Mower cutting deck having operator controlled discharge opening using intuitively operable handle

[0001] This invention relates to a rotary mower cutting deck having a discharge opening through which grass clippings may be discharged from the deck.

[0002] Lawn mowers are known having rotary cutting decks attached to or carried by the frame of the mower. Rotary cutting decks carry one or more cutting blades that rotate in substantially horizontal cutting planes. The decks are called rotary decks because of the rotary nature of the blade(s). The grass clippings created by the rotating action of the blade(s) are usually discharged through a discharge opening, often located on the right side of the deck. A discharge chute often extends outwardly from the side of the deck to shield the discharge opening to guard against inadvertent contact with the blade by a bystander and to control the direction of the discharged clippings.

[0003] Multi-bladed rotary cutting decks of this type are often carried on riding lawn mowers that are operated by an operator who is seated on a seat on the frame of the mower. In addition, rotary cutting decks of this type are also often convertible between a discharge mode of operation, in which the discharge opening is open, and a non-discharge mode of operation, in which the discharge opening is blocked. When the discharge opening is blocked, the grass clippings cannot escape through the discharge opening.

[0004] The reason for having a non-discharge mode of operation is to save time when cutting around areas in which the discharge of grass clippings would not be desirable. For example, if the operator is mowing or trimming around flower beds, sidewalks, driveways, or the like, the operator normally wants to prevent grass clippings from being discharged into the flower beds or onto the sidewalks and driveways. In a mower with a continuously open discharge opening oriented on the right side of the mower deck, this meant that the operator always had to place the left or non-discharge side of the cutting deck adjacent the flower beds, sidewalks, driveways, etc. when passing past such areas. Thus, the operator would frequently have to change directions while mowing to get the left side of the cutting deck up against the areas where the clippings should not be discharged. This need to change direction takes extra time and can be annoying to the operator.

[0005] Some riding mowers have a blocking member adjacent the discharge opening that comprises a pivotal flap or gate. The gate has a closed position in which the gate covers the discharge opening in the non-discharge mode. The gate also has an open position in which the gate is clear of the discharge opening in the discharge mode.

[0006] Thus, when the operator is mowing, if the operator comes to an area where grass clippings should not be discharged and the discharge opening is adjacent such areas, the operator can simply temporarily pivot the gate into its closed position to block the discharge opening. In this position, the grass clippings simply hit the closed gate and fall down to the ground without being discharged outside the deck. When the mower clears this area, the operator can pivot the gate back to its open position to resume discharging grass clippings from the deck. Moving the gate between its open and closed positions can be done quickly and on a temporary basis to block the grass clippings for even very short periods of time without having to change the direction of motion of the mower.

[0007] The gate in such mowers is connected by a linkage to an operating handle placed near the operator's seat. The operator can swing the gate between its open and closed positions simply by moving the operating handle from one handle position to another. This can be done without stopping the mower and without the operator dismounting the mower. U.S. Pat. No. 6,874,309 to Bellis, Jr. discloses a handle operated, pivotal gate of this type.

[0008] There are disadvantages with handle operated gates of this type. It is not always apparent which way the handle should be moved in order to open and close the gate. Accordingly, the operator has to learn this or pay attention to any type of operating instructions that might be placed on the mower near the handle. Until the operator has thoroughly learned the proper operation of the handle, it may be difficult to smoothly open and close the gate. Accordingly, there is a need in the art for a pivotal gate that is arranged and linked to an operating handle in which the proper operation of the handle is more intuitively apparent to the operator.

[0009] In addition, known gates pivot about substantially horizontal pivot axes. This arrangement provides little opportunity to offer effective intermediate positions of the gate. In such intermediate positions, the grass clippings tend to be deposited as a narrow band or windrow. This is not desirable.

[0010] One aspect of this invention relates to a mower cutting deck having a discharge opening for discharging grass clippings from the cutting deck with the mower having an operator's station for carrying an operator thereon during mowing. This aspect of the invention comprises a movable gate having a closed position in which the gate substantially blocks the discharge opening to place the cutting deck in a non-discharge mode of operation and an open position in which the gate substantially clears the discharge opening to place the cutting deck in a discharge mode of operation. A pivotal handle can be pivoted by the operator to move the gate between the closed and open positions thereof. The handle has a hand grip. The position of the hand grip relative to the mower mimics the position of the gate relative to the discharge opening such that the operator can observe the hand grip of the handle and set the hand grip in the same relative position on the mower as a desired setting of the gate relative to the discharge opening on the cutting deck.

[0011] Another aspect of this invention relates to a mower having a rotary cutting deck with a discharge opening covered by a discharge chute. A pivotal gate is placed beneath the discharge chute to pivot relative to the discharge opening between a closed position in which the gate substantially blocks the discharge opening and an open position in which the gate substantially opens the discharge opening, thereby providing discharge and non-discharge modes of operation respectively. A pivotal handle can be pivoted between first and second positions to thereby pivot the gate between the open and closed positions thereof. The handle and gate are arranged so that at least some portion of the handle extends in directions relative to the mower that are the same as the directions the gate extends relative to the discharge opening so that an operator can properly position the handle by observation of the handle portion to position the handle portion in an orientation corresponding to a desired orientation of the gate.

[0012] Yet another aspect of this invention relates to a mower having a rotary cutting deck with a discharge opening covered by a discharge chute. The discharge chute has a flexible body that is formed into a downwardly facing chute-like form by a shaping frame along one side of the discharge chute. A pivotal gate is placed beneath the discharge chute to pivot relative to the discharge opening between a closed position in which the gate substantially blocks the discharge opening and an open position in which the gate substantially opens the discharge opening, thereby providing discharge and non-discharge modes of operation respectively. The pivotal gate is attached to a vertically upwardly extending pivot pin. The pivot pin of the gate extends upwardly through the discharge chute and is rotatably journalled on the shaping frame of the discharge chute so as to be carried on the discharge chute.

[0013] An additional aspect of this invention relates to a mower having a rotary cutting deck formed by a top wall and a peripheral wall that enclose a plurality of cutting chambers each of which houses at least one rotary cutting blade that rotates in a substantially horizontal cutting plane. The peripheral wall of the cutting deck includes a discharge opening for allowing grass clippings to exit from the cutting deck. The discharge opening is covered by a generally U-shaped discharge chute that includes a top wall, a front wall and a rear wall. The discharge chute faces downwardly towards the ground and extends outwardly away from the discharge opening of the cutting deck. A pivotal gate is carried beneath the top wall of the discharge chute and pivots about a substantially vertical axis located adjacent the front wall of the discharge chute.

[0022] FIGS. 1 and 2 show a rotary cutting deck 2 of the type that is attached to or carried by the frame of a lawn mower (not shown). Cutting deck 2 has a top wall 4, a peripheral wall 6 that extends downwardly from top wall 4 and forms the peripheral boundary of cutting deck 2, and three cutting chambers 8 beneath top wall 4. Each cutting chamber 8 houses a rotary cutting blade (not shown) that rotates in a substantially horizontal cutting plane about a substantially vertical axis. As the cutting blades rotate, grass clippings are generated by the impact of the cutting edges of the blades with standing stalks of grass.

[0023] Referring to FIG. 2, cutting chambers 8 are open to one another so that the grass clippings created by the cutting blades can flow between cutting chambers 8 towards a common discharge opening 10. Discharge opening 10 is provided somewhere in the peripheral boundary of cutting deck 2 and usually on one side of cutting deck 2. In FIGS. 1 and 2, discharge opening 10 is shown blocked by a pivotal gate 12 that forms part of one embodiment of the present invention. FIGS. 1 and 2 show gate 12 in a closed position substantially overlying discharge opening 10.

[0024] As is customary in mowers of this type, discharge opening 10 is also covered by a generally U-shaped, downwardly facing, discharge chute 14 that extends outwardly from peripheral wall 6 for a short distance. Discharge chute 14 serves to protect bystanders from any objects that might be entrained in the grass clippings and be thrown through discharge opening 10. Discharge chute 14 will deflect such objects downwardly towards the ground and will prevent bystanders from inadvertently sticking their feet into discharge opening 10. Gate 12 is positioned beneath discharge chute 14 as shown in FIG. 1.

[0025] Discharge chute 14 is preferably constructed in accordance with the assignee's prior U.S. Pat. No. 6,986,240 to Kallevig, which is hereby incorporated by reference. Discharge chute 14 has a main body 17 that is formed out of a flexible material, such as rubber. Main body 17 is shaped into a chute-like form by a rigid shaping frame 18 forming part of the entrance to discharge chute 14. However, discharge chute 14 could be made entirely out of a rigid material if so desired.

[0026] One embodiment of this invention also includes a pivotal handle 16 carried in or adjacent the operator's station (not shown) of the mower. The operator's station is provided on the frame of the mower and usually includes either a seat on which the operator is seated or a platform on which the operator stands. As shall be explained in more detail hereafter, handle 16 is operatively connected to gate 12. The operator can swing or pivot handle 16 with his or her hand while the operator is carried on the mower at the operator's station to control the position of gate 12 relative to discharge opening 10.

[0027] Referring now to FIGS. 3-5, gate 12 comprises a rectangular flexible flap 20, made of a stiffer but still flexible rubber material similar to that used in discharge chute 14, that is bolted to a rigid upper support plate 22. A vertically extending gate pivot pin 24 is attached to a front end of support plate 22 at the front of flap 20. Pivot pin 24 is journalled in the front end of the shaping frame 18 of discharge chute 14 for rotation about a substantially vertical pivot axis. Gate 12 is approximately the same size as or slightly less in size than the size of discharge opening 10 to block discharge opening 10 when gate 12 is closed. See FIG. 2.

[0028] A pair of Bowden cables 25 connect gate 12 to handle 16. The top of gate pivot pin 24 includes a gate pulley 26_g fixed thereto such that gate pivot pin 24 is rotated when gate pulley 26_g is rotated. Gate pulley 26_g includes a pair of spaced upper and lower flanges 28 that include a pair of aligned openings 30 and 32 therein. The inner cable 34 of a Bowden cable 25 has an enlarged circular head 36 that is received in one pair of the aligned openings 30 or 32 with inner cable 34 lying in the groove between upper and lower flanges 28. Since there are two Bowden cables 25, the inner cable 34 of one Bowden cable 25 is connected to the pair of openings 30 in gate pulley 26_g and the inner cable 34 of the other Bowden cable 25 is connected to the other pair of openings 32 in gate pulley 26_g. Note that cable heads 36 are shown disconnected from openings 30 and 32 in the drawings for the purpose of clarity.

[0029] Handle 16 is L-shaped having a vertical shaft 38 and a horizontal hand grip 40. Handle shaft 38 is rotatably journalled for rotation about a substantially vertical axis in a bracket 42. Bracket 42 is fixed to the frame of the mower in or adjacent to the operator's station. Thus, hand grip 40 of handle 16 is close to the operator's hand while the operator is operating the mower.

[0030] The lower end of handle shaft 38 includes a handle pulley 26_h that is identical to gate pulley 26_g. The other ends of the inner cables 34 of Bowden cables 25 are connected to the pairs of openings 30 and 32 in handle pulley 26_h. Again, the other ends of the inner cables 34 of Bowden cables 25 are shown disconnected from handle pulley 26_h in the drawings simply for the purpose of clarity. In addition, the drawings also depict handle 16 more forwardly relative to cutting deck 2 than is the case in practice. In reality, handle 16 would normally be carried on the frame of the mower rearwardly of the rear ends of the inner cables 34 of Bowden cables 25.

[0031] Bowden cables 24 are set up to produce an identical direction of rotation in both handle 16 and gate pivot pin 24, i.e. when handle pulley 26_h rotates clockwise so does gate pulley 26_g and when handle pulley 26_h rotates counter-clockwise so does gate pulley 26_g. Also, as is typical of Bowden cables 25, each Bowden cable 25 has an outer sheath 44 that is appropriately clamped to a bracket 46 on discharge chute 14 and to bracket 42 with inner cable 34 sliding back and forth within outer sheath 44. In addition, sheath 44 can be clamped or tied at other locations to cutting deck 2 or the frame of mower 4 to help secure cable 25 in place as it extends between gate 12 and handle 16. However, there is enough slack in cable 25 to accommodate any relative movement between cutting deck 2 and the frame of the mower during a mowing operation.

[0032] A spring 48 bears between the underside of a horizontal flange 50 on bracket 42 and the top of handle pulley 26_h. Spring 48 is not strong enough to prevent handle pulley 26_h or handle shaft 38 from rotating when handle 16 is turned by the operator. However, spring 48 is strong enough to engage a detent pin 52 on handle shaft 38 with one detent groove in a series of detent grooves 54, 56, or 58 carried on the top of horizontal flange 50 on bracket 42. The detent pin/detent groove structure helps hold handle 16, and thus gate 12, in one of a series of positions.

[0033] The detent grooves include a first longitudinal detent groove 54 that is parallel to a forward direction of motion of the mower. When detent pin 52 is engaged in the first longitudinal detent groove 54, hand grip 40 of handle 16 is also parallel to a forward direction of motion of the mower since hand grip 40 is parallel to detent pin 52. When detent pin 52 is engaged in the first longitudinal detent groove 54, gate 12 is arranged in its closed position to block discharge opening 10. In this closed position, gate 12 is also parallel to the forward direction of motion of the mower.

[0034] Accordingly, the orientation of hand grip 40 of handle 16 mimics the orientation of gate 12 relative to discharge opening 10. When hand grip 40 is parallel to the forward direction of motion, namely when hand grip 40 is pointing to the rear as shown in the drawings, gate 12 will be similarly oriented on the cutting deck to block discharge opening 10.

[0035] If the user wants to open discharge opening 10, the user grips hand grip 40 of handle 16 and pulls up slightly against the bias of spring 48 to disengage detent pin 52 from the first longitudinal detent groove 54. The user can then swing handle 16 to the side by 90° until hand grip 40 of handle 16 is pointing outwardly towards the side. As handle 16 so rotates, this rotation is transmitted by the Bowden cables 25 to gate pivot pin 24 to similarly rotate gate 12. Gate 12 will swing forwardly inside discharge chute 14 until gate 12 is generally adjacent or aligned with the front wall 60 of discharge chute 14.

[0036] In this open position of gate 12 as shown in FIG. 6, discharge opening 10 is now clear or unblocked and the grass clippings can exit through discharge opening 10. Again, in this open position of gate 12, the positions of gate 12 and hand grip 40 of handle 16 mimic one another. Both will be pointing straight out to the side. After making this rotational adjustment, the operator can let go of handle 16. Spring 48 is effective to reseat detent pin 52 in a second transverse detent groove 56.

[0037] A third detent groove 58 is provided that is midway between the first longitudinal detent groove 54 and the second transverse detent groove 56. This third inclined detent groove 58 allows the operator to position gate 12 in an intermediate position that is halfway between the open and closed positions of gate 12. In this intermediate position, gate 12 deflects the grass clippings and any debris or objects entrained therein rearwardly. The intermediate position of the gate disperses the grass clippings over a distance of approximately one half the dispersal distance in the fully open position. Again, in this position, handle 16 and gate 12 have positions that mimic each other, namely handle 16 and gate 12 are each now inclined outwardly at a 45° angle relative to the forward direction of motion of the mower. See FIG. 7.

[0038] In this invention, the operator knows the position of gate 12 from the position of handle 16 because the position of hand grip 40 visually mimics the location of gate 12 in a particular desired position. For example, to block discharge opening 10, the operator knows that gate 12 should lie flat against discharge opening 10 with gate 12 being parallel to the forward direction of motion of the mower. All the operator has to do is to position hand grip 40 of handle 16 similarly, i.e. to place hand grip 40 so that hand grip 40 extends rearwardly but parallel to the forward direction of motion of the mower.

[0039] Similarly, if the user wants discharge opening 10 to be unblocked by gate 12, the user knows that gate 12 should be pivoted 90° to the side to be oriented transversely to the forward direction of motion of the mower. All the user has to do is to pivot handle 16 similarly, i.e. to swing hand grip 40 forwardly 90° until hand grip 40 points to the side. If the user stops the swinging motion of hand grip 40 after only 45° of rotation, both hand grip 40 and gate 12 will be rotated into the intermediate partially open/partially closed position described above. Again, both the motion and position of hand grip 40 mimic the motion and position of gate 12. The user will intuitively understand how to control the position of gate 12 simply by observing the position of hand grip 40 and setting hand grip 40 in the same relative position on the mower as the desired setting of gate 12 on the cutting deck.

[0040] Various modifications of this invention will be apparent to those skilled in the art. Thus, the scope of this invention will be limited only by the appended claims.