Abstract:
A mower deck having movable chamber gate members that permit the deck to selectively operate in either a discharge or mulching mode of operation. The deck includes a control structure that operates the gate members to permit the operator to quickly and easily switch between the discharge mode and the mulching mode while mowing.

Description:
FIELD OF THE INVENTION 
     This invention relates to mower cutting decks, and more specifically, to converting those decks between discharge and mulching modes of operation. 
     BACKGROUND OF THE INVENTION 
     Mower cutting decks are available in at least two types. The first of these decks is ordinarily provided as a side or rear discharge deck. In other words, after grass and other vegetation has been cut, it is circulated within the deck and conveyed toward a discharge outlet to be thrown onto the adjacent ground surface. A second type of mower deck is the mulching deck. With this mulching type, the deck does not have a discharge outlet. The grass is cut and recut within a closed cutting chamber, ultimately being distributed by the blade onto the ground surface beneath the deck. This process offers a first advantage of providing finely cut grass and other vegetation as mulch which acts as a natural fertilizer. A second advantage exists since an operator need not spend additional time in raking or otherwise collecting clippings which have been cut since the mulch is dispersed over the ground surface. 
     Kits are available to convert a discharge deck into a mulching deck. These kits often require the operator to first stop mowing and to reposition the deck in order to install them. Such installation can be inconvenient and time consuming, thereby reducing the operator&#39;s efficiency since the amount of vegetation that can be mowed in a given time period is decreased. 
     The use of these kits also raises concerns when it is required that they be removed. Their removal ordinarily arises when the grass conditions are either too wet, too tall and/or too thick so as to not permit proper mulching of the grass and other vegetation. First, the kits are time consuming to remove. Second, in instances in which mulching is attempted in one or more of the above conditions, clogging often occurs within the cutting chamber which causes diminished cut quality. Third, when these kits are removed, their storage and the ability to again locate their different components become added responsibilities to be addressed by the operator. 
     Thus, it would be beneficial to provide a mower cutting deck capable of being selectively operable between discharge and mulching modes without having to separately attach or detach additional components to the deck each time that conversion between these modes is desired or necessary. It would be also desirable to be able to allow the operator to selectively make the conversion while remaining seated on the mower. Providing such a deck enables an operator to avoid the inconvenience of having to stop mowing to either remove or install a mulch kit so as to allow mowing of vegetation in either the discharge or mulching mode, respectively. 
     SUMMARY OF THE INVENTION 
     Accordingly, there is provided a mower cutting deck which can be selectively converted and operated between discharge and mulching modes. This conversion can be accomplished “on the fly”, i.e., while the operator remains seated on the mower and continues to mow. The appropriate mode of operation is often determined by factors including the moisture content, length and/or thickness of the vegetation being mowed. 
     To permit the discharge or mulching of vegetation while continuing to mow, the deck is equipped with adjustable gates. The gates can be selectively moved to an open or first position in which vegetation is permitted to move between the chambers and through the discharge opening. From this first position, the gates may be moved or shifted to a closed or second position in which vegetation is restricted from moving between the chambers and out of the discharge opening. Opening of the gates permits the deck to operate in its discharge mode so that the vegetation may be simply thrown on the ground. Closing of the gates causes the cut vegetation to be reflected off of them and a wall member formed by adjacent baffle portions and portions of the deck skirt. After moving off of the gates and the wall member, the vegetation is recut before it is forced downwardly toward the ground and deposited as mulch. 
     The gates are selectively moveable to each of the above positions through use of a handle attached to the top surface of the deck. Either the discharge or mulching mode can be selected during mowing simply through movement of the handle. Use of the handle permits an operator to avoid the need to stop mowing to have to install or remove equipment such as a mulch kit since the handle is reachable from the operator&#39;s seat. Additionally, while the preferred embodiment contemplates the use of a manually operated handle to control movement of the gates, it is to be further understood that the gates could be controlled by motorized means or devices which may, for instance, be either hydraulically or electrically driven. 
     The above and additional features and advantages of the present invention will become apparent from a reading of the following detailed description of the invention when taken in conjunction with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a side and elevated perspective view of the mower of the present invention. 
     FIG. 2 is a front and side elevated perspective view of the mower cutting deck, as seen in FIG. 1, in which there is shown a mode selection handle that is positioned to place the deck in its discharge mode. 
     FIG. 3 is a view of the underside of the cutting deck showing a series of gates that are moved by the handle of FIGS. 1 and 2 to their open position. 
     FIG. 4 is a front and side elevated perspective view of the deck wherein the handle is positioned to place the deck in its mulching mode. 
     FIG. 5 is a view of the underside of the cutting deck showing the gates moved to their closed position, as controlled by the handle. 
     FIG. 6 is an enlarged view, taken along lines  6 — 6  of FIG. 2, of the handle and an associated pin that is positioned within the bracket so as to dispose the gates in their open position. 
     FIG. 7 is an enlarged view, taken along lines  7 — 7  of FIG. 4, of the handle and its pin whereby the pin is positioned within the bracket so as to dispose the gates in their closed position. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Looking first to FIG. 1, there is shown a mower  10  having a frame  11  supported upon ground engaging wheels  12 . The mower  10  is powered by an engine  14  located behind an operator&#39;s seat  16 . A cutting deck (discussed below) is attached to the front of the mower  10  for mowing vegetation in either a discharge or mulching mode. 
     Looking now to FIG. 2, there is shown a multi-chamber cutting deck  18  that is seen attached to the mower  10  of FIG.  1 . The deck  18  includes a top member  20  having a top surface  22  and a bottom surface  24  (shown in FIG.  3 ). The deck  18  further includes a skirt  26  extending downwardly from the top member  20 . The skirt  26  provides an exterior or side surface of the deck  18  from which a plurality of wheels, including anti-scalp wheels  28 , 30 , extend to prevent the deck  18  from becoming too close to the ground when traveling over uneven portions thereof. 
     Also shown on the top surface  22  is a control structure  32  mounted therewith for selectively operating or shifting a plurality of attached gates (discussed below) between open or closed positions. Still looking to FIG. 2, it can be seen that the control structure  32  includes a left and a right set of cranks  34 , 36 . The cranks  34 , 36  include driven members  38 , 40  and respective follower members  42 , 44 . Each of these members is seated on pivot shafts  46 . The cranks  34 , 36  are interconnected by a rod or linkage  48 . The right crank  36  is also connected by a rod  50  to a handle  52  that is used to move the sets of cranks  34 , 36  and their associated gates which are shown in FIGS. 3 and 5. 
     As seen in FIG. 1, the handle  52  is reachable from the operator&#39;s seat  16 . The ability to reach and move the handle  52  from the operator&#39;s seat permits easy shifting between the discharge and mulching modes while mowing. 
     Now looking to FIGS. 6 and 7, the handle  52  is mounted to the deck  18  through a pair of brackets  53 , 54  and by a pivot pin  55 . The handle  52  includes a bracket  58  that is mounted or welded on its outer surface. An end  59  of rod  50  extends through the bracket  58  and into a slot  56  in the bracket  54  for moving within the slot  56 . The rod  50 , moving within the slot  56 , limits travel of the handle  52  in one direction. The handle  52  further includes a pin  60  which extends therefrom and into the slot  56 . The pin  60  may be seated within notches or detents  62 , 64  provided in the bracket  54  for selectively locking the handle  52 , and thus the control structure  32 , into position. The pin  60  may be moved up and down within a vertical slot  65  formed in the outer surface of the handle  52  and its attached bracket  58 , as seen in FIG. 6. A push button  66  at the top end of the handle  52 , and as shown most clearly in FIGS. 2 and 4, controls movement of the pin  60 . Depression of the button  66  releases the pin  60  from engagement with one of the notches  62  or  64 . Afterward, the handle  52  may be moved to shift the gates between their open and closed positions. 
     Looking next to the underside of the deck  18  as shown in FIG. 3, closure members or gates  70 ,  72  and  74  are shown. Also shown are a collection of front baffles  76 ,  78 ,  80  and a rear baffle  82  that are attached to the bottom surface  24  of the deck  18 . The baffles extend from the skirt  26 , and together with the skirt  26 , form a substantially continuous wall or wall member that substantially defines three adjacent cutting chambers  84 ,  86  and  88 . It is to be noted that the manner in which the wall is formed constitutes no part of the present invention. 
     As further shown in FIG. 3, one of three cutting blades  90 ,  92  and  94  is housed within a single chamber. Each of these blades is powered by the engine  14  and is supported on a respective spindle  96 ,  98  or  100 , as shown for example in FIG. 2, for rotation therewith. Referring again to FIG. 3, as the blades rotate, vegetation is cut and swept along a flow pathway “A” which extends between the cutting chambers and which continues through a discharge opening  67  formed along the skirt portion of the wall member. The vegetation moves between the chambers  84 ,  86  and  88  and out of the discharge opening  67  since the gates  70 ,  72  are substantially aligned with the front baffles  76 ,  78  and  80  and gate  74  is substantially aligned with the top surface  22  of the deck  18 . This alignment corresponds with the open position of the gates. 
     As also shown in FIG. 3, the gates  70  and  72  are formed by pairs of plates  102 , 104 . The plates  102 , 104  are mounted with the pivot shafts  46  so as to swing or shift when the driven and follower members  38 ,  40 ,  42  and  44  are moved in response to movement of the handle  52 . Each of the pairs of plates  102 , 104  are swingable to their open position or toward the front  106  of the deck  18  to permit vegetation to flow toward the discharge opening  67 . They may also be swung to a closed position or away from the front  106 . When in this position, the plates  102 , 104  block the pathway “A”. As mentioned below, the gates  70  and  72 , as formed by the plates  102  and  104 , angularly extend or project from portions of the wall member and the gate  74  blocks the discharge opening  67  in their closed position. This restricts vegetation flow to permit a deck configuration compatible for mulching as shown and discussed with reference to FIGS. 4-5 below. 
     In the preferred embodiment, the baffle portions and gates, when in the their closed position, provide a circumferential lower periphery which falls below the cutting plane established by each of the blades. When the gates are in this closed position, they and the wall member substantially enclose the blades and thereby provide the necessary recirculation for mulching capability. While the preferred embodiment utilizes gates that leave a small opening  108  in the chamber periphery as seen in FIG. 5, this opening does not significantly affect the mulching capability of the particular chamber. It is to be understood that gates with other effective configurations that achieve this objective could be utilized. 
     With reference to FIGS. 4-5, the deck  18  is shown in its mulching mode. The handle  52 , as shown in FIGS. 4 and 7, is moved forwardly and rests adjacent a front portion  110  of the bracket  54 . When the handle  52  is in this position, the pin  60  is positioned to be seated within the forward notch  64  as shown in FIG.  7 . As this forward movement of the handle  52  occurs, the cranks  34 , 36  move in the opposite or rearward direction. 
     Each of the baffles  82  includes an extension  112 . When the gates  70 ,  72  and  74  are drawn to their closed position, they angularly extend or project from the front baffles  76 ,  78  and  80  and align with the extensions  112  of the rear baffle  82 . Further, gate  74  blocks the discharge opening  67 . After such projection and blocking occurs, the pathway “A” is substantially closed so as permit operation of the deck in its discharge mode. 
     As further shown in FIG. 5, the discharge gate  74  is preferably provided as a single swingable plate that is hingedly connected with the deck  18 . A rod  114  is connected at one of its ends to the gate  72  and at its other end to the discharge gate  74 . Because of this connection, the discharge gate  74  may be moved downwardly to block the discharge opening  67  when the gates  70 , 72  are moved to their closed position. With the gates  70 , 72  and  74  in their closed position, movement of vegetation clippings through the pathway “A” is restricted. This restriction forces cut vegetation to be deflected off of the gates  70 , 72  and  74  and baffle portions  76 ,  78 ,  80 , and  82  into the path of the blades. After being deflected, the vegetation is cut again and then forced downwardly toward the ground surface. 
     As also shown in FIG. 5, each of the extensions  112  are slightly smaller in height than the plates  104  and the full length of their extensions  116 , as shown at  118 . Such a difference in height prevents contact between each of the blades and the extensions  112  and  116  as the blades rotate, all without substantially affecting the mulching capability of a particular cutting chamber. 
     Additionally, when the gates  70  and  72  move from their mulching to discharge position, their plates  102  move toward the front  106  of the deck  18  first. Plates  104  follow and overlap or lay on top of the plates  102  as shown in FIG.  3 . When this overlay occurs, a substantially continuous surface is provided along the length of gates  70  and  72  along which vegetation may flow without contacting any edge or opposing surface thereof. If plates  104  folded toward the front  106  of the deck  18  first, plates  102  would provide an edge that would create a small crevice in which vegetation could collect and disrupt proper functioning of the gates  70 , 72 . Also, such an overlay would provide an edge  119  along the end of plate  102 , as shown in FIG. 3, that would oppose the flow of vegetation toward the discharge opening  67  and thereby interrupt its proper circulation within the cutting chamber(s). Also, with retraction of the gates  70 , 72  toward the front  106  of the deck  18  in the order described, extensions  116  are able to deflect vegetation into the pathway “A”. This deflection prevents the vegetation from moving behind the gates  70 , 72 . Further, if the plates  104  folded first so as to cause plates  102  to overlap them, the extensions  116  of the plates  104  would cause a large gap in which vegetation would collect rather than be circulated within the chamber(s). Thus, it may be understood that each of these benefits as described in connection with the overlay of gates  70  and  72  assists in permitting proper circulation of vegetation in the cutting chamber(s). Also, proper functioning of the gates  70 , 72  and proper discharge of the vegetation is also permitted. 
     As shown in each of FIGS. 3 and 5, an angled bracket  120  is secured to the underside of the deck  18  and acts as a stop that prevents unintended movement of the gates  70 , 72  into the pathway of the blades  90 ,  92  and  94  as they rotate. 
     Thus, there is provided a cutting deck which is convertible between a discharge mode of operation and a mulching mode of operation. In providing such a deck, an operator can avoid having to install or remove separate mulching equipment on a stock discharge deck. Accordingly, the operator does not have to spend additional time and/or money when desiring the capability to mow in either of these modes as conditions may require. 
     Having described the preferred embodiment, it will become apparent that various modifications can be made without departing from the scope of the invention as defined in the accompanying claims.