Abstract:
Methods and apparatus for fabricating articles having apertures from a flat feedstock, such as gutter covers, are provided herein. In some embodiments, an apparatus for fabricating articles having apertures from a flat feedstock includes an uncoiler for receiving and metering out a desired quantity of a flat feedstock in roll form; a feeder/straightener for receiving the feedstock from the uncoiler; a first press for receiving the feedstock from the feeder/straightener, the first press housing a tool and die that forms one or more apertures in the feedstock; a second press for receiving the feedstock from the first press, the second press housing a tool and die that cuts the feedstock into a finished length; and a roll former for receiving the feedstock from the second press, the roll former comprising a plurality of rollers that create a desired profile along the width of the feedstock.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Patent Application entitled “GUTTER COVER MANUFACTURING APPARATUS”, Ser. No. 60/747,555, filed May 18, 2006, which is hereby incorporated by reference. 
     
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    Embodiments of the present invention generally relate to the manufacture of gutter covers. More specifically, embodiments of the present invention generally relate to manufacturing apparatus for the manufacture of gutter covers. 
         [0004]    2. Description of the Related Art 
         [0005]    Gutter covers, such as those depicted in U.S. Pat. No. 5,339,575 and D382,944, have conventionally been fabricated using a variety of apparatus. In one conventional embodiment, gutter covers may be fabricated using a turret press. In this manner of manufacture, flat metal sheets are sheared to specified sizes and then manually inserted into the turret press to fabricate the apertures one hole at a time. The fabricated sheet with prescribed apertures is then formed with prescribed radius bends in a manually operated brake. Due to the nature of the manual brake, each radius bend is formed one at a time. 
         [0006]    This method of fabrication is very time consuming and has high risk of variations in the finished product. For example, it has been found that forming radius bends utilizing a manual brake may lead to production of up to 4% off-spec material. While technology exists to automate feeds to the turret press, the size and weight of the equipment limits it to principally being operated by machine shops with highly skilled repair technicians. 
         [0007]    In another conventional manufacturing method, gutter covers may be fabricated using a punch and die apparatus containing a series of manufacturing elements. In this embodiment, flat metal feedstock in coil form is introduced into a feeder which straightens the metal, which is subsequently fed in a prescribed length to a large press that forms the apertures and cuts the cover to a prescribed length. The fabricated sheet with prescribed apertures is then formed with prescribed radius bends one at a time in a manually operated break as described above. 
         [0008]    While this method of manufacture is faster than the turret press, the size of the equipment limits production to machine and specialty shops employing highly skilled technicians. 
         [0009]    Another problem associated with these conventional fabrication apparatus is that the extremely large size and weight (approximately four tons) of both the punch and die press and the turret press requires special rigging companies to transport and deliver the equipment. In addition, the turret presses and presses required to operate the tool and die are expensive and require a large investment. Moreover, the sophistication of the equipment also limits manufacture to certain specialty or machine shops, thereby requiring substantially more shipping and handling expense for the distribution of the rain gutter products. 
         [0010]    Therefore, there is a need for a manufacturing apparatus that can be easily acquired for much less than the cost of equipment previously used and that may be easily installed in a fabricator&#39;s warehouse. 
       SUMMARY OF THE INVENTION 
       [0011]    The present invention generally provides an improved apparatus for fabricating articles having apertures from a flat feedstock, such as gutter covers. The present invention overcomes the disadvantages associated with the prior art. Specifically, the present invention includes equipment used for fabricating gutter covers which is light in weight as compared to the conventional equipment presently used. The new equipment can easily be moved and installed with typical equipment used in warehousing, such as a fork lift. 
         [0012]    In some embodiments, an apparatus for fabricating articles having apertures from a flat feedstock includes an uncoiler for receiving and metering out a desired quantity of a flat feedstock in roll form; a feeder/straightener for receiving the feedstock from the uncoiler; a first press for receiving the feedstock from the feeder/straightener, the first press housing a tool and die that forms one or more apertures in the feedstock; a second press for receiving the feedstock from the first press, the second press housing a tool and die that cuts the feedstock into a finished length; and a roll former for receiving the feedstock from the second press, the roll former comprising a plurality of rollers that create a desired profile along the width of the feedstock. 
         [0013]    In some embodiments, an apparatus is provided including, in order, an uncoiler, a feeder/straightener, a first press, a second press, a roll former, a collection table, and a control module. An input material, such as a flat metal sheet in roll form, is loaded onto the uncoiler and is fed to the straightener/feeder. The straightener/feeder moves the material through a series of rollers which bends the flat metal in opposing directions removes any curl or memory the metal may have from being stored in coiled form. The feeder portion of the feeder/straightener measures and delivers a specified length of the material to the two presses in series. The first press houses a tool and die that pierces and forms the apertures of the gutter cover. The number of apertures formed with each hit from the press can range from one at a time to any number. The second press houses a tool and die that separates the material into a finished length and forms any prescribed apertures and notches specified in the finished parts for installation on a rain gutter such that the individual rain gutter covers overlap and are fastened together. As the part, complete with all apertures formed, leaves the second press in flat form, a set of feed rollers pull the part into the roll former. The roll former forms the radius bends as specified for the finished part through a series and combination of rollers. The finished part exits the roll former and is dropped into the collection table. The components of the apparatus are equipped with controls and instrumentation which automatically counts the number of hits made on each press, controls each press and feeder, and counts each part manufactured for reporting purposes. Alternatively, the equipment can be also operated in manual form without any controlling equipment. 
         [0014]    In some embodiments, an apparatus for fabricating articles having apertures from a flat feedstock includes an uncoiler for receiving and metering out a desired quantity of a flat feedstock in roll form; a feeder/straightener for receiving the feedstock from the uncoiler; a press for receiving the feedstock from the feeder/straightener, the press configured to form one or more apertures in the feedstock and to cut the feedstock into a finished length; and a roll former for receiving the feedstock from the press, the roll former comprising a plurality of rollers that create a desired profile along the width of the feedstock. 
         [0015]    In some embodiments, an apparatus is provided including, in order, an uncoiler, a feeder/straightener, a press, a roll former, a collection table, and a control module. The press contains both a first tool and die and a retractable second tool and die encapsulated by connecting members in one housing unit. The first tool and die is configured to form from one or more apertures with each stroke. The retractable second tool and die may consist of one or more independent sections that are configured to separate the parts and make any apertures or notches that may be specified to be located at the end of the parts. The retractable second tool and die creates both apertures and notches located at the end of the part of the material being cut off and the beginning of the part of the material being moved through the press. This apparatus is otherwise similar to the apparatus described above. 
         [0016]    In some embodiments, a method of fabricating articles having apertures from a flat feedstock includes providing, in alignment, an uncoiler for receiving and metering out a desired quantity of a flat feedstock in roll form, a feeder/straightener for receiving the feedstock from the uncoiler, a first press for receiving the feedstock from the feeder/straightener, and a roll former for receiving the feedstock from the press; metering out a desired quantity of a flat feedstock in roll form from the uncoiler to the feeder/straightener; forming one or more apertures in the straightened feedstock using the first press; cutting the feedstock into a finished length; and creating a desired profile along the width of the feedstock using the roll former. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0017]    The teachings of the present invention will become apparent by considering the following detailed description in conjunction with the accompanying drawings, in which: 
           [0018]      FIG. 1  is a schematic plan view showing one embodiment of a gutter cover forming apparatus. 
           [0019]      FIG. 2  is a schematic side view of another embodiment of a gutter cover forming apparatus. 
           [0020]      FIG. 3  is a schematic plan view showing another embodiment of a gutter cover forming apparatus. 
           [0021]      FIG. 4  is a schematic plan view showing another embodiment of a gutter cover forming apparatus. 
           [0022]      FIG. 5  is a schematic plan view showing another embodiment of a gutter cover forming apparatus. 
           [0023]      FIG. 6  is a schematic plan view showing another embodiment of a gutter cover forming apparatus. 
           [0024]      FIGS. 7A-B  are perspective views of one embodiment of a gutter cover that may be fabricated with the apparatus of the present invention. 
       
    
    
       [0025]    Where possible, identical reference numerals are used herein to designate identical elements that are common to the figures. The images in the drawings are simplified for illustrative purposes and are not depicted to scale. The appended drawings illustrate exemplary embodiments of the invention and, as such, should not be considered as limiting the scope of the invention that may admit to other equally effective embodiments. 
       DETAILED DESCRIPTION 
       [0026]    Embodiments of the present invention generally relate to the manufacture of articles having apertures from a flat feedstock. In one illustrative embodiment, embodiments of the present invention may be utilized to fabricate gutter covers, such as are depicted in U.S. patent Ser. No. 5,339,575, issued Aug., 23, 1994, and D382,944, issued Aug. 26, 1997, or any other gutter cover containing one or two rows of apertures (see, for example, gutter cover  700  depicted in  FIGS. 7A-B ). The manufacturing apparatus of the present invention is advantageously relatively small in size, can be easily installed without special rigging equipment, and can be easily operated by a relatively unskilled workman. Although described below in reference to manufacturing gutter covers, it is contemplated that the inventive apparatus may be utilized to manufacture other articles having apertures from a flat feedstock. 
         [0027]    The present invention utilizes a series of readily available equipment arranged in a specific order to manufacture specified rain gutter covers utilizing flat metal stock available in coil form. These presses are readily commercially available from companies such as Minster Machine Co, located in Minster, Ohio; Cincinnati, located in Cincinnati, Ohio; Niagara Machine and Tool Works, located in Buffalo, N.Y.; Komatsu Industries Corp., located in Tokyo, Japan; Chicago Dreis &amp; Krump (D&amp;K), located in Chicago, Ill.; and the like. 
         [0028]      FIG. 1  is a schematic showing one embodiment of a gutter cover forming apparatus of the present invention. As depicted in  FIG. 1 , a gutter cover manufacturing apparatus  100  includes an uncoiler  102 , a feeder/straightener  104 , a first press  106 , a second press  108 , a roll former  110 , a collection table  112 , and a control module  114 . 
         [0029]    The uncoiler  102  may be a powered uncoiler, such as are commercially available through companies such as ASC Machine Tools, Inc., of Spokane Valley, Wash., and the like. In addition, uncoilers are typically available through most metal handling industrial supply houses such as Rapid Air, of Rockford, Ill. The uncoiler  102  is typically mounted horizontally, such that the shaft or mandrel for holding a coil of feedstock, or material, (not shown) is horizontal to the floor. The uncoiler  102  is typically motorized and controlled by a set of micro switches or a photo beam that controls the uncoiler  102  as it selectively feeds material to the feeder/straightener  104 . 
         [0030]    Because the feeding speed of the uncoiler  102  may be different than that of the feeder/straightener  104 , there is typically a distance of up to approximately 6 to 8 feet between the uncoiler  102  and the feeder/straightener  104  to allow for excess material to drop near the floor during operation. In operation, as the material drops towards the floor or a predetermined point near the floor, a micro switch turns off the feed of material from the uncoiler  102 . As the feeder/straightener  104  uses up the material, the excess material disposed between the uncoiler  102  and the feeder/straightener  104  raises in elevation to the location of a second micro switch which turns on the uncoiler  102 , causing it to resume feeding material. 
         [0031]    It is contemplated that any method of controlling the uncoiler  102  may be utilized, including photo cell technology, control arms that may be included as a part of uncoiler  102 , other arrangements of micro switches, and the like. It is further contemplated that the uncoiler  102  and the straightener can be combined in one unit, such as is commercially available from Tomac Corp., located in Taishan, Taiwan (http://www.toptran.com.tw/cproducts_thin.htm). It is further contemplated that the uncoiler  102  may be unmotorized and/or mounted vertically, such as in a pallet reel format, also commercially available from companies such as Rapid Air, of Rockford, Ill., such that either the feeder or straightener or both pull the coil of material from the uncoiler without having the necessity of a loop in the coil to make up for different speeds of the equipment. 
         [0032]    The feeder/straightener  104  may be manufactured as one device which straightens as it feeds and removes coil from an unmotorized uncoiler  102 . The feeder/straightener  104  may be either of a servo feed nature, where the precise rotation of rollers are controlled to deliver a specific length of material, or air feed, wherein the material is clamped with air pressure by a feeding clamp and advanced for a specified length at which point the feeding clamp is released and a stationery clamp is engaged to keep the material stationary while the feeding clamp is slid back to a feed position to begin the feed cycle once again. The stationary clamp is released while the feed clamp is engaged. 
         [0033]    The feeder/straightener  104  contains a series of rollers (not shown) disposed on either side (e.g., above and below) the material. As the material passes between the rollers, the material is bent in opposite directions, thereby straightening the material and removing any memory of the material from having been stored in roll form. The rollers are typically adjustable to increase or decrease the degree of bend required to flatten or straighten the material, although they can be fixed. Typically at least three rollers are provided. However, the number of rollers may vary. 
         [0034]    The feeder portion of the feeder/straightener  104  can be adjusted to deliver a specified length of flat material to the press  106 . The feeder/straightener  104  is typically controlled by the control module  114  such that the feeder/straightener  104  feeds a specified length of straightened material to the press  106  during operation. 
         [0035]    The press  106  is typically an approximately two-ton or less press containing a tool and die for forming one or more apertures in a workpiece with each stroke of the press  106 . The number and arrangement of the apertures is designed into the press  106  as desired to produce the particular end product. For example, the press  106  may be configured to form one or more apertures  710  as depicted in  FIGS. 7A and 7B . A signal indicating the end of feed from the feeder/straightener  104  causes the press  106  to perform a stroke. The feed and stroke series occurs a prescribed number of times as controlled by control module  114 . 
         [0036]    When the prescribed number of strokes is complete, a signal from the control module  114  is sent to the press  108  causing it to stroke. The press  108  may be similar in size to press  106  and contains a tool and die for cutting the material to a desired length and making any apertures or notches that may be specified to be located at either the end of the material. The tool and die of the press  108  creates both apertures and notches located at the end of the part of the material being cut off and the beginning of the part of the material being moved through the press  108 . For example, in addition to cutting the material to length, the press  108  may be used to form apertures  720 ,  734  and notches  722  as depicted in  FIGS. 7A-B . At the completion of the stroke of the press  108 , a signal is sent to control module  114  which begins the counting sequence once again. Those skilled in the art will recognize that depending on the number of apertures formed by the press  106 , the feed length may be altered for the press  108  to cause separation of the material into parts of a desired length without deviating from the scope of this invention. 
         [0037]    As the separated part of the material containing all apertures and notches leaves the press  108 , a feed roller in the front portion of the roll former  110  guides the material into the main body of the roll former  110 . The roll former  110  contains a series of rollers, typically a minimum of four rollers, that pulls the material through the roll former  110 , thereby causing the material to be gradually be shaped with the specified radius bends as it exits the end of the roll former  110 . For example, the roll former  110  may be configured to bend the material to form a front ledge  716 , a front face  730 , and a cover portion  708 , as depicted in  FIGS. 7A-B . It is understood that technology for roll forming is well known in the trade and that a roll former suitable for creating the bends as desired in the finished product may be manufactured by many different manufacturers with various modifications. 
         [0038]    As the finished material leaves the roll former  110  it drops onto the collection table  112  where finished product is stacked. Optionally, the control module  114  can provide a signal and/or shut down the entire system after a prescribed number of parts are stacked, thereby providing time for manual packaging. It is also recognized that those skilled in the art may employ robotics controlled by the control module  114  to collect a prescribed number of parts and package them automatically. The control module  114  may also provide a confidential count of total parts produced for calculating royalties with or without automatic reporting features to an outside party. Those skilled in the art will recognize that presses larger or smaller than a two ton rating may be used to achieve the same results depending on the size of the tooling and number of apertures being formed by each tool and die without departing from the scope of this invention. Optionally, the components of the apparatus  100  as described above may be performed manually, without the need for the control module  114 . 
         [0039]    Optionally, both the press  106  and the press  108  shown in  FIG. 1  may be replaced with a single press. For example,  FIG. 2  depicts a schematic side view of a gutter cover forming apparatus  200 . The apparatus  200  is similar to the apparatus  100  of  FIG. 1  except that the press  106  and the press  108  are replaced by a single press  206 . 
         [0040]    As shown in  FIG. 2 , the press  206  is typically an approximately up to ten ton press containing a tool and die  214  and a retractable tool and die  216  encapsulated by connecting members  210  in one housing unit  212 . The tool and die  214  is configured to form from one or more apertures with each stroke. The retractable tool and die  216  may consist of one or more independent sections that are configured to separate the parts and optionally to make any apertures or notches that may be specified to be located at the end of the parts. The independent sections of the retractable tool and die  216  may be disposed adjacent to each other or separated by other components. The retractable tool and die  216  may create both apertures and notches located at the end of the part of the material  220  being cut off and the beginning of the part of the material  220  being moved through the press  206 . 
         [0041]    Specifically, an end of feed signal from the feeder/straightener  104  causes the press  206  to complete a stroke. With each stroke of the press  206 , the tool and die  214  is actuated to make apertures in the material  220 . When a specified number of strokes is complete (e.g., one or more), a signal from control module  114  is sent to feeder/straightener  104  causing it to actuate either a gag feed (e.g., feed of a different length of material) to the press  206  at which time the retractable die  216  is also actuated in whole or part, or the retractable die  216  in whole or in part without the need for a gag feed. 
         [0042]    It is recognized that those skilled in the art may choose to have the retractable die  216  as one integral unit or that it may be divided into two independently operated units to separate the material  220  into separate parts and accomplish the formation of apertures on the ends of the separated part. 
         [0043]    After the press  206  completes its stroke, the retractable tool and die  216  is retracted for the next stroke or series of strokes by the press  206 . Those skilled in the art will recognize that by altering the number of apertures formed by the tool and die  214 , arrangement and activation of the retractable tool and die  216 , and the gag feed (change in feed length) can be in any combination without departing from the scope of the present invention. 
         [0044]    From this point, the separated portion of the material  220  produced by the retracting tool and die  216  is guided into the roll former  110  as described above with respect to  FIG. 1 . 
         [0045]      FIG. 3  depicts another embodiment of a gutter cover forming apparatus  300 . The apparatus  300  is similar to the apparatus  100  of  FIG. 1  except that the press  108  is replaced with a flying shear  308 . In this embodiment, as the material continuously moves through the press  106 , the flying shear  308  is actuated by control module  114  as described above with respect to  FIG. 1 . When actuated, the flying shear  308  moves at the same speed of the material being fed through the apparatus  300  and causes the parts of the material to be sheared apart along with any prescribed apertures or notches as formed with the press  108  described above with respect to  FIG. 1 . 
         [0046]      FIG. 4  depicts another embodiment of a gutter cover forming apparatus  400 . The apparatus  400  is similar to the apparatus  100  of  FIG. 1  except that the press  106  is replaced with a sprocket former  406 . In this embodiment, the feeder/straightener  104  is set to feed a full length of material that, when complete, actuates the press  108  to cut the material and form any apertures or notches as described above with respect to  FIG. 1 . The material is then passed from the press  108  to the sprocket former  406 . As the material passes through the sprocket former  406 , housing feed and guide rollers engage the material and a rotating sprocket forms apertures in the material similar to those formed by the press  106  as described above with respect to  FIG. 1 . The control module  114  controls the operation of the sprocket former  406  to cause the sprockets to be engaged and disengaged. It is recognized that those skilled in the art may choose to actuate the sprocket former  406  via other means such as micro switches. The material is then guided into the roll former  110  where the part is completed as described above with respect to  FIG. 1 . 
         [0047]      FIG. 5  depicts another embodiment of a gutter cover forming apparatus  500 . The apparatus  500  is similar to the apparatus  100  of  FIG. 1  except that the press  108  is replaced with a flying shear  508 . In this embodiment, the flying shear  508  is located after the roll former  110  and otherwise is similar to the flying shear  308  described above with respect to  FIG. 3 . In operation, the flying shear  508  cuts the material to a desired length as well as forms the notches and apertures formed by the press  108  as described above with respect to  FIG. 1 . 
         [0048]      FIG. 6  depicts another embodiment of a gutter cover forming apparatus  600 . The apparatus  600  is similar to the apparatus  100  of  FIG. 1  except that the press  106  is replaced by a sprocket former  606  and the press  108  is replaced by a flying shear  608 . The flying shear  608  may be located after the roll former  110 . Alternatively, the flying shear  608  may be located between the sprocket former  606  and the roll former  110 . 
         [0049]    It is contemplated that other variations to any of the embodiments of the above-disclosed apparatus may be made without departing from the scope of the invention. For example, alternative material guidance systems may be utilized or incorporated into components of the apparatus that would eliminate the need for the feeder and/or the straightener. In one example, the sprocket former  606  of the embodiment disclosed in  FIG. 6  could be devised to also function as a feeder/straightener, thereby eliminating the need for the feeder/straightener  104 . Moreover, the material being worked upon may be fed into the apparatus in pre-cut lengths of flat stock, thereby eliminating the need for the uncoiler  102  and the straightener portion of the feeder/straightener  104 . Other variants may further be devised by those skilled in the art without departing from the spirit of the invention. 
         [0050]    Thus, a novel manufacturing apparatus and method are disclosed herein for fabricating articles having apertures from a flat feedstock. The present invention overcomes the disadvantages associated with the prior art. Specifically, the present invention includes equipment used for fabricating gutter covers which is light in weight as compared to the conventional equipment presently used. The inventive apparatus can easily be moved and installed with typical equipment used in warehousing, such as a fork lift. 
         [0051]    While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof may be determined by the following claims.