Abstract:
The invention provides a collection system for containing grass clippings cut by a lawn mower. The collection system comprises a hopper and at least one door. The hopper comprises at least one wall defining a perimeter of the hopper. The wall has an upper portion and a lower portion. The hopper is disposed to receive the grass clippings and contain the grass clippings. The door is disposed near the lower portion of the wall to support at least some of the grass clippings. Additionally, the door is movable from a closed position to an open position by raising the entire door such that at least some of the grass clippings are emptied from the hopper. Because the door is raised when emptying the hopper, the operator of the mower may drive the mower away from the disposal site with the door open and avoid disturbing the pile of grass clippings.

Description:
FIELD OF THE INVENTION  
       [0001]     The invention pertains to a collection system for a riding lawn mower, and more particularly, to a collection system that permits the dumping of the contents of the collection system.  
       BACKGROUND OF THE INVENTION  
       [0002]     Collection systems for riding lawn mowers are generally known in the art. They are typically disposed near the rear of a riding lawn mower, and they are used to collect grass clippings after they have been cut by the riding mower. Oftentimes, the grass clippings are accumulated in one or more bags. The bags include an open top portion that receives the grass clippings. When the bag becomes full, a user must lift the bag to remove it from the collection system and carry the bag to the grass disposal site. To empty the contents of the bag, the user must then lift the bottom end of the bag to tip the top portion towards the ground. Although bags are suitable for some applications, bags become less suitable for other applications, such as collecting grass over large scale cutting areas. These bags are typically heavy when loaded with grass and can be difficult to carry and empty for certain individuals. Cutting larger areas requires more frequent emptying of the bags, which results in even greater effort by the operator. Furthermore, significant time is expended for the operator to walk to the rear of the mower, remove the bag, move the bag to the dumping location, dump the contents of the bag, reattach the bag, and finally, return to the seat of the mower. Even for individuals that are able to lift a loaded bag relatively easily, an individual will still tire out from the energy required to frequently empty the bags.  
         [0003]     In comparison, certain mowers utilize a collection system capable of dumping its contents. Dumping collection systems typically comprise a hopper that holds the grass clippings after they have been cut. These types of collection systems permit a user to position the riding mower such that the collection system is disposed above a desired dumping area. The user may then activate a mechanism to dump the clippings. Although there are certain advantages of a dumping system over a bag system, one problem with current dumping collection systems is that the hopper is maintained relatively high above the ground. The problem with having a collection system that is disposed relatively high above the ground is that it raises the center of gravity for the entire mower and, thus, creates a possibility of tipping the riding mower when cutting on a hill or other uneven surface. Similar to bag systems, these types of collection systems also typically require a user to leave the seat of the riding mower to actuate the dumping mechanism.  
         [0004]     Many dumping collection systems dump the contents of the hopper from the bottom of the collection system. The hopper must be maintained relatively high above the ground because after dumping takes place and a pile of grass clippings are on the ground, there must be sufficient clearance between the bottom of the collection system and the pile of grass on the ground. If there is not sufficient clearance, then the pile of grass will be knocked over as the riding mower is driven away from the dumping location.  
         [0005]     Certain other dumping collection systems are similarly disposed relatively high above the ground and have additional problems. For example, dumping is accomplished by a complicated mechanism that lifts and rotates the hopper to empty the contents of the hopper. These collection systems require a large number of interacting parts, which increases the potential for maintenance problems and the need for repairs.  
         [0006]     Therefore, there is a need for a collection system that addresses these problems in current collection systems.  
       BRIEF SUMMARY OF THE INVENTION  
       [0007]     The invention provides a collection system that permits a user to dump the contents of a hopper with little effort by the user and without leaving the seat of the riding mower, maintains a low center of gravity to resist tipping during both normal operation and dumping, permits an operator to dump the grass clippings and drive the mower away from the dumping site without disturbing the grass pile, and has a relatively small number of moving parts to minimize the need for repair and maintenance.  
         [0008]     The invention further provides a collection system for a riding mower that permits a user to dump grass clippings at a desired location without leaving the seat of the riding lawn mower. The collection system is mounted to the rear of the riding mower and is disposed such that the mower maintains a relatively low center of gravity. The collection system comprises a hood assembly, a hopper assembly, and a dumping assembly. The hood assembly is pivotably attached to the hopper assembly and has a receiving portion for receiving grass clippings. The hopper assembly contains the grass clippings until they are dumped. The hopper assembly comprises a wall defining a perimeter of the hopper assembly, a forward door, and a rear door. Both doors are disposed near the bottom of the wall and are movable to an open position to allow the grass clippings to be emptied from the collection system. The forward door is pivotably attached to the wall and disposed near the front of the collection system. The rear door is disposed near the rear of the collection system, and the entire rear door rises to an open position to permit grass clippings to fall out of the collection system. Considering the relatively close proximity of the collection system to the ground, having a rear door that rises from the closed position to the open position permits a user to drive the mower away from a pile of grass without disturbing the pile of grass. The dumping assembly comprises a handle and linkage assembly connected to the doors that permits the user to open the doors without leaving the seat of the riding mower.  
         [0009]     The invention further provides a collection system for containing grass clippings cut by a lawn mower. The collection system comprises a hopper having at least one wall defining a perimeter of the hopper. The at least one wall has an upper portion and a lower portion. The collection system also comprises a door disposed near the lower portion when in a closed position. The door is movable from the closed position to an open position such that the door is moveable to the open position by raising the entire door.  
         [0010]     The invention further provides a riding lawn mower for cutting grass. The riding lawn mower comprises a cutting deck, a hose, and a hopper. The hose has a first end and a second end. The first end is disposed to receive grass clippings from the cutting deck. The collection system is disposed to receive grass clippings from the second end of the hose. The collection system comprises a hopper, and the hopper comprises at least one wall defining a perimeter of the hopper. The at least one wall has an upper portion and a lower portion. The collection system further comprises a door disposed near the lower portion when in a closed position. The door is movable from the closed position to an open position such that the door is moveable to the open position by raising the entire door.  
         [0011]     The invention further provides a collection system for containing grass clippings cut by a lawn mower. The collection system comprises a hopper and a door. The hopper comprises at least one wall defining a perimeter of the hopper. The at least one wall has an upper portion and a lower portion. The door is disposed near the lower portion when in a closed position such that the entire door defines at least a portion of a bottom of the collection system, and the door is movable from the closed position to an open position.  
         [0012]     The invention further provides a collection system for containing grass clippings cut by a lawn mower. The collection system comprises a hopper, a forward door, and a rear door. The hopper comprises a forward wall and a rear wall. The forward door is disposed near a lower portion of the forward wall when in a forward door closed position. The forward door is movable from the forward door closed position to a forward door open position. The rear door is disposed near a lower portion of the rear wall when in a rear door closed position. The rear door is movable from the rear door closed position to a rear door open position.  
         [0013]     The invention further provides a method of emptying grass clippings from a collection system attached to a riding mower. The collection system comprises a handle and a door. The door is disposed near a lower portion of the collection system when in a closed position. In the closed position the door supports at least some of the grass clippings and in an open position, at least some of the grass clippings exit from the collection system. The method comprises maneuvering the riding mower to a disposal location, moving the handle from a first position to a second position such that as the handle is moved from the first position to the second position, the entire door is raised from the closed position to the open position, and driving the riding mower away from the disposal location with the door in the open position providing clearance above the grass clippings such that the grass clippings are not disturbed. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]      FIG. 1  is a perspective view of a riding lawn mower with a collection system attached thereto.  
         [0015]      FIG. 2  is a perspective view of a riding lawn mower chassis attached to a hitch.  
         [0016]      FIG. 3  is an exploded perspective view of the riding lawn mower chassis and hitch of  FIG. 2 .  
         [0017]      FIG. 4  is a perspective view from the front of the collection system of  FIG. 1 .  
         [0018]      FIG. 5  is an elevational front view of the collection system of  FIG. 1 .  
         [0019]      FIG. 6  is a bottom view of the collection system of  FIG. 1 .  
         [0020]      FIG. 7  is an elevational side view of the collection system of  FIG. 1 .  
         [0021]      FIG. 8  is a perspective view of a collection system door for the collection system of  FIG. 1 .  
         [0022]      FIG. 9  is a perspective view of another collection system door for the collection system of  FIG. 1 .  
         [0023]      FIG. 10  is a perspective view from the front of the collection system of  FIG. 1  in the open position.  
         [0024]      FIG. 11  is a perspective view from the rear of the collection system of  FIG. 1  in the open position.  
         [0025]      FIG. 12  is an elevational side view showing the collection system of  FIG. 1  with the collection system doors in both the open and closed position.  
         [0026]      FIG. 13  is an elevational side view of the collection system of  FIG. 1  attached to the mower of  FIG. 1  with the collection system doors in the dumping position and a pile of grass on the ground.  
         [0027]      FIG. 14  is an elevational side view of another embodiment of a handle assembly for the collection system of  FIG. 1 .  
         [0028]      FIG. 15  is a perspective view of a lock plate for the handle assembly of  FIG. 14 . 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0029]     Turning to the figures, there is shown in  FIG. 1 , a riding lawn mower  100  with a grass collection system  200  mounted thereto. The riding mower  100  has a cutting deck  110  that includes one or more cutting blades (not shown) that are used to trim blades of grass. The mower may also include wheels  104 , a motor  106  and a seat  108 . A blower assembly  120  is mounted on the cutting deck  110  such that as grass is discharged out of the cutting deck  110 , the grass passes into the blower assembly  120 . The blower assembly  120  has an internal impeller. The grass exits out of the rear of the blower assembly  120  into a hose  130 . The grass is forced up the hose  130  from the air flow that is created from the impeller and the deck  110 . As the grass exits the hose  130 , it is dispersed into the collection system  200 . The blower may be located at another position along the hose  130 . For example, the blower may be located near the collection system  200 .  
         [0030]     A hitch assembly  150  is used to mount the collection system  200  to the rear of the mower  100 . An example of a suitable hitch assembly  150  that may be utilized with the collection system  200  is shown in  FIGS. 2 and 3 , and is described in more detail in U.S. patent application Ser. No. ______, (LVM Matter No. 235459, Express Mail EV420403000US) filed Jun. 3, 2005, and entitled “MOUNTING HITCH,” inventor Nickolas T. Moore, which is incorporated by reference in its entirety herein. The hitch assembly  150  comprises hitch attachment portions  152  that are directly connected to the riding mower  100  (at the riding mower chassis  102 , for example) and a removably attachable portion  164  that attaches to the riding lawn mower  100  via the hitch attachment portions  152 . The hitch attachment portions  152  may be individual components that may be connected to the riding mower  100 , or they may be constructed as part of the riding mower  100 . The hitch attachment portions  152  comprise one or more hitch brackets  154 , one or more skid plates  156 , one or more support straps  158 , a rear guard  160 , and one or more support brackets  162 .  
         [0031]     The removably attachable portion  164  is designed to be relatively simple for a single individual to attach and detach. Thus, the operator can readily attach a collection system  200  when collecting grass and similarly, detach a collection system  200  when mulching or leaving grass clippings on the lawn. The removably attachable portion  164  may comprise a hitch weldment  168 , a latch  172 , and one or more adjustable linkages  174 . The hitch weldment may comprise a support plate  170  and one or more substantially L-shaped members  195 . Further, the hitch weldment  168  may be attached to a main support member  196  for an accessory. The main support member  196 , if provided, may be any suitable shape or size. Although only the above described hitch assembly embodiment is shown in the figures, any suitable structure may be utilized to attach the collection system  200  to a riding mower  100  such that the collection system  200  can receive grass that has been cut by the riding mower  100 .  
         [0032]     Referring to  FIGS. 4-7 , there is shown a collection system  200 . Among other features, the collection system  200  has a structure that permits an operator to unload the contents of a hopper  220  with little effort by the operator and without the operator needing to leaving the seat  140  of the riding mower  100 . The collection system  200  maintains a low center of gravity to prevent tipping during both normal operation and emptying. The collection system  200  permits an operator to dump the grass clippings and drive the mower  100  away from the dumping site without disturbing the grass pile. Furthermore, the collection system  200  may operate using a relatively small number of moving parts to minimize the need for repair and maintenance.  
         [0033]     The collection system comprises a hood assembly  210 , a hopper assembly  220 , and a dumping actuation assembly  240 . The hood assembly  210  is designed to direct grass and air entering into the collection system  200  rearward and downward, and is hinged to allow for internal cleanout and/or maintenance. The hopper assembly  220  is designed to retain the grass until it is ready to be dumped. The dumping actuation assembly  240  releases the grass from the hopper assembly  220 .  
         [0034]     The hood assembly  210  comprises a hood  212 , hood hinge  214 , a hose receiving portion  216 , and a ventilation portion  218 . The hood  212  provides a cover over the hopper assembly  220 . The hood hinge  214  pivotably attaches the hood  212  to the hopper assembly  220  and permits access to the hopper assembly  220  from above by pivoting the hood assembly  220  up and toward the rear of the riding mower  100 . In addition to being pivotably attached via the hood hinge  214 , the hood assembly  210  may also be secured to the hopper assembly  220  by any suitable structure such that an operator can engage the structure to prevent inadvertent opening of the hood  212  and disengage the structure to open the hood  212 .  
         [0035]     The hose receiving portion  216  is attached to the hose  130  and serves as an inlet for grass clippings into the hopper assembly  220 . Along with grass clippings, a relatively large amount of air from the blower assembly  120  also enters the collection system  200 . The hood assembly  210  has a ventilation portion  218  having a structure that allows air, but not grass clippings, to easily escape from underneath the hood  212 . The ventilation portion  218  is disposed near the rear of the hood  212  and is generally arcuately shaped. The lower portion of the ventilation portion  218  extends beyond a rear wall  222  of the hopper assembly  220 . As air and grass enter through the hose receiving portion  216 , the weight of the grass causes it to fall into the hopper assembly  220  while the air is directed downward by the arcuately shaped ventilation portion  218 . The air exits through the space between the ventilation portion  218  and the rear wall of the hopper assembly  220 . The hood may be any suitable shape and/or size, and may include any suitable feature to permit the ventilation of air from inside the collection system  200  to outside the collection system  200 .  
         [0036]     The hopper assembly  220  comprises one or more walls, such as a front wall  221 , rear wall  222 , and side walls  223 ,  224 , a forward door  226 , and a rear door  230 . The walls  221 ,  222 ,  223 ,  224  form the perimeter of the hopper assembly  220  and support the sides of a pile of grass in the hopper assembly  220 . The hopper assembly  220  may be any suitable shape or size such that the hopper assembly  220  can retain grass clippings. Additionally, the hopper assembly  220  may have a support plate  225  attached to the front wall  221  that may be used, for example, to connect to the hitch assembly  150 .  
         [0037]     As shown in  FIG. 8 , the forward door  226  has a structure that is suitable for pivoting with respect to the hopper  220  and for receiving one or more forward door lift arms  270  for exerting a force on the forward door  226  to open the door  226 . The forward door  226  may comprise, for example, one or more lift tabs  227  and one or more hinges  228 . The hinges  228  may be mounted near the top and front of the forward door  226  such that the forward door  226  is pivotably connected to the front and lower portion of the hopper assembly front wall  221 .  
         [0038]     Referring to  FIG. 9 , the rear door  230  may comprise a structure and/or be connected to components that permit the rear door  230  to be moved between a closed position and an open position. The rear door  230  may comprise one or more lift tabs  232  and one or more roller bearings  234 . A track  236  is disposed at each side of the hopper assembly  220 . The tracks  236  enable the rear door  230  to be raised to the open position and release grass from the hopper assembly  220 . The roller bearings  234  are disposed within these tracks  236  such that the rear door  230  is movable within the tracks  236  and raisable from a closed position to an open position.  
         [0039]     Turning back to  FIGS. 4-7 , the dumping actuation assembly  240  comprises a structure suitable for maneuvering the forward door  226  and the rear door  230  between an open and closed position when a user operates the dumping actuation assembly  240  (see  FIGS. 10 and 11  for examples of the collection system with the doors  226 ,  230  and hood  212  in the open position). The dumping actuation assembly  240  may comprise a handle assembly  242 , a latch assembly  250 , and a linkage assembly  260 . The handle assembly  242  is connected to and activates both the linkage assembly  260  and the latch assembly  250 . The latch assembly  250  prevents the forward door  226  and rear door  230  from separating when bearing the weight of the grass clippings and also prevents the handle  244  from moving and unintentionally opening the doors  226 ,  230 . The linkage assembly  260  opens and closes the forward door  226  and the rear door  230  when an operator moves the handle  244 .  
         [0040]     As mentioned above, the operation of the collection system  200  is such that an operator can open and close the doors  226 ,  230  without leaving the seat of the mower  100 . The handle assembly  242  is pivotably attached to the front wall  221  of the hopper  220  and comprises a handle  244 . A grip  246  may be attached to the handle assembly  242 . The grip  246  is also connected to a cable  248  attached to a latch strap  252 . The latch strap  252  is part of the latch assembly  250  and is connected to one or more latch pins  254 . The latch pins  254  are L-shaped members that are disposed near the intersection of the forward door  226  and the rear door  230 , and prevent the forward door  226  and rear door  230  from separating under the weight of the grass in the hopper  220  and leaking grass. When the latch strap  252  is laterally moved by the cable  248 , the latch pins  254  rotate. After being rotated a certain distance, the latch pins  254  no longer engage the doors  226 ,  230  and thus, permit the separation of the forward door  226  from the rear door  230 . A tension spring  256  may be attached to the latch strap  252  to help retain the latch pins  254  in the locked position. It should be noted, however, that any suitable latch assembly  250  may be utilized such that the doors are restrained from unintended separation and/or the handle is prevented from unintentionally moving and opening the doors  226 ,  230 .  
         [0041]     Referring to  FIG. 12 , the linkage assembly  260  comprises a plurality of links  262 ,  264 ,  266 ,  268 ,  270 ,  272  and a shaft  274  that allow an operator to open and close the forward door  226  and rear door  230  by moving the handle  244 .  FIG. 12  shows a comparison of these components of the collection system  200  in both the open and the closed positions. Referring to  FIG. 4 , when the grip  246  is squeezed toward the handle  244 , the cable  248  pulls on the latch strap  252  to disengage the latch pins  254 , and the operator can pull down on the handle  244 . Referring to  FIGS. 7 and 12 , moving the handle  244  causes the handle link  262 , which is fixed to the handle assembly  242 , to rotate a cross shaft  274 . At each end of the cross shaft  274 , there is a link arm  264 . The link arms  264  are attached to adjustable links  266 , which are connected to link  268 . The link  268  is attached to a forward door lift arm  270  and a rear door lift arm  272 . The rear door lift arms  272  are fixed to the links  268 , and the links  268  and rear door lift arms  272  are pivotal around a bushings  276  that are secured to the side walls  223 ,  224  of the hopper  220 . The forward door lift arms  270  are attached to the forward door  226  via lift tabs  227 , and the rear door lift arms  272  are attached to the rear door  230  via lift tabs  232 .  
         [0042]     Referring to  FIG. 12 , as the handle  244  is rotated, the handle links  262  rotate the cross shaft  274 . This, in turn, rotates the link arms  264 , which pulls the adjustable links  266  forward. The link  268  then rotates around the bushing  276  to rotate the rear door lift arm  272  around the bushing  276  and move the forward door lift arm  270  downward and forward. The rear door  230  is swung open moving upward and to the rear. As the handle  244  is moved further, the roller bearings  234  begin to roll in the tracks  236  and the rear door  230  lifts up and to the rear. As the rear door  230  begins to open, the forward door lift arms  270  begin to push down and forward on the forward door  226 . In response, the forward door  226  pivots around the forward door hinge  228  and opens downward and forward.  
         [0043]     The arrangement of the dumping actuator assembly  240  and the weight of the forward door  226  help to retain the doors  226 ,  230  in the open position. Since the grass clippings are maintained in the hopper  220  by the forward door  226  and rear door  230  when they are in the closed position, when the doors  226 ,  230  are opened, the grass clippings are no longer restrained and fall to the ground by gravity as shown in  FIG. 13 . The operator can then pull the riding mower away from the pile of grass  278  without dragging the pile of grass  278  with the rear door  230 . To close the doors  226 ,  230 , the operator lifts the handle  244  and squeezes the grip  246 . This moves the links  262 ,  264 ,  266 ,  268 ,  270 ,  272 , shaft  274 , and doors  226 ,  230  in a direction opposite the direction described above until the doors  226 ,  230  are once again adjacent to one another. The operator then releases the grip  246 , and the latch pins rotate to secure the doors  226 ,  230  in the closed position.  
         [0044]     The distance  300  from the bottom of the rear door to the ground may be in the range of 6 inches to 24 inches. In one embodiment, the distance  300  is approximately 14 inches. The collection system has a center of gravity  302  when the collection system is full of grass. The distance  304  of the center of gravity to the ground may be in the range of 12 inches to 48 inches. In one embodiment, the distance  304  is approximately 22 inches.  
         [0045]     In another embodiment shown in  FIGS. 14-15 , the grip  246  may be connected to a cable  280  that is attached to a lock pin  282 . The lock pin  282  has a tension spring  284  that forces the pin  282  into an aperture  286  in a lock plate  288 . The lock plate  288  is mounted to the support plate  225  or other suitable structure. When the pin  282  is disposed within the aperture  286 , the handle assembly  242  cannot be moved. The grip  246  and cable  280  operate to disengage the lock pin  282  from the aperture  286  so that the handle  244  may be moved. When the doors  226 ,  230  are in the fully open position, the operator can release the grip  246 , which will cause the tension spring  284  to force the lock pin  282  down into another aperture  290  in the lock plate  288  to lock the doors  226 ,  230  in the open position. To close the doors  226 ,  230 , the operator may squeeze the grip  246  on the handle assembly  242 . The lock pin  282  will disengage from the lock plate  288  and allow the doors  226 ,  230  to be returned to the closed/locked position.  
         [0046]     Although the collection system has been described for use with a riding mower, it may be used with any suitable mower.  
         [0047]     All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.  
         [0048]     The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.  
         [0049]     Preferred embodiments of this invention are described herein, including the best mode known to the inventor(s) for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventor(s) expect skilled artisans to employ such variations as appropriate, and the inventor(s) intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.