Variable mulching system for a lawnmower

• US 20030217542A1
• Filed: 05/23/2002
• Published: 11/27/2003
• Est. Priority Date: 05/23/2002
• Status: Active Grant

• Current Assignee: Honda Giken Kogyo Kabushiki Kaisha (Honda Motor Company)
• Original Assignee: Honda Giken Kogyo Kabushiki Kaisha (Honda Motor Company)
• Inventors: Osborne, Christopher M.
• Granted Patent: US 6,735,932 B2
• Time in Patent Office: Days
• US Class Current: 56/320.1
• CPC Class Codes: A01D 2101/00 Lawn-mowers
• CPC Class Codes: A01D 42/005 Mulching shredders or like cutting implements for comminuting plant waste per se A01G3/002

Abstract

A lawnmower includes a cutter housing and an engine mount on the cutter housing. A prime mover is supported on the engine mount and a blade is coupled to the prime mover to rotate within the cutter housing. A plate translates within the cutter housing between a first position and a second position. Preferably, the cutter housing includes a discharge opening and the blade is a mulching blade. The first position is a full bagging position where the discharge opening is substantially unobstructed by the plate and the second position is a full mulching position where the plate substantially obstructs the discharge opening.

Claims

1. A lawnmower comprising:

a cutter housing;

an engine mount on the cutter housing;

a prime mover supported on the engine mount;

a blade coupled to the prime mover to rotate within the cutter housing; and

a plate that translates within the cutter housing between a first position and a second position.

2. The lawnmower according to claim 1, wherein the cutter housing includes a discharge opening;

the blade comprises a mulching blade;

the first position comprises a full bagging position where the discharge opening is substantially unobstructed by the plate; and

the second position comprises a full mulching position where the plate substantially obstructs the discharge opening.

3. The lawnmower according to claim 1, further comprising at least one position intermediate the first position and the second position.

4. The lawnmower according to claim 1, wherein the blade rotates in a blade circle lying in a cutting plane and the plate includes:

a horizontal wall extending parallel to the blade circle; and

a cover extending from the horizontal wall and away from the blade circle.

5. The lawnmower according to claim 4, wherein the cover extends obliquely from the horizontal wall.

6. The lawnmower according to claim 1, further comprising a ramp secured in the cutter housing proximate the plate.

7. The lawnmower according to claim 1, wherein the cutter housing is annular and the plate extends across a sector of the cutter housing.

8. The lawnmower according to claim 7, wherein the plate extends radially from the inner radius of the annular cutter housing to the outer radius of the annular cutter housing when the plate is in each of the first position, the second position and the at least one intermediate position.

9. The lawnmower according to claim 7, wherein the cutter housing includes:

an inner scroll centered about the engine mount; and

an outer scroll centered about the inner scroll, the discharge opening is in the outer scroll; and

the plate spans from the inner scroll to the outer scroll in each of the first position, the second position and the at least one intermediate position.

10. The lawnmower according to claim 9, further comprising an outer plate support connected to the outer scroll;

wherein the plate is slidably received on the outer plate support.

11. The lawnmower according to claim 10, wherein the plate includes a flange slidably received on the outer plate support.

12. The lawnmower according to claim 10, wherein the outer plate support extends across the discharge opening.

13. The lawnmower according to claim 10, wherein the outer plate support has a curvature equal to the curvature of the outer scroll.

14. The lawnmower according to claim 10, further comprising an inner plate support adjacent the inner scroll;

wherein the plate is slidably received on the inner plate support.

15. A lawnmower convertible between a bagging mode and a mulching mode, the convertible lawnmower comprising:

a cutter housing having a discharge opening;

an engine mount centrally positioned on the cutter housing;

a prime mover supported on the engine mount;

a mulching blade coupled to the prime mover to rotate in a blade circle within the cutter housing;

a cover that translates across the discharge opening between a full bagging position where cover is laterally spaced from the discharge opening and a full mulching position where the cover spans the discharge opening; and

a fin connected to and extending from the cover toward the mulching blade.

16. The convertible lawnmower according to claim 15, further comprising at least one position intermediate the full bagging position and the full mulching position where the cover partially obstructs the discharge opening.

17. The convertible lawnmower according to claim 15, wherein the cover translates between each of the full bagging positions, the at least one intermediate position and the full mulching position along a linear path.

18. The convertible lawnmower according to claim 15, wherein

the cutter housing further includes:

a horizontal slot spaced from the discharge opening;

a vertical slot adjacent the discharge opening; and

a cover support aligned with the vertical slot and extending across the discharge opening; and

wherein the convertible lawnmower further comprises;

a horizontal wall laterally extending from the cover and slidably engaging the horizontal slot; and

a flange extending downwardly from the plate and slidably engaging the vertical slot and the cover support.

19. The convertible lawnmower according to claim 18, wherein the fin includes a first end connected to the cover and a second end positioned beyond the extent of the cover.

20. The convertible lawnmower according to claim 19, wherein the cutter housing further includes:

an inner scroll centered about the engine mount;

an outer scroll centered about the inner scroll, the discharge opening is formed in the outer scroll;

wherein the second end of the fin engages the inner scroll when the fin is in the full bagging position, the second end of the fin is intermediate the inner scroll and the outer scroll when the fin is in the at least on intermediate position and the second end of the fin engages the outer scroll when the fin is in the full mulching position.

21. The convertible lawnmower according to claim 20, wherein the cutter housing further comprises a shelf extending from the inner scroll, the second of the fin slidingly engages the shelf when the fin is in the full bagging position.

22. The convertible lawnmower according to claim 20, wherein the first end of the fin lies adjacent the outer scroll at a first location when the fin is in the full bagging position, the first end of the fin lies adjacent the outer scroll at a second location spaced from the first location when the fin is in the full mulching position and the first end of the fin lies adjacent the outer scroll at a location intermediate the first location and the second location when the fin is in the at least one intermediate position.

23. The convertible lawnmower according to claim 19, wherein the fin further comprises a guide extending from the first end of the fin and toward the horizontal wall and spaced above the plate to define a slot therebetween, wherein the guide engages the support when the fin translates from the full bagging position and the full mulching position.

24. The convertible lawnmower according to claim 23, wherein the guide further comprises an arcuate face engaging the outer scroll in each of the full bagging position, the at least one intermediate position and the full mulching position

25. The convertible lawnmower according to claim 24, wherein the horizontal wall includes a flange slidably engaged with the vertical slot.

26. The convertible lawnmower according to claim 25, wherein the flange extends tangentially from the arcuate face of the guide.

27. The convertible lawnmower according to claim 18, wherein the cover extends away from the blade circle.

28. The convertible lawnmower according to claim 27, wherein the fin extends from the cover toward the blade circle and beyond the level of the horizontal wall.

29. The convertible lawnmower according to claim 28, wherein the cover is concave, the fin is arcuate and the horizontal wall is flat.

30. The convertible lawnmower according to claim 18, further comprising a belt drive housing extending into the cutter housing adjacent the discharge opening;

the horizontal slot opening into the belt drive housing.

31. The convertible lawnmower according to claim 30, wherein the cutter housing further includes a recess intermediate the discharge opening and the belt drive housing, the recess receives the cover when the cover is in the fall bagging position.

32. A lawnmower convertible between a bagging mode and a mulching mode, the convertible lawnmower comprising:

a cutter housing having a discharge opening;

an engine mount centrally positioned on the cutter housing;

a prime mover supported on the engine mount;

a mulching blade coupled to the prime mover to rotate in a blade circle within the cutter housing; and

a cover that translates along an arcuate path in the cutting chamber between a full bagging position where the cover is laterally spaced from the discharge opening and a full mulching position where the cover obstructs the discharge opening.

33. The convertible lawnmower according to claim 32, further comprising at least one position intermediate the full bagging position and the full mulching position where the cover partially obstructs the discharge opening.

34. The convertible lawnmower according to claim 32, further comprising a horizontal wall connected to the cover at an oblique angle.

35. The convertible lawnmower according to claim 32, wherein the cutter housing is annular and includes:

inner scroll centered about the engine mount and includes an inner slot; and

an outer scroll centered about the inner scroll and the discharge opening is in the outer scroll;

wherein the horizontal plate and the cover each span from the inner scroll to the outer scroll in each of the full bagging position, the at least one intermediate position and the full mulching position.

36. The convertible lawnmower according to claim 35, wherein the arcuate path is parallel to each of the inner scroll and the outer scroll.

37. The convertible lawnmower according to claim 35, wherein the inner scroll includes an inner slot and the outer scroll includes an outer slot;

wherein the horizontal wall is slidably received in each of the inner slot and the outer slot.

38. The convertible lawnmower according to claim 37, further comprising an outer plate support connected to the outer scroll, the outer plate support extends from the outer slot across the discharge opening.

39. The convertible lawnmower according to claim 37, wherein the inner scroll includes a radially inner surface;

the outer scroll includes a radially inner surface and a radially outer surface; and

the convertible lawnmower further comprises;

an inner flange extending down from the horizontal wall toward the blade circle; and

an outer flange extending down from the horizontal wall toward the blade circle;

an inner track including;

a first guide connected to the engine mount adjacent the inner surface of the inner scroll, the first guide extends parallel to the horizontal wall; and

a second guide connected to and extending along the inner surface of the inner scroll, the second guide is spaced from the first guide by the inner slot;

an outer track including;

a third guide connected adjacent the outer surface of the outer scroll, the third guide extends parallel to the horizontal wall; and

a fourth guide connected to and extending along the outer surface of the outer scroll, the fourth guide is spaced from the third guide by the outer slot;

the inner flange is radially inward of the second guide and the outer flange is radially outward of the fourth guide;

the inner flange is guided by the second guide and the outer flange is guided by the fourth guide as the cover translates between the full bagging position and the full mulching position.

40. The convertible lawnmower according to claim 39, wherein the fourth guide is aligned with the outer support.

41. The convertible lawnmower according to claim 40, wherein the fourth guide is integral with the outer support.

42. The convertible lawnmower according to claim 35, further comprising:

an inner flange extending down from the horizontal wall toward the blade circle;

an outer flange extending down from the horizontal wall toward the blade circle; and

an outer plate support extending across the discharge opening;

wherein the inner flange is radially inward of the inner scroll and the outer flange is radially outward of the outer scroll;

wherein the inner flange slides along the inner scroll and the outer flange slides along the outer scroll and the outer plate support.

43. The convertible lawnmower according to claim 35, further comprising a first deflector inclined from the horizontal wall toward the outer scroll.

44. The convertible lawnmower according to claim 43, wherein the cover includes a second deflector aligned with the first deflector.

45. A lawnmower convertible between a bagging mode and a mulching mode, the convertible lawnmower comprising:

a cutter housing having a discharge opening;

an engine mount centrally positioned on the cutter housing;

a prime mover supported on the engine mount;

a mulching blade coupled to the prime mover to rotate in a blade circle within the cutter housing;

a cover that slides within the cutter housing between a full bagging position where the discharge opening is substantially unobstructed by the cover, a full mulching position where the cover substantially obstructs the discharge opening and at least one position intermediate the full bagging position and the fall mulching position; and

a handle connected to the cover and extending external to the cutter housing, the handle is displaceable between a first position, a second position and at least one position intermediate the first position and the second position such that displacement of the handle between each of the first position, the second position and the at least one intermediate position of the handle translates the cover between each of the full bagging position, the full mulching position and the at least one intermediate position of the cover, respectively.

46. The convertible lawnmower according to claim 45, further comprises:

a gear assembly connecting the handle to the cover, the gear assembly includes;

a first gear connected to the handle; and

a second gear connected to the cover.

47. The convertible lawnmower according to claim 46, wherein the first gear is a pinion gear and the second gear is a rack wherein the pinion engages the rack such that rotary movement of the handle results in linear translation of the cover between each of the full bagging position, the at least one intermediate position and the full mulching position.

48. The convertible lawnmower according to claim 47, wherein the positions of the cover and the fin are infinitely variable between each of the full bagging position, the at least on intermediate position and the full mulching position.

49. The convertible lawnmower according to claim 45, further comprises:

a link including a first end connected to the cover and a second end, wherein the handle is pivotally connected to the second end of the link;

a selector plate mounted external to the cutter housing and including a plurality of slots selectively receiving the handle; and

a torsion spring connected between the handle and the link to bias the handle toward engagement with any one of the plurality of slots;

wherein the handle is selectively received in any one of the plurality of slots to secure the cover in a position between the full bagging position and the full mulching position.

50. The convertible lawnmower according to claim 49, wherein the cover is positionable in a plurality of discrete positions between the full bagging position and the full mulching position, each of the plurality of positions corresponding to a respective one of the plurality of slots in the selector plate.

51. A control for a lawnmower accessory comprising:

a selector having a first position, a second position and at least one position intermediate the first position and the second position;

a slidable plate connected to the selector, the plate including a first wall and a second wall extending obliquely from the first wall.

52. The control for a lawnmower accessory according to claim 51, wherein the first position is a full bagging position and the second position is a full mulching position;

53. The variable mulching control according to claim 51, further comprising a fin connected to the mulching degree selector and extending from the plate and away from the cover.

54. The variable mulching control according to claim 53, wherein the fin is connected to the cover and extends perpendicular to the wall.

55. A lawnmower convertible between a bagging mode and a mulching mode, the convertible lawnmower comprising:

a cutter housing having a discharge opening;

an engine mount on the cutter housing;

a prime mover supported on the engine mount;

a mulching blade coupled to the prime mover to rotate within the cutter housing;

a plate that translates within the cutter housing between a full bagging position where the discharge opening is substantially unobstructed by the plate and a full mulching position where the plate substantially obstructs the discharge opening;

a rotary knob operatively connected to the plate; and

indicia adjacent the rotary knob indicating the operational state of the plate based on the position of the rotary knob relative to the indicia.

56. The convertible lawnmower according to claim 55, wherein the rotary knob includes:

a circular base; and

an elongated grip extending from the circular base, the width of the elongated grip being less than one-half of the diameter of the circular base;

57. The convertible lawnmower according to claim 56, further comprising an actuation transmission having a first end connected to the rotary knob and a second end connected to the plate.

58. The convertible lawnmower according to claim 57, wherein the actuation transmission further includes:

a first gear connectable to the plate; and

a second gear at the second end engaging the first gear.

59. The convertible lawnmower according to claim 58, wherein the first gear is a pinion gear and the second gear is a rack such that rotation of the rotary knob causes translation of the plate.

60. A lawnmower convertible between a bagging mode and a mulching mode, the convertible lawnmower comprising:

a cutter housing having a discharge opening;

a rotary mulching blade mounted to rotate in a cutting plane within the cutter housing; and

a plate translating within the cutter housing, the plate projecting an area onto the cutting plane at a location where the plate overlaps the cutting plane as the plate moves between a full bagging position where the discharge opening is unobstructed by the plate and a full mulching position where the plate obstructs the discharge opening.

61. The convertible lawnmower according to claim 60, wherein the plate comprises a major operating face that extends obliquely relative to the cutting plane and the major operating face defines the projected area.

62. A method for converting a lawnmower between a first operational mode and a second operational mode, the lawnmower including a discharge chute coupled to a cutter housing via a discharge opening, the method comprising:

establishing a first effective cross-sectional area for the discharge opening when the lawnmower is in the first operational mode;

establishing a second effective cross-sectional area different from the first effective cross-sectional area for the discharge opening when the lawnmower is in the second operational mode; and

establishing a third effective cross-sectional area different from the second effective cross-sectional area for the discharge opening when the lawnmower is in a third operational mode.

63. A method of converting a lawnmower between a first operational mode, a second operational mode, and a third operational mode, the lawn mower including a discharge chute coupled to a cutter housing via an discharge opening, the method comprising:

varying the effective cross-sectional area of the discharge opening to switch the lawnmower between the first operational mode, the second operational mode, and the third operational mode.

64. A method of varying operational modes of a lawnmower comprising:

changing the effective cross-sectional area of a discharge opening that couples a discharge chute to a cutter housing between one of a first area, a second area different from the first area, and a third area different from the second area.