Cutting tool for seamless gutter machine

A cutter for cutting a formed gutter discharged from a seamless gutter machine. The cutter may be positioned to cut a back wall of a formed gutter below a front upper edge of a front wall of the gutter. In turn, a gutter may be mounted to a building (e.g., a fascia board thereof) to achieve additional lift, thereby providing increased pitch over a given length of gutter while maintaining overlap between a gutter apron and a back upper edge of the back wall of the formed gutter.

BACKGROUND

Rain gutters are often affixed to a building to assist in directing runoff water from a roof or other portion of the building. Seamless gutter machines been developed that are capable of forming a continuous length of gutter. Seamless gutter machines generally act on flat stock in the form of a roll or the like that is passed through the machine. The seamless gutter machines include breaks, rollers, and other sheet material forming apparatuses arranged along the path of the sheet material through the seamless gutter machine to form a finished gutter. In turn, the continuous length of formed gutter is discharged from a discharge of the seamless gutter machine.

When affixing seamless gutters to a building, the gutters are installed to the building such that the gutters define a desired path along which water will travel. In this regard, the pitch of the gutter relative to gravity allows for the control of the flow water in the gutter. However, in various applications, it may be difficult to obtain sufficient pitch to ensure adequate water drainage in a desired direction. One such example of a scenario where additional pitch may be desired are for relatively long runs of gutters. Gutters are often affixed to a fascia board, open rafter tails, or other portion of a roof such that a gutter apron or other structure that is attached to the roof extends into a channel defined by the gutter along the back wall of the gutter. The gutter apron extends for a limited distance from the surface from which water drains into the gutter to help reduce water draining from the roof from passing behind the gutter and against the fascia board. As such, the gutter apron may have a limited dimension to extend relative to the gutter when the gutter is attached to the fascia board. As such, there may be a limited ability to provide sufficient pitch when attaching seamless gutters to maintain the overlap between the gutter apron and a back wall of the gutter.

SUMMARY

In view of the foregoing, it has been recognized that formed gutters from a seamless gutter machine may be modified to provide additional pitch over a given length of the seamless gutter. While such modification may occur in the form manually cutting a portion of the seamless gutter using scissors, snips, shears, or the like to remove material for attachment of the gutter to a building to achieve greater pitch over a given length of gutter, manual modification of gutters may be inefficient and add additional cost, complexity, and/or the potential for injury to gutter projects. In turn, the present disclosure generally relates to a cutting tool that may be fixedly connected to a seamless gutter machine to cut a formed gutter that is discharged from a seamless gutter machine. The cutting tool may be generally attached at a discharge of a seamless gutter machine. Accordingly, as the formed gutter is discharge from the seamless gutter machine, the cutting tool may act to cut the gutter along the longitudinal axis along which the formed gutter is discharged from the seamless gutter machine. That is, the cutting tool may cut along a cutting axis extending along the length of the formed gutter machine being discharge from the seamless gutter machine. The cutting tool may be passive. That is, the motion imparted on the formed gutter by the seamless gutter machine when discharging the formed gutter may drive the formed gutter relative to the cutting tool. That is, the action of the seamless gutter machine discharging the formed gutter therefrom may also drive the formed gutter relative to the cutting tool to perform the cutting operation on the formed gutter.

The trimming of the gutter as discussed herein may provide a number of significant benefits. For example, as described above, for a given length of gutter, trimming a portion of the gutter may result in the ability of providing a greater angle relative to horizontal for the given length of gutter. This may be particularly useful in applications where it is desirable to remove or relocate a downspout for cosmetic purposes or to better control the flow of water away from structure. Furthermore, where additional pitch is sought over a length of gutter, it may be necessary to mount the downstream portion of the gutter relatively low on the gutter apron. This may result in a relatively large portion of the gutter apron being exposed. As the gutter apron is often not cosmetically appealing, is desirable to have as little of the gutter apron exposed as possible. Furthermore, in certain scenarios such as a case of a settling roofline or other sagging portion of a building, it may be difficult or impossible to provide a downspout were necessary. By using a trimmed portion of gutter, it may be possible to achieve a greater pitch on the gutter to compensate for any sagging or settling a portion of the building to allow for proper drainage even in the case of a sagging or settling portion of the building. Furthermore, providing increased pitch may provide benefits in relation to reduction of sediment deposits within the gutter channel. Further still, when the portion of a gutter is mounted relatively low on the gutter apron it may be more susceptible to have water flowing from the building overtop the gutter such that the water is not directed in the channel. By providing the trimmed force in the gutter as discussed herein, the height of the gutter relative to the roof may be raised to reduce the likelihood of water overtopping the gutter upon entering the gutter channel.

The cutting tool may be specifically positioned at the discharge of the seamless gutter machine so as to cut the formed gutter at a predefined specific location of the formed gutter. Specifically, formed gutter may include a front wall having a front upper edge and a back wall having a back upper edge. The form gutter also includes a bottom wall extending between the front wall the back wall opposite the front upper edge and back upper edge. In this regard, the formed gutter may generally form a U-shaped channel. Accordingly, the cutting tool may be disposed at the discharge of the seamless gutter machine to cut a portion of the back wall of the formed gutter. Specifically, the back wall may be cut at a level below (i.e., closer to the bottom wall) than the front upper edge. It may be appreciated, removal of a portion of the back wall below the level the front upper edge may allow for the gutter to be fixed to a building (e.g., a fascia board, open rafter tail, or other structure) such that a greater pitch may be realized when mounting the gutter as compared to a gutter without any portion of the back wall removed.

In another aspect of the present invention, a cutting tool as described herein may be utilized to cut any formed sheet metal. For instance, in addition to rain gutters as described above, other forms of products may be generated by use of formed sheet metal material. One such example includes formed metal roofing material such as standing seam roofing panels. In this instance, the formed metal roofing material may also be formed by use of a machine that acts to bend, cut, or otherwise shape a sheet metal roll into a desired shape. In this regard, the cutting tool described herein may be affixed at the discharge of any sheet metal forming apparatus that forcibly passes the sheet (either prior to forming or after forming) through the cutting tool.

Accordingly, a first aspect includes a cutter for use with a seamless gutter machine. The cutter includes a cutting assembly that is supportably engaged by a frame that is attachably engageable with a seamless gutter machine adjacent to a discharge of the seamless gutter machine. The seamless gutter machine discharges a formed gutter along a longitudinal axis extending from the discharge. Specifically, the formed gutter includes a front wall having a front upper edge, a back wall having back upper edge, and a bottom wall extending between the front and back walls opposite the front and back upper edges. The cutter includes a cutting assembly having a cutting axis along which a work piece is moved to cut the work piece along the cutting axis. The cutting assembly is disposable at the discharge of the seamless gutter machine in a first position where the cutting axis is parallel to the longitudinal axis and extends along the back wall of the formed gutter a first distance from the bottom wall less than a second distance the front wall extends from the bottom wall.

A number of feature refinements and additional features are applicable to the first aspect. These feature refinements and additional features may be used individually or in any combination. As such, each of the following features that will be discussed may be, but are not required to be, used with any other feature or combination of features of the first aspect.

For instance, in one embodiment the cutting assembly may include a plurality of cutting rollers rotatably mounted to the cutting assembly and offset to have overlapping peripheral edges defining the cutting axis along which a work piece is moved through the cutting rollers to cut the work piece along the cutting axis. However, other types of cutting assemblies may be provided that are capable of cutting the gutter as it is discharged from the seamless gutter machine.

In at least some embodiments, the cutting assembly may be positionable relative to the frame between the first position and a second position. In one embodiment, when the cutting assembly is in the second position, the cutting axis is spaced apart from the formed gutter so that the cutting assembly does not contact the formed gutter. In another embodiment, when in the first position, the cutting assembly may engage formed gutter of a first size discharged from the seamless gutter machine and when in the second position, the cutting assembly engages formed gutter of a second size discharged from the seamless gutter machine.

For example, the first size of the gutter may comprise a five-inch gutter. In this embodiment, when in the first position, the cutting axis may extend along the back wall at least about 0.10 of an inch (0.25 cm) from the second upper edge. In alternative embodiments, the cutting axis may extend along the back wall at least about 0.25 of an inch (0.64 cm), at least about 0.3 of an inch (0.76), at least about 0.4 of an inch (1.0 cm), at least about 0.5 of an inch (1.3 cm), at least about 0.6 of an inch (1.5 cm), at least about 0.75 of an inch (1.9 cm), or even at least 1 inch or more (2.5 cm), from the second upper edge. Additionally, when in the first position, the cutting axis may extend along the back wall not more than about 0.75 of an inch (1.9 cm) from the second upper edge. In alternative embodiments, the cutting axis may extend along the back wall not more than about 1 inch (2.5 cm), not more than about 1.25 in (3.2 cm), not more than about 1.5 in (3.8 cm), not more than about 1.75 in (4.4 cm), not more than about 2 in (5.1 cm), not more than about 2.5 in (6.4 cm), or even not more than about 3 in (7.6 cm), from the second upper edge. The second size of the gutter may correspond to a six-inch gutter. When the cutting assembly is in the second position, the cutting axis may extend along the back wall at least about 0.625 of an inch (1.6 cm) from the second upper edge. In alternative embodiments, the cutting axis may extend along the back wall at least about 0.75 of an inch (1.9 cm), at least about 1 inch (2.5 cm), at least about 1.25 in (3.2 cm), at least about 1.5 in (3.8 cm), at least about 1.75 in (4.4 cm), at least about 2 in (5.1 cm), at least about 2.5 in (6.4 cm), or even at least about 3 in (7.6 cm), from the second upper edge. Additionally, when the cutting assembly is in the second position, the cutting axis may extend along a back wall not more than about 1 inch (2.5 cm) from the second upper edge. In alternative embodiments, the cutting axis may extend along the back wall not more than about 1.5 in (3.8 cm), not more than about 2 in (5.1 cm), not more than about 2.5 in (6.4 cm), not more than about 3 in (7.6 cm), not more than about 3.5 in (8.9 cm), or even not more than about 4 in (10 cm), from the second upper edge. In still another embodiment, a first position may correspond to a gutter of a first size, a second position may correspond to a gutter of a second size, and a third position may correspond to a position where the cutting assembly does not engage the gutter when discharged from the seamless gutter machine.

In an embodiment, the cutting assembly may be positionable relative to the frame without removal of the cutting assembly from the frame. For example, the cutting assembly may be slideably positionable relative to the frame between at least the first position and the second position. This may be the case whether the first and second position correspond to different sizes of gutters or a position where the gutter is cut and another position where the cutter does not engage the gutter.

Furthermore, the cutting wheel may be passive. That is, the cutting wheel may not be actively powered to cut the gutter. Rather, the cutting assembly may contact the formed gutter as the formed gutter is discharged from the seamless gutter machine to separate a portion of the back wall from the cutting axis to the second upper edge from the formed gutter.

A second aspect includes a method of cutting a gutter. The method includes locating a cutting assembly adjacent to a discharge of a seamless gutter machine to a dispose a cutting axis defined by the cutting assembly relative to a formed gutter discharged from the seamless gutter machine. The method further includes discharging a length of the formed gutter from the seamless gutter machine along a longitudinal axis extending from the discharge. The formed gutter includes a front wall having a front upper edge, a back wall having a back upper edge, and a bottom wall extending between the front and back walls opposite the front and back upper edges. The method further includes passing the formed gutter relative to the cutting assembly such that cutting axis intersects the back wall and cutting the back wall of the gutter along the cutting axis at a first distance from the bottom wall less than a second distance the front wall extends from the bottom wall.

A number of feature refinements and additional features are applicable to the second aspect. These feature refinements and additional features may be used individually or in any combination. As such, each of the following features that will be discussed may be, but are not required to be, used with any other feature or combination of features of the second aspect.

For instance, in an embodiment, the cutting assembly may include a plurality of cutting rollers rotatably mounted to the cutting assembly and offset to have overlapping peripheral edges defining the cutting axis along which a work piece is moved through the cutting rollers to cut the work piece along the cutting axis. In this regard, the method may also include positioning the cutting assembly relative to the frame between a first position and a second position. For instance, when the cutting assembly is in the second position, the cutting axis may be spaced apart from the formed gutter so that the cutting assembly does not contact the formed gutter. Alternatively, when in the first position, the cutting assembly may engage formed gutter of a first size discharged from the seamless gutter machine and when in the second position, the cutting assembly may formed gutter of a second size discharged from the seamless gutter machine. In particular, the cutting assembly may be positionable relative to the frame without removal of the cutting assembly from the frame. Furthermore, as described above in relation to the first aspect, the cutting wheel may be passive and contacts the formed gutter as the formed gutter is discharged from the seamless gutter machine to separate a portion of the back wall from the cutting axis to the second upper edge from the formed gutter.

DETAILED DESCRIPTION

The following description is not intended to limit the invention to the forms disclosed herein. Consequently, variations and modifications commensurate with the following teachings, skill and knowledge of the relevant art, are within the scope of the present invention. The embodiments described herein are further intended to explain modes known of practicing the invention and to enable others skilled in the art to utilize the invention in such, or other embodiments and with various modifications required by the particular applications(s) or use(s) of the present invention.

FIG. 1illustrates a prior art example of a seamless gutter machine10. The seamless gutter machine10generally includes rolls of sheet material12that are fed into a rear portion14of the seamless gutter machine10. The seamless gutter machine includes a number of breaks, rollers, cams, anvils, and/or other sheet forming tools disposed within the seamless gutter machine10that operate on the sheet material entering the rear portion14of the seamless gutter machine10. Accordingly, as the sheet material12is fed into the rear portion14of the machine10and is advanced toward a discharge16(e.g., by drive rollers within the seamless gutter machine), the sheet material is bent, creased, folded, and/or otherwise shaped into a formed gutter product that is discharged from the discharge16of the seamless gutter machine10. In an embodiment, the formed gutter20may have a cross-sectional profile as depicted inFIG. 2. In any regard, the formed gutter20is generally discharged along a longitudinal axis18extending from the seamless gutter machine10.

With further reference toFIG. 2, there is depicted an embodiment of a cross-sectional profile the formed gutter20. The formed gutter20generally includes a front wall22, a bottom wall24, and a back wall26. The front wall22may include a front upper edge28and the back wall may include a back upper edge30. As appreciated inFIG. 2, the front upper edge28and the back upper edge30may be disposed on sides of the respective front wall22and back wall26opposite the bottom wall24. In this regard, the formed gutter20may generally include a U-shaped cross-section that may define a channel through which water may be directed (e.g., when attached to a building or the like). As can further be appreciated inFIG. 2the front wall22may include contours including, for example, lips, curves, or folds. Such contours may be provided for structural rigidity of the formed gutter20and/or for decorative purposes. The back wall26may also include a rolled bead portion32to provide structural rigidity to the back wall26. The formed gutter20may define a front upper edge plane34at the front upper edge28. It may further be appreciated, the back wall26of the formed gutter20may generally extend above (e.g., further from the bottom wall24) than the front upper edge plane34. The form gutter product20may be formed in various different standardized sizes and formats, all with the general shape described above including a front wall, bottom wall, and back wall. For instance, the cutter described herein may be used with K-style or fascia style gutters. With respect to K-style gutters, for example, some seamless gutter machines10may be operative to form five inch K-style formed gutter product, wherein the distance from the widest extent of the form gutter product (designated as W inFIG. 2) measures 5 inches (12.7 cm). Additionally, some seamless gutter machines10may be operative form six inch K-style form gutter product, wherein the distance from the widest extent of the formed gutter (W) is 6 inches (15.2 cm). While one particular cross-sectional profile of formed gutter20is depicted inFIG. 2, it may be appreciated that other profiles may be provided without limitation that generally include a front wall22, bottom wall24, and back wall26, the front wall22having a front upper edge28and the back wall26having a back upper edge30.

With further reference toFIG. 3, an embodiment of a cutter100is depicted. The cutter100may include a cutting assembly200that is supportably engaged by a frame110. The frame110may include a plurality of mounting holes112. The mounting holes112may generally correspond to mounting locations114provided at the discharge16of the seamless gutter machine depicted inFIG. 1. The location of the mounting locations114may be standardized for at least some seamless gutter machines10. For example, a proprietary standard may exist for a particular manufacturer of seamless gutter machines and/or an industry-wide standard may be adopted by a number of different manufacturers of seamless gutter machines. Any regard, the frame110may be securely mountable adjacent to the discharge16of the seamless gutter machine10. While coordination of mounting holes112and fasteners at the mounting locations114are depicted herein, other means of attachment of the frame110adjacent to the discharge16of the seamless gutter machine10may be provided without limiting the scope of the present disclosure. Such additional potential attachment mechanisms may include, but are not limited to, a welded attachment, a clamping attachment, an adhesive attachment, use of straps, etc. In at least some embodiments the frame110may also be integrated into the seamless gutter machine10.

For instance, the cutter100may be attached (e.g., the frame110) may be attached directly to the discharge of the seamless gutter machine10. Additionally or alternatively, the cutter100may be attached to another structure adjacent to the discharge of the seamless gutter machine10. For instance, a guillotine cutter or other device for severing the discharged from the seamless gutter machine10may also be provided at the discharge of the seamless gutter machine10. In this regard, the cutter100may be attached to the guillotine cutter or other device attached to the discharge of the seamless gutter machine10. Furthermore, the cutter100may be a standalone device that is positionable near the discharge of the seamless gutter machine10. For example, the cutter10may be supported by a separate structure (e.g., a stand or the like) that may be positionable adjacent to the discharge of the seamless gutter machine10.

In any regard, the frame110may define an aperture118through which formed gutter20may pass when discharged from the discharge16of the seamless gutter machine10. In other embodiments, the aperture118may be defined by the seamless gutter machine10itself or another device (e.g., a guillotine cutter or the like). In this regard and as will be described in greater detail below, the frame110may simply position the cutting assembly200in a position relative to the discharge of the seamless gutter machine10. As such, the cutter100may include a cutting assembly200is disposed relative to the frame110such that the cutting assembly200extends relative to the aperture118or portion of the frame110. In this regard, the cutting assembly200may be disposed relative to the aperture118and/or frame110so as to operationally engage the formed gutter20when discharged from a seamless gutter machine10to which the frame110is attached to cut a portion of the formed gutter20in a manner described in more detail below.

With further reference toFIGS. 4, 5, and 6, an embodiment of a cutting assembly200is depicted. However, it may be appreciated that other sheet metal cutting devices may be utilized that are capable of cutting a sheet material and the specific cutting assembly200described herein is exemplary and not limiting. For example, the cutting assembly may include blades or other cutting devices other than those described below. In this regard, the cutting assembly may include sharpened cutting edges, anvils, breaks, or other mechanisms for cutting the gutter being discharged. However, with further reference to the specific embodiment of the cutting assembly200, the cutting assembly200may include a body210to which and upper cutting roller212and a lower cutting roller214are mounted. The upper cutting roller212and the lower cutting roller214may be mounted for rotational movement relative to a central axis of the respective roller212or214. The body210may define an upper material channel216and a lower material channel218. As best appreciated inFIG. 6, the upper cutting roller212may be overlappingly positioned with the lower cutting roller214. That is, the upper cutting roller212and the lower cutting roller214may have overlapping peripheral edges. To this end, the upper cutting roller212may be offset from the lower cutting roller214in a direction corresponding to the respective axis of rotation of each respective roller212and214.

Accordingly, the cutting assembly200may define a cutting axis220along which sheet material may be advanced relative to the cutting assembly200. Upon engagement of the sheet material advanced along the cutting axis220with the upper and lower cutting rollers212and214, the overlapping peripheral edges of the upper cutting roller212and lower cutting roller214may shear the sheet material along the cutting axis220. In this regard, a first cut side of the sheet material may be advanced in the upper material channel216and a second cut side of the sheet material may be advanced in the lower material channel218. Accordingly, the cutting assembly200may shear the sheet material as it is advanced along the cutting axis220relative to the cutting assembly200to separate a first portion of the sheet material from the remainder of the sheet material.

Accordingly, with further reference toFIGS. 7-10, when the cutting assembly200is disposed adjacent to the discharge16of the seamless gutter machine10. As may be appreciated fromFIG. 7, the cutting assembly200may be disposed such that the cutting axis220is generally arranged parallel to the longitudinal axis18along which the formed gutter20is discharged from the seamless gutter machine10. As such, when the form gutter20is discharged from the seamless gutter machine10, the formed gutter20may impinge on the cutting assembly200. For example, as can be seen inFIG. 7, the seamless gutter machine10may include drive rollers36that forcibly discharge the formed gutter20along the longitudinal axis18. The cutting assembly200may be positioned relative to the discharge16to engage a back wall26of the form gutter20. For instance, as best shown inFIG. 2in relation to the formed gutter20cross section, the cutting assembly200may be positioned such that the cutting axis220engages the back wall26at a distance L from the bottom wall24. As may be appreciated, the result may be the back wall26being cut at the distance L from the bottom wall24such that an upper portion38of the back wall26may be severed from the remainder of the formed gutter20. Accordingly, a remaining intact section40of the back wall26adjacent the bottom wall24may continue along a path through the lower material channel218. The severed upper portion38adjacent to the back upper edge30may be severed from the back wall26and be diverted through the upper material channel216.

Of particular note, the cutting axis220may intersect the back wall26at the distance L from the bottom wall24such that the back wall26is cut below (i.e., nearer the bottom wall24) the level of the upper edge plane34. That is, the cutting axis220may intersect the back wall26a distance from the bottom wall24less than the distance the front wall22extends from the bottom wall24. As will be discussed in greater detail in relation toFIGS. 17A, 17B, and 17Cbelow, this may assist in attachment of the formed gutter20to achieve a greater pitch (e.g., more of an angle relative to horizontal) over a given distance of gutter run.

FIGS. 11-13depict progression of a formed gutter20being discharged from the discharge16of the seamless gutter machine10. In this regard, inFIG. 11, the back wall26of the formed gutter20is discharged from the seamless gutter machine10along the longitudinal axis18such that the back wall26is aligned with the cutting axis220as described above. As may be appreciated, the upper edge portion30of the back wall26may extend above the interface of the overlapping peripheral edges of the upper cutting roller212and the lower cutting roller214. In this regard, as the formed gutter20is discharged by the drive rollers36, the back wall26impinges upon the overlapping peripheries of the upper cutting roller lower212and the lower cutting roller214. That is, the back wall26intersects the cutting axis220of the cutting assembly200. As such, upon advancement of the formed gutter20relative to the cutting assembly200, the upper portion38of the back wall26may be cut from the remainder formed gutter20. This is depicted inFIGS. 12 and 13(depicting different sizes of formed gutter20) where the formed gutter20has been further advance with respect to the cutting assembly200such that the upper portion38of the back wall26is severed from the back wall26and directed into the upper material channel216and away from the remainder of the formed gutter portion20that continues through the lower material channel218.

With further reference toFIGS. 14A-14C, the cutting assembly200may be adjustable with respect to the frame110. In this regard,FIG. 14Adepicts the cutting assembly200in a first position relative to the frame110,FIG. 14Bdepicts the cutting assembly200in a second position relative to the frame110, andFIG. 14Cdepicts the cutting assembly200in a third position relative to the frame110. As can be appreciated best inFIG. 14A, the frame110may include a plurality of slots300through which guide bolts310are disposed. The guide bolts310may pass through the cutting assembly200. In this regard, the cutting assembly200may be slidable relative to the frame110as the guide bolts310may slide relative to the slots300. In this regard, the cutting assembly200may be slideably positionable between the3positions depicted inFIGS. 14A, 14B, and 14C.

Furthermore, the cutting assembly200may include an index pin312. The index pin312may be positioned into one of a plurality of indexing holes314A,314B, or314C provided in the frame110. For example, indexing hole314A be provided in the frame110such that when the indexing pin312is disposed in indexing hole314A, the cutting assembly200is in the first position as shown inFIG. 14A. The first position shown inFIG. 14Amay dispose the cutting assembly200away from the formed gutter20at the discharge16of the seamless gutter machine10such that the cutting assembly200does not contact the formed gutter20when discharged from the seamless gutter machine10. As such,FIG. 14Amay correspond to a position of the cutting assembly200wherein the cutting assembly200does not engage the formed gutter20discharged from the seamless gutter machine10. The cutting assembly may also be slidingly positioned relative to the frame such that the indexing pin312is selectively provided in indexing hole314B or314C for positions shown inFIGS. 14B and 14C, respectively. In this regard, index holes314B and314C may correspond to different positions of the cutting assembly200to engage corresponding different sizes of gutters as discussed above in relation toFIG. 2. For example, inFIG. 14B, cutting assembly200may be position for engagement of the back wall26of a six inch gutter, whereas inFIG. 14C, the cutting assembly200may be disposed for engagement with the back wall26of a 5 inch gutter. In any regard, a plurality of different positions may be established for the cutting assembly200such that the cutting assembly200engages different sizes of formed gutter discharged from the seamless gutter machine10and/or provides the cutting assembly200in a position spaced away from the discharged formed gutter20such that the cutting assembly200does not engaged the form gutter20.

When in a position to cut a five inch K-style gutter, the cutting assembly200may engage the back wall26of the gutter a distance of at least about 0.1 of an inch (0.25 cm) from the back upper edge. Alternatively, the cutting assembly200may engage the back wall26at least about 0.25 of an inch (0.64 cm), at least about 0.3 of an inch (0.76), at least about 0.4 of an inch (1.0 cm), at least about 0.5 of an inch (1.3 cm), at least about 0.6 of an inch (1.5 cm), at least about 0.75 of an inch (1.9 cm), or even at least 1 inch or more (2.5 cm), from the back upper edge. When in this position, the cutting assembly may engage the back wall26of the gutter a distance not more than about 0.75 of an inch (1.9 cm) from the back upper edge. In alternative embodiments, the cutting assembly200may engage the back wall26not more than about 1 inch (2.5 cm), not more than about 1.25 in (3.2 cm), not more than about 1.5 in (3.8 cm), not more than about 1.75 in (4.4 cm), not more than about 2 in (5.1 cm), not more than about 2.5 in (6.4 cm), or even not more than about 3 in (7.6 cm), from the back upper edge. Additionally, when in a position to cut a six inch K-style gutter, the cutting assembly may engage the back wall26of the gutter a distance at least about 0.625 of an inch (1.6 cm) from the back upper edge. In alternative embodiments, the cutting assembly200may engage the back wall26at least about 0.75 of an inch (1.9 cm), at least about 1 inch (2.5 cm), at least about 1.25 in (3.2 cm), at least about 1.5 in (3.8 cm), at least about 1.75 in (4.4 cm), at least about 2 in (5.1 cm), at least about 2.5 in (6.4 cm), or even at least about 3 in (7.6 cm), from the back upper edge. When in this position, the cutting assembly may engage the back wall26of the gutter a distance of not more than about 1 inch (2.5 cm) from the back upper edge. In alternative embodiments, the cutting assembly200may engage the back wall26not more than about 1.5 in (3.8 cm), not more than about 2 in (5.1 cm), not more than about 2.5 in (6.4 cm), not more than about 3 in (7.6 cm), not more than about 3.5 in (8.9 cm), or even not more than about 4 in (10 cm), from the back upper edge. In an embodiment, the cutting assembly20may cut the gutter along a longitudinal axis of the formed gutter such that the cutting axis is parallel to the length of the gutter. In other embodiments, at least a portion of the cut may be made such that the cutting axis extends toward the back upper edge (e.g., so as to taper the amount of material removed from the gutter for at least a portion of the cut).

A further embodiment of a cutter100′ is shown inFIGS. 15A-16C. InFIG. 15Athe cutter100′ is shown assembled. InFIG. 15Bthe cutter100′ is shown in an exploded view.FIGS. 15C, 15D, 15E, and 15Fshow detailed views of various components of the cutter100′. Finally16A,16B, and16C show the cutting assembly200of the cutter100′ in a first, second, and third position respectively. The following description of the cutter100′ uses like reference numerals for like elements.

Thus, with collective reference toFIGS. 15A-15F, the cutter100′ may include a cutting assembly200as described above. The cutting assembly200may be supportably engaged by a slider assembly400. For instance, the cutting assembly200may be mounted to the slider assembly400by way of fasteners410. In an application, the cutting assembly200may be integrally provided with the slider assembly300.

The slider assembly400may include a platform430that supportably engages the cutting assembly200. The platform430may be engaged with a mounting plate440. A slider420may be attached to the mounting plate440on a side opposite the platform430. The mounting plate440may also receive an indexing pin312.

The frame110may have a rail422mounted thereto. The slider420may engage the rail422and be slidable with respect to the rail422. The rail422may have bumpers424disposed at opposite ends of the rail422to prevent the slider420from sliding off either or both ends of the rail422.

When the sliding assembly400is slideably positioned relative to the rail422, the indexing pin312may be selectively disposable in one of a plurality of indexing holes314A,314B,314C to position the cutting assembly200in a first, second, or third position, respectively, as described above. The slider420may engage the rail422with machined surface bearings, a roller bearing interface, or any other appropriate bearing surface to promote a low friction sliding relation between the slider420and the rail422. As such, the cutting assembly200may be easily positioned between the plurality of positions defined by engagement of the indexing pin312relative to the indexing holes314A,314B, and314C.

Accordingly, with further reference toFIGS. 16A, 16B, and 16C, the cutter100′ including the slider assembly400is shown in a plurality of positions similar to those described above in relation toFIGS. 14A, 14B, and 14C. That is, inFIG. 16A, the slider assembly400may be positioned relative to the rail422such that the indexing pin312is positionable in indexing hole314A (not shown inFIG. 16A, shown inFIGS. 16B and 16C). In the first position shown inFIG. 16A, the cutting assembly200may be disposed such that the cutting assembly200does not engage a formed gutter200which passes through the aperture118of the frame110. InFIG. 16B, the slider assembly400may be positioned relative to the rail422such that the indexing pin312is positionable in indexing hole314B (shown inFIG. 16A) to position the cutting assembly200in a second position. In the second position shown inFIG. 14B, the cutting assembly200may be disposed relative to the frame110such that a formed gutter of a first size (e.g., a six inch gutter) is engaged by the cutting assembly200such that an upper portion38of the back wall26is cut therefrom as described above. InFIG. 16C, the slider assembly400may be positioned relative to the rail422such that the indexing pin312is positionable in indexing hole314C (shown inFIG. 16A) to position the cutting assembly200in a third position. In the third position shown inFIG. 14C, the cutting assembly200may be disposed relative to the frame110such that a formed gutter of a second size (e.g., a five inch gutter) is engaged by the cutting assembly200such that an upper portion38of the back wall26is cut therefrom as described above.

FIGS. 18-23relate to another embodiment of a cutter100′. Like reference numerals will be used to denote components common to the embodiment of the cutter100′ described above. As shown inFIG. 18, the frame110of the cutter100′ may include a generally L-shaped member. In this regard, the frame110may include a plurality of mounting holes112for attachment of the frame110to the discharge16of a seamless gutter machine. As the frame110is L-shaped, the frame110may attach to generally two sides of the discharge16rather than extending about the discharge entirely forming an aperture118as described above. This L-shaped frame110may accommodate easier mounting to the seamless gutter machine and may also accommodate other fixtures at the discharge of the seamless gutter machine such as, for example, a guillotine cutter538(e.g., shown inFIG. 1). In yet another embodiment shown inFIG. 24, the frame110may extend along a single edge of the discharge of the seamless gutter machine. As such, the frame110may attach using two mounting bolts arranged along one single edge of the discharge. In further embodiments, the frame110may be attached with a single bolt. Furthermore,FIG. 24depicts that the mounting holes112may be provided out of round. For example, the mounting holes112may be slightly oblong to allow for fine adjustments in relation to the positioning of the cutter100′ relative to the discharge of the seamless gutter machine. Furthermore, the mounting holes112may be slightly oversized provide for adjustments in both the vertical and horizontal aspects for fine tune adjustment of the positioning of the cutter100′ relative to the discharge of the seamless gutter machine.

The frame110may be attached a rail422(best seen inFIG. 20). The rail422may include mounting holes532that coordinate with mounting holes530on the frame (shown inFIG. 19). The rail422may also include indexing holes314A,314B, and314C that allow for positioning of the cutting assembly200in various positions as described above. Namely, a mounting plate440as shown inFIG. 21may include an integrated slider422that interfaces with the rail422for sliding engagement of the rail422by the slider422of the mounting plate440. The mounting plate440may accommodate or include an indexing pin312that may engage the indexing holes314A,314B, and314C to position the mounting plate440in various positions relative to the rail422. The mounting plate440may have attached thereto the cutting assembly200by way of interaction between mounting holes534on the mounting plate440and mounting holes536on the cutting assembly200. The indexing pin312may pass through a hole in the cutting assembly200as shown inFIG. 18for access by a user to slide the mounting plate440and attached cutting assembly200between various positions as described above. As best seen inFIG. 18, the cutting assembly200may include an upper cutting roller212and a lower cutting roller214, which are also depicted inFIG. 23. In this regard, the cutting assembly200may have a design similar to that described above for cutting material advanced relative to the cutting assembly200along the cutting axis220.

In relation to any of the foregoing embodiments of the cutter100or100′, it may be appreciated that the cutters may be manufactured in any appropriate manner using any appropriate material. For instance, various ones of or all of the components above may be manufactured using appropriate techniques such as casting, forging, machining, or other appropriate manufacturing technique. The components may be made from any appropriate material including, for example, polymer, metal, or the like. For instance, various ones of or all of the components described above may be manufactured from steel, stainless steel, aluminum, or other appropriate metals.

As discussed above briefly, formed gutters20are affixed to a building or the like at a pitch or predefined angle to control the direction in which water entering the formed gutter20flows to direct runoff water away from the building in a predetermined desired manner. As may be appreciated, the amount of pitch (i.e., the angle) at which the formed gutter20is attached to the building relative to horizontal (i.e., relative to gravity) may be important to correctly control the flow of water directed by the gutter20. As will be described in greater detail below, the selective removal of a portion38of the back wall26of the formed gutter20may assist in providing the necessary amount of pitch to a formed gutter20for a given length of gutter20when mounted to a building (e.g., especially in the context of relatively long lengths of formed gutter20).

In this regard,FIG. 17Adepicts a typical mounting structure to which formed gutter20is mounted on a building. In this regard, a gutter apron512is generally disposed between roofing material and an underlying substrate of the roof pitch510. In this regard, the gutter apron512extends a partial distance adjacent to a fascia board514. The fascia board514is disposed at the end portion of the roof soffit516. The formed gutter20is generally attached to the fascia board514as shown inFIG. 17B. In this regard, a first end of the formed gutter524is attached to the fascia board514such that the gutter apron512overlaps the back upper edge of the back wall26of the formed gutter20. In this regard, the gutter apron512overlaps the back wall26of the formed gutter20to help reduce water traveling behind the gutter20to the fascia board514. A second end526of the formed gutter20is attached to the fascia board514such that a free end of the gutter apron512opposite the roof pitch510overlaps the back upper edge of the back wall26of the gutter20. As can be appreciated, the resulting pitch provided by the differential in height between the first end524and the second and526of the formed gutter20results in a pitch angle520for the gutter as shown relative to horizontal inFIG. 17B.

However for a given length of formed gutter20to be attached to a building, the differential in height between the first end524and the second end526of the formed gutter20may be insufficient to provide the requisite amount of pitch over the given length of the formed gutter20while maintaining overlap between the gutter apron512and the back wall26of the gutter20. In this regard and with further reference toFIG. 17C, a former gutter20′ is provided that includes a section522along which the upper portion38of the back wall26of the gutter20′ has been removed as described above. As such, the first end524′ of the formed gutter20′ is affixed to the fascia board514such that the gutter apron512overlaps the resulting top edge30′ of the back wall26′ of the gutter20′ after the upper portion38of the back wall26′ has been removed therefrom. The second end526of the formed gutter20′ is attached to adjacent to the fascia board514such that the free end of the gutter apron512overlaps the back wall26of the formed gutter20as shown inFIG. 17C. In effect, the removal of the upper portion38of the back wall26of the formed gutter20′ along the cut section522provides additional lift to the first end524′ of the formed gutter20′. Accordingly and as can be appreciated inFIG. 17C, the resulting pitch angle520′ is greater for a length of formed gutter20′ shown inFIG. 17Cthan the pitch angle520for the same length of formed gutter20shown inFIG. 17B. For a given length of gutter20′, the additional lift provided by the cut section522of the gutter20′ may provide the necessary additional pitch angle520″.

The cutter100or100′ described above may be of particular benefit in cutting the portion522of the gutter20′ to achieve a desired increased pitch angle520′ to facilitate installation of a given length of gutter20′. Furthermore, as the cutter100or100′ may allow for cutting of the formed gutter20upon discharge from the seamless gutter machine10in response to the seamless gutter machine10advancing the formed gutter20from the discharge, a user may be alleviated from the manual process of cutting the section522of the formed gutter20to remove the upper portion38of the back wall26to achieve the additional pitch angle520′. The cutter100or100′ may therefore provide an efficient, safe, and controllable way in which to cut the formed gutter20in contexts where removal of a portion of the back wall26is necessary to achieve the additional pitch angle520′ as described above in relation to FIG.17C. Accordingly, use of the cutter100or100′ may beneficially reduce the cost and/or time associated with a gutter installation process.

Furthermore, providing larger pitch (e.g., greater angle relative to horizontal) may provide the benefits described above in relation to a more aesthetically pleasing gutter finish by reducing the amount of gutter apron shown. Furthermore, the larger pitch may allow for greater flexibility in determining where to locate downspouts for the gutters. Further still, potential benefits in relation to reduction in sediment deposits and prevention of overtopping of the gutters may also be realized as described above.

While the invention has been illustrated and described in detail in the drawings and foregoing description, such illustration and description is to be considered as exemplary and not restrictive in character. For example, certain embodiments described hereinabove may be combinable with other described embodiments and/or arranged in other ways (e.g., process elements may be performed in other sequences). Accordingly, it should be understood that only the preferred embodiment and variants thereof have been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected.