Gutter cover

Abstract

This disclosure describes rain gutter covers that can include a mesh surface comprising: a plurality of stadium shaped raised regions in an alternating pattern that alternates between a first orientation and a second orientation, wherein the second orientation is rotated substantially orthogonal the first orientation; a first edge; and a second edge on an opposite side of the mesh surface than the first edge, the second edge comprising a lip protruding from the second edge away from a plane formed by the mesh, the first edge, and the second edge.

Description

TECHNICAL FIELD

[0001] This disclosure generally relates to a cover for a rain gutter.BACKGROUND

[0002] Gutter covers are designed to prevent leaves, twigs, pine needles, and other debris from clogging gutters. In general, they allow rainwater to flow freely into the gutters and away from your home, protecting your roof, foundation, and landscaping from water damage while preventing debris from entering, thereby reducing maintenance, preventing clogs and extending the lifespan of the gutters.SUMMARY

[0003] The present disclosure involves, systems, and an apparatus for providing a debris cover for a gutter. The cover can include a mesh surface comprising: a plurality of stadium shaped raised regions in an alternating pattern that alternates between a first orientation and a second orientation, wherein the second orientation is rotated substantially orthogonal the first orientation; a first edge; and a second edge on an opposite side of the mesh surface than the first edge, the second edge comprising a lip protruding from the second edge away from a plane formed by the mesh, the first edge, and the second edge.

[0004] Implementations can optionally include one or more of the following features.

[0005] In some instances, an edge of each raised region in the first orientation is substantially perpendicular to an edge of each raised region in the second orientation.

[0006] In some instances, the first edge and second edge are bent aluminum panels crimped onto the mesh.

[0007] In some instances, the alternating pattern is a cross-hatch pattern configured to slow liquid flowing over the mesh.

[0008] In some instances, the mesh includes a dam of raised mesh extending in rows between the raised regions.

[0009] In some instances, an edge of the dam forms a substantially 45 degree angle with an edge of each raised region.

[0010] In some instances, the dam and the raised regions are formed in the mesh by a stamping process.

[0011] The present disclosure further describes a cover comprising: a single piece of metal comprising: an upper portion, wherein the upper portion is folded thereby forming a shingle and gutter interface that is configured to slide under roof shingles and interface with a back rail of a gutter; a lower portion, wherein the lower portion is folded thereby forming a front lip interface that is engageable with the front lip of a gutter; and a middle portion, wherein the middle portion is a mesh of expanded metal that extends between the upper portion and the lower portion.

[0012] In some instances, the single metal piece is formed of stamped aluminum.

[0013] In some instances, the lower portion is folded to include a lip extending away from a plane defined by the middle portion.

[0014] In some instances, the upper portion is folded to include a slot extending away from a plane define by the middle portion, and a tab extending away from the plane in a different direction than the slot.

[0015] In some instances, the expanded metal comprises perforations that are longer in a horizontal direction than they are in a vertical direction.

[0016] In some instances, the expanded metal comprises sloped regions configured to direct water into the gutter.

[0017] The subject matter discussed herein can provide one or more of the following advantages. For example, certain implementations can be constructed of three or fewer individual pieces, and in some implementations, a single piece. By reducing the number of individual components, the gutter cover is simplified, and costs are reduced. Another advantage is that the disclosed mesh patterns can be more effective at slowing the flow of water, and therefore enabling increased flow into the gutter, while still preventing the entry of debris. Further, the disclosed system can be readily installed on conventional gutter systems, with little or no additional hardware or tools required to connect.

[0018] The details of these and other aspects and embodiments of the present disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the disclosure will be apparent from the description and drawings, and from the claims.DESCRIPTION OF DRAWINGS

[0019] FIG. 1 is a perspective view of a gutter with a cover installed.

[0020] FIG. 2 illustrates a top view of an example pattern that has enhanced water absorption.

[0021] FIG. 3 illustrates a top view of an alternative example pattern that has enhanced water absorption.

[0022] FIG. 4 illustrates a top view of an alternative example pattern that has enhanced water absorption.

[0023] FIG. 5 illustrates a top view of an example pattern that uses an expanded metal mesh.

[0024] FIG. 6 is a side view of expanded metal mesh with a preferred water flow orientation.

[0025] FIG. 7 is a perspective view of a cover with an integral lip and slot for toolless installation.DETAILED DESCRIPTION

[0026] This disclosure describes implementations for improved rain gutter covers. The disclosed improvements enhance water collection while preventing debris from entering the gutter and minimizes debris (e.g., leaves) from sticking to the cover. Further, this disclosure proposes a cover construction that minimizes material and fabrication costs, resulting in an effective, low-cost gutter cover.

[0027] FIG. 1 is a perspective view of a gutter 104 with a cover 102 installed. The gutter 104 can be mounted to a wall or roof of a structure and be configured to collect rainwater or other precipitation as it flows from rooftop 114. The collected rainwater is then drained into a downspout, preventing water from falling from the rooftop 114 directly to the ground to prevent erosion, pooling, or other water damage. If leaves, sticks, loose shingle material, or other debris enters the gutter 104, it can clog the downspout, and prevent the gutter 104 from functioning properly. To minimize this, and reduce cleaning, a cover 102 can be installed over the gutter 104.

[0028] The cover 102 includes a rear edge 106, mesh 108, and front edge 110 with a lip 112. In some implementations, the rear edge 106 and front edge 110 are a solid, structural material that supports the mesh 108 as it covers the gutter 104. In some implementations, the rear edge 106 and front edge 110 are folded aluminum that is crimped or pressed onto a wire mesh 108. In some implementations, the rear edge 106, front edge 110, and mesh 108 are formed of a single piece, such as a single piece of aluminum that has a portion expanded to create the mesh 108.

[0029] The front edge 110 can include a lip 112 that engages with an outer lip of the gutter 104 and ensures the cover 102 stays in place during heavy water flow or wind. Additionally, rear edge 106 can be angled, or include a tab and slot (illustrated below) that interfaces with the rooftop 114 to secure the back or building-side portion of the cover 102.

[0030] FIG. 2 illustrates a top view of an example pattern that has enhanced water absorption. The illustrated pattern can be formed on a mesh 108 by embossing, pressing, or otherwise distorting portions of the mesh to create raised stadium shapes 202 and raised symbols 204.

[0031] These raised portions of the mesh can improve the function of the mesh by a couple means. First, they can cause flowing water to flow in a longer path across the mesh 108. That is, the flowing water changes directions as it encounters the raised regions (stadiums 202 and symbols 204). This causes the flowing water to spend more time on the mesh, thereby allowing more water to flow through the mesh into the gutter. Additionally, by forcing the flowing water to change directions, its flow is slowed, further increasing the quantity of liquid that passes through the mesh 108. In the illustrated pattern, stadiums 202 raised in an alternating pattern with different 45-degree or 90-degree orientations cause liquid that flows down the edge of one stadium to impact the next stadium at a perpendicular angle, causing a maximum liquid slowdown and inducing maximum flow through the mesh 108. It should be noted that the raised stadiums 202 need not be oriented exactly perpendicular or orthogonal to each other. Instead, they can be orthogonal within a given range, for example plus or minus ten degrees of orthogonal can be considered substantially orthogonal.

[0032] Second, the raised stadium shapes 202 reduce the upper surface area of the mesh 108 that is likely to come into contact with debris such as leaves or sticks. The raised regions can provide volumes under which water can flow and reduce the likelihood of wet leaves sticking to the mesh 108 instead of being washed away by flowing water.

[0033] In some implementations, raised symbols 204 can be decorative additional shapes, and can be selected by a customer for their particular application. In some implementations, raised symbols 204 further demarcate the bottom edge of the mesh 108, for straightforward identification during assembly (e.g., when front edge 110 is pressed onto mesh 108).

[0034] FIG. 3 illustrates a top view of an alternative example pattern that has enhanced water absorption. The illustrated cover 306 is similar to cover 206 of FIG. 2, except that it includes a dam 308 and a number of intermediate dams 310. These dams 310 and 308 can be additional raised surfaces, which can be embossed, folded, or otherwise raised portions of the mesh 108.

[0035] The intermediate dams 310 can further slow and block water flowing between the raised stadiums 202, while the dam 308 can extend the entire length of, or a majority of the length of the cover 306. In some implementations, the dams 308 and 310 can be lowered portions, or bend into the mesh in the opposite direction of the raised stadiums 202. In some implementations, the dams 308 and 310 create continuous horizontal raised portions of the mesh 108. In some implementations, there are spaces between dams 310 and the raised stadium 202, and those spaces are smaller a water droplet formed by natural surface tension (e.g., about 4 mm or smaller) such that water flowing between the surfaces is likely to come into contact with either a raised stadium 202 or a dam 310 and be wicked into the gutter by the changing mesh geometry.

[0036] In general, the configuration illustrated in FIG. 3 further slows water flow across the mesh, further encouraging water to pass through the mesh into the gutter.

[0037] FIG. 4 illustrates a top view of an alternative example pattern that has enhanced water absorption. The illustrated cover 402 includes rows of repeated stadiums 406, which are in the same orientation as one or more adjacent rows. Rotated stadiums 404 are rotated orthogonally or substantially orthogonally to the repeated stadiums 406 and can themselves be repeated (as illustrated in the bottom two rows of FIG. 4).

[0038] Repeating orientation of the stadiums can be advantageous in that it can better induce diagonal or sideways flow across the top of the mesh 108, which creates a longer flow path for fluid traveling from the rear edge 106 to the front edge 110. It should be noted that the illustrated pattern is an example only, and other configurations of stadiums and orientations should be considered within the scope of this disclosure.

[0039] FIG. 5 illustrates a top view of an example pattern that uses an expanded metal mesh. The illustrated cover 502 can have a similar configuration to those above (e.g., cover 102) however the mesh portion can be made of an expanded metal mesh 508.

[0040] The expanded metal mesh 508 can be aluminum or other metal that is cut and stretched to form a mesh-like pattern. In general, a solid metal sheet is cut with a series of slits, then stretched causing the slits to expand and form diamond shaped (or other patterned) mesh. In this configuration, the entire cover 502 can be a single piece of aluminum sheet that was, for example, stamped, or roll formed to include a rear edge 506, the expanded mesh 508, and the front edge 510.

[0041] In some implementations, when the metal is stretched, and the expanded mesh 508 is formed, the remaining strands of metal are tilted, or the opened slits have a specific orientation. As shown in FIG. 6, the expanded mesh 508 can include a number of sloped regions 604, which can be positioned to encourage water flow 602 down into, and through the mesh 508. Thus, the expanded metal mesh 508 can have a preferred water flow orientation, and the cover 502 can be formed with that orientation selected.

[0042] FIG. 7 is a perspective side view of a cover with an integral lip and slot for toolless installation. Cover 502 is illustrated with expanded mesh 508, however other mesh patterns such as wire mesh, nylon mesh, etc. (e.g., mesh 108 of FIG. 1) are considered within the scope of this solution.

[0043] The rear edge 506 can be folded or rolled to form a slot 514 and a roof tab 512. The roof tab 512 can be configured to slide under the shingles or roofing components and ensure water flows from the roof onto the cover 502. Slot 514 can be configured to receive a back lip of the gutter, and allow the cover 502 to “snap” or index onto the top of the gutter without the use of additional hardware such as screws, clamps, or other fasteners.

[0044] The slot 514 can be formed by folding the metal five or more times. For example, a side of the slot closest to the expanded mesh 508 can be formed by folding the metal down, and then up again. The top of the slot 514 can then be formed by twice folding the metal in the same direction e.g., in a clockwise direction as illustrated. The second side of the slot 514 (e.g., closest to the roof tab 512) can be formed by folding the metal back up relative to the prior fold. After the slot 514 is formed, the roof tab 512 can then be formed by folding the metal in an opposite direction of the prior fold that completed the formation of the slot 514. As illustrated the final fold used to create the roof tab 512 would be a fold in a clockwise direction.

[0045] Similarly, front edge 510 can be folded, rolled, or pressed to include a lip 516. The lip 516 can index or catch on the front edge of the gutter and hold the cover 502 in place. In some implementations, the front edge 510 and the lip 516 are configured to deform some as the cover 502 is pressed into the gutter, and then “snap” or return to shape, allowing the cover 502 to positively engage with the gutter. In some implementations, the lip 516 is formed by first folding the metal extending past the desired width of the font edge 510 (e.g., the desired location of the end of the front edge 510) back under the front edge 510 and toward the expanded mesh 508, and then completing formation of the lip 516 by folding the metal down relative to the width of the front edge 510 (e.g., in a clockwise direction).

[0046] Although this disclosure has been described in terms of certain embodiments and generally associated methods, alterations and permutations of these embodiments and methods will be apparent to those skilled in the art. Accordingly, the above description of example embodiments does not define or constrain this disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of this disclosure.

[0047] The foregoing description is provided in the context of one or more particular implementations. Various modifications, alterations, and permutations of the disclosed implementations can be made without departing from scope of the disclosure. Thus, the present disclosure is not intended to be limited only to the described or illustrated implementations but is to be accorded the widest scope consistent with the principles and features disclosed herein.

Claims

1. A cover comprising:a mesh surface comprising:a plurality of stadium shaped raised regions in an alternating pattern that alternates between a first orientation and a second orientation, wherein the second orientation is rotated substantially orthogonal the first orientation;a first edge; anda second edge on an opposite side of the mesh surface than the first edge, the second edge comprising a lip protruding from the second edge away from a plane formed by the mesh, the first edge, and the second edge.

2. The cover of claim 1, wherein an edge of each raised region in the first orientation is substantially perpendicular to an edge of each raised region in the second orientation.

3. The cover of claim 1, wherein the first edge and second edge are bent aluminum panels crimped onto the mesh.

4. The cover of claim 1, wherein the alternating pattern is a cross-hatch pattern configured to slow liquid flowing over the mesh.

5. The cover of claim 1 the mesh comprising:a dam of raised mesh extending in rows between raised regions.

6. The cover of claim 5, wherein an edge of the dam forms a substantially 45 degree angle with an edge of each raised region.

7. The cover of claim 5, wherein the dam and the raised regions are formed in the mesh by a stamping process.

8. A cover comprising:a single piece of metal comprising:an upper portion, wherein the upper portion is folded thereby forming a shingle and gutter interface that is configured to slide under roof shingles and interface with a back rail of a gutter;a lower portion, wherein the lower portion is folded thereby forming a front lip interface that is engageable with the front lip of a gutter; anda middle portion, wherein the middle portion is a mesh of expanded metal that extends between the upper portion and the lower portion.

9. The cover of claim 8, wherein the single metal piece is formed of stamped aluminum.

10. The cover of claim 8, wherein the lower portion is folded to include a lip extending away from a plane defined by the middle portion.

11. The cover of claim 8, wherein the upper portion is folded to include a slot extending away from a plane define by the middle portion, and a tab extending away from the plane in a different direction than the slot.

12. The cover of claim 8, wherein the expanded metal comprises perforations that are longer in a horizontal direction than they are in a vertical direction.

13. The cover of claim 8, wherein the expanded metal comprises sloped regions configured to direct water into the gutter.

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