REAR RECEIVER FOR USE WITH GUTTER GUARD SYSTEMS
A modular platform for configuring gutter guard systems is disclosed and claimed herein. Such gutter guard systems are designed and arranged to be positioned across the opening of a rain gutter to prevent debris from entering the rain gutter. The modular platform includes a number of interchangeable components. Select interchangeable components can be assembled to form a gutter guard system for use with a specific rain gutter based on the rain gutter's style, size, color and the mechanism used to secure the rain gutter to a structure and/or roofline. In one embodiment, a rear receiver is arranged such that it can accommodate a number of interchangeable component to reduce the number of components needed to accommodate various gutter guard system and provide more versatility to the gutter guard system.
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This Application is a continuation-in-part application of (i) pending U.S. patent application Ser. No. 17/820,714, titled System and Methods for Modular Platform For Gutter Guard Systems with Interchangeable Components” and filed on Aug. 18, 2022, which is a continuation-in-part of U.S. patent application Ser. No. 17/328,609, titled “Rear Receiver and Methods for Use with Modular Platform for Gutter Guard Systems with Interchangeable Components” and filed on May 24, 2021, which is a divisional of pending U.S. patent application Ser. No. 16/204,140, titled “Rear Receiver and Methods for Use with Modular Platform for Gutter Guard Systems with Interchangeable Components” and filed on Nov. 29, 2018, which is a continuation of U.S. patent application Ser. No. 16/126,487, titled “Main Bodies and Methods for use with Modular Platform for Gutter Guard System with Interchangeable Component” and filed on Sep. 10, 2018, which is a continuation-in-part of U.S. patent application Ser. No. 16/049,233, titled Systems and Methods for Modular Platform for Gutter Guards Systems with Interchangeable Components” and filed on Jul. 30, 2018, which claims priority to pending U.S. Provisional Patent Application Ser. No. 62/618,210, titled “Systems and Methods for Modular Platform for Gutter Guards Systems with Interchangeable Components” and filed on Jan. 17, 2018, and (ii) U.S. patent application Ser. No. 18/051,165, titled “Modular Assembly for Gutter Guard Systems with Customizable Main Bodies and Screens” and filed on Oct. 31, 2022. Each of the forgoing related applications and any subsequent issued patents are expressly incorporated by reference herein in its entirety.
FIELD OF INVENTIONThe present disclosure generally relates to systems and methods for preventing debris from entering rain gutters while optimizing water flow and infusion into the rain gutter. More specifically, the present disclosure relates to a modular platform for gutter guard systems with interchangeable components for: 1) forming gutter guard systems for positioning onto a variety of rain gutter styles and sizes for a variety of structures and rooflines; 2) preventing debris from entering the rain gutters once the gutter guard system is positioned onto the rain gutter; and 3) managing the flow of water across the gutter guard system such as to optimize the infusion of the water into the rain gutter. In particular, the present disclosure relates to interchangeable rear receiver components that can accommodate a variety of main bodies used for forming gutter guard systems and secure such gutter guard systems to a structure or a rain gutter attached to a structure.
BACKGROUNDRain gutter systems are commonly used for residential homes, building, and other structures to manage rainwater by collecting the rainwater and channeling that rainwater away from the structure. Such management of rainwater can be critical for the overall maintenance and condition of the structure by reducing or eliminating damage to the structure and its foundation that can be caused by uncontrolled rainwater. Gutter guards are components or systems that are typically attached to or incorporated into rain gutters to prevent leaves, pine needles, branches, soot, and other such debris from entering the rain gutter. Such debris can clog the rain gutter and reduce its effectiveness in channeling rainwater away from a residential home, building, or other structure. In addition, such debris can damage and shorten the service life of a rain gutter system by causing corrosion, pitting, or other deleterious effects on the rain gutter system. Unfortunately, prior art gutter guard systems do not effectively channel water away from a structure. Inefficient water management designs, matting of debris onto the gutter guard system over time, and ill-fitting gutter guard systems cause unnecessary damage to homes and other structures, which reduces property values, increases maintenance costs, and causes dangerous conditions for occupants of structures.
Gutter guards are typically manufactured to fit a specific style and specific size of rain gutter. Such gutter guards are typically manufactured as a single component or assembly of subcomponents, where the subcomponents are irreversibly joined together. Thus, gutter guard manufacturers, distributors, and/or dealers typically choose between making and/or stocking a limited number of products that accommodate a limited segment of the market or making and/or stocking a large number of products to accommodate the substantial number of variations of rain gutter guards.
There are many different sizes and styles of rain gutters on the market in the United States and internationally. The differences in rain gutter sizes and styles are driven by a number of factors including different architectural styles for homes and buildings in different geographical regions and regional homebuilder and contractor trade practices that develop over time. Such different architectural styles can also be driven by differences in climate and weather patterns (for example, annual rain and snow fall), historical influences, availability of building materials, and so on. The different architectural styles often dictate the rooflines of structures, which in large part dictates the style and size of rain gutters and how the rain gutter is attached to the structure/roofline. The term “structure” is used herein generically to mean a residential home, multi-residential buildings, office buildings, warehouses, commercial building, or any other structure for which rain gutter systems are used to channel rainwater away from the structure. The term “roofline” is used herein generically to mean the intersection of the underside of the roof of a structure with the exterior walls of the structure and/or other proximal exterior features such as rafter tails, fascia board, starter strips, flashing, drip edges, and so on. Once a particular style of rain gutter becomes dominant in a region or market, the regional or local homebuilder and contractor trade practices are heavily influenced by the dominant rain gutter style and homebuilders and installation contractors become accustomed to installing that rain gutter style, thus reinforcing the dominance of the rain gutter style in the geographic region. The particular size of this dominant style gutter is variable due to considerations such as the surface area of the roof of a specific structure and regional architectural influences.
As will be appreciated from the following discussion, the number of variations in types of rain gutters, sizes of rain gutters, mechanisms for securing rain gutters to structures and/or rooflines, etc. creates a plethora of potential combinations of rain gutter arrangements. Thus, designing a generic gutter guard product to accommodate such a large number of potential combinations is a challenge that has yet to be met in the marketplace.
With regard to standard rain gutters, there are generally three styles that make up a majority of the market— “K-style” gutters, “half-round gutters,” and “fascia-style” gutters.
Examples of exemplary hardware and accessories used to attach half-round gutters to structures and/or rooflines are illustrated in
It will be appreciated that with such diversity in attachment mechanisms used with a half-round gutter, it is difficult to anticipate the specific requirements and/or challenges for installing a gutter guard system because of the unpredictability of what portions of attachment mechanisms are extending from within and/or around the body of the gutter and/or what obtrusions and/or obstructions are present along the front lip 40, 60 and rear lip 36, 56. Sizes for half-round gutters 30, 50 are determined by the approximate distance from the front lip 40, 60 of the front section to the reinforced rear lip or hem 36, 56 of the back section 34, 54 and typically come in sizes from about four inches to about six inches.
The extended edge or wing 82 illustrated in
Additional types of more ad hoc rain gutters include trough-style and built-in gutter systems. Such systems present unique problems for manufacturers and distributors of gutter guards. Generally, a trough-style gutter system is a rain gutter system that is integrally incorporated into a roof of a house or other structure. Trough-style gutter systems are incorporated into the roof above the roofline and are often formed from flashing and other common roofing materials.
Both the trough-style and built-in gutter systems are prone to issues of debris collection in the trough or box gutter and the clogging issues that result from such debris collection. For trough-style gutters, the lining material (rubber sheeting, tar paper, etc.) discussed above functions to protect the structure from water damage. Debris interacting with this lining material can puncture or otherwise damage the lining material, which can result in water passing through the lining material and damages the structure. Additionally, when the roof is arranged at a steep incline and/or the structure is subject to heavy and sustained rainfall, rainwater can flow rapidly into the trough-style and built-in gutter systems, overwhelming such rain gutter systems resulting in rainwater flowing over the rain gutter system and falling to the ground at the base of the home or structure.
Thus, both the trough-style and built-in gutter systems can greatly benefit from the installation of gutter guard systems. However, as will be appreciated, all trough-style gutter systems are custom built and do not adhere to any general standards of design, size, or dimensions. Additionally, built-in gutter systems also include significant customization in general design that facilitates installation of the system into a roof. Thus, built-in gutter systems also do not adhere to standard sizing and dimensions. It will be appreciated that with such diversity in design, size, and dimensions, it is difficult to anticipate the specific requirements and/or challenges for installing a gutter guard system in trough-style or built-in gutter systems because of the unpredictability of the design, size, and dimensions. Because of the variety of requirements, there are no current gutter guard products that are applicable to trough-style and built-in gutter systems.
Throughout this disclosure rain gutters will be described by reference to the rain gutter “size,” i.e., four inch, five inch, etc. However, it will be understood that such descriptions of size do not indicate that a rain gutter is exactly four inches or five inches in width. Such naming conventions indicate to those in the industry that a rain gutter is approximately four inches in width or five inches in width. Additionally, certain rain gutter styles are described as typically coming in a range of sizes. It will be understood that such styles of rain gutters can come in larger or smaller sizes as well, where size of gutter is typically determined by the volume of rain water that the rain gutter will be expected to handle, which in turn is determined by the surface area of the roof of a structure and the local climate. Such wide variations and approximations in size of rain gutters further complicate the task of designing gutter guard systems for rain gutters.
Because of the variety of sizes and styles of gutters in the marketplace, current business models in the industry are for manufacturers, distributors, and/or dealers to manufacture and/or stock a limited number of gutter guard products that accommodate a limited segment of the market, or to manufacture and/or stock a large number of gutter guard products to accommodate the large number of variations of rain gutters. Such approaches are both limited and inefficient. There is a need for improvement to existing gutter guards, systems, and/or methods for gutter guard protection to accommodate a more efficient and effective business model for manufacturing, distributing, and installing gutter guards to the diverse and disparate national and regional marketplace.
SUMMARYA modular platform for configuring gutter guard systems is disclosed and claimed herein. Such gutter guard systems are designed and arranged to be positioned across the opening of a rain gutter to prevent debris from entering the rain gutter. The modular platform includes a number of interchangeable components. Select interchangeable components can be assembled to form a gutter guard system for use with a specific rain gutter based on the rain gutter's style, size, color, and the attachment mechanism used to secure the rain gutter to a structure and/or roofline.
In one embodiment, the components of a modular platform for configuring gutter guard systems include a number of main bodies, a front receiver, a number of rear receivers, and a number of screens. Such components are arranged to be interchangeable. This is to say that, for example, components such as a main body can be used with some or all of the front receivers and rear receivers. Such arrangements can result in the components combining to form a substantially large number of combinations for use with a substantially large number of different rain gutters, attachment mechanisms, and accompanying structures and/or rooflines.
In one embodiment of a rear receiver, the rear receiver is arranged to accommodate a number of varying gutter guard systems with various main bodies to facilitates securing the gutter guard system to the rear of a rain gutter or to the structure itself. Such a rear receiver includes a first member running the length of the rear receiver, a second member running the length of the rear receiver parallel to the first member, and a connecting member running the length of the rear receiver that connects the first member and second member. The connecting member is generally perpendicular to the first and second members. A first end of the connecting member terminates at its connection with the first member and a second end of the connecting member extending past the second member and terminating in space. A channel is formed between the first member, second member, and a portion of the connecting member. One or more apertures are formed in the connecting member along the length of the rear receiver. The channel is arranged to accommodate any number of main bodies and/or combinations of main bodies and mesh screens. The apertures are arranged such that the rear receiver, and thus a gutter guard system, can be secured to a rain gutter or directly a structure with a rain gutter.
In the accompanying drawings, structures are illustrated that, together with the detailed description provided below, describe example embodiments of the disclosed systems, methods, and apparatus. Where appropriate, like elements are identified with the same or similar reference numerals. Elements shown as a single component can be replaced with multiple components. Elements shown as multiple components can be replaced with a single component. The drawings may not be to scale. The proportion of certain elements may be exaggerated for the purpose of illustration.
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 modular platforms that include a number of interchangeable components that can be assembled to form gutter guard systems for use with a variety of rain gutters based on the rain gutters' style, size, and the attachment mechanism used to secure the rain gutters to a structure and/or roofline are hereinafter disclosed and described in detail with reference made to
As will be described in detail herein, an exemplary embodiment of a novel gutter guard system includes four major components: a main body, a front receiver, a rear receiver, and a screen. Such components can be assembled to form the gutter guard system and subsequently positioned proximate to the top opening of a rain gutter installed on a structure. Typically the gutter guard system generally spans the top opening of the rain gutter. The gutter guard system includes certain features that are arranged to effectively and efficiently channel rainwater away from the structure and into the rain gutter. The gutter guard system further includes other features arranged to block debris from entering the rain gutter.
Each component of the gutter guard system can be made in a plurality of styles and/or sizes to accommodate various styles, shapes, materials, sizes, and colors of rain gutters. For example, the main body can be made in different widths to accommodate different sizes of rain gutter, such as three inch rain gutters, four inch rain gutters, five inch rain gutters, five and a half inch rain gutters, and six inch rain gutters. 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 injection molding, additive manufacturing (i.e., 3D printing), machining, metal casting, metal stamping and the like. In some embodiments, more than one manufacturing process can be used. For example, a main body can be machined after it is formed via injection molding or a polymer can be injection molded or 3D printed onto a stamped metal component. When an injection molding process is used, any polymeric material can be used that has acceptable flow characteristics for injection molding that yields a main body with relatively rigid properties.
In another example, the structure of the front and rear receivers relative to the main body can be arranged to accommodate both different style of rain gutters, such as K-style, half-round, fascia style, and even custom designed rain gutters and different structures and rooflines dictated by different architectural styles. One novel feature of the components of a gutter guard system is that the components can be arranged to be interchangeable such that the gutter guard systems can be quickly and easily assembled to accommodate a large variety of styles, shapes, materials, sizes, and color of rain gutters and structures and rooflines of various architectural styles. The components are designed such that the assembly of components into a gutter guard system can be accomplished at the place of manufacture, at a distributor's or dealer's facility prior to shipping to job site, or at the job site itself just prior to installation. The front and rear receivers can be fabricated from any number of materials such as metal or relatively rigid polymeric material such as polyvinyl chloride (PVC), polyethylene (PE), and/or polyolefin (PO). The front and rear receivers can be fabricated using a variety of methods including extrusion, injection molding, additive manufacturing (i.e., 3D printing), machining, metal casting, metal stamping and the like. Similar to the main body, in some embodiments, more than one manufacturing process can be used to fabricate the front and rear receivers. As will be further explained herein, coatings and/or films of various colors can be applied to the front and rear receivers to enhance the aesthetic appeal and weather resistance of the front and rear receivers.
Another novel feature of the components is that once the components are assembled into a gutter guard system, the system can be disassembled and the components reused in different arrangements. This is to say, for example, different styles of front and rear receivers can be assembled with the different sizes of main bodies. If a gutter guard system were to be installed in a four inch K-style gutter, front and rear receivers for K-style gutters can be assembled with a three inch main body. Conversely, the same front and rear receivers can be assembled with a four inch main body for a five inch K-style gutter, and the four inch main body can be assembled with front and rear receivers for half round gutters in order to install on a five inch half round gutter. Thus, creating multiple combinations to accommodate multiple size and styles of gutters and different structures and rooflines. Furthermore, an installed gutter guard system can be upgraded after installation. For example, a gutter guard system can be assembled with a certain front receiver and subsequently upgraded by disassembling the front receiver and replacing it with a front receiver that includes a heating element to manage the formation of ice during winter months. In such an arrangement, all the components of the gutter guard system remain the same except for the front receiver. It will be understood that the examples provided herein are exemplary only and that any number of components can be reused or interchanged when configuring a gutter guard system.
Referring to
The main body 110 can be manufactured in different widths to accommodate different widths of rain gutter such as, for example, three inch, four inch, and five inch widths for residential use. Such an arrangement provides for structural integrity of the gutter guard system because the components are typically used as designed. It is currently common in the industry to cut or plane a larger main body (such as a six inch width) before assembly to accommodate a rain gutter with a smaller width (such as a four inch width). Such modifications before assembly result in degraded structural integrity and inferior gutter guard systems. The main body 110 of the present disclosure provides sufficient stiffness and strength such that the main body 110, and the gutter guard system 100 remains planar when installed on a rain gutter without the requirement for any ancillary support structures such as hangers and straps. The main body 110 provides the required rigidity despite the main body 110 having a greater percentage of open area than present gutter guard systems currently on the market. Thus, the combination of the main body 110 and the screen 140 result in greater percentage of open area to facilitate water infusion through the screen 140 and main body 110, while providing the rigidity and structural integrity required to efficiently install the gutter guard system 100 without the need for hangers, straps, and the like.
For structures, such as large homes or commercial buildings, with large roof surface areas, larger rain gutters can be utilized to accommodate the greater flow of rain water from the roof and into the rain gutter. For such larger rain gutters, including rain gutters that are six, seven, eight inches in width or more, the main body can be arranged generally as illustrated in
The channels of the front 120 and rear 130 receivers can be arranged such that the main body 110 can move laterally such that the width of the gutter guard system can be adjusted to accommodate for imperfections and different manufacturing tolerances amongst rain gutters. For example, as illustrated in
Securing the front 120 and rear 130 receivers and the main body 110 and screen 140 forms a stable assembly that can be unassembled as necessary. In another embodiment, the screen 140 can be secured to the main body 110 via a bonding method such as heat staking. The screen 140 can be placed on the main body 110 and subsequently set in place in a staking machine, where the screen 140 is heat staked to certain features on the top surface of the main body 110. As illustrated in
For installation of a gutter guard system 100 onto the rain gutter, the rear receiver 130 is designed to engage with the rear lip of the rain gutter (i.e., the lip that is closest to the roofline and/or structure), and the front receiver 120 is designed to engage with the front lip of the rain gutter (i.e., the lip that is spaced away from the roofline and/or structure). As will be subsequently discussed, front receivers and rear receivers can have a number of different designs, often driven by regional architectural styles, rooflines, structures, and contractor trade practices, to accommodate various installations for the gutter guard system 100.
In certain embodiments, the gutter guard system can be secured to the rain gutter, roofline, and/or the structure. For example, the front receiver can be secured to the front lip of the rain gutter with one or more fasteners, and the rear receiver can be secured to the rear lip of the gutter or secured directly to the roofline and/or structure with one or more fasteners. In yet another embodiment, clips or brackets can be used to secure or hold the gutter guard in position. It will also be understood that the gutter guard systems can also be positioned within a rain gutter without any fasteners, brackets, clips, or hangers. In such embodiments, features of the front and rear receivers can engage with the rain gutter to retain the gutter guard system within the rain gutter.
As will be appreciated, the gutter guard systems are installed at a downward angle so that rainwater from the roof of the structure flows away from the structure and/or roofline. The rainwater flows across the screen, where contact points between the screen and the main body encourage the flow of rainwater downward through the screen and main body and into the rain gutter. The main body can include a number of configurations to facilitate the flow of water downward into the rain gutter. Once installed, the elastomeric strip 150 extending from the rear receiver 130 can engage the side of the structure and/or roofline and seal the gutter guard system 100 against the structure and/or roofline to further facilitate the flow of rain water across the gutter guard system 100 and prevent the entrapment of debris between the side of the structure and/or roofline and the gutter guard system and/or rain gutter.
The embodiment of a main body 110 illustrated in
With regard to the arrangement of the apertures (400, 410, and 420) within a main body 110,
It will be appreciated that the positioning, shape, and arrangement of the apertures form a relatively rigid structure for the main body 110. Such rigid structure lessens the need for elements to support the gutter guard system once installed in a rain gutter. In certain embodiments, the main body 110 has sufficient rigidity for the gutter guard system 100 to be installed in a rain gutter without the need for any additional support structures such as hangers or similar hardware.
As will be understood upon reading and understanding this disclosure, the gutter guard system, particularly the main body 110, includes a number of features and combinations of features to manage water flowing across the gutter guard system that result in water flowing downward into the rain gutter. In addition to the large open areas provided by both the screen 140 and apertures in the main body 110, the main body includes extended edges 430 extending upward that contact the screen to encourage wicking of water downward into the rain gutter, extended edges 430 that extend downward from the main body 110 to create additional wicking and eliminate or reduce water walk, and the arrangement of apertures 400, 410, 420 into staggered columns (as illustrated in
While apertures as discussed and illustrated herein are described as oval, semi-oval, circular, truncated key-hole shaped and the like, it will be understood that this disclosure encompasses and includes arrangements of apertures in the main body that include a variety of specific shapes, a variety of specific locations, and a variety of mixture of different shaped apertures. It will be appreciated that embodiments of the main bodies and screens as disclosed herein include openings that facilitate and do not inhibit the flow of water through the screens and main bodies into the rain gutter. The proportions and relationship between the open areas of the main body and screen promotes a maximum and optimal infusion of water into the rain gutter. Additionally, the prevalence of wicking features further facilitates the flow of water from the screen and main body into the rain gutter. Additionally, openings in the main bodies and screens promote and maximize airflow through the screen, main body and rain gutter. Thus, providing the gutter guard system with a number of benefits. For example, such airflow provides for the rain gutter, gutter guard system, and any debris resting on the screen to dry quickly and efficiently. The drying of the gutter guard system and rain gutters can extend the longevity and durability of the gutter guard system and rain gutter. When debris resting on the gutter guard system dries quickly and efficiently, biological growth such as moss and mold are reduced or prevented. Also such efficient drying discourages attachment of debris to the screen or main body. The drying of debris makes it much more likely that such debris is carried away by winds or the next flow of water across the screen further reducing the ill effects of debris resting on the screen.
The gutter guard system 600 can be assembled such that the screen 640 is placed in contact with a top surface of the main body 610, a front receiver 620 is attached to a first or front edge the main body 610, and the rear receiver 630 is attached to a second and opposite edge or rear edge of the main body 610.
The front 620 and rear 630 receivers each include a channel (as illustrated in
Once assembled, the gutter guard system 600 can be placed onto or into a rain gutter to channel water into the rain gutter and stop debris from entering the rain gutter. As illustrated in
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, enhances 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.
As noted above, the main body 610 can be manufactured in different widths to accommodate different widths of rain gutter such as, for example, three inch, four inch, and five inch widths for residential use. As previously discussed, such an arrangement provides for structural integrity of the gutter guard system because the components are typically used as designed. There is no need to cut or plane a larger main body to accommodate a rain gutter with a smaller width. Additionally, the lattice or diamond pattern (hereinafter the “diamond pattern”) of the structural members of the main body 610 provides sufficient stiffness and strength such that the main body 610 and the gutter guard system 600 remain generally planar when installed on a rain gutter without the requirement for any ancillary support structures such as hangers and straps. The main body 610 provides the required rigidity despite the main body 610 having a greater percentage of open area than traditional gutter guard systems currently on the market. Thus, the combination of the main body 610 and the screen 640 result in greater percentage of open area to facilitate water infusion through the screen 640 and main body 610, while providing the rigidity and structural integrity required to efficiently install the gutter guard system 600 without the need for hangers, straps, and the like.
For structures, such as large homes or commercial buildings, with large roof surface areas, larger rain gutters can be utilized to accommodate the greater flow of rain water from the roof and into the rain gutter. For such larger rain gutters, including rain gutters that are six, seven, eight inches in width or more, the main body can be arranged generally as illustrated in the figures, but the width and thickness of the main body can be increased to accommodate substantially wider rain gutters and provide additional rigidity and structural integrity for the gutter guard system to span such substantially wider rain gutters. Such increased in width and thicknesses can be achieved by modifications to injection molding tooling, but such modifications can maintain the thickness of the edges of the main body such that the front and rear receivers as described herein can continue to be used to accommodate the assembly of gutter guard systems for substantially wider rain gutters. Additionally, a rear receiver can be widened or multiple rear receivers can be used with main bodies disclosed herein to span gutter openings greater than six inches in width.
In one embodiment, a sonic welding manufacturing process is used to join the first 680 and second 690 main body subsections. The first 680 and second 690 main body subsections include mating features that facilitate the sonic welding process. For example, as illustrated in detail views in
As best illustrated in
As illustrated in
As illustrated in
As illustrated in
In the exemplary embodiment, the mesh screen 820 is a series of threads secured together to form a lattice structure with the threads evenly spaced apart along the width (W) and length (L) of the mesh screen 820. In one embodiment, the threads are made of 316L stainless steel wire with a diameter of 0.0085 inches. The wires are secured together through weaving and spaced evenly along the length (L) and width (W) such that there are approximately thirty threads per inch along both the length (L) and width (W) of the mesh screen 820. In such an arrangement, the surface area of the screen includes approximately 55% open area. The mesh screen 820 forms a structure that provides a plurality of openings for rainwater to pass through; however, at the same time creates a barrier that stops unwanted debris from passing through the mesh screen 820. While the exemplary embodiment of the mesh screen 820 is described as a specific metal wire woven together, it will be understood that other materials and arrangements can be used to achieve the functionality of forming a mesh screen that simultaneously allows rainwater to pass through the mesh screen and stops unwanted debris from passing through the mesh screen.
In one embodiment, the mesh screen 820 can be positioned on top of the main body 110 and reply on the engagement of the mesh screen 820 and main body 810 with the front 830 and rear 840 receivers to maintain the position of the mesh screen 820. In another embodiment, the mesh screen 820 can be directly secured to the main body 810 by a spot welding process, adhesives, or other such methods.
In one embodiment, the front receiver 830 is arranged as follows. The extending front edge 860 is comprised of two sections—a straight section 862 and an angled section 864. The straight section 862 is arranged such that it is generally parallel with the lower front member 865, and parallel to the main body subassembly 850 once the front receiver 830 is assembled with the main body subassembly 850. The angled section 864 is positioned at an angle A that is approximately 16 degrees as compared to the straight section 862. In this embodiment, the width W1 of the channel 870 is approximately 0.226 inches and the height H1 of the channel 870 is approximately 0.200 inches. In this embodiment, the width W2 of the leg 880 is approximately 0.125 inches and the height H2 of the leg 880 is approximately 0.082 inches. It will be understood that such dimensions are exemplary only and can be altered to accommodate any number of varying main body subassemblies.
In one embodiment, the rear receiver 840 is arranged as follows. The extending rear edge 940 is comprised of two sections—a straight section 942 and an angled section 944. The straight section 942 is arranged such that it is generally parallel with the lower rear member 945, and parallel to the main body subassembly 850 once the rear receiver 840 is assembled with the main body subassembly 850. The angled section 944 is positioned at an angle C that is approximately 864 degrees as compared to the straight section 942. Additionally, the angle D between the angled section 944 and the connecting member 948 is approximately 117 degrees. In this embodiment, the width W3 of the channel 950 is approximately 0.677 inches and the height H3 of the channel 950 is approximately 0.200 inches. In this embodiment, the width W4 of the leg 960 is approximately 0.163 inches and the height H4 of the leg 260 is approximately 0.082 inches. It will be understood that such dimensions are exemplary only and can be altered to accommodate any number of varying main body subassemblies.
The various embodiments of gutter guard systems disclosed herein have generally been described as having a rear receiver that is designed to accommodate a specific gutter guard system. However, disclosed herein is also a rear receiver that is arranged to accommodate a number of different gutter guard systems.
As illustrated in
It will be appreciated from the examples illustrated in
In the arrangements illustrated in
The foregoing description of examples has been presented for purposes of illustration and description. It is not intended to be exhaustive or limiting to the forms described. Numerous modifications are possible in light of the above teachings. Some of those modifications have been discussed, and others will be understood by those skilled in the art. The examples were chosen and described in order to best illustrate principles of various examples as are suited to particular uses contemplated. The scope is, of course, not limited to the examples set forth herein, but can be employed in any number of applications and equivalent devices by those of ordinary skill in the art.
Claims
1. A rear receiver for use with gutter guard systems, the rear receiver comprising:
- a first member running the length of the rear receiver;
- a second member parallel to the first member running the length of the rear receiver; and
- a connecting member running the length of the rear receiver.
2. The rear receiver of claim 1, wherein the connecting member connects the first member and second member.
3. The rear receiver of claim 2, wherein the connecting member is generally perpendicular to the first member and perpendicular to the second member.
4. The rear receiver of claim 3, wherein the connecting member comprises:
- a first end; and
- a second end;
- wherein, the first end of the connecting member terminates at the first member and a second end of the connecting member extends past the second member and terminates in space.
5. The rear receiver of claim 4, wherein the connecting member engages with and is connected to the second member at a position located between the first end of the connecting member and the second end of the connecting member.
6. The rear receiver of claim 5, further comprising a channel formed by the first member, the second member, and a portion of the connecting member between the first end of the connecting member and the position at which the connecting member engages with the second member.
7. The rear receiver of claim 6, wherein the channel of the rear receiver is arranged to accommodate a plurality of main bodies of gutter guard systems.
8. The rear receiver of claim 7, further comprising a plurality of apertures through the connecting member.
9. The rear receiver of claim 8, wherein the plurality of apertures are located between the second end of the connecting member and the position at which the connecting member engages with the second member.
10. The rear receiver of claim 1, wherein the rear receiver is five feet in length.
11. The rear receiver of claim 1, wherein the rear receiver is arranged such that the rear receiver can be trimmed to a custom length.
12. A gutter guard system comprising:
- a main body comprising: a top surface; a bottom surface; a first edge; and a second edge;
- a screen positioned in contact with the top surface of the main body;
- a front receiver arranged to engage the first edge of the main body; and
- rear receiver arranged to engage the second edge of the main body, the rear receiver comprising: a first member running the length of the rear receiver; a second member parallel to the first member running the length of the rear receiver; and a connecting member running the length of the rear receiver.
13. The gutter guard system of claim 12, wherein the connecting member connects the first member and second member and the connecting member is generally perpendicular to the first member and perpendicular to the second member.
14. The gutter guard system of claim 13, wherein the connecting member comprises:
- a first end that terminates at the first member; and
- a second end that extends past the second member and terminates in space.
- wherein, the connecting member engages with and is connected to the second member at a position located between the first end of the connecting member and the second end of the connecting member.
15. The gutter guard system of claim 14, further comprising a channel arranged to accommodate the main body and formed by the first member, the second member, and a portion of the connecting member between the first end of the connecting member and the position at which the connecting member engages with the second member.
16. The gutter guard system of claim 15, wherein:
- the first member includes a first surface and a second surface; and
- the second member includes a first surface and a second surface.
17. The gutter guard system of claim 16, wherein the second surface of the first member and the first surface of the second member form a portion of the channel.
18. The gutter guard system of claim 17, wherein when the main body and screen are positioned within the channel, the screen engages the second surface of the first member and the bottom surface of the main body engages the first surface of the second member.
19. The gutter guard system of claim 17, wherein when the main body and screen are positioned within the channel, the screen engages the first surface of the second member and the bottom surface of the main body engages the second surface of the first member.
20. The gutter guard system of claim 17, wherein when the main body and screen are positioned within the channel, the top surface of the main body is at an angle to the second surface of the first member and the first surface of the second member.
21. The gutter guard system of claim 17, wherein when the main body are screen are positioned within the channel, the top surface of the main body is generally parallel to the second surface of the first member and the first surface of the second member.
22. The gutter guard system of claim 12, wherein the rear receiver further comprising a plurality of apertures through the connecting member, located between the second end of the connecting member and the position at which the connecting member engages with the second member.
Type: Application
Filed: Mar 3, 2023
Publication Date: Jun 29, 2023
Applicant: LeafFilter North, LLC (Hudson, OH)
Inventors: Michael Gori (Norton, OH), Jason Alan Crowell (Akron, OH)
Application Number: 18/178,350