Electrified hybrid product integrated with on-board charger

Abstract

An electrified utility product includes a chassis, an energy storage device supported by the chassis, a tool, a traction element, one or more motors powered by the energy storage device, a charging port configured to facilitate connection of the energy storage device with an external power source, and an integrated charger. One or more motors are provided to drive at least one of the tool or the traction element. The integrated charger is connected between the energy storage device and the charging port.

Description

Cross - reference to Related Patent Applications

[0001] This application claims the benefit and priority of U.S. Provisional Patent Application No. 63 / 415,822, filed on October 13, 2022, which is incorporated herein by reference in its entirety. Background Art

[0002] Current trends in outdoor power equipment, including lawn mowers, include an increase in electrified components (such as batteries, battery packs, electric motors, blade motors, drive / traction motors, etc.) to replace or supplement the power traditionally provided by internal combustion engines. Summary of the Invention

[0003] One embodiment relates to an electrified chore product. The electrified chore product includes a chassis, a energy storage device supported by the chassis, a tool, a traction element, one or more electric motors powered by the energy storage device, a charging port configured to facilitate connection of the energy storage device to an external power source, and an integrated charger. One or more electric motors are arranged to drive at least one of the tool or the traction element. The integrated charger is connected between the energy storage device and the charging port.

[0004] Another embodiment relates to an electrified riding lawn mower. The electrified riding lawn mower includes a frame and body assembly, a seat, a mowing deck, a plurality of traction elements, an energy storage device, one or more first electric motors, one or more second electric motors, a charging port, and an integrated charger. The frame and body assembly provides an operator area with a chamber below the operator area. The seat is disposed within the operator area and above the chamber. The mowing deck is connected to the frame and body assembly. The plurality of traction elements are connected to the frame and body assembly. One or more first electric motors are powered by the energy storage device. One or more first electric motors are arranged to drive the mowing deck. One or more second electric motors are powered by the energy storage device. One or more second electric motors are arranged to drive one or more of the plurality of traction elements. The charging port is configured to facilitate connection of the energy storage device to an external power source. The integrated charger is disposed within the chamber. The integrated charger is connected between the energy storage device and the charging port.

[0005] Another embodiment relates to an electrified lawn mower. The electrified lawn mower includes a frame and body assembly providing an operator area, a mowing deck connected to the frame and body assembly, a plurality of traction elements connected to the frame and body assembly, an energy storage device, one or more first electric motors powered by the energy storage device, one or more second electric motors powered by the energy storage device, a charging port, and an integrated charger. One or more first electric motors are configured to drive the mowing deck. One or more second electric motors are configured to drive one or more of the plurality of traction elements. The charging port is configured to facilitate connection of the energy storage device to an external power source. The integrated charger is connected between the energy storage device and the charging port. The integrated charger includes circuit components that enable the electrified lawn mower to receive alternating current directly from an external power source through the charging port, and the integrated charger is configured to modulate the alternating current to direct current for storage by the energy storage device.

[0006] The present disclosure is merely illustrative and is not limiting in any way. Other aspects, inventive features, and advantages of the apparatus or process described herein will become apparent from the detailed description in conjunction with the drawings, in which like reference numerals refer to like elements. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figure 1 is a schematic view of a chore product according to an exemplary embodiment.

[0008] Figure 2 is according to an exemplary embodiment of Figure 1 the perspective view of the chore product shown.

[0009] Figure 3 is according to another exemplary embodiment of Figure 1 the perspective view of the chore product shown.

[0010] Figure 4 is according to an exemplary embodiment of Figure 1 the detailed view of the charging port of the chore product shown.

[0011] Figure 5 is according to an exemplary embodiment of Figure 1 the detailed view of the integrated charger of the chore product shown. DETAILED DESCRIPTION

[0012] Before turning to the drawings that illustrate the exemplary embodiments in detail, it should be understood that the present application is not limited to the details or methods set forth in the specification or shown in the drawings. It should also be understood that the terminology used is for the purpose of description only and should not be regarded as limiting.

[0013] As used herein, a "chore product" refers to any type of device, machine, or vehicle that can be used to perform chores (such as outdoor chores, indoor chores, lawn care, etc.). For example, a chore product may include an electric motor, a pump, an actuator, a compressor, and / or other devices that are driven by electricity to operate certain functions of the chore product, thereby facilitating the performance of chores. In some embodiments, a chore is a task that is performed by a user or autonomously at or near a home, farm, agricultural facility, building, sidewalk, park, parking lot, forest, field, and / or lawn. In some embodiments, the chore product transports an operator and performs the chore. In some embodiments, the chore product operates autonomously to perform the chore without the operator physically / manually operating on or of the chore product.

[0014] According to Figures 1 to 5 the exemplary embodiment shown, a chore product (such as a device, machine, vehicle, outdoor power equipment, indoor power equipment, lawn care vehicle or device, lawn mower, etc.), illustrated as chore product 10, is configured as an electrified chore product. In some embodiments, chore product 10 is a fully electric chore product (i.e., does not include an internal combustion engine). According to Figure 2 the exemplary embodiment shown, chore product 10 is configured as a zero-turn radius ("ZTR") lawn mower. According to Figure 3 the exemplary embodiment shown, chore product 10 is configured as a stand-on lawn mower. In some embodiments, chore product 10 is configured as a ride-on lawn mower (i.e., a ride-on lawn mower with a non-zero turn radius). In some embodiments, chore product 10 is configured as a walk-behind lawn mower.

[0015] Although the chore product 10 is illustrated as configured as a lawn mower, it is contemplated that the chore product 10 may be configured as other electrified chore products or "light" electrified vehicles, machines, or devices, or its functionality may be implemented on other electrified chore products or "light" electrified vehicles, machines, or devices, including outdoor power equipment, indoor power equipment, light vehicles, floor care equipment, golf carts, forklifts and other industrial vehicles, pavement treatment equipment, recreational utility vehicles, industrial utility vehicles, lawn and garden equipment, and / or other suitable vehicles, machines, or devices. Outdoor power equipment may include lawn mowers, riding tractors, snow blowers, pressure washers, tillers, log splitters, walk-behind lawn mowers, riding lawn mowers, and lawn equipment such as sod cutters, aerators, spreaders, sprayers, seeders, power rakes, and blowers. For example, outdoor power equipment may use one or more electric motors to drive tools such as the rotary blades of a lawn mower, the pump of a pressure washer, the auger of a snow blower, the alternator of a generator, and / or the drive train of the outdoor power equipment. Indoor power equipment may include floor sanders, floor polishers, vacuum cleaners, etc. Recreational utility vehicles may include all-terrain vehicles ("ATV"), utility task vehicles ("UTV"), etc. Industrial utility vehicles may include forklifts, aircraft tractors, aerial work equipment such as scissor lifts and boom lifts, etc.

[0016] As Figures 1 to 5 shown, the chore product 10 includes: a chassis, illustrated as the frame assembly 12; a chassis cover, illustrated as the chore product body 14, located above the frame assembly 12 and extending along at least a portion of the frame assembly 12 (e.g., its rear half, its rear portion, and / or its middle portion, etc.); an operator area, illustrated as the operator area 16, including various operator interfaces, illustrated as the operator controls 18; a storage device (e.g., a battery pack, a battery array, etc.), illustrated as the battery module 20, connected to or otherwise supported by the frame assembly 12; one or more electric motors, illustrated as the electric motors 30, including one or more first electric motors, illustrated as the tool electric motor 32, and / or one or more second electric motors, illustrated as the traction electric motor 34; a tool assembly, illustrated as the tool 40; a plurality of traction elements, illustrated as the traction elements 50; a power input, illustrated as the charging port 60; and an integrated on-board charging circuit, illustrated as the integrated charger 70, located between the battery module 20 and the charging port 60.

[0017] According to Figure 2 the exemplary embodiment shown, the operator area 16 is a seating area including a seat for an operator to sit on while driving or otherwise controlling the operation of the chore product 10. According to Figure 3In the exemplary embodiment shown, the operator area 16 is a standing area and includes a platform on which the operator stands while driving or otherwise controlling the operation of the utility product 10. In some embodiments, the operator area 16 is a handle or a steering bar or includes a handle or a steering bar, and the operator walks behind it. The operator control device 18 may include various input and / or output devices to facilitate the operator in controlling the utility product 10 (such as a joystick, a steering wheel, a shifter, an accelerator or an acceleration pedal, a brake lever or a brake pedal, a switch, a knob, a display, an instrument, etc.).

[0018] As Figure 2 shown, the battery module 20 is located behind the operator area 16 and the utility product body 14. As Figure 3 shown, the battery module 20 is located below the utility product body 14. In other embodiments, the battery module 20 is arranged in other ways. As Figure 1 shown, the battery module 20 is electrically connected to various electrical components or systems of the utility product 10 (such as the motor 30, the tool motor 32, the traction motor 34, etc.) and is configured to supply power to them. The battery module 20 may include a plurality of battery packs and / or battery cells. In some embodiments, the battery module 20 is detachable. In some embodiments, the battery module 20 is rechargeable. The battery cells of the battery module 20 may have one or more battery chemistries, including but not limited to lithium-ion, lithium iron phosphate, lithium polymer, nickel-cadmium, lead-acid, nickel-metal hydride, etc. The battery module 20 can be interchanged between different utility products (such as between the utility product 10, a lawn mower, a snow blower, a UTV, an ATV, a golf cart, a hole puncher, etc.). In some embodiments, the battery module 20 can be detached without tools. For example, the battery module 20 can be detachably connected to the utility product 10 through one or more latches, straps, claws, magnets, electrical connectors, slots, compartments, etc. or any combination thereof.

[0019] According to the exemplary embodiment, the tool motor 32 is arranged to drive one or more components of the tool 40. As Figure 2 and Figure 3As shown, the tool 40 is configured as a mowing tool, illustrated as a mowing deck 42, which is connected to the frame assembly 12 and is located in front of the utility product body 14 and the operator area 16. The mowing deck 42 may include a housing or shroud, within which one or more cutting blades are disposed and are driven by a tool motor 32. Although the mowing deck 42 is illustrated as being located near the front of the utility product 10, in other embodiments, the mowing deck 42 is located below the operator area 16 (e.g., on a riding mower) or is towed behind and pulled by the utility product 10. In other embodiments, depending on the intended end use of the utility product 10, the mowing deck 42 may be replaced or supplemented by various other types of tools 40 (e.g., a auger assembly of a snow blower, a punching mechanism of a hole puncher, etc.). In such non-mower embodiments, the tool motor 32 may drive components different from the cutting blades (e.g., a blower, a spreader, a power rake, a polisher, an auger, a hole puncher, etc.).

[0020] According to an exemplary embodiment, a traction motor 34 is provided to drive one or more traction elements 50. In some embodiments, each rear traction element 50 is independently driven by a corresponding traction motor 34. In some embodiments, the rear traction elements 50 are driven by a single traction motor 34. In some embodiments, additionally or alternatively, the traction motor 34 may drive the front traction elements 50. According Figure 2 and Figure 3 to the exemplary embodiment shown, the traction elements 50 are configured as wheels. In other embodiments, the traction elements 50 are configured as tracks.

[0021] As Figure 2 shown, a charging port 60 is located along the frame assembly 12 at the front end of the utility product 10. In other embodiments, the charging port 60 is provided along another portion of the frame assembly 12 (e.g., the rear end, the side, etc.). As Figure 3 shown, the charging port 60 is provided along the side of the utility product body 14. In other embodiments, the charging port 60 is provided along another portion of the utility product body 14 (e.g., the rear end, the front end, etc.). According to an exemplary embodiment, the charging port 60 is located in front of the operator area 16 and / or is visible from the operator area 16 so that the operator can see whether the utility product 10 is plugged in (e.g., to prevent driving away while the utility product 10 is plugged in). In one embodiment, the charging port 60 is provided along the armrest of the operator area 16.

[0022] As Figure 4As shown, the charging port 60 includes: a housing, illustrated as charging housing 62, which is recessed into the frame assembly 12 or the utility product body 14; a lid, illustrated as charging port lid 64, which facilitates selectively closing the charging housing 62; and a connector, illustrated as electrical connector 66, which is disposed within the charging housing 62. According to an exemplary embodiment, the electrical connector 66 is a male connector that facilitates electrically connecting the integrated charger 70 and the battery module 20 to the female connector of a charging cable external to the utility product 10. For example, the electrical connector 66 can be a power male connector or plug according to the US standard (such as a type B male connector or plug). As another example, the electrical connector 66 can be other types of male connectors (such as type A, type C, type D, etc. male connectors or plugs). In some embodiments, the electrical connector 66 is configured to interface with a conventional low voltage alternating current (such as 110 VAC, 120 VAC, 220 VAC, 240 VAC, etc.) power system and receive power directly from it without any filtering, conversion, inversion, transformation, modulation, or other processing of the power before it is transmitted to the utility product 10.

[0023] As Figure 5 shown, the integrated charger 70 is disposed within a chamber, illustrated as internal compartment 15, which is defined by the frame assembly 12 and / or the utility product body 14 (such as below the operator area 16, etc.). As Figure 5 shown, the integrated charger 70 includes various protrusions or fins. These fins allow for heat exchange to facilitate cooling of the integrated charger 70 (such as when air flows through). However, during normal operation, the fins may get dirty or otherwise covered with debris, which may have an adverse effect on the charging ability of the integrated charger 70. According to an exemplary embodiment, the internal compartment 15 is semi - enclosed to mitigate or reduce the amount of dirt or debris reaching the integrated charger 70. According to an exemplary embodiment, the internal compartment 15 is easily accessible (such as through a liftable / pivotable panel, seat, etc.), such that the integrated charger 70 is easily accessible for cleaning and maintenance to ensure it operates in an optimal and efficient manner.

[0024] According to an exemplary embodiment, the integrated charger 70 includes various circuit components (such as transformers, inverters, converters, etc.) such that the utility product 10 can directly receive alternating current from an external power source (such as the main power supply, etc.) through the charging port 60, and the integrated charger 70 is configured to modulate / process (such as convert, step - down, etc.) the alternating current and convert it into direct current for storage by the battery module 20 and / or for powering electrical components operating on direct current on the utility product 10.

[0025] Its advantage lies in that the charging port 60 and the integrated charger 70 are provided on the chore product 10, facilitating the direct connection of the chore product 10 to an external power source (such as a main power supply, a wall socket, a generator, etc.) using a standard extension cord, without relying on a dedicated charging cable or system external to the chore product 10 as in traditional electrified power tools and equipment. Therefore, the operator does not need to ensure that a specially designed charging cable is always stored with or carried along with the chore product 10. Instead, any suitable and available extension cord can be used to directly connect to the electrical connector 66 of the charging port 60 to directly connect the chore product 10 to an external power source and charge the battery module 20.

[0026] As used herein with respect to numerical ranges, the terms "about", "approximate", "substantially" and similar terms generally mean + / - 10% of the disclosed value. When these terms "about", "approximate", "substantially" and similar terms are applied to structural features (such as describing its shape, size, orientation, direction, etc.), these terms are intended to cover minor deviations in structure that may result from the manufacturing or assembly process and are intended to have a broad meaning consistent with the common and accepted usage of those of ordinary skill in the art to which the subject matter of the present disclosure pertains. Accordingly, these terms should be construed to indicate that non-substantive or immaterial modifications or alterations to the described and claimed subject matter are considered to be within the scope of the present disclosure as set forth in the appended claims.

[0027] It should be noted that the term "exemplary" and its variants as used herein to describe various embodiments are intended to indicate that these embodiments are possible examples, representatives or illustrations (and these terms are not intended to imply that these embodiments are necessarily particularly outstanding or optimal examples).

[0028] The term "connected" and its variants as used herein refer to two components being linked to each other directly or indirectly. Such a connection can be fixed (e.g., permanent or stationary) or movable (e.g., detachable or releasable). Such a connection can be achieved by directly connecting the two components to each other, or by using a single intermediate component to connect the two components to each other, and by using any additional intermediate components that are interconnected to connect the two components to each other, or by using an intermediate component that is integrally formed with one of the two components as a single entity to connect the two components to each other. If "connected" or its variants are modified by additional terms (such as "directly connected"), the general definition of "connected" above will be modified by the literal meaning of the additional term (e.g., "directly connected" means that two components are connected without any separate intermediate component), resulting in a narrower definition than the general definition of "connected" above. Such connections can be mechanical, electrical or fluid.

[0029] References to element positions in this document (e.g., "top", "bottom", "above", "below") are for describing the orientations of various elements in the drawings only. It should be noted that, according to other exemplary embodiments, the orientations of various elements may be different, and such variations are intended to be included within the scope of the present disclosure.

[0030] It is worth mentioning that the structures and arrangements of the chore product 10 shown in various exemplary embodiments are for illustration only. Additionally, any element disclosed in one embodiment can be combined with or used in any other embodiment disclosed herein. Although only one example of an element in one embodiment being combinable or usable in another embodiment is described above, it should be understood that other elements of each embodiment can also be combined with or used in any other embodiment disclosed herein.

Claims

1. An electrified chore product, comprising: A chassis; An energy storage device supported by the chassis; A tool; A traction element; One or more electric motors powered by the energy storage device, the one or more electric motors being configured to drive at least one of the tool or the traction element; A charging port configured to facilitate connection of the energy storage device to an external power source; And An integrated charger connected between the energy storage device and the charging port.

2. The electrified chore product according to claim 1, wherein, The charging port is located at the front end of the electrified chore product.

3. The electrified chore product according to claim 1, further comprising an operator area, wherein the charging port is located in front of the operator area and is visible from the operator area.

4. The electrified chore product according to claim 3, wherein, The operator area includes a seat, and the integrated charger is located in a chamber under the seat.

5. The electrified chore product according to claim 4, wherein, The integrated charger includes a plurality of protrusions or fins, and the chamber is at least partially enclosed to reduce or minimize the amount of dirt or debris reaching the integrated charger.

6. The electrified chore product according to claim 5, wherein, The seat is movable to facilitate access to the integrated charger.

7. The electrified chore product according to claim 1, wherein, The charging port includes an electrical connector that facilitates electrical connection of the integrated charger and the energy storage device to a charging cable located external to the electrified chore product and connected to an external power source, and without performing any filtering, conversion, inversion, voltage transformation, modulation, or processing on the alternating current received from the external power source before delivery to the electrified chore product.

8. The electrified household chore product according to claim 7, wherein, The electrical connector is a male connector configured to mate with a female connector of the charging cable.

9. The electrified chore product according to claim 8, wherein, The charging cable is a standard extension cord.

10. The electrified household chore product according to claim 7, wherein, The integrated charger includes circuit components that enable the electrified chore product to receive alternating current directly from the external power source through the charging port, and the integrated charger is configured to modulate the alternating current into direct current for storage by the energy storage device.

11. The electrified household chore product according to claim 7, wherein, The charging port includes a housing and a lid for selectively enclosing the housing, and the electrical connector is disposed within the housing.

12. The electrified household chore product according to claim 1, wherein, The electrified chore product is a lawn mower, and the tool is a mowing deck.

13. The electrified chore product according to claim 12, wherein, The lawn mower is a ride-on lawn mower.

14. An electrified ride-on lawn mower, comprising: A frame and body assembly that provides an operator area and has a chamber below the operator area; A seat disposed within the operator area and above the chamber; A mowing deck connected to the frame and body assembly; A plurality of traction elements connected to the frame and body assembly; An energy storage device; One or more first electric motors powered by the energy storage device, the one or more first electric motors being configured to drive the mowing deck; One or more second electric motors powered by the energy storage device, the one or more second electric motors being configured to drive one or more of the plurality of traction elements; A charging port configured to facilitate connection of the energy storage device to an external power source; And An integrated charger located within the chamber and connected between the energy storage device and the charging port.

15. The electrified ride-on mower according to claim 14, wherein, The charging port is located in front of the operator area and is visible from the operator area.

16. The electrified ride-on mower according to claim 14, wherein, The integrated charger includes a plurality of protrusions or fins, and the chamber is at least partially enclosed to mitigate or reduce the amount of dirt or debris reaching the integrated charger.

17. The electrified ride-on mower according to claim 16, wherein, The seat is movable to facilitate access to the integrated charger.

18. The electrified ride-on mower according to claim 14, wherein, The charging port includes an electrical connector that facilitates electrically connecting the integrated charger and the energy storage device to a charging cable located outside the electrified ride-on mower and connected to an external power source, and without performing any modulation on the alternating current received from the external power source before delivering it to the electrified ride-on mower.

19. The electrified ride-on mower according to claim 18, wherein, The integrated charger includes a circuit assembly that enables the electrified ride-on mower to receive alternating current directly from the external power source through the charging port, and the integrated charger is configured to modulate the alternating current into direct current for storage by the energy storage device.

20. An electrified mower, comprising: A frame and body assembly that provides an operator area; A mowing deck connected to the frame and body assembly; A plurality of traction elements connected to the frame and body assembly; An energy storage device; One or more first electric motors powered by the energy storage device, the one or more first electric motors being configured to drive the mowing deck; One or more second electric motors powered by the energy storage device, the one or more second electric motors being configured to drive one or more of the plurality of traction elements; A charging port configured to facilitate connection of the energy storage device to an external power source; And An integrated charger connected between the energy storage device and the charging port, wherein the integrated charger includes a circuit assembly that enables the electrified mower to receive alternating current directly from the external power source through the charging port, and the integrated charger is configured to modulate the alternating current into direct current for storage by the energy storage device.

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