Preferred embodiments of the invention are shown in the drawings, wherein:
The gutter cover 2 shown in
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
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
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 over a folded or rolled inside edge of a metal eavestrough such as a rolled aluminum eavestrough. As shown in
The cover segment 4 includes a textured upper surface 29 (
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 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 miter. The thin gauge of the plastic gutter cover makes it very easy to cut either with a saw or with a razor knife.
As shown in
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.
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
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 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
In
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.
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 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 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.