Patent Publication Number: US-2004040219-A1

Title: Plastic gutter system and components therefor

Description:
FIELD OF THE INVENTION  
       [0001] The invention relates to gutter systems that may be assembled and secured to a building for catching and channelling rainwater.  
       BACKGROUND  
       [0002] Rainwater gutter systems for buildings are traditionally made from metal or plastic. Gutter systems made of plastic offer significant benefits over those made of metal in terms of durability and appearance. There are a number of problems associated with plastic gutter systems however.  
       [0003] One problem with plastic gutter systems is that the plastic tends to expand, contract or otherwise deform in temperature extremes. A typical plastic gutter system that spans up to 40 ft. may experience expansion or contraction of 1″ or more over diverse climatic conditions. In addition, plastic gutter systems can become permanently deformed when exposed to extreme temperature conditions.  
       [0004] Conventional plastic gutter systems use various structures of joints and seals to attempt to provide a watertight seal while permitting the gutter section to slide within the joint as it undergoes expansion and contraction. Examples of such systems are disclosed in U.S. Pat. Nos. 4,257,716, 4,297,053, 4,313,693, 4,954,015, 5,035,092, 5,038,528 and 5,687,510. A problem with these systems is that the gutter sections are still relatively pliable and are not adequately secured in the joints to deter deformation. Thus, over a period of time, the gutter sections tend to deform and shift from the joints to a sufficient extent that the gutter system leaks.  
       [0005] The problem is compounded by consumer preference for a “K style” gutter that, by virtue of its shape, is not effectively sealed using conventional joint and gasket systems. The conventional “K-style” gutter also tends to allow debris to collect within the gutter which reduces the effectiveness of the gutter system.  
       [0006] Another problem with conventional gutter systems is the manner in which downspouts are mounted to walls. Generally, an adjustable metal strap is wrapped around the downspout and mounted to the wall surface with screws on either side of the downspout.  
       [0007] Examples of such mounting systems are disclosed in U.S. Pat. Nos. 4,631,342 and 5,794,348. A problem with these systems is that the mounting fasteners are exposed and unsightly and the mounting attachments do not allow for simple installation and temporary disassembly of the downspout installation.  
       [0008] Another problem with conventional gutter systems is the manner in which the drainpipe is connected to the downspout. Conventional gutter systems employ a downspout to deliver water from the roof level gutters to ground level. The downspout is typically connected to a drainpipe that extends along the ground away from the building for delivering water to a desired location for drainage. A problem with conventional connectors is that they do not allow sufficient flexibility in the movement of the drainpipe. This causes inconvenience where the positioning of the drainpipe interferes with household chores such as lawn mowing and raking of leaves.  
       [0009] Accordingly, there is a need for an improved gutter system, and components thereto, that overcome one or more of the above identified problems.  
       SUMMARY OF THE INVENTION  
       [0010] According to one aspect of the present invention there is provided a gutter section for use in a rain gutter system, the gutter section comprising an inner wall defining a channel for receiving and channelling rain water, and an outer wall spaced from said inner wall to define a substantially hollow area between the inner wall and the outer wall.  
       [0011] According to another aspect of the claimed invention there is provided a gutter section for use in a rain gutter system comprising:  
       [0012] an inner wall defining a channel for receiving and channelling rain water;  
       [0013] an outer wall defining a desired aesthetic outer shape for said gutter section; and  
       [0014] a heat sink between said inner wall and said outer wall to deter substantial expansion and contraction of said gutter under ranging thermal conditions.  
       [0015] According to another aspect of the claimed invention, there is provided a gutter system comprising:  
       [0016] (a) a plurality of gutter sections defining a channel for receiving and channelling rain water; and  
       [0017] (b) a plurality of joint members for joining said gutter sections, each including in outer sleeve and an inner sleeve defining a passageway corresponding in shape to a substantial portion of the cross-sectional shape of said gutter sections for slidably receiving at least one of said gutter sections.  
       [0018] According to another aspect of the claimed invention, there is provided a joint member for adjoining one or more gutter sections of a gutter system, the joint member comprising:  
       [0019] (a) an outer sleeve and an inner sleeve received defining a passageway corresponding in shape to a substantial portion of the cross-sectional shape of a gutter section for slidably receiving said gutter section; and  
       [0020] (b) a gasket assembly having a gasket and an attachment member for supporting said gasket and attaching said gasket assembly to said joint member.  
       [0021] According to another aspect of the claimed invention, there is provided a clip for attaching a downspout to a wall, said clip comprising first and second clip members, at least one of said clip members having a means for attaching said clip to said wall, each of said clip members having a releasable interlocking device for releasably interlocking said clip members together around the downspout.  
       [0022] According to another aspect of the claimed invention, there is provided a drainpipe connector system for connecting a downspout to a drainpipe, the drainpipe connector system comprising:  
       [0023] a downspout connector including a first end and a second end, said first end being shaped for slidably engaging a downspout; and  
       [0024] a hinge member having a first portion that is hingeably connected to said second end of said downspout connector and a second portion that is shaped for slidably engaging a drainpipe, the hinge member being rotatable relative to the downspout connector between a raised position and a lowered position; and  
       [0025] a locking tab disposed on one or both of said downspout connector and said hinge member for releasably locking said hinge member in said raised position. 
     
    
    
     DESCRIPTION OF THE DRAWINGS  
     [0026]FIG. 1 is an exploded perspective view of a gutter system in accordance with the present invention;  
     [0027]FIG. 2 is a sectional view of a gutter section for the gutter system of FIG. 1 as viewed along lines  2 - 2  of FIG. 1;  
     [0028]FIG. 3 is an exploded perspective view, with a portion cut away, of a joint member and gasket assembly for the gutter system of FIG. 1;  
     [0029]FIG. 4 is a perspective view of a first corner joint member for the gutter system of FIG. 1;  
     [0030]FIG. 5 is a perspective view of a second corner joint member for the gutter system of FIG. 1;  
     [0031]FIG. 6 is a perspective view of a downspout joint member for the gutter system of FIG. 1;  
     [0032]FIG. 7 is a perspective view of a hanger for the gutter system of FIG. 1;  
     [0033]FIG. 8 is an exploded perspective view of a downspout clip for the gutter system of FIG. 1; and  
     [0034]FIG. 9 is a perspective view of a downspout connector for a drainpipe hinge assembly for the gutter system of FIG. 1;  
     [0035]FIG. 10 is a perspective view of a hinge member mounted to the downspout connector for the drainpipe hinge assembly of FIG. 9; and  
     [0036]FIG. 11 is a perspective view of the hinge member of FIG. 10. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
     [0037] A gutter system  20  in accordance with the present invention is shown in FIG. 1. The gutter system  20  comprises a plurality of gutter sections  30  that are each supported and secured to a building (not shown) by hangers  34 . The gutter sections  30  are adjoined using joint members  36 . The gutter system  20  also includes downspout sections  42  that are secured to the building with downspout clips  44 . The downspout sections  42  are adjoined using downspout joint members  45  and elbows  47 . A lockable hinge assembly  140  pivotably connecting a drainpipe  135  to a downspout section  42  is also provided.  
     [0038] Referring to FIG. 2, gutter section  30  is shown in cross section. Gutter section  30  has a front side  38 , a base  40  and a rear side  46 . The gutter section  30  has a continuous inner wall  48  that defines a channel  49  for channelling rainwater along the gutter section  30 . The gutter section  30  also has an outer wall  50  that is spaced from the inner wall  48  by a plurality of longitudinally extending ribs  52  to form a substantially hollow space  53  between the inner and outer walls  48 ,  50 . The ribs  52  preferably extend at right angles to the walls  48 ,  50  in order to optimize the rigidity of the overall structure. The thickness of the ribs  52  is preferably less than the thickness of the walls  48 ,  50  to optimise the construction of gutter section  30  using an extrusion process.  
     [0039] The hollow space  53  defined between walls  48 ,  50  of gutter section  30  acts as a heat sink to reduce the sensitivity of the gutter section  30  to extreme temperatures. The ribs  52  add strength to the overall structure and enhance the ability of the gutter system to withstand permanent deformation when subjected to heavy snow loads and ice build-up. Also the strength and rigidity provided by the ribs  52  is helpful for home renovation, maintenance and repair applications where it is desired that the gutter section  30  support the weight of a ladder.  
     [0040] It is contemplated that the gutter section  30  could be formed without ribs  52  and that structural support and heat sink functionality can be accomplished by disposing an alternate material in the hollow space  53  such as a cellular foam material. It is also contemplated that hollow space  53  could be left unfilled although the benefits of rigidity will be lessened due to the absence of ribs  52  or other suitable structural support.  
     [0041] The channel  49  defined by inner wall  48  of gutter section  30  has radiused inner corners  54 ,  56  which reduce the likelihood of debris becoming caught in channel  49 . The outer wall  50  preferably defines an aesthetically pleasing shape as desired for the gutter system  20 . The outer wall  50  of the embodiment depicted in the figures has a recessed edge  58  and a conventional “k-style” profile.  
     [0042] Gutter section  30  includes a first hanger attachment member  62  and a second hanger attachment member  64  which engage corresponding attachment members  108  and  110  on hanger  34  as shown in FIG. 8 and described in more detail below.  
     [0043] The gutter sections  30  are preferably constructed of a plastic material. Preferably, the gutter sections are made of vinyl using an extrusion process. The twin wall ribbed structure of gutter sections  30  reduces the cost of production relative to conventional gutter sections designed with a solid profile because less raw material is required to manufacture gutter sections  30  without sacrificing rigidity.  
     [0044] Referring to FIGS.  3 - 6 , joint members for joining gutter sections  30  are shown generally at  36 . A joint member for joining straight sections of gutter sections  30  is shown at  36   a  in FIG. 3. Joint member  36  has an inner sleeve portion  63  and an outer sleeve portion  65 . Inner sleeve portion  63  is positioned to slidably fit inside and adjacent to a substantial portion of the inner wall  48  of the gutter section  30 . The outer sleeve portion  65  is positioned to slidably fit outside and adjacent to a substantial portion of the outer wall  50  of the gutter section  30 . The inner sleeve portion  63  and the outer sleeve portion  65  therefore define a passageway  66  between them for receiving and enveloping a substantial portion of an end of the gutter section  30 . Preferably, the passageway  66  has tapered edges  67  to guide the end of the gutter section  30  in place. An abutment  68  is disposed in the passageway  66  against which the end of the gutter section  30  abuts.  
     [0045] The joint members  36  have passageways  66  at both ends for receiving gutter sections  30 . In this manner joint members  36  connect the gutter sections  30  end to end. The joint member  36  effectively envelopes the end of gutter section  30  to deter deformation of the gasket section  30 .  
     [0046] Joint member  36  also includes support rings  72  that are disposed along inner sleeve portion  63  at both ends of the joint member  36 . The support rings have first and second opposing walls  73  and  75  that define a groove  77  between them. Attachment apertures  79  are defined in second wall  75  of support ring  72  for receiving attachment tabs  98  of a gasket assembly  82  as detailed below. First wall  73  of support ring  72  also defines a first gasket locking recess  81  as described below.  
     [0047] Gasket assembly  82  has a gasket  84  and an attachment ring  86 . The gasket  84  has a double headed locking tab  88  and a double neck  90 . The attachment ring  86  has a tongue  94 , a collar  96  and attachment tabs  98 . A second gasket locking recess  99  is defined in collar  96 . Each of the tabs  98  of attachment ring  86  are positioned to lockably engage attachment apertures  79  on the support ring  72 . Gasket  84  is preferably made of rubber. EPDM or other sealing materials that are sufficiently durable for exterior applications. Neck  90  of gasket  84  is removably secured around the tongue  94  of attachment ring  86  and is secured in place between collar  96  and first wall  73  of gasket ring  72  when the attachment ring  86  is lockably engaged within groove  77  of support ring  72 . Locking tab  88  engages locking recesses  81  and  99  when the gasket  84  is secured to support ring  72  using attachment ring  86 .  
     [0048] This gasket assembly  82  ensures that the joint between gutter sections  30  and joint member  36  is substantially sealed against water leakage. The gasket assembly  82  also ensures that the gasket  84  stays in place when the gutter system  20  is installed and on an ongoing basis when it is subjected to repeated movement of the gutter sections  30  caused by ongoing periods of thermodynamic expansion and contraction of the gutter system  20 .  
     [0049] Further embodiments of joint members are shown in FIGS.  4 - 6 . FIG. 4 shows a joint member  36   b  that is adapted to join two corner gutter sections. The embodiment shown in FIG. 4 has an outside corner  92  that defines a 90° angle. FIG. 5 shows an alternate embodiment  36   c  that has an outside corner  93  that defines a 135° angle. FIG. 6 shows a further embodiment  36   d  of a joint member that is adapted to join a gutter section that has a downspout. The joint member  36   d  has a front flange  95 , a rear flange  97  and a tapered drainage section  100  leading to a drop outlet  101 . The joint member  36   d  has apertures  102  for receiving fasteners (not shown) for fastening joint member  36  directly to a building. Flanges  95  and  99  are configured to slidably engage gutter sections  30  without the need for a gasket assembly  82  (since drainage section  100  will serve to catch rain water from the end of gutter sections  30 ).  
     [0050]FIG. 1 also shows a further embodiment of joint member  36  in the form of an end cap  36   e . End cap joint member  36   e  includes passageway  66  for receiving the end of a gutter section  30  as described for joint member  36   a  above. End cap joint member  36   e  also includes a gasket assembly  82  for securely sealing the end of the gutter section  30 .  
     [0051] Joint members  36  are preferably constructed from a plastic material using an injection moulding process. While it is contemplated that plastic joint members  36  will be used to support plastic gutter sections  30  it is possible that the joint members  36  could be used to support gutter sections  30  could be constructed of metal.  
     [0052] Referring to FIG. 7, a perspective view of a hanger  34  is shown. The hanger  34  has a rear wall  104  which can be fastened to the building with nails or screws disposed through aperture  105 . The hanger has a base  106  and attachment members  108 ,  110  for engaging first and second hanger attachment members  62 ,  64  of the gutter section  30 . The hanger also has upper flanges  107  and  109  for engaging a leaf screen  111  as shown in FIG. 1.  
     [0053] Referring to FIG. 8, a downspout clip  44  is shown. The downspout clip  44  has a first clip member  112  and a second clip member  114 . The first and second clip members each have male locking members  116  and female locking members  118 . The male locking members  116  each have an engaging member  120  having teeth  122 . The female locking members  118  have a receiving mechanism  124  having angular receivers  128  corresponding to the teeth  122  of the engaging member  120  of male locking member  116 . The engaging member  120  is received in the receiving mechanism  124  of female locking member  118  to form an interlock. The male and female locking members  116 ,  118  are preferably of reverse orientation relative to each other. However, other embodiments are also possible where the orientation of the locking members is the same. For example, the clips may be connected at one side by a hinge thus removing the necessity for the locking members to be of reverse orientation.  
     [0054] Each of the clip members  112 ,  114  has an inner surface  126  and an outer surface  129 . A sealed aperture  132  is formed on the inner surface  126  of each of the clip members  112 ,  114 . The aperture may be broken for receiving a screw or nail in order to facilitate the mounting of one of the clip members  112 ,  114  to the side of the building.  
     [0055] Thus, one of the clip members  112 ,  114  is mounted to a wall or other surface of a building with a screw or nail (not shown) through the aperture  132 . The down spout section  42  is placed in the clip member  112 ,  114  and other the clip member  112 .  114  is preferably reversed in orientation and slid in place over the mounted clip member  112 ,  114 . As the inner surface  126  of the second clip member  114  is pushed tight against the downspout  42 , the teeth  122  on the clip members  112 ,  114  interact to lock the clip members  112 ,  114  together. The adjustable locking member  116 ,  118  work over a range of distance that can effectively compensate for both flat wall surfaces and wall sections with overlapping longitudinal sections.  
     [0056] Referring to FIGS.  9 - 11 , a lockable drainpipe hinge assembly  140  is shown. The hinge assembly has a downspout connector  141  for connecting to a downspout  42  and a hinge member  142  for slidably engaging a drainpipe  135  in a friction fit.  
     [0057] Pins  144  are disposed inwardly on an interior surface  146  of the hinge member  142 . Preferably there are two pins  144 . One or more pins are possible in other embodiments. In other embodiments the interior surface  146  may define recesses for receiving pins that are disposed on the downspout connector  141 .  
     [0058] The hinge member  142  has an opening  150  defined between pins  144  to provide sufficient clearance for the hinge member  142  to pivot about the pins  144  when the pins  144  are connected to openings  152  in the downspout connector  141  as discussed below A peripheral edge  154  of hinge member  142  is engaged by tab  156  on downspout connector  141  as detailed below to lock the hinge member  142  in place.  
     [0059] Downspout connector  141  has downspout connecting portion  158  for slidably engaging a downspout section  42  and a hinge connector portion  160  that connects to hinge member  142 . The downspout connector  141  defines openings or recesses  152  for receiving pins  144 . A resilient tab  156  is located on the surface of the downspout connector  141  for releasably engaging the peripheral edge  154  of the hinge member  142 .  
     [0060] In operation, hinge member  142  is attached to the hinge connector portion  160  or downspout connector  141  such that pins  144  are received in the openings  152 . Pins  144  and openings  152  are proportioned such that the pins  144  are rotatable in the openings  152 . The hinge member  142  is pivotable between a lower position where the drain pipe is substantially lowered to the ground and a raised position where the drain pipe is substantially raised from the ground. The tab  156  releasably engages the peripheral edge  154  to retain the hinge member  142  in the raised position.  
     [0061] A person skilled in the art will appreciate that although specific embodiments have been described, the invention is not to be limited to the specific embodiments described herein.