Disc cutter and excavation equipment

Claim 2

A rolling disc cutter for use in a mechanical excavation apparatus to exert pressure against substantially solid matter such as rock, compacted earth, or mixtures thereof by acting on a face thereof, said cutter of the type which upon rolling forms a kerf by penetration into said face so that, when two or more cutters are used, solid matter between a proximate pair of said kerfs is fractured to produce chips which separate from said face, wherein said rolling disc cutter comprises: (a) a relatively stiff shaft, said shaft comprising (i) a proximal end, said proximal end further comprising an outwardly extending sloped flange with a radially inward sealing face surface, (ii) a distal end, and (iii) an axis for rotation thereabout; (b) a cutter ring assembly, said cutter ring assembly further comprising (i) a cutter ring, said cutter ring further comprising (A) an interior annulus, said interior annulus having a distal side, and (B) an outer ring portion, said outer ring portion including a cutting edge having an outside diameter OD and radius R 1 , and (C) a proximal side, said proximal side further comprising a proximally inwardly extending flange with a radially inward sealing face surface; (ii) a bearing, said bearing (A) substantially fitting into said interior annulus of said cutter ring, and (B) positioned in a close fitting relationship with said shaft, so that said cutter ring rotates with respect to and is supported by said shaft; (c) a seal, said seal adapted to fit sealingly between (i) said sealing face surface of said sloped flange of said shaft, and (ii) said sealing face of said inwardly extending sloped flange of said cutter ring, to form a lubricant retaining seal; (d) a retainer, said retainer adapted to retain said cutter ring assembly on to said shaft; (e) a cap, said cap sealingly joined against said cutter ring to cover said distal end of said interior annulus so that, in cooperation with said seal and said cutter ring, a lubricant retaining chamber is provided to lubricate said bearing.

Claim 3

A rolling disc cutter for use in a mechanical excavation apparatus to exert pressure against substantially solid matter such as rock, compacted earth, or mixtures thereof by acting on a face thereof, said cutter of the type which upon rolling forms a kerf by penetration into said face so that, when two or more cutters are used, solid matter between a proximate pair of said kerfs is fractured to produce chips which separate from said face, wherein said disc cutter comprises: (a) a relatively stiff shaft, said shaft comprising (i) a proximal end, said proximal end further comprising an outwardly extending sloped flange with a radially inward sealing face surface, (ii) a distal end, and (iii) an axis for rotation thereabout; (b) a cutter ring assembly, said cutter ring assembly further comprising (i) a cutter ring, said cutter ring further comprising (A) an interior annulus, said interior annulus having a distal side, and (B) a proximal side, said proximal side further comprising a proximally inwardly extending flange with a radially inward sealing face surface (C) a pair of laterally spaced apart support ridges, said ridges having therebetween a groove forming portion, said groove forming portion including (1) a pair of interior walls, and (2) an interior bottom surface interconnecting with said interior walls (3) wherein said pair of interior walls outwardly extend relative to said interior bottom surface to thereby define a peripheral groove around the outer edge of said cutter ring, (D) two or more hardened, wear-resistant inserts, said inserts positioned within and located in a radially outward relationship from said groove, said inserts further comprising (1) a substantially continuous engaging contact portion of having outside diameter OD and radius R 1 , said contact portion on the outer side of each of said two or more inserts and adapted to act on said face, and (2) a lower groove insert portion, said lower groove insert portion, having (I) a bottom surface shaped and sized in complementary matching relationship relative to said interior bottom surface of said peripheral groove, and (II) first and second opposing exterior side surfaces, said first and second exterior side surfaces being shaped and sized in a complementary matching relationship relative to said pair of interior walls, and (III) a rotationwise, a front portion and a rear portion, (3) wherein said lower groove insert portion of said inserts fit within said peripheral groove in a close fitting relationship which defines a slight gap between said inserts and each of said pair of interior walls, and (4) a somewhat elastic preselected filler material, said preselected filler material placed between yet securely joining said inserts in a spaced apart relationship to said interior bottom surface and to said pair of interior sidewalls, said preselected filler material having a modulus of elasticity so that said inserts can slightly move elastically relative to said cutter ring so as to tend to relieve stress and strain acting on said inserts; and (ii) a bearing, said bearing (A) substantially fitting into said interior annulus of said cutter ring, and (B) positioned in a close fitting relationship with said shaft, so that said cutter ring rotates with respect to and is supported by said shaft; (c) a seal, said seal adapted to fit sealingly between (i) said sealing face surface of said sloped flange of said shaft, and (ii) said sealing face of said inwardly extending sloped flange of said cutter ring, to provide a lubricant retaining seal; (d) a retainer, said retainer retaining said cutter ring assembly on to said shaft; (e) a cap, sealingly joined against said cutter ring to cover said distal end of said interior annulus so that, in cooperation with said seal and said cutter ring, a lubricant retaining chamber is provided to lubricate said bearing.

Claim 4

A rolling disc cutter for use in a mechanical excavation apparatus to exert pressure against substantially solid matter such as rock, compacted earth, or mixtures thereof by acting on a face thereof, said cutter of the type which upon rolling forms a kerf by penetration into said face so that, when two or more cutters are used, solid matter between a proximate pair of said kerfs is fractured to produce chips which separate from said face, wherein said disc cutter comprises: (a) a relatively stiff shaft, said shaft comprising (i) a proximal end, said proximal end further comprising an outwardly extending sloped flange with a radially inward sealing face surface, (ii) a distal end, and (iii) an axis for rotation thereabout; (b) a cutter ring assembly, said cutter ring assembly further comprising (i) a cutter ring, said cutter ring further comprising (A) an interior annulus, said interior annulus having a distal side, and (B) a proximal side, said proximal side further comprising a proximally inwardly extending flange with a radially inward sealing face surface (C) a pair of laterally spaced apart support ridges, said ridges having therebetween a groove forming portion, said groove forming portion including (1) a pair of interior walls, and (2) an interior bottom surface interconnecting with said interior walls (3) wherein said pair of interior walls outwardly extend relative to said interior bottom surface to thereby define a peripheral groove around the outer edge of said cutter ring, (D) two or more hardened, wear-resistant inserts, said inserts positioned within and located in a radially outward relationship from said groove, said inserts further comprising (1) a substantially continuous engaging contact portion of having outside diameter OD and radius R 1 , said contact portion on the outer side of each of said two or more inserts and adapted to act on said face, and (2) a lower groove insert portion, said lower groove insert portion, having (I) a bottom surface shaped and sized in complementary matching relationship relative to said interior bottom surface of said peripheral groove, and (II) first and second opposing exterior side surfaces, said first and second exterior side surfaces being shaped and sized in a complementary matching relationship relative to said pair of interior walls, and (III) a rotationwise, a front portion and a rear portion, (3) wherein said lower groove insert portion of said inserts fit within said peripheral groove in a close fitting relationship which defines a slight gap between said inserts and each of said pair of interior walls, and (4) a somewhat elastic preselected filler material, said preselected filler material placed between yet securely joining said inserts in a spaced apart relationship to said interior bottom surface and to said pair of interior sidewalls, said preselected filler material having a modulus of elasticity so that said inserts can slightly move elastically relative to said cutter ring so as to tend to relieve stress and strain acting on said inserts; and (ii) a bearing, said bearing (A) substantially fitting into said interior annulus of said cutter ring, and (B) positioned in a close fitting relationship with said shaft, so that said cutter ring rotates with respect to and is supported by said shaft; (c) a seal, said seal adapted to fit sealingly between (i) said sealing face surface of said sloped flange of said shaft, and (ii) said sealing face of said inwardly extending sloped flange of said cutter ring, to provide a lubricant retaining seal; (d) a retainer, said retainer retaining said cutter ring assembly on to said shaft; (e) a cap, sealingly joined against said cutter ring to cover said distal end of said interior annulus so that, in cooperation with said seal and said cutter ring, a lubricant retaining chamber is provided to lubricate said bearing.

Claim 5

The rolling disc cutter as set forth in claim 2, wherein each of said two or more inserts further comprise: (a) a peripheral groove insert portion, said peripheral groove insert portion further comprising (i) a bottom surface shaped and sized in complementary matching relationship relative to said interior bottom surface of said peripheral groove, and (ii) first and second opposing exterior side surfaces, said first and second side surfaces being shaped and sized in a complementary matching relationship relative to said pair of interior walls; (b) a face engaging contact portion of radius R 1 , and (c) rotationwise, (i) a rounded leading edge surface portion of reduced curvature relative to said face engaging contact portion of radius R 1 , and (ii) a rounded trailing edge surface portion of reduced curvature relative to said face engaging contact portion of radius R 1 .

Claim 6

The rolling disc cutter as set forth in claim 2 or claim 3, wherein said face engaging contact portion of each of said two or more inserts further comprise, in transverse cross-section, a smoothly curved face engaging contact portion edge.

Claim 7

The rolling disc cutter as set forth in claim 4, wherein, in transverse cross-section, said face engaging contact portion edge is symmetrical.

Claim 8

The rolling disc cutter as set forth in claim 5, wherein, in transverse cross-section, said face engaging contact portion edge is semi-circular.

Claim 9

The rolling disc cutter as set forth in claim 2, or claim 3, wherein (a) said cutter ring is comprised of a first material, and (b) said two or more inserts are comprised of a second material, (c) wherein said second material is chosen for maximizing service life when in a position of direct contact said substantially solid matter being excavated, and (d) wherein said first material wears at a rate comparable, given the service location, to the rate of said second material, so that during the life of said cutter ring, the overall wear of said first and said second material results in a substantially uniform radial reduction (i) in said face engaging contact portion, and (ii) in said pair of laterally spaced apart support ridges, (iii) to thereby provide a substantially self sharpening cutter ring.

Claim 10

The rolling disc cutter as set forth in claim 1 or claim 2, wherein said cap further comprises an exterior portion, said exterior portion further comprising a tool engaging portion.

Claim 11

The rolling disc cutter as described in claim 8 wherein said tool engaging portion is adapted to be engaged by a hand tool, so that said cap is affixible or removable with hand tools.

Claim 12

The rolling disc cutter as described in claim 8, wherein said tool engaging portion comprises a slot.

Claim 13

The rolling disc cutter as set forth in claim 1 or claim 2, wherein each of said two or more rolling disc cutters comprise cutter rings with an outside diameter OD, and a shaft with a shaft diameter SD, and wherein the ratio of SD to OD is between about 0.3 and about 0.5.

Claim 14

The rolling disc cutter as set forth in claim 1, or claim 2, wherein said bearing occupies a bearing radial space of B 2 on each side of said shaft, and wherein a total bearing space (B 2 +B 2 ) is occupied, said total bearing space comprising approximately twenty (20) percent or less of the outside diameter OD of said cutter ring.

Claim 15

The rolling disc cutter as set forth in claim 1 or 2, wherein said bearing comprises a needle type bearing.

Claim 16

The rolling disc cutter as set forth in claim 1 or 2, wherein said bearing comprises a roller-ball type bearing.

Claim 17

The rolling disc cutter as set forth in claim 1 or 2, wherein said seal comprises a full face type seal.

Claim 18

The rolling disc cutter as set forth in claim 1 or 2, wherein said seal comprises a single, half-face type seal.

Claim 19

The rolling disc cutter as set forth in claim 1 or 2, wherein said radius R 1 is in the range from about one and one-half (1.5) inches (3.81 cm) to about ten (10) inches (25.4 cm).

Claim 20

The rolling disc cutter as set forth in claim 1 or 2, wherein said radius R 1 is in the range from about two (2) inches 5.08 cm) to about four and one-half (4.5) inches (11.43 cm).

Claim 21

The rolling disc cutter as set forth in claim 1 or 2, wherein said radius R 1 is in the range from approximately two and one-half (2.5) inches (6.35 cm) to about three (3) inches (7.62 cm).

Claim 22

The rolling disc cutter as set forth in claim 1 or 2, wherein said apparatus further comprises (a) a bore running generally axially through at least a portion of said shaft to an opening at the distal end thereof, said bore defined by interior sidewalls, and (b) a pressure compensator, (c) wherein said bore defined by said interior sidewalls serves as a lubricant reservoir, said reservoir in fluid communication with (i) said lubricant retaining chamber, and (ii) with said pressure compensator, (d) so that in response to external fluid pressure such as water pressure acting on said pressure compensator, the pressure of said lubricant in said lubricant retaining chamber is substantially equalized to said external fluid pressure, so as to prevent said external fluid pressure from tending to cause fluid to migrate into said lubricant retaining chamber.

Claim 23

The rolling disc cutter as set forth in claim 20, wherein said pressure compensator further comprises a biasing spring, said biasing spring tending to cause lubricant contained in said bore to migrate outward toward said lubricant reservoir.

Claim 24

The rolling disc cutter s set forth in claim 1 or 2, wherein said cutter ring assembly is sufficiently lightweight that it is manually portable by a single worker.

Claim 25

The rolling disc cutter as set forth in claim 1 or 2, wherein said cutter ring assembly is 40 pounds (18.14 kg) or less.

Claim 26

The rolling disc cutter as set forth in claim 23, wherein said cutter ring assembly is 20 lbs. (9.07 kg) or less.

Claim 27

The rolling disc cutter as set forth in claim 24, wherein said cutter ring assembly is 8 lbs. (3.63 kg) or less.

Claim 28

The rolling disc cutter as set forth in claim 2, wherein inserts are comprised of hard metal, and wherein said inserts further comprise substantially annular shaped segments of outer radius R 1 and inner radius of R 2 .

Claim 29

The rolling disc cutter as set forth in claim 26, wherein said hard metal inserts are fixedly secured in said peripheral groove with a pre-selected filler material comprised of a slightly elastic brazing material.

Claim 30

The rolling disc cutter as set forth in claim 27, wherein said preselected filler material is comprised of a ductile braze alloy, so that said inserts tend not to crack despite the difference in thermal expansion coefficients between said cutter ring and said inserts.

Claim 31

The rolling disc cutter as set forth in claim 26, wherein said hard metal inserts are assisted by shims for secure fixation in said peripheral groove.

Claim 32

The rolling disc cutter as set forth in claim 26 wherein said inserts are sized and shaped so that a slight gap is provided between said inserts and said bottom and said interior walls of said peripheral groove, and wherein said brazing material substantially fills said slight gap, so as to cushion said bottom and said first and said second sidewalls of said insert from directly impinging upon said cutter ring.

Claim 33

The rolling disc cutter as set forth in claim 26, wherein said insert is comprised of hard metal, and wherein a slight gap is provided between said front portion of a first hard metal insert and said rear portion of a second hard metal insert, and wherein said slight gap is filled with a slightly elastic braze material.

Claim 34

The rolling disc cutter as set forth in claim 26, wherein said hard metal inserts further comprise (a) a leading edge surface portion of radius R 4 , (b) a trailing edge surface portion of radius R 3 , (c) a leading edge corner portion of radius R 6 , and (d) a trailing edge corner portion of radius R 5 , (e) wherein said radii R 4 and R 3 are each slightly less than said radius R 1 , so that a smooth curved leading edge and a smooth curved trailing edge is provided for each segment in the rolling direction.

Claim 35

The rolling disc cutter as set forth in claim 32, wherein said inserts are comprised of hard metal, and wherein said inserts further comprise a leading edge surface portion and a trailing edge surface portion, and wherein said leading edge surface portion has a radius R 4 slightly less than the outer radius R 1 of said annular segment.

Claim 36

The rolling disc cutter as set forth in claim 32, wherein said inserts are comprised of hard metal, and wherein said inserts further comprise a leading edge surface portion and a trailing edge surface portion, and wherein said trailing edge surface portion has a radius R 3 slightly less than the outer radius R 1 of said annular segment.

Claim 37

The rolling disc cutter as set forth in claim 26, wherein four (4) or more hard metal segments are provided.

Claim 38

The rolling disc cutter as set forth in claim 26, wherein twelve (12) hard metal segments are provided.

Claim 39

The rolling disc cutter as set forth in claim 2, wherein said opposing interior sidewalls of said cutter ring provide lateral support to more than fifty (50) percent of the radial height of said first and of said second exterior side surfaces of said inserts.

Claim 40

The rolling disc cutter as set forth in claim 2, wherein said opposing interior walls of said cutter ring provide lateral support to approximately seventy five (75) percent of the radial height of said first and of said second exterior side surfaces of said hard metal inserts.

Claim 41

The rolling disc cutter as set forth in claim 2, wherein said opposing interior sidewalls are (a) parallel, and (b) substantially normal to said shaft.

Claim 42

The rolling disc cutter as set forth in claim 2, wherein said two or more inserts form a substantially continuous contact cutting surface peripherally around said cutter ring.

Claim 43

A kit for replacement of wear parts in a rolling disc cutter, said kit comprising: (a) a cutter ring assembly, said cutter ring assembly further comprising (i) a cutter ring, said cutter ring further comprising (A) an interior annulus, said interior annulus having a distal side, and (B) an outer ring portion, said outer ring portion including a cutting edge having an outside diameter OD and radius R 1 , and (C) a proximal side, said proximal side further comprising a proximally inwardly extending flange with a radially inward sealing face surface; (ii) a bearing, said bearing (A) substantially fitting into said interior annulus of said cutter ring, and (B) positioned in a close fitting relationship with said shaft, so that said cutter ring rotates with respect to and is supported by said shaft; (b) a seal, said seal adapted to fit sealingly between (i) said sealing face surface of said sloped flange of said shaft, and (ii) said sealing face of said inwardly extending sloped flange of said cutter ring, to form a lubricant retaining seal.

Claim 44

A kit for replacement of wear parts in a rolling disc cutter, said kit comprising: (a) a cutter ring assembly, said cutter ring assembly further comprising (i) a cutter ring, said cutter ring further comprising (A) an interior annulus, said interior annulus having a distal side, and (B) an outer ring portion, said outer ring portion including a cutting edge having an outside diameter OD and radius R 1 , and (C) a proximal side, said proximal side further comprising a proximally inwardly extending flange with a radially inward sealing face surface; (ii) a bearing, said bearing (A) substantially fitting into said interior annulus of said cutter ring, and (B) positioned in a close fitting relationship with said shaft, so that said cutter ring rotates with respect to and is supported by said shaft; (b) a seal, said seal adapted to fit sealingly between (i) said sealing face surface of said sloped flange of said shaft, and (ii) said sealing face of said inwardly extending sloped flange of said cutter ring, to form a lubricant retaining seal.

Claim 45

The kit as set forth in claim 41, further comprising a retainer.

Claim 46

The kit as set forth in claim 41, further comprising a cap.

Claim 47

The rolling disc cutter or kit as set forth in claim 1, 2, or 41, wherein said bearing comprises a journal bearing.

Claim 48

A cutterhead apparatus for a repetitive motion mechanical excavation apparatus, said apparatus adapted to form a bore through substantially solid matter such as rock, compacted earth, or mixtures thereof by acting on a face thereof, said apparatus of the type which forms adjacent kerfs in said face so as to fracture said solid matter between a proximate pair of said kerfs to produce chips which separate from the face being bored to form muck, said apparatus comprising: (a) a hollow type cutterhead body, said cutterhead body comprising a forward side directed toward said face and a rearward side directed toward said bore, said forward side further comprising a muck collector for collecting said muck from said forward side of said cutterhead body; (b) at least rolling disc two cutters rotatably affixed to said cutterhead body, said rolling disc cutters each comprising (i) a relatively stiff shaft, said shaft comprising (A) a proximal end, said proximal end further comprising an outwardly extending sloped flange with a radially inward sealing face surface, (B) a distal end, and (C) an axis for rotation thereabout; (ii) a cutter ring assembly, said cutter ring assembly further comprising (A) a cutter ring, said cutter ring further comprising (1) an interior annulus, said interior annulus having a distal side, and (2) an outer ring portion, said outer ring portion including a cutting edge having diameter OD and radius R 1 , and (3) a proximal side, said proximal side further comprising a proximally inwardly extending flange with a radially inward sealing face surface; (B) a bearing, said bearing (1) substantially fitting into said interior annulus of said cutter ring, and (2) positioned in a close fitting relationship with said shaft, so that said cutter ring rotates with respect to and is supported by said shaft; (iii) a seal, said seal adapted to fit sealingly between (A) said sealing face surface of said sloped flange of said shaft, and (B) said sealing face of said inwardly extending sloped flange of said cutter ring, to form a lubricant retaining seal; (iv) a retainer, said retainer adapted to retain said cutter ring assembly on to said shaft; (v) a cap, said cap sealingly joined against said cutter ring to cover said distal end of said interior annulus so that, in cooperation with said seal and said cutter ring, a lubricant retaining chamber is provided to lubricate said bearing.

Claim 49

A cutterhead apparatus for a repetitive motion mechanical excavation apparatus, said apparatus adapted to form a bore through substantially solid matter such as rock, compacted earth, or mixtures thereof by acting on a face thereof, said apparatus of the type which forms adjacent kerfs in said face so as to fracture said solid matter between a proximate pair of said kerfs to produce chips which separate from the face being bored to form muck, said apparatus comprising: (a) a hollow type cutterhead body, said cutterhead body comprising a forward side directed toward said face and a rearward side directed toward said bore, said forward side further comprising a muck collector for collecting said muck from said forward side of said cutterhead body; (b) at least rolling disc two cutters rotatably affixed to said cutterhead body, said rolling disc cutters each comprising (i) a relatively stiff shaft, said shaft comprising (A) a proximal end, said proximal end further comprising an outwardly extending sloped flange with a radially inward sealing face surface, (B) a distal end, and (C) an axis for rotation thereabout; (ii) a cutter ring assembly, said cutter ring assembly further comprising (A) a cutter ring, said cutter ring further comprising (1) an interior annulus, said interior annulus having a distal side, and (2) an outer ring portion, said outer ring portion including a cutting edge having diameter OD and radius R 1 , and (3) a proximal side, said proximal side further comprising a proximally inwardly extending flange with a radially inward sealing face surface; (B) a bearing, said bearing (1) substantially fitting into said interior annulus of said cutter ring, and (2) positioned in a close fitting relationship with said shaft, so that said cutter ring rotates with respect to and is supported by said shaft; (iii) a seal, said seal adapted to fit sealingly between (A) said sealing face surface of said sloped flange of said shaft, and (B) said sealing face of said inwardly extending sloped flange of said cutter ring, to form a lubricant retaining seal; (iv) a retainer, said retainer adapted to retain said cutter ring assembly on to said shaft; (v) a cap, said cap sealingly joined against said cutter ring to cover said distal end of said interior annulus so that, in cooperation with said seal and said cutter ring, a lubricant retaining chamber is provided to lubricate said bearing.

Claim 50

The cutterhead as set forth in claim 45, wherein each of said rolling disc cutters is sufficiently lightweight so that said cutters may be moved by a single workman acting alone without lifting devices, and wherein said cutters are manually removable from said cutterhead body.

Claim 51

The cutterhead of claim 45, wherein said muck collector is disposed less than 1 ft. (30.48 cm) from said face.