Patent ID: 12215501

DETAILED DESCRIPTION

The apparatus, systems, arrangements, and methods disclosed in this document are described in detail by way of examples and with reference to the figures. It will be appreciated that modifications to disclosed and described examples, arrangements, configurations, components, elements, apparatus, methods, materials, etc. can be made and may be desired for a specific application. In this disclosure, any identification of specific techniques, arrangements, method, etc. are either related to a specific example presented or are merely a general description of such a technique, arrangement, method, etc. Identifications of specific details or examples are not intended to be and should not be construed as mandatory or limiting unless specifically designated as such. Selected examples of gutter guard systems are hereinafter disclosed and described in detail with reference made toFIGS.1-10.

As will be described in detail herein, an exemplary embodiment of a novel gutter guard system includes two major components: (i) a main body with an integrated front receiver, rear receiver, with a water management section extending between and connecting the front receiver and rear receiver and (ii) a screen that is positioned over the water management section and secured to the main body by engagement with the front receiver and rear receiver. The gutter guard system is arranged to be positioned proximate to the top opening of a rain gutter installed on a home or other structure. Typically the gutter guard system generally spans the top opening of the rain gutter. As will be described herein, the screen and water management section include a number of features that assist in managing the flow of rainwater across the gutter guard system to provide for efficient and effective flow of rainwater across the screen and down toward the water management section and subsequently through the water management section and into the rain gutter. The screen is arranged to discourage the matting of debris on the top side of the screen through the screen's construction, positioning, and design features. The main body is arranged to promote airflow in and around the water management section in both in the vertical and horizontal directions. Such flow of air in multiple directions effectively discourages debris from resting on and subsequently matting on the top side of the screen.

The gutter guard system can be manufactured in a plurality of sizes to accommodate various sizes of rain gutters. For example, as will be described and illustrated herein, the gutter guard system can be manufactured to accommodate a five-inch rain gutter or a six-inch rain gutter. The gutter guard system can be manufactured to accommodate various styles of rain gutters. In particular, the structure of the front receiver and rear receiver relative to the main body can be arranged to accommodate a number of different style of rain gutters, such as K-style, half-round, fascia style, and even custom designed rain gutters. The examples described and illustrated herein are directed to a gutter guard system designed and manufactured to accommodate five-inch and six-inch K-style rain gutters. However, it will be understood that such examples are non-limiting. As will be further explained herein, coatings and/or films of various colors can be applied to the front receivers and/or rear receivers to enhance the aesthetic appeal and weather resistance of the front and rear receivers.

The main body can be manufactured from a number of materials, including metal and polymeric material such as polyvinyl chloride (PVC), polyethylene (PE), polyolefin (PO), or any other relatively rigid polymer. The main body can be manufactured using a variety of methods including extrusion, injection molding, additive manufacturing (i.e., 3D printing), machining, metal casting, metal stamping, punching, and the like. In some embodiments, more than one manufacturing process can be used. For example, a main body can be machined, stamped, punched, or otherwise modified, after it is formed via extrusion or injection molding. In one embodiment, the main body is manufactured from a polymeric material using an extrusion process. Slots in the channels of the water management section are formed by a punching process. The punching process can be performed in-line with the extrusion process or can be an off-line process that punches the holes after the extrusion process is complete. The examples of gutter guard systems described and illustrated herein are not limiting or exhaustive, and one of ordinary skill in the art will readily understand that components of the gutter guard system can be manufactured in any number of ways.

In one embodiment, the screen is a 30 mesh metal screen. In one example, the screen can be made of 316L stainless steel wire, more specifically, 316L stainless steel wire that is 0.0085 inches in diameter. The screen can be arranged in a square weave such that there are 30 wires for each linear inch of screen in both the width and length directions. In such an arrangement, the surface area of the screen includes approximately 55% open area. It will be understood with such a large percentage of open area, the screen can facilitate water flowing through the screen toward the water management section and into the rain gutter even when debris such as leaves temporarily come to rest on top of the screen. The 0.0085 inch diameter 316L stainless steel wire arranged as such provides a number of benefits, including resistance to corrosion and rust when exposed to the elements, generally prevents common debris from passing through the screen, facilitates self-cleaning of the screen due to debris passing over the screen, and promotes water infusion through the screen as water travels across the screen. Furthermore, in one embodiment, such an arrangement maintains a generally flat surface when exposed to the elements so that the screen maintains its functionality and aesthetic appeal over time. In other embodiments, as will be described herein, the screen includes features and contours that rise above the general plane of the screen to promote rainwater infusion through the screen and to prevent or limit the matting of debris on the top of the screen.

FIGS.1-4schematically illustrate a first embodiment of a gutter guard system100for use with a five-inch K-style rain gutter. The gutter guard system100includes a main body110with a front receiver120, a rear receiver130, and a water management section140positioned between and connecting the front receiver120and rear receiver130. The front receiver120, the rear receiver130, and the water management section140are integrally formed into a continuous main body110. The gutter guard system100further includes a screen150spanning the water management section140and secured to the main body110by interior extending portions of the front receiver120and rear130receiver. As illustrated inFIG.3, a side view of the main body110, the front receiver120, rear receiver130, and water management section140include multiple features that will be subsequently described in detail.

As illustrated inFIGS.3and3A, the front receiver120includes an outward extending edge160, an inward extending edge170, and a forward angled leg180. Furthermore, the end of the inwardly extending edge170includes a downward rounded feature190. When the gutter guard system100is installed in a rain gutter, typically a hanger system is used to support the gutter guard system100proximate to the top of the rain gutter. The front receiver120can be positioned to engage with the front edge of the rain gutter. For example, once installed, the outward extending edge160of the front receiver120can be positioned over the top of and in contact with the front edge of the rain gutter. Furthermore, the forward angled leg180can engage with an interior wall of the front of the rain gutter to stabilize the location of the gutter guard system100relative to the rain gutter. As illustrated inFIGS.2and4, an aperture200is provided in the front receiver120that can be used to further secure the front receiver120to the rain gutter using a fastener such as a screw or rivet. It will be understood that multiple apertures can be formed in the front receiver120to provide multiple locations to fasten the front receiver120(and thus, secure the gutter guard system100) to the distal edge of the rain gutter.

The rear receiver130includes an inward extending edge210and a rearward angled leg220. The rearward angled leg220includes a foot230extending rearward from the end of the rearward angled leg220. The end of the inward extending edge210includes a downward rounded feature240. The foot230and rearward angled leg220of the rear receiver130are arranged to provide for flexibility in the installation of the gutter guard system100in a rain gutter. For example, in some arrangements, the foot230can be in contact with a hanger or other support structure installed with or on the rain gutter. In other embodiments, the foot230can be in contact with the side of the house or structure or can be positioned in contact with a rear portion of the rain gutter. In other embodiments, a hanger system can be installed such that the foot230is not in contact with either the house or rain gutter.

When the screen150is installed onto the main body110, one edge of the screen150is positioned under the inward extending edge170of the front receiver120, and the opposite edge of the screen150is positioned under the inward extending edge210of the rear receiver130. The edges of the screen150are slightly deformed by their engagement with the downward rounded feature190of the front receiver120and the downward rounded feature240of the rear receiver130. Such slight deformation creates a friction fit that secures the screen150in place relative to the main body110. Additionally, an adhesive or other similar substance can be used to secure the screen150to the main body110.

The water management section140includes a number of features to manage the flow of water across the gutter guard system100. In the first embodiment illustrated inFIGS.1-4, the water management section140includes a total of five channels, including a pair of shallow channels250,260and three deep channels270,280,290. The pair of shallow channels250,260extend the length of the main body110and include generally straight vertical walls and a flat bottom. In the illustrated embodiment, the two shallow channels250,260are generally similar in dimensions. As best illustrated inFIG.4, the pair of shallow channels250,260include a series of slots300extending along the flat bottom of the pair of shallow channels250,260. The slots300are generally rectangular in shape and elongated in the lateral direction of the channel250,260. The three deep channels270,280,290extend the length of the main body110and include angled walls and a rounded interior bottom to form a generally U-shaped channel. The deep channels270,280,290include slots310that run along the angled walls and rounded bottom of the deep channels270,280,290to form relatively large openings in the deep channels270,280,290. As best illustrated inFIG.3, the three deep channels270,280,290differ in dimension from each other. Deep channel290, which is located proximate to the rear receiver130, is the largest of the three deep channels270,280,290, having the greatest width and depth. Deep channel270, which is located proximate to the front receiver120, is the smallest of the three deep channels270,280,290, having the smallest width and depth. Deep channel280, which is located between the other two deep channels270,290and has a depth and width that is between that of the other two deep channels270,290.

The deep channels270,280,290are designed to be progressively larger from the front receiver120to the rear receiver130to accomplish two goals. First, when rainwater is channeled from the roof of a home or structure onto the gutter guard system100, the largest volume of rainwater is experienced proximate to the home or structure. Thus, the deep channel290located proximate to the rear receiver130is designed to be large enough to accommodate a large volume of rainwater passing though the deep channel290. The volume of rainwater is reduced as the rainwater moves across the gutter guard system100toward the front receiver120. Therefore, deep channels270,280are proportionally sized to accommodate the reduced volume of rainwater. Secondly, the varying depths of the deep channels270,280,290result in the bottoms of the deep channels270,280,290effectively engaging with a horizontal component of a hanger system used to support the installed gutter guard system100. Because the gutter guard system100is installed so that the screen150generally slopes downward from the rear receiver130to the front receiver120, the progressively varying depth of the forward-most deep channel270to the rear-most deep channel290results in all the bottom surfaces of the deep channels270,280,290positioned on a common horizontal plane (as illustrated by line Ph inFIG.3). Thus, the bottom surfaces of the deep channels270,280,290can all engage and be supported by a horizontal component of a hanger system.

FIGS.5-8schematically illustrate a second embodiment of a gutter guard system500for use with a six-inch K-style rain gutter, which shares many structural and functional features with the first embodiment of the gutter guard system100illustrated inFIGS.1-4. The gutter guard system500includes a main body510with a front receiver520, a rear receiver530, and a water management section540positioned between and connecting the front receiver520and the rear receiver530. The gutter guard system500further includes a screen550spanning the water management section540and secured to the main body510by interior portions of the front520and rear530receivers. As illustrated inFIG.7, a side view of the main body510, the front receiver520, rear receiver530, and water management section540include multiple features that will be subsequently described in detail.

As illustrated inFIGS.7and7A, the front receiver520includes an outward extending edge560, an inward extending edge570, and a forward angled leg580. Furthermore, the end of the inwardly extending edge570includes a downward rounded feature590. When the gutter guard system500is installed in a rain gutter, typically a hanger system is used to support the gutter guard system500proximate to the top of the rain gutter. The front receiver520can be positioned to engage with the front edge of the rain gutter. For example, once installed, the outward extending edge560of the front receiver120can be positioned over the top of and in contact with the front edge of the rain gutter. Furthermore, the forward angled leg580can engage with an interior wall of the front of the rain gutter to stabilize the location of the gutter guard system500relative to the rain gutter. As illustrated inFIGS.6and8, an aperture600is provided in the front receiver520that can be used to further secure the front receiver520to the rain gutter using a fastener such as a screw or rivet. It will be understood that multiple apertures can be formed in the front receiver520to provide multiple locations to fasten the front receiver520(and thus, secure the gutter guard system500) to the distal edge of the rain gutter.

As illustrated inFIGS.7and7B, the rear receiver530includes an inward extending edge610and a rearward angled leg620. The rearward angled leg620includes a foot630extending rearward from the end of the rearward angled leg620, and the end of the inward extending edge610includes a downward rounded feature640. The foot630and rearward angled leg620of the rear receiver530are arranged to provide for flexibility in the installation of the gutter guard system500in a rain gutter. For example, in some arrangements, the foot630can be in contact with the side of the house or structure or can be positioned in contact with a rear portion of the rain gutter. In other embodiments, a hanger system can be installed such that the foot630is not in contact with either the house or rain gutter.

As in the first embodiment of the gutter guard system100, when the screen550is installed onto the main body510of the second gutter guard system500, one edge of the screen550is positioned under the inward extending edge570of the front receiver520, and the opposite edge of the screen550is positioned under the inward extending edge610of the rear receiver530. The edges of the screen550are slightly deformed by the downward rounded feature590of the front receiver520and the downward rounded feature640of the rear receiver530. Such slight deformation creates a friction fit that secures the screen550in place relative to the main body510. Additionally, an adhesive or other similar substance can be used to secure the screen550to the main body510.

The water management section540includes a number of features to manage the flow of water across the gutter guard system500but differs from the first embodiment of gutter guard system100. In the second embodiment illustrated inFIGS.5-8, the water management section540includes three shallow channels650,660,670and four deep channels680,690,700,710. The shallow channels650,660,670extend the length of the main body510and include generally straight vertical walls and a flat bottom. The dimensions of the shallow channels650,660,670are all generally similar. As best illustrated inFIG.8, the shallow channels650,660,670include a series of slots720extending along the flat bottom of the shallow channels650,660,670. The deep channels680,690,700,710extend the length of the main body510and include angled walls and a rounded bottom to form a U-shaped channel. The deep channels680,690,700,710also include slots730that run along the angled walls and rounded bottom of the deep channels680,690,700,710. Similar to the embodiment illustrated inFIGS.1-4, the size and dimensions of the deep channels680,690,700,710increase progressively from the forward-most deep channel680to the rear-most deep channel710and generally provide the same benefits as described with the embodiment illustrated inFIGS.1-4.

The mixture of shallow channels and deep channels, the structure of those channels, and the size and positioning of the slots provide for a gutter guard system with superior management of water flow and air flow to provide for an efficient system that manages large amounts or rainwater and prevents matting of debris on the surface of the screen. The slots310,730of the deep channels are relatively large and run along both the bottom of the deep channels and side walls of the deep channels. This provides for significant open area in the main body to capture a significant amount of water and promote the free flow of air through the main body. The slots extending to the side walls of the deep channels promotes airflow in a horizontal direction in addition to the vertical direction. This free flow of air assists in the management of debris that settles on the surface of the screen. Foremost, this free flow of air creates currents that can dislodge debris from the screen. Secondly, this free flow of air encourages evaporation of moist debris that is matted on the screen so that, once dry, currents can more easily dislodge debris.

Additional features include tapered edges at the tops of the shallow and deep channels. Such tapered edges are in contact with the underside of the screen and function as wicking edges. As water flows across the screen, the contact points created by the tapered edges create a wicking phenomena that cause water flowing across the screen to change direction at the point of contact between the tapered edges and the screen and flow downward through the screen and along the walls of the channels. Once in the channels, the water freely flows through the slots and into the rain gutter.

Additional features of the gutter guard system include: (i) curved bottoms of the deep channels provide for stiffness and general structural integrity of the main body; (ii) the slots of the channels are staggered (as best illustrated inFIGS.4and8), which provides for openings to accommodate hangers and ensure that at least some portion of the main body engages with and is supported by the hanger system; and (iii) the arrangements described and illustrated herein provide for a wider screen than many prior art gutter guard systems, which provides for more time and opportunity for rainwater passing across the screen to be directed downward into the rain gutter.

In addition to the screen150,550illustrated inFIGS.1-8, other alternative designs for screens can be used with the gutter guard systems disclosed herein. For example,FIG.9illustrates a screen800that includes a raised and rounded area810running along the length of the screen800. The raised and rounded area810serves as a hurdle or obstacle that slows down rainwater as it passes over the screen800. This slowing of rainwater keeps the rainwater on the surface of the screen for a longer period of time, providing more opportunity for the water to wick downward, pass through the screen and into the rain gutter. The raised area additionally promotes air flow across the surface of the screen800and results in less matting of debris on the top surface of the screen800.

In another example illustrated inFIG.10, a screen900includes a flat area910positioned proximate to the rear receiver and an upwardly angled area920positioned proximate to the front receiver. Attached to the front edge of the screen900is an adapter930that connects that front edge of the screen900to the front receiver. The upwardly angled area920causes rainwater flowing across the screen900to slow and providing additional time for the rainwater to pass through the screen900and into the rain gutter.