Gutter Expansion Joint Using TPO-Coated Steel Sheets
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Solution Overview
Problem
The existing gutter expansion joints are inefficient and expensive to manufacture due to the use of costly materials like aluminum and neoprene, and the finished sheet assemblies are difficult to flatten and shear, making them challenging to shape into a cross-sectional gutter form.
Innovation Solution
A gutter expansion joint composed of two metal sheets with a thermoplastic polyolefin-coated galvanized steel coating and a roof membrane strip, where the strips are secured with hot air and bent to fit the inner perimeter of adjacent gutters, accompanied by a non-curing sealant and a cover with matching cross-sectional elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If aluminum sheets and neoprene are used to construct the gutter expansion joint, then the joint can accommodate expansion and contraction of adjacent gutter ends, but the manufacturing cost increases significantly
Solution Approach 1:
The patent replaces expensive aluminum sheets and neoprene with cheaper materials: steel sheets with galvanized metal coating and thermoplastic polyolefin coating, and a roof membrane strip made from thermoplastic polyolefin. These materials achieve the same functional reliability at lower cost, embodying the principle of using more economical materials that still fulfill the required function.
Solution Approach 2:
The invention uses composite material structures: steel sheets with galvanized metal coating and thermoplastic polyolefin coating, combined with a thermoplastic polyolefin roof membrane strip. This composite approach provides the necessary durability and flexibility for expansion/contraction accommodation while reducing overall material cost compared to solid aluminum and neoprene construction.
2Ease of manufacture
If a finished sheet assembly is used for the gutter expansion joint, then the joint can be manufactured with standardized components, but the assembly cannot be completely flattened making it difficult to shear and shape
Solution Approach 1:
The patent divides the gutter expansion joint into separate components: first and second metal sheets, a roof membrane strip, sealant, and a cover. Each component can be manufactured and handled independently, then assembled together. This segmentation allows each part to be flattened and shaped separately without the constraints of a pre-assembled roll, simplifying the overall shaping process while maintaining standardized manufacturing benefits.
Solution Approach 2:
The metal sheets and roof membrane strip are provided in a flattened state before assembly, allowing them to be easily sheared and shaped using standard metal shears and bending operations. The preliminary flattening of individual components eliminates the difficulty of flattening a pre-assembled roll, enabling straightforward fabrication while still utilizing standardized material sources.
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
This solution reduces manufacturing costs and complexity by using more affordable materials and simplifies the shaping process, enabling efficient assembly and installation of the gutter expansion joint.
Implementation Method 1
A thermoplastic polyolefin coating is applied to one side of the first and second metal sheets
Implementation Method 2
A first end of the roof membrane strip overlaps the first metal sheet and is secured to the first metal sheet by heating the first metal sheet and the roof membrane strip with hot air or the like
Data Source
AI summary
A gutter expansion joint includes a first metal sheet, a second metal sheet and a roof membrane strip. A thermoplastic polyolefin coating is applied to one side of the first and second metal sheets. A first end of the roof membrane strip overlaps the first metal sheet and is secured to the first metal. A second end of the roof membrane strip overlaps the second metal sheet and is secured to the second metal sheet. The first metal sheet, the roof membrane strip and the second metal sheet are bent to be received by an inner perimeter of two adjacent gutters. A bead of non-curing sealant is applied to an inside surface of the two adjacent gutters, before insertion of the gutter expansion joint. A gutter expansion joint cover is attached to an outside perimeter of the two adjacent gutters.