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 drip edge of the roof so as to collect the runoff from the overlying surface. The water collected in the trough flows down gradient to a downspout where it is collected, or dispersed onto the ground. The efficiency of rain gutters is substantially hampered by the amount of debris and detritus within the troughs. In particular, leaves, branches, and the like entrained within the runoff are captured within the trough and act as a dam to the flow of water to the downspout.  
         [0006]     To alleviate the capture of unwanted debris, wire mesh was used to capture the debris. 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.  
         [0007]     Later designs to keep debris from entering the gutters included the use of a solid sheet of metal or plastic material that substantially covered the rain gutter. The outer edge of the sheet included a predetermined radius intended to direct the water runoff into the trough using the physical properties of adhesion. 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.  
         [0008]     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.  
       SUMMARY OF THE INVENTION  
       [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.  
         [0011]     In another form of the invention, a unique machine is devised for manufacturing gutter caps that carryout the foregoing objects.  
         [0012]     According to another form of the invention, a gutter cap is provided having a gently sloped upper surface positioned beneath the roofing surface of the building or other structure. Spaced along the sloped upper surface may be one or more ridges extending along at least a portion of the length of the gutter cap. The gutter cap may also contain one or more rows of perforation up-slope of the ridges to permit the passage of water directly into the underlying gutter trough. Down slope of the ridges or ripples, the gutter cap is radiused such that the terminal end or lower limb of the gutter cap extends at least partially above the trough.  
         [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.  
         [0014]     Another form of the invention includes a flange that is angled and received beneath a downwardly extending flange of a drip edge normally attached to the edge of the roof structure. Away from the angled flange, the gutter cap forms a sloping surface to a point slightly beyond the outer edge of the gutter trough. At that point, the gutter cap is radiused to form a nose. The radius of the nose portion is preferably greater than 0.03125 inch, but may be smaller so long as the degree of the bend does not disturb the substantially smooth texture of the sloped surface to interfere with the flow of water over the surface. The edge of the gutter cap opposite the flange extends back under the sloped surface and terminates above the gutter trough to divert the water into the trough. The terminal end of the gutter cap is retained in position by the mounting bracket used to fix the gutter trough to the building.  
         [0015]     In yet another form of the invention, a gutter trough is attached to the fascia board of a structure by a mounting bracket located within the gutter trough. The mounting bracket includes a plurality of step-like structures, one of which engages the outmost edge of the gutter trough. The opposite end of the mounting bracket engages the opposite side of the trough and is adapted to receive at least one downwardly-angled fastener to attach the gutter trough to the fascia. An overlying gutter cap is provided and includes a sloped planar upper-surface designed to be received under the roofing material by a predetermined distance such that runoff from the roofing material flows onto the gutter cap. The opposite edge of the gutter cap is directed back under the sloped surface to form a nose of predetermined profile. The end extending back under the sloped surface terminates above the gutter trough. This edge of the gutter cap terminating above the gutter trough includes a flange that is attached at a predetermined location to the mounting bracket.  
         [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.  
         [0018]     These and other advantages will become readily apparent when taken in combination with the following detailed description and the drawing figures.  
     
    
     BRIEF DESCRIPTION OF THE DRAWING FIGURES  
       [0019]      FIG. 1  is an oblique view of one embodiment of a rain gutter cap.  
         [0020]      FIG. 2  is a schematic side elevation view of one embodiment of a roll-forming machine for creating the gutter cap shown in  FIG. 1 .  
         [0021]      FIG. 3  is a plan view of the invention shown in  FIG. 2 .  
         [0022]      FIG. 4  is a bottom view of the invention shown in  FIG. 2 .  
         [0023]      FIG. 5  is a section view of the invention taken along line V-V.  
         [0024]      FIG. 6  is a section view of the invention taken along line VI-VI.  
         [0025]      FIG. 7  is a section view of the invention taken along line VII-VII.  
         [0026]      FIG. 8  is a section view of the invention taken along line VIII-VIII.  
         [0027]      FIG. 9  is a section view of the invention taken along line IX-IX.  
         [0028]      FIG. 10  is a section view of the invention taken along line X-X.  
         [0029]      FIG. 11  is a section view of the invention taken along line XI-XI.  
         [0030]      FIG. 12  is a section view of the invention taken along line XII-XII.  
         [0031]      FIG. 13  is a section view of the invention taken along line XIII-XIII.  
         [0032]      FIG. 14  is a section view of the invention taken along line XIV-XIV.  
         [0033]      FIG. 15  is a section view of the invention taken along line XV-XV.  
         [0034]      FIG. 16  is an oblique view of another embodiment of a gutter cap manufactured according to the method and providing improved capture of water run-off.  
         [0035]      FIG. 17  is an oblique view of an alternate embodiment of the gutter assembly. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0036]     The instant invention include a novel cap for a rain gutter intended to exclude debris, yet capture water runoff from the roof structures of buildings and the like. In combination with the novel gutter cap is a novel and unique bracket used to mount a rain gutter to a fascia board of the structure. In addition, a unique method and machine are disclosed for making this inventive gutter cap.  
         [0037]      FIG. 1  generally illustrates an embodiment of a rain gutter assembly  20  including a rain gutter  22  having a predetermined profile and mounted to a fascia board  24  of a structure or building  26 . In this particular case, the rain gutter  22  includes an inside vertical flange  28  integral with a bottom flange  30  extending generally perpendicular there from. Extending upward from the distal edge of the flange  30  is an outer flange  32  often shaped into a decorative profile. In the rain gutter  22  shown, the outer flange  32  terminates with a capture surface  34  inclined in towards the interior of the rain gutter  22 . Depending from the inner edge of capture surface  34  is a drip edge  36  angled back towards the outer flange  32 . The angling of capture surface  34  and drip edge  36  create a partially enclosed space  38  for reasons that will become readily apparent below. As is conventional in rain gutters, aluminum or plastic may be used to build the gutter trough  22 .  
         [0038]     Anchoring and fixing the rain gutter  22  to the fascia board  24  are a plurality of stepped mounting-brackets  40 . Each mounting bracket  40  includes a lower flange  42  connected by a plurality of webs  44  to a cascading series of stepped flanges  46 , each having one end terminating in a vertical wall of an adjacent step, and the other end forming the crest of the subsequent step. As shown in  FIG. 1 , each step  48  has an upper surface inclined toward the fascia board  24 . The first end  50  of each mounting bracket  40  includes at least one inclined port  52  adapted to receive a fastener therein intended to penetrate the flange  28  of the rain gutter and pass into the fascia board  24  to secure the rain gutter  22  in place. The inclined angle provided by port  52  when taken in combination with the angle of the first end  50  provides a preventive measure to keep the gutter from sagging over time. The opposite end  54  of each mounting bracket  40  terminates in a vertical flange  56  which is intended to be received within the space  38  of the rain gutter  22  formed by capture surface  34  of drip edge  36  to support the cantilevered section (outer flange  32 ) and add strength.  
         [0039]     In the embodiment shown in  FIG. 1 , the gutter cap  22  is intended for use below the drip-edge  62  at the edge of the roof  64 . For the sake of simplicity, the plywood underlayment or subsurface features of the roof  64  are omitted from the drawing figures. However, it is generally understood that the drip edge  62  is mounted to the plywood or similar material. Overlying the flange of the drip edge  62  on the roof is typically a felt or similar material. In the case of a composite roof, the felt is followed by a number of courses of fiberglass and asphalt shingles (not shown). In certain instances, the drip edge  62  includes a downwardly depending flange  66  for forcing water away from the joint between the fascia board and the underlayment or roof material.  
         [0040]     In situations where a drip edge similar to that designated by numeral  62  is used, the vertical flange  70  is placed between the fascia board  24  and the vertically extending flange  56  of the drip edge  62 . In this manner, water received on surface  72  is restricted from flowing onto the fascia board  22 . Coupled with the generally downward slope of surface  72 , water cascading off of the roof  64  is dispersed over the gutter cap surface and flows away from the fascia board  22 . The upper surface  72  of the gutter cap  20  increases in slope and merges into a bull-nose section  74  overlying the outer flange  32  of the rain gutter  22 . The radius of the bull-nose section  74  is created by the angular arc between the inwardly directed flange  76  of the cap and the arcuate or planar portion  72 . The relative position between the two components is fixed by anchoring a flange  78  (later referred to as a water break flange  78 ) to the vertical wall of one of the stepped flanges  46  on the mounting bracket  40 .  
         [0041]     The relative angle between the inward flange  76  and planar-arcuate surface  72  can vary within a range so long as the adhesion properties of the water with the gutter cap surface  72  are maintained. For it is the purpose of this structure to take advantage of the adhesion property of water to the surface  72  to direct the runoff down the surface  72 , around the bull-nose section  74  and into the gutter trough  22 . Debris over a preferred size and mass lacks the adhesion properties of the water, or is of a mass and momentum that exceeds the force of adhesion and causes the debris to be propelled off the bull-nose section and onto the underlying surface.  
         [0042]     A slightly different embodiment of the gutter cap assembly described above may not have one end attached to the fascia board  22  described above, but extends a predetermined distance up the roof surface. It is envisioned that depending upon the weather considerations, one edge of the gutter cap extending up the roof may vary, as well as its relative position to the other components. For the purposes of this description, it will be assumed the roof underlayment is covered with a traditional roofing felt material (not shown). The edge of the gutter cap may then be laid over the felt and extend upslope a predetermined distance and fastened in place by nails, roofing tar or other method. Overlaying that portion of the gutter cap on the roof underlayment may be the asphalt shingles or other roofing material. In this method, should there be a failure in the overlying asphalt shingles, moisture passing therethrough will trickle down slope onto the gutter cap flange  82  instead of penetrating to the underlayment. In event the breach occurs further up-slope, the felt or underlying course(s) of shingles or roofing material should prevent the moisture from penetrating to the underlayment.  
         [0043]     As in the previous embodiment, the opposite edge of the gutter cap may be secured to the mounting brackets  40  described earlier. However, because of spatial differences between the location of the rain gutter and the upper surface of the roof mounted gutter cap, the profile of the nose section may not be as drastic, but not effect the flow of water into the gutter.  
         [0044]     The roof mounted gutter cap can also be used when there is no fascia board available to mount the rain gutter  22 . In those situations, the rain gutter  22  may be suspended from the overlying gutter cap by way of the mounting brackets  40  described earlier.  
         [0045]     In each of the embodiments described above, additional improvements may be used to help facilitate the flow of water into the rain gutter such as  22  described above. For example, in a preferred embodiment of this invention, each section of gutter cap  20  may be formed from a single continuous piece of material (aluminum, galvo-aluminum, or plastic) to the desired profile and width, depending upon the particular mounting application. During the forming process, at least one or more ridges or ripples  94  may be formed in the planar or gently sloped surface  72  parallel to the length of the gutter cap or, in other words, perpendicular to the slope of the surface. In the alternative or in combination with the ripples, one or more perforations may be formed in the surface  72  to permit runoff water to pass directly into the gutter trough. The perforations are preferably positioned within the within the first third of the cap width closest to the fascia or roof drip edge. In this zone, it has been shown that run-off is substantially free of debris. Should debris be deposited on the first third of the gutter cap surface, it is of a size small enough to pass through the perforations.  
         [0046]      FIGS. 2 through 10  illustrate one embodiment of a roll-forming machine  100  used to manufacture a continuous-piece gutter cap such as described above. To form a continuous piece gutter cap the method contemplates using a coil of aluminum or galvo-aluminum sheet material, preferably having a gauge between 1 and 30 gauge, and most preferably 18 to 26 gauge. Additionally, the roll-forming machine is adapted to manufacture continuous-piece gutter caps for both roof and fascia installation. As a result, the machine  100  will need to be able to accept stock of different widths. For example, it is contemplated the stock mentioned above have a width within the range of 8 to 24 inches, and most preferably within the range of 12 to 18 inches. Regardless of the width of the gutter cap  20 , the forming process is substantially the same but for the finishing along one edge as will be described in greater detail below.  
         [0047]     The roll-forming machine  100  comprises a series of inline stations including an intake section  102 , a nose station  104 , a brake station  106 , and a shear station  110 . Optional sections include a crease and perforation station  108 . Each station is aligned and shares a common box-like frame including four parallel and spaced-apart longitudinal members. The four longitudinal embers are paired to form an upper and lower pair of longitudinal ladder assemblies  112 ,  114  interconnected by solid metal plates and/or bar stock  116  intended to support internal components described in greater detail below. The upper ladder assembly  112  is supported relative to ladder assembly  114  by a plurality of vertical stiles  118  as is customary. To the extent desired, the stiles  118  may also be formed from solid plate or bar stock and provide suitable substrates for particular operative devices just as members  116  briefly mentioned above.  
         [0048]     Beginning at the left hand side of  FIGS. 2-4 , the machine  100  receives a sheet of stock  120  in the free end  122  of the intake station  102 . The intake station  102  includes a first and a second intake roller assembly  124  and  126  cooperating to draw the stock into the machine  100 . The two intake roller assemblies  124 ,  126  each include a lower roller  128  supported above the lower longitudinal assembly  114  by a cross member  116 , and a pair of spaced-apart vertical members  130 . Each lower intake roller  128  is preferably coupled to a drive system generally designated by numeral  132 . To keep the stock  120  in position, and to transfer the motion of the lower intake rollers  128  to the stock  120 , an upper intake roller  134  is positioned opposite, and is dependent from the upper ladder assembly  112  by a like cross member  116  and a pair of spaced-apart supports  130 .  
         [0049]     Intermediate the intake roller assemblies  124  and  126  may be a shear roller assembly  136  should it be determined to trim the stock to the proper size as it is fed into the machine  100 . The shear roller assembly  136  may include an upper and a lower roller  138 ,  140 , respectively, each slightly off-set relative to the other, and positioned so that the distance between the rollers cuts the stock  120  as it enters the machine  100 . The waste material removed from the stock  120  by the shear roller assembly  136  is diverted down a separate channel  142  and is collected at a remote station. As suggested above, the shear roller assembly  136  is an optional component in one embodiment, yet in another, may be an integral aspect of the invention and to be used at the discretion of the operator. Moreover, other shear assemblies may be used other than the roller design described above. Laser and high-pressure water cutting devices may be used if desired. Alternatively, blade devices may be used such as a band saw or scissor shear system may be used at approximately the same location. The object of the different devices is of course to trim the material to the proper width before roll forming. The same or similar systems may also be employed post-roll forming to remove or trim any waste.  
         [0050]     Subsequent to the intake station  102  may be the bull-nose station  104 . The bull-nose section  104  is responsible for the bending or forming of the metal stock  120  into the bull-nose cross section  74  identified earlier. The station  104  includes two tubular or rod-shaped mandrels  144 ,  146  positioned a predetermined distance from one another starting downstream from the second  126  of the intake roller assemblies. The mandrels  144 ,  146  extend through each of the subsequent stations  106  and  108  and terminate just prior to the entry into the shear station  110  described below. The stock  120  is formed relative to the position of the mandrels  144 ,  146 . In addition, the mandrels support the stock  120  as it moves through the machine  100 .  
         [0051]     Depending from the upper ladder assembly  112  in the bull-nose station  104  may be a plurality of rollers  148  supported by at least one, and possibly several lengths of steel or other rigid plate member  150  to position each of the rollers  148  at a predetermined depth or distance below the two mandrels  144 ,  146 . As the stock  120  proceeds through the station, the change in elevation of the mandrels  144 ,  146  relative to the rollers  150  begins the formation of the bull-nose section  74 . To provide the desired radius or profile, curved die-rollers  152  extend upwardly from the lower ladder assembly  114 , and each configured to be placed opposite a punch-roller having a profile to be received with the die roller  152 . For example, the profile of each roller  148  may be configured to mate with the profile of any die roller  152 . As shown in the figures, it is contemplated at least one, preferably two, and possibly more die rollers  152  mate with a respective punch roller  148  to impart the desired radius to bull-nose section  74 .  
         [0052]     After completing the passage through the bull-nose station  104 , the stock has been bent so that a desired amount of stock  120  may be available to form the respective structures along each edge  70  and  78  of the cap  20 , or edges  82  and  88  of cap  80 . The two angled flanges of the cap  20  ride along and are supported by the mandrels  144 ,  146  and the bull-nose section  74  may be engaged by a drive roller assembly  154  similar in function to the intake assemblies  124 ,  126 . The difference between the previously described intake assembly  124 ,  126  and drive roller assembly  154  lies primarily in the profile of the upper roller  156 . In this situation, the profile of roller  156  should closely approximate the profile of the bull-nose section so as to impart the needed amount of friction to force the stock  120  into the break station  106 . The lower roller  158  may also have a matching profile to act in cooperation with roller  156  although not required. Energy may be imparted to rollers  156 ,  158  by the drive system  132  mentioned above through a chain drive engaging a sprocket connected to the lower roller  158 .  
         [0053]     The break station  106  bends the edges of the stock  120  to form the vertical flange  70  and the rain break  88  mentioned above. As the stock  120  travels along the mandrel rods  142 ,  146 , the sheet of the stock  120  has a general V-shaped configuration. Positioned to engage a respective edge of the stock  120  are a first and a second break roller assembly  160 ,  162 . Each break roller assembly  160 ,  162  includes a plurality of rollers cooperating with each other to progressively bend a predetermined amount of stock to a desired angle. In a preferred embodiment of the invention, substantially right-angle bends are made along the longitudinal edges of the stock  120 . In order to make such bends, each edge may be engaged by two rollers  164 ,  166  as shown. Both rollers  164 ,  166  are mounted by spindles to a plate  168  which in turn is supported at the desired angle by struts or bar stock  170  depending from the upper ladder assembly  112 . Roller  164  includes a chamfered surface  172  oriented at a preferred angle. Below the chamfered surface  172 , the roller has a substantially cylindrical surface  174  intended to guide the stock  120 . Adjacent break roller  164  may be the cooperating roller  166 . In this embodiment, roller  166  may be only as thick as the cylindrical flat of roller  164  and is spaced to nearly engage the cylindrical flat  174  to support the stock  120  as the edge is partially formed by chamber  172 . Should a partial bending or break be desired, a simple assembly such as just described would be sufficient. However, in the instant invention, it is desired the bends be generally perpendicular to the root portion of the stock  120 . To complete the end, a second pair of rollers identified by numerals  176 ,  178  are also mounted to plate  168  by spindles. Roller  176  may have a composite form and include a first diameter portion  180  and a lesser diameter portion  182 . The larger or first diameter portion may overlap a portion of the second roller  178  such that portion  182  may be substantially opposite and in close proximity to roller  178 . In this configuration, the partially bent edge is bent the remaining distance by the overlapping portion of the rollers  176 ,  178 . Just as in the prior description of rollers  164 ,  164 , sufficient space may be provided between rollers  176 ,  178  to receive the thickness of the stock  120 . If desired, springs in the form of coil or leaf springs may be used on break rollers such as  164 ,  166  or  176 ,  178  to automatically adjust to different gauge stock  120 .  
         [0054]     Downstream of the break station  106  may be the crease/perforation station  108 . In the embodiments of the gutter cap mentioned above, it may be desirable to improve the capture of water runoff by improving the sheeting action of the water as it flows over surfaces  72  to direct it unto the gutter trough. To promote the sheeting action, the gutter cap  22  may have one or more parallel and cascading beads, ridges, ripples formed along the sloped surface along the length of the cap  22 . These structures are roll-formed in the stock  120  by an inclined punch roller  184  extending downwardly from the upper ladder assembly  112  and positioned to engage the bottom side  186  of stock  120  forming the crown or upper surface  72  of the cap  22 . A corresponding mating die roller  188  may be situated adjacent roller  184  but positioned to engage the upper surface  72 ,  90 . As the stock  120  passes between the rollers  184 ,  188 , the roller profiles emboss the linear cascaded features.  
         [0055]     Adjacent the assembly for producing the ridges or linear cascading ripples  94  may be a perforation assembly generally referenced by numeral  190 . The perforation assembly may be positioned downstream of the break and ridge-forming roller assemblies  160 ,  162  and  184 ,  188 , but is not restricted to this particular location. The function of the perforation assembly is to produce a linear series of at least one row of oblong breaches or perforations  96  through upper surface  72 ,  90  intermediate the ridges  94  and the fascia flange  70  (in the case of the fascia mount version). In the embodiment where one edge is underlaying the roofing material, the perforations  96  may be formed intermediate the ridge  94  and that portion of the stock  120  first exposed or extending from beneath the roofing material.  
         [0056]     The perforation assembly  190  includes two cooperating rollers  192 ,  194  mounted to spindles which in turn are fixed to a plate just as substantially all of the tools implemented in this machine  100 . The roller  192  may have a profile of one or more rows of intermittent chamfered punches  196  that shear the stock at preferred locations in the first third of the gutter cap flange to create a series of water entry points that route water directly into the underlying gutter trough. The adjacent die roller  194  includes a profile intended to mate with the punches in a manner to effect the shearing action. It should be understood the perforations  96  created by this station  108  may be oriented so the openings may face up slope or down slope, depending upon the desired function. The slots may face up slope to divert run off directly unto the gutter trough or they may be oriented down slope to capture a portion of the water running over the crests, and directing run off along small rivulets over sloped upper surface  78 .  
         [0057]     Following the formation of the perforations  96 , the machine  100  may complete formation of the nose section  74  and the angular orientation between the opposing edges. This is achieved by passing the partially formed cap through a series of larger diameter roller assemblies  198 . For each assembly  198 , the lower roller  200  may have a generally flat to concave roller surface upon which the bull-nose section  74 ,  92  rests. The upper roller  202  in each assembly may have a smaller radius and narrow profile to produce progressively greater bends in the bull-nose section to push the edges toward each other and ultimately to the desired angle. This may be the final stage of bending or roll-forming for the cap  20 .  
         [0058]     The final station of the machine  100  may include the shearing station  110 . The shear station  110  forms the exit point for the stock  120  from the machine  100 . The shear station  110  includes a die plate  204  oriented generally perpendicular to the length of the machine  100  and having an opening  206  formed therein through which the bent stock  120  passes as it exits the machine. The opening  206  has been machined so as to approximate the angled form of the cap  22  and to provide a sharp cutting edge along predetermined portions of the opening. Adjacent the die plate may be a shear plate  208  also having a profile approximating the interior of the bent cap  22 . The shear plate  208  and the opening  206  are substantially aligned to permit he cap  22  to exit the machine. When the desired length of the cap  22  has exited the machine  100 , hydraulic cylinders connecting the shear plate  208  to the frame  112 ,  114  of the machine causes the shear plate  208  to move relative to the die plate  204 , shearing the stock  120 . Rather than a hydraulic system to cause the shear station to operate, manually operated levers may also be used to perfect the shear.  
         [0059]      FIG. 17  illustrates another embodiment of a gutter assembly  300  for capturing water run-off from the roof or other sloping structure while directing debris onto the underlying surface. As shown in the figure, gutter assembly  300  includes a gutter trough  302  mounted to a fascia board or similar vertical support  304  located generally below a drip edge of a sloping surface, in this case a roof  306 . Disposed above the gutter trough  302  is a unique gutter cap  308  wherein one edge may be defined by an upwardly extending flange  310  designed to be received behind a flange of the drip edge  312  or other shield adjacent the fascia board. Extending from the flange  310  in a direction away from the fascia board  304  is the upper surface  312  oriented so as to slope downwardly at a predetermined angle relative to the fascia. The degree of slope has not yet been determined to be a critical element so long as it is sufficient to direct the flow of water down gradient away from the fascia. For example, it is contemplated that the slope of surface  312  be less than forty-five degrees but greater than zero degrees, preferably less than fifteen degrees but greater than one degree, and most preferably less than ten degrees but greater than two degrees.  
         [0060]     To help maximize the diversion of water into the gutter trough  302 , periodic perforations or slots  314  may be formed in the upper surface  312  such that the openings face either up slope or down lope as described earlier. It has been found that if the gutter cap is to include such slots, the location may be best within the first one-third of the gutter cap width as measured relative to the fascia board  304 . It has been observed that water run-off within this zone onto the gutter cap contains less detritus and debris than any point down slope, and thus less likely to interfere with the flow of water into the perforations.  
         [0061]     Down slope of the first one-third portion of the gutter cap width, additional structures may be formed to help increase the amount of water captured within the trough while minimizing the capture of unwanted debris. For example, it may be contemplated that at least one or more beads, ridges, or grooves  316  may be formed in the upper surface  312 . These structures may be formed periodically or continually along the length of the gutter cap  308 . The function of these structures is to provide temporary dams or obstacles to reduce the current speed as the water flows over the surface  312  for reasons that will become more apparent below.  
         [0062]     The downwardly sloping surface  312  of the gutter cap transitions into what has been described above as the nose or bull-nose section, designated by numeral  318  in the Figure. However, in this embodiment, the nose section  318  is not formed in a continuous radiused structure as described above. Rather, the nose section may be more aptly described as substantially rectangular or angular, formed by a tightly radiused first-bend  320 , followed by a substantially planar intermediate section  322 , then a second tightly radiused second-bend  324 . In a preferred embodiment, each of the tightly-radiused bends  322  and  324  are such that they do not disrupt the relatively smooth surface characteristics of the metal or finish that may cause to disrupt the flow of water over that portion of the cap. For example, it is contemplated the radius for making such bends may be less than one-quarter of inch, but greater than one-thirty-second of an inch. The object here is to avoid a truly sharp angular change in the profile, but rather an arcuate profile within a small distance. In this manner, the molecular attraction (adhesion) of the flowing water with the surface of the gutter cap can be maintained within a given flow rate to direct the water into the underlying gutter trough, yet provide a very appealing finish to the edge of the gutter cap that complements most gutter trough profiles.  
         [0063]     As in the previous embodiments, the opposite edge  326  extends back toward the fascia board  304  and terminates above the gutter trough  302  such that water flowing along the upper surface  312  and around radius  320 , over surface  322 , and around radius  324  flows into the gutter trough. The edge  326  of the gutter cap  308  may also contain a break flange similar to that described above to break the adhesion of the water and increase the turbulence to maintain any detritus in suspension so that it may ultimately flow to a downspout.  
         [0064]     The description of the different aspects of the invention provided above is considered that of a limited number of a wide range of variations that can be implemented. Other modifications or configurations will occur to those skilled in the art and to those who use and/or make the invention. Thus, it is understood the foregoing description and structure shown in the drawing figures are provided merely for illustrative purposes and are not intended to limit the scope of the invention claimed herein or in any subsequent related application.