Abstract:
A dust and debris evacuator is provided for a cut-off saw. The cut-off saw having a rapidly rotating disk-shaped cutting blade for cutting material and thereby producing and ejecting the dust and debris. The evacuator having a channel to receive the ejected dust and debris, and the channel having a front opening facing the cutting blade. A vacuum cleaner is preferably connected to the evacuator to clear the dust and debris from the channel. In a preferred embodiment, the cut-off saw is pivotally mounted to the evacuator.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/022,150, filed Jan. 19, 2008, which application is hereby incorporated by reference in its entirety. 
     
    
     TECHNICAL FIELD 
       [0002]    The present disclosure relates to dust and debris collection and removal from cutting operations performed by cutting tools. 
       BACKGROUND 
       [0003]    Cut-off saws are widely used in construction industries for cutting through existing structures and materials. Concrete and asphalt floors, roadways, and parking lots are examples of such structures that are modified from time to time by cutting operations. The typical cut-off saw includes a thin disk-shaped rotating saw blade with a perimeter featuring hard cutting surfaces. An internal combustion engine typically powers the rotating saw blade, spinning the blade at high speeds about a rotational axis. As the hard rotating cutting surfaces engage the material to be cut at a cutting location, the material is physically ground and/or pulverized and transformed into dust and/or debris thus eroding the material. The cut-off saw is typically driven into the material perpendicular to the rotational axis of the saw blade. The saw blade thus engages the material along its perimeter at the cutting location and erodes a thin cut along a path that the cut-off saw is driven. The eroded dust and debris typically are ejected by the cut-off saw blade at high speeds and can travel a considerable distance before coming to rest. Much of the dust created by the cut-off saw is fine and forms a dust cloud in surrounding air. Furthermore, the dust cloud is suspended by the air for a considerable amount of time and can drift with air currents before settling. The dust may contaminate a wide indoor and/or outdoor area as it settles. 
         [0004]    In most applications, the cut-off saw leaves material adjacent the cut intact and undamaged making the cut-off saw suitable in remodeling projects. Remodeling projects often require removal of material, such as portions of concrete floors, within an existing building. The dust and debris generated by the cut-off saw contaminates the building interior and typically requires clean-up. In many cases, the dust and debris clean-up can take more time to accomplish than the cutting process. 
         [0005]    The dust generated by the cut-off saw also contaminates close running surfaces of the cut-off saw and eventually plugs an air filter of the internal combustion engine powering the saw. Concrete dust is particularly abrasive and accelerates wear on the close running surfaces of the cut-off saw. In addition, an operator of the cut-off saw is exposed to the dust and can inhale the dust. Furthermore, the dust may irritate the operator&#39;s eyes and may reduce the operator&#39;s visibility. Eye protection, and dust masks can be worn by the operator but also can become covered in dust. 
         [0006]    Injecting water at the cutting location can capture the dust and thus reduce or eliminate airborne dust. The captured dust and water form a slurry which typically must be collected and cleaned-up. The slurry can coat and contaminate a large area and flows downhill and into the cut. In many cases, cleaning the slurry can take more time to accomplish than the cutting process. 
         [0007]    There is a need for a dust collecting device to effectively and conveniently collect dust and debris created by the operation of cut-off saws. The present disclosure satisfies these and other needs. 
       SUMMARY 
       [0008]    One aspect of the present disclosure relates to a dust and debris evacuator for collecting dust and debris created while operating a cut-off saw. In a preferred embodiment, the evacuator is adaptable for pivotally mounting various cut-off saws produced by a number of manufactures. A vacuum cleaner is preferably attached via a vacuum hose to a vacuum port on the evacuator to continuously remove the dust and debris collected by the evacuator. 
         [0009]    Upon selecting a particular cut-off saw and vacuum cleaner for use with the evacuator, an adaptor bracket is selected and installed that matches the cut-off saw and a vacuum port adapter is selected that matches the vacuum cleaner or the vacuum hose. In a preferred embodiment, the adaptor bracket is integrated with a pivot mount that is configured to pivotally mount the particular cut-off saw to the evacuator. 
         [0010]    In a preferred embodiment, the cut-off saw includes a saw blade that rotates downwardly through material being cut. As mentioned above, the saw blade grinds and/or pulverizes the material at high speed and ejects the material rearward as dust and/or fine debris. The evacuator is positioned behind the saw blade and includes a channel with a forward opening at a first end configured to capture and collect the ejected material. The channel is downwardly open over the material being cut and is connected to a passage of the vacuum port. The ejected material typically strikes the channel and thereby looses momentum. Suction created by the vacuum cleaner creates airflow along the channel which entrains the dust and debris. The entrained dust and debris follow the airflow through the passage of the vacuum port and into the vacuum hose and the vacuum cleaner. The dust and debris can be collected and accumulated in the vacuum cleaner and disposed of. 
         [0011]    In a preferred embodiment, the cut-off saw further includes a blade guard covering an upper portion of the saw blade and the evacuator includes a blade guard surround for closely surrounding a rear portion of the blade guard. 
         [0012]    A variety of additional aspects will be set forth in the description that follows. The aspects can relate to individual features and to combinations of features. It is to be understood that both the forgoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the broad concepts upon which the embodiments disclosed herein are based. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]      FIG. 1  is a left elevation view of a cut-off saw assembled to a dust evacuator, the cut-off saw including a saw blade raised above a concrete slab; 
           [0014]      FIG. 2  is a left elevation view of the cut-off saw and the dust evacuator of  FIG. 1 , the cut-off saw rotatably positioned such that the saw blade tangentially contacts the concrete slab; 
           [0015]      FIG. 3  is a right elevation view of the cut-off saw and the dust evacuator of  FIG. 1 , the cut-off saw rotatably positioned such that the saw blade penetrates the concrete slab; 
           [0016]      FIG. 4  is a left elevation view of the cut-off saw and the dust evacuator of  FIG. 1 , the cut-off saw rotatably positioned such that the saw blade penetrates the concrete slab to a greater depth than that of  FIG. 3 ; 
           [0017]      FIG. 5  is a left and top perspective view of the cut-off saw and the dust evacuator of  FIG. 1 , the dust evacuator connected to a vacuum cleaner by a vacuum port adapter and a vacuum hose, the cut-off saw rotatably positioned such that the saw blade penetrates the concrete slab; 
           [0018]      FIG. 6  is a left and front perspective view of the cut-off saw and the dust evacuator of  FIG. 1 , the cut-off saw rotatably positioned such that the saw blade penetrates the concrete slab; 
           [0019]      FIG. 7  is a left, front, and top perspective view of the cut-off saw and the dust evacuator of  FIG. 1 , the cut-off saw including a blade guard and the dust evacuator including a blade guard surround closely surrounding the blade guard; 
           [0020]      FIG. 8  is a front elevation view of the cut-off saw and the dust evacuator of  FIG. 1 , the cut-off saw rotatably positioned as in  FIG. 2 ; 
           [0021]      FIG. 9  is a rear elevation view of the cut-off saw and the dust evacuator of  FIG. 1 , the cut-off saw rotatably positioned as in  FIG. 4 ; 
           [0022]      FIG. 10  is a front elevation view of the cut-off saw and the dust evacuator of  FIG. 1 , the cut-off saw rotatably positioned such that the evacuator is angled upward as the saw blade contacts the concrete slab; 
           [0023]      FIG. 11  is a left, rear, and top perspective view of the dust evacuator of  FIG. 1 ; 
           [0024]      FIG. 12  is a right, front, and bottom perspective view of the dust evacuator of  FIG. 1 ; 
           [0025]      FIG. 13  is a top plan view of the dust evacuator of  FIG. 1 ; 
           [0026]      FIG. 14  is a bottom plan view of the dust evacuator of  FIG. 1 ; 
           [0027]      FIG. 15  is a left elevation view of the dust evacuator of  FIG. 1  further including a vacuum port adapter; 
           [0028]      FIG. 16  is a front elevation view of the dust evacuator of  FIG. 1 ; 
           [0029]      FIG. 17  is a rear elevation view of the dust evacuator of  FIG. 1 ; 
           [0030]      FIG. 18  is an exploded left, rear, and top perspective view of the dust evacuator of  FIG. 1  illustrating a detail of a cut-off saw adapter integrated with a mounting bracket for the cut-off saw; 
           [0031]      FIG. 19  is a partially exploded right, rear, and bottom perspective view of the dust evacuator of  FIG. 1 ; 
           [0032]      FIG. 20  is a front and bottom perspective view of the dust evacuator of  FIG. 1  further including a pair of evacuator side shields; 
           [0033]      FIG. 21  is a left elevation view of the dust evacuator of  FIG. 1  further including the pair of evacuator side shields of  FIG. 20 ; 
           [0034]      FIG. 22  is a left elevation view of the dust evacuator of  FIG. 1  further including the pair of evacuator side shields of  FIG. 20 , the dust evacuator angled upward as in  FIG. 10  and the side shields remaining in contact with the concrete slab; 
           [0035]      FIG. 23  is a left elevation view of a dust evacuator including four wheels connected to a frame; and 
           [0036]      FIG. 24  is a perspective view of another cut-off saw adapter integrated with another mounting bracket for the cut-off saw. 
       
    
    
     DETAILED DESCRIPTION 
       [0037]    The present disclosure relates to cut-off saws and collecting and containing dust and debris created in their operation. As mentioned above, the dust and debris contaminate a large area around the cut-off saw and may form a dust cloud and thereby further contaminate other areas where the dust cloud is carried. In addition, the dust and debris are harmful to the cut-off saw and to its operator and may reduce the visibility of the operator. Collecting and containing the dust and debris largely reduces or eliminates these problems thus providing economic benefits. 
         [0038]    An example cut-off saw  200  is illustrated at  FIGS. 1-10  and generally described above. Other example cut-off saws include models K 650, K 700, K750, K 950, K 960, and K1250 manufactured by Husqvarna of Olathe, Kans.; models DPC 6400, DPC 6401, DPC 6410, DPC 6411, DPC 7300, DPC 7301, DPC 7310, DPC 7311, and DPC 8112 manufactured by Makita of LaMirada, Calif.; models TS 400, TS 410, TS 420, TS 460, TS 700, TS 760, TS 800, and TS 860 manufactured by Stihl of Virginia Beach, Va.; and models BTS 930L3, BTS 935L3, BTS 1030L3, and BTS 1035L3 manufactured by Wacker of Menomonee Falls, Wis. The example cut-off saw  200  at  FIGS. 1-10  is known as a down-cutting cut-off saw and includes a saw blade  210  and a saw blade guard  220 . The “down-cutting” nomenclature refers to a direction  212  of saw blade  210  rotation typically used when the cut-off saw  200  is undertaking a cutting operation as further described below. 
         [0039]    As illustrate at  FIG. 10 , a cut  310  can be initiated on a concrete slab  300  by positioning the cut-off saw  200  such that the saw blade  210  tangentially contacts the concrete slab  300 . The rotational direction  212  and speed of the saw blade  210  erodes the cut  310  into the concrete slab  300  and ejects dust and/or debris  320  rearward. As illustrated at  FIG. 3 , continued operation of the cut-off saw  200  causes the saw blade  210  to penetrate the concrete slab  300  to a depth D B . Upon the depth D B  reaching a desired depth or upon the saw blade  210  cutting through the concrete slab  300 , the cut-off saw  200  can be driven in a forward direction  214  as illustrated at  FIG. 5 . Continued driving in the forward direction  214  results in lengthening the cut  310  and in the continued ejection of dust and/or debris  320 . 
         [0040]    The present disclosure provides a dust and debris evacuator  100  for capturing and containing most, if not all, of the dust and debris  320  generated by the operation of the cut-off saw  200 . The dust and debris evacuator  100  can also provide other valuable functions such as supporting the cut-off saw  200  when in a non-cutting configuration as illustrated at  FIG. 1  (the saw blade  210  is a distance H B  above the concrete slab  300 ). The dust and debris evacuator  100  has numerous embodiments and optional features, several of which are further described below and others which are arrived at by combining the various features and embodiments in different combinations. 
         [0041]    In a preferred embodiment, illustrated at  FIGS. 1-10 , the dust and debris evacuator  100  is positioned behind the saw blade  210  and below an internal combustion engine of the cut-off saw  200 . The dust and debris evacuator  100  includes an evacuator shroud  102  extending from a forward end to a rearward end. In a preferred embodiment, the evacuator shroud  102  is molded of polyurethane. In other embodiments, the evacuator shroud  102  can be made of other materials and include multiple pieces. As illustrated at  FIGS. 6 and 12 , the evacuator shroud  102  includes an evacuator channel  103  that is open facing downward towards the concrete slab  300 . A forward opening  104  from the channel  103  is provided at the forward end of the evacuator shroud  102 . A pair of funneling flaps  106  is optionally connected to the forward opening  104 . Preferably integrated with the funneling flaps  106  is a blade guard surround  130  also known as “heads”. The blade guard surround  130  closely surrounds a portion of the saw blade guard  220  and serves to keep the ejected dust and debris  320  from upwardly escaping. In a preferred embodiment, areas near an outer radius R G  of the saw blade guard  220  substantially seal against the blade guard surround  130 . The blade guard surround  130  is preferably mounted to and/or made of a flexible material such as polyurethane to allow flexible and compliant sealing between the saw blade guard  220  and the blade guard surround  130 . 
         [0042]    The arrangement of the funneling flaps  106 , the blade guard surround  130 , the forward opening  104 , and the channel  103  serves to effectively collect and gather the dust and debris  320  being ejected by the cut-off saw  200  both in a cut initiation configuration, illustrated at  FIG. 10 , and in a sustained cutting configuration, illustrated at  FIGS. 5 and 6 . (A cut may also be initiated in the sustained cutting configuration.) In the sustained cutting configuration, as illustrated at  FIGS. 5 and 6 , the channel  103  is open to and covers a portion of the cut  310  and a bottom  108  of the evacuator shroud  102  at least partially seals against the concrete slab  300 . In the cut initiation configuration, the channel  103  provides a backstop to the ejected dust and debris  320 . A length L H  of the evacuator shroud  102  provides distance for the ejected dust and debris  320  to loose momentum and be collected. In certain embodiments, the length L H  ranges from 1 to 8 times a radius R B  of the saw blade  210 . In a preferred embodiment, the length L H  ranges from 2 to 6 times the radius R B  of the saw blade  210 . In a more preferred embodiment, the length L H  ranges from 3 to 4 times the radius R B  of the saw blade  210 . A width W H  of the evacuator shroud  102  provides space for the ejected dust and debris  320  to diverge from a direction tangential to the saw blade  210  and still be collected. In certain embodiments, the width W H  ranges from 0.2 to 2 times the radius R B  of the saw blade  210 . In a preferred embodiment, the width W H  ranges from 0.5 to 1.5 times the radius R B  of the saw blade  210 . In a more preferred embodiment, the width W H  ranges from 0.75 to 1.25 times the radius R B  of the saw blade  210 . 
         [0043]    Near the rearward end of the evacuator shroud  102  a vacuum port  180  is provided to allow a pneumatic connection between the dust and debris evacuator  100  and a suction port  402  of a vacuum cleaner  400 . The vacuum port  180  includes a vacuum port passage  182  connecting the vacuum port  180  with the channel  103  and also includes one or more connection surfaces  188 . A vacuum port adapter  181 ,  181 ′ and a vacuum hose  410  may additionally be used to pneumatically connect the dust and debris evacuator  100  and the vacuum cleaner  400  (see  FIG. 5 ). Suction, generated by the vacuum cleaner  400 , creates airflow, flowing toward the vacuum cleaner  400 , through the vacuum hose  410 , the vacuum port adapter  181  or  181 ′, the vacuum port passage  182 , and the channel  103 . The airflow along the channel  103  entrains the dust and debris  320 . The entrained dust and debris  320  follow the airflow through the channel  103 , the passage of the vacuum port  182 , the vacuum port adapter  181  or  181 ′, the vacuum hose  410 , and the suction port  402  into the vacuum cleaner  400 . The dust and debris  320  can be collected and accumulated in the vacuum cleaner  400  and disposed of. 
         [0044]    In a preferred embodiment, as illustrated at  FIG. 15 , the vacuum port  180 , as idealized by a centerline  183 , is angled at an angle α above the evacuator shroud bottom  108 . The angle α promotes airflow in a direction advantageous for the entrainment and evacuation of the dust and debris  320 . In certain embodiments, the angle α can range from 0 to 180 degrees. In a preferred embodiment, the angle α can range from 20 to 90 degrees. In a more preferred embodiment, the angle α can range from 30 to 60 degrees. 
         [0045]    In a preferred embodiment of the present disclosure, an adaptor bracket is provided to connect to one of the example cut-off saws mentioned above and another adaptor bracket is provided to connect to another one of the example cut-off saws. Each of the adaptor brackets can individually connect to a mounting bracket of the dust and debris evacuator  100 . By this method, many different models of cut-off saws may be mounted to the same model dust and debris evacuator  100 . In a more preferred embodiment of the present disclosure, an integrated adaptor bracket/mounting bracket  190  (see  FIG. 18 ) is provided to connect to one of the example cut-off saws  200  mentioned above and another integrated adaptor bracket/mounting bracket  190 ′ (see  FIG. 24 ) is provided to connect to another one of the example cut-off saws. Each of the integrated adaptor bracket/mounting bracket  190 ,  190 ′ also includes a pivot mount  110  for pivotally mounting to the dust and debris evacuator  100 . By this method, many different models of cut-off saws may be pivotally mounted to the same model dust and debris evacuator  100 . Features that vary between the integrated adaptor bracket/mounting brackets  190  and  190 ′ may include, for example, the distance between cut-off saw mounting holes D M1  and D M2 . 
         [0046]    In a preferred embodiment, the dust and debris evacuator  100  connects to the mounting bracket that is connected to the adaptor bracket that is connected to one of the example cut-off saws. In a more preferred embodiment, the dust and debris evacuator  100  includes a front support bracket with integrated pivot mount  120 . The front support bracket with integrated pivot mount  120  is pivotally connected to the integrated adaptor bracket/mounting bracket  190 ,  190 ′. A pivot joint is thereby formed between the cut-off saw  200  and the dust and debris evacuator  100  as illustrated at  FIGS. 1-10 . 
         [0047]    The front support bracket with integrated pivot mount  120  can further connect to a pair of wheels  140  as illustrated at  FIG. 18 . The front support bracket with integrated pivot mount  120  in combination with a second support bracket  128  can optionally support a pair of evacuator side shields  160 . 
         [0048]    The evacuator side shields  160  can fit within a gap  164  between the brackets  120 ,  128  and the sides of the dust and debris evacuator  100 . Mounting holes  162  engage slots to retain the side shields  160 . The side shields  160  can slide up and down thereby variably increasing and decreasing the effective depth of the evacuator channel  103 . 
         [0049]    A brush  172  is provided to fill the cut  310 . 
         [0050]    A cut-off saw used with the dust and debris evacuator  100  may be powered by pneumatics, hydraulics, or an electric motor. 
         [0051]    Materials other than concrete may be cut by the cut-off saw and have the dust collected by the dust and debris evacuator  100 . 
         [0052]    A slurry may be evacuated by the dust and debris evacuator  100  and a wet-vac. 
         [0053]    The above specification, examples and data provide a complete description of the manufacture and use of the composition of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.