U.S. patent application number 11/105653 was filed with the patent office on 2006-10-19 for solid edge gutter screen.
Invention is credited to James E. SR. Ealer.
Application Number | 20060230687 11/105653 |
Document ID | / |
Family ID | 37107104 |
Filed Date | 2006-10-19 |
United States Patent
Application |
20060230687 |
Kind Code |
A1 |
Ealer; James E. SR. |
October 19, 2006 |
Solid edge gutter screen
Abstract
A one-piece, integral metal gutter screen includes an expanded
metal screen section for covering a gutter. A front edge margin is
sized and shaped to engage the gutter, the front edge margin having
no sharp edges. A rear edge margin is sized and shaped to engage at
least one of a gutter hanger and a roof, the rear edge margin
having no sharp edges. The gutter screen is formed of a single
piece of elongate, flexible, resilient metal. The gutter screen
includes strands and non-circular holes between the strands in at
least the screen section. The strands and non-circular holes are
sized and shaped to prevent leaves and debris from falling into the
gutter. At least the front edge margin of the screen is solid,
unperforated metal for facilitating safe handling of the screen and
for ease of installation.
Inventors: |
Ealer; James E. SR.; (Union,
MO) |
Correspondence
Address: |
SENNIGER POWERS
ONE METROPOLITAN SQUARE
16TH FLOOR
ST LOUIS
MO
63102
US
|
Family ID: |
37107104 |
Appl. No.: |
11/105653 |
Filed: |
April 14, 2005 |
Current U.S.
Class: |
52/12 |
Current CPC
Class: |
E04D 13/076
20130101 |
Class at
Publication: |
052/012 |
International
Class: |
E04D 13/00 20060101
E04D013/00 |
Claims
1. A metal gutter screen adapted for covering a gutter and
preventing leaves and debris from falling into the gutter, the
gutter having front, back and bottom walls and a flange projecting
rearwardly from the front wall of the gutter and spaced above the
bottom wall of the gutter, said flange extending substantially
continuously along the entire length of the gutter, the gutter
supported by a hanger extending forward from the back wall of the
gutter to a position under the gutter flange, the gutter screen
comprising: an expanded metal screen section for covering the
gutter, a front edge margin bent to form a forwardly-opening
channel generally V-shaped in transverse section extending
substantially continuously along the entire length of the screen
for receiving the gutter flange therein, the forwardly-opening
channel including: an upper rearwardly extending portion bent back
from the front edge of the resilient member and adapted to overlie
the gutter flange and engage the gutter flange for supporting the
screen on the flange and to inhibit sagging of the screen, and a
lower forwardly extending portion bent forward from the upper
rearwardly extending portion and adapted to underlie the gutter
flange, the upper and lower portions being divergent in the forward
direction with respect to the channel to form a relatively wide
channel mouth for permitting ready passage of the gutter flange
through the channel mouth into a position where the gutter flange
is between the upper and lower portions, a solid, unperforated rear
edge margin adapted for engaging the gutter hanger, the screen
section being generally planar when uninstalled and being adapted
to be resiliently bent to an arcuate configuration in which the
front edge margin and rear edge margin are adapted for pressure
engagement with the gutter and gutter hanger to thereby securely
maintain the gutter screen on the gutter, the gutter screen being
formed integrally of a single piece of elongate, flexible,
resilient metal, at least the lower forwardly extending portion of
the channel and the rear edge margin being solid, unperforated
metal for stiffening the gutter screen, for facilitating safe
handling of the screen and for ease of installation.
2. The gutter screen of claim 1 wherein at least a portion of the
upper rearwardly extending portion is solid, unperforated
metal.
3. The gutter screen of claim 2 wherein all of the front edge
margin is solid, unperforated metal.
4. The gutter screen of claim 3 wherein said screen section
includes criss-crossing ribs extending at non-perpendicular angles
to said edge margins.
5. The gutter screen of claim 1 wherein the screen is made of an
aluminum alloy or a steel alloy.
6. The gutter screen of claim 1 wherein the upper rearwardly
extending portion extends generally parallel to the screen
section.
7. The gutter screen of claim 6 wherein the forwardly extending
portion is at an angle of approximately 45 degrees from the
rearwardly extending portion.
8. A combination rain gutter and gutter screen, the rain gutter
comprising front, back and bottom walls and a flange projecting
rearwardly from the front wall of the gutter and spaced above the
bottom wall of the gutter, the flange extending substantially
continuously along the entire length of the gutter, and a hanger
for hanging the gutter under the edge of a roof, the hanger
extending forwardly from the back wall of the gutter to a position
under the gutter flange; the gutter screen comprising an expanded
metal screen section covering the gutter, an integral front edge
margin bent to form a forwardly-opening channel generally V-shaped
in transverse section extending continuously along the entire
length of the screen for receiving the gutter flange therein, the
forwardly-opening channel including: an upper rearwardly extending
portion bent back from the front edge of the screen section and
overlying the gutter flange and engaging the gutter flange along
substantially the entire length of the gutter screen for supporting
the screen on the flange and to inhibit sagging of the screen, and
a lower forwardly extending portion bent forward from the upper
rearwardly extending portion and underlying the gutter flange, the
upper and lower portions being divergent in the forward direction
with respect to the channel to form a relatively wide channel mouth
for permitting ready passage of the gutter flange through the
channel mouth during installation into the installed position where
the gutter flange is between the upper and lower portions, the
gutter screen further having a rear edge margin engaging the gutter
hanger on the back wall of the gutter, the gutter screen being
resiliently bent to an arcuate configuration in which the front
edge margin and rear edge margin are in pressure engagement with
the gutter and gutter hanger thereby securely maintaining the
gutter screen on the gutter, the gutter screen being formed
integrally of a single piece of elongate, flexible, resilient
metal, the lower forwardly extending portion of the channel and the
rear edge margin being solid, unperforated metal for stiffening the
gutter screen, for facilitating safe handling of the screen and for
ease of installation.
9. A gutter screen as set forth in claim 8 wherein at least a
portion of the upper rearwardly extending portion is solid,
unperforated metal.
10. A gutter screen as set forth in claim 8 wherein all of the
front edge margin is solid, unperforated metal.
11. A gutter screen as set forth in claim 8 wherein the screen
section includes criss-crossing ribs extending at non-perpendicular
angles to the edge margins.
12. A gutter screen as set forth in claim 8 wherein the screen is
made of an aluminum alloy.
13. A gutter screen as set forth in claim 8 wherein the upper
rearwardly extending portion extends generally parallel to the
screen section.
14. A gutter screen as set forth in claim 8 wherein the forwardly
extending portion is at an angle of approximately 45 degrees from
the rearwardly extending portion.
15. A metal gutter screen adapted for covering a gutter and
preventing leaves and debris from falling into the gutter from a
roof above the gutter, the gutter having front, back and bottom
walls and a flange projecting rearwardly from the front wall of the
gutter and spaced above the bottom wall of the gutter, said flange
extending substantially continuously along the entire length of the
gutter, the gutter supported by a hanger extending forward from the
back wall of the gutter to a position under the gutter flange, the
gutter screen comprising: an expanded metal screen section for
covering the gutter, a front edge margin sized and shaped to engage
the gutter, the front edge margin having no sharp edges, a rear
edge margin sized and shaped to engage at least one of the gutter
hanger and the roof, the rear edge margin having no sharp edges,
the screen section being generally planar when uninstalled, the
gutter screen being formed of a single piece of elongate, flexible,
resilient metal, the gutter screen including strands and
non-circular holes between the strands in at least the screen
section, the strands and non-circular holes being sized and shaped
to prevent leaves and debris from falling into the gutter, the
front edge margin being solid, unperforated metal for stiffening
the gutter screen, for facilitating safe handling of the screen and
for ease of installation.
16. The metal screen of claim 15 wherein each strand has a width
between 0.02 inches and 0.05 inches and the holes have a diamond
shape with a length of between 0.25 and 0.63 inches to prevent
leaves and debris from falling into the gutter
17. The metal screen of claim 16 wherein the screen is formed by
expanding a single piece of metal.
18. The metal screen of claim 17 installed over the gutter, the
rear edge margin engaging the roof.
19. The metal screen of claim 17 installed over the gutter, the
rear edge margin engaging the gutter hanger.
20. The metal screen of claim 17 wherein the strands are about 0.04
inches.
21. The metal screen of claim 20 wherein the rear edge margin is
solid, unperforated metal.
Description
BACKGROUND OF THE INVENTION
[0001] This invention relates generally to rain gutters, and more
particularly to a solid edge gutter screen for such gutters.
[0002] Since leaves and other debris frequently clog up rain
gutters, some kind of guard or screen which prevents leaves from
falling into the gutter is desirable. However, cheap conventional
gutter screens may become overburdened by such debris and collapse
into the gutter, thereby aggravating the problem instead of solving
it.
[0003] One popular type of gutter screen S (FIG. 9) is designed so
that the back edge slides under the shingles and the front edge
lays on top of the gutter. This screen has diamond-shaped openings
extending transverse to a longitudinal axis of the screen. The long
edges LE (the front and back edges) are very sharp due to the
orientation of the openings, and the sharp back edge often snags
against the shingles, making it hard to install. Also, there is a
significant risk the installer will cuts his hands on these sharp
edges. Despite these drawbacks, this screen is sold because it is
cheap to manufacture, requiring limited manual labor. The screen is
formed by feeding a coil of metal into an expanding machine in a
continuous process. Some screens eliminate the sharp front edge by
covering it with a solid metal bar that is made separate from the
screen portion. This metal bar is roll-formed into a Z-shaped
cross-section on a roll-former machine. The front edge of the
screen is inserted into one of the channels of the Z-shaped
cross-section. A pinch roller pinches the channel to fasten the bar
and the screen together. The front edge thereby has a solid smooth
front edge, and the risk of cutting the installer's hands is
reduced or eliminated. However, the back edge is left very sharp
and can still snag the shingles.
[0004] Another popular screen has what is called a "bonded edge,"
meaning that the diamond-shaped openings extend longitudinally,
rather than transverse to the screen length. This screen is also
produced using an expanding machine, but is produced "by length
size". Importantly, the length size is actually determined by the
width of the input coil, rather than input coil length. For
example, a 4 foot long screen uses a 4 foot wide coil. If the
product design requires a 5 inch wide by 4 foot long section, the
expanding machine is set for 5 inches. When the expanded material
reaches 5 inches, the machine must stop, the material is then
sheared and the expanding machine starts over. The operator stacks
the loose sections and moves them to a roll-former to bend or form
a desired screen profile. At this secondary roll-former station,
the operator manually inserts each piece through the roll-former to
produce a finished screen.
[0005] This latter screen is more expensive than the
first-mentioned screen because of all the manual labor and time
required in manufacturing. However, the screen is an improvement
over the above-mentioned screen because of the semi-smooth long
edges or "bonded edges." While each bonded edge is irregular in
shape due to the diamond holes, it is not a sharp edge. With the
smoother long edges, the operator will not cut his hands during
installation, and the back edge will not snag on the shingles.
Thus, though it is higher priced, the screen is easier to
install.
[0006] The gutter screen of U.S. Pat. No. 4,907,381 represents one
satisfactory solution to the above problems. However, the process
of making this gutter screen is also time-consuming and relatively
expensive. Moreover, the material required is relatively heavy and
expensive.
SUMMARY OF THE INVENTION
[0007] In one aspect, the invention is directed to a metal gutter
screen adapted for covering a gutter and preventing leaves and
debris from falling into the gutter. The gutter has front, back and
bottom walls and a flange projecting rearwardly from the front wall
of the gutter and spaced above the bottom wall of the gutter. The
flange extends substantially continuously along the entire length
of the gutter and the gutter is supported by a hanger extending
forward from the back wall of the gutter to a position under the
gutter flange. The gutter screen comprises an expanded metal screen
section for covering the gutter. A front edge margin is bent to
form a forwardly-opening channel generally V-shaped in transverse
section extending substantially continuously along the entire
length of the screen for receiving the gutter flange therein. The
forwardly-opening channel includes an upper rearwardly extending
portion bent back from the front edge of the resilient member and
adapted to overlie the gutter flange and engage the gutter flange
for supporting the screen on the flange and to inhibit sagging of
the screen. A lower forwardly extending portion is bent forward
from the upper rearwardly extending portion and is adapted to
underlie the gutter flange. The upper and lower portions are
divergent in the forward direction with respect to the channel to
form a relatively wide channel mouth for permitting ready passage
of the gutter flange through the channel mouth into a position
where the gutter flange is between the upper and lower portions. A
solid, unperforated rear edge margin is adapted for engaging the
gutter hanger. The screen section is generally planar when
uninstalled and is adapted to be resiliently bent to an arcuate
configuration in which the front edge margin and rear edge margin
are adapted for pressure engagement with the gutter and gutter
hanger to thereby securely maintain the gutter screen on the
gutter. The gutter screen is formed integrally of a single piece of
elongate, flexible, resilient metal. At least the lower forwardly
extending portion of the channel and the rear edge margin are
solid, unperforated metal for stiffening the gutter screen, for
facilitating safe handling of the screen and for ease of
installation.
[0008] Another aspect is directed to a combination rain gutter and
gutter screen. The rain gutter comprises front, back and bottom
walls and a flange. A hanger supports the gutter under the edge of
a roof. The gutter screen comprises an expanded metal screen
section covering the gutter. An integral front edge margin is bent
to form a forwardly-opening channel generally V-shaped in
transverse section extending continuously along the entire length
of the screen for receiving the gutter flange therein. The
forwardly-opening channel includes an upper rearwardly extending
portion bent back from the front edge of the screen section and
engaging the gutter flange along substantially the entire length of
the gutter screen for supporting the screen on the flange and to
inhibit sagging of the screen. A lower forwardly extending portion
is bent forward from the upper rearwardly extending portion and
underlies the gutter flange. The upper and lower portions are
divergent in the forward direction with respect to the channel to
form a relatively wide channel mouth for permitting ready passage
of the gutter flange through the channel mouth during installation
into the installed position where the gutter flange is between the
upper and lower portions. The gutter screen further has a rear edge
margin engaging the gutter hanger on the back wall of the gutter.
The gutter screen is resiliently bent to an arcuate configuration
in which the front edge margin and rear edge margin are in pressure
engagement with the gutter and gutter hanger thereby securely
maintaining the gutter screen on the gutter. The gutter screen is
formed integrally of a single piece of elongate, flexible,
resilient metal. The lower forwardly extending portion of the
channel and the rear edge margin are solid, unperforated metal for
stiffening the gutter screen, for facilitating safe handling of the
screen and for ease of installation.
[0009] In still another aspect, a metal gutter screen comprises an
expanded metal screen section for covering the gutter. A front edge
margin is sized and shaped to engage the gutter, the front edge
margin having no sharp edges. A rear edge margin is sized and
shaped to engage at least one of the gutter hanger and the roof,
the rear edge margin having no sharp edges. The screen section is
generally planar when uninstalled. The gutter screen is formed of a
single piece of elongate, flexible, resilient metal. The gutter
screen includes strands and non-circular holes between the strands
in at least the screen section. The strands and non-circular holes
are sized and shaped to prevent leaves and debris from falling into
the gutter. The front edge margin is solid, unperforated metal for
stiffening the gutter screen, for facilitating safe handling of the
screen and for ease of installation.
[0010] Other features of the present invention will be in part
apparent and in part pointed out hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a transverse cross-section of a gutter screen of
one embodiment on a gutter;
[0012] FIG. 2 is a top plan view of the gutter screen and gutter of
FIG. 1;
[0013] FIG. 3 is a transverse cross-section of the gutter screen
but showing the screen unbent prior to installation in the
gutter;
[0014] FIG. 4 is a transverse cross-section of another embodiment
of the gutter screen;
[0015] FIG. 5 is a fragmentary plan view of another embodiment of
the gutter screen;
[0016] FIG. 6 is a fragmentary plan view of yet another embodiment
of the gutter screen;
[0017] FIG. 7 is a transverse cross-section of a gutter screen of
still another embodiment on a gutter;
[0018] FIG. 8 is a transverse cross-section similar to FIG. 7 but
showing the screen of FIG. 6 on a gutter;
[0019] FIG. 9 is a fragmentary plan view of a prior art gutter
screen.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0020] Now referring to FIGS. 1 and 2, a gutter screen of one
embodiment of the present invention is designated in its entirety
by the reference numeral 1. Gutter screen 1 is particularly adapted
for covering a conventional rain gutter, such as indicated
generally at 3, and preventing leaves, debris and the like from
falling into the gutter. Note that the gutter screen is not made of
hardware cloth or wire mesh.
[0021] As shown in FIG. 1, gutter 3 has a front wall 5, a back wall
7 and a bottom wall 9, which form a channel 11 for drainage of
rainwater. Front wall 5 may be provided with a decorative and/or
strengthening configuration, as shown. A conventional lip or flange
13 projects rearwardly from the front wall 5 and is spaced above
the bottom wall 9 of the gutter 3. The flange 13 extends
substantially continuously along the entire length of the gutter
3.
[0022] Gutter 3 is suitably attached to the outside wall 15 of a
building by gutter hangers, one of which is shown and designated
17. The hanger 17 has a back portion 19 bent to hook over the back
wall 7 of gutter 3 and adapted to receive a fastening device, such
as a screw or nail, to secure the gutter to a cornice or fascia 21
on wall 15 adjacent the roof 23. Hanger 17 extends over channel 11
to a section 25 of front wall 5 under flange 13 to support the
front wall and reinforce it against inwardly directed pressures. A
front portion 27 of hanger 17 is bent to fit inside flange 13 to
reinforce the front wall 5 against outwardly directed forces.
[0023] The gutter screen 1 has an integral rear edge margin 29
adapted for engaging a bend 31 on hanger 17 adjacent back wall 7 of
the gutter 3, and an integral front edge margin 33 extending
generally parallel to the rear edge margin. Front edge margin 33 is
bent to form a forwardly-opening channel 35 having a generally
V-shaped configuration in transverse section and is thereby adapted
for receiving flange 13 therein. For example, a rearwardly
extending upper portion 37 may be bent back from the front edge 33
of the screen member 1 so as to extend generally parallel to the
screen member, and a forwardly extending lower portion 39 may be
bent forward from the upper portion at an angle of approximately
forty-five degrees therefrom to form channel 35. Upper and lower
portions 37, 39 are divergent in the forward direction relative to
the channel 35 to form a relatively wide channel mouth for ready
passage of the gutter flange 13 through the mouth into a position
where the flange is disposed between the portions and the screen 1
is thereby securely engaged in the gutter 3. The upper and lower
portions 37, 39 engage the gutter flange 13 substantially
continuously along the entire length of the screen 1.
[0024] The gutter screen 1 is formed of flexible resilient metal,
such as an aluminum alloy or steel alloy, and is of integral
construction, i.e., it is formed from a single continuous piece of
metal. The integral rear edge margin 29 and the integral front edge
margin 33 are both solid, unperforated metal. This solid,
unperforated metal strengthens the screen 1. This strengthening
function allows a lighter, less expensive material, such as
aluminum allow to be used. The solid long edges are not sharp like
the prior art, thus enabling safer handling and easier
installation.
[0025] An expanded metal screen section 40, disposed between the
rear and front edge margins 29, 33, is adapted to cover the gutter
channel 11. The screen section includes criss-crossing ribs 41, 43
extending at non-perpendicular angles.
[0026] In a second embodiment 1' (FIG. 4), the criss-crossing ribs
41', 43' continue into the front edge margin 33'. As shown, only a
small area of the upper portion 37' is solid metal. But the lower
portion 39' of the channel 35' is made entirely of solid,
unperforated metal.
[0027] The width of the gutter screens 1, 1' (i.e., from front edge
margin to rear edge margin) is greater than the width of the gutter
3 (i.e., between bend 31 of the hanger 17 and flange 13) so that
the screen may be resiliently bent to the arcuate configuration
shown in FIG. 1 wherein the front edge margin and rear edge margin
of the screen member are in pressure (spring-like) engagement with
the gutter and gutter hanger, respectively, thereby securely to
maintain the gutter screen on the gutter until such time as it is
manually removed. The arched configuration of the screens 1, 1'
also increases the load-bearing capability of the screens. As shown
in FIGS. 3 and 4, however, the screen section is generally planar
when uninstalled.
[0028] In another embodiment shown in FIG. 5, gutter screen 1''
includes a front edge margin 33'' that is not bent. However, the
front edge margin is solid, unperforated metal. The rear edge
margin 29'' is a bonded edge, meaning that it is smooth, but not
solid metal. In another embodiment, screen 1''' shown in FIG. 6,
the rear edge margin 29''' also includes solid, unperforated
metal.
[0029] The screens of this invention may be secured in other ways.
For example. In FIG. 7, the rear edge margin 29 of the screen 1 is
slipped under the shingles and the front edge margin 33 is secured
to the gutter flange as described above. In FIG. 8, the front edge
margin 33'' of screen 1'' simply rests on the gutter flange 13.
[0030] Gutter screens of the invention are suitably manufactured in
an expanding machine, though other manufacturing methods are
contemplated within the scope of the invention. For example, a coil
of metal can be slit and expanded in a one-step process that is
less expensive and faster than prior art manufacturing methods.
[0031] As described in the Background section, many "expanded
metal" screen products have disadvantages because they are either
cheaply manufactured with sharp edges or produced with a more
costly semi-smooth bonded edge. A new method of expanding gutter
screen is possible with a new expanding machine that combines the
economical expanded width method with smooth long edges. In other
words, this new method eliminates the sharp long edges without the
costly manual labor required in the above-described secondary stage
of roll-forming. This new method forms a screen having either a
solid single edge and a bonded edge (FIG. 5), or two solid edges
(FIGS. 1-4 and FIG. 6), and does so efficiently by coil length,
rather than by coil width. There are no machines on the market that
produce a single solid edge (or two solid edges) by coil length,
and such screens have not been used in the gutter industry. There
are also expanding machines that produce expanded screen coil with
a semi-smooth bonded edge, like in the plaster lath industry. The
plaster lath industry does not require precise dimensional control.
Plaster lath is non-uniform, with holes that are too large for use
as gutter screens.
[0032] This new gutter screen can now be economically designed with
the precise tolerance needed because of advancements made in
expanding machines. The precise tolerance relates to the screen
strand width and the length and width of the holes.
[0033] In the above embodiments, a strand width of the screen
ranges from 0.02 and 0.05 inches, e.g., about 0.04 inches. This
strand width is significantly smaller, and proven to be
significantly better for gutter screen than lath. The lath strand
width is non-uniform and varies from 0.0625 to 0.125.
[0034] In these embodiments, each hole has a non-circular shape,
e.g., a diamond shape. Each diamond has a long dimension, (commonly
referred to as LWD) of between 0.25 and 0.63 inches, e.g., about
0.50 inches. Each diamond has a short dimension (SWD) of between
0.13 and 0.38, e.g., about 0.25 inches. These dimensions are
significantly smaller, more uniform and proven to be better than
lath. The lath holes have a long dimension varying from 0.75 to
1.00 inch and the short dimension varies from 0.38 to 0.50
inches.
[0035] When introducing elements of the present invention or the
preferred embodiment(s) thereof, the articles "a", "an", "the" and
"said" are intended to mean that there are one or more of the
elements. The terms "comprising", "including" and "having" are
intended to be inclusive and mean that there may be additional
elements other than the listed elements.
[0036] As various changes could be made in the above constructions
without departing from the scope of the invention, it is intended
that all matter contained in the above description or shown in the
accompanying drawings shall be interpreted as illustrative and not
in a limiting sense. For example, the various gutter screen
profiles shown herein can be installed over the gutter in a variety
of ways.
* * * * *