of the outlet  35 ′ of the hopper  31 ′ onto the spinner plate  37 ′ for distribution therefrom. The user adjusts this offset distance and thus controls the feed rate of the dispensing mechanism  33 ′ by raising or lowering position of the lower housing part  51 B relative to the upper housing part  51 A. In conjunction with the position adjustment of the lower housing part  51 B, the user may also adjust the position of the lower end of the return spring  60  along the rotating shaft  38 ′ by moving the spring stop  62 . The user can also move the return spring  60  and/or the hose clamp  63  up or down the spring stop  62  and tighten the clamp  63  to a user-selected portion of the spring stop  62  to i) adjust the position of the lower end of the return spring  60  along the rotating shaft  38 ′, ii) adjust the effective length of the return spring  60 , and iii) adjust the spring force applied by the return spring  60 . Advantageously, such adjustments enable the user to quickly and easily select an appropriate offset distance/feed rate over a wide range and thus allow the dispensing mechanism  33 ′ to be used effectively for a broad range of products with varying size and weight. 
   Note that in certain configurations, the natural length of the return spring  60  is insufficient to counteract the weight of the feed material against the spinner plate  37 ′ and frictional forces and thus cannot produce the required spring forces to close the opening between the spinner plate  37 ′ and the outlet  35 ′ of the hopper  31 ′ when the rotation of the shaft is stopped (i.e., the electric motor  39 ′ is powered OFF). In such configurations, the user can move the return spring  60  and/or the hose clamp  63  up the spring stop  62  and tighten the clamp  63  to thereby decrease the effective length of the return spring  60  and increase the spring force applied by the return spring  60  such that the “clamped” return spring  60  produces the spring forces required to close this opening. Such adjustments are particularly useful to provide a wide gap opening for large-sized granular material or seed and/or fast distribution rates. 
   In the preferred embodiment, the raising and lower of the second housing part  51 B relative to the first housing part  51 A is provided by a set of vertical slots  65  in the opposing sidewalls  66 A,  66 B of the lower housing part  51 B.  FIGS. 4 and 6  show, for example, two vertical slots  65  in the sidewall  66 A. Two additional vertical slots (not shown) are provided in the opposing sidewall  66 B of the lower housing part  51 B. The vertical orientation of the slots  65  ensure that they extend in a direction parallel to the rotating shaft  38 ′. External wing nuts  67  interface to bolts  68  that pass through the sidewalls  69 A,  69 B of the first housing part  51 A and through the vertical slots  65  in the corresponding sidewalls  66 A,  66 B of the second housing part  51 B. With the wing nuts  67  loosened, the vertical slots  65  allow the user to raise or lower the second housing part  51 B relative to the first housing part  51 A. With the two housing parts positioned as desired, the user tightens the wing nuts  67  to fix the position of the two housing parts  51 A,  51 B. This functionality can also readily be obtained by employing similar vertical slots in the first housing part  51 A with external wing nuts that interface to bolts that pass through the sidewalls  66 A,  66 B of the second housing part  51 B, or by employing aligned vertical slots in both housing parts  51 A,  51 B with external wing nuts that interface to bolts that pass through the aligned vertical slots. Other quick-operating fasteners can be used as a substitute for the wing nuts  67  and bolts  68  for fixing the relative distance between the first and second housing parts  51 A,  51 B. Such alternative quick-operating fasteners include lever-actuated devices, other turn-operated devices, slide-action devices, push-pull devices, lift-and-turn devices, and spring-loaded devices. 
   The first housing part  51 A also preferably includes two lateral slots  71 A,  71 B that are formed in the sidewalls  69 A,  69 B of the first housing part  51 A. The slots  71 A,  71 B allow for distribution of material therethrough as the material is thrown radially by the spinner plate  37 ′. The slots  71 A,  71 B can be covered by slidable members (e.g., slotted metal pieces) that are movable by the user along the lengthwise dimensions of the respective slots  71 A,  71 B to block user-selected portions of the slots  71 A,  71 B. Wing nut fasteners  73 A,  73 B (or other suitable quick-operating fasteners) may be used to fix the slidable covers at user-selected positions along the lengthwise dimensions of the respective slots  71 A,  71 B. In this manner, the user-selected positioning of the slidable members that cover the slots  71 A,  71 B enables the user to vary the distribution pattern of the material that is thrown radially by the spinner plate  37 ′. 
   It will be appreciated that ATVs typically include a rear hitch point that is used to removably couple a trailer thereto. The dispensing mechanisms described herein are preferably located above the horizontal plane of the rear hitch point such that it does not interfere with the use of the rear hitch point. 
   The ATV accessory of the present invention has many advantages. Because the hopper and dispensing apparatus are operably disposed under the extension rack  12  and completely out of the way of the user, they may be left in place. This feature enables the operator to avoid the time required to switch between accessories. It also provides the operator with an unobstructed view while operating the ATV together with unobstructed normal access and use of the extension rack. In addition, supporting the spreader accessory beneath the deck of the extension rack  12  lowers the center of gravity of the vehicle, thereby enhancing stability and making the vehicle a bit more resistant to rollover. 
   There have been described and illustrated herein embodiments of a multipurpose accessory for an all terrain vehicle. While particular embodiments of the invention have been described, it is not intended that the invention be limited thereto, as it is intended that the invention be as broad in scope as the art will allow and that the specification be read likewise. Thus, while particular hopper and dispensing mechanisms have been disclosed, it will be appreciated that other hopper and dispensing mechanisms can be used as well. For example, and not by way of limitation, the hopper and possibly the dispensing mechanism (or parts thereof) may be partitioned into multiple sections (e.g., with baffle(s)) in a manner that allows mixing of seeds and/or fertilizer of varying size and weight to be distributed simultaneously at the desired rate of dispersion. In another example, the hopper (and/or dispensing mechanism) can be designed to slide in and out of position below the extension rack utilizing, for example, a rail system. To load material into the hopper, the hopper would be slid out to allow the material to be poured into the hopper. After loading, the hopper is slid into position under the extension rack and secured for normal operation. Alternatively, one or more doors may be provided at (or near) the top of the side(s) of the hopper which are opened to load material into the hopper. In these configurations, the door through the floor of the extension rack may be omitted, and the hopper and dispensing mechanism can be readily adapted to be mounted under pre-existing extension racks by attachment to the extension rack, by attachment to the ATV frame or by other suitable means. Moreover, while particular configurations have been disclosed in reference to extension rack and mechanism for mounting the extension rack to the rear carrier rack of the all terrain vehicle, it will be appreciated that other configurations could be used as well. For example, the hopper and dispensing mechanism may be integrated with extension racks that have different sizes and shapes as those described herein. For example, a multi-level extension rack and/or an extension rack that extends down below the pre-existing rack cargo area may be used. In another example, the extension rack and the dispensing mechanism mounted therebelow may be integrated into a front carrier rack of the ATV. In yet another example, the hopper and spreader assembly of the present invention may be adapted to mount to commercially available ATV extension racks. It will therefore be appreciated by those skilled in the art that yet other modifications could be made to the provided invention without deviating from its spirit and scope as claimed.