Gutter guard apparatuses and methods

Gutter guard apparatuses and methods of making the same are provided. A gutter guard apparatus for preventing debris from entering rainwater collection gutters on a structure. A gutter guard apparatus can comprise a guard panel and mesh layer that cooperate to prevent debris from entering a rainwater collection gutter. The mesh layer can be secured to the guard panel at substantially all points of contact between the mesh layer and guard panel to thereby provide a secure and durable gutter guard apparatus. Methods and devices for forming a gutter guard can comprise bonding the mesh layer to a guard panel using a radiant heater, heated roller, adhesive applicator, ultrasonic welder and/or combinations thereof.

TECHNICAL FIELD

This presently disclosed subject matter relates to gutter guard apparatuses and methods of making the same. The presently disclosed subject matter is directed to gutter guard apparatuses for preventing debris from entering rainwater collection gutters on a structure. Methods of making gutter guard apparatuses are also provided.

BACKGROUND

Gutters used for collecting and distributing rainwater runoff from the roofs of residential homes and other buildings can become clogged with debris, e.g. twigs, leaves, pine needles, acorns, and other debris from rainwater. Existing devices for preventing the clogging of gutters are ineffective, deteriorate over time, and/or are cost-prohibitive.

As such, a need exists for gutter guard apparatuses for preventing debris from entering rainwater collection gutters. A need exists for methods of making such gutter guards.

SUMMARY

It is an object of the presently disclosed subject matter to provide novel gutter guard apparatuses, methods and devices for making the same.

An object of the presently disclosed subject matter having been stated hereinabove, and which is achieved in whole or in part by the presently disclosed subject matter, this and other objects will become evident as the description proceeds when taken in connection with the accompanying drawings as best described hereinbelow.

DETAILED DESCRIPTION

The presently disclosed subject matter relates to a gutter guard. The presently disclosed subject matter can be positioned over the opening of a conventional, longitudinally-extending, generally U-shaped gutter used for collecting and distributing rainwater runoff from the roofs of residential homes and other buildings. In some embodiments the presently disclosed subject matter employs a dual filtering system applicable for separating small twigs, leaves, pine needles, acorns, and other debris from rainwater entering the gutter. The presently disclosed subject matter effectively prevents this debris from passing into the gutter and clogging the downspouts. The gutter guard of the presently disclosed subject matter comprises a connecting member for securing the gutter guard in position on the gutter, provides added support to help prevent the gutter guard from collapsing under the weight of wet leaves and other debris, and resists separation of the gutter guard from the gutter in windy conditions.

Unlike existing gutter guards, the gutter guard of the presently disclosed subject matter can in some embodiments include a coated mesh layer and perforated guard panel formed of like polymer materials, such as polyvinyl chloride (PVC). The design of the gutter guard of the presently disclosed subject matter can facilitate an effective and secure attachment of the mesh layer to the gutter guard. Other structures and types of attachment mechanisms used in gutter guards conventionally are generally less effective, and more costly, time consuming, and labor intensive. Moreover, the core material of the mesh layer, according to one embodiment of the invention, can be fiberglass fabric. As compared to metal, fiberglass fabric is generally easier to handle, is chemically more stable, and resists corrosion. Fiberglass fabric is also more durable than plastic and possesses greater natural strength which allows for a substantially finer and thinner construction.

In some aspects, a gutter guard as disclosed herein can comprise an elongate guard panel defining a plurality of spaced filter openings, the guard panel being adapted to extend laterally across an opening of a gutter and longitudinally along the length of the gutter. In some aspects the gutter guard can comprise a mesh layer overlying the guard panel in an area of the filter openings, the mesh layer having first and second opposing side edges, first and second opposing end edges, and a surface extending across the filter openings. In some aspects the gutter guard can comprise a continuous heat weld or other bonding, such as chemical bonding for example, securing the mesh layer to the guard panel, wherein the heat weld or other bond extends across substantially the entire surface of the mesh layer from the first side edge to the second side edge, and extends from one end edge of the mesh layer to the opposing end edge of the mesh layer. In some aspects, the heat weld or other bond extending at least substantially across the entire surface of the mesh layer provides for the mesh layer to be secured to the guard panel at substantially all points of contact between the mesh layer and guard panel.

In some embodiments, the gutter guard is a composite gutter guard. The gutter guard can in some embodiments include an elongate polymer guard panel defining a plurality of spaced filter openings. A mesh layer, in some aspects a polymer-coated fiberglass mesh layer, overlies the guard panel in an area of the filter openings and cooperates with the guard panel to capture and separate debris from rainwater runoff entering the gutter. Any other suitable materials for the structures of the gutter guard can be used as well.

In some embodiments, the mesh layer comprises a polymer-coated mesh. In some embodiments, the mesh layer can be formed of fiberglass fabric. In some embodiments, the mesh layer can comprise a PVC coating. In some embodiments, the mesh layer can comprise a PVC-coated, woven fiberglass fabric which readily fuses to the polymer guard panel during welding.

In some embodiments, the filter openings in the guard panel can be between 0.5 and 1.5 centimeters in diameter. In some aspects, the mesh layer can include between 30 and 40 openings per square centimeter.

In some embodiments, gutter guard apparatuses, devices and/or systems of the presently disclosed subject matter can comprise a connecting member for securing the guard panel in position at the opening of the gutter. In some embodiments, the connecting member can comprise a generally C-shaped connecting strip having resilient spaced-apart top and bottom walls adapted for receiving an inwardly-extending flange of the gutter to hold the gutter guard in position during use.

Following long-standing patent law convention, the terms “a” and “an” mean “one or more” when used in this application, including the claims.

As used herein, the term “about” and/or “substantially,” when referring to a value or to a unit of measure, area, temperature, an amount of mass, weight, time, volume, concentration or percentage is meant to encompass variations of in some embodiments ±20%, in some embodiments ±10%, in some embodiments ±5%, in some embodiments ±1%, in some embodiments ±0.5%, and in some embodiments ±0.1% from the specified amount, as such variations are appropriate with respect to the disclosed subject matter and/or to perform the disclosed methods.

Turning now to the Figures, an embodiment of a gutter guard according to the presently disclosed subject matter is illustrated inFIG. 1. The gutter guard is shown generally as reference numeral10. The gutter guard10is in some embodiments can be adapted for use on standard, generally U-shaped gutters attached to structures such as residential homes, garages, sheds, commercial buildings and other buildings. Gutter guard10can in some embodiments be formed of a composite filter assembly including a mesh layer12applied to a semi-rigid, polymer guard panel20. The mesh layer12overlies an area of filter openings22formed in the guard panel20, and can be attached, affixed or secured to the guard panel20by continuous heat welding, including ultrasonic welding, or other bonding such as chemical bonding for example, across the entire surface of the mesh layer12, or substantially the entire surface of the mesh layer12.

Continuing withFIG. 1, guard panel20can comprise a plurality of filter openings22through which rain water from a roof can pass into a gutter upon which gutter guard10is attached. In some embodiments, filter openings22in guard panel20can have a diameter ranging from about 0.5 centimeters to about 1.5 centimeters. Filter openings22can be evenly spaced apart in a repeating pattern over an area of guard panel20having a width W2 as discussed below. Guard panel20can have a width W3 (dimensions discussed below) extending from a first longitudinal side edge24and a second longitudinal side edge26. Guard panel20can have an end edge28and can extend a length L1 (FIG. 2) extending any desirable length as discussed below.

As illustrated inFIG. 1, in some aspects gutter guard10can comprise a mesh layer12overlying the guard panel20in an area of the filter openings22, the mesh layer12having first14and second16opposing side edges and a surface extending across filter openings22. Mesh layer12can in some embodiments cooperate with guard panel20, and particularly filter openings22, to capture and separate debris from rainwater runoff entering the gutter. In some aspects, mesh layer12can comprise a mesh material comprising between 30 and 40 openings per square centimeter. In some embodiments, mesh layer12can comprise a polymer-coated mesh material, a fiberglass fabric, a flexible fine-mesh fabric and/or a mesh material with a PVC coating. In some embodiments, mesh layer12can comprise a PVC-coated, woven fiberglass fabric which readily fuses to a polymer guard panel20during welding or bonding as discussed herein.

Continuing withFIG. 1, and referring also toFIG. 2, guard panel20can further comprise a longitudinal, generally C-shaped connecting member30(or connector strip). Connecting member30can in some embodiments be integrally formed with guard panel20along a first longitudinal side edge24of guard panel20. In some embodiments connecting member30can be made of the same composite material as guard panel20, but can in some embodiments have an increased rigidity as compared to guard panel20. In some embodiments, connecting member30can comprise resilient spaced-apart top and bottom walls32and34, respectively, formed with end wall36and adapted for receiving a portion of a gutter to thereby hold gutter guard10in position during use.

FIG. 2is a cross-sectional perspective view of a composite gutter guard according to one embodiment. For illustrative purposes only, portions ofFIG. 2, e.g. mesh layer12and bond40, have been enlarged and may not be to scale. InFIG. 2bond40between mesh layer12and guard panel20is shown. In some embodiments, bond40can comprise a heat weld, an ultrasonic weld, a chemical bond, an adhesive bond, or any other suitable bond sufficient to adhere mesh layer12to guard panel20. In some embodiments, bond40is a continuous bond that can extend across the entire, or substantially the entire, width W1 of mesh layer12from the first side edge14to the second side edge16of mesh layer12, and extends from one end edge17of mesh layer12to the opposing end edge (not shown) of mesh layer12. In some embodiments, bond40exists at all, or substantially all, areas of mesh layer12that is in contact with guard panel20, i.e. the entire width and length of mesh layer12. By extending across the entire surface of mesh layer12, or at least substantially across the entire surface of mesh layer12, bond40, e.g. a continuous heat weld, provides for mesh layer12to be secured to the guard panel20at substantially all points of contact between mesh layer12and guard panel20. A gutter guard10as provided herein, particularly where mesh layer12is secured to guard panel20at substantially all points of contact between mesh layer12and guard panel20, is longer-lasting and more resilient to environmental exposure, particularly as compared to a gutter guard where mesh layer12is secured to guard panel20only at select locations. The disclosed gutter guard10is less likely to result in tearing, ripping or separation of mesh layer12from guard panel20.

Referring toFIG. 3, gutter guard10can be positioned over the opening of longitudinally-extending gutter100, and functions to separate small twigs, leaves, pine needles, acorns, and other debris from rainwater entering the gutter100and passing through downspouts outwardly away from the foundation of the house or building. As depicted inFIG. 3, gutter guard10can be adapted to extend laterally across the opening of gutter100and longitudinally along the length of the gutter100. A longitudinal, generally C-shaped connecting member30, of increased rigidity in some embodiments, can be integrally formed with guard panel20along a first longitudinal side edge24of guard panel20, and includes resilient spaced-apart top and bottom walls32and34, respectively, formed with end wall36and adapted for receiving an inwardly-extending flange102of gutter100to hold gutter guard10in position during use. The opposite or second longitudinal side edge26of guard panel20of gutter guard10can in some embodiments fit beneath a lowermost row of shingles104attached to roof106of house or building108, such that rainwater and debris runs from shingle104of roof106directly to gutter guard10before entering gutter100. Mesh layer12cooperates (enlarged inFIG. 3for illustration purposes only) with guard panel20to capture and separate debris from rainwater to prevent the debris from entering gutter100while the rainwater passes freely into gutter100. Continuous bond40(illustrated inFIG. 2) ensures that mesh layer12is secured to guard panel20at substantially all points of contact between mesh layer12and guard panel20so as to prevent debris and environmental exposure from loosening or removing mesh layer12from guard panel20, thereby ensuring a long-lasting and durable gutter guard.

Gutter guard10can in some embodiments be formed in predetermined lengths and widths depending on the dimensions of the gutter to which it is to be applied. The dimensions of guard panel20, filter openings22and mesh layer12can be vary correspondingly. In some embodiments, mesh layer12can have a width W1 sufficient to cover filter openings22, including the width W2 of the area of filter openings22(seeFIG. 1and/orFIG. 2). For example, in some embodiments, mesh layer12can have a width W1 ranging from about 3 inches to about 7 inches, including a width W1 of about 3 inches, 3.5 inches, 4 inches, 4.5 inches, 5 inches, 5.5 inches, 6 inches, 6.5 inches or 7 inches. In some embodiments mesh layer12can be cut to a length corresponding to the length of guard panel20upon which it is applied. In some embodiments, guard panel20can have a width W3 sufficient to fit the opening of a gutter100such as that depicted inFIG. 3. For example, in some embodiments, guard panel20can have a width W3 ranging from about 4 inches to about 10 inches, including a width W3 of about 4 inches, 4.5 inches, 5 inches, 5.5 inches, 6 inches, 6.5 inches, 7 inches, 7.5 inches, 8 inches, 8.5 inches, 9 inches, 9.5 inches or 10 inches. In some embodiments guard panel20can have a length L1 corresponding to a given length of gutter to which gutter guard10is to be applied. In some embodiments, guard panel20, and therefore gutter guard10, can be provided in pre-determined lengths suitable convenient for handling, storage, delivery and application to sections of gutter. By way of example and not limitation, gutter guard10can be provided in 3 foot lengths, 4 foot lengths, 5 foot lengths, 6 foot lengths, 7 foot lengths, 8 foot lengths and the like. In some aspects the finished gutter guard10cut in pre-determined lengths is also provided in a substantially flat condition to avoid pinching connecting member30and destroying its operability.

In some aspects, the width W2 of the area of guard panel20covered by filter openings22can vary depending on the width W3 of guard panel20. In some aspects, width W2 of the filter openings22can be less that width W3 of guard panel20, but can in some embodiments be cover a substantial portion of width W3 of guard panel20so as to provide sufficient surface area through which rain water can pass into gutter100(seeFIG. 3). In some aspects, the width W2 of the area of guard panel20covered by filter openings22can range from about from about 3 inches to about 7 inches, including a width W2 of about 3 inches, 3.5 inches, 4 inches, 4.5 inches, 5 inches, 5.5 inches, 6 inches, 6.5 inches or 7 inches. In some embodiments, filter openings22can extend the entire length L1, or substantially the entire length L1, of guard panel20.

In some embodiments, a method of forming a gutter guard10can comprise forming a plurality of filter openings22in an elongate polymer guard panel20. A mesh layer12, e.g. a polymer-coated mesh layer, can be applied over the guard panel20in an area of the filter openings22and attached or affixed to guard panel20by creating a secure bond between mesh layer12and guard panel20. The mesh layer12can be bonded to guard panel20across substantially the entire surface of mesh layer12whereby mesh layer12is secured to guard panel20at substantially all points of contact between mesh layer12and guard panel20.

In some embodiments, the bonding of mesh layer12to guard panel20can comprise the use of heat welding, ultrasonic welding, hot rollers, pressure rollers, a heat lamp, and/or combinations thereof. Bond40(seeFIG. 2) can comprise a heat weld, an ultrasonic weld, a chemical bond, an adhesive bond, or any other suitable bond sufficient to adhere mesh layer12to guard panel20. In some embodiments, ultrasonic welding can comprise a welding horn, a knurl roller and an amplifier. In some aspects, a flat horn can press against the bottom of the gutter guard being formed while a knurl roller presses against the top. In some aspects multiple horns can be used in an ultrasonic welding method. In some aspects, an amplifier can be used in conjunction with one or more horns in an ultrasonic welding method. In some embodiments, a continuous roll of guard panel20can be fed into a welding device, while a continuous roll of mesh layer12can also be fed into the welding device, such that mesh layer12is heat welded to guard panel20. Gutter guard10can in some embodiments be formed in predetermined lengths, such as for example 3 foot lengths, and in a substantially flat condition to avoid pinching or kinking the gutter guard.

In some embodiments, the temperature of the bonding method, e.g. heat weld, can for example and without limitation, range from about 160 degrees Fahrenheit to about 250 degrees Fahrenheit. In some embodiments, the temperature of the bonding, e.g. heat weld, can range from about 210 degrees Fahrenheit to about 230 degrees Fahrenheit. In some embodiments, the temperature of the heat weld can be about 220 degrees Fahrenheit. In some embodiments, the mesh layer will begin to melt at about 160 degrees Fahrenheit.

Turning now toFIGS. 4A-4D, devices, systems and methods for making the composite gutter guards as illustrated inFIGS. 1-3are schematically illustrated.FIGS. 4A-4Dillustrate exemplary devices or welding devices for affixing or adhering mesh layer12to the guard panel20to thereby form gutter guard10.

Device50A, as illustrated inFIG. 4A, can in some embodiments comprise a mechanism for feeding mesh layer12and guard panel20, one or more pressure rollers (52,52′), a radiant heater56, and a control device70.

Using device50A, as illustrated inFIG. 4A, mesh layer12can be bonded to guard panel20using a radiant heater56, such as for example a heat lamp. Radiant heater56can heat one or both of guard panel20and/or mesh layer12just prior to bonding or pressing the two together using pressure rollers52and/or52′, e.g. knurl rollers. Mesh layer12and guard panel20can be continuously fed into device50A. In some embodiments, mesh layer12can be fed into device50from roll68of mesh layer12by rotating roll68in a first rotational direction RD1. Guard panel20can be continuously fed into device50A using one or more rollers or guides, such as for example roller51, rotating in a second rotational direction RD2. In some aspects, both mesh layer12and guard panel20are fed into and through device50in the same direction D. Radiant heater56can be positioned such that one or both of guard panel20and/or mesh layer12are heated to a desired temperature just prior to bonding or pressing the two together using pressure rollers52and/or52′ to thereby create a continuous heat weld, or bond40(seeFIG. 2), between all points of contact between mesh layer12and guard panel20.

In some embodiments, guard panel20and/or mesh layer12are heated to a range from about 160 degrees Fahrenheit to about 250 degrees Fahrenheit. In some embodiments, the temperature of the bonding, e.g. heat weld, can range from about 210 degrees Fahrenheit to about 230 degrees Fahrenheit. In some embodiments, the temperature of the heat weld can be about 220 degrees Fahrenheit. In some embodiments, mesh layer12will begin to melt at about 160 degrees Fahrenheit at which point it can be heat welded or bonded to guard panel20.

As guard panel20and/or mesh layer12are heated using radiant heater56, or shortly after heating, the bonding between guard panel20and mesh layer12can in some embodiments be facilitated using one or more pressure rollers52and/or52′, e.g. knurl rollers. Pressure can in some embodiments be applied to pressure rollers52and/or52′ using pressure applicators54and54′, respectively. In some embodiments, control device70can control the rate at which mesh layer12and/or guard panel20are fed into and through device50A, the temperature applied by radiant heater56, and/or the pressure applied by pressure rollers52and/or52′.

Device50B, as illustrated inFIG. 4B, can in some embodiments comprise a mechanism for feeding mesh layer12and guard panel20, one or more heated rollers (53,53′), and a control device70. Using device50B, as illustrated inFIG. 4B, mesh layer12can be bonded to guard panel20using one or more heated rollers53,53′. The one or more heated rollers53,53′ can heat one or both of guard panel20and/or mesh layer12while simultaneously bonding or pressing the two together. In some aspects, heated rollers53,53′ can comprise heated knurl rollers that apply pressure to guard panel20and/or mesh layer12simultaneous with heat. Mesh layer12and guard panel20can be continuously fed into device50B. In some embodiments, mesh layer12can be fed into device50from roll68of mesh layer12by rotating roll68in a first rotational direction RD1. Guard panel20can be continuously fed into device50using one or more rollers or guides, such as for example roller51, rotating in a second rotational direction RD2. In some aspects, both mesh layer12and guard panel20are fed into and through device50B in the same direction D. Heated rollers53,53′ can heat one or both of guard panel20and/or mesh layer12to a desired temperature just prior to bonding or pressing the two together to thereby create a continuous heat weld, or bond40(seeFIG. 2), between all points of contact between mesh layer12and guard panel20.

In some embodiments, guard panel20and/or mesh layer12are heated to a range from about 160 degrees Fahrenheit to about 250 degrees Fahrenheit. In some embodiments, the temperature of the bonding, e.g. heat weld, can range from about 210 degrees Fahrenheit to about 230 degrees Fahrenheit. In some embodiments, the temperature of the heat weld can be about 220 degrees Fahrenheit. In some embodiments, mesh layer12will begin to melt at about 160 degrees Fahrenheit at which point it can be heat welded or bonded to guard panel20.

As guard panel20and/or mesh layer12are heated using one or more of heated rollers53,53′ a bond or heat weld between guard panel20and mesh layer12can in some embodiments be facilitated by simultaneously applying pressure via pressure applicators54and54′ which can be mechanically coupled to heated rollers53,53′. In some embodiments, control device70can control the rate at which mesh layer12and/or guard panel20are fed into and through device50B, the temperature and/or pressure applied by heated and/or pressured rollers53and/or53′.

Device50C, as illustrated inFIG. 4C, can in some embodiments comprise a mechanism for feeding mesh layer12and guard panel20, an adhesive applicator58, one or more pressure rollers (52,52′), and a control device70. Using device50C, as illustrated inFIG. 4C, mesh layer12can be bonded to guard panel20using an adhesive or other bonding compound applied in some embodiments using an adhesive applicator58, e.g. a glue roller. In some aspects, one or more pressure rollers52,52′ can apply pressure to bond guard panel20and/or mesh layer12together after application of the adhesive compound. In some aspects, pressure rollers52,52′ can comprise knurl rollers. Mesh layer12and guard panel20can be continuously fed into device50B. In some embodiments, mesh layer12can be fed into device50from roll68of mesh layer12by rotating roll68in a first rotational direction RD1. Guard panel20can be continuously fed into device50using one or more rollers or guides, such as for example roller51, rotating in a second rotational direction RD2. In some aspects, both mesh layer12and guard panel20are fed into and through device50B in the same direction D.

Adhesive applicator58can apply an adhesive compound to one or both of guard panel20and/or mesh layer12(depicted as being applied to guard panel20inFIG. 4Cfor illustrative purposes only). Adhesive can be applied to one or both of guard panel20and/or mesh layer12, and the two bonded together, such that a continuous bond, e.g. bond40(seeFIG. 2), is created between all points of contact between mesh layer12and guard panel20. In some embodiments, adhesive applicator58can comprise a glue applicator roll, a Kiss roller or doctor blade. In some aspects the adhesive can comprise an adhesive compound, glue, chemical bonding agent or any suitable bonding agent suitable for securely adhering mesh layer12to guard panel20. In some embodiments, control device70can control the rate at which mesh layer12and/or guard panel20are fed into and through device50C, the pressure applied by pressure rollers52and/or52′, and/or adhesive applicator58.

Device50D, as illustrated inFIG. 4D, can in some embodiments comprise a mechanism for feeding mesh layer12and guard panel20, one or more rollers52, an ultrasonic welding horn60, and a control device70. Using device50D, as illustrated inFIG. 4D, mesh layer12can be bonded to guard panel20using an ultrasonic welding device comprising in some embodiments an ultrasonic welding horn60and roller52. The welding horn60, alone or in combination with pressure applied by one or more rollers52, can create a weld, or bond40(seeFIG. 2), that adheres mesh layer12to guard panel20such that a secure bond exists between all points of contact between mesh layer12and guard panel20. In some aspects, roller52can comprise a knurl roller that applies pressure to guard panel20and/or mesh layer12simultaneous while welding horn60creates a weld. Mesh layer12and guard panel20can be continuously fed into device50D. In some embodiments, mesh layer12can be fed into device50D from roll68of mesh layer12by rotating roll68in a first rotational direction RD1. Guard panel20can be continuously fed into device50D using one or more rollers or guides, such as for example roller51, rotating in a second rotational direction RD2. In some aspects, both mesh layer12and guard panel20are fed into and through device50D in the same direction D.

In some embodiments, guard panel20and/or mesh layer12are heated to a range from about 160 degrees Fahrenheit to about 250 degrees Fahrenheit. In some embodiments, the temperature of the bonding, e.g. heat weld, can range from about 210 degrees Fahrenheit to about 230 degrees Fahrenheit. In some embodiments, the temperature of the heat weld can be about 220 degrees Fahrenheit. In some embodiments, mesh layer12will begin to melt at about 160 degrees Fahrenheit at which point it can be heat welded or bonded to guard panel20.

Ultrasonic welding device can in some embodiments comprise an ultrasonic welding horn60, e.g. a flat horn, an amplifier62and roller52, e.g. a knurl roller. In some aspects, ultrasonic welding horn60, and particularly a flat horn, can press against the bottom of gutter guard10being formed while roller52, and particularly a knurl roller, presses against the top. In some aspects, multiple ultrasonic welding horns60, can be used in an ultrasonic welding method. In some aspects, an amplifier62can be used in conjunction with one or more welding horns60in an ultrasonic welding method. As guard panel20and/or mesh layer12are heated using ultrasonic welding horn60a bond or heat weld between guard panel20and mesh layer12can in some embodiments be facilitated by simultaneously applying pressure via pressure applicator54which can be mechanically coupled to roller52. In some embodiments, control device70can control the rate at which mesh layer12and/or guard panel20are fed into and through device50B, the operation of ultrasonic welding horn60, amplifier62and/or roller52.

In some embodiments, features of any one of devices50A,50B,50C and/or50D can be combined any manner suitable to adhere mesh layer12to guard panel20. For example, any one or more of a radiant heater56, heated roller53, adhesive applicator58and/or ultrasonic welding horn60can combined and/or used simultaneously in a device, system or method of making a gutter guard10.

In some embodiments, a method of forming a gutter guard10is provided. A gutter guard10formed by such method can be adapted for being positioned at an opening of a longitudinally extending, generally U-shaped gutter used for collecting and distributing rainwater runoff from the roofs of residential homes and other buildings. Such a method can in some embodiments comprise the use of a device, system or apparatus as illustrated inFIGS. 4A-4Dand as disclosed herein.

In some embodiments, a method of forming a gutter guard10can comprise forming a plurality of filter openings in an elongate polymer guard panel, the guard panel being adapted to extend laterally across the opening of the gutter and longitudinally along the length of the gutter. The method can further comprise applying a polymer-coated mesh layer over the guard panel in an area of the filter openings, the mesh layer having first and second opposing side edges and first and second opposing end edges, and the mesh layer cooperating with the guard panel to capture and separate debris from rainwater runoff entering the gutter. Finally, in some embodiments the method can comprise bonding the mesh layer to the guard panel across substantially the entire surface of the mesh layer from the first side edge to the second side edge, and extending from one end edge of the mesh later to the opposing end edge of the mesh layer, whereby the mesh layer is secured to the guard panel at substantially all points of contact between the mesh layer and guard panel.

In some embodiments, the bonding can comprise heat welding, such as for example the use of ultrasonic welding, a hot roller, radiant heater and/or heat lamp. In some embodiments, the ultrasonic welding comprises a welding horn, a knurl roller and/or an amplifier. In some embodiments, the temperature of the heat weld ranges from about 160 degrees Fahrenheit to about 250 degrees Fahrenheit. In some embodiments, the method can comprise the use of one or more heated rollers. In some embodiments, the method can comprise coating the mesh layer and/or the guard panel with a chemical bonding agent. In some embodiments, the method can comprise using a Kiss roller or doctor blade to apply the chemical bonding agent.

The present subject matter can be embodied in other forms without departure from the spirit and essential characteristics thereof. The embodiments described therefore are to be considered in all respects as illustrative and not restrictive. Although the present subject matter has been described in terms of certain preferred embodiments, other embodiments that are apparent to those of ordinary skill in the art are also within the scope of the present subject matter.