ELECTRIC SNOW-THROWER

Abstract

An electric snow-thrower is disclosed having a frame, an axle supported by and extending from the frame, a snow-engaging implement supported by the frame, and an electric motor. In some forms the electric snow thrower includes a transversely oriented electric motor configured to selectively drive the axle and the snow-engaging implement, a support bracket engaging the electric motor and a battery container, and a battery container having a control panel.

Description

CROSS REFERENCES TO RELATED APPLICATIONS

This application claims priority to U.S. provisional application No. 61/255,384 filed Oct. 27, 2009, which is hereby incorporated by reference as if fully set forth herein.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

Not Applicable.

BACKGROUND OF THE INVENTION

The present invention relates generally to electric snow-throwers, and more particularly to battery powered electric snow-throwers.

The design and manufacture of a commercially viable electric snow-thrower presents numerous challenges. While many of the individual components are available, the relative arrangement of and between certain components has a substantial impact upon the ultimate performance of the electric snow-thrower. For example, the placement and packaging of the electric motor and batteries can impact the performance of the resulting snow-thrower by, for example, altering the weight distribution, maneuverability, and overall form factor of the snow-thrower.

In light of at least the above considerations, a need exists for an electric snow-thrower including a battery container and an electric motor configuration that improves the performance of the electric snow-thrower.

SUMMARY OF THE INVENTION

In one aspect, a snow-thrower comprises a frame, an axle supported by the frame and extending from the frame, a snow-engaging implement supported by the frame, and an electric motor supported by the frame and having a drive shaft. The electric motor is oriented such that the drive shaft is transverse to the axle. The electric motor is configured to selectively drive the axle and the snow-engaging implement.

In another aspect, a snow-thrower comprises a frame, an axle supported by the frame and extending from the frame, a snow-engaging implement supported by the frame, a support bracket mounted to the frame and having a substantially vertical portion and a substantially horizontal portion, an electric motor mounted to the substantially vertical portion of the support bracket, and a battery container housing at least one battery and mounted to the substantially horizontal portion of the support bracket.

In yet another aspect, a snow-thrower comprises a frame, an axle supported by the frame and extending from the frame, a snow-engaging implement supported by the frame, an electric motor supported by the frame, and a battery container supported by the frame wherein the battery container includes a control panel.

These and still other aspects will be apparent from the description that follows. In the detailed description, a preferred example embodiment is described with reference to the accompanying drawings. This embodiment does not represent the full scope; rather, the invention may be employed in other embodiments. Reference should therefore be made to the claims for interpreting the breadth of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front isometric view of an example snow-thrower in accordance with an aspect of the invention;

FIG. 2 is a rear isometric view of the example snow-thrower of FIG. 1;

FIGS. 3A and 3B are side plan views of the example snow-thrower of FIG. 1;

FIGS. 4A and 4B are top plan views of the example snow-thrower of FIGS. 3A and 3B, respectively;

FIGS. 5A and 5B are partial section views along line 5-5 shown in FIGS. 4A and 4B, respectively;

FIG. 6 is an isometric exploded view including the example battery container;

FIG. 7 is a rear isometric view of the example snow-thrower with batteries removed from the battery container;

FIG. 8 is a partial rear isometric view showing the battery container removed from the example snow-thrower of FIG. 1;

FIG. 9 is a partial front isometric view of the snow-thrower of FIG. 8 generally depicting the example pulleys and belts;

FIG. 10 is an exploded isometric view including an example support bracket;

FIG. 11 is an isometric view of the example support bracket;

FIGS. 12 through 14 are various views of the example support bracket components;

FIG. 15 is an isometric exploded view of a portion of the example electric snow-thrower shown in FIG. 1;

FIG. 16 is a partial side plan view showing an example charge port; and

FIG. 17 is a simplified schematic of the example controls.

DETAILED DESCRIPTION OF THE PREFERRED EXAMPLE EMBODIMENT

The term “snow-thrower” as used herein generally describes single-stage snow-throwers, multi-stage (i.e., two or more stages) snow-throwers, snow blowers, and the like, and does not limit the application of the disclosure. Additionally, orientation and directional terms (e.g., vertical, horizontal, upward, downward, etc.) are in reference to a snow-thrower positioned on a level surface and in a substantially horizontal orientation relative to the level surface. Lastly, the term “fore” is in a direction toward the implement (e.g., auger), the term “aft” is in a direction toward the control members (e.g., handles), and the term “lateral” is in a direction substantially perpendicular to the fore and aft directions.

The following description assumes that certain aspects of snow-throwers are well-known to those of ordinary skill in the art. As such, these common elements are not described in detail so as to not obscure the various aspects of the invention as found in the claims.

An example electric snow-thrower 100 is generally shown in FIGS. 1 and 2. The electric snow-thrower 100 includes a frame 110 having a wheel axle 112 rotatably mounted thereto. Wheels 114 are secured to opposite ends of the wheel axle 112 by conventional techniques. As one skilled in the art will appreciate, the wheel axle 112 may be a drive axle that is configured to engage one or more tracks. An implement housing 116 is mounted toward the fore end of the frame 110. In the example electric snow-thrower 100, the implement housing 116 houses an auger assembly 118 including an auger 120 and an impeller (not shown) for directing snow through the rotatable discharge chute 122. Again, as one skilled in the art will appreciate, the auger assembly 118 may be any other form of snow-engaging implement, such as a paddle wheel assembly or a brush assembly. Two control members 124 (e.g., handles) are coupled to the frame 110, and extend aftward and upward from the frame 110. Various operator controls 130 (e.g., auger control, drive wheel control, speed control, direction control, etc.) are preferably integrated proximate the control members 124, thereby allowing a user to operate various aspects of the electric snow-thrower 100.

A battery container 132 is mounted in part to a horizontal portion 133 of a support bracket 134 (shown, for example, in FIGS. 5A and 9) by a plurality of fasteners 136 (e.g., screws, bolts, rivets, etc.) engaged with a plurality of mating openings 138 formed in the support bracket 134 (see, for example, FIGS. 5A, 5B, 7, and 10). The battery container 132 preferably includes an upper portion 140 that is contoured to cap a lower portion 142 and is secured thereto by fasteners 144. The battery container 132 is preferably molded from polyethylene, and may be manufactured from any number of materials such as other plastics, metals, composites, and the like. Additionally, a gasket (not shown) may be provided at the interface between the upper portion 140 and the lower portion 142, and the battery container 132 may be insulated to moderate the temperature of a battery 146 therein (best shown in FIGS. 3-6).

The battery container 132 is generally shown in FIGS. 3-5 with the upper portion 140 removed and is shown in the exploded view of FIG. 6. In the example embodiment, two banks of batteries 152, 154 are arranged into and supported by the lower portion 142 of the battery container 132. In the example configuration shown, the first bank of batteries 152 is supported by an upper ledge 156 of the lower portion 142 and is positioned such that the vertical height of the first bank of batteries 152 is minimized (as best shown in FIG. 5A). For example, as best shown in FIG. 5A, the longer dimension (as shown in cross-section) is aligned generally with the fore-aft orientation of the snow-thrower 100. The second bank of batteries 154, positioned aft of the first bank of batteries 152, is supported by a lower ledge 158 and is positioned generally upright (as shown best in FIG. 5A) to minimize the fore-aft dimension of the battery container 132. In the example embodiment, the first bank of batteries 152 and the second bank of batteries 154 each comprise a forty-eight volt, fifteen amp hour pack connected in parallel to each other to provide a total of approximately thirty amp hours of total power supply. Additionally, each of the first bank of batteries 152 and the second bank of batteries 154 include four, direct current twelve volt batteries connected in series to establish the forty-eight volts. The example batteries 146 are conventional sealed, lead-acid, AGM (Absorbed Glass Mat) batteries. One skilled in the art will appreciate the variety of battery types (e.g., nickel metal hydride, lithium-ion, etc.) and wiring configurations available to construct the preferred forty-eight volt circuit. Additionally, the nominal voltage may vary depending upon the requirements of the particular electric motor in use.

In the example embodiment, the lower portion 142 of the battery container 132 has an aft opening into which a controller 145 mounted to a plate 148 is secured via fasteners 150 (best shown in FIGS. 6 and 7). The controller 145 of the example embodiment operates on a forty-eight volt supply and includes an aluminum heat sink and nylon cover. Additionally, the controller 145 preferably includes self-diagnostic capabilities such that a fault (e.g., low voltage, high temperature, or other unexpected condition) in the overall electrical system 238, shown generally in FIG. 17, can be readily identified. The battery 146 may be recharged via a charge port 240 that is preferably mounted proximate the operator controls 130 by a port bracket 242, as shown best in FIGS. 6 and 16 of the example electric snow-thrower 100. In some configurations, a charging unit (not shown) converts conventional one hundred and ten volt alternating current to a suitable direct current to accomplish charging of the battery 146. Alternatively, the functionality of the charging unit may be integrated into the overall electrical system 238, eliminating the use of a separate charging unit.

The upper portion 140 of the battery container 132 includes an integrated control panel 160 (shown also in FIGS. 1 and 2) that is preferably angled upward toward the control members 124, and therefore toward a user. In the example embodiment, the control panel 160 includes a key switch 162, a battery-life indicator 164, a power switch 166, and an hour meter (not shown). The controller 145 is in communication with these components via wire harness 168 to control the operation and provide information to the user (schematically depicted in FIG. 17). As best shown in FIG. 4A, the battery container 132 also generally houses the wire harness 168 such that the wire harness 168 is substantially covered and shielded from external factors (e.g., snow). One skilled in the art, given the benefit of this disclosure will appreciate the many controls available.

The controller 145 is also in communication with an electric motor 170 positioned substantially vertically beneath the battery container 132 (best shown in FIG. 5). With additional reference to FIGS. 8-14, the electric motor 170 is mounted to a vertical portion 135 of the support bracket 134 (shown in detail in FIGS. 10-14). Specifically, a main body 184 defines the vertical portion 135 and a flange 137. The support bracket 134 includes a cap 183 having a pair of sides 182 (shown in FIG. 14) formed substantially perpendicular to the horizontal portion 133 (shown best in FIGS. 11 and 14) of the support bracket 134. Additionally, a support bar 186 is secured (e.g., welded) proximate an aft end of the support bracket 134 and includes openings 138 for securing a portion of the battery container 132. In the example embodiment, the support bracket 134 is generally made from steel, but may be made from a plastic, composite, or other material, and may be of unitary or multi-piece construction.

The electric motor 170 includes a mounting flange 172 that abuts an interior side 174 of the vertical portion 135 (shown best in FIGS. 5, 8, and 10). A disc 176 of the electric motor 170 extends into an opening 178 formed in the vertical portion 135 of the support bracket 134 such that a drive shaft 180 of the electric motor 170 extends beyond the vertical portion 135.

The single electric motor 170 provides rotation to both the drive wheels 114 via a drive train (not shown) and to the auger assembly 118 via gear train (not shown). In the example embodiment, the electric motor 170 is preferably a forty-eight volt DC motor capable of producing approximately four horsepower, up to approximately six foot-pounds of torque, and operating between approximately thirty-two hundred and thirty-six hundred revolutions per minute. Additionally, one skilled in the art, given the benefit of this disclosure will appreciate the arrangement and construction of suitable drive trains and gear trains, as well as the variety of electric motors 170 that may be incorporated into an electric snow-thrower 100.

In the example embodiment illustrated, the drive shaft 180 of the electric motor 170 is secured to a sheave 188 defining a drive pulley portion 90 and an implement pulley portion 192. With specific reference to FIGS. 5, 9, 10, and 15, the structure and operation of the sheave 188 are described in greater detail. The sheave 188 is generally cylindrical in shape having a first end 194 proximate the electric motor 170 when coupled to the drive shaft 180. The drive pulley portion 190 is formed proximate the first end 194 and includes a generally V-shaped groove 196. A drive belt 198 rides in the drive pulley portion 190 and tension is selectively applied to the drive belt 198 via an drive idler pulley 200 rotatably mounted to a drive idler arm 202, which is in turn pivotally mounted to the frame 110 (best shown in FIG. 15). As will be appreciated by one skilled in the art, the user (via control members 124) may selectively pivot the drive idler pulley 200 causing rotation of the wheels 114; however, the wheels 114 need not be driven (e.g., in snow blower applications).

The implement pulley portion 192 is formed proximate a second end 204 and also includes a generally V-shaped groove 206. An implement belt 208 rides in the implement pulley portion 192 and tension is selectively applied to the implement belt 208 via an implement idler pulley 210 rotatably mounted to an implement idler arm 212, which is in turn pivotally mounted to the frame 110 (best shown in FIG. 15). As noted above, the operation of the drive idler pulley 200 and the implement idler pulley 210, given the benefit of this disclosure, will be understood by one of ordinary skill in the art.

The sheave 188 includes an interior bore 214 into which a fastener 216 is inserted to secure the sheave 188 to the drive shaft 180 of the electric motor 170. A pair of L-shaped fingers 220 are secured to the vertical portion 135 of the support bracket 134 and extend fore toward the sheave 188 and proximate the drive belt 198 and implement belt 208. The fingers 220 help retain the drive belt 198 and implement belt 208 in engagement with the sheave 188 when tension is not applied to each.

In the example embodiment, the sheave 188 is preferably of one-piece construction made from aluminum or any similar material with a relatively comparable or better strength-to-weight ratio. In one alternative configuration the sheave 188 may be integrally formed with the electric motor 170 such that the drive shaft 180 is contoured to included the drive pulley portion 190 and the implement pulley portion 192.

The preferred, example configuration of the battery container 132, support bracket 134, and electric motor 170 help maximize the performance of the example snow-thrower 100. As best illustrated in FIGS. 3 and 4, an axle plane 222 (i.e., a substantially vertical plane passing through the wheel axle 112) defines a fore side 224 and an aft side 226. The electric motor 170 is preferably substantially at or on the fore side 224 of the axle plane 222 to optimize the weight distribution relative to the wheel axle 112. Additionally, the electric motor 170 defines a motor axis 228 (best shown in FIG. 4) that is oriented substantially perpendicular to the wheel axle 112.

The battery container 132 is arranged to minimize the obstruction of the user's view V while standing proximate the control members 124 and facing the fore direction (best shown in FIGS. 3 and 4). The control members 124 define an aft line 230 that is substantially horizontal and extends between the control members 124 approximately at the line of first obstruction as moving downward from the user's view V. Similarly, the implement housing 116 defines a fore line 232 that is substantially horizontal and located proximate the fore end of the implement housing 116. A sight plane 234 extends through both the aft line 230 and fore line 232 (illustrated only in FIG. 3). As a result, the user's view V is generally unobstructed above this sight plane 234 as the battery container 132 and electric motor 170 are configured to be mounted substantially at or below the sight plane 234. Additionally, the viewing shadow 236 fore of the implement housing 116 is substantially minimized. Of course, given the height of the user, the ultimate obstructed viewing area may be smaller than the defined viewing shadow 236.

With continued reference to FIGS. 3-5, the first bank of batteries 152 is generally positioned on the fore side 224 of the axle plane 222 and the second bank of batteries is generally positioned on the aft side 226 of the axle plane 222. The position of the batteries 152, 154 is beneficial in establishing a desired weight distribution relative to the wheel axle 112. For example, it is desirable for the snow-thrower 100 to have enough weight fore of the wheel axle 112 to keep the snow-thrower 100 from tipping counterclockwise (as viewed in FIG. 3) and to ensure that the auger assembly 118 adequately engages the snow. However, this is preferably balanced with the effort required by a user to tilt the snow-thrower about the wheel axle 112.

In operation, the controller 145 manages the operation of the electric motor 170 based upon input from the battery 146. For example, a user may turn the key switch 162 causing the controller 145 to monitor the charge of the battery 146. The user may pull out the power switch 166 causing the controller 145 to energize the electric motor 170, provided the battery 146 has a sufficient charge. As a result, the sheave 188 begins rotating and is ramped up to between approximately thirty-two hundred and thirty-six hundred revolutions per minute. Then, as described generally above, the user may operate the control members 124 and operator controls 130 to select and engage the desired direction, speed, chute orientation, etc. The controller 145 continues to monitor the remaining charge in the battery 146 and updates the battery-life indicator 164 to provide the user information regarding the remaining useful life. The controller 145 is preferably configured to shut down the electric motor 170 when the instantaneous voltage of the battery 146 is approximately thirty-five volts (the typical operating range of the example battery 146 is between approximately forty-four volts and fifty-two volts).

The logic of the example controller 145 is optionally configured such that if the key switch 162 is in the off position and the power switch 166 is in the off position, the controller 145 and thus electric motor 170 are de-energized. With the key switch 162 in the on position and the power switch 166 in the off position, the controller 145 is energized and the electric motor 170 remains de-energized. With the key switch 162 in the on position and the power switch 166 in the on position, both the controller 145 and the electric motor 170 are energized. Turning the key switch 162 to the off position with the power switch 166 in the on position de-energizes both the controller 145 and the electric motor 170. Finally, the controller 145 may be configured such that the electric motor 170 remains de-energized if the power switch 166 is in the on position as the key switch 162 is moved from the off position to the on position, thereby preventing the electric motor 170 from being energized substantially simultaneously with the controller 145.

While what is presently considered the preferred embodiment has been shown and described, it will be obvious to those skilled in the art, given the benefit of this disclosure, that various changes and modifications can be made without departing from the scope of the invention defined by the following claims.

Claims

1. A snow-thrower, comprising:

a frame;

an axle supported by the frame and extending from the frame;

a snow-engaging implement supported by the frame; and

an electric motor supported by the frame and having a drive shaft;

wherein the electric motor is oriented such that the drive shaft is transverse to the axle; and

wherein the electric motor is configured to selectively drive the axle and the snow-engaging implement.

2. The snow-thrower of claim 1, further comprising a battery supported by the frame and positioned at least partially above the electric motor.

3. The snow-thrower of claim 1, further comprising:

an axle plane defined by a substantially vertical plane passing through the axle;

a first battery positioned substantially on an aft side of the axle plane; and

a second battery positioned substantially on a fore side of the axle plane.

4. The snow-thrower of claim 1, further comprising:

an axle plane defined by a substantially vertical plane passing through the axle;

wherein the electric motor is mounted substantially on a fore side of the axle plane.

5. The snow-thrower of claim 1, further comprising:

a support bracket mounted to the frame and having a vertical portion;

a battery container mounted to the support bracket;

wherein the electric motor is mounted to the vertical portion of the support bracket; and

wherein the battery container at least partially surrounds the electric motor.

6. The snow-thrower of claim 1, wherein the drive shaft of the electric motor is oriented substantially perpendicular relative to the axle.

7. The snow-thrower of claim 1, wherein the snow-engaging implement is at least one of an auger, a paddle, and a brush.

8. A snow-thrower, comprising:

a frame;

an axle supported by the frame and extending from the frame;

a snow-engaging implement supported by the frame;

a support bracket mounted to the frame and having a substantially vertical portion and a substantially horizontal portion;

an electric motor mounted to the substantially vertical portion of the support bracket; and

a battery container housing at least one battery and mounted to the substantially horizontal portion of the support bracket.

9. The snow-thrower of claim 8, wherein the support bracket is mounted vertically above the axle.

10. The snow-thrower of claim 8, further comprising:

an axle plane defined by a substantially vertical plane passing through the axle;

a first battery housed within the battery container and positioned substantially on an aft side of the axle plane; and

a second battery housed within the battery container and positioned substantially on a fore side of the axle plane.

11. The snow-thrower of claim 10, wherein the electric motor is mounted substantially on the fore side of the axle plane.

12. The snow-thrower of claim 10, wherein the support bracket is integral with the frame.

13. A snow-thrower, comprising:

a frame;

an axle supported by the frame and extending from the frame;

a snow-engaging implement supported by the frame;

an electric motor supported by the frame; and

a battery container supported by the frame;

wherein the battery container includes a control panel.

14. The snow-thrower of claim 13, wherein the control panel is oriented transverse to a vertical plane.

15. The snow-thrower of claim 13, wherein the control panel includes at least one of a key switch, an hour meter, a battery-life indicator, and a power switch.

16. The snow-thrower of claim 13, further comprising:

a first battery housed in the battery container;

a second battery housed in the battery container; and

a wire harness electrically engaging the first battery and the second battery;

wherein the wire harness is housed within the battery container.

17. The snow-thrower of claim 13, further comprising a controller mounted to the battery container.

18. The snow-thrower of claim 13, further comprising:

a control member mounted to the frame and extending upward and aftward from the frame, and defining a substantially horizontal aft line; and

an implement housing mounted to the frame and extending forward from the frame, and defining a substantially horizontal fore line;

wherein the battery container is mounted substantially at or below a sight plane extending through the substantially horizontal aft line and the substantially horizontal fore line.

19. The snow-thrower of claim 13, wherein:

the electric motor includes a drive shaft;

the electric motor is oriented such that the drive shaft is transverse to the axle; and

the electric motor is configured to selectively drive the axle and the snow-engaging implement.

20. The snow-thrower of claim 13, further comprising:

a battery housed in the battery container;

a control member mounted to the frame; and

a charge port mounted to the control member and operatively engaged with the battery.