Electro-mechanical interlock and module system for lawn mower or other electrical device

An electrically powered device having an electric motor, a housing for said electric motor, a power circuit including a rechargeable battery for providing electrical power to the motor and an electrical connector adapted for connection to an external source of electrical current for charging the battery, and an interlock system comprising:

• an interlock switch connected in said power circuit and having an actuator for controlling the state of said interlock switch, said interlock switch having a first normal state for disabling said power circuit and a second state for enabling said power circuit;
• support and alignment means for positioning said interlock switch within said housing adjacent a specially configured first opening in such housing such that the actuator of said interlock switch is aligned with said first opening, including a support bracket having mounting means for mounting said interlock switch in a predetermined position on said support bracket and alignment means for fixing the position of said support bracket relative to said housing;
• and
• a key member configured for insertion into said first opening in said housing and including actuating for engaging said actuator of said interlock switch and causing said interlock switch to switch from said first state to said second state to thereby enable said power circuit when said key member is fully inserted into said first opening in said housing and further including means for blocking access to said electrical connector when said key member is fully inserted into said first opening in said housing to thereby prevent said battery from being charged when said interlock switch is in said second state.

An interlock system for an electrically powered device having an electric motor, a housing for said electric motor, a power circuit including a rechargeable battery for providing electrical power to the motor and an electrical connector adapted for connection to an external source of electrical current for charging the battery, and a first manually operable electric switch connected in said power circuit and having ON and OFF positions for controlling the application of electrical power to the motor, comprising:

• an interlock switch connected in said power circuit and having an actuator for controlling the state of said interlock switch;
• said interlock switch having a first normal state for disabling said power circuit and a second state for enabling said power circuit, such that when said interlock switch is in said first state the electric motor cannot be energized by said power circuit regardless of the position of said first electric switch, and when said interlock switch is in said second state the electric motor is energizable by said power circuit in accordance with the position of said first electric switch;
• means for mounting said interlock switch within said housing adjacent a specially configured opening in such housing such that the actuator of said interlock switch is accessible through said opening;
• and
• a key member configured for insertion into said opening in said housing and including actuating means for engaging said actuating of said interlock switch and causing said interlock switch to switch from said first state to said second state to thereby enable said power circuit and further including means for blocking access to said electrical connector when said key member is fully inserted into said opening in said housing to thereby prevent said battery from being charged when said interlock switch is in said second state.

A cordless, electric lawn mower comprising a mower deck, an electric motor mounted to the mower deck for rotatably driving a cutting blade located beneath the mower deck, a rechargeable battery for providing electrical power to the motor, a handle connected to the mower deck, a shroud covering the motor and battery, a power circuit for providing electrical power to the motor, a manually operable electric switch mounted to the handle and connected in said power circuit and having ON and OFF positions for controlling the application of electrical power to the motor, an electrical connector adapted for connection to an external source of electrical current for charging the battery, and an interlock system for controlling the enabling of said power circuit, including

• an interlock switch connected in said power circuit and having an actuator for controlling the state of said interlock switch;
• said interlock switch having a first normal state for disabling said power circuit and a second state for enabling said power circuit, such that when said interlock switch is in said first state the electric motor cannot be energized by said power circuit regardless of the position of said handle mounted switch, and when said interlock switch is in said second state the electric motor is energizable by said power circuit in accordance with the position of said handle mounted switch;
• means for mounting said interlock switch within said shroud adjacent a specially configured first opening in said shroud such that the actuator of said interlock switch is accessible through said first opening, including a bracket member having mounting means for mounting said interlock switch in a predetermined position thereon and alignment means for coupling said bracket member to said shroud to fix the position of said bracket member relative to said shroud;
• and
• a key member having a stem portion configured for insertion into said first opening in said shroud and including actuating means on said stem portion for engaging said actuator of said interlock switch and causing said interlock switch to switch from said first state to said second state to thereby enable said power circuit when said key member is fully inserted into said first opening in said shroud, and further including means for blocking access to said electrical connector when said key member is fully inserted into said first opening in said shroud to thereby prevent the battery from being charged when said power circuit is enabled.