Notice of Pre-AIA or AIA Status
The present application, filed on or after March 16, 2013, is being examined under the first inventor to file provisions of the AIA .
DETAILED ACTION
Claim Rejections - 35 USC § 102
In the event the determination of the status of the application as subject to AIA 35 U.S.C. 102 and 103 (or as subject to pre-AIA 35 U.S.C. 102 and 103) is incorrect, any correction of the statutory basis for the rejection will not be considered a new ground of rejection if the prior art relied upon, and the rationale supporting the rejection, would be the same under either status.
The following is a quotation of the appropriate paragraphs of 35 U.S.C. 102 that form the basis for the rejections under this section made in this Office action:
A person shall be entitled to a patent unless –
(a)(1) the claimed invention was patented, described in a printed publication, or in public use, on sale or otherwise available to the public before the effective filing date of the claimed invention.
Claim(s) 1 is/are rejected under 35 U.S.C. 102(a)(1) as being anticipated by Harris (4899526).
[AltContent: textbox (Noise reducing different material shroud)][AltContent: arrow][AltContent: arrow][AltContent: textbox (Skirt having a lip)][AltContent: arrow]
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“(3) In conventional rotary lawnmowers, the mower deck generally serves as a frame for the mower with the engine, handle, wheels and other accessories being attached to various portions thereof. Such decks typically include an upper mounting surface to which the engine is mounted. The output shaft of the engine extends through a central opening in the deck so as to enable the mower blade to be operatively secured thereto. The deck normally incorporates a shroud covering the rotating blade which serves to both restrict access to the blade and also to direct the flow of grass clippings to a discharge opening in the side of the deck. A protective shield or a grass catcher can be attached to the deck, covering the discharge opening.”
“(3) As shown, mower deck 10 is specifically designed to be integrally formed as a one piece structure from a suitable polymeric composition such as preferably a high density polyethylene material by means of a blow molding operation. In order to thus form mower deck 10, granules or pellets of the high density polyethylene is extruded to form a hollow, generally cylindrical ribbon. This ribbon is then encased between a pair of suitably contoured heated blow molding dies with one die half having the desired contour to form the top of the deck and the other die half having the desired contour to form the bottom of the deck. The die halves mold the double walls of polyethylene together at 40 around the center opening 12 and at 42 around the discharge opening 22. Air or a suitable pressurized gas is then blown into the mold between the double walls of the ribbon thereby forcing the polyethylene against the mold dies to form the outer contour of the deck. In so doing, a cavity is formed between the walls where they are not joined together. Once the forming operation is complete, the dies are opened and the thus formed mower deck is removed.”
“(4) Thereafter, the cavity is filled with a suitable lightweight filling such as a polyurethane foam. Preferably, the polyurethane foam will be of a type which will adhere or bond to the polyethylene material used to form the mower deck. The foam is injected into the cavity through opening 52 in the bottom of the mower deck and will expand to substantially completely fill the cavity. Once the foam has cured it will become relatively rigid and because it also bonds to the inner surface of the walls refining the cavity, it will serve to substantially increase the rigidity and strength of the resulting mower deck. Additionally, the use of this foam filling will also dampen operational noise producing vibrations thus serving to reduce the overall noise level produced by the mower.”
1. A lawnmower comprising:
a mower deck (10) including a skirt defining a volume bounded by a lip (marked up),
wherein the skirt comprises a first material (taught above);
a plurality of wheels supporting the mower deck;a motive device supported by the mower deck; a cutting implement driven by the motive device; (quoted/taught above) and
a shroud disposed at the lip (marked up),
wherein the shroud comprises a second material having greater sound-reducing characteristics than the first material (quoted/taught above, foam).
Claim(s) 1-20 is/are rejected under 35 U.S.C. 102(a)(1) as being anticipated by Derra et al (WO 2016/025530).
[AltContent: textbox (Lip of the deck skirt)]
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“[000107] Figure 19 is a bottom perspective view illustrating mower deck insert 1220, another example implementation of mower deck insert 420. As with the above described deck inserts, deck insert 1220 is formed from one or more non-metallic materials such as polymers, fiberglass, ceramics, rubbers or the like. Such materials may be in the form of a solid material or layer, a foamed material or layer and/or multiple solid or foamed layers of material laminated to one another. Mower deck insert 1220 is for insertion and mounting to a deck of a mower, within the underside cavity of the deck. In one implementation, mower deck insert 1220 is for mounting within deck 504 shown in Figure 12. In other implementations, mower deck insert 1220 may be mounted within other decks or may be modified for mounting within other decks. [000108] 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.”
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“Figure 23A is a fragmentary sectional view illustrating deck 1404 and deck insert 1420, another implementation of deck insert 1220. Deck 1404 is similar to deck 1304 and deck 504 described above except that deck 1404 comprises at least one opening 1408 extending through the downwardly extending portion 1409 of deck 1404. In the example illustrated, deck 1404 is formed from one or more layers of non-metallic materials such as one or more layers of a polymer, ceramic, fiberglass or composites thereof. In one implementation, portions of the non-metallic layers of material forming deck 1404 encapsulate or in case metal inserts, such as metal insert 1410. In other implementations, inserts 1410 may be omitted or deck 1404 may be formed from a metal material.”
1. A lawnmower comprising:
a mower deck including a skirt defining a volume bounded by a lip, wherein the skirt comprises a first material (metal, par. 96);
a plurality of wheels supporting the mower deck;a motive device supported by the mower deck; a cutting implement driven by the motive device; (fig 9) and
a shroud disposed at the lip (shown above),
wherein the shroud comprises a second material having greater sound-reducing characteristics than the first material (quoted/taught above).
2. The lawnmower of claim 1, wherein the shroud comprises an elastomer (plastics / polymer, quoted text / par. 141), and wherein the shroud covers the lip with an internal segment of the shroud disposed on an inside of the volume and an external segment of the shroud disposed on an outside of the volume (shown/taught above).
3. The lawnmower of claim 1, wherein the shroud comprises a channel, and wherein the lip extends into the channel (marked up).
4. The lawnmower of claim 1, wherein the shroud defines an inner surface canted with respect to a central axis of the motive device, and wherein the canted inner surface is canted away from an opening defined by the lip (see the insert lower portion designed to be canted / curved away).
5. The lawnmower of claim 4, wherein the inner surface has a portion with a convex cross-sectional profile (convex design shape as shown/taught above).
6. The lawnmower of claim 1, wherein the skirt defines a height H, wherein an inner segment of the shroud configured to be disposed within the volume extends along a portion L.sub.1 of the height H, and wherein L.sub.1 is at least 0.3 H (intended range is shown/taught above).
The following are already addressed above, unless otherwise noted:
13. A shroud for a lawnmower to reduce noise emanating from a mower deck of the lawnmower, the shroud comprising:
a body defining a shape corresponding to a shape of the mower deck (shown above or figs 23-24B),
wherein the body comprises:
an inner segment configured to be disposed within a volume of the mower deck; an outer segment configured to be disposed outside the volume; (see cl. 2) and
a channel extending into the body at a location between the inner segment and the outer segment, wherein the channel is shaped to receive a lip of the mower deck (cl. 3).
14. The shroud of claim 13, wherein the body has one or more conforming features that conform to a shape of the mower deck (figs 23-24B).
15. The shroud of claim 14, wherein the one or more conforming features comprise slots configured to receive ribbing of the mower deck (fig 23A, shown/taught above).
16. The shroud of claim 13, wherein the inner segment has an inner surface canted with respect to a central axis of the volume (cl. 4).
17. The shroud of claim 13, wherein the inner segment defines a first length in a direction parallel to a central axis of the volume, wherein the outer segment defines a second length in the direction parallel to the central axis of the volume, and wherein the first and second lengths are different from each other (figs 23, 23A, 24).
“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.”
18. The shroud of claim 13, wherein the shroud is segmental comprising a plurality of discrete segments, and wherein the plurality of segments is used together to fully surround the volume (see quote above).
19. The shroud of claim 13, wherein a cross-sectional profile of the inner segment is different than a cross-sectional profile of the outer segment (shown/taught above, compare figs 23, 23A, 24).
“Insert module 2120 is to be mounted to the underside of deck using mechanical attachment with fasteners, such as screws, bolts, clips, …”
20. The shroud of claim 13, wherein the body further comprises one or more fastener attachment locations at which a fastener is received to couple the shroud to the mower deck (see quote).
The following method steps are already met by the apparatus above, unless otherwise noted:
7. A method of retrofitting a noise reducing component to a lawnmower, the method comprising:
repositioning the lawnmower to permit installation of a shroud at a lip of a skirt of a mower deck of the lawnmower, wherein the shroud is formed from an acoustic-reducing material; aligning at least a portion of a channel of the shroud with a portion of the lip, wherein the lip bounds a volume housing a cutting implement; translating the portion of the shroud towards the lip to engage the portion of the lip in the channel; continuing to translate the shroud towards the lip until the shroud is engaged with the lip around an entire perimeter of the volume; and repositioning the lawnmower to a ready-state orientation for a mowing operation (cl. 1, 3).
8. The method of claim 7, further comprising fastening the shroud to the lip using a fastener, an adhesive, or a mechanical deformation technique (cl. 20).
9. The method of claim 7, wherein aligning the channel of the shroud comprises rotationally aligning the shroud to a correct rotational orientation based on one or more conforming features of the shroud that conform to a shape of a body of the mower deck; and radially aligning the shroud such that the channel is aligned with respect to the lip in a radial direction with respect to the volume (figs 23, 23A, 24).
10. The method of claim 7, wherein translating the portion of the shroud towards the lip is performed such that a first cross-sectional portion of the shroud is disposed inside the volume, a second cross-sectional portion of the shroud is disposed outside the volume, and a third cross-sectional portion of the shroud is disposed between the first and second cross-sectional portions, and wherein translating the portion of the shroud towards the lip is performed until the lip contacts a leading end of the lip (fig 23).
11. The method of claim 7, wherein translating the shroud towards the lip causes the channel to lie flush against an inner sidewall of the skirt (fig 23).
12. The method of claim 7, wherein the shroud has an inner surface canted with respect to a central axis of the volume, and wherein the canted inner surface has a straight cross-sectional profile (cl. 17, fig 23).
Conclusion
The prior art made of record and not relied upon is considered pertinent to applicant's disclosure. See form 892.
Derra et al (2017/0245433) teaches a deck insert (2120) made of material having sound insulating capability, such as polymeric material:
“[0143] 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.
[0144] 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.”
Any inquiry concerning this communication or earlier communications from the examiner should be directed to ARPAD FABIAN-KOVACS whose telephone number is (571) 272-6990. The examiner can normally be reached Mo-Th.
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/ARPAD FABIAN-KOVACS/
Primary Examiner, Art Unit 3671
