AU2011100297A4

AU2011100297A4 - Gutter including a downpipe attachment means and method of manufacturing the same

Info

Publication number: AU2011100297A4
Application number: AU2011100297A
Authority: AU
Inventors: Kevin Blaik
Original assignee: BlueScope Steel Ltd
Current assignee: BlueScope Steel Ltd
Priority date: 2010-08-04
Filing date: 2011-03-17
Publication date: 2011-04-21
Anticipated expiration: 2018-08-04
Also published as: AU2010100836B4; AU2010100836A4

Description

1 Gutter including a downpipe attachment means and method of manufacturing the same The present invention relates to a gutter including integral attachment means for direct attachment of a downpipe thereto. In particular, the invention relates to a gutter including at least one punched downpipe tab configured to be neatly folded out to enable a correspondingly 5 shaped downpipe to be attached thereto without the need for separate connectors. The invention also relates to an apparatus and method of manufacturing such gutters. BACKGROUND OF THE INVENTION It has been common practice in securing downpipes to rain gutters to require a separate, additional connector to achieve the connection. Such additional connectors add cost to the 0 installation by the price of the connectors, and by the cost of the additional labour required for installation. There have been attempts at simplifying this process and removing the need for any additional connecting components. One such method has been to crudely punch out a portion of the bottom surface of the gutter and either placing a downpipe a spaced distance 5 therebeneath or frictionally attaching a downpipe to the punched out portion of the gutter. Such methods lend themselves to a number of problems including leakage, eventual rust, and an overall displeasing appearance. It is an object of the present invention to overcome the aforementioned problems, or at least provide the public with a useful alternative. 20 SUMMARY OF THE INVENTION Therefore, in one form of the invention there is proposed a method of manufacturing a gutter including at least one downpipe tab formed along its length, each downpipe tab being configured to be folded out to form a downwardly extending surface for attachment of a downpipe, said method including the steps of: 25 - inputting design data relating to the location of at least one downpipe along a length of gutter into a computing means, said computing means adapted to translate said data into operational instructions for a punching machine adapted to form said downpipe tabs; and 2 - feeding a strip of material through said punching machine to thereby form said at least one downpipe tab at a position long the length of the strip of material in accordance with said input design data. Preferably said method includes the further steps of: 5 - inputting design data relating to the cross section of the gutter into a computing means, said computing means adapted to translate said data into operational instructions for a roll former adapted to transform said strip of material into a cross sectional gutter shape; and - feeding the strip of material through the roll former to produce said gutter cross 0 section in accordance with the input design data. In preference said method includes the further steps of: - inputting design data relating to a length of the gutter and a cut angle required at either end of the gutter into a computing means, said computing means adapted to translate said data into operational instructions for a cutter adapted to cut ends of the 5 gutter; and - feeding the strip of material through the cutter to produce straight and/or angled cuts through the strip material in accordance with said input design data. In a further form of the invention there is proposed a gutter manufactured in accordance with the above steps. 20 In a still further form of the invention there is proposed an apparatus for producing a gutter, said apparatus including: a roll former adapted to receive a longitudinal strip of material and form the strip of material into a gutter cross sectional shape; a punching machine adapted to foldable attachment tabs along the length of the longitudinal 25 strip of material, said foldable attachment tabs being configured for attachment of a downpipe thereto; a cutter adapted to cut a leading and trailing edge of said strip of material to form a length of gutter, said cutter being capable of forming straight or angled ends; computing means adapted to translate input design data into operational instructions for each of 30 the roll former, punching machine and cutter to thereby produce a gutter having a cross section, 3 length, leading and trailing end cut, and one or more downpipe attachment tabs along its length, all in accordance with said input design data. Preferably said downpipe attachment tab includes a punched out section defining fold lines and surfaces adapted to be folded out along said fold lines in a generally downward 5 direction from said bottom surface, the dimensional extent of said punched out section corresponding with the cross sectional shape of a downpipe to be attached thereto such that each folded out surface is adapted to extend inside and parallel with a wall of said downpipe. BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings, which are incorporated in and constitute a part of this 0 specification, illustrate several implementations of the invention and, together with the description, serve to explain the advantages and principles of the invention. In the drawings, Figure 1 illustrates an exploded perspective view of an attachment between a gutter and a gutter downpipe attachment tab in accordance with the present invention; Figure 2 illustrates an assembled perspective view of the attachment of Figure 1; 5 Figures 3-5 illustrates progressively the manner of manufacturing a gutter having punched downpipe attachment tabs and a roll formed cross section in accordance with the invention; Figure 6 illustrates an enlarged perspective view of a punched downpipe attachment tab formed in the bottom surface of the gutter; and 20 Figure 7 illustrates an enlarged perspective view of the punched downpipe attachment tab of Figure 6 after having been folded downwardly to enable attachment of a downpipe. DESCRIPTION OF THE PREFERRED EMBODIMENTS The following detailed description of the invention refers to the accompanying drawings. 25 Although the description includes exemplary embodiments, other embodiments are possible, and changes may be made to the embodiments described without departing from the spirit and scope of the invention. Wherever possible, the same reference numbers will be used throughout the drawings and the following description to refer to the same and like parts.

4 The present invention relates to a gutter 10 including at least one punched downpipe attachment tab 12 formed in the bottom surface 14 of the gutter 10 which when folded downwardly forms a neat, aesthetically pleasing means of attachment for a downpipe 16 which is not prone to leakage and/or rust. The present invention further relates to a method of 5 manufacturing such gutters such that the length, cross section, end cut, and downpipe attachment tab locations of each gutter are based on design input data, as described further below. Figure 1 illustrates one end of the gutter 10 including a single punched downpipe attachment tab 12 in a folded out state ready to be received inside the hollow, correspondingly 0 shaped cross section of downpipe 16. Figure 2 shows that rivets 18 or the like can then be used to secure each surface 20 of the downpipe to each of the downwardly folded surfaces 22 of the tab 12, the end result being a very neat, secure, aesthetically pleasing attachment between downpipe and gutter. This type of attachment ensures that there is minimal leakage, if any at all. The fact that the tabs 12 are folded outwardly from the bottom surface 14 ensures that the 5 surface across which liquid travels into the downpipe is free of fixings or other obstacles, ensuring there is no liquid build-up and potential for rust. One of the main reasons the attachment means of the present invention is so effective is because of the precise folds which can be achieved, which is a direct result of the configuration of the punched out tab 12. Figures 3-5 illustrate schematically how the gutter 10 of the present 0 invention can be constructed in accordance with one embodiment. The gutter starts out as a strip of material 24, typically sheet metal, which firstly undergoes a punching process to form tabs 12 along the gutter at appropriate downpipe positions (this process being described in more detail below), and which then undergoes roll forming operations to form the cross sectional shape of the gutter. 25 Whilst the hole punching apparatus 26 and roll forming apparatus 28 are depicted in very simple schematics for the purpose of brevity, it is to be understood that these machines are more sophisticated and can obviously be larger in reality. For example, a typical roll-forming machine can extend a number of metres in length. Also not shown is a conveyor used to transport the strip of material 24 through the various operations. 30 Turning now to the shape of the tab 12, the skilled addressee would realise that this will depend on the shape of the punching die 30 in the hole punching apparatus 26. Preferably the dimensional extent of the punched out section corresponds with the cross sectional shape of 5 the downpipe such that the folded out surfaces 22 extend inside and parallel with the internal surfaces 20 of the downpipe 16. In the embodiment shown, the die 30 is shaped for attachment of rectangular cross section downpipes 16 to the gutter. As shown most clearly in the top view of Figure 4, the 5 punched out tab 12 includes a central rectangular portion 32 which extends in the same direction as the longitudinal axis of the gutter 10, a pair of diagonal portions 34 extending outwards from corners of the rectangular portion 32, and two small rectangular portions 36 disposed on either side and extending parallel to the central rectangular portion 32. The spaced apart distance between the central longitudinal axis of the rectangular 0 portion 32 and the longitudinal axis of each of the offset rectangular portions 36 is approximately the same as the distance between the central longitudinal axis and the point where the diagonal portions 34 on the corresponding side of the central portion 32 terminate. The skilled addressee would realise that the tab 12 is to be folded out along the longitudinal lines 38, and also along the transverse lines 40. 5 As mentioned, the neat attachment which is achieved is a result of the configuration of tab 12. In particular, the small rectangular portions 36 extending parallel to the central portion 32 provide assistance to folding out the tab along longitudinal lines 38. If those punched out portions were not present, the longitudinal folds would not be as accurate and then securing the upper downpipe surfaces 20 to the folded out surfaces 22 would be more difficult and more 0 prone to leakage, particularly in the case of downpipes having a significant elongate length. It is to be understood that these principles could equally well be applied to downpipes having different cross sectional shapes, and the present invention is not intended to be limited to attachment of downpipes of rectangular cross section. This invention is particularly concerned with the apparatus and method used in the 25 manufacture of such gutters 10. In a preferred embodiment, the method of manufacturing the gutter 10 is fully automated in that each of the punching and roll forming machines 26 and 28 are configured to receive operational instructions from a computing means (not shown) into which data relating to the gutter dimensions and location of downpipes can be input. Those skilled in the art would realise that once a house plan is drawn up, the dimension of gutters and 30 the location of downpipes is known, and so such data can be input into the computing means for translation into operational instructions for the punching and roll forming machines.

6 Thus, a gutter 10 could be transported to a building site in its punched and roll-formed state, and the downpipe attachment tabs 12 folded out either prior to or post attachment of the gutter 10 to the fascia. Any suitable tool could be used to fold out the tab along likes 38 and 40, or this process could even be undertaken offsite as part of the automated manufacturing 5 process mentioned above. The skilled addressee should now realise the benefits of the present invention. There is provided a gutter 10 having an improved means of gutter downpipe attachment and an apparatus and method of manufacturing such gutters according to predetermined house plans. The end result is a gutter of superior quality, an aesthetically pleasing look, and a downpipe 0 attachment that is not prone to leakage and/or rust. Further advantages and improvements may very well be made to the present invention without deviating from its scope. Although the invention has been shown and described in what is conceived to be the most practical and preferred embodiment, it is recognized that departures may be made therefrom within the scope and spirit of the invention, which is not to be limited to 5 the details disclosed herein but is to be accorded the full scope of the claims so as to embrace any and all equivalent devices and apparatus. In any claims that follow and in the summary of the invention, except where the context requires otherwise due to express language or necessary implication, the word "comprising" is used in the sense of "including", i.e. the features specified may be associated with further 0 features in various embodiments of the invention.

Claims

1. An apparatus for producing a gutter, said apparatus including: a roll former adapted to receive a longitudinal strip of material and form the strip of material into a gutter cross sectional shape; 5 a punching machine adapted to foldable attachment tabs along the length of the longitudinal strip of material, said foldable attachment tabs being configured for attachment of a downpipe thereto; a cutter adapted to cut a leading and trailing edge of said strip of material to form a length of gutter, said cutter being capable of forming straight or angled ends; 0 computing means adapted to translate input design data into operational instructions for each of the roll former, punching machine and cutter to thereby produce a gutter having a cross section, length, leading and trailing end cut, and one or more downpipe attachment tabs along its length, all in accordance with said input design data.

2. A method of manufacturing a gutter including at least one downpipe tab formed along its 5 length, each downpipe tab being configured to be folded out to form a downwardly extending surface for attachment of a downpipe, said method including the steps of: - inputting design data relating to the location of at least one downpipe along a length of gutter into a computing means, said computing means adapted to translate said data into operational instructions for a punching machine adapted to form said 0 downpipe tabs; and - feeding a strip of material through said punching machine to thereby form said at least one downpipe tab at a position long the length of the strip of material in accordance with said input design data.

3. A method according to claim 2 including the further steps of: 25 - inputting design data relating to the cross section of the gutter into a computing means, said computing means adapted to translate said data into operational instructions for a roll former adapted to transform said strip of material into a cross sectional gutter shape; and - feeding the strip of material through the roll former to produce said gutter cross 30 section in accordance with the input design data.

4. A method according to claim 2 or claim 3 including the further steps of: 8 - inputting design data relating to a length of the gutter and a cut angle required at either end of the gutter into a computing means, said computing means adapted to translate said data into operational instructions for a cutter adapted to cut ends of the gutter; and 5 - feeding the strip of material through the cutter to produce straight and/or angled cuts through the strip material in accordance with said input design data.

5. A gutter manufactured using the apparatus and/or method defined in any one of claims 1-4.