Abstract:
A gutter guard apparatus and method of making the same is disclosed. In some embodiments, the gutter guard apparatus is made from at least two different types of materials, thereby enabling, for example, lighter weight, non-conductive plastics that are best suited for coupling to an existing rooftop gutter system in a corrosion preventing manner to be employed while at the same time providing for a central portion spanning the gutter opening made from a more durable material (e.g., lightweight expanded metals). The gutter guard apparatus may be manufactured by a variety of means, including a desirable, low-cost, and highly effective co-extrusion process through which end portions are extruded from raw materials of different colors into desired configurations and simultaneously extruded onto and effectively integrated with the central portion formed from a different material, thereby creating a unitary gutter guard apparatus that desirably incorporates two or more materials.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    None. 
       STATEMENT REGARDING GOVERNMENT SUPPORT 
       [0002]    None. 
       FIELD 
       [0003]    The present disclosure generally relates to gutter guard apparatuses and methods for making the same. More specifically, the presently disclosed subject matter is directed to easily installable gutter guard apparatuses made from two or more materials for preventing debris from entering rooftop rainwater collection systems, and related methods for making the same. 
       BACKGROUND 
       [0004]    The present disclosure pertains generally to gutter guard systems used in relation to rooftop rainwater collection systems (e.g., gutters or gutter systems) to prevent accumulation of debris in the gutter system while still capturing the water the system is intended to collect. 
         [0005]    In general, rainwater collection systems are installed to collect rainwater from rooftops and direct the water to desirable drainage locations around a structure. Often times, gutter systems can become undesirably clogged with debris (e.g. sticks, pine straw, leaves, acorns, etc.). To prevent such accumulation, there are numerous systems available that may be installed on or within the gutter system to enable collection of water while preventing the accumulation of debris within the gutter system. (See, e.g., U.S. Patent Pub. No. 2015/0033638 titled Gutter Guard Apparatuses and Methods). 
         [0006]    Unfortunately, existing systems are often expensive, and are frequently either ineffective, or deteriorate quickly. Also, known systems are made from single materials (for example, only plastic or only metal), rather than combinations of metals and plastics that effectively combine to match each material&#39;s best qualities to their most suitable function. For example, plastics are lightweight and typically comprise desirable characteristics for easily coupling the apparatus to a gutter system. On the other hand, these lighter weight plastics typically lack the strength and durability needed in the central portion of the gutter where the greatest wear and stresses are felt. It is therefore metals, not plastics, which are typically better suited for this central spanning portion. 
         [0007]    Unfortunately, the use of metal materials on metal gutters can lead to undesirable corrosion. For example, the use of an aluminum or steel gutter guard on a copper gutter can lead to significant corrosion. Corrosion can occur in a host of other metal combinations as well. Such corrosion can be avoided despite the use of materials that might otherwise corrode, however, where non-reactive materials prevent contact between the otherwise reactive materials. For example, plastics may be used to provide a non-conducting buffer between otherwise reactive materials such that the free electrons that might otherwise lead to corrosion cannot pass between the reactive materials. Plastics may also offer lighter overall weight, greater flexibility, and other desirable attributes. 
         [0008]    Accordingly, what is needed is a gutter guard apparatus that is easy to manufacture at a low cost that effectively utilizes a combination of materials to exploit the best characteristics of such materials in different aspects of the apparatus. Also desirable would be a gutter guard apparatus that can utilize materials that might otherwise react with certain types of gutter systems, which can result in unwanted corrosion. 
       SUMMARY 
       [0009]    The present disclosure pertains generally to gutter guard systems for preventing accumulation of debris while capturing water. 
         [0010]    In one embodiment, a gutter guard apparatus for attachment to a gutter in a rainwater collection system and configured for mounting to a longitudinal edge of a rooftop is disclosed, the gutter defining a longitudinal and upward facing rainwater collection opening with a bead at an upper lip of the gutter. The gutter guard apparatus may include a central portion extending longitudinally along the length of the gutter and laterally across at least a portion of the upward facing rainwater collection opening, the central portion comprising a first metallic material defining perforations permitting rainwater to pass into the upward facing rainwater collection opening, and first and second end portions comprising a second non-metallic material, the first and second end portions extending longitudinally along the length of the central portion; wherein the first end portion is coupled to a side of the central portion configured for placement adjacent to the edge of the rooftop, and the second end portion is coupled to a side of the central portion configured for placement opposite the rooftop; wherein the second end portion is adapted to couple to an upper portion of the gutter proximate to the bead; and further wherein the first end portion, the central portion, and the second end portion extend substantially across the water collection opening. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]      FIG. 1  illustrates a perspective view of the gutter guard apparatus according to one embodiment. 
           [0012]      FIG. 2  illustrates a plan view of an exemplary co-extrusion device. 
           [0013]      FIG. 3  illustrates a perspective view of the gutter guard apparatus according to one embodiment. 
           [0014]      FIG. 4  illustrates a top view of one embodiment of the present disclosure comprising a mesh overlaying at least a portion of the gutter guard apparatus disclosed herein. 
           [0015]      FIG. 5  illustrates a perspective view of the gutter guard apparatus according to another embodiment. 
           [0016]      FIG. 6  illustrates a plan view of another exemplary co-extrusion device. 
       
    
    
     DETAILED DESCRIPTION 
       [0017]    The presently disclosed subject matter now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the presently disclosed subject matter are shown. Like numbers refer to like elements throughout. The presently disclosed subject matter may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Indeed, many modifications and other embodiments of the presently disclosed subject matter set forth herein will come to mind to one skilled in the art to which the presently disclosed subject matter pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the presently disclosed subject matter is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. 
         [0018]    In some embodiments, the presently disclosed subject matter provides a gutter guard apparatus for installation on new and/or existing rooftop rainwater collection systems. Advantageously, the gutter guard apparatus may be constructed of two or more materials. For example, expanded metals (e.g. expanded galvanized steel, aluminum, etc.) may be used in a central portion of the apparatus to provide a sturdy, long-lasting structure across the opening of the gutter system where the apparatus will encounter the greatest loads and stresses. On the edges of the apparatus, however, plastics may be used which advantageously offers reduced weight, reduced cost, greater flexibility, and non-conductive properties at the points where the apparatus attaches to the rainwater collection system and/or rooftop. The result is an overall lighter weight apparatus that embodies the durability and strength of heavier and more expensive metallic gutter guard devices, and the lower weight, greater flexibility, superior adapting ability, and non-conductive qualities of plastics. 
         [0019]    Referring now to  FIG. 1 , a first embodiment of the presently disclosed gutter guard apparatus  10  is shown, having a central portion  12  made from a first material, and end portions  14 ,  16  extending along either edge of central portion  12  made from a second material. Central portion  12  may include a plurality of perforations  19  sufficient to allow water to flow through to a gutter below. Central portion  12  may be made, for example, from lightweight expanded metal (e.g., galvanized steel, aluminum, or other material). In some embodiments, the central portion  12  may also be made from materials that could potentially react chemically with certain gutter systems (e.g. copper gutter systems with an aluminum central portion). 
         [0020]    End portions  14 ,  16  may be made of a second material having a reduced weight and cost and better suited for mounting the apparatus to the rainwater collection system and/or rooftop. The second material may also be non-conducting, such that free electrons in the gutter system and/or the central portion  12  cannot be conducted to one another, which can lead to unwanted corrosion. In some embodiments, end portions  14 ,  16  may be made primarily from, for example, plastic or vinyl (e.g. polyvinyl chloride (PVC), polypropylene, or polyethylene), though any suitable material may be used. 
         [0021]    End portions  14  and  16  will typically (though not necessarily) take on different configurations depending on the gutter system and rooftop onto which the apparatus will be installed. For example, end portion  14  may, in some circumstances, take on an elongated, flat form to facilitate sliding end portion  14  under shingles that may be installed on the rooftop. End portion  14  may, alternatively, take on any other shape or configuration to facilitate attachment to the roof structure and/or gutter that enables rainwater to flow from the rooftop to the gutter system. 
         [0022]    End portion  16 , on the other hand, may be configured for attachment to the non-roof side edge of the gutter system. In some embodiments, end portion  16  may include a mechanism for coupling to the non-roof edge of the gutter system. Such mechanisms may include, for example, a snap attachment that snaps onto an outer edge of the gutter system. 
         [0023]    For example, end portion  16  may include a mechanism that includes a gutter receiving portion  17  for receiving an upper portion of the outer edge of the gutter system. The gutter receiving portion  17  may also include a securing component for securing end portion  16  of the apparatus  10  to the gutter. The securing component may, in some embodiments, include teeth  18  that extend substantially perpendicularly from gutter receiving portion  17 . The teeth may be continuous or spaced incrementally along receiving portion  17 . Similarly, the securing component (e.g. receiving portion  17 ) may extend continuously along the end portion  16 , or may be spaced incrementally. 
         [0024]    In such exemplary embodiments, the upper portion of the outer edge of the gutter may include a roll or other type of bead structure that adds strength to the gutter system. Accordingly, the roll or bead may fit into the gutter receiving portion  17  and teeth  18  may snap around the roll or bead to facilitate a secure connection between end portion  16  and the gutter system. A person having skill in the art will appreciate that this is but one example of how the gutter guard apparatus  10  could be coupled to the outer edge of the gutter system, and that other coupling mechanisms could likewise be employed (e.g. screws, glue, magnets, fasteners, etc.). 
         [0025]    In application, central portion  12  and end portions  14 ,  16  may be coupled together to form the single gutter guard apparatus  10 . Referring now to  FIG. 2 , in some embodiments, a plastic extrusion method is used to form the end portions  14 ,  16  and affix them to the central portion  12 . For example, a plastic extruder  20  capable of forming the respective end portions  14 ,  16  and extruding end portions  14 ,  16  onto material suitable for central portion  12  (e.g., lightweight expanded metal) may be employed. In this exemplary co-extrusion production process, the extruder  20  may be configured to receive raw materials in a raw material receiver  25  for end portions  14 ,  16  (e.g. plastics such as PVC), receive materials for central portion  12  (e.g. lengths of rolled expanded metals  28 ), melt the raw material for end portions  14 ,  16 , and subsequently extrude such raw materials as end portions  14 ,  16  that are affixed to central portion  12 . The result is a gutter guard apparatus  10  that includes desired end portions  14 ,  16  coupled to central portion  12 , wherein end portions  14 ,  16  may advantageously be made of, for example, plastic, and central portion  12  may advantageously be made of, for example, expanded metal. Additionally, the end portions  14 ,  16  are securely coupled to central portion  12  through the co-extrusion process such that the gutter guard apparatus  10  comprises a unitary apparatus composed of its securely coupled component parts. 
         [0026]    Alternatively, gutter guard apparatus  10  may be manufactured in other ways. For example, end portions  14 ,  16  may be manufactured using a more simplified extrusion process, or any other manufacturing means to produce end portions  14 ,  16  of desired lengths. Referring now to  FIG. 3 , such embodiments of end portions  14 ,  16  may be manufactured to include, for example, a central portion receiver  30  to facilitate attachment to the central portion  12 . The central portion receiver  30  may, in some embodiments, include a top portion  31  and a bottom portion  32  that are spaced apart by a width substantially equal to the thickness of the central portion  12 . In this manner, end portions  14 ,  16  may each receive alternate sides of central portion  12 . End portions  14 ,  16  may then be secured to central portion  12  by any appropriate means. For example, in some embodiments, end portions  14 ,  16  may be heat staked to central portion  12 . In certain other embodiments, end portions  14 ,  16  may be glued to central portion  12 . In yet other embodiments, other fastening means may be used, including for example, screws, snaps, hooks, or any other appropriate fasteners. 
         [0027]    The size of the perforations  19  in central portion  12  may vary depending on the configuration of the apparatus. In some embodiments, very fine perforations may be employed, allowing water to flow through the perforations  19  but preventing larger debris from flowing through and entering the gutter system. In certain other embodiments, larger perforations may be employed, which advantageously reduces the weight and amount of raw material required for central portion  12 . For example, the perforations  19  may, in some embodiments, comprise substantially evenly spaced openings approximately 0.25 inches by 0.125 inches in size. 
         [0028]    Undesirably, however, larger perforations may allow an unacceptable amount of debris to pass through the central portion  12  and into the gutter system. Accordingly, with reference to  FIG. 4 , in embodiments where a lighter weight central portion is desired (i.e. larger perforations  19 ), a lightweight perforated or woven mesh  35  may be applied adjacent to the central portion  12 , for example on an upward facing portion of the central portion  12  opposite the gutter system. The lightweight perforated or woven mesh  35  may also be installed on a downward facing portion of the central portion  12 , or optionally woven within the perforations  19 . In either configuration, a sturdy metal central portion  12  with relatively large perforations to minimize the weight of the central portion  12  may be employed while still preventing the passage of undesirable debris into the gutter system by the lightweight perforated or woven mesh  35 . In such embodiments, perforated or woven mesh  35  may comprise, for example, substantially evenly spaced openings approximately 0.0625 inches by 0.0625 inches in size. Additionally, perforated or woven mesh  35  may comprise, for example, vinyl coated fiberglass, or any other suitable material(s). 
         [0029]    In some embodiments of the present disclosure, the gutter guard apparatus  10  may be reversible, allowing for installation of the gutter guard apparatus  10  in at least two configurations on the gutter system. An exemplary embodiment of such a reversible configuration is shown with reference to  FIG. 5 . In such embodiments, end portion  14  may include a first facing surface  52  and a second facing surface  54  opposite first facing surface  52 . Similarly, end portion  16  may include a first facing surface  62  and a second facing surface  64  opposite first facing surface  62 . Finally, central portion  12  may include a first facing surface  72  and a second facing surface  74  opposite first surface  72 . 
         [0030]    One advantage of such a reversible configuration of the gutter guard apparatus  10  is the ability to have the first surfaces  52 ,  62 , and  72  colored a first color, and second surfaces  54 ,  64 , and  74  colored a second color. Advantageously, the first and second colors may optionally be distinguishable from one another, thereby giving consumers the option of installing the gutter guard apparatus  10  with the first color exposed or the second color exposed (the opposite surface being effectively hidden as facing to the gutter and/or rooftop). Having both colors available on a single apparatus has a further advantage of giving the consumer the option of seeing both color options on their house before fully installing one color versus the other. Indeed, many consumers would prefer to have their gutter guard system  10  match the color of their roof, and having two colors to choose from on one device  10  enables more effective color matching (i.e. the ability to actually see the color on the house rather than relying on a color sample). Other exemplary advantages include the ability of sellers of gutter guard apparatus  10  to carry less inventory, effectively carrying half the inventory that may otherwise be required to provide options to match the myriad roof color options available in the marketplace. Of course, in some embodiments the first and second color may be the same, but in preferred embodiments the first and second colors will be distinguishable from one another. 
         [0031]    To manufacture end portions  14 ,  16  with the first surfaces  52 ,  62  a the first color and second surfaces  54 ,  64  a the second color, a co-extrusion process may, in some embodiments, be used. The co-extrusion process may rely on, for example, an extruder mechanism  600  such as the exemplary mechanism shown in  FIG. 6 . Raw materials for producing the first color may be loaded into a first raw material receiver  602 , and raw materials for producing the second color may be loaded into a second raw material receiver  604 . 
         [0032]    During the extrusion process, the extruder  600  may be configured to produce the first surfaces  52 ,  62  of end portions  14 ,  16  with melted raw materials from the first raw material receiver  602 , thereby yielding the first surface  52 ,  62  of end portions  14 ,  16  having the first color. Similarly, the extruder  600  may be further configured to produce the second surfaces  54 ,  64  of end portions  14 ,  16  with raw materials from the second raw material receiver  604 , thereby yielding the second surface  54 ,  64  of end portions  14 ,  16  having the second color. Advantageously, the co-extruder may be further configured to yield the first surface  52  and second surface  54  (and likewise the first surface  62  and second surface  64 ) together such that they are each produced as a single unit. The co-extrusion process may further be used to extrude end portions  14 ,  16  together with central portion  12  as discussed above (see  FIG. 2 ). Central portion  12  may be painted to match the first and second colors, either before or after the co-extrusion process. This exemplary process may yield the gutter guard apparatus  10  having the first color on one side and the second color on the other side. The multi-color gutter guard  10  discussed herein may also be manufactured according to other methods, including those methods discussed hereinabove with reference to, for example,  FIG. 3 , among others. 
         [0033]    Following long-standing patent law convention, the terms “a,” “an,” and “the” refer to “one or more” when used in this application, including the claims. Thus, for example, reference to “a subject” includes a plurality of subjects, unless the context clearly is to the contrary (e.g., a plurality of subjects), and so forth. 
         [0034]    Throughout this specification and the claims, the terms “comprise,” “comprises,” and “comprising” are used in a non-exclusive sense, except where the context requires otherwise. Likewise, the term “include” and its grammatical variants are intended to be non-limiting, such that recitation of items in a list is not to the exclusion of other like items that can be substituted or added to the listed items. 
         [0035]    For the purposes of this specification and appended claims, unless otherwise indicated, all numbers expressing amounts, sizes, dimensions, proportions, shapes, formulations, parameters, percentages, parameters, quantities, characteristics, and other numerical values used in the specification and claims, are to be understood as being modified in all instances by the term “about” even though the term “about” may not expressly appear with the value, amount or range. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are not and need not be exact, but may be approximate and/or larger or smaller as desired, reflecting tolerances, conversion factors, rounding off, measurement error and the like, and other factors known to those of skill in the art depending on the desired properties sought to be obtained by the presently disclosed subject matter. For example, the term “about,” when referring to a value can be meant to encompass variations of, in some embodiments, ±100% in some embodiments ±50%, in some embodiments ±20%, in some embodiments ±100/0, in some embodiments ±5%, in some embodiments ±1%, in some embodiments ±0.5%, and in some embodiments ±0.1% from the specified amount, as such variations are appropriate to perform the disclosed methods or employ the disclosed compositions. 
         [0036]    Further, the term “about” when used in connection with one or more numbers or numerical ranges, should be understood to refer to all such numbers, including all numbers in a range and modifies that range by extending the boundaries above and below the numerical values set forth. The recitation of numerical ranges by endpoints includes all numbers, e.g., whole integers, including fractions thereof, subsumed within that range (for example, the recitation of 1 to 5 includes 1, 2, 3, 4, and 5, as well as fractions thereof, e.g.,  1 . 5 ,  2 . 25 ,  3 . 75 ,  4 . 1 , and the like) and any range within that range. 
         [0037]    Although the foregoing subject matter has been described in some detail by way of illustration and example for purposes of clarity of understanding, it will be understood by those skilled in the art that certain changes and modifications can be practiced within the scope of the appended claims.