Microtrencher having an improved vacuum system and method of microtrenching

A microtrencher having a vacuum system configured to clean spoil from a microtrench having a side shroud and a suction nozzle. A method of using the microtrencher to cut a microtrench in a roadway and using the vacuum system to clean spoil from the roadway and microtrench.

FIELD OF THE INVENTION

The invention generally relates to a microtrencher having an improved vacuum system and a method of microtrenching using the improved vacuum system.

BACKGROUND OF THE INVENTION

The microtrencher saw usually creates a pile of spoil (dirt, asphalt, concrete, etc.) alongside the formed microtrench and the microtrench must be carefully cleaned before laying the cable in the trench. The pile of spoil must then be removed. A fill, also referred to as cement or grout, is inserted into the trench on top of the cable or innerduct/microduct.

Industrial vacuum trailers have been used to remove the piled up spoil. However, the industrial vacuum trailers are slow, inefficient and do not provide a clean microtrench, especially when creating a microtrench more than 16 inches deep.

Installing new optical fiber networks in a city is expensive and time consuming. Many installations require a far deeper microtrench to provide enhanced protection, such as more than 16 inches deep, and often up to 26 inches deep. When cutting a deep microtrench, cleaning spoil from the microtrench is far more difficult. There is a great need for faster and less expensive installation of optical fiber networks.

SUMMARY OF THE INVENTION

The above objectives and other objectives can be obtained by a microtrencher having an improved vacuum system configured for continuously cutting a microtrench in a roadway and cleaning spoil from the microtrench comprising:a motorized vehicle;a side-discharge cutting wheel connected to the vehicle and being configured to continuously cut through a roadway to create a microtrench in the roadway and deposit spoil removed from the microtrench along at least one side of the microtrench;a cutting wheel shroud covering at least a portion of the side-discharge cutting wheel;a vacuum device comprising a storage container configured to contain spoil vacuumed from a microtrench; anda first side shroud disposed on at least one side of the cutting wheel shroud, the first side shroud being connected to the vacuum device and being configured to vacuum the spoil from the at least one side of the microtrench to the storage container.

The above objectives and other objectives can also be obtained a method of cutting a microtrench in a roadway comprising a method of continuously cutting a microtrench in a roadway comprising:providing a microtrencher comprising;a motorized vehicle;a side-discharge cutting wheel connected to the vehicle and being configured to continuously cut through a roadway to create a microtrench in the roadway and deposit spoil removed from the microtrench along at least one side of the microtrench;a cutting wheel shroud covering at least a portion of the side-discharge cutting wheel;a vacuum device comprising a storage container configured to contain spoil vacuumed from a microtrench; anda first side shroud disposed on at least one side of the cutting wheel shroud, the first side shroud being connected to the vacuum device and being configured to vacuum the spoil from the at least one side of the microtrench to the storage container;cutting the microtrench in the roadway with side-discharge cutting wheel;depositing the spoil from the microtrench on at least one side the microtrench; andvacuuming the spoil through the first side shroud and into the storage container.

DETAILED DESCRIPTION OF THE INVENTION

In the following description, for purposes of explanation and not limitation, specific details are set forth, such as particular networks, communication systems, computers, terminals, devices, components, techniques, data and network protocols, software products and systems, operating systems, development interfaces, hardware, etc. in order to provide a thorough understanding of the present invention with reference to the attached non-limiting figures.

However, it will be apparent to one skilled in the art that the present invention may be practiced in other embodiments that depart from these specific details. Detailed descriptions of well-known networks, communication systems, computers, terminals, devices, components, techniques, data and network protocols, software products and systems, operating systems, development interfaces, and hardware are omitted so as not to obscure the description.

During installation of the optical fiber, a microtrench is cut in a roadway, the optical fiber and/or innerduct/microduct is laid in the microtrench and then a fill and sealant are applied over the optical fiber and/or innerduct/microduct to protect them from the environment. Microtrenchers, other devices used in microtrenching, and methods of microtrenching that can be utilized in the present invention include the devices and methods described in my previous U.S. patent publication Nos. 20190226603, 20190086002, 20180292027, 20180156357, and 20180106015, the complete disclosures of which are incorporated in their entirety herein by reference.

Any suitable microtrencher2can be utilized in the present invention. Non-limiting examples of suitable micro trenchers include those made and sold by Ditch Witch, Vermeer, and Marais. A Vermeer RTX 1250 tractor can be used as the motorized vehicle for the microtrencher2. A microtrencher2is a “small rock wheel” specially designed for work in rural or urban areas. The microtrencher2is fitted with a cutting wheel10that cuts a microtrench11with smaller dimensions than can be achieved with conventional trench digging equipment. Microtrench11widths usually range from about 6 mm to 130 mm (¼ to 5 inches) with a depth of 750 mm (about 30 inches) or less. Other widths and depths can be used as desired.

With a microtrencher2, the structure of the road, sidewalk, driveway, or path is maintained and there is no associated damage to the road. Owing to the reduced microtrench11size, the volume of waste material (spoil12) excavated is also reduced. Microtrenchers2are used to minimize traffic or pedestrian disturbance during cable laying. A microtrencher2can work on sidewalks or in narrow streets of cities, and can cut harder ground than a chain trencher, including cutting through for example but not limited to solid stone, concrete, and asphalt. The term ground as used herein includes, son, asphalt, stone, concrete, grass, dirt, sand, brick, cobblestone, or any other material the trench11is cut into and the optical fiber buried within.

Vermeer discloses on its website www.vermeer.com that “Microtrenching is an installation method in which a narrow and relatively shallow trench is cut, typically on one side of an asphalt roadway. Trench dimensions range from 0.75″-2.25″ (19.1 mm-57.2 mm) wide and 8″-16″ (20.3 cm-40.6 cm) deep. While cutting, a vacuum system connected to the cutter wheel attachment cleanly diverts and transports the dry and dusty spoil away from the worksite. Once the conduit pipe is laid, the trench is backfilled with a grout compound.” However, while attaching conventional vacuum systems to the cutter wheel attachment may work satisfactory for depths up to 16 inches, Vermeer's systems are not capable of adequately removing spoil from deeper microtrenches.

Vermeer has not solved the problems with quickly and efficiently removing the spoil from the roadway and a microtrench having a depth more than 16 inches. Additional crew members and equipment are currently required and used to clean up the spoil and ensure no spoil remains in the microtrench. This problem is further exacerbated by the increased speed of microtrenching achieved by my novel methods of microtrenching.

To solve this problem, I used a side-discharge cutting wheel10having a size sufficient to cut a microtrench11deeper than 16 inches. For example, I have cut a microtrench11up to 26 inches deep, and the depth can be deeper as required for the particular application. The term “side-discharge cutting wheel10” includes any microtrench cutting wheel configured to deposit the spoil12to a side or both sides of the cut microtrench11, examples of which are conical and diamond cutting wheels.

FIGS. 1-9show an exemplary embodiment of the present invention. A microtrencher2is used to cut a microtrench11. The microtrencher2has a cutting wheel shroud20covering at least a portion of the side-discharge cutting wheel10. The side-discharge cutting wheel10deposits spoil12to the side of the microtrench11. A side shroud22is connected to a source of vacuum and is configured to vacuum up the spoil12. The side shroud22can be connected to the cutting wheel shroud20that covers at least a portion of the side-discharge cutting wheel10. The side shroud22can be connected to the cutting wheel shroud20by a shroud positioner44which can adjust the position of the side shroud22in relation to the cutting wheel shroud22, preferably in all directions, up, down, left or right. For example, the shroud positioner44can include a spring loaded mechanism similar to a shock absorber that forces the side shroud22to ride snugly or biased against the roadway surface.

The side shroud22can have any desired size and shape, depending upon the size and shape of the cutting wheel shroud20. For example, the side shroud can have a width W of 6 to 30 inches, a height H of 6 to 30 inches and a length L of 6 to 30 inches. The side shroud22can be formed of any desired material, such as metal, plastic or composites. Side shrouds22can be mounted on both sides of the cutting wheel shroud20. The side shroud22has a vacuum attachment30for connection to the source of vacuum. The side shroud22defines a chamber having an opening for the spoil12to enter. A flap40can be provided on one or both sides of the opening to guide the spoil12into the chamber. The flap40can be adjustable to open or close to provide a wider or narrower path for the spoil12to enter the opening. The spoil12in the chamber is sucked into the vacuum attachment30. The side shroud22can be on wheels28so that the side shroud22can glide along the roadway surface during use. The sides of the side shroud22can be provided with roadway seals42to at least partially seal the side shroud22to the roadway surface during use and increase the flow of air into the opening of the side shroud22during use. The front of the side shroud22can have ski like tips on the flaps40or the walls of the side shroud22allowing the side shroud22to glide over rocks, debris or uneven surfaces of the roadway.

A suction nozzle24is configured to be inserted into the microtrench11to vacuum out any remaining soil12. The suction nozzle24has an opening26at a bottom end to suck spoil12from the microtrench and a nozzle vacuum attachment30at an opposing end. The suction nozzle24is elongated and has a central hollow chamber. The length of the nozzle24can be any desired length, such as up to 30 inches. The width of the nozzle24should be sized to fit within the microtrench11, such as less than 5 inches. The suction nozzle24can be on wheels28and be depth adjustable to adjust how far the suction nozzle24is inserted into the microtrench11.

The source of vacuum can be any desired vacuum device130, such as those made by SCAG Giant Vac., DR Power, Vermeer, and Billy Goat. A preferred source of vacuum is a Guzzler vacuum truck, www.guzzler.com. The Guzzler type vacuum truck124has a large storage container104for holding spoil12and a vacuum device130for creating a vacuum in the storage container104. The storage container104is sized to hold spoil12created by the side-discharge cutting wheel10cutting a microtrench11in the roadway15. The vacuum device130has an inlet111that can be connected to the side shroud(s)22, cutting wheel shroud20and the suction nozzle24. The Guzzler vacuum truck can provide sufficient vacuum to the side shrouds22, suction nozzle24and the cutting wheel shroud20so that the speed of microtrenching can be greatly increased and still provide a clean microtrench11. Furthermore, the large storage container104provides a long running time for the microtrencher2before having to be emptied. WhileFIG. 1shows use of the truck124, the truck124can be replaced with any suitable vacuum device130.

FIG. 10illustrates another embodiment of the invention. The vacuum truck124can be provided with a vacuum head attachment50having optional wheels28. The vacuum head attachment50can be rotated or moved as desired to vacuum up the spoil12. The vacuum head attachment50can be used alone or in combination with the side shroud22and/or suction nozzle24.FIGS. 11-14show different vacuum head attachments50having a vacuum attachment60for attaching the vacuum head attachment50to a source of vacuum. The suction nozzle64operates in the same way as the suction nozzle24.

FIG. 11shows a vacuum head attachment50have two side shrouds52and54which are configured to vacuum up spoil12from both sides of the microtrench11.FIG. 12shows a vacuum head attachment50have two side shrouds52and54which are configured to vacuum up spoil12from both sides of the microtrench11and a suction nozzle64to vacuum up spoil12from the microtrench11.FIG. 13illustrates a vacuum head attachment50have a large opening to vacuum spoil12from both sides of the microtrench11and an area over the microtrench11.FIG. 14illustrates a vacuum head attachment50have a large opening to vacuum spoil12from both sides of the microtrench11and an area over the microtrench11, and also a suction nozzle64to vacuum up spoil12from the microtrench11. The vacuum attachment60can be attached to a vacuum device130to provide a vacuum to the vacuum head attachment50. The vacuum head attachment50can be sized for the particular application as desired. For example, inFIGS. 11 and 12, the width W of each of the openings can be from 6-30 inches when sized for vacuuming each side of the microtrench11separately. InFIGS. 13 and 14, when vacuuming both sides of the microtrench11and the area over the microtrench11simultaneously, for example, the width2can be from 12-60 inches. The length L can be, for example, 6 to 30 inches, or any size as desired. The height H can be any desired height.

FIG. 17shows the vacuum head attachment50attached to a push cart70that can be pushed by a user. The push cart can have a body65, a push handle67connected to the body, and wheels28connected to the body.FIG. 18shows the vacuum head attachment50attached to a vacuum device130that can be pushed or self-powered walk behind by a user, such as such as those made by SCAG Giant Vac., DR Power, Vermeer, and Billy Goat.

Street sweepers are now well-known in the art and, thus, the conventional structures of a street sweeper will not be discussed herein, including the vehicle having a motor, wheels, frame, etc., and how the street sweeper operates.FIGS. 19-21illustrate a modified street sweeper198having a rotating brush200for sweeping spoil12from the roadway15surrounding the microtrench11. A microtrench guide202is attached to the street sweeper198to keep the rotating brush200aligned with the microtrench11. The microtrench guide202can an adjustable width for use with different microtrench11widths. The microtrench guide202can be sized as desired. For example, the width can be about 0.5 to about 5 inches and the length can be from about 0.5 inch to about 12 inches. The microtrench guide202can also include a microtrench seal204that prevents spoil12from falling back into the microtrench11during sweeping with the rotating brush200. The microtrench seal204can be sized as desired. The microtrench seal204can have an adjustable width. For example, the width can be from about 1 to about 12 inches and the length from about 1 inch to about 3 feet. A vacuum attachment206can attached to the shroud201at least partially surrounding the rotating brush200to provide a vacuum inside the street sweeper198and vacuum spoil12swept up by the rotating brush200.

My invention provides numerous advantages over the previous methods. Additional crew and equipment are no longer necessary to clean the microtrench11. During use of the improved vacuum system, the microtrencher2can now continuously cut a microtrench11while efficiently and quickly removing the spoil12from the roadway15and microtrench12using the side shrouds22and the suction nozzle24and the spoil collected in the storage container104, all without the use of additional road crew and machinery. The improved vacuum system results in significantly faster microtrenching speeds and far less disruption to traffic.

To facilitate an understanding of the principles and features of the various embodiments of the present invention, various illustrative embodiments are explained below. Although example embodiments of the present invention are explained in detail, it is to be understood that other embodiments are contemplated. Accordingly, it is not intended that the present invention is limited in its scope to the details of construction and arrangement of components set forth in the following description or examples. The present invention is capable of other embodiments and of being practiced or carried out in various ways.

As used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural references unless the context clearly dictates otherwise. For example, reference to a component is intended also to include composition of a plurality of components. References to a composition containing “a” constituent is intended to include other constituents in addition to the one named.

Also, in describing the example embodiments, terminology will be resorted to for the sake of clarity. It is intended that each term contemplates its broadest meaning as understood by those skilled in the art and includes all technical equivalents that operate in a similar manner to accomplish a similar purpose.

It is also to be understood that the mention of one or more method steps does not preclude the presence of additional method steps or intervening method steps between those steps expressly identified. Similarly, it is also to be understood that the mention of one or more components in a composition does not preclude the presence of additional components than those expressly identified. Such other components or steps not described herein can include, but are not limited to, for example, similar components or steps that are developed after development of the disclosed technology.

It is to be understood that the foregoing illustrative embodiments have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the invention. Words used herein are words of description and illustration, rather than words of limitation. In addition, the advantages and objectives described herein may not be realized by each and every embodiment practicing the present invention. Further, although the invention has been described herein with reference to particular structure, materials and/or embodiments, the invention is not intended to be limited to the particulars disclosed herein. Rather, the invention extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims. Those skilled in the art, having the benefit of the teachings of this specification, may affect numerous modifications thereto and changes may be made without departing from the scope and spirit of the invention.