Corrugated Mesh Gutter Guard for Debris Filtering Without Support
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Solution Overview
Problem
Existing mesh-based gutter guards require a two-part structure with an underlying support to effectively filter water and prevent debris, increasing manufacturing costs and assembly complexity.
Innovation Solution
A single-part corrugated mesh gutter guard with a corrugated form, such as undulating or zig-zag cross-section, provides structural support and overcomes water adhesion without an underlying support, allowing water to drop into the gutter while preventing debris.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mesh-based gutter guard is used with an underlying support, then water can pass through while debris is precluded, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The patent combines the mesh filter layer and the underlying support structure into a single integrated component. The support structure is formed directly as part of the mesh assembly, eliminating the need for separate support pieces and reducing assembly steps while maintaining the dual function of debris filtration and structural support.
Solution Approach 2:
The mesh is divided into multiple layers with different functions: an upper mesh layer for debris filtration and a lower support structure with openings for water passage. This segmentation allows each layer to be optimized for its specific function while being manufactured as a single integrated component.
2Strength
If a mesh-based gutter guard with underlying support is used, then structural support is provided, but manufacturing cost increases
Solution Approach 1:
The support structure and mesh filter are manufactured as a single integrated component using continuous forming processes. This merging eliminates the need for separate manufacturing of support pieces and subsequent assembly, reducing manufacturing cost while maintaining structural integrity.
Solution Approach 2:
The mesh is constructed as a flexible yet structurally sound thin film that can be formed into the final shape with integrated support features. This allows the mesh to provide structural support through its formed geometry rather than requiring additional rigid support components.
3Reliability
If water tension and molecular cohesion act on the mesh, then water clings to the mesh, but water passage through the mesh is frustrated
Solution Approach 1:
The mesh structure incorporates varying opening sizes and patterns in different regions. Areas with larger openings are positioned where water flow is greatest, while smaller openings are used where debris filtration is most critical. This local variation in mesh quality optimizes both water passage and debris preclusion.
Solution Approach 2:
The patent introduces a vertical dimension to water passage by creating a multi-layer mesh structure with downward-sloping channels. Water is directed along the slope of the channels, using gravity to overcome surface tension and adhesion forces, thereby improving water passage efficiency while maintaining debris filtration.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The corrugated mesh effectively filters debris and directs water into the gutter, reducing manufacturing costs and assembly complexity while maintaining structural integrity.
Implementation Method 1
providing a corrugated form of either an undulating sinusoidal nature or a zig-zag toothed nature, or other cross-section. Such a cross-section for the mesh causes the mesh to have greater strength particularly in resisting bending.
Implementation Method 2
The phenomena of water tension and molecular cohesion tend to cause water to not want to pass through such mesh layers, but rather to cling to the mesh.
Implementation Method 3
These forces thus frustrate the ability of mesh based gutter guards to allow water to pass through the mesh while precluding debris from passing into the gutter.
Implementation Method 4
Holes in the underlying support then allow water to drop through in larger drops where the weight of the drops is sufficient that the surface tension and adhesion forces cannot resist such dropping.
Data Source
AI summary
Corrugated fine mesh material is configured to be located overlying a gutter. The fine mesh material has an upper edge opposite a lower edge with the upper edge configured to fit beneath shingles on a roof adjacent the gutter. The lower edge is configured to be held to a lip at a forward edge of the gutter. The corrugations add strength to the material and collect water at troughs thereof where the collected water more readily forms droplets that fall down into the gutter. A lower strip is preferably provided to hold the lower edge of the mesh to a lip of the gutter. An upper strip is optionally provided which includes a tab, which can fit beneath shingles to the roof. A barrier such as a bead of caulk can optionally be coupled to an underside of the corrugated mesh to further encourage water droplets to fall.