Microtrenching blade with progressive cutter configuration

Abstract

Microtrenching blades and methods of manufacturing the same. A blade includes a blade body comprising a cutting edge, wherein the cutting edge is disposed around a perimeter of the blade body, and wherein the cutting edge comprises a centerline and a width. The blade comprises a plurality of cutters attached to the cutting edge. The blade is such that three or more of the plurality of cutters are each attached to the cutting edge of the blade body at a different position relative to the centerline of the cutting edge of the blade body.

What is claimed is: 
     
         1 . A blade comprising:
 a blade body comprising a cutting edge, wherein the cutting edge is disposed around a perimeter of the blade body, and wherein the cutting edge comprises a centerline and a width; and   a plurality of cutters attached to the cutting edge;   wherein three or more of the plurality of cutters are each attached to the cutting edge of the blade body at a different position relative to the centerline of the cutting edge of the blade body.   
     
     
         2 . The blade of  claim 1 , wherein the cutting edge comprises a first side and a second side, and wherein the second side is located on an opposite side of the centerline relative to the first side, and wherein:
 a first cutter of the plurality of cutters is located on the first side of the cutting edge;   a second cutter of the plurality of cutters is located on the second side of the cutting edge; and   a third cutter of the plurality of cutter is located at a different position with respect to the first cutter and the second cutter relative to the centerline.   
     
     
         3 . The blade of  claim 2 , further comprising a center arbor bore, wherein the blade rotates about an axis of rotation that is disposed within the center arbor bore, and wherein the first cutter is a leading cutter relative to the second cutter and the third cutter when the blade is rotated about the axis of rotation. 
     
     
         4 . The blade of  claim 3 , wherein a position of each of the plurality of cutters across the width of the cutting edge is alternated such that neighboring cutters are located on opposite sides of the width of the cutting edge relative to the centerline. 
     
     
         5 . The blade of  claim 3 , further comprising a cutting profile defining where a leading edge of each of the plurality of cutters is located relative to the centerline of the cutting edge, and wherein the plurality of cutters are attached to the cutting edge at different locations across the width of the cutting edge such that the cutting profile comprises eight or more different positions for the leading edge of a cutter relative to the centerline of the cutting edge. 
     
     
         6 . The blade of  claim 1 , wherein the blade is a microtrenching blade, and wherein the plurality of cutters are configured for shearing a material during operation. 
     
     
         7 . The blade of  claim 6 , wherein the plurality of cutters are attached to the cutting edge at different locations across the width of the cutting edge relative to the centerline of the cutting edge such that each of the plurality of cutters performs the same work when shearing the material during operation of the blade. 
     
     
         8 . The blade of  claim 1 , wherein each of the plurality of cutters is attached to the cutting edge at a back rake angle, and wherein the back rake angle is defined by a first axis that is perpendicular to the cutting edge of the blade at a center point of the cutter and is further defined by a second axis that is parallel to a leading edge of the cutter. 
     
     
         9 . The blade of  claim 8 , wherein the back rake angle of any of the plurality of cutters is from zero degrees to twenty degrees. 
     
     
         10 . The blade of  claim 8 , wherein the back rake angle of any of the plurality of cutters is from five degrees to fifteen degrees. 
     
     
         11 . The blade of  claim 8 , wherein the blade comprises two or more cutters attached to the cutting edge at different back rake angles. 
     
     
         12 . The blade of  claim 1 , wherein each of the plurality of cutters comprises a leading edge configured for shearing a material during operation, wherein the material comprises one or more of dirt, rock, asphalt, or concrete. 
     
     
         13 . The blade of  claim 1 , wherein each of the plurality of cutters comprises two or more chamfers and a shearing point, and wherein a dimension of the two or more chamfers is optimized for shearing a material during operation. 
     
     
         14 . The blade of  claim 1 , wherein the plurality of cutters is removably attached to the blade such that each of the plurality of cutters is interchangeable. 
     
     
         15 . The blade of  claim 1 , wherein the blade body is constructed of steel. 
     
     
         16 . The blade of  claim 1 , wherein the plurality of cutters are constructed of one or more of polycrystalline diamond compact (PDC), tungsten carbide, silicon carbide, boron nitride, or steel. 
     
     
         17 . The blade of  claim 1 , wherein the cutting edge of the blade is separated into a plurality of blade segments, and wherein each of the plurality of blade segments comprises four or more of the plurality of cutters. 
     
     
         18 . The blade of  claim 17 , further comprising a plurality of cutter trenches cut into the cutting edge of the blade, wherein each of the plurality of cutter trenches comprises a leading edge and a trailing edge relative to rotation of the blade during operation, and wherein one or more of the plurality of cutters is attached to the cutting edge of the blade at a trailing edge of a cutter trench. 
     
     
         19 . The blade of  claim 18 , wherein each of the plurality of blade segments comprises a leading edge and a trailing edge relative to the rotation of the blade during operation, and wherein a leading cutter attached to a blade segment does not comprise a corresponding cutter trench. 
     
     
         20 . The blade of  claim 1 , wherein the blade body is constructed of steel and the plurality of cutters are constructed of polycrystalline diamond compact (PDC) or carbide, and wherein the plurality of cutters are manufactured separately and independently of the blade body.