Lawnmower Mulch Plug Ramps for Even Grass Distribution

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Solution Overview

Problem

Conventional mulch plugs in lawnmowers allow lawn clippings to accumulate and cause uneven distribution, leading to clumping or striped patterns due to decreased cutting volume and increased pressure in the cutting deck.

Innovation Solution

A mulch plug with a plurality of ramps securely attached to the cutting deck, deflecting lawn clippings out of the deck, which reduces accumulation and ensures even distribution by snap-fitting to the lower plane and interference-fitting to the upper plane, preventing clumping and stripes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional mulch plug is used to block the collector opening, then clippings are contained in the cutting deck, but clippings accumulate and cause uneven distribution leading to clumping and stripes

Engineering Contradiction:

Improvemulching performanceVSAvoidclipping distribution uniformity

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The mulch plug is segmented into multiple functional ramps (first ramp on lower plane, second ramp on trailing edge) that are positioned at different locations and angles to deflect clippings in different directions, preventing accumulation and ensuring even distribution across the lawn surface

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different ramps are designed with specific orientations and positions tailored to their local function - the first ramp deflects clippings from the lower plane while the second ramp handles clippings from the trailing edge, creating localized clipping flow control that results in overall even distribution

Inventive Principle:

Principle #3Local quality

2Ease of operation

If mulch plug ramps deflect clippings out of the cutting deck, then clipping distribution improves, but attachment security to the cutting deck must be maintained

Engineering Contradiction:

Improveclipping distribution uniformityVSAvoidmulch plug attachment security

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The attachment mechanisms (snap-fit features and interference-fit surfaces) are merged into the mulch plug structure itself, combining the security function with the ramp deflection function in a single integrated component that maintains both attachment strength and clipping distribution capabilities

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The mulch plug utilizes composite attachment methods combining snap-fit plastic deformation (for quick installation) with interference-fit mechanical engagement (for secure mounting), creating a composite attachment system that ensures both ease of installation and strong attachment security

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS11160205B2Lawnmower mulch plug ramps to improve mulching performance

Publication Date: 2021.11.02 HONDA MOTOR CO LTD

AI summary

A lawnmower with a mulch plug with a plurality ramps for deflecting lawn clippings out of a cutting deck with more than one depth planes. The mulch plug is configured to attach to the lawnmower by one or more attachment points to block a collector opening of the lawnmower. The plurality of ramps comprises a first ramp and a second ramp on the lower plane of the cutting deck extending downward from the mulch plug. The second ramp is positioned further in the cutting rotation of the lawnmower on a trailing edge of the mulch plug. The secure attachment of the mulch plug with a plurality of ramps provides a more even distribution of grass clippings.