LAYBOX FOR MICROTENCHING AND METHOD OF MICROTRENCHING USING THE LAYBOX

Abstract

A laybox having a body formed from opposing first and second elongated sheets of steel defining an elongated chamber between them, a front end of the body configured to face a microtrencher cutting blade and a back end of the body opposing the first end; a microtrench plug installer; a cable guide disposed in the elongated chamber configured to guide an optical fiber cable and/or microduct/innerduct through the chamber, and a microtrench plug installer. A method of cutting a microtrench and installing optical fiber cable and/or innerduct/microduct in the microtrench and securing the optical fiber cable and/or innerduct/microduct with a microtrench plug.

Description

FIELD OF THE INVENTION

The invention generally relates to a laybox for use in microtrenching and a method of microtrenching using the laybox to install optical fiber cable and/or microduct/innerduct in a microtrench. A microtrench plug is utilized to secure optical fiber cable and/or microduct/innerduct in a microtrench.

BACKGROUND OF THE INVENTION

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. Methods of microtrenching that can be utilized in the present invention include the methods described in my previous U.S. Pat. Nos. 10,641,414; 10,571,047; 10,571,045; 10,781,942; 10,808,379; 10,808,377 and U.S. patent publication Nos. 20180292027; 20180156357, and 20180106015, the complete disclosures of which are incorporated in their entirety herein by reference.

Installing optical fiber in a microtrench often has problems with the optical fiber cable and/or microduct/innerduct in a microtrench bowing up from the bottom of the microtrench and/or rising up from the bottom of the microtrench during filling the microtrench with a fill.

Installing optical fiber in a microtrench often has problems with the microtrench side walls caving in when the microtrench is formed in soft dirt, sand or gravel below the hard roadway (asphalt or cement), along a side the hard roadway or in a soft roadway such as a dirt or gravel roadway.

SUMMARY OF THE INVENTION

An objective of the invention is to provide a solution to the problem of sidewalls of a microtrench caving in.

Another objective of the invention is to provide a solution to the problem of the optical fiber and/or innerduct/microduct bowing up from the bottom of the microtrench before or during filling of the microtrench.

The objectives of the invention and other objectives are obtained by a laybox configured for installing optical fiber cable in a microtrench comprising:

• • a body comprising opposing first and second elongated sheets of steel defining an elongated chamber between them, the body having a thickness configured to fit within a microtrench, and a front end of the body configured to face a microtrencher cutting blade and a back end of the body opposing the first end;
  • a cable guide disposed in the elongated chamber configured to guide an optical fiber cable and/or microduct/innerduct through the chamber; and
  • a microtrench plug installer configured to install a microtrench plug into the microtrench above the optical fiber and/or innerduct/microduct to secure the optical fiber and/or innerduct/microduct in the microtrench and reduce bowing of the optical fiber and/or innerduct/microduct up from a bottom of the microtrench.

The objectives of the invention and other objectives are also obtained by a method of microtrenching comprising:

• • cutting a microtrench in a roadway with a microtrencher and depositing spoil from the microtrench on one side of the microtrench;
  • moving a laybox in the microtrench behind the microtrencher in a direction the microtrencher is travelling, the laybox comprising opposing first and second elongated sheets of steel defining an elongated chamber between them and a cable guide in the elongated chamber;
  • flowing an optical fiber cable and/or innerduct/microduct through the chamber and cable guide so that the optical fiber cable and/or innerduct/microduct is laying in the microtrench;
  • using a microtrench plug installer to install a microtrench plug above the optical fiber cable and/or microduct/innerduct to secure the optical fiber cable and/or microduct/innerduct in the microtrench and reduce bowing of the optical fiber and/or innerduct/microduct up from a bottom of the microtrench;
  • pushing the spoil into the microtrench using a spoil diverter; and
  • compressing the spoil in the microtrench.

The objectives of the invention and other objectives can also be obtained by a method of microtrenching comprising:

• • cutting a microtrench in a roadway comprising asphalt or cement with a microtrencher;
  • vacuuming spoil from the microtrench using a vacuum device;
  • moving a laybox in the microtrench behind the microtrencher in a direction the microtrencher is travelling, the laybox comprising opposing first and second elongated sheets of steel defining an elongated chamber between them and a cable guide in the elongated chamber;
  • flowing an optical fiber cable and/or innerduct/microduct through the chamber and cable guide so that the optical fiber cable and/or innerduct/microduct is laying in the microtrench;
  • using a microtrench plug installer to install a microtrench plug above the optical fiber cable and/or microduct/innerduct to secure the optical fiber cable and/or microduct/innerduct in the microtrench and reduce bowing of the optical fiber and/or innerduct/microduct up from a bottom of the microtrench; and
  • flowing a fill from a fill device to a fill conduit in the laybox so that the fill flows through the fill conduit and into the microtrench to seal the microtrench and protect the optical fiber cable and/or innerduct/microduct.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a view of a first embodiment of a laybox connected to a microtrencher.

FIG. 2 illustrates a side view of a laybox.

FIG. 3 illustrates a top view of a laybox.

FIG. 4 illustrates a view of a second embodiment of a laybox connected to a microtrencher, a vacuum device and a fill device.

FIG. 5 illustrates a side view of the second embodiment of a laybox.

FIG. 6 illustrates a top view of the second embodiment of a laybox.

FIG. 7A [Prior Art] illustrates a conventional optical fiber or innerduct/microduct bowing off the bottom of the microtrench.

FIG. 7B illustrates the use of microtrench plugs to reduce bowing of the optical fiber or innerduct/microduct.

FIG. 7C illustrates a foam microtrench plug.

FIG. 7D illustrates a spring microtrench plug.

FIG. 7E illustrates a compression microtrench plug.

FIG. 7F illustrates a compression microtrench plug.

FIG. 7G illustrates a compression microtrench plug.

FIG. 7H illustrates a compression microtrench plug.

FIG. 7I illustrates a compression microtrench plug.

FIG. 8A illustrates a compression plug installation device installed in the laybox.

FIG. 8B illustrates a foam plug installation device installed in the laybox.

FIG. 8C illustrates a cutter continuous compression plug installation device installed in the laybox.

FIG. 8D illustrates a spring plug installation device installed in the laybox.

FIG. 9A illustrates a compression plug installation device installed in the laybox.

FIG. 9B illustrates a foam plug installation device installed in the laybox.

FIG. 9C illustrates a cutter continuous compression plug installation device installed in the laybox.

FIG. 9D illustrates a spring plug installation device installed in the laybox.

FIG. 10A illustrates a cutting and pushing wheel.

FIG. 10B illustrates a cutter.

FIG. 10C illustrates the cutting and pushing wheel mounted on a side wall.

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 cable, a microtrencher is used to cut a microtrench in the roadway, optical fiber cable and/or innerduct/microduct is then laid in the microtrench, and then the microtrench is filled with a fill and sealant over the optical fiber cable and/or innerduct/microduct to protect them from the environment. The present method utilizes a motorized vehicle, a microtrencher, and a laybox to install the optical fiber cable within the microtrench.

Microtrenchers, other devices used in microtrenching, fills, 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 microtrencher 2 can be utilized in the present invention. Non-limiting examples of suitable microtrenchers 2 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 microtrencher 2. A microtrencher 2 is a “small rock wheel” specially designed for work in rural or urban areas. The microtrencher 2 is fitted with a cutting wheel 10 that cuts a microtrench 11 with smaller dimensions than can be achieved with conventional trench digging equipment. Microtrench 11 widths 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 microtrencher 2, the structure of the road, sidewalk, driveway, or path is maintained and there is no associated damage to the road. Owing to the reduced microtrench 11 size, the volume of waste material (spoil 12) excavated is also reduced. Microtrenchers 2 are used to minimize traffic or pedestrian disturbance during cable laying. A microtrencher 2 can 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 hard surfaces solid stone, concrete, and asphalt. Softer surfaces include, soil, grass, dirt, sand, and gravel.

In a first embodiment, an example of which is shown in FIGS. 1-3, a side-discharge cutting wheel 10 is utilized, which deposits spoil 12 to one side of the microtrench, as shown in FIG. 2. The first embodiment is usually used for softer surfaces 70, such as dirt roads, gravel roads, and the soft sides of a hard (asphalt or cement) roadway 77. The term “side-discharge cutting wheel 10” includes any microtrench cutting wheel configured to deposit the spoil 12 to a side of the cut microtrench 11, examples of which are conical and diamond cutting wheels.

The laybox 3 can be formed by two opposing side walls 6 defining a elongated chamber 8 therebetween. The chamber 8 defined by the side walls 6 should be sized so that the optical fiber cable and/or innerduct/microduct 121 can flow into and through the chamber 8 during use. Examples of suitable chamber 8 widths are from 0.5 to 10 inches, more preferably from 1 to 4 inches in width between the interior surfaces of the opposing side walls 6. The side walls 6 are preferably formed from sheets of steel. Examples of suitable thickness of a side wall 6 formed from a steel sheet is 0.1 to 1.5 inches, preferably 0.1 to 1 inches. The length of the of the wall 6 can be as desired for the particular application. In general, the longer the length of the wall 6, the greater the radius of any turns with the laybox 3 inside the microtrench 11. When turning, the laybox 3 may have to be removed from the microtrench 3. Exemplary lengths of the wall 6 is from 6 inches to 5 feet, preferably from 1 to 2 feet. The height of the laybox 3 can vary as desired for the particular application, such as higher for a deeper microtrench 11 and lower for a shallower microtrench 11. An example of suitable heights of the side walls 6 are from 6 inches to 3 feet, preferably from 6 inches to 2 feet.

The side walls 6 can be connected to each other by one or more spacers 30. The spacers 30 can also have the function of guiding the optical fiber cable and/or innerduct/microduct 121 into and through the laybox 3 and then to bottom of the microtrench 11. For example, the spacers 30 can be bolts that bolt the sides walls 6 together.

A crummer 4 can be located at the front of the laybox 3. The crummer 4 is configured to remove remaining spoil 12 or other objects from the microtrench 12. The crummer 4 can have a pointed or angled surface to facilitate removal of the spoil 12.

A microtrencher connector 19 can be located near the front of the laybox 3 for connecting the laybox 3 to the microtrencher 2. The microtrencher connector 19 can have holes 21 for bolting the microtrencher connector 19 to the microtrencher 2.

A spoil diverter 60 can be located near the back of the laybox 3, which is configured to push the spoil 12 deposited on the roadway surface 5 into the microtrench 11 after the optical fiber cable and/or innerduct/microduct 121 has been laid in the bottom of the microtrench 11.

A compression wheel 50 can be mounted at the back of the laybox 3 for compressing the spoil 12 in the microtrench 11. The compression wheel 50 can be mounted to compression wheel mount 40 and mount support arm 42 by a swing arm 44, which allows the compression wheel 50 to move up and down. To adjust the amount of compression applied by the compression wheel 50, weight 120 can be added to swing arm 44. The compression wheel 50 can be formed from steel, or any other suitable material.

In addition to the compression wheel 50 or replacing the compression wheel 50, a compactor 210 can be included as shown in FIG. 1. The compactor 210 can be a vibrating tamper or compactor. Commercial examples of suitable compactor 210 include the plate compactors made by Bartell, Yuutool, Powerhouse, Nordco, Honda, Waymag, Yardmax, Rammer, and others.

During use in the first embodiment, the microtrench 11 can be cut in the soft roadway using the blade 10 to deposit spoil 12 on one side of the microtrench 11. The laybox 3 connected to the microtrencher 2 is dragged forward inside the microtrench 11 as the microtrencher 2 moves forward. The crummer 4 pushes any spoil 12 or other debris in the microtrench 11 up and out of the way of the laybox 3. As the laybox 3 moves forward in the microtrench 11, the optical fiber cable and/or innerduct/microduct 121 is fed through the chamber 8, the path being controlled by the spacers 30, until the optical fiber cable and/or innerduct microduct 121 lays at the bottom of the microduct. The spoil diverter 30 pushes the spoil 12 on the roadway surface into the microtrench 11 on top of the optical fiber cable and/or innerduct/microduct 121. The compression wheel 50 rotates over the spoil 12 and compresses the spoil 12 into the microtrench 11 over the buried optical fiber cable and/or innerduct/microduct 121.

In the second embodiment, as shown in FIGS. 4-6, the spoil 12 is vacuumed by a vacuum device 130, which can be mounted on a vacuum truck 124. The vacuum device 130 can be any desired device, such as those made by SCAG Giant Vac., DR Power, Vermeer, and Billy Goat. A preferred vacuum truck 124 is a Guzzler vacuum truck, www.guzzler.com. The Guzzler type vacuum truck 124 has a large storage container for holding spoil 12 and a vacuum device 130 for creating a vacuum in the storage container. The storage container can be sized to hold spoil 12 created by the side-discharge cutting wheel 10 cutting a microtrench 11 in the roadway. The microtrencher 2 can also include the vacuum systems disclosed in my copending U.S. patent application Ser. No. 16/806,335, filed 2 Mar. 2020, the complete disclosure of which is incorporated herein by reference. The vacuum device 130 can be connected to a microtrencher shroud 20 by a vacuum hose 131, or to a separate shroud as disclosed in my copending application. In this manner, the spoil 12 can be easily removed from the roadway and microtrench 11.

In the second embodiment, the laybox 3 should be sized to fit within a microtrench 11 cut into the roadway 77. The laybox 3 can be formed by two opposing side walls 6 defining an elongated chamber 8 therebetween. The chamber 8 defined by the side walls 6 should be sized so that the optical fiber cable and/or innerduct/microduct 121 can flow into and through the chamber 8 during use. Examples of suitable chamber 8 widths are from 0.5 to 10 inches, more preferably from 1 to 4 inches in width between the interior surfaces of the opposing side walls 6. The side walls 6 are preferably formed from sheets of steel. Examples of suitable thickness of a side wall 6 formed from a steel sheet is 0.1 to 1.5 inches, preferably 0.1 to 1 inches. The length of the of the wall 6 can be as desired for the particular application. In general, the longer the length of the wall 6, the greater the radius of any turns with the laybox 3 inside the microtrench 11. When turning, the laybox 3 may have to be removed from the microtrench 3. Exemplary lengths of the wall 6 is from 6 inches to 5 feet, preferably from 1 to 2 feet. The height of the laybox 3 can vary as desired for the particular application, such as higher for a deeper microtrench 11 and lower for a shallower microtrench 11. An example of suitable heights of the side walls 6 are from 6 inches to 3 feet, preferably from 6 inches to 2 feet.

The side walls 6 can be connected to each other by one or more spacers 30. The spacers 30 can also have the function of guiding the optical fiber cable and/or innerduct/microduct 121 into and through the laybox 3 and then to bottom of the microtrench 11. For example, the spacers 30 can be bolts that bolt the sides walls 6 together.

A crummer 4 can be located at the front of the laybox 3. The crummer 4 is configured to remove remaining spoil 12 or other objects from the microtrench 12. The crummer 4 can have a pointed or angled surface to facilitate removal of the spoil 12.

A microtrencher connector 19 can be located near the front of the laybox 3 for connecting the laybox 3 to the microtrencher 2. The microtrencher connector 19 can have holes 21 for bolting the microtrencher connector 19 to the microtrencher 2.

A fill conduit 126 can be located at the rear of the laybox 3, which is configured to direct fill 127 to flow through the fill conduit 126 and into the microtrench 11. The microtrench 11 containing the optical fiber cable and/or innerduct/microduct 121 can be filled with fill 127 from a fill device 200 connected to the fill conduit 126 by a fill hose 201. Preferably, the fill device 200 and the fill 127 are as disclosed in my U.S. publication No 20190086002 or U.S. publication No. 20180292027, which are incorporated herein by reference.

During use of the second embodiment, the microtrench 11 can be cut in the hard roadway (asphalt or cement) using the blade 10. The spoil 12 from the blade 10 is vacuumed away using the vacuum device 130. The laybox 3 connected to the microtrencher 2 is dragged forward inside the microtrench 11 as the microtrencher 2 moves forward. The crummer 4 pushes any spoil 12 or other debris in the microtrench 11 up and out of the way of the laybox 3. As the laybox 3 moves forward in the microtrench 11, the optical fiber cable and/or innerduct/microduct 121 is fed through the chamber 8, the path being controlled by the spacers 30, until the optical fiber cable and/or innerduct microduct 121 lays at the bottom of the microduct. Fill 127 is fed from the fill device 200 to the fil conduit 126 through a fill hose 131. The fill 127 flows through the fill conduit 126 to cover the optical fiber cable and/or innerduct/microduct 121 and fill the microtrench 11. During forming curves in the microtrench 11, the laybox 3 may have to be removed from the curved portion of the microtrench 11 and then reinstalled within the microtrench 11 as the microtrench 11 straightens out. A lifting device on the microtrencher 2 can be used to raise and lower the laybox 3, which can also be used in the first embodiment. Any suitable lifting device can be utilized, such as hydraulic, electric, spring, and or manual.

The present invention provides an improvement over my previous inventions by utilizing a plurality of microtrench plugs 16 to hold down the optical fiber and/or innerduct/microduct 121 during filling of the microtrench 11 with the fill 127. A typical problem with conventional microtrenching is that the optical fiber and/or innerduct/microduct 121 can bow up from the bottom of the microtrench 11 as shown in FIG. 7A [Prior Art].

The microtrench plugs 16 reduce the bowing of the optical fiber and/or innerduct/microduct 121 as shown in FIG. 7B. The microtrench plugs 16 can also prevent the optical fiber and/or innerduct/microduct 121 from rising during filling of the microtrench 11 with the fill 127. The microtrench plugs 16 provide the added advantage that if the fill 127 fails, the microtrench plugs 16 will retain the optical fiber and/or innerduct/microduct 121 within the microtrench 11.

The microtrench plugs 16 can have different forms. Suitable examples of the microtrench plug 16 include a foam plug 17, FIG. 7C, a spring plug 18, FIG. 7D, and compression plugs 22, FIGS. 7E-71. The microtrench plug 16 contacts at least one inside surface of the microtrench 11. During insertion of the microtrench plug 16, the optical fiber and/or innerduct/microduct 121 can be pushed towards the bottom of the microtrench 11 by the microtrench plug 16 and then the microtrench plug 16 prevents the optical fiber and/or innerduct/microduct 121 from rising towards the roadway surface 5. The microtrench plugs 16 are preferably spaced apart along a length of the optical fiber and/or innerduct/microduct 121. Examples of suitable spacings are from 2 inches to 200 feet, preferably 6 inches to 48 inches.

The microtrench plugs 16 can be formed from any suitable material. For example, compression type microtrench plugs 22 can be formed from a compressible material such as rubber, plastics, polymers, and composites. The spring type microtrench plugs 18 can be formed from a spring material, such as metals, plastics, and composites.

The microtrench plugs 16 contact the surfaces of the microtrench 11. The microtrench plugs 16 are held in place by any of friction against the surface of the microtrench 11, bonding to a surface of the microtrench 11, and/or penetrating into to the surface of the microtrench 11. For example, the microtrench plugs 16 can be compressed and then released within the microtrench 11 so that the microtrench plugs 16 expand to contact the surfaces of the microtrench 11. Alternatively, the microtrench plugs 16 can be formed in the microtrench, such as by using a foam plug 17, which bonds to the surfaces of the microtrench 11. Examples of suitable widths for the microtrench plugs 6 is from 0.5 inch to 6 inches.

During installation, the microtrench plugs 16 can be pushed down into the microtrench 11 a desired depth, which pushes the optical fiber and/or innerduct/microduct 121 down to a desired depth before filling and sealing the microtrench 11 with the fill 212. Examples of suitable depths include from 0.5 inch to 60 inches.

The microtrench plugs 16 are preferably spaced apart to allow the fill 212 to contact and/or surround the optical fiber and/or innerduct/microduct 1210. If desired, the microtrench plugs 16 can be in the form of a long continuous plug so that the fill 127 does not contact the optical fiber and/or innerduct/microduct 121.

FIGS. 8A and 9A show a compression microtrench plug installation device 300 for inserting compression type microtrench plugs 19 into the microtrench 11, such as those shown in FIGS. 3C-3G. The device 300 has a hollow plug dispenser 310 sized to fit within the microtrench 11, which is connected to a control 312. When the plug dispenser 310 is within the microtrench 11 at the desired depth and location, the control 312 can be actuated to expel the compression type microtrench plug 9 from the end of the plug dispenser 312 and into the microtrench 11. When inside the plug dispenser 310, the compression type microtrench plug 19 is in a compressed state and when expelled into the microtrench 11, the compression type microtrench plug 19 expands until the plug 19 contact the sides of the microtrench 11. The process can be repeated to install additional compression type microtrench plugs 19 into the microtrench 11 to hold the optical fiber and/or innerduct/microduct 121 in place. The chamber 310 can include a spring to bias the plugs 19 towards the end. The control 312 can be any desired control for controlling a flow of plugs 19 from the chamber 310, which controls are now well-known in the art.

FIGS. 8B and 9B show a foam microtrench plug installation device 400 for inserting foam type microtrench plugs 16 into the microtrench 11, such as shown in FIG. 3A. The device 400 includes a hollow shaft 424 configured to fit within the microtrench 11. The hollow shaft 424 is connected to a source of foam 420 and a foam controller 422. Foam controllers are now well-known and any suitable controller for controlling the flow of a foam forming material can be utilized. Foams are also well-known, and any suitable foam forming material can be utilized, such as commercially available spray cans of foam including Loctite tite foam, Great Stuff, Max Fill, and others. The hollow shaft 424 is inserted into the microtrench 11 and pushes down the optical fiber and/or innerduct/microduct 121 to a desired depth and then the foam controller 422 can be activated to release a source of foam 420 into the microtrench 11 where a small amount of foam 17 contacts the sides of the microtrench 11 and hardens quickly to secure the optical fiber and/or innerduct/microduct 121 in place.

FIGS. 8C, 9C and 10A-C show a cutter compression microtrench plug installation device 500 for inserting compression microtrench plugs 22 into the microtrench 11. A rotatable cutting and compaction wheel 512 having a plurality of compaction teeth 510 and cutting blades 512 is configured to fit within the microtrench. The cutting and compaction wheel 512 can have a shaft mount 511 configured to mount rotatably on a shaft 515 mounted to at least one of the side walls 6. A reel 530 contains wound continuous plug 122. The continuous plug 122 is fed to the compaction teeth 510, the compaction teeth 510 cut the continuous plug 122 to a desired length using the cutting blades 512 to form the compression plug 22 and push the compression plug 22 and the optical fiber and/or innerduct/microduct 121 down to a desired location in the microtrench 11. The continuous plug 122 is cut to size using the cutting teeth 512 and/or an alternative cutter 520. The cutter 520 has a cutting blade 522 that is move towards and away from a cutting surface 521 by a blade moving device 523. The depth of the compression plug 22 can be adjusted by using different size wheel 513 and/or lifting/lowering the wheel 513 to different depths within the microtrench 11.

FIGS. 8D and 9D show a spring microtrench plug installation device 600 for inserting spring type microtrench plugs 18 into the microtrench 11, such as shown in FIG. 3B. The device 600 includes a shaft 610 configured to hold a spring type microtrench plug 18 and insert the spring type microtrench plug 18 into the microtrench 11. During installation, the plug 18 is pushed down into the microtrench pushing down the optical fiber and/or innerduct/microduct 121 down to a desired location. Once the spring type microtrench plug 18 is pushed into place, the spring type microtrench plug 18 slides off the end of the shaft 610, and the sides of the plug 18 press against the surfaces of the microtrench 11 holding the plug 18 and optical fiber and/or innerduct/microduct 121 in place.

The different microtrench plug installation devices described herein can be manual, gas powered, power activated, electric, or compressor driven as desired.

Reference numbers:
2   Microtrencher
3   Laybox
4   Crummer
5   Roadway surface
6   Side wall
8   Elongated chamber defined by side walls 6
10  Cutting wheel
11  Microtrench
12  Spoil
14  Spoil 12 returned to the microtrench 11
16  Microtrench plug
17  Foam plug
18  Spring plug
19  Microtrencher connector
20  Microtrencher shroud
21  Holes
22  Compression plug
30  Spacer
40  Compression wheel mount
42  Mount support arm
44  Swing arm to allow wheel 50 to move up and down
50  Compression wheel for compressing spoil 12 in the microtrench 11
60  Spoil diverter
70  Softer surface
77  Roadway
120 Weight
121 Optical fiber cable or innerduct/microduct
122 Continuous compression plug
124 Vacuum truck
126 Fill conduit in laybox
127 Fill in microtrench 11
130 Vacuum device
131 Vacuum hose
150 Reel device containing reels of optical fiber cable and/or
    innerduct/microduct 121
200 Fill Device
201 Fill hose
210 Compactor
300 Compression microtrench plug installation device
310 Plug dispenser chamber
312 Plug pusher
400 Foam microtrench plug installation device
420 Source of foam
422 Handle and controller
424 Nozzle
500 Cutter Compression microtrench plug installation device
510 Compaction teeth
511 Shaft mount
512 Cutting teeth
513 Cutting and compaction wheel
515 Shaft
520 Cutter
522 Cutting blade
521 Cutting surface
523 Cutting blade moving device
530 Reel of microtrench plug
600 Spring microtrench plug installation device
610 Shaft

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.

Claims

1. A laybox configured for installing optical fiber cable in a microtrench comprising: a body comprising opposing first and second elongated sheets of steel defining an elongated chamber between them, the body having a thickness configured to fit within a microtrench, and a front end of the body configured to face a microtrencher cutting blade and a back end of the body opposing the first end;a cable guide disposed in the elongated chamber configured to guide an optical fiber cable and/or microduct/innerduct through the chamber; anda microtrench plug installer configured to install a microtrench plug into the microtrench above the optical fiber and/or innerduct/microduct to secure the optical fiber and/or innerduct/microduct in the microtrench and reduce bowing of the optical fiber and/or innerduct/microduct up from a bottom of the microtrench.

2. The laybox according to claim 1, further comprising a microtrencher connector for connecting the laybox to a microtrencher disposed at the front end of the body;

3. The laybox according to claim 1, wherein the cable guide comprises a plurality of spacers disposed in the elongated chamber.

4. The laybox according to claim 3, wherein the plurality of spacers connect the first and second sheets together.

5. The laybox according to claim 1, further comprising a spoil diverter at the back end of the body configured to push spoil into a microtrench.

6. The laybox according to claim 1, further comprising a compression wheel at the back of the body configured to compress spoil in a microtrench.

7. The laybox according to claim 1, further comprising a compactor configured to compress spoil in a microtrench.

8. The laybox according to claim 1, further comprising a fill conduit at the back end configured to flow fill through the laybox and into a microtrench.

9. The laybox according to claim 1, wherein the microtrench plug installer comprises a compression microtrench plug installation device configured to insert the microtrench plug into the microtrench, and the microtrench plug is a compression type microtrench plug.

10. The laybox according to claim 1, wherein the microtrench plug installer comprises a foam microtrench plug installation device configured to insert the microtrench plug into the microtrench, and the microtrench plug is a foam type microtrench plugs.

11. The laybox according to claim 1, wherein the microtrench plug installer comprises a cutter compression type microtrench plug installation device configured to insert the microtrench plug into the microtrench, cut the microtrench plug to a desired length, and the microtrench plug is a compression type microtrench plug.

12. The laybox according to claim 1, wherein the microtrench plug installer comprises a spring microtrench plug installation device configured to insert the microtrench plug into the microtrench, and the microtrench plug is a spring type microtrench plug.

13. A method of microtrenching comprising: cutting a microtrench in a roadway with a microtrencher and depositing spoil from the microtrench onto a roadway surface on one side of the microtrench;moving a laybox in the microtrench behind the microtrencher in a direction the microtrencher is travelling, the laybox comprising opposing first and second elongated sheets of steel defining an elongated chamber between them and a cable guide in the elongated chamber;flowing an optical fiber cable and/or innerduct/microduct through the chamber and cable guide so that the optical fiber cable and/or innerduct/microduct is laying in the microtrench;using a microtrench plug installer to install a microtrench plug above the optical fiber cable and/or microduct/innerduct to secure the optical fiber cable and/or microduct/innerduct in the microtrench and reduce bowing of the optical fiber and/or innerduct/microduct up from a bottom of the microtrench;pushing the spoil into the microtrench using a spoil diverter; andcompressing the spoil in the microtrench.

14. The method according to claim 13, further comprising pushing a first microtrench plug into the microtrench to push the optical fiber and/or innerduct/microduct down to a desired depth within the microtrench.

15. The method according to claim 13, further comprising using a compression microtrench plug installation device to insert the plurality of microtrench plugs into the microtrench, and the plurality of microtrench plugs are compression type microtrench plugs.

16. The method according to claim 13 further comprising using a foam microtrench plug installation device to insert the plurality of microtrench plugs into the microtrench, and the plurality of microtrench plugs are foam type microtrench plugs.

17. The method according to claim 13, further comprising using a cutter compression type microtrench plug installation device to insert the plurality of microtrench plugs into the microtrench, cut the plurality of microtrench plugs to a desired length, and the plurality of microtrench plugs are compression type microtrench plugs.

18. The method according to claim 13, further comprising using a spring microtrench plug installation device to insert the plurality of microtrench plugs into the microtrench, and the plurality of microtrench plugs are spring type microtrench plugs.

19. The method according to claim 13, further comprising inserting a fill into the microtrench above the optical fiber or innerduct/microduct.

20. The method according to claim 13, wherein the microtrench plugs are spaced-apart.

21. The method according to claim 13, wherein the microtrench plugs are compressible and after insertion into the microtrench the microtrench plugs expand and contact sidewalls of the microtrench.

22. The method according to claim 21, wherein the microtrench plugs comprise a spring.

23. The method according to claim 21, wherein the microtrench plugs comprise a rubber.

24. The method according to claim 13, wherein the microtrench plugs comprise a foam.

25. A method of microtrenching comprising: cutting a microtrench in a roadway comprising asphalt or cement with a microtrencher;vacuuming spoil from the microtrench using a vacuum device;moving a laybox in the microtrench behind the microtrencher in a direction the microtrencher is travelling, the laybox comprising opposing first and second elongated sheets of steel defining an elongated chamber between them and a cable guide in the elongated chamber;flowing an optical fiber cable and/or innerduct/microduct through the chamber and cable guide so that the optical fiber cable and/or innerduct/microduct is laying in the microtrench;using a microtrench plug installer to install a microtrench plug above the optical fiber cable and/or microduct/innerduct to secure the optical fiber cable and/or microduct/innerduct in the microtrench and reduce bowing of the optical fiber and/or innerduct/microduct up from a bottom of the microtrench; andflowing a fill from a fill device to a fill conduit in the laybox so that the fill flows through the fill conduit and into the microtrench to seal the microtrench and protect the optical fiber cable and/or innerduct/microduct.