Abstract:
The present invention is a gutter cover formed of sheet metal, with perforations in the cover deck for passage of water. The prism shaped perforations allow water to pass even when blocked by leaves, and is self-cleaning from winds.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     The present invention generally relates to gutters and gutter covers, and more specifically relates to a gutter cover formed in a machine that fabricates the gutter cover from a continuous strip of sheet metal.  
         [0003]     1. Background Information  
         [0004]     Gutters are structures that are placed at the edges of the roofs of buildings to capture the runoff water from the roof, and to direct the water to a place where the water is discharged. Gutters serve the purpose of removing the drip zone from around the perimeter of buildings, and concentrating the runoff water into one location. This location can then be directed so that the water is disposed of safely, such as at a distance from the foundation of the building or into a storm water disposal system. There are a large number of types of gutters that are adjacent to the roof edges of buildings. These include plastic gutters that are sections that snap together, gutters that snap together by the use of a joining strip and gutters that are built to run the entire length of a section of roofline. Gutters are made of various materials including plastic and metal. The metal can be painted to match the trim of a building, and it can also be a stock color such as green, brown or white. Gutters can also be made of copper or other materials.  
         [0005]     Gutters can take a number of configurations, but are generally a U-shaped channel that collects water and directs it to an exit point. There are also a number of covers that fit over the gutters that are available. Some gutter covers attach to the top edges of the gutter, some gutter covers attach to the roof under the last row of shingles on the roof, and some gutter covers attach to the fascia below the edge of the roof. There are a number of gutters that are available, and a number of ways of making those gutters.  
         [0006]     Therefore, it is an object of the present invention to provide a gutter cover that attaches securely to a gutter edge in a way that reinforces and strengthens the gutter assembly. It is a further object of the invention to provide a gutter cover that is made from a continuous strip of sheet metal. It is a further object of the invention to provide a gutter cover forming machine that makes gutter covers out of a continuous strip of sheet metal. Another object is to make a gutter assembly that includes a gutter cover, and does not require the use of an additional bracket other than that used in a non-covered gutter. Another object is to make a gutter cover that attaches to an existing gutter and does not require the use of an additional bracket.  
         [0007]     Additional objects, advantages and novel features of the invention will be set forth in part in the description which follows and in part will become apparent to those skilled in the art upon examination of the following or may be learned by practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.  
       SUMMARY OF THE INVENTION  
       [0008]     One version of the invention is a gutter cover for use with a gutter. The gutter would typically be placed on fascia at the roof edge of a structure. The gutter that the gutter cover would be used with would have a gutter inner wall, a gutter floor and a gutter outer wall with a lip on the outer wall. The gutter cover of the invention includes a cover deck with perforations, a cover inner wall attached to said cover deck for mounting to the fascia of the structure, and an L-shaped cover outer wall attached to the outer side of the cover deck, which includes a generally vertical riser and a generally horizontal cover lip. The cover lip fits adjacent to the gutter lip and is designed to be attached to the gutter lip, such as by screws. The gutter cover is typically configured so that it may be mounted so the cover deck is at a downward angle toward the gutter outer wall. This is accomplished by the cover inner wall being at the appropriate angle to the cover deck to allow the cover deck to be sloping after installation. The perforations include multiple rows of first perforations adjacent to the cover inner wall and may also include one or more rows of second perforations adjacent to the vertical riser. The second perforations are larger than the first perforations, and preferably there is an unperforated area in the cover deck between the two groups of perforations. The perforations may be part of a generally triangular prismatic depression formed in the metal, with a longitudinal perforation at the apex of the triangular prism depression. This configuration of perforations has been found to effectively isolate the gutter from debris, and to be self-cleaning. This configuration of perforations allows water to pass through the gutter cover, even when leaves fall on the perforations. The perforations are self-cleaning by wind action removing leaves from the gutter cover after the leaves have dried out. The size of the perforations can vary, but perforations of ½ to 2 inches function well, with 1 inch being the preferred length.  
         [0009]     When the cover deck is mounted at a downward sloping angle towards the gutter outer wall, the vertical riser of the cover outer wall forms a reservoir or basin for holding water on the cover deck. This reservoir or water basin allows water to pool on the cover deck if it is not able to drain through the perforations fast enough.  
         [0010]     Another embodiment of the invention is a gutter cover configured as described above, which is made from a strip of sheet metal that is pressed between perforation rollers. The perforation rollers perform the function of forming the perforations in the strip of sheet metal. The perforation rollers consist of a first roller with a first roller surface, which has a number of projections that form ridges that circumvolve the roller. There are spaces between the projections in each ridge. The second perforation roller has a second roller surface, with a number of grooves or depressions that correspond to the ridges of the first perforation roller. The perforation rollers are held together so that the first and second rollers&#39; surfaces are adjacent to each other, so that when a strip of sheet metal is fed between the two perforation rollers, the projections of the first perforation roller press into the grooves or depression of the second perforation roller, and the sheet metal between them is perforated by the projections.  
         [0011]     The above gutter cover is preferably made so that the perforations take the form of generally linear slots, and are arranged in parallel rows. The projections on the first roller may take the form of generally triangular prisms with sloped or tapered ends. The sloped or tapered ends serve the function of disengaging from the sheet metal cleanly so that the sheet metal does not become snagged on the projections. By having the projections be in the form of triangular prisms with sloped or tapered ends, the perforations thus made are linear slots at the apex of a triangular prismatic depression, and are arranged in parallel rows.  
         [0012]     Another embodiment of the invention is a machine that forms gutter covers. The gutter cover forming machine includes a frame on which other components are mounted. Attached to the frame are a first perforation roller and a second perforation roller. Both perforation rollers have a first roller surface and a second roller surface, which are mounted adjacent to each other. The first perforation roller has a number of projections that form multiple ridges that circumvolve the first perforation roller. There are typically spaces between the projections in each ridge. The second perforation roller includes a number of depressions or grooves, which correspond to the ridges or projections of the first perforation roller.  
         [0013]     The gutter cover forming machine includes a motor for driving the first and second perforation rollers. The first and second perforation rollers are positioned on the frame so that the roller surfaces are adjacent to each other so that when a strip of sheet metal is fed between the two rollers, the projections of the first perforation rollers press into the grooves of the second perforation roller and the sheet metal between them is perforated by the projections.  
         [0014]     The gutter cover forming machine described above may additionally include a pair of feed rollers that grip the sheet of metal and propel it through the machine. The gutter cover forming machine may also include one or more forming rollers for bending the strip of sheet metal into desired shapes as it passes through the machine. One operation with the forming rollers can be to form an inside edge that is angled from the cover deck. Another forming operation can be to form an L-shaped outer edge that is attached to an angle from the cover deck. The gutter cover forming machine may also include one or more guides for aligning and guiding the strip of sheet metal as it passes through the machine. The guides can take the form of rollers that press against the lateral edges of the strip of sheet metal. The guides can also take the form of another type of guide such as a metal bar or an L-shaped section.  
         [0015]     The gutter cover forming machine can be designed so that the projections on the first perforation roller form generally linear perforations in the sheet metal as it is formed into a gutter cover. The linear perforations are preferably in the shape of a triangular prism, with sloping or tapered edges. The perforation through the sheet metal itself would be found at the apex of the triangular prism. The projections on the first perforation roller are preferably triangular prismatic in shape with tapered edges, so that the projections and sheet metal separate cleanly.  
         [0016]     The gutter cover forming machine described above is preferably configured to produce a gutter cover from a piece of sheet metal, with the gutter cover having an upturned inside edge, a generally flat cover deck and an upturned L-shaped outside edge with a vertical riser and a generally horizontal cover lip. The vertical riser and the cover lip are generally L-shaped and attach to the cover deck of the gutter cover in a generally perpendicular angle. The inside edge of the gutter cover is attached to the opposite edge of the cover deck and is generally perpendicular to the cover deck. The gutter cover forming machine is typically configured to utilize strips of sheet metal from a roll, with the roll attached to or mounted adjacent to the frame. The gutter cover forming machine may also have a cut-off device for cutting off a section of formed gutter cover. The cut off device can take a number of configurations and may be a guillotine type cutter, or may be powered sheers; a power saw or other automated cutting or sawing devices.  
         [0017]     Although the gutter cover forming machine would typically be used in a shop, it could easily be mounted to a vehicle such as a truck or a trailer, and could be utilized on a work site. The machine can be outfitted with a support table that is positioned adjacent to the frame. The support table would serve to support a section of gutter cover as they came out of the machine. Preferably the cover tray would include a length selection device, which an operator could use to select how long a particular section of gutter cover would be. A sensor associated with the tray would sense when a length of gutter cover had been made at the selected length. When the chosen length was reached, the gutter cover would be cut off at the selected length. This would preferably be done when the machine had stopped. The selected length of gutter cover could be sensed by a light sensor, a laser sensor, or a mechanical limit switch that is tripped by the gutter cover.  
         [0018]     Another embodiment of the invention is as a gutter assembly that includes a gutter body and a gutter cover joined together. The gutter assembly is for placement on the fascia at the roof edge of a structure. The gutter body includes a gutter inner wall, a gutter floor, a gutter outer wall with the gutter outer wall having a gutter lip. The gutter cover attaches to the gutter body, and includes a cover deck with perforations for the passage of water through the cover deck into the gutter body. The gutter cover also includes a cover inner wall attached to the cover deck and is configured for attachment to the fascia of the structure. The gutter cover also includes a cover outer wall configured for attachment to the gutter lip of the gutter outer wall. When the gutter cover is attached to the gutter body, a unitary tubular gutter assembly is formed.  
         [0019]     The gutter assembly described above can also include a number of gutter body brackets that attach to the fascia and to the gutter outer wall. Preferably these attach to the inside of the gutter lip on the outer wall of the gutter body.  
         [0020]     The gutter cover outer wall is generally L-shaped, and has a vertical riser and a generally horizontal cover lip. The gutter cover is configured so that when mounted, the cover deck slopes at an angle away from the fascia of the structure towards the gutter lip of the outer wall of the gutter body. Because of this slope and because of the L-shaped cover outer wall, a reservoir for holding water is formed. If more water falls on the cover deck than can pass through the perforations, the cover deck forms a reservoir to hold the water until it can pass through the perforations.  
         [0021]     The purpose of the foregoing Abstract is to enable the United States Patent and Trademark Office and the public generally, and especially the scientists, engineers, and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection, the nature and essence of the technical disclosure of the application. The Abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.  
         [0022]     Still other objects and advantages of the present invention will become readily apparent to those skilled in this art from the following detailed description wherein I have shown and described only the preferred embodiment of the invention, simply by way of illustration of the best mode contemplated by carrying out my invention. As will be realized, the invention is capable of modification in various obvious respects all without departing from the invention. Accordingly, the drawings and description of the preferred embodiment are to be regarded as illustrative in nature, and not as restrictive in nature.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0023]      FIG. 1  is a perspective view of a gutter cover and a gutter assembly of the invention.  
         [0024]      FIG. 2  is an end view of the gutter cover and the gutter assembly of the invention.  
         [0025]      FIG. 3  is a top view of the gutter cover of the invention.  
         [0026]      FIG. 4  is a side view of the gutter cover forming machine of the invention.  
         [0027]      FIG. 5  is a perspective view of the perforation forming part of the gutter cover forming machine of the invention.  
         [0028]      FIG. 6  is a side view of the gutter cover forming machine showing a side table.  
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0029]     While the invention is susceptible of various modifications and alternative constructions, certain illustrated embodiments thereof have been shown in the drawings and will be described below in detail. It should be understood, however, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.  
         [0030]      FIG. 1  shows the gutter cover  10  of the invention. It is shown mounted in  FIG. 1  to a gutter body  22 , and the gutter cover and the gutter body together form an embodiment of the invention; the gutter assembly  6 . The gutter cover  10  includes an inside edge  14  that is attached to a cover deck  12 . Opposite the inside edge  14  is an outer edge  16 , also attached to the cover deck  12 . The outer edge  16  includes a generally vertical riser  17  and a generally horizontal cover lip  20 . On the cover deck  12  are located a number of perforations  18 . As shown in  FIG. 1 , the preferred, but not the sole, embodiment of the perforations  18  is for them to be in parallel rows. Optionally, one of the rows can include a number of second perforations  19  which are larger than the first perforations  18 , with a separation from the rows of first perforations  18 . The gutter cover  10  is attached to fascias  62  of a building at the edge of a roof, and below the drip edge of the roof. The gutter cover  10  is attached to the gutter  22  at the gutter lip  74 . The gutter includes a gutter inner wall  76 , a gutter floor  78 , a gutter outer wall  80  and a gutter lip  74 , and may include a bracket  84 . The angle of the gutter cover can be variable, driven by the particular fascia or surface it is to be mounted on. The figures show the gutter cover being mounted at a sloping angle from the fascia, and this angle is variable, and can be mounted so that the gutter cover is flat.  
         [0031]     The gutter cover  10  is preferably made of sheet metal with a thickness dictated by the material it is made of, and the particular application it is made for. By way of example, if made of aluminum for residential gutters, a thickness might be 0.027 to 0.032 inches. If made of galvalume for residential gutters, a thickness might be 26 to 29 gauge. If made of copper for residential gutters, a thickness might be 16 oz to 20 oz copper. The preferred types of metal include copper, aluminum, and galvalume, because these materials do not rust at the perforations. However, other suitable metals or plastics could be used.  
         [0032]     The gutter cover  10  is attached to the fascia  62  using attachment screws  82 . Attachment screws  82  can also be used to attach the outer edge  16  of the gutter cover  10  to the gutter lip  74 .  
         [0033]      FIG. 2  shows the gutter cover  10  mounted to the gutter body  22  mounted on the fascia  62  of a building. The gutter assembly  6  includes a bracket  84 , which is attached by an attachment screw  82  to the gutter inner wall  76  and the fascia  62 .  
         [0034]      FIG. 3  shows the preferred configuration of perforations  18  and  19  on the cover deck  12 . The preferred perforation is generally a triangular prism shape with an opening in the sheet metal of the gutter cover  10  at the peak of the prism. This results in a generally rectangular opening surrounded by a sloping region on all four sides of the opening itself A preferred opening size is about 1/16 inch to ⅛ inch. A row of larger perforations  19  are preferred in addition to the smaller openings, as shown in the figures.  
         [0035]     The invention is also a gutter assembly  6 , which is the combined structure formed of the gutter cover  10  and the gutter  22 , as shown in  FIGS. 1 and 2 . It includes a bracket  84 .  
         [0036]     The invention is also a gutter cover forming machine  4  as shown in  FIG. 4 . The gutter cover forming machine  4  includes a frame  48  in which the components of the gutter cover forming machine are mounted. The device includes a motor  44 , which powers a drive gear  46 . The drive gear  46  turns two separate loops of chain, the feed roller chain  30  and the perforation roller chain  31 . As the drive gear  46  rotates clockwise in the view seen in  FIG. 4 , the perforation roller chain  31  first passes over the entry gear  40 . It then passes over the second perforation roller drive gear  38 , which is attached to the second perforation roller  34 . As the chain passes over it it causes the second perforation roller  34  to rotate in a counter-clockwise direction in the view seen in  FIG. 4 . The chain then passes over the first perforation roller drive gear  36 , which is attached to the first perforation roller  32 . This roller is made to turn clockwise. The chain  30  then passes over the exit gear  42  and returns to the drive gear  46 . Thus, rotation of this gear in a clockwise direction causes the two perforation rollers to rotate together in a manner that perforates a strip of sheet metal  58  and simultaneously pulls the sheet metal from right to left through the machine in the view shown in  FIG. 4 . The sheet metal  58  is unwound from a sheet metal roll  56 .  
         [0037]     The dimensions of the sheet metal used to make the gutter cover and gutter are variable depending on the particular installation. Some gutters are very wide, but residential gutters are narrower. A typical range of width of sheet metal for the gutter cover is 5.5 to 8 inches wide. This results in a gutter cover that is compatible with gutters  22  that are generally used on residential installations.  
         [0038]     The preferred perforation rollers in the machine that makes the gutter covers are sized according to the width of gutter covers being formed, and depend on the material being used.  
         [0039]     The drive gear  46  also causes the rotation of a first and second feed roller  24  and  26  through a feed roller drive gear  28 . The rubber covered feed rollers grip the sheet metal strip  58 , and by frictional contact push it towards the perforation rollers  32  and  34 . Shown in this view is also a guide roller  70 , which is positioned to keep the sheet metal strip  58  aligned as it passes through the device. More than one of the guide rollers  70  may be used in order to guide the sheet metal. The guides for the sheet metal can also be devices other than rollers, such as stationary metal bars, cylinders, angle iron or metal strips. Also shown is a pair of forming rollers  86 . The forming rollers  86  shape the sheet metal strip  58  into desired contours. In the preferred embodiment this includes an angled inside edge  14  and an L-shaped outside edge  16 , as shown in  FIGS. 1 and 2 . The forming rollers may be covered in plastic to aid in forming the desired shapes.  
         [0040]      FIG. 5  shows a view of the end of the gutter cover forming machine  4 , showing more detail of the first perforation roller  32  and the second perforation roller  34 . The first perforation roller  32  includes projections  54  which correspond with grooves  52  in the second perforation roller  34 . Shown in  FIG. 5  are the perforation roller chain  31 , the entry gear  40 , the second perforation roller drive gear  38 , the first perforation roller drive gear  36  and the exit gear  42 . A motor  44  is shown, and the drive gear  46  is not visible behind the motor  44 . As a strip of sheet metal passes between the rollers  32  and  34 , it becomes perforated by the projections  54 . In operation, the perforation rollers grab the sheet metal of the gutter cover and pull it through the process.  
         [0041]      FIG. 6  shows the gutter cover forming machine  4  with a support table  68  mounted along side it. The support table  68  has a length sensor  72  that detects when a gutter cover of a chosen length has been extended out onto the support table  68 . The length sensor  72  can be a photo cell, a laser sensing device, or a mechanical limit switch that detects the presence of a strip of gutter cover material that extends out from the gutter cover forming machine  4 . Other control sensor types can also be used. When the length sensor  72  detects a gutter cover of the selected length, the machine has a cutter  64  that cuts off the sheet metal of the gutter cover. The preferable sequence for doing this is to first stop the gutter cover forming machine  4  in order for the cutter  64  to cut the gutter cover at the chosen length. The cutter  64  can be a shear, a guillotine type cutter, a saw or other type of cutter. The version of the cutter  64  shown in  FIG. 6  is powered by a hydraulic cylinder  66 , but the cutter can take a number of configurations. A safety is preferably included which prevents restart of the machine until the cut off is disengaged.  
         [0042]     While there is shown and described the present preferred embodiment of the invention, it is to be distinctly understood that this invention is not limited thereto but may be variously embodied to practice within the scope of the following claims. From the foregoing description, it will be apparent that various changes may be made without departing from the spirit and scope of the invention as defined by the following claims.