Abstract:
A shelf extends inwardly to the gutter trough from the front containment wall of a gutter trough to cooperate with a lip of a cavity structure of a hanger to provide structural stability and optional deflector attachment facility in a rain collection and diversion system. The hanger cavity structure has a containment lip a portion of which extends over a portion of the inwardly extending shelf of the front containment wall to allow functional water bearing capacity of the trough and a lengthened back trough wall to accommodate hanger placement and deflector inclination. The hanger can include deflector-mating cavities that open toward each other to allow compression attachment of the deflector. In a preferred embodiment, the deflector may be attached to a formed trough in which hangers are positioned to allow movement of the trough-deflector combination as a unit from the machine-site to the installation location on the structure. Associated installation methods are provided.

Description:
TECHNICAL FIELD 
     The present invention relates to rain and run-off collection and diversion systems and, in particular, to systems and methods for such systems that exhibit reduced debris accumulation. 
     BACKGROUND OF THE INVENTION 
     Diversion of rain from buildings is a well-known and beneficial practice. For centuries, architects and builders have understood the benefits of diverting rain to forestall erosion, maintain structural stability, and preserve vegetation. In recent decades, a multitude of systems have been developed to divert rain from structures and homes. Typically, such systems have been placed beneath or adjacent to the roofline to allow collection and diversion of rain accumulated from across the surface area of the structure roof. Such systems are sometimes called “gutter” systems. 
     Frequently, rain diversion systems employ gutters that are open channels to collect run-off from the roof. Diversion or gutter systems devised with open-channeled rain gutters tend to accumulate debris including sticks, leaves and other matter that is swept toward the gutter by the gravity-induced flow of water down the pitch of the roof. Such debris can cause malfunction of the system as well as significant problems with leakage and corrosion. Roof and structural rotting as well as erosion can be precipitated by the consequent accumulation of water without appropriate attendant diversion. 
     Consequently, a variety of gutter systems of varying complexity have been developed to inhibit debris accumulation in gutter systems. Simple systems have merely placed screens across open-faced gutter channels. These techniques commonly have their own debris accumulation problems. Other systems employ a deflector described by various terms such as “hood” or “shield” that deflect debris while the gutter accumulates water for diversion to determined locations. For example, in U.S. Pat. No. 4,757,649 to Vahldieck, a system is described that purportedly preferentially collects water and deflects debris over a continuous double-curved shield through which a spike passes to affix the shield to a back support wall of the gutter. The use of shields and other deflectors is well known, and a variety of prior systems modify the shape of the deflector to purportedly take better advantage of the surface tension qualities of diverted run off. For example, in U.S. Pat. No. 4,404,775 to Demartini, a system of longitudinal ridges is imposed on a deflector and is said to improve adhesion of the water to the deflector to improve transference to the gutter. 
     Others have developed systems to support debris deflectors or affix the deflector to the gutter. For example, in U.S. Pat. No. 4,497,146 to Demartini, a rain deflector support is described that purports to support the underside of a rain gutter deflector while positioning the deflector in relation to the gutter. 
     As diversions systems have become more complicated, so have the associated issues of cost, specialized material stock, and installation efficiency become more unwieldy. For example, most systems that employ a deflector affix the deflector with screws or clips that reduce flexibility of the system or add an extra part (in addition to the hanger) to the assembly. If the deflector cannot be easily unfastened from the gutter, repair and maintenance are complicated. 
     For a variety of reasons, diversion systems that deflect debris have not been adopted as widely as demand would suggest. There are a variety of reasons for this result. One reason for the minimal market penetration is the use of non-standard widths of metal stock or “coil” for the gutter trough above which the deflector is positioned. Non-standard coil sizes add significantly to the cost and availability of such systems. 
     There are two principal sizes of coil used to form the gutter channels known in the art as “troughs.” For the widely found five inch-wide (5″) gutter troughs, standard coil material of 11 and ⅞ inches ( 11⅞″) is employed (except in the Northeastern U.S. where  5″ gutter troughs are formed from 11 and ¾ inch ( 11¾″) stock). For the less widely found, but still common, six inch ( 6″) trough, fifteen inch (15″) coil is used. 
     In almost all deflection systems, when installed, a deflector must be inclined by a degree sufficient to impart velocity to the run-off great enough to impel debris from the deflector. This requires that the back of the trough, proximal to which the deflector is attached, be high enough to provide sufficient incline for the deflector. Debris deflection systems for 5″ trough gutters employ non-standard coil for the gutter as a result of taking material from the front of the trough to raise the back wall of the gutter. With known designs, if standard width coil of  11⅞ inches were used to form the trough, the shift of material around the standard trough form factor (as employed in the art to create the “OG”  5 inch gutter) from the front trough channel containment wall to the back wall of the trough to provide sufficient deflector inclination leaves insufficient material for the front This process takes, however, material from the front border area of the trough to create the stiffening front channel edge that provides installation stability and standard hanger affixation capability. 
     The shape of the front of the gutter trough contributes to structural stability and, in some systems, provides an interface for hanger or deflector attachment. In particular, the shape of the border area of the gutter trough can significantly affect gutter stability during installation, an important consideration in any gutter system. Typically, lengths of gutter trough are formed in runs approximately 40 feet long. Without sufficient resistance to deformation, the gutter trough may fold or crease, to particularly when being moved during installation, thus limiting run lengths and increasing installation difficulty. Consequently, 5″ gutter troughs with debris deflectors have typically used coil wider than  11⅞″ or    11¾″ for gutter formation to provide material sufficient to provide a stabilizing front gutter channel configuration with a raised back gutter trough wall to accommodate appropriate inclination of the deflector. Consequently, because of the higher cost of nonstandard material, in particular, deflector-fitted  5″ trough gutter systems have cost significantly more than open-faced 5 ″trough gutter systems crafted from standard sized coil material. 
     Previous system design, whether with 5″or 6″ gutter troughs, has also contributed to unwieldy installation techniques, further increasing the expense of diversion systems that employ deflection hoods or shields. Some deflection systems form the trough and deflector from one piece of material. More commonly, the trough and deflector are separately formed and joined in place at the structure roof edge. Typically, two forming machines are employed during installation of a two-piece deflection system. One machine is dedicated to gutter trough formation, while the other is configured to form the deflector. The machines are typically placed side-by-side. The installation team typically first forms trough lengths sufficient to gutter the structure. The troughs are then affixed in place on the structure. After the troughs are fastened to the building, corresponding deflectors are formed and affixed to the in-place troughs. This process requires multiple trips to and from the forming machines as well as at least two trips up a ladder to install separately, the two large pieces of the system. The described process requires dexterity which, even if applied, cannot ameliorate the difficulty of moving long lengths of deflector that lack structural rigidity unless affixed to, and combined with, the gutter trough. 
     The inflexible nature of the affixation between hood and trough in prior systems results in several shortcomings. Replacement of deflector sections is made difficult by the inflexible nature of the affixation between deflector and trough. Nail or screw attachment of the deflector is at least semi-permanent, and when the deflector is attached by such means, the system is less easily repaired, serviced, or replaced. Other systems have more sophisticated deflector-attachment techniques, but those systems lack installation flexibility. For example, in U.S. Pat. No. 5,845,435 to Knudson, there is there purportedly described a system having a hood which snaps into particularly configured hangers affixed along the length of the gutter trough. In this system however, the deflector is opened wider to embrace coupling portions of a fastening support device. This is difficult to do with one hand. Installation flexibility is also minimal because, as described in Knudson, the hanger and trough are affixed to the structure before the deflector is attached to the gutter trough. As in other prior systems, this prevents creation of a structurally sound member before the deflector and gutter trough assembly is moved from the machine site to the eventual installation location, an advantage for installation having considerable value in reducing labor cost and inconvenience. 
     Consequently, what is needed therefore, is a rain collection and diversion system that employs standard-sized coil, has structural soundness and strength, and can be partially assembled close to the machine-site while being easily installed. 
     SUMMARY OF THE INVENTION 
     A shelf extends inwardly to the gutter trough from the front containment wall of a gutter trough to cooperate with a lip of a cavity structure of a hanger to provide structural stability and optional deflector attachment facility in a rain collection and diversion system. The hanger cavity structure has a containment lip, a portion of which extends over a portion of the inwardly extending shelf of the front containment wall to allow functional water bearing capacity of the trough and a lengthened back trough wall to accommodate hanger placement and deflector inclination. The hanger can include deflector-mating cavities that open toward each other to allow compression attachment of the deflector. 
     In a preferred embodiment, the deflector may be attached to a formed trough in which hangers are positioned to allow movement of the trough-deflector combination as a unit from the machine-site to the installation location on the to structure. Associated installation methods are provided. 
    
    
     BRIEF DESCRIPTION OF THE INVENTION 
     FIG. 1 depicts a cross-sectional view of a prior art trough of a configuration that is common in the field. 
     FIG. 2 depicts a cross-sectional view of a trough configured in accordance with a preferred embodiment of the present invention. 
     FIG. 3 depicts a cross-sectional view of a trough, hanger and deflector assembly in accordance with a preferred embodiment of the present invention. 
     FIG. 4 depicts a cross-sectional view of a half-round trough, hanger and deflector assembly in accordance with a preferred embodiment of the present invention. 
     FIG. 5 depicts a cross-section of an enlarged area of the trough, hanger, and deflector depicted in FIG.  3 . 
     FIG. 6 depicts another embodiment of trough, hanger, and deflector devised in accordance with a preferred embodiment of the present invention. 
     FIG. 7 is an enlarged depiction showing a containment wall border area of a trough configured in accordance with a preferred embodiment of the present invention. 
     FIG. 8 is an enlarged depiction of a receptive cavity structure of a hanger configured in accordance with a preferred embodiment. 
     FIG. 9 depicts the border area of a trough and a receptive cavity structure of a hanger configured in accordance with a preferred embodiment of the present invention. 
     FIG. 10 depicts the border area of a trough and a receptive cavity structure of a hanger configured in accordance with an alternative embodiment of the present invention. 
     FIG. 11 depicts the border area of a trough and a receptive cavity structure of a hanger configured in accordance with an alternative embodiment of the present invention. 
     FIG. 12 depicts the border area of a trough and a receptive cavity structure of a hanger configured in accordance with another alternative embodiment of the present invention. 
     FIG. 13 is an end-on depiction of a forming machine disposed above a second forming machine as employed in a preferred embodiment of the present invention. 
     FIG. 14 is a plan view of two offset forming machines as employed in a preferred embodiment of the present invention. 
     FIG. 15 depicts two-armed run-out stands as employed in a preferred embodiment of the present invention. 
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     FIG. 1 depicts a cross-sectional view of a prior art trough  5  of standard configuration that is common in the field. As shown in FIG. 1, the depicted trough  5  has a folded edge or shelf along its front containment wall. 
     FIG. 2 depicts a cross-sectional view of a trough  10  configured in accordance with a preferred embodiment of the present invention. Trough  10  has a front containment wall  12  that has an inwardly projecting shelf  14  that is part of containment wall border area  16  of front containment wall  12 . Trough  10  has a back wall  18 . As shown, containment wall  12  need not be a planar wall but may take a variety of shapes and configurations to provide a containment function for collected liquid. Between front containment wall  12  and back wall  18 , a channel is formed for water collection and diversion bottomed with floor  20 . In an embodiment having a rounded or “half-round” trough, it will be recognized that there is no distinct floor  20  and front containment wall  12  and back wall  18  will not have traditional “wall” planar areas but blend into an arcuate floor area. 
     In a 5-inch embodiment of trough  10  in which there is approximately 5 inches between back wall  18  and the farthest reach of containment wall border area  16 , standard material coil of  11⅞ inches may be employed. As those of skill in the art will recognize, standard material coil may exhibit some variation in width depending upon manufacturer or local custom. Consequently, in a preferred embodiment employing standard material, standard material between    11⅝ inches and  12 inches in width may be employed to create trough  10  with a 5 inch opening. Certainly other sizes of troughs can be created to advantage by employment of the present invention. For example, the well-known 6-inch trough can be created in conformity with an alternative embodiment of the present invention by use of 15 inch material coil. Containment wall border area  16  may be formed by bending, folding, forming or other of the well-known means for configuring trough  10 . A preferred method for creating containment wall border area  16  is with a roller-based machine at the same time that the configuration of trough  10  is created from coil stock. When a 5 inch trough in accordance with a preferred embodiment of the present invention is created with a roller-based machine, the standard material coil stock is positioned so as to move the furthest reach of the formed back wall between ¾ and 1 inch from the place the furthest reach of the back wall would occupy in formation of a standard OG gutter trough so as to bring greater height to the back wall for deflector inclination during trough formation. As well as using forms in accordance with the present invention, the material is shifted around the form relative to the material placement employed-in forming the OG gutter. 
     FIG. 3 depicts as assembly  15 , a cross-sectional view of trough  10  in use with hanger  30  and deflector  40  in accordance with a preferred embodiment of the present invention. The system described can be used either with or without deflector  40 . 
     As shown in FIG. 3, hanger  30  includes optional deflector attachment cavities  32  and  34 . In the depicted embodiment, hanger  30  is stamped from metal, but any number of materials and formation techniques may be used to create a hanger  30  having the features described here. For example, hanger  30  may be made of metal or plastic such as Teflon, or higher strength polys. If made of metal, hanger  30  can be forged, stamped, extruded, die cut or cast or other technique familiar to the trade. Hanger  30  includes receptive cavity structure  31  that will be later described in more detail while front containment wall  12  exhibits containment wall border area  16  that will be described in more detail. FIG. 4 depicts a cross-sectional view of a half-round trough assembled with a hanger and deflector in accordance with a preferred embodiment of the present invention. 
     With reference to FIGS. 3 and 5 (which figure illustrates an enlarged portion of FIG. 3 about the area of flex fold  42 ), deflector  40  is selectably attached to hanger  30  by insertion of flex fold  42  into cavity  34  and insertion of attachment fold  46  into cavity  32 . In a preferred compression embodiment, curve  44  provides a ready method to accomplish this selective attachment. Those of skill in the art will recognize that flex fold  42  and attachment fold  46  are first and second long axis perimeters of deflector  40  and need not be “folds” but may be any edge or fold or border of the deflector which may be inserted into the appropriate cavity of the hanger. This selectable attachment feature of deflector  40  as shown in this depiction of a preferred embodiment of the present invention allows assemblage of deflector  40  to hanger  30  before the assembly  15  is installed on a structure. 
     As shown in conjunction with FIGS.  3  and FIG. 5, hanger  30  has optional penetrative prongs  36  shown penetrating back wall  18  of trough  10 . As shown more closely in FIG. 5, prongs  36  preferably have a concavity  38  that cooperates with dimple  39  on back wall  18  to preliminarily position hanger  30  for prong insertion through back wall  18  with an appropriate compression tool such as a specialized pliers or other readily available and adapted instrument. Back abutment  41  of hanger  30  is placed against back wall  18  with concavity  38  placed against dimple  39  and the compression tool pushes prongs through the back wall  18 . There need not be a specially configured structure for an abutment for hanger  30 , the back of the structure of hanger  30  disposed against back wall  18  being the abutment. The prongs are folded by the compression tool against the back of back wall  18  to affix hanger  30 . This operation can be performed before attachment of the trough to the structure and may be performed at the machine site or elsewhere to affix back wall  18  in relation to front containment wall  12  while creating a mechanically sound structure ready for attachment of deflector  40 . Hanger  30  need not have prongs  36  but their use is advantageous. 
     As described with continuing reference to FIGS. 3 and 5, flex fold  42  of deflector  40  cooperates with cavity  34  to allow a resistance hinge-like action of deflector  40 . In particular, deflector  40  may be lifted from hanger  30  by compression of curve  44  of deflector  40  to remove attachment fold  46  of deflector  40  from cavity  32 . The forward part of deflector  40  is then lifted from its position as flex fold  42  and cavity  32  allow a spring-like rotational opening of a gap between deflector  40  and hanger  30  through which fastener  50  may manipulated to install assembly  15  on the structure as fastener  50  is screwed or pounded or otherwise inserted into place. In embodiments with penetrative fasteners, fastener  50  may be a nail or screw or spike or other such projecting fastener, many of which are common in the field. Other techniques for hanging assembly  15  are known in the art. Hanger  30  includes, in a preferred embodiment, indent  48  to mate with ridge  52  of deflector  40  while stop  54  of hanger  30  inhibits deflector  30  from unpredicted separation from hanger  30 , particularly during installation or servicing. In a preferred embodiment, fastener  50  slides into a guide slot  56  created in hanger  30  to avoid addition of height or special platforms to hanger  30 . The compression fitting of deflector  40  into cavities  32  and  34  allows ready placement of deflector  40  on the trough  10  and hanger  30  combination at the machine-site to allow a single installation trip from machine site to installation site with the combined structure of deflector and trough. 
     FIG. 6 depicts another embodiment of assembly  15  devised in accordance with the present invention and which employs an extruded hanger  30 . FIG. 6 depicts fastener  50  as it would be engaged into a structure. Those of skill in the art will recognize that the disclosed configuration allows the front of deflector  40  to be lifted from hanger  30  to insert fastener  50  into the structure. 
     FIG. 7 is an enlarged depiction showing containment wall border area  16  of trough  10  of FIG.  3 . As shown in FIG. 7, containment wall border area  16  includes containment edge or shelf  52  that extends inwardly to the trough. Either part or all of containment shelf  52  may extend inwardly to the trough and that inward extension may be at an angle or horizontal orientation. In a preferred embodiment, containment wall border area  16  includes rise  53 . Containment shelf  52  may be folded, or a single material thickness and may extend horizontally (as shown in the preferred embodiment view of FIG. 7) or at an angle from the horizontal as shown in FIG. 10, or have a vertical extension as shown, for example, in FIG.  11 . Part or all of shelf  52  can, but need not, be canted at an angle to match the configuration of containment lip  54  of receptive cavity structure  31  of hanger  30 . Consequently, those of skill in the art will recognize that containment lip  54  may take a variety of configurations to cooperate with the variety of configurations of containment shelf  52  within the scope of the invention to extend a portion of containment lip  54  over a portion of containment shelf  52  and thereby, according to the vernacular of the present disclosure, “mate” containment lip  54  with containment shelf  52 . The part of containment shelf  52  that extends inwardly to the trough need not be the portion of shelf  52  over which a portion of containment lip  54  extends to mate with containment shelf  52 . When a portion of containment lip  54  extends over a portion of containment shelf  52 , the elements are mated. 
     FIG. 8 is an enlarged depiction of receptive cavity structure  31  of hanger  30  in a preferred embodiment. Receptive cavity structure  31  as shown in FIG. 8, includes fulcrum ridge  56  over which, rise  53  of front containment wall border area  16  tents. 
     FIG. 9 depicts a preferred disposition of containment lip  54  mated with containment shelf  52  to provide functional water bearing capacity for trough  10  while still allowing sufficient standard material coil to provide a back wall  18  of sufficient height to provide necessary inclination for deflector  40 . In this preferred depiction, containment lip  54  is mated with containment shelf  52 . 
     FIGS. 10,  11 , and  12  depict alternative arrangements for the mating between containment lip  54  and containment shelf  52  and they are included only as example embodiments and not as limitations for the scope of the present invention. FIG. 10 depicts an alternative embodiment of the invention showing containment shelf  52  as angled upward and containment lip  54  as angled downward as shelf  52  and lip  54  are mated. In other alternative and exemplar but not to be construed as limiting embodiments, containment lip  54  may be horizontal while containment shelf  52  is angled or containment lip  54  may be angled while containment shelf  52  exhibits a horizontal character or each may be independently angled or horizontal. 
     FIG. 11 shows another alternative embodiment of the present invention in which containment lip  54  extends over a vertical extension portion of containment shelf  52 . This is another example of the mating of containment lip  54  and containment shelf  52 . 
     FIG. 12 shows yet another alternative embodiment of the present invention in which containment lip  54  has an extension that deflects downward over a portion of containment shelf  52 . Containment lip  54  and containment shelf  52  are mated in the depiction of FIG.  12 . 
     The present invention provides numerous advantages during installation of the system. A preferred method for installation includes formation of deflector  40  with a machine placed above a forming machine dedicated to formation of trough  10 . FIG. 13 depicts forming machine  72  disposed above forming machine  70  in the bed  74  of a truck. The machines need not be placed on the truck bed that is merely shown as an exemplar setting. Preferably, a track is employed that allows forward and backward movement of upper machine  72  relative to the bottom machine  70  for maintenance of the lower machine  70  as will be recognized by those of skill in the art. Machine  70  is configured to form lengths of trough  10  configured in accordance with the present invention, while machine  72  is configured to form lengths of deflector  40  configured in accordance with the present invention. 
     In a preferred method in accordance with the present invention, material cradles  74  and  76  of the respective machines  70  and  72  are loaded with coil. Trough machine  70  consumes coil material  75  of  11⅞ inches in width in an application configured to produce troughs  5 inches in width. Other widths of coil may also be used. Cradle  76  of deflector machine  72  is loaded with coil material  77  of between  7⅝ inches and  8 inches to produce deflectors. Other widths may be used for larger or smaller configurations. Emergent from machine  70  are lengths  78  of trough  10 . Emergent from machine  72  are lengths  80  of deflector  40 . 
     As shown in FIG. 15, two-armed run-out stands  82  and  84  having upper arms  86  and lower arms  88  provide work placement for lengths of deflector  40  and trough  10 . End caps  90   a  are placed in appropriate locations. In a preferred embodiment, end caps are two-piece, with piece  90   a  fitted to troughs  10  and piece  90   b  fitted to deflector  40 . 
     A preferred method for installation of the present system proceeds as follows. As length  78  of trough  10  is run from machine  70 , end caps  90   a  are installed where appropriate, outlet sites are punched and outlets installed for joinder with downspouts, miters are cut and cavity structure  31  of hanger  30  is brought into place to mate containment lip  54  of hanger  30  with containment shelf  52  of trough  10 . Hangers  30  are punched through the back wall  18  of trough  10  and prongs  36  are crimped. These steps can be performed either at the machine or with the assistance of the run-out stands. Hanger fitted trough  10  is rested on run-out stands. 
     Corresponding length  80  of deflector  40  is run from machine  72  and is installed with end caps  90   b  and miters are cut appropriate. Length  80  of deflector  40  is placed on length  78  of trough  10  as deflector attachment cavities  34  and  32  are used to retain deflector  40 . In alternative methods, cavity  34  is used to retain deflector  40  for conveyance to the installation location on the structure but, where some distance is involved, use of both cavities  32  and  34  keeps deflector  40  more securely retained. In either case, the entire assembly may then be transported to a location on a lower level such as ground, for example, corresponding to the eventual installation location on the structure. The process is repeated until all assemblies of trough, hangers and deflector have been processed. 
     Two installers are then employed on ladders or other riser to position each length of assembled trough, hangers, and deflector into place against the structure where the assembly is fastened into place in at least two locations. This is simplified by the feature of the present invention that allows compression fitting of the deflector into the appropriate cavities of hanger  30 . The process of two-installer positioning continues around the structure. One installer takes up a position on the roof of the structure or ladder and completes the affixation of the fasteners  50 . This can be readily performed by one person due to the compression fitting of deflector  40  that allows opening the assembly to reach fastener  50 . Once fasteners for a length of the assembly have been affixed, deflector  40  is compressed to fit flex fold  42  and attachment fold  46  of deflector  40  to cavities  34  and  32  respectively of deflector  40 . As the roof or ladder positioned installer proceeds with this procedure of fastener affixation, the second installer forms downspouts and attaches them to the structure. 
     Although the present invention has been described in detail, it will be apparent to those skilled in the art that the invention may be embodied in a variety of specific forms and that various changes, substitutions and alterations can be made without departing from the spirit and scope of the invention. The described embodiments are only illustrative and not restrictive and the scope of the invention is, therefore, indicated by the following claims.