Mowers typically include one or more rotating blades and a deck which covers the rotating blades. Mower decks and blades that produce enough air flow for good quality of cut are often noisy and inefficient and require a lot of power to drive the blades.
Mower deck 4 comprises a deck for being mounted beneath a chassis of a tractor unit so as to enclose a pair of rotating cutting blades. Mower deck 4 has an underside cavity 6 with an interior profile 8. For purposes of this disclosure, the phrase “interior profile” refers to the shape and proportionate size of the interior surfaces that direct airflow produced by the rotation of the cutting blades. In the example illustrated, mower deck 4 comprises a ceiling 10 and sidewalls 12 that form two side-by-side cutting chambers 14A, 14B (collectively referred to as chambers 14), a discharge passage 15 extending alongside cutting chamber 14A and a discharge opening 16 through which cut grass is discharged from chambers 14. Unfortunately, the interior profile of deck 4 may not promote efficient airflow, optimize mowing performance, or reduce noise.
Mower deck insert 20 comprises an additional structure and is either removably or permanently mounted to the underside of deck 4, wherein the structure has an interior profile different than the interior profile of deck 4. In one implementation, mower deck insert 20 is mounted to the underside of deck 4 using mechanical attachment with fasteners, such as screws, bolts, clips, “Christmas trees” and the like, or various fittings. In another implementation, mower deck insert 20 is mounted to the underside of mower deck 4 using a multitude of bonding processes including adhesives and coatings. In yet another implementation, mower deck insert 20 is mounted to the underside of mower deck 4 through welding, latches or other securement mechanism.
In one implementation, mower deck insert 20 is formed from one or more polymeric materials or plastics, providing mower deck insert 20 with flexibility and enabling mower deck insert 20 to bend or flex to fit to an existing mower deck 4 without substantially increasing the weight of the cutting unit of the mower. Polymeric forming processes for the mower deck insert 20 could include thermoforming, injection molding, blow molding, rotational molding, and polystyrene foam (or alternative functional equivalent material) coated with a polymeric material. In other implementations, mower deck insert 20 is formed from fiberglass or a stamped metal, such as steel or aluminum. A stamped metal deck insert may be coated or treated with a chemical compound (such as boron nitride) to provide wear resistance and/or reduced friction/anti-stick properties. In yet other implementations, mower deck insert 20 is formed from a foam material or an alternative functional equivalent material (such as wood), wherein at least the underside of the material is coated with a wear resistant coating and/or a low friction/anti-stick coating, such as polytetrafluoroethylene (TEFLON), boron nitride, or polyurea/polyurethane. In addition to providing wear resistance and/or low friction, the coating may also be used to bond the mower deck insert 20 to the mower deck 4.
In some implementations, deck insert 20 may be employed permanently to the mower deck. In some implementations, deck insert 20 is removably mountable to mower deck 4, facilitating easy replacement of deck insert 20 when deck insert 20 becomes worn or damaged or when a different interior profile is preferred to optimize performance for a specific application need, such as side-discharging, bagging, mulching, or atypical mowing conditions. Differently configured cutting blades can be used with different interior profiles to provide optimal airflow and/or reduced noise characteristics and/or reduced power consumption characterisitics, for a specific application need. A reduced power consumption characteristic is especially desirable if the blade drive system is a battery-powered electric motor. Because deck insert 20 extends on the inside of deck 4, deck insert 20 protects deck 4 which now serves as a backing, substrate or base structure. In some implementations, sound insulating material can be used between deck insert 20 and deck 4. Deck insert 20 being of favorable shape for enhanced airflow with less drag and turbulence, reduces unwanted grass buildup on the underside of the mower deck, usually experienced when cutting wet grass. This effect can be enhanced via use of reduced friction/anti-stick coatings in combination with the favorable deck insert 20 shape. Deck insert 20 being of favorable shape for enhanced airflow and vacuum generation reduces or eliminates blow-out from underneath the deck lip, thus improving cut-quality of the mowing unit.
In the example illustrated, mower deck insert 20 comprises a panel or body 22 forming or providing discharge passage 24, far side cutting chamber 26 and nearside cutting chamber 28. Discharge passage 24 comprises an elongated channel formed on an underside of body 22 and having a ceiling 34 (appearing as a floor in the inverted mower deck illustrating
Far side cutting chamber 26 comprises a cavity formed on the underside of body 22 for receiving and shielding the far side cutting blade (not shown). Far side cutting chamber 26 comprises hub 40 and axial scroll 42. Hub 40 comprises a portion of body 22 centrally located within chamber 26 and providing a blade mounting portion 44 to rotatably support the far side cutting blade for rotation about far side axis 46. In the example illustrated, blade mounting portion 44 comprises an aperture extending through hub 40 of body 22 through which a blade shaft or blade bearing assembly extends.
Axial scroll 42 comprises a channel helically extending about axis 46. Axial scroll 42 comprises an upper surface 50 (appearing as a floor in the inverted deck of
In the example illustrated, scroll 42 extends at least 180° and nominally 240° about axis 46. Upper surface 50 of scroll 42 has scroll height change of less than 2 inches from start region 56 to end region 58. With such an example, a sufficiently large amount of airflow is produced to move grass clippings and other cut material while at the same time maintaining a low profile for the deck insert 20, allowing deck insert 20 to better fit beneath a mower chassis. In other implementations, scroll 42 may scroll about axis 46 by other extents and have a different scrolling rate with a different height change.
Near side cutting chamber 28 comprises a cavity formed on the underside of body 22 for receiving and shielding the near side cutting blade (not shown). Near side cutting chamber 28 comprises hub 60 and axial scroll 62. Hub 60 comprises a portion of body 22 centrally located within chamber 28 and providing a blade mounting portion 64 to rotatably support the far side cutting blade for rotation about near side axis 66. In the example illustrated, blade mounting portion 64 comprises an aperture extending through hub 60 of body 22 through which a blade shaft or blade bearing assembly extends.
Axial scroll 62 comprises a channel helically extending about axis 66. Axial scroll 62 comprises an upper surface 70 (appearing as a floor in the inverted deck of
In the example illustrated, scroll 62 extends at least 180° and nominally 240° about axis 66. Upper surface 70 of scroll 62 has scroll height change of less than 2 inches from start region 76 to end region 78. With such an example, a sufficiently large amount of airflow is produced to move grass clippings and other cut material while at the same time maintaining a low profile for the deck insert 20, allowing deck insert 20 to better fit beneath a mower chassis. In other implementations, scroll 62 may scroll about axis 66 by other extents and have a different scrolling rate with a different height change.
Upper surface 70 of scroll 62 feeds into discharge passage 24 at end region 78 at a height below (above in the inverted view of deck insert 20 shown by
Because the configuration of mower deck insert 20 offers greater airflow for a particular pair of cutting blades being rotatably driven at a particular speed, mower deck insert 20 further facilitates the provision of a mower cutting unit that produces less noise, for a given airflow.
In one implementation, cutting unit 100 is configured such that cutting blades 102 and 104 have a combined or total net radial weighted frontal area AWFnet such that cutting unit 100 outputs bulk airflow through discharge opening 32 at a rate of at least 600 cubic feet per minute at standard condition (SCFM) at a sound power of less than or equal to 104 decibels (dB). In another implementation, cutting unit 100 is configured such that cutting blades 102 and 104 have a combined or total net radial weighted frontal area such that cutting unit 100 outputs bulk airflow through discharge opening 32 at a rate of at least 700 cubic feet per minute at standard condition (SCFM) at a sound power of less than or equal to 104 decibels (dB), nominally less than or equal to 103.2 dB. In one implementation, cutting unit 100 is configured such that cutting blades 102 and 104 have a combined or net radial weighted frontal area AWFnet and such that cutting unit 100 outputs bulk airflow through discharge opening 32 at a rate of at least 340 SCFM plus 70 times the net radial weighted frontal area AWFnet of blades 102 and 104.
For purposes of this disclosure, the net radially weighted frontal area comprises the radially weighted frontal area of all the blades of a cutting unit. A radially weighted frontal area of a cutting blade is calculated according to the following: AWF (per side)=Σbihiri/r, where b=increment width, i=increment, h=rise or drop of increment and r=radius of increment, examples of which are illustrated in
Transmission 304 transmits power or torque from drive 302 to each of cutting blades 102, 104 of cutting unit 100. In one implementation, transmission 304 comprises a series of belts and pulleys which transmit torque to each of blades 102, 104. In other implementations, transmission 304 may have other configurations such as chain and sprocket or gear train assemblies. As noted above, in other implementations, cutting unit 100 and deck insert 20 may alternatively be utilized in walk behind self-propelled and push mowers, and ZTR units.
As shown by those portions of deck 4 broken away in
Although mower deck insert 20 is illustrated for deck insertion into mower deck 4, mower deck insert 20 is also configured to be mounted into other mower decks having two adjacent or side-by-side cutting chambers 14 leading to a discharge opening 16. The precise configuration or interior profile of mower deck 4 may have various configurations while still being different than the configuration and interior profile provided by mower deck insert 20. For example, in one implementation, mower deck insert 20 may alternatively be mounted into a mower deck 4 that has a continuous square or rectangular underside cavity, omitting projection 17 shown in
Intermediate cutting chamber 428 is similar to nearside cutting chamber 28 except that intermediate cutting chamber 428 feeds airflow and cut vegetation into a different vertical cross-sectional area or volume of discharge chute to reduce potential airstream interference to increase bulk deck airflow. In the example illustrated, intermediate cutting chamber 428 feeds airflow and cut vegetation into a cross-sectional area of discharge passage 24 that is vertically between ceiling 34 of discharge passage 24 and upper surface 70 of scroll 62 at the junction of scroll 62 with discharge passage 24.
Intermediate cutting chamber 428 comprises a cavity formed on an underside of body 22 for receiving and shielding an intermediate cutting blade (not shown). Intermediate cutting chamber 428 comprises hub 460 and axial scroll 462. Hub 460 comprises a portion of body 22 centrally located within chamber 428 and providing a blade mounting portion 464 to rotatably support the intermediate cutting blade for rotation about intermediate axis 466. In the example illustrated, blade mounting portion 464 comprises an aperture extending through hub 460 of body 22 through which a blade shaft or blade bearing assembly extends.
Axial scroll 462 comprises a channel helically extending about axis 466. Axial scroll 462 comprises an upper surface 470 (appearing as a floor in the inverted deck of
In the example illustrated, scroll 462 extends at least 180° and nominally 240° about axis 466. Ceiling 470 of scroll 462 has scroll height change of less than 2 inches from start region 476 to end region 478. With such an example, a sufficiently large amount of airflow is produced to move grass clippings and other cut material while at the same time maintaining a low profile for the mower deck insert 420, allowing mower deck insert 420 to better fit beneath a mower chassis. In other implementations, scroll 462 may scroll about axis 466 by other extents and have a different scrolling rate with a different height change.
Upper surface 470 of scroll 462 feeds into discharge passage 24 at end region 478 at a height below (above in the inverted view of deck insert 420 shown by
Because mower deck insert 420 discharges airflow from chambers 26, 28, 428 into distinct vertical portions of discharge passage 24, the airflow streams represented by arrows 92, 90 and 490 from chambers 26, 28 and 428, respectively, are less likely to interfere with one another. As a result, mower deck insert 420 provides greater bulk deck airflow, the total airflow exiting mower deck insert 420 from chambers 26, 28 and 428 through discharge opening 32. The greater airflow provided by mower deck insert 420 more effectively disperses cut materials over the terrain or more effectively propels cut materials into a collection volume carried by the mower. The greater airflow provided by mower deck insert 420 additionally creates a stronger upward vacuum below mower deck insert 420, more effectively lifting grass or vegetation for cutting by the cutting blades. Moreover, the greater airflow allows the creation of cutting units that produce the same or greater airflow but with less noise as compared to existing cutting units.
As shown by
As shown by
As shown by
Mounting collars 630 are provided for each of chambers 26, 28 and 428. Each of collars 630 includes one or more opening through which fasteners extend for bolting or otherwise fastening spindles 632 to deck insert 620. In other implementations, mounting collars 630 have other configurations or are omitted.
Mower deck insert 1220 is similar to mower deck insert 420 in that mower deck insert 1220 has an interior profile shape different than the interior profile or shape of the underside cavity of the deck in which insert 1220 is received. Mower deck insert 1220 is similar to mower deck insert 420 except that mower deck insert 1220 additionally comprises divider walls 1222, openings 1224, drag reducing surface treatments 1226 and drag reducing surface treatments 1228. Those remaining structures are components of insert 1220 correspond to similar components of insert 420 and are numbered similarly.
Divider walls 1222 comprise structures extending downward from the upper surface of deck 1220 towards the underlying ground or terrain. Divider walls 1222 extend between consecutive or adjacent chambers 26 and 428 and between adjacent chambers 428 and 28. Divider walls 1222 project downwardly towards the underlying terrain by a greater distance than the upper surface or ceilings of the chambers 26, 28, 428. Divider walls 1222 extend adjacent to discharge passage 24 so as to direct airflow from the adjacent chambers 26, 28, 428 into and along discharge passage 24, rather than across the adjacent chamber 26, 28, 428. As a result, divider walls 1222 promote enhanced flow efficiency or better airflow within each of chambers 26, 28, 428 and along discharge passage 24.
Openings 1224 extend from an adjacent divider wall 1222 between adjacent chambers 26, 28, 428. Openings 1224 facilitate overlapping of the cutting swaths of the blade within the respective chambers. In other implementations, openings 1224 may be omitted such as where chambers 26, 28 and 428 overlap one another in fore and aft directions but do not substantially overlap in a sideways or transverse direction. In such implementations, divider wall 1222 may extend from adjacent discharge passage 24 completely across and between chambers 26, 28, 428.
In the example illustrated, divider walls 1222 comprise triangular shaped, downwardly projecting plateaus. In other implementations, divider walls 1222 may comprise other shapes. In the example illustrated, divider walls 1222 are integrally formed as a single unitary body and homogenously formed as part of deck insert 1220. In other implementations, divider walls 1222 may comprise separate structures fastened, snapped or otherwise mounted to an underside of other portions of deck insert 1220.
Drag reducing surface treatments 1226, 1228 comprise surface irregularities formed upon the underside surface or ceiling of deck insert 1220. Surface treatments 1226, 1228 may reduce airflow drag for enhanced performance of deck insert 1220 during mowing. In the example illustrated, drag reducing surface treatments 1226, 1228 are formed upon an undersurface of deck insert 1220 along the ceilings of each of chambers 26, 28, 428. In yet other implementations, surface treatments 1226, 1228, or other drag reducing surface treatments, may be formed upon other ceiling surfaces of deck insert 1220, such as along the ceiling above the discharge passage. In one implementation, surface treatments 1226, 1228 are sized, shaped or located so as to not diminish or at least not increase a tendency of grass to clump or collect along such surfaces including surface streams 1226, 1228.
As shown by
As shown by
In one implementation, insert 1220 is formed from a molded polymer. In such an implementation, grooves 1232 and dimples 1234 are formed during molding of insert 1220. In yet other implementations, grooves 1232 and/or dimples 1234 or alternatively formed using material removal processes. Although insert 1220 is illustrated as having both types of drag reducing surface treatments 1226, 1228, in other implementations, insert 1220 may comprise one or the other of surface treatments 1226, 1228. In yet other implementations, insert 1220 may comprise other types of drag reducing surface treatments that breakup airflow to reduce airflow drag along such surfaces.
As shown by
In one implementation, an entire outer perimeter of deck 1304 comprises rim 1306 while an entire outer perimeter of insert 1220 comprises flange 1322. In yet other implementations, insert 1220 comprises a plurality of spaced flanges 1322 which interact with corresponding rims 1306 of deck 1304. In one implementation, deck 1304 also comprises a plurality of spaced rim portions 1306 corresponding to the location of the plurality of spaced flanges 1322 when insert 1220 is mounted to an insert within deck 1304.
In the example illustrated, bumper 1422 has a thickness T greater than a thickness t of the wall forming insert 1222 within deck 1304. The increased thickness provides enhanced protection. In one implementation, bumper 1422 comprises multiple walls forming a hollow interior 1426. In one implementation, interior 1426 is empty, reducing the weight of insert 1220. In one implementation, portions of the walls extending about interior 1426 are resiliently flexible, allowing such walls to resiliently and temporarily collapse into the void within interior 1426 when encountering another structure. In yet another implementation, interior 1426 is at least partially filled with a resiliently compressible material 1428, such as an open celled or close celled foam. In still other implementations, bumper 1422 may be formed from a single wall of polymeric material having substantially the same thickness is that of the remainder of insert 1220.
As further illustrated by
Deck insert 1420 is similar to deck insert 1220 described above except that deck insert 1420 additionally comprises for bumper portion 1432. Bumper portion 1432 projects, juts or extends through opening 1408 and beyond opening 1408 horizontally outwardly beyond the outer surface 1411 of downward extending portion 1409 of deck 1404. In one implementation, bumper portion 1432 projects outwardly beyond outer surface 1411 by at least 0.5 inches and nominally at least 2 inches. In other implementations, bumper portion 1432 extends outwardly beyond surface 1411 by other extends.
In the example illustrated, bumper portion 1432 is hollow, having a hollow interior 1434 in communication with the interior of insert 1420. In another implementation, the hollow interior 1434 is filled with a gel, foam or other filler material having a greater degree of compressibility or lower density than that of the material forming the walls of insert 1420. In another implementation, hollow interior 1434 may be omitted and replaced with a honeycomb structure formed from the same material forming insert 1420. In yet other implementations, bumper portion 1432 is solid.
Insert 1520 is similar to insert 1220 except that insert 1520 additionally comprises protuberant portion 1522. Protuberant portion 1522 comprises those portions of insert 1520 that stick out, project or jut upwardly beyond a lower surface of deck 1504 and nominally above the upper surface of deck 1504. In one implementation, protuberant portion 1522 is prominent with respect to and juts through and above opening 1506. As shown by
Protuberant portions 1522 are integrally formed as a single unitary body and homogenous with portions of insert 1520 that extend below deck 1504 and which form at least portions of the interior profile provided by deck 1520. In one implementation, protuberant portion 1522 are integrally formed as a single unitary body as part of a single layer that forms both protuberant portion 1520 and the ceiling of at least one of chambers 26, 28 and 428 (shown in
Protuberant portion 1522 has an underside which forms a ceiling 1526 that forms part of the interior profile provided by insert 1520. Ceiling 1526 extends at or above and beyond a top surface of deck 1504. Because protuberant portion 1522 juts or projects above and beyond the top of deck 1504, the height of ceiling 1526 is not restricted to the vertical distance between the underlying terrain and the underside of deck 1504. As a result, ceiling 1526 may have a greater height, providing a greater volume below ceiling 1526.
In one implementation, ceiling 1526 of protuberant portion 1522 serves as the ceiling for passage 24. As a result, those portions of passage 24 provided with ceiling 1526 have a greater cross-sectional area or volume to provide greater space for grass movement and airflow. In one implementation, ceiling 1526 of protuberant portion 1522 is located in the region of passage 24 identified by reference 1423 in
In other implementations, protuberant portion 1522 and its ceiling 1526 may be provided at other portions of insert 1520. For example, protuberant portion 1522 may additionally or alternatively form part of the ceiling or underside of one or more of channels 26, 28 and 428. In one implementation, deck 1504 merely comprises a framework or skeleton, wherein at least a majority and nominally two thirds of the horizontal surface area of deck 1504 is open and wherein the underlying insert 1520 projects through, above and beyond such open areas or regions of deck 1504.
As further shown by
In one implementation, the mower including deck 1804 is provided with insert 22 (shown and described above with respect to
Chute 1924 comprises a conduit which extends from bagging opening 1922 through bagging opening 1814 to a clippings containment structure, such as a bag. In one implementation, chute 1924 is integrally formed as a single unitary body with the remainder of deck insert 1920 that is contained below deck 1804. In another implementation, chute 1924 is releasably mounted to the remainder of deck insert 1920. In some implementations, chute 1924 is pre-existing as part of the bagging mechanism of the mower, wherein the chute 1924 simply abuts a top of the wall of deck insert 22 when the mower is in a side discharge mode and is not being presently used for bagging of clippings.
In one implementation, mower deck insert module 2120 is formed from one or more polymeric materials or plastics, providing mower deck insert module 2120 with flexibility and enabling mower deck insert mother 2120 to bend or flex to fit to an existing mower deck without substantially increasing the weight of the cutting unit of the mower. Polymeric forming processes for the mower deck insert module 2120 could include thermoforming, injection molding, blow molding, rotational molding, and polystyrene foam (or alternative functional equivalent material) coated with a polymeric material. In other implementations, mower deck insert module 2120 is formed from fiberglass or a stamped metal, such as steel or aluminum. A stamped metal deck insert may be coated or treated with a chemical compound (such as boron nitride) to provide wear resistance and/or reduced friction/anti-stick properties. In yet other implementations, mower deck insert module 2120 is formed from a foam material or an alternative functional equivalent material (such as wood), wherein at least the underside of the material is coated with a wear resistant coating and/or a low friction/anti-stick coating, such as polytetrafluoroethylene (TEFLON), boron nitride, or polyurea/polyurethane. In addition to providing wear resistance and/or low friction, the coating may also be used to bond the mower deck insert module 2120 to the mower deck.
In some implementations, deck insert module 2120 may be employed permanently to the mower deck. In some implementations, deck insert mother 2120 is removably mountable to mower deck, facilitating easy replacement of deck insert module 2120 when deck insert mother 2120 becomes worn or damaged or when a different interior profile is preferred to optimize performance for a specific application need, such as side-discharging, bagging, mulching, or atypical mowing conditions. Differently configured cutting blades can be used with different interior profiles to provide optimal airflow and/or reduced noise characteristics and/or reduced power consumption characteristics, for a specific application need. A reduced power consumption characteristic is especially desirable if the blade drive system is a battery-powered electric motor. Because deck insert model 2120 extends on the inside of a deck, deck insert module 2120 protects the deck which now serves as a backing, substrate or base structure. In some implementations, sound insulating material can be used between deck insert 2120 and the deck. Deck insert module 2120 being of favorable shape for enhanced airflow with less drag and turbulence, reduces unwanted grass buildup on the underside of the mower deck, usually experienced when cutting wet grass. This effect can be enhanced via use of reduced friction/anti-stick coatings in combination with the favorable deck insert model 2120 shape. Deck insert module 2120 being of favorable shape for enhanced airflow and vacuum generation reduces or eliminates blow-out from underneath the deck lip, thus improving cut-quality of the mowing unit.
In the example illustrated, mower deck insert module 2120 comprises a panel or body 2122 having a perimeter including a linear side portion or vertical wall that forms side of the discharge passage and a curved side portion extending from the linear side portion. Body 2122 further comprises a hub 2140 and axial scroll 2142. Hub 2140 comprises a portion of body 2122 centrally located to provide a blade mounting portion 2144 for rotatably supporting a cutting blade. In the example illustrated, blade mounting portion 2144 comprises an aperture extending through hub 2140 of body 2122 through which a blade shaft or blade bearing assembly extends.
Axial scroll 2142 comprises a surface 2150 helically extending about axis 2146 and above the linear and curved side portions forming the perimeter of body 2122. Axial scroll 2142 forms a ceiling 2150 above the cutting chamber. As shown by
In the example illustrated, axial scroll 2142 axially scrolls about axis 2146 such that scroll 2142 is shallowest and such that upper surface 2150 is vertically lowest at start region 2156 of scroll 2142 and such that scroll 2142 is the deepest and vertically highest at end region 2158, the junction between scroll 2142 and discharge passage formulation part by the overlying deck or shell. In the example illustrated, upper surface 2150 smoothly blends with or ramps into the ceiling of discharge passage 24 at end region 2158. In other implementations, the junction between upper surface 2150 at region 2158 and the discharge passage may have a distinctive ramp or step.
In the example illustrated, scroll 2142 extends at least 180° and nominally 240° about axis 2146. Upper surface 2150 of scroll 2142 has scroll height change of less than 2 inches from start region 2156 to end region 2158. With such an example, a sufficiently large amount of airflow is produced to move grass clippings and other cut material while at the same time maintaining a low profile for the deck insert model 2120, allowing deck insert model 2120 to better fit beneath a mower chassis. In other implementations, scroll 2142 may scroll about axis 2146 by other extents and have a different scrolling rate with a different height change.
Mower deck 2304 comprises a deck for being mounted beneath a chassis of a tractor unit so as to enclose a single rotating cutting blade. Mower deck 2304 has an underside cavity 2306 with an interior profile 2308. In the example illustrated, mower deck 2304 comprises a ceiling 2310, outer sidewalls 2311 and inner sidewalls 2312 that form two cutting chambers 2314, a discharge passage 2315 extending alongside cutting chambers 2314 and a discharge opening 2316 through which cut grass is discharged from chambers 2314. Outer sidewalls 2311 form a perimeter of deck 2304 and define portions of discharge passage 2315. Inner sidewalls 2312 circumferentially extend about sides of inserts 2120 and define the partial circumferential outer profile of each of cutting chambers 2314. In some implementations, those portions of outer sidewalls 2311 outside of inner sidewalls 2312 may be omitted. In other implementations, deck 2304 may have other configurations.
Mower deck 2404 comprises a deck for being mounted beneath a chassis of a tractor unit so as to enclose a single rotating cutting blade. Mower deck 2404 has an underside cavity 2406 with an interior profile 2408. In the example illustrated, mower deck 2404 comprises a ceiling 2410, outer sidewalls 2411 and inner sidewalls 2412 that form three cutting chambers 2414, a discharge passage 2415 extending alongside cutting chambers 2414 and a discharge opening 2416 through which cut grass is discharged from chambers 2414. Outer sidewalls 2411 form a perimeter of deck 2304. Inner sidewalls 2412 circumferentially extend about sides of inserts 2120 and define the partial circumferential outer profile of each of cutting chambers 2314. In the example illustrated come inner sidewalls 2412 additionally extend alongside discharge passage 2415 two formed sides of discharge passage 2415. In some implementations, those portions of outer sidewalls 2411 outside of inner sidewalls 2312 may be omitted. In other implementations, deck 2404 may have other configurations.
Although the claims of the present disclosure are generally directed to a more, the present disclosure is additionally directed to the features set forth in the following definitions.
1. A mower comprising:
a deck comprising an underside cavity with a first interior profile; and
a deck insert mounted within the underside cavity, the deck insert having a deck insert interior with a second interior profile different than the first interior profile.
2. The mower of definition 1, wherein the deck insert has an outer profile, wherein portions of the outer profile are horizontally spaced from interior side surfaces of the deck.
3. The mower of definition 1, wherein the deck insert has an outer profile, wherein portions of the outer profile are vertically spaced from upper interior surfaces of the deck.
4. The mower of definition 1, wherein the first interior profile comprises upper interior deck surfaces having a first shape and wherein the second interior profile has upper interior deck insert surfaces having a second shape different than the first shape.
5. The mower of definition 1, further comprising a filler material between the first interior profile of the deck and the deck insert.
6. The mower of definition 1, wherein the deck comprises a linear sidewall and wherein the deck insert comprises a plurality of concave side walls along the linear sidewall and facing away from the linear sidewall.
7. The mower of definition 1, wherein the deck is metallic and wherein the deck insert is formed from a material selected from a group of materials consisting of one or more polymers, fiberglass, metals, organic materials and composites in the form of a coating, layer, laminate or foam.
8. The mower of definition 1, wherein the deck defines a first discharge opening for the underside cavity and where the deck insert defines a second discharge opening for the deck insert interior, the second discharge opening being geometrically different than the first discharge opening.
9. The mower of definition 8, wherein the second interior profile comprises a circular chamber having sidewalls extending partially across the first discharge opening.
10. The mower of definition 1, wherein the deck defines a first discharge opening the underside cavity and where the deck insert comprises a continuous layer of material forming a first chamber for a first cutting blade, a second chamber for a second cutting blade and a mulching blockage portion blocking the first discharge opening.
11. The mower of definition 1, wherein the first interior profile comprises a first linear side and a second pointed side opposite the first linear side and wherein the second interior profile comprises a plurality of circular blade chambers and a curved discharge passage along the plurality of blade chambers and along the second pointed side with the deck insert forming both opposite sides of the curved discharge passage.
12. The mower of definition 1, wherein the first interior profile comprises a first linear side and a second pointed side opposite the first linear side and wherein the second interior profile comprises a plurality of circular blade chambers and an angled discharge passage along the plurality of blade chambers and along the second pointed side with the deck insert forming both opposite sides of the angled discharge passage.
13. The mower of definition 1, wherein the second interior profile of the deck insert comprises:
a discharge passage having a ceiling and terminating at a discharge opening;
a first chamber tangent to the discharge passage to receive a first blade that rotates about a first axis, the first chamber having a first upper surface and feeding into the discharge passage and
a second chamber tangent to the discharge passage and adjacent to the discharge opening to receive a second blade that rotates about a second axis, the second chamber having a second upper surface scrolling about the second axis and feeding into the discharge passage at a height below an adjacent portion of the ceiling of the discharge passage.
14. The mower of definition 13, wherein the discharge opening circumferentially extends at least 75 degrees about the second axis.
15. The mower of definition 13, wherein the height of the second upper surface feeding into the discharge passage is at least 0.5 inches below the adjacent portion of the ceiling of the discharge passage.
16. The mower of definition 13, wherein the height of the second upper surface feeding into the discharge passage is at least 1 inch below the adjacent portion of the ceiling of the discharge passage.
17. The mower of definition 13, wherein the second upper surface terminates at a step below the adjacent portion of the ceiling of the discharge passage.
18. The mower of definition 13, wherein the second upper surface scrolling about the second axis has a drop of at least 1 inch.
19. The mower of definition 13 further comprising a third chamber tangent to the discharge passage between the first chamber and the second chamber to receive a third blade that rotates about a third axis, the third chamber having a third upper surface scrolling about the third axis and feeding into the discharge passage at a second height below an adjacent portion of the ceiling of the discharge passage
20. The mower of definition 13, wherein the first upper surface feeds into the ceiling of the discharge passage at a height of the ceiling.
21. The mower of definition 13, wherein the first upper surface scrolls about the first axis and feeds into the ceiling of the discharge passage at a height of the ceiling.
22. The mower of definition 13 further comprising:
a first blade;
a second blade;
at least one power source operably coupled to the first blade and the second blade
23. The apparatus of definition 13, further comprising:
a first blade;
a second blade, wherein the first blade and the second blade output bulk airflow through the discharge opening of at least 700 SCFM at a sound power of less than or equal to 104 dB.
24. The apparatus of definition 13, further comprising:
a first blade;
a second blade, wherein first blade and the second blade output bulk airflow through the discharge opening at a rate of at least 70 times a net of a radial weighted net frontal area of the first blade and the second blade plus a minimum constant of 340 SCFM.
25. The apparatus of definition 24, wherein the second upper surface feeds into the discharge passage at a step having a height of at least 0.5 inches below the adjacent portion of the ceiling of the discharge passage.
26. The mower of definition 1, wherein the second interior profile of the deck insert comprises:
a discharge passage having a ceiling and terminating at a discharge opening;
a first chamber tangent to the discharge passage to receive a first blade that rotates about a first axis;
a second chamber tangent to the discharge passage and adjacent the discharge opening to receive a second blade that rotates about a second axis; and
a divider wall between the first chamber and the second chamber.
27. The mower of definition 26, wherein the first chamber has a first upper surface scrolling about the first axis and feeding into the discharge chute and wherein the second chamber has a second upper surface scrolling about the second axis and feeding into the discharge passage at a height below an adjacent portion of the ceiling of the discharge passage.
28. The mower of definition 26 further comprising an opening extending through the divider wall between the first chamber and the second chamber.
29. The mower of definition 1, wherein the second interior profile comprises a ceiling, the ceiling comprising a drag reducing surface treatment.
30. The mower of definition 29, wherein the drag reducing surface treatment comprises dimples.
31. The mower of definition 29, wherein the drag reducing surface treatment comprises grooves.
32. The mower of definition 1, wherein the deck insert comprises a plurality of modules mounted adjacent to one another and to the deck.
33. The mower of definition 32, wherein each of the plurality of modules corresponds to a chamber of the deck insert, each module to extend above a rotatable blade.
34. The mower of definition 1, wherein the deck insert comprises a deck insert module comprising a body comprising:
a first side portion that forms a side of a discharge passage;
a second curved side portion extending from the first side portion; and
a scrolling surface above the first side portion and the second curved side portion.
35. The mower of definition 1, wherein the second interior profile comprises deflectors to direct grass towards ground.
36. The mower of definition 1, wherein the deck insert extends outwardly beyond an outer surface of the deck to form a bumper.
37. The mower of definition 36, wherein the deck comprises a lower outwardly extending rim and wherein the insert extends beneath and around the lower outwardly extending rim.
38. The mower of definition 36, wherein the deck comprises a downwardly extending wall having an opening and wherein the insert horizontally extends through the opening outwardly beyond the outer surface of the deck to form the bumper.
39. The mower of definition 1, wherein the deck insert snaps under and about a lower edge of the deck.
40. The mower of definition 1, wherein the deck comprises a deck ceiling over the underside cavity and wherein the deck insert extends from the underside cavity through the deck ceiling.
41. The mower of definition 40, wherein the deck insert comprises a deck insert ceiling above the deck ceiling.
42. The mower of definition 40, wherein the second interior profile of the deck insert comprises a discharge passage having a discharge passage ceiling, wherein at least a portion of the discharge passage ceiling extends above the deck ceiling.
43. The mower of definition 1, wherein the deck comprises a side discharge opening and a rear bagging opening and wherein the deck insert extends across and closes at least one of the side discharge opening and the rear bagging opening.
44. The mower of definition 1, wherein the deck insert comprises a polymeric body encasing at least one metallic insert.
45. The mower of definition 1 further comprising:
a spindle extending through the deck and through the deck insert to support a blade; and
a retainer about the spindle, wherein the deck insert is captured between the retainer and the deck, about the spindle.
46. The mower of definition 1, wherein the deck comprises a non-metallic body encapsulating a metal insert.
47. A deck insert for a mower having a mower deck having an underside cavity with a first interior profile, the deck insert comprising:
a body to be mounted within the underside cavity, the body having a deck insert interior with a second interior profile different than the first interior profile.
48. The deck insert of definition 47, wherein the deck insert is shaped so as to be horizontally spaced from interior side surfaces of the deck when mounted to the deck.
49. The deck insert of definition 47, wherein deck insert is shaped so as to be vertically spaced from upper interior surfaces of the deck when mounted to the deck.
50. The deck insert of definition 47, wherein the first interior profile comprises upper interior deck surfaces having a first shape and wherein the second interior profile has upper interior deck insert surfaces having a second shape different than the first shape.
51. The deck insert of definition 47, wherein the deck comprises a linear sidewall and wherein the deck insert comprises a plurality of concave side walls to extend along the linear sidewall and face away from the linear sidewall when the deck insert is mounted to the deck.
52. The deck insert of definition 47, wherein the deck insert is formed from a material selected from a group of materials consisting of one or more polymers, fiberglass, metals, organic materials and composites, in the form of a coating, laminate, layer or foam.
53. The deck insert of definition 47, wherein the deck defines the first discharge opening for the underside cavity and where the deck insert defines a second discharge opening for the deck insert interior, the second discharge opening being smaller than the first discharge opening.
54. The deck insert of definition 47, wherein the second interior profile comprises a circular chamber having sidewalls to extend partially across the first discharge opening when the deck insert is mounted to the deck.
55. The deck insert of definition 47, wherein the first interior profile comprises a first linear side and a second pointed side opposite the first linear side and wherein the second interior profile comprises a plurality of circular blade chambers and a curved discharge passage along the plurality of blade chambers and along the second pointed side with the deck insert forming both opposite sides of the curved discharge passage.
56. The deck insert of definition 47, wherein the first interior profile comprises a first linear side and a second pointed side opposite the first linear side and wherein the second interior profile comprises a plurality of circular blade chambers and an angled discharge passage along the plurality of blade chambers and along the second pointed side with the deck insert forming both opposite sides of the angled discharge passage.
57. The deck insert of definition 47, wherein the second interior profile of the deck insert comprises:
a discharge passage having a ceiling and terminating at a discharge opening;
a first chamber tangent to the discharge passage to receive a first blade rotates about a first axis, the first chamber having a first upper surface; and
a second chamber tangent to the discharge passage and adjacent the discharge opening to receive a second blade that rotates about a second axis, the second chamber having a second upper surface scrolling about the second axis and feeding into the discharge passage at a height below an adjacent portion of the ceiling of the discharge passage.
58. The deck insert of definition 57, wherein the discharge opening circumferentially extends at least 75 degrees about the second axis.
59. The deck insert of definition 57, wherein the height of the second upper surface feeding into the discharge passage is at least 0.5 inches below the adjacent portion of the ceiling of the discharge passage.
60. The deck insert of definition 57, wherein the height of the second upper surface feeding into the discharge passage is at least 1 inch below the adjacent portion of the ceiling of the discharge passage.
61. The deck insert of definition 57, wherein the second upper surface terminates at a step below the adjacent portion of the ceiling of the discharge passage.
62. The deck insert of definition 57, wherein the second upper surface has a drop of at least 1 inch during an arc of 240 degrees about the second axis.
63. The deck insert of definition 57 further comprising a third chamber tangent to the discharge passage between the first chamber and the second chamber to receive a third blade that rotates about a third axis, the third chamber having a third upper surface scrolling about the third axis and feeding into the discharge passage at a second height below an adjacent portion of the ceiling of the discharge passage and above the first height.
64. The deck insert of definition 57, wherein the first upper surface feeds into the ceiling of the discharge passage at a height of the ceiling.
65. The deck insert of definition 57, wherein the first upper surface scrolls about the first axis and feeds into the ceiling of the discharge passage at a height of the ceiling.
66. The deck insert of definition 47, wherein the deck insert comprises a deck insert module, the module consisting of a single opening and a single scrolling surface.
While the preferred embodiments of the invention have been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention. For example, although different example embodiments may have been described as including one or more features providing one or more benefits, it is contemplated that the described features may be interchanged with one another or alternatively be combined with one another in the described example embodiments or in other alternative embodiments. One of skill in the art will understand that the invention may also be practiced without many of the details described above. Accordingly, it will be intended to include all such alternatives, modifications and variations set forth within the spirit and scope of the appended claims. Further, some well-known structures or functions may not be shown or described in detail because such structures or functions would be known to one skilled in the art. Unless a term is specifically and overtly defined in this specification, the terminology used in the present specification is intended to be interpreted in its broadest reasonable manner, even though it may be used in conjunction with the description of certain specific embodiments of the present invention.
The present application is a continuation application claiming priority under 35 USC Section 120 from co-pending application number PCT/US15/44730 filed on Aug. 11, 2015 and entitled MOWER DECK INSERT by Derra et al., the full disclosure of which is hereby incorporated by reference. Application number PCT/US15/44730 claims priority to U.S. provisional application Ser. No. 62/035,606 filed on Aug. 11, 2014 by Derra et al. and entitled MOWER DECK INSERT, the full disclosure of which is hereby incorporated by reference.
Number | Date | Country | |
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62035606 | Aug 2014 | US |
Number | Date | Country | |
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Parent | PCT/US15/44730 | Aug 2015 | US |
Child | 15430304 | US |