Cutter and housing assembly for lawn mower
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a cutter and housing assembly for a lawn mower. 
     2. Description of the Relevant Art 
     Lawn mowers have cutter housings below lawn mower vehicle bodies. In a riding-type lawn mower, particularly, a plurality of cutter blades are usually disposed dispersely or at spaced positions in a cutter housing. The cutter housing has a grass clipping discharge outlet defined in a side portion thereof and a grass clipping discharge passage defined in a front portion thereof and communicating with the grass clipping outlet. As shown in Japanese Laid-Open Utility Model Publication No. 61(1986)-98424, the grass clipping discharge passage is defined above an upper surface of the cutter housing. 
     In operation, grass clippings cut off by the cutter blades are discharged laterally of the lawn mower through the grass clipping discharge passage and the grass clipping discharge outlet. 
     When lawn grass is clipped by a lawn mower, it is desirable that the clipped lawn surface be uniformly even. However, the conventional lawn mowers tend to leave some grass uncut and hence leave the clipped lawn surface irregular, so that the lawn may not have a desired neat appearance. 
     The present invention has been made in an effort to effectively solve the aforesaid problems of the conventional lawn mowers. 
     SUMMARY OF THE INVENTION 
     It is an object of the present invention to provide a cutter and housing assembly for a lawn mower, which can clip lawn grass to a uniformly even surface for a neat lawn appearance and which can discharge grass clippings effectively. 
     According to the present invention, there is provided a cutter and housing assembly for a lawn mower, comprising means for cutting including a plurality of blades disposed dispersely as viewed in plan, and a cutter housing accommodating the cutting means therein and having at least an upper panel and a side grass clipping discharge outlet. The upper panel has an elevated panel portion which defines within the cutter housing a grass clipping discharge passage positioned forwardly, with respect to the lawn mower, of paths of rotational motion of the blades and contiguous to the grass clipping discharge outlet. The elevated panel portion is spaced from lower ends of the blades by a distance ranging from 120 mm to 140 mm, and the elevated panel portion is higher than the upper panel by a distance ranging from 0 mm to 20 mm. 
     According to the present invention, there is also provided a cutter and housing assembly for a lawn mower, comprising means for cutting including a single center blade and two side blades disposed one on each side of the center blade, and a cutting means housing accommodating the cutter therein and having at least an upper panel and a side grass clipping discharge outlet. The upper panel has an elevated panel portion which defines within the cutter housing, a grass clipping discharge passage positioned forwardly, with respect to the lawn mower, of paths of rotational motion of the blades and contiguous to the grass clipping discharge outlet, and the cutter housing has a rear panel, a side panel joined to the rear panel, and a front panel joined to the side panel. One of the side blades which is positioned remotely from the grass clipping discharge outlet has a path of rotational motion which is spaced from the rear panel, the side panel, and the front panel by respective distances which are progressively larger along the direction in which the one side bade rotates, whereby an upstream portion of the grass clipping discharge passage around the one side blade is of a scroll shape. 
     According to the present invention, there is further provided a cutter and housing assembly for a lawn mower, comprising means for cutting including a plurality of blades disposed dispersely as viewed in plan, and a cutter housing accommodating the cutting means therein and having at least an upper panel and a side grass clipping discharge outlet. The upper panel has an elevated panel portion which defines within the cutter housing a grass clipping discharge passage positioned forwardly, with respect to the lawn mower, of paths of rotational motion of the blades and contiguous to the grass clipping discharge outlet. One of the side blades which is positioned closely to the grass clipping discharge outlet, is being rotatable at a speed higher than speeds at which the other blades rotate. 
     The above and further objects, details and advantages of the present invention will become apparent from the following detailed description of a preferred embodiment thereof, when read in conjunction with the accompanying drawings. 
    
    
     DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a side elevational view of a riding-type lawn mower having a cutter and housing assembly according to a preferred embodiment of the present invention; 
     FIG. 2 is a plan view of a cutter housing of the cutter and housing assembly; 
     FIG. 3 is a side elevational view of the cutter housing; 
     FIG. 4 is a vertical cross-sectional view of the cutter housing; 
     FIG. 5 is a schematic plan view of the cutter housing; 
     FIG. 6 is a cross-sectional view taken along line 6--6 of FIG. 5; 
     FIG. 7 is a schematic side elevational view of center and side blades in the cutter housing; 
     FIG. 8 is a cross-sectional view taken along line 8--8 of FIG. 5; 
     FIG. 9 is a table showing the relationship between dimensions of the cutter housing and lawn grass left uncut; 
     FIGS. 10A and 10b are diagrams showing lawn grass left uncut on the lefthand side of the cutter housing; 
     FIGS. llA and llB are diagrams showing lawn grass left uncut on the righthand side of the cutter housing; 
     FIGS. 12A and 12B are diagrams showing areas in which grass clippings are scattered laterally of the lawn mower; and 
     FIGS. 13A and 13B are cross-sectional views of clipped lawn surfaces. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     As shown in FIGS. 1 through 4, a riding-type lawn mower 100 has a cutter and housing assembly including a cutter 80 and a cutter housing 22 according to the present invention. 
     The lawn mower 100 comprises a vehicle frame 1, front wheels 2 rotatably mounted on the vehicle frame 1, rear wheels 3 rotatably mounted on the vehicle frame 1, a rider&#39;s seat 4 supported on the vehicle frame 1, and an engine E mounted on the vehicle frame 1. The vehicle frame 1 also supports thereon a steering gearbox 7 with a support frame 8 mounted thereon. A steering shaft 13 with a steering wheel 12 on its upper end is inserted through a support pipe 10 which is fixed to the rear end of the support frame 8. 
     A radiator 15 and a cooling fan 16 are disposed within the support frame 8. The cooling fan 16 can be operated by the engine E through a belt and pulley mechanism 17. 
     The cutter housing 22 is vertically adjustably connected to the lower surface of the vehicle frame 1 through links 20, 21. In the illustrated embodiment, the cutter housing 22 is slightly tilted forwardly at about 1° with respect to the horizontal plane as shown in FIG. 1. 
     As shown in FIG. 2, the cutter housing 22 comprises a front panel 22a angularly projecting or bulging forwardly (with respect to the lawn mower 100) at its center, a side panel 22b extending rearwardly (with respect to the lawn mower 100) from the lefthand end of the front panel 22a, a rear panel 22c having a side end joined to the rear end of the side panel 22b and having a shape complementary to the rear edges of circular paths of cutter blades (described later), a flange 22d extending rearwardly from the lower edge of the rear panel 22c, a first corner 22e lying between the front panel 22a and the side panel 22b, a second corner 22f disposed in the projecting center of the front panel 22a, and an upper panel 22g (see FIGS. 1 and 3) disposed on the upper edges of the front panel 22a, the side panel 22b, and the rear panel 22c. The front panel 22a, the side panel 22b, the rear panel 22c, the first corner 22e, the second corner 22f, and the upper panel 22g jointly define a space S within the cutter housing 22. 
     The cutter housing 22 has a grass clipping discharge outlet 23 defined in its righthand side, and a discharge adapter 25 is mounted in the grass clipping discharge outlet 23. The discharge adapter 25 has a width (extending vertically in FIG. 2) which is progressively greater in the outward direction (rightward in FIG. 2), i.e., in the downstream direction along which grass clippings are discharged from within the cutter housing 22 laterally of lawn mower 100. As shown in FIG. 5, the discharge adapter 25 has a front wall 25a which is inclined with respect to the front panel 22a of the cutter housing 22 at an angle θ1 of about 8°, and a rear wall 25b which is inclined with respect to the rear panel 22c of the cutter housing 22 at an angle θ2 of about 18°. 
     A front center wheel 28 is rotatably mounted on the center of the front panel 22a by brackets 27. Left and right side wheels 30, 31 are also mounted on the front panel 22a at laterally spaced positions by respective brackets 29. Left and rear rear wheels 33 are mounted on a rear portion of the cutter housing 22 by respective brackets 32. 
     The upper panel 22g has, on its front portion, an elevated panel portion 35a which defines a grass clipping discharge passage 35 (see FIGS. 5 and 6) in the cutter housing 22, the grass clipping discharge passage 35 communicating with the grass clipping discharge outlet 23. The elevated panel portion 35a is positioned upwardly of the upper panel 22g by a distance l1 (FIG. 6) ranging from 0 to 20 mm. The grass clipping discharge passage 35 has a width l2 (vertically in FIG. 5) along the longitudinal axis of the lawn mower 100, the width l2 being progressively larger in the downstream direction along which grass clippings are discharged. The grass clipping discharge passage 35 angularly projects forwardly at its center. 
     The cutter 80 is positioned within the cutter housing 22. The cutter 80 comprises a center blade 37, a lefthand side blade 38, and a righthand side blade 39, the blades 37, 38, 39 being dispersely positioned as viewed in plan. The lefthand side blade 38 is positioned remotely from the grass clipping discharge outlet 23, and the righthand side blade 39 is positioned closely to the grass clipping discharge outlet 23. Each of the blades 37, 38, 39 is twisted to a height l3 (FIG. 4) of 30 mm, and doubles as a fan for generating air streams to discharge grass clippings. As shown in FIG. 6, the lower end of the lefthand side blade 38 and the elevated panel portion 35a which defines the grass clipping discharge passage 35 are vertically spaced from each other by a distance l4 ranging from 120 to 140 mm. The lower end of the front portion of the cutter housing 22 and the lower end of the side blade 38 are vertically spaced from each other by a distance l5 of 7 mm. The lower end of the rear portion of the cutter housing 22 and the lower end of the side blade 38 are vertically spaced from each other by a distance l6 of 15 mm. The grass clipping discharge passage 35 is positioned forwardly of the paths of rotational motion of the blades 37, 38, 39. 
     The center blade 37 is positioned centrally in the cutter housing 22, and the side blades 38, 39 are positioned on the lefthand and righthand sides, respectively, of and also rearwardly of the center blade 37. As illustrated in FIG. 4, the center blade 37 is higher than the side blades 38, 39 by about 2.5 mm. 
     As shown in FIG. 4, the center blade 37 is mounted on the lower end of a shaft 41 which is rotatably supported in a support bushing 40 that is fastened to the upper panel 22g. A pulley 42 is fixed to an upper end portion of the shaft 41, and another pulley 43 is also fixed to the upper end portion of the shaft 41 above the pulley 42. Likewise, the side blades 38, 39 are mounted on the lower ends of shafts 47, 48, respectively, which are rotatably supported in respective support bushings 45, 46 that are fastened to the upper panel 22g. Pulleys 50, 51 are fixed to upper end portions, respectively, of the shafts 47, 48. Since the cutter housing 22 is tilted forwardly, the center blade 37 and the side blades 38, 39 are also tilted forwardly (to the left) as shown in FIG. 7 such that a front tip 37a of the center blade 37 and front tips 38a, 39a of the side blades 38, 39 are held in the same vertical position. The forward inclination of the center blade 37 and the side blades 38, 39 is effective to reduce the amount of power which is required to clip lawn grass by the lawn mower 100. 
     As shown in FIG. 2, a tension pulley 53 is disposed behind the pulley 42 connected to the center blade 37. The tension pulley S3 is rotatably supported by a shaft 56 on a bracket 55 which is swingably supported on the cutter housing 22. A spring 58 acts between the shaft 56 and a bracket 57 fixed to the cutter housing 22. 
     A V-belt 59 is trained around the pulleys 42, 50, 51 and the tension pulley 53. Another V-belt (see FIG. 1) is trained around the pulley 43 and a pulley which is operatively coupled to an output shaft of the engine E. Therefore, when the pulleys 43, 42 are rotated by the engine E, the rotation is transmitted to the pulleys 50, 51 by the V-belt 59 to rotate the center blade 37 and the side blades 38, 39 in the same direction (i.e., clockwise in FIG. 2). When the blades 37, 38, 39 are rotated, they cut off lawn grass, and grass clippings are discharged laterally of the lawn mower 100 through the grass clipping discharge passage 35, the grass clipping discharge outlet 23, and the discharge adapter 25. 
     The pulleys 42, 50 have the same outside diameter, and the outside diameter of the pulley 51 is smaller than the outside diameter of the pulleys 42, 50. Therefore, the lefthand side blade 38 and the center blade 37 rotate at the same speed, and the righthand side blade 39 rotates at a speed higher than the blades 38, 37. In the illustrated embodiment, the rotational speed of the righthand side blade 39 is 10 % higher than the rotational speed of the center blade 37 and the lefthand side blade 38. For example, the rotational speed of the lefthand side blade 38 and the center blade 37 is about 80 m/sec at their tip ends, i.e., about 3,350 r.p.m., and that of the righthand side blade 39 is about 88 m/sec at its tip end, i.e., about 3,690 r.p.m., where the while length or rotational diameter of each of the three blades 37,38 and 39 is about 456 mm. The former and latter rotational speeds may vary within the ranges of 3,000 to 3,400 r.p.m. and 3,100 to 3,700 r.p.m., respectively, as the case may be. Further, where the whole length of each of the blades 37,38 and 39 is about 530 mm, the rotational speeds of the former two and the last one are about 84m/sec and 88 m/sec, i.e., about 3,036 r.p.m and 3,181 r.p.m., respectively. 
     As shown in FIG. 5, the gap or clearance between the lefthand side blade 38 and the rear panel 22c, the side panel 22b, the first corner 22e, and the front panel 22a is progressively greater in the downstream direction along which grass clippings are discharged, so that the gap is of a scroll shape. More specifically, the gap is of a scroll shape from a point A to a point B in FIG. 5. The side blade 38 and the rear panel 22c are spaced from each other by a distance l8 of 5 mm. The side blade 38 and the side panel 22b are spaced from each other by a distance l9 of 21 mm. The side blade 38 and the front panel 22a are spaced from each other by a distance l10 of 68 mm. Therefore, the gap as defined by the distances l8, l9, l10 is progressively larger in the direction in which the lefthand side blade 38 rotates. 
     The center blade 37 and the second corner 22f are spaced from each other by a distance l11 which is greater than the distance l10 The righthand side blade 39 and the front panel 22a are spaced from each other by a distance l12 which is greater than the distance l11. Therefore, the gap referred to above is continuously scroll-shaped. Specifically, the distance l11 is 76 mm and the distance l12 is 110 mm in the illustrated embodiment. 
     As shown in FIGS. 5 and 8, a flange 60 extending into the cutter housing 22 is attached to the lower end of the rear panel 22c. The flange 60 serves to prevent grass clippings from dropping while the grass clippings are flowing in the cutter housing 22. The flange 60 extends continuously from the point A on the rear panel 22c through the side panel 22b, the first corner 22e, the front panel 22a to the grass clipping discharge outlet 23. The flange 60 is progressively wider in the downstream direction along which grass clippings are discharged. The flange 60 has a width l13 of about 20 mm at a most upstream portion thereof as shown in FIG. 8. 
     The construction of the cutter 80 and the housing 22 in the lawn mower 100 offers the following advantages: 
     (1) Since the vertical distance l1 between the elevated panel portion 35a of the grass clipping discharge passage 35 and the upper panel 22g of the cutter housing 22 is selected to be 20 mm, and the vertical distance l4 between the lefthand or upstream side blade 38 and the elevated panel portion 35a is selected to be 120 mm, any grass which may be left uncut by the lawn mower 100 is reduced. 
     FIG. 9 is a table showing amounts of grass which remain uncut with respect to different dimensions of the distances l1, l4 in respective columns and rows. The amounts of grass which remain uncut are indicated in planes C, L, R normal to the paths of rotational motion of the center blade 37 and the side blades 38, 39. 
     The table clearly indicates that the distances l1, l4 should preferably be in the ranges of 0≦l1≦20 mm and 120≦l4≦140 mm, respectively. Particularly, the distance l1=20 mm and the distance l4=120 mm are optimum. Since the distances l1, l4 are selected to be of these optimum values in the illustrated embodiment, any grass which may remain uncut is substantially eliminated, and the clipped lawn surface is made even. 
     (2) It is known that the clipped lawn surface configuration is rendered better if the vertical distance l5 between the lower end of the front portion of the cutter housing 22 and the lower end of the upstream side blade 38 is larger. However, if the dimension l5 were too large, then the amount of air drawn into the cutter housing 22 would become insufficient. In the illustrated embodiment, the distance l5 is selected to be 7 mm, so that the clipped lawn surface configuration is made good and sufficient air is drawn into the cutter housing 22. 
     (3) If the vertical distance l6 between the lower end of the rear portion of the cutter housing 22 and the lower end of the side blade 38 is larger, grass clippings in the cutter housing 22 and air drawn into the cutter housing 22 is less liable to leak out of the cutter housing 22. However, if the dimension l6 were too large, the clipped lawn surface would become irregular. In the illustrated embodiment, the distance l6 is selected to be 6 mm, so that the leakage of grass clippings and air is prevented and the clipped lawn surface is rendered even. 
     (4) The gap between the upstream side blade 38 and the rear panel 22c, the side panel 22, the first corner 22e, and the front panel 22a is progressively greater in the downstream direction so that the gap is scroll-shaped. This gap configuration is effective to make the clipped lawn surface even. FIG. 10A shows lawn grass X which remains uncut on the lefthand side of the cutter housing when both the dimensions l8, l9 are 5 mm. FIG. 10B shows lawn grass Y which remains uncut on the lefthand side of the cutter housing when the dimension l8 is 5 mm and the dimension l9 is 21 mm according to the illustrated embodiment of the present invention. It is apparent from FIGS. 10A and 10B that the clipped lawn surface is finished better when l8=5 mm and l9=21 mm. 
     (5) Inasmuch as the distances l10, l11, l12 between the upstream side blade 38, the center blade 37, the downstream side blade 39 and the front panel 22a are progressively greater in the downstream direction, any grass which remains uncut on the righthand side (side blade 39) of the cutter housing 22 is reduced, and the clipped lawn surface is neatly finished. 
     FIG. 11 A shows lawn grass Z which remains uncut on the righthand side (side blade 39) of the cutter housing when all the dimensions l10, l11, l12 are 80 mm. FIG. 11B shows no lawn grass left uncut when the dimension l10 is 68 mm, the dimension l11 is 76 mm, and the dimension l12 is 110 mm according to the illustrated embodiment. Therefore, the clipped lawn surface is better when l10=68 mm, l11=76 mm, and l12=110 mm. 
     With l10=68 mm, l11=76 mm, and l12=110 mm rather than l10=l11=l12=80 mm, the amount of grass clippings which are blown from between the center blade 37 and the downstream side blade 39 downwardly of the cutter housing 22 is greatly reduced, and the flow of grass clippings becomes smooth. 
     Since the distances l10, l11, l12 between the upstream side blade 38, the center side blade 37, the downstream side blade 39 and the front panel 22a are progressively greater in the downstream direction, the angle through which grass clippings discharged from the grass clipping discharge outlet 23 are scattered is increased. 
     FIG. 12A shows the angle through which grass clippings are scattered when all the dimensions 10, l11, l12 are 80 mm. FIG. 12B illustrates the angle through which grass clippings are scattered when the dimension l10 is 68 mm, the dimension l11 is 76 mm, and the dimension l12 is 110 mm. Comparison of FIGS. 12A and 12B indicates that the angle through which grass clippings are scattered is larger with l10=68 mm, l11=76 mm, and l12=110 mm according to the illustrated embodiment. 
     (6) Because the discharge adapter 25 is progressively wider outwardly (i.e., in the downstream direction), the angle through which grass clippings are scattered when they are discharged from the discharge adapter 25 is increased. 
     (7) As the rotational speed of the downstream side blade 39 near the grass clipping discharge outlet 23 is about 10% higher than the rotational speed of the center blade 37 and the upstream side blade 38, grass clippings are discharged with large energy and scattered over a large distance. 
     (8) In order to reduce the power required to clip lawn grass, the center blade 37 and the side blades 38, 39 are tilted forwardly at about 1°. Furthermore, the center blade 37 is higher than the side blades 38, 39 by about 2.5 mm (=blade length×sin 1°). Therefore, as shown in FIG. 7, the front tip 37a of the center blade 37 is vertically positioned at the same height of the front tips 38a, 39a of the side blades 38, 39, with the result that lawn grass can be clipped to a uniform height. 
     FIG. 13A shows a clipped lawn surface F produced when the center blade 37 and the side blades 38, 39 are tilted forwardly without height difference therebetween. Since the front tip 37a of the center blade 37 is positioned 39, the clipped lawn surface is lower at center than surrounding portions, and hence is irregular. FIG. 13B shows a clipped lawn surface G produced when the center blade 37 is higher than the side blades 38, 39 by about 2.5 mm (=blade length×sin 1°) and the blades 37, 38, 39 are tilted forwardly according to the illustrated embodiment. As shown in FIG. 13B, when the blades 37, 38, 39 are forwardly tilted and vertically positioned relatively to each other according to the embodiment, the clipped lawn surface is of uniform height. 
     (9) The flange 60 which continuously extends from the point A in FIG. 5 to the grass clipping discharge outlet 23 and is attached to the lower end of the cutter housing 22, is effective to prevent grass clippings from dropping out of the cutter housing 22. 
     With the present invention, as described above, the distance l4 between the elevated panel portion 35a defining the grass clipping discharge passage 35 and the lower ends of the cutter blades 37, 38, 39 is selected to be in the range of from 120 mm to 140 mm, and the elevated panel portion 35a is higher than the upper panel 22g of the cutter housing 22 by a distance ranging from 0 mm to 20 mm. These dimensional features allow the lawn mower 100 to clip lawn grass to a uniform level for a neat lawn surface, and to discharge grass clippings effectively and efficiently. 
     Although there has been described what is at present considered to be the preferred embodiment of the present invention, it will be understood that the invention may be embodied in other specific forms without departing from the essential characteristics thereof. The present embodiment is therefore to be considered in all aspects as illustrative, and not restrictive. The scope of the invention is indicated by the appended claims rather than by the foregoing description.