Apparatus and method for cutting asphalt, concrete and other materials

Abstract

An apparatus for dry cutting asphalt, concrete and other hard construction materials. The apparatus has a forward direction of operation and includes a circular saw, blade guard, and vacuum collection means. The circular saw includes a housing having front and back ends, a rotatable shaft extending from the housing, a blade fixed to the shaft, and means for rotating the shaft and blade in a direction that upcuts the material when the saw is conveyed in the forward direction. The blade guard is mounted to the housing. The blade guard includes a cover surrounding the upper portion of the blade, a shoe surrounding the lower portion of the blade, and an adjustable connection interface between the cover and the shoe. The vacuum collection means is connected to the blade guard.

1 . An apparatus for dry cutting materials, said apparatus having a forward direction of operation, comprising: 
 a) a circular saw, including: 
 i) a housing having front and back ends;  
 ii) means for conveying said housing over the surface of the material;  
 iii) rotatable shaft extending from said housing;  
 iv) a blade fixed to said shaft, said blade having an upper portion and a lower portion;  
 v) means for rotating said shaft and blade in a direction that upcuts the material when the saw is conveyed in the forward direction;  
   b) a blade guard mounted to said housing, including: 
 i) a cover surrounding the upper portion of said blade;  
 ii) a shoe surrounding the lower portion of said blade;  
 iii) an adjustable connection interface between said cover and said shoe; and,  
   c) vacuum collection means connected to said blade guard.    
   
   
       2 . The apparatus recited in  claim 1 , including means for setting the blade at different cut depths.  
   
   
       3 . The apparatus recited in  claim 2 , wherein said blade guard adjusts and surrounds the entire portion of the blade above the material surface at each cut depth setting.  
   
   
       4 . The apparatus recited in  claim 3 , wherein said adjustable connection interface comprises a receptacle portion in said shoe and said cover telescopes within said receptacle portion.  
   
   
       5 . The apparatus recited in  claim 1 , said blade guard including front and back ends, an air intake port in said back end, and a discharge port in said front end connected to said vacuum collection means.  
   
   
       6 . The apparatus recited in  claim 5 , wherein said exhaust port has an internal opening proximate the projection point between said blade and the material road surface.  
   
   
       7 . The apparatus recited in  claim 6 , wherein said internal opening is aligned directly in the trajectory of the road dust from the projection point so that road dust is projected directly into said exhaust port without contacting the interior of said blade guard.  
   
   
       8 . The apparatus recited in  claim 5 , wherein said exhaust port extends upwardly at an inclined angle relative to the trajectory of the dust from the projection point so that the dust impinges on said exhaust port at an angle less than  90  degrees.  
   
   
       9 . The apparatus recited in  claim 1 , including an air flow regulator on said air intake port.  
   
   
       10 . The apparatus recited in  claim 5 , wherein said intake port has an internal opening aligned in the plane of the blade and above the groove, and located proximate the trailing contact point between the blade and the material surface.  
   
   
       11 . The apparatus recited in  claim 5 , wherein said blade guard creates an air flow pattern flowing through said intake port, into the groove behind the trailing contact point of the blade and the groove, around the blade, and out the discharge port.  
   
   
       12 . An apparatus for dry cutting a groove in road surfaces, comprising: 
 a) a flat saw having a masonry blade, a forward direction of operation, means for rotating said shaft and blade in a direction that upcuts the road surface when the saw is conveyed in the forward direction, and means for setting the blade at different cut depths;    b) an adjustable blade guard, having: 
 i) front and back ends;  
 ii) primary collecting means at the front end of the blade guard for collecting road dust before it contacts the road surface;  
 iii) secondary collecting means at the back end of the blade guard for collecting road dust on the road surface and in the groove;  
 iv) means for completely surrounding the portion of said blade above the road surface at each cut depth setting.  
   
   
   
       13 . The apparatus recited in  claim 12 , wherein said primary collecting means comprises a discharge port in the front end of the blade guard proximate the projection point between the blade and the road surface and a vacuum and collection means connected to said intake port of said blade.  
   
   
       14 . The apparatus recited in  claim 13 , wherein said discharge port is located directly in the trajectory of the road dust from the projection point between the blade and the road surface.  
   
   
       15 . The apparatus recited in  claim 13 , wherein said secondary collecting means comprises an intake port in the back end of the blade guard proximate the projection point between the blade and the road surface  
   
   
       16 . A method of dry cutting materials, comprising the steps of: 
 a) providing a saw having a blade and a forward direction of operation;    b) upcutting the material with the saw;    c) collecting the dust created during cutting by applying a vacuum proximate the projection point between the blade and the material surface.    
   
   
       17 . The method recited in  claim 16 , including the step of enclosing the portion of the blade above the material surface.  
   
   
       18 . A method of dry cutting and cleaning a road surface, comprising the steps of: 
 a) providing a saw having a road-surface blade and a forward direction of operation;    b) upcutting the road surface with the saw;    c) collecting road dust projected from the projection point between the blade and road surface before it contacts the road surface;    d) cleaning the trailing groove and adjacent road surface of any residual road dust by directing a flow of air onto the groove and adjacent road surface and vacuum collecting the residual road dust.    
   
   
       19 . The method recited in  claim 18 , wherein road dust is collected proximate the projection point between the blade and the road surface.  
   
   
       20 . The method recited in  claim 18 , including the step of enclosing the area surrounding the blade and containing the road dust within the enclosed area.  
   
   
       21 . A blade guard for a flat saw having a forward direction of operation and a vacuum collection means, comprising: 
 a) means for mounting said blade guard mounted to the saw:    b) a cover surrounding the upper portion of the blade of the saw;    c) a shoe surrounding the lower portion of the blade of the saw;    d) an adjustable connection interface between said cover and said shoe;    e) front and back ends;    f) an air intake port in said back end; and,    g) a discharge port in said front end connected to said vacuum collection means.