Patent Application
20240227241
The present subject matter relates to concrete cutting tools, and particularly concrete cutting saws having a unique cutting enclosure and dust and debris collection system. The present subject matter also relates to methods of cutting and/or forming joints in concrete using the tools and saws described herein.
A disadvantage associated with concrete cutting saws is the large amount of dust and debris resulting from a typical cutting operation. Such dust and debris can be particularly problematic when cutting indoors. Although dust collecting assemblies are known, their use often obscures an operator's view of the cutting area, and particularly blade position.
Recently, a practice gaining popularity in the concrete industry is “green cutting” or “early entry.” This refers to forming cuts or crack control joints in freshly poured concrete and prior to the concrete fully curing. In many green cutting operations, cutting is performed as recently as only several hours after pouring. This practice is beneficial as it enables cutting and forming crack lines to be performed in the same job phase as the concrete pour.
With the advent of green concrete cutting saws, the use of water as a cooling agent to the blade can not be used. This is due to the concrete not being fully cured, and thus additional water would weaken the uncured concrete. As a result, currently known green concrete saws fully enclose the blade to reduce the escape of dust and debris generated from the cutting process. As a consequence, a fully enclosed blade prevents an operator from viewing the blade while cutting.
Related to this is an increased risk of chipping the green concrete which has not yet fully cured or hardened. In order to reduce the potential for chipping, it is important for an operator to be able to view the region of concrete undergoing cutting by a blade. It is also beneficial for the operator to maintain a desired blade position and orientation relative to the cut surface of the concrete during a cutting operation. Improper positioning of the blade can cause chipping or other damage to uncured green concrete.
As a result of the large amount of dust and debris generated from cutting, typically, the blade and particularly the region of concrete undergoing cutting is not visible to an operator. Furthermore, since the blade and cutting region is obscured from view as a result of copious amounts of dust and debris, maintaining blade position and orientation becomes problematic.
In view of these and other concerns, a need exists for an improved cutting tool.
The difficulties and drawbacks associated with previous approaches are addressed in the present subject matter as follows.
In one aspect, the present subject matter provides a concrete saw cutting enclosure and dust collection system comprising a dust enclosure housing defining an interior region and entryway providing access to the interior region. The system also comprises a door releasably secured to the housing and upon securement thereto generally covering the entryway. The system further comprises a rotary cutting blade at least partially disposed within the interior region of the housing. The blade defines an outer face and an oppositely directed inner face. The system additionally comprises at least one baffle positioned within the interior region of the housing and extending along at least one of the inner face and the outer face of the blade. The system also comprises a vacuum port on at least one of the door and the housing providing airflow communication with the interior region of the enclosure. The door defines a blade sight window enabling viewing of a portion of the blade disposed within the interior region of the housing, through the door.
In another aspect, the present subject matter provides a concrete saw cutting enclosure and dust collection system comprising a dust enclosure housing having an interior region. The system also comprises a rotary cutting blade positioned within the interior region of the housing. The system further comprises a door releasably attached to the housing. The door defines a blade sight window for providing viewing of at least a portion of the blade. The system further comprises at least one baffle disposed within the interior region of the housing and alongside the blade. And, the system comprises a vertically positionable skid plate disposed along a lower region of the housing. The skid plate is selectively positionable relative to the blade.
In still another aspect, the present subject matter provides a concrete saw comprising a base unit including at least one wheel. The saw also comprises a handle assembly secured to the base unit. The saw additionally comprises a rotary power source. And, the saw comprises a cutting enclosure and dust collection system including a housing defining an interior region, a door releasably attached to the housing, a rotary cutting blade in operable engagement with the rotary power source, and at least one baffle disposed within the interior region of the housing alongside the blade.
In yet another aspect, the present subject matter provides a method for cutting green concrete. The method comprises providing a concrete saw having a cutting enclosure and dust collection system. The method also comprises positioning the concrete saw such that a blade of the saw is aligned with a line or joint to be cut in the green concrete. The method also comprises actuating the saw so that the blade is rotating at a desired cutting speed. The rotating blade is contacted with the green concrete along the line or joint to be cut. The method also comprises moving the concrete saw along the line to be cut while the rotating blade contacts and cuts the green concrete.
As will be realized, the subject matter described herein is capable of other and different embodiments and its several details are capable of modifications in various respects, all without departing from the claimed subject matter. Accordingly, the drawings and description are to be regarded as illustrative and not restrictive.
The present subject matter provides a wide array of cutting tools that utilize a unique cutting enclosure and dust collection system. The system collects dust and debris from a cutting operation, enables viewing of a cutting operation by a user, and enables desired positioning of a blade and maintaining such position throughout a cutting operation. As described herein, the cutting enclosure and dust collection system is particularly beneficial for concrete saws in green cutting operations. The present subject matter, i.e., the concrete saws and cutting enclosures and dust collection systems described herein, are particularly directed to cutting green concrete. The present subject matter enables an operator to visually monitor and assess cutting while maintaining excellent dust control. The term “green concrete” as used herein refers to concrete that has set but has not hardened completely. Typically, such a state is exhibited by concrete from 1 to 8 hours after a pour, and more particularly from 1 to 3 hours after a pour. The cutting enclosure and dust collection system can be used in nearly any concrete saw having a powered rotary blade that is incorporated in a wheeled base. The cutting tools include one or more handles positioned for an operator typically standing or walking in front or behind the wheeled cutting tool. The cutting tools include provisions for collecting dust and debris resulting from a cutting operation.
The cutting devices and assemblies can be used for cutting an assortment of materials including concrete, masonry materials, and tile, for example. In many versions of the present subject matter, the cutting devices and systems as described herein are particularly adapted for cutting concrete. However, it will be understood that the present subject matter systems and devices are not limited to cutting concrete and instead, include a wide array of other applications and uses.
As noted, the cutting tools and related devices include provisions for collecting dust and debris. One or more dust collection tube(s) or vacuum ports is provided in the system at which a reservoir can be connected. In certain applications, it may be beneficial to attach a vacuum source at the dust collection tube, or in communication therewith, to promote or facilitate such collection of dust and debris. These and other aspects of the present subject matter are described herein and depicted in the referenced drawings.
Rotatably supported within the interior 42 of the housing 40 is a rotary cutting blade 180. Typically, a portion of the blade 180 extends beyond the interior 42 of the housing 40 and is exposed below the housing 40. The cutting blade 180 is engaged with a shaft (not shown) providing rotary power and rotation to the blade 180. Blade mounting hardware 190 secures the blade 180 to the shaft. The blade 180 defines an outer face 182 and an oppositely directed inner face 184. The blade 80 also defines a cutting edge 186, typically having a plurality of cutting teeth. Typically, a diamond cutting blade as known in the art can be used. However, the present subject matter includes other blade types and blade materials.
The system 10 also comprises at least one baffle positioned within the interior 42 of the housing 40 and extending alongside the blade 180. In the particular embodiment illustrated in the referenced figures, the system 10 comprises a plurality of baffles or baffle assemblies, such as a first baffle assembly in the form of an enclosure baffle seat 60 affixed to the housing 40 for supporting an enclosure baffle 90, and a second baffle assembly in the form of a door baffle seat 80 affixed to the door 20 for supporting a door baffle 80. Referring to
The system 10 additionally comprises one or more vacuum ports in airflow communication with the interior 42 of the housing 40. In the embodiment illustrated in the referenced figures, a vacuum port 200 is provided on the door 20. However, it will be understood that one or more vacuum port(s) can be located on the housing 40. It is also contemplated that multiple vacuum ports can be provided on the door 20 and on the enclosure 40.
Referring to
The present subject matter includes a wide array of locations, shapes and/or sizes for the window 30. In many embodiments, the window 30, defined in the door 20, is located such that at least a portion of the outer face 182 and the center of the blade 180 and likely the blade mounting hardware 190 can be viewed by an operator. The window 30 as defined in the door 20 can also extend to allow an outer edge of the blade 180 such as the cutting edge 186, to be visible to the operator. The window 30 can be sized relative to the total surface area of the outer face 182 of the blade 180, such that the area of the window 30 is at least 10%, in other embodiments at least 20%, and in still other embodiments at least 30% of the surface area of the outer face 182 of the blade 180. The present subject matter includes windows having areas less than 10% of the total surface area of a blade face, and greater than 30% of the total surface area of a blade face.
The window 30 can include a transparent or semi-transparent material covering the window 30. A wide array of materials can be used and particularly abrasion-resistant polymeric materials. It is also contemplated that suitable glass and crystalline materials could be used. The present subject matter also includes windows free of a covering material.
The present subject matter also provides particular orientations and positioning of the at least one baffle relative to a rotary cutting blade and to a vacuum port. Referring to
The baffles and baffle assemblies can be formed from a wide array of materials. In many embodiments, the baffles and baffle assemblies are formed from steel and can be coated with abrasion-resistant materials, such as a ceramic powder coating. In one version, the baffle seats are formed from steel and the baffles retained thereon are formed from a suitable polymeric material such as an acrylic material. In this version, the polymeric baffles can be replaced and provide less costly maintenance than periodically replacing an entire steel baffle assembly.
In particular versions, the concrete saw cutting enclosure and dust collection system also comprises a skid plate and particularly a biased skid plate assembly 100. The biased skid plate assembly 100 generally includes a skid plate 104 disposed along a lower region of the housing 40 and the door 20. The skid plate 104 defines a blade slot 106 through which the rotary blade 180 extends. The blade slot 106 typically extends along a longitudinal axis of the skid plate 104. The skid plate 104 is vertically positionable relative to the blade 180 and is retained along the lowermost region of the housing 40 and door 20 by a first support member 130 at one end of the housing 40, and a second support member 140 at another end of the housing 40. Vertical positioning assemblies of adjusters, biasing members, and stops associated with each of the support members provide for vertical positioning of the skid plate 104 relative to the housing 40 and the blade 180 rotatably supported therein. Specifically, referring to
The handle assembly 320 defines a distal end 322 typically having one or more grips or laterally extending members 324 for an operator to grasp, and an opposite proximal end 326 hingedly or movably affixed to the wheeled base 310. A pivoting handle base assembly 330 provides selective and adjustable positioning of the handle 320 relative to the wheeled base 310. In many embodiments, the pivoting handle base assembly 330 enables the handle 320 to be positioned toward a rear of the saw 300 up to 45° from vertical. And, in particular versions, the pivoting handle base assembly 330 enables the handle 320 to be positioned toward a front of the saw 300 up to 45° from vertical. In addition to enabling such positions for the handle 320, the pivoting handle base assembly 330 also enables selective securement or “locking” of the handle 320 in a desired angular position relative to the wheeled base 310. These features promote operator ease of use and enable an operator to stand or walk behind or in front of the cutting system during use. In many versions of the concrete saw 300, the handle assembly 320 includes a controller 340 having a power input, a power output, and one or more switches for controlling electrical power to the output. The concrete saw 300 can also comprise additional provisions such as but not limited to tracking provisions for promoting or assisting in maintaining a desired cut path. Blade speed control provisions can be included. In many cutting operations the blade rotates at a cutting speed within a range of from about 1,000 to about 6,000 RPM. Thus, it will be appreciated that the present subject matter is not limited to the particular embodiments described herein, and instead includes a variety of other configurations.
In many embodiments of the present subject matter, the concrete saw includes one or more vacuum system(s) 360 which are configured to collect such dust and debris which are generated or emitted from the cutting area, i.e., the interface between the cutting tool blade and surface or substrate being cut. In such embodiments, a collection hose extends between the vacuum port 200 of the system 10 and the vacuum system 360.
During operation of a concrete saw using the cutting enclosure and dust collection system 10, the saw can be operated such that the blade 180 rotates in an “up-cut” or a “down-cut.” In an up-cut blade rotation, a leading edge of a rotating blade pushes or otherwise displaces concrete material upward to a surface of the concrete, at which the skid plate smooths or “trowels” the surface. In some applications, this practice may be undesirable since the cut appears smooth, however the concrete aggregate is disturbed. A down-cut refers to an opposite direction of blade rotation and in some applications may be preferred because the potential for disturbing the concrete aggregate is reduced. The present subject matter includes both configurations and methods of green cutting.
The present subject matter also provides methods of cutting concrete and/or forming joints or recesses within concrete, and particularly green concrete. In a preferred method, a concrete saw including a cutting enclosure and dust collection system as described herein is provided. The concrete saw is positioned relative to the concrete and particularly such that the blade is aligned with a line or path to be cut in the concrete. The saw is activated so that the blade is rotating at a desired cutting speed. The rotating blade is then contacted with the concrete and particularly with the line to be cut therein. The saw is then moved or otherwise displaced along the line to be cut while the rotating blade contacts and cuts the concrete. Prior to and during cutting, an operator can view the blade through a blade sight window provided in the cutting enclosure and dust collection system. Providing visual confirmation and/or inspection of a cutting operation is highly beneficial and improves cut quality and consistency.
Many other benefits will no doubt become apparent from future application and development of this technology.
The present subject matter includes all operable combinations of features and aspects described herein. Thus, for example if one feature is described in association with an embodiment and another feature is described in association with another embodiment, it will be understood that the present subject matter includes embodiments having a combination of these features.
As described hereinabove, the present subject matter solves many problems associated with previous strategies, systems and/or devices. However, it will be appreciated that various changes in the details, materials and arrangements of components, which have been herein described and illustrated in order to explain the nature of the present subject matter, may be made by those skilled in the art without departing from the principle and scope of the claimed subject matter, as described herein.
| Number | Date | Country | |
|---|---|---|---|
| 20240131749 A1 | Apr 2024 | US |
| Number | Date | Country | |
|---|---|---|---|
| 63418656 | Oct 2022 | US |
