Roll-forming machine for gutter cap and method for making same

Abstract

A novel roll-forming machine is disclosed for making caps to cover rain gutters and prevent the entry of debris into the rain gutters that cause damming and overflow. The roll-forming machine may be used in a predetermined manner to manufacture caps of different profiles in substantially any desired length, thus substantially reducing the number of joints between adjacent sections and increasing the amount of water run-off captured within the rain gutters. Also disclosed is a unique rain gutter cap profile substantially complementing the generally angular design of standard rain gutters while still maximizing the redirection of water into the underlying rain gutter while keeping potentially clogging debris from entering the rain gutter.

Description

CROSS-REFERENCE TO RELATED APPLICATION [0001] This application claims priority from U.S. Provisional Patent Application filed Jul. 1, 2004 and assigned application Ser. No. 60 / 584,932, the contents of which are incorporated herein by reference.BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] This invention relates to devices for diverting water from a surface and particularly to a unique device for reducing the amount of detritus allowed to fill a rain gutter while maximizing the diversion of water into the gutter. This invention also relates to a method and apparatus for manufacturing such a device as well as a unique gutter cap configuration. [0004] 2. Discussion of the Related Art [0005] Gutters are mounted to the drip edges of houses and other structures to capture water runoff from the roof structures and divert the water to predetermined locations. These traditional structures consist of a trough attached to the fascia board or similar structure adjacent the...

AI Technical Summary

Benefits of technology

[0009] It is an object of the instant invention to substantially increase the flow of water from a gutter cap into an underlying gutter trough.

[0010] It is another object of the instant invention to produce a gutter cap that can be formed from a continuous length of metal without the need for creating spices, butt-joints or overlapping joints.

[0013] According to another form of the invention, a gutter trough is attached to the fascia board of a building a predetermined distance below the drip edge of the roof. A mounting bracket having a number of stepped segments engages the outer most edge of the gutter to provide structural rigidity for the trough. The opposite end of the mounting bracket engages the opposite surface of the gutter trough. At least one fastener is passed through the mounting bracket and into the underlying fascia board to hold the gutter trough in position.

[0016] In each of the embodiments described above, the flow of the water down the upper surface of the gutter cap is dispersed to generally form a sheet. Because of surface tension (molecular attraction) between the substrate and the water, the water flows substantially evenly over the cap surface. As the water approaches the nose, the adhesion property directs the water around the nose and into the gutter trough. In the embodiments where a water break or flange is provided above the trough, the water impacting the flange is redirected in a spray-like fashion into the trough. This intentional agitation of the runoff water helps keep small particles of detritus in suspension to flow down gradient. Larger debris entrained in the water runoff over the gutter cap is unable to remain in suspension and is forced over the nose and away from the gutter trough, leaving the gutter free of clogging debris.

[0017] The advantages of the instant invention include the dispersal effect of the water on the cap surface, increasing the adhesion property of the water to the surface and increasing the amount of water deposited within the trough. Another advantage of the instant invention is the capture of a substantial portion of the water runoff as a result of the water passing into the perforated opening up slope surface of the cascading ridges or ripples. Another advantage of the instant invention is the unique mounting bracket used to mount the gutter trough to the fascia board and its function of anchoring the lower edge of the cap within the trough. The mounting bracket, in combination with the downwardly depending flange of the cap continuously agitates the water, keeping small sediment in suspension as it moves along the trough and down the downspouts. This results in a cleaner trough and improved water flow.

Problems solved by technology

The efficiency of rain gutters is substantially hampered by the amount of debris and detritus within the troughs.

The debris accumulating along the wire mesh would then present an emergent obstacle that would divert water runoff at angles that often overshot the trough.

Over time, the debris field on top of the wire mesh often caused a collapse of the mesh such that the debris ultimately dammed the water flow to the drain pipe.

The adhesion coefficient for debris was much lower resulting in the debris being swept off the end and onto the ground below.

However, depending upon the amount of rainfall, the radius of curvature was too great, resulting in water cascading off of the radius curve and falling onto the ground, essentially defeating the purpose of the gutter guard in the first place.

Another disadvantage with gutter cap systems is that they are precut into fixed lengths.

At times, these precut lengths are insufficient to span the entire distance of a single run, resulting in the need to splice and overlap joints.

Coefficients of expansion and contraction also influenced these caps, causing the caps to become dislodged and unsightly.

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