Note: Descriptions are shown in the official language in which they were submitted.
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TITLE: GUTTER COVER
FIELD OF THE INVENTION
The present invention relates to a gutter cover
and in particular, to a gutter cover that can be applied
to a number of different types of eavestrough systems and
is designed to produce a water sheeting effect as the
rain water moves across the gutter cover.
BACKGROUND OF THE INVENTION
In many situations, eavestroughing systems are a
significant maintenance problem with respect to the
accumulation of seeds, sticks and leaves that fall from
adjacent trees. It is known to retrofit such eavestrough
systems with a perforated mesh of a metal or plastic
which is basically supported in the eavestrough at or
slightly below the edge of the eavestrough. Such
perforated eavestrough covers are effective in some
situations, however, the perforations allow some debris
to pass therethrough and depending upon the particular
environment, these perforated eavestrough covers are not
satisfactory. Leaves and sticks can also become lodged
in the perforations and cause further difficulties.
Often such perforation covers reduce the problem
associated with debris accumulation in the eavestrough
but may require cleaning of the covers themselves from
accumulated debris.
A different approach for eavestrough covers is to
use a solid cover and provide the cover with a rounded
transition section positioned adjacent the front edge of
the eavestrough. Water due to surface tension, tends to
follow the rounded transition whereas debris tends to be
discharged off the eavestrough cover. Below the rounded
t:ransition is a series of gaps for allowing the water to
enter the eavestrough. With these systems there are no
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perforations on the upper surface and thus, the
accumulation of debris on the cover is significantly
reduced.
The present invention relates to improvements in
eavestrough solid covers and to disperse of rivulets of
water which are formed on the roof. Such rivulets are
effectively disbursed to form a sheet like water layer on
the eavestrough cover. This sheet like layer more
closely follows the rounded transition contour of the
eavestrough cover and directs water into the eavestrough
while separating debris from the water. In addition, the
present invention is directed to a system which can be
secured in a quick and effective retrofit manner to a
number of different eavestrough systems of different
materials.
The invention is also directed to an efficient
method for producing the solid eavestrough gutter cover.
SUMMARY OF THE INVENTION
An eavestrough gutter cover according to the
present invention is made of an extruded plastic material
and comprises a cover segment, a rounded transition edge,
and an undercut angled section joining with a perforated
pass through portion located beneath the covered segment.
The perforated pass through portion allows water to
freely pass therethrough. The perforated pass through
portion includes an integral resilient clip sized for
securing of the gutter cover to an eavestrough edge or to
an upper fastening portion of an eavestrough hook.
The eavestrough gutter cover is designed for use
on many plastic eavestrough systems that include what is
referred to as a hidden hook. The hidden hook engages
the inside front edge of the eavestrough and is
effectively hidden from view by the eavestrough. These
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hooks typically include an upper flange for engaging an
eavestrough cover and retaining an eavestrough cover.
The present eavestrough gutter cover has the resilient
clip for securing to such hooks. In addition, the
5-resilient clip is somewhat oversized to define a
significant recess therebehind. This recess is designed
:Eor accommodating the rolled or folded edge of a metal
eavestrough. With aluminum eavestroughing systems, the
gutter cover directly engages the inside rolled edge of
the eavestrough.
In a preferred aspect of the eavestrough gutter
cover, the resilient clip extends below the pass through
portion.
In a further aspect of the invention, the
resilient clip includes an upwardly and outwardly angled
return ramp formed to one side of the pass through
portion.
In yet a further aspect of the invention, the ramp
terminates at a position below the rounded transition
edge and at a forward position inwardly of the rounded
transition edge.
In a further aspect of the invention, the covered
segment includes a textured upper surface adjacent the
rounded transition edge that serves to slow water runoff,
break up rivulets, and improve flow of water runoff
around the transition edge for collection and discharge
through the pass through portion of the gutter cover.
In yet a further aspect of the invention, the
,covered segment includes in a generally central position
across the width thereof, an integral hinge allowing the
cover segment when installed to have an angled section
joining a horizontal section with the horizontal section
separating the angled section from the rounded transition
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edge. This serves to further slow the water prior to the
water encountering the transition edge. The slowing of
the water and the textured upper surface will also serve
to spread any rivulets of water.
In yet a further aspect of the invention, the
resilient clip includes an oversized recess located
behind a narrow forward slot that when forced open
includes a memory function urging the resilient clip to
return towards the narrow forward slot position and thus
secure the resilient clip to a component inserted
therein.
The resilient clip is preferably installed on
metal eavestrough by first inserting an end portion of
the clip onto the eavestrough and then progressively
insert the edge of the eavestrough into the clip along
the length of the gutter cover.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are shown
in the drawings, wherein:
Figure 1 is a sectional view showing the
eavestrough cover secured above a plastic eavestroughing
system;
Figure 2 is a partial perspective view from
underneath showing the gutter cover and the trapezoidal
ports and "C" clip fastening arrangement;
Figure 3 is a partial perspective view of the
eavestrough gutter cover and the textured upper surface
thereof;
Figure 4 is a partial perspective view of the
extension die;
Figure 5 is a partial perspective view of the
gutter cover as outputted from the extension die;
Figure 6 is a partial perspective view of the
gutter cover passing through a first preformer;
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Figure 7 is a partial perspective view of the
gutter cover downstream of the first preformer being
embossed;
Figure 8 is a partial perspective view of the
gutter cover passing through a second preformer with an
angled transition added adjacent the "C" clip;
Figure 9 is a partial perspective view of the
gutter cover passing through a calibrator completing the
forming of the transition segment adjacent the "C" clip;
Figure 10 is a partial sectional view through the
calibrator cooling tank;
Figure 11 is a partial perspective view of the
gutter cover after the calibrator; and
Figure 12 illustrates the final punching
operation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The gutter cover 2 shown in Figure 1 has a cover
segment 4 which extends across the top of the eavestrough
and partially extends under the shingles of the roof as
shown at 5. The rounded transition 6 merges with the
cover 4 at a forward edge of the eavestrough 100 with the
undercut angled section 8 located beneath the rounded
transition 6. Water passes over the cover segment 4 as
it leaves the roof 9 and effectively spreads out and
slows on the cover segment 4. The water then follows the
rounded transition whereas debris such as leaves and
sticks will merely fall outside of the eavestrough. The
undercut angled section 8 directs the water downwardly
and rearwardly.
The perforated pass through portion 10 is provided
at the base of the undercut angled section 8 and allows
the water to leave the gutter cover and enter the
eavestrough 100. The perforated pass through as shown in
Figures 2 and 3 have a series of alternating trapezoidal
sections 15 such that the walls 17 between adjacent
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perforations 15 are at an angle. In this way, water
that passes along the undercut angled section 8 will
encounter a perforation and will have a tendency to pass
through the eavestrough gutter cover and into the
eavestrough. The water either encounters the top edge of
a perforation 15 or leaves the angled wall 17.
The integral resilient clip 14 is located at a
front edge of the eavestrough cover 2 and is designed for
engaging a rearwardly extending flange 101 of the plastic
hidden eavestrough hook 102 as shown in Figure 1.
Adjacent a front edge of the gutter cover and above the
resilient clip 14 is the ramp edge 18. The ramp edge 18
is preferably parallel outwardly angled relative tot he
angled section 8 of the final product. This provides
easier access for the eventual pending operation. This
serves to partially stiffen the upper arm 24 of the
resilient clip and to also act as a last barrier for any
water which has not been discharged through the
perforated pass through portion 10. As can be
appreciated, due to surface tension and a capillary
action, water will pass around the rounded transition 6
and this desirable property allows the redirection of
water towards the perforated section 10. This same
surface tension can result in some water clearing the
perforated pass through portion 10. The ramp edge 18
further slows any water and acts as a final deterrent
whereby water is directed to the perforated pass through
10.
The lower arm 26 of the resilient clip includes a
weakened portion 29 forming an integral hinge point 28.
This runs the length of the eavestrough cover. The
resilient clip 14 is designed to have sufficient strength
for engaging and being retained by the hidden eavestrough
hook 102 where these eavestrough hooks are spaced every
several feet along the front edge of the eavestrough. In
addition, the resilient clip is designed to be inserted
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over a folded or rolled inside edge of a metal
eavestrough such as a rolled aluminum eavestrough. As
shown in Figure 1, the resilient clip 14 is oversized for
engaging a rolled edge of a metal eavestrough, such as
aluminum eavestrough commonly used in new construction
installation and for retrofit applications. The
resilient clip 14 is relatively strong and for insertion
on the metal eavestrough, it is more convenient to
initially insert the clip at one end of the eavestrough
cover and progressively apply the clip to the edge by
moving along the eavestrough cover. The clip is forced
open and includes an integral return bias due to memory
of the clip.
The cover segment 4 includes a textured upper
surface 29 (Figure 3) formed during the forming process
of the gutter cover. An embossing operation applies a
textured surface which is recognizable by touch but is
relatively minimal. The textured surface varies
approximately 2.8 to 3.6 microns.
It has been found that a typical roofing system is
designed to direct water away from the edge of the roof
and often the rain water strikes the gutter cover in
rivulets. These rivulets have a significant flow and the
water is somewhat concentrated in the rivulets as it
strikes the gutter cover. This flow of rainwater off the
roof also tends to bring with it leaves, seeds and other
debris. It is important with the eavestrough gutter
cover to provide a system where debris does not
accumulate in the eavestrough, however, this must be
balanced with the ability of the system to effectively
direct the water towards the eavestrough system. It has
been found that the texturing of the upper surface of the
gutter cover acts to disperse the rivulets and cause a
sheeting action of the water across the gutter cover.
This serves to improve the properties of the water
flowing around the rounded transition 6 and also serves
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to slow the water as it travels across the cover. In
some conditions, certain debris may remain on the gutter
cover temporarily, however, it will blow off or flow off,
depending upon the particular circumstances. Thus, it is
desirable to slow the water flow and improve the
redirection of the water flow around the rounded
transition and rearwardly and downwardly towards the
eavestrough. At the base of the angled section 8, it is
desirable for the water to not encounter any portion of
the plastic cover so it can enter the eavestrough located
below this perforated portion. The angling of the
perforation walls and the minimal size of any connecting
walls 17 assures more water enters the eavestrough.
It has been found that this gutter cover is
effective with many different eavestroughing systems
including conventional rolled metal eavestroughing
systems as well as plastic/vinyl systems. In many
eavestroughing systems about a house, there may be a
particular area where leaf accumulation within the
eavestrough is a problem. The solid vinyl gutter cover
:in the present invention can easily be applied to the
sections of the eavestrough having such problems.
The gutter cover sections are sold in lengths of
:1.8 inch increments and can easily be cut to the required
length. Any obstructions such as hooks, for example, in
a metal eavestrough, can be accommodated merely by
cutting out a portion of the clip of the gutter cover.
At corners, it is preferable to provide a 45 degree
initer. The thin gauge of the plastic gutter cover makes
it very easy to cut either with a saw or with a razor
knife.
Figure 4 shows the extrusion die 150 used to
initially extrude the eavestrough cover 2. The die 150
includes a semi circular gap 152 whereby the gutter cover
is extruded in a shape corresponding to about two thirds
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of a circular pipe. This partial circular shape allows
better balancing of the extrusion process and thus allows
faster extrusion of the solid gutter cover. After the
initial extrusion, the gutter cover goes through a series
of steps to apply the textured surface and to effectively
impart the desired shape to the gutter cover. These
progressively alter the semi circular type shape to the
generally flat final shape of Figure 12. One of the
significant problems associated with extruding of the
gutter cover is the ability to maintain the shape of the
resilient clip 14.
As shown in Figure 4, a cooling pipe 160 is
associated with the gutter cover immediately downstream
of the extrusion die 150 and this cooling pipe serves to
maintain the separation and shape of the upper arm 24 and
lower arm 26 and the clip 14. This pipe 160 removes heat
from the extruded product as it is positioned within the
resilient clip and serves to maintain this initial shape.
This cooling pipe extends a certain distance downstream
of the die until sufficient heat has been removed that
the arms of the resilient clip are still resilient but
the tendency of the clip to collapse on itself has been
removed. An air flow is provided through the pipe and
discharged out the end of pipe 160 into the length of the
clip.
The gutter cover subsequently passes through a
series of steps including first and second performers to
partially flatten the eavestrough cover and progressively
form the transition edge. Figures 4 through 12
illustrate the process.
The semi-circular shape of the product extruded
from die 150 is required to go through a number of
transitional steps to produce the product as finally
shown in Figure 12. The "C" clip 14 has a tendency to
collapse upon itself and the cooling pipe 160 effectively
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separates the upper arm 24 from the lower arm 26 and
maintains the shape of the clip. The product as it exits
the die 150, depending upon the particular material, may
be at a temperature of approximately 350 F and the plastic
5:is very soft and somewhat flowing. The cooling pipe 160
starts to remove heat from the "C" clip while maintaining
the desired shape thereof. In addition, as the product
exits the die, additional air may be provided to
partially cool the remaining portion of the gutter cover
as shown by the air outlet 165.
Figure 6 shows the gutter cover passing through a
first preformer 170 where the semi-circular product is
partially flattened but remains in an arc shape. The
preformer 170 has a particular slot 172 which acts as a
guide for the desired shape and the preformer 170 is
water cooled. The preformer does have a significant
clearance with respect to the product but it does impart
the general shape as shown in Figure 6. Heat is
continuing to be removed from the product between the
extrusion die 150 and the preformer 170. Downstream of
the first preformer is an embossing arrangement
comprising a support roller 180 provided on the lower
surface of the gutter cover and a textured embossing
roller 182 engaging the upper surface of the gutter
cover. The embossing roller 182 effectively embosses a
large portion of the upper surface of the gutter cover
but does not engage the resilient clip 14.
The purpose of the embossing roller is to texture
the upper surface to effect dispersion of the water and
evening of the water flow across the surface of the
gutter cover. The textured surface also improves water
adhesion as water passes around the rounded transition
for discharge through the trapezoidal ports. Preferably,
the textured surface stops at the trapezoidal ports. The
embossing roller and the support roller 180 are both
water cooled and are quite effective in removing heat
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from the gutter cover. The more significant problem is
trying to remove heat from the resilient clip and keep it
within a reasonable temperature range relative to the
cooler portion of the gutter cover contacted by the
embossing roller and support roller. The product leaving
the embossing roller may be in the order of 150 F to
200 F.
Although the gutter cover has passed through the
embossing rollers, the gutter cover is relatively flat
and it is necessary to form the transition edge of the
gutter cover. A second preformer 190 is shown in Figure
8 and forms the angled section 8 and what will become the
rounded transition 6. Again the preformer 190 is water
cooled and the product defining slot 192 is slightly
oversized relative to the gutter cover. This is
important as the embossed surface 19 is to be maintained.
In Figure 9, the calibrator 200 is shown which is
used to impart the final shape and dimensions to the
product. The calibrator 200 includes a vacuum
arrangement engaging the lower surface of the gutter
cover but the top surface is not subject to a vacuum
which would provide more accuracy with respect to the
gutter cover. Such a top vacuum would draw the surface
:19 into engagement with a calibrator 200 and seriously
reduce the embossed surface 19 provided on the upper
surface of the gutter cover.
Figure 10 shows a section through the calibrator
with a series of vacuum ports 210 provided on the lower
surface of the calibrator while the top surface of the
gutter cover is not subject to a vacuum. The calibrator
200 connects to and forms part of the cooling tank 230
having a water level 232 slightly above the upper surface
of the gutter cover. Some leakage of water along the
upper surface of the gutter cover is shown as 234,
however, the movement of the gutter cover through the
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calibrator avoids any water on the upper surface at the
inlet to the calibrator. The gutter cutter is discharged
to the tank below the water level and the product is
finally cooled. The final shaping does impart a hinged
line 240 which allows bending of the cover adjacent a
roof side edge necessary to form a transition between the
angled roof and a more flat surface of the gutter cover
used to slow the water.
Figure 11 shows the final shape of the gutter
cover with the exception that the trapezoidal ports 15
have not been formed in the cover. At the base of the
undercut angled section 8, a punch 300 can enter through
the gap 302 to effect the formation of the ports provided
at the base of the angled section 8. The gap 302 tapers
inwardly but has a sufficiently large mouth to allow the
punch 302 to enter the gap and effect the formation of
the ports. Typically, two punches are used at a time for
forming two ports with the gutter cover progressively
moving through a punching station. Preferably, one of
these punches is not operated at a position where the
gutter cover is to be cut. Typically, the gutter cover
is provided in a certain length, such as three or four
feet, and at a cut position, one of the trapezoidal ports
14 is not punched and this provides an end section to
each of the two gutter cover pieces.
As outlined above, a significant problem
encountered in manufacturing this product is effecting
heat removal in a controlled manner to reduce or
eliminate distortion. The embossing rollers remove a
large amount of heat while the clip area remains at a
higher temperature. Additional cooling air is directed
to the clip portion which is not in contact with the
embossing rollers. The process reduces the temperature
differential across the width of the gutter cover to
avoid warpage.
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The gutter cover is progressively altered in shape
by first and second performers that are water cooled. As
can be appreciated, once the textured surface has been
applied to the gutter cover any precise sizing of the
gutter cover downstream of the embosser, such as common
in double sided vacuum arrangements, would remove this
desired textured surface. In the final forming shape
carried out at the calibrator 200, the calibrator is
associated with a water tank 230 and there is some water
weepage along the calibrator to provide the necessary
seal for vacuum forming. A vacuum source is provided at
the bottom of the die, however, the top surface does not
have vacuum ports supplied thereto in order to maintain
the textured surface. Thus, the water in the tank 230 is
above the surface of the gutter cover. The water level
in the tank is adjusted to maintain the seal of the final
calibrator with the gutter cover while avoiding water
flow through the die. The water on the upper surface of
the gutter cover in the die effectively provides the
vacuum seal. In this way, the part can be sized and
shaped to its final shape and shown in the drawings while
maintaining the textured upper surface.
The final part after leaving the final sizing die
is passed through a water bath and effectively cooled.
The gutter cover then continues to be punched and cut in
a cutting and punch station. Typically, two perforations
are cut at the same time and thus, a gutter cover of a
length of 1.8 inch increments has a series of punching
steps as it moves through the device. Two punches are
used at a cut transition, one of the punches does not
strike. This provides a solid section and this solid
section is then cut to provide a strong end portion.
As can be appreciated, the present method extrudes
a generally semi circular type product with a resilient
clip at one end thereof. This product is then partially
straightened and embossed on a substantial portion of the
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width of the product as part of the manufacturing
process. The angled section is then imparted to the
product with the clip at an exposed end thereof.
Subsequent steps are taken to effect final forming of the
product through a die in a manner to impart a reversed
transition of the angled section while defining a
progressively opening gap in an undercut portion. This
progressively opening portion is located below the
:rounded transition and is necessary to allow effective
punching of the gutter cover to form the perforated pass
through section. The punches used to form the perforated
section are of a trapezoidal shape with these trapezoidal
shapes partially overlapping to form angled bridging
sections. These angled bridging sections are maintained
to a minimum and are disposed at alternate angles whereby
water flow around the rounded transition will encounter a
perforation.
It has been found that the particular gutter cover
works effectively and can be manufactured in a cost
effective manner.
The formation of the spring clip and the large
cavity between the upper and lower arms is possible due
to effective heat removal immediate downstream of the
extrusion die. Heat is typically removed from this
clipped portion by means of the initial copper pipe as
well as the direction of air to this section. The heat
from the remaining portion of the gutter cover is removed
by contact with the embossing rollers and contact with
the various performers, all of which are water cooled.
In the discussion of the angled walls of the
perforated section, the angled walls improve the amount
of water entering the trough. These angled walls 17 also
have the purpose of acting as a brace or support edge for
the front clip and serve to connect the front clip to the
remaining portion of the cover. This bracing serves to
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provide sufficient strength to maintain the shape of the
cover and avoid sagging between eavestrough hooks which
may be present or effective support between the front
edge of the eavestrough and where the cover is supported
beneath the shingles. As can be appreciated, the bracing
strength is balanced against the ability of the system to
direct water into the eavestrough.
Although various preferred embodiments of the
present invention have been described herein in detail,
it will be appreciated by those skilled in the art, that
variations may be made thereto without departing from the
spirit of the invention or the scope of the appended
claims.
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