GB2360231A

GB2360231A - Guttering

Info

Publication number: GB2360231A
Application number: GB0006104A
Authority: GB
Inventors: Zbigniew Zygmunt Wereszczynski
Original assignee: MARLEY ALUTEC Ltd
Current assignee: MARLEY ALUTEC Ltd
Priority date: 2000-03-15
Filing date: 2000-03-15
Publication date: 2001-09-19
Also published as: GB0006104D0

Abstract

A method of providing guttering comprising applying a protective coating (7) to one side (3) of a sheet (1a), cutting the sheet (1a) to the required length and width, applying a further protective coating (7') to the other side of the sheet (1a) and forming the further coated sheet (1a) into a length of guttering (20). Application of the further coating (7') preferably ensures that all exposed edges (11, 12) are covered therewith. An associated length of guttering (20), as well as a corresponding gutter system, is also provided.

Description

2360231 GUTTERING DESCREPTION This invention relates to guttering and

specifically to a method of manufacturing guttering which is hard wearing and corrosion resistant.

Conventionally, guttering is used on buildings to direct rainwater, or other precipitation which 'runs off of the building, into an associated drain. It is usually attached to the building such that it is mounted below the periphery of the roof to collect the run-off.

Guttering generally consists of lengths of channel, which may be formed with various cross-sectional profiles, manufactured in either plastics or metal and can be bought off-the-shelf as a proprietary assembly of components- Plastics gutter systems are mainly formed from PVCu and are relatively low in price. However, they offer a limited life expectancy, and consequently they are used by the do-it-yourself enthusiast and by people in the trade for domestic housina or for buildings where a high level of external maintenance is acceptable. Metal gutter systems are generally only used by tradesmen and are normally installed on commercial, municipal or listed buildings, luxury housing, or buildings which require a low level of external maintenance.

Gutter systems formed from PVCu are available in a limited range of colours, whereas those formed from metal are normally supplied in their base colour or with a primer finish and consequently require painting on-site prior to installation. To obtain a metal gutter which is supplied pre-painted to the desired finish, involves ordering the goods from a manufacturer, which can cause a delay typically of up to two to three weeks.

1 1 Alternatively, an on-site manufacturing and installation process is a'lable 'n which a specialist cuts the required length ing val 1 1 1 1 1 and width of gutter' from a colt of pre-painted sheet metal, which coils may be up to 1.2 m wide, and machine forms into the gutter section of the required cross- section.

However, a problem of corrosion persists with such guttering. As the prepainted sheet is cut to the required length and width, unpainted or uncoated metal is exposed. The exposed edges provide a point of attack at which the guttering can become corroded due to the action of the elements and, for example, pollutants such as acidic gases present and, at some locations, prevalent in the atmosphere.

Furthermore, when installing such bespoke guttering it is conventional to rivet the lengths together, which can cause further abrasion or erosion of the _gutter coating and thereby provide another point of attack. A gutter system which is riveted together is rigid and, consequently, makes no allowance for differential thermal expansion of the components and moreover, it can only be installed by a skilled professional to whom the owner must refer any future repairs or alterations.

Similarly, Joining the lengths of guttering together using bolts creates points of attack at the exposed edges of the drilled holes, and soldering may similarly cause damage to a coating due to the topical application of heat.

It is an object of the invention to provide lower cost guttering which is not susceptible to the problems associated with prior art guttering or, at least, to substantially reduce or mitigate those associated problems and which is available off-the-shelf to both trades people or DIY enthusiasts and which Is a'lable 'n a variety of colours providing a durable and decorative finish.

val 1 Accordingly, a first aspect of the invention resides in a method of providing guttering comprising applying a protective coating to one side of a sheet, cutting the sheet to the required length and width, applying a further protective coating to the other side of the sheet and forming the further coated 5 sheet into a length of guttering.

The application of the further protective coating preferably ensures that all exposed edges of the sheet are covered therewith. The protective coating may comprise a powder coating and each side of the sheet may be primed io prior to the application of the protective coating thereto.

In a preferred embodiment the sheet comprises a metal, which may be aluminium or steel.

The forming of the sheet into a length of guttering may comprise roll forming, and the protective coatings are preferably flexible such that forming of the sheet into guttering does not cause mechanical damage thereto.

The guttering may be formed into lengths with substantially semi- circular or alternatively substantially rectangular cross section, or with, for example the ogee profile.

A second aspect of the invention provides a length of guttering, the entirety of which is covered with a protective coating, and which has been roll-formed from a sheet subsequent to the application of the protective coating.

A third aspect of the invention provides a gutter system comprising a plurality of lengths of guttering, the entirety of each of which is covered with a o protective coating, and each of which has been roll-formed from a sheet subsequent to the application of the protective coating, and at least one snap- z fit clip which is arranged to join two or more lengths of guttering to form a gutter channel.

The protective coating may comprise a powder coating and each side of the sheet may be primed prior to the application of the protective coating, thereto.

In a preferred embodiment the sheet comprises a metal, which may be aluminium of steel.

Each length of guttenina may be formed with a substantially semi circular or alternatively substantially rectangular cross section, or with, for example, the ogee profile as hereinafter defined.

The snap-fit clip may, comprise a spacer element comprising a resiliently compressible material, a resilently deformable material or an elastomeric material and which, in use, is interposed between the clip and one end of an abutting length of cutterinc, to provide a water-tight seal therebetween.

In order that the various aspects of the invention are more fully understood, the invention will now be described by way of example only and with reference to the following drawings in which Figure 1 shows a schematic diagram of the first stage in the coating process., Figure 2 shows a schematic diagram of a further stage of the coating process; Figure 3 shows a schematic diagram of a part of a gutter section., and Figure 4 shows a further gutter length and a snap-fit union clip.

Referring firstly to Figure 1, there is shown a roll of material 1, which preferably comprises a metal, for example aluminium or steel, a portion of which has been unrolled to provide a sheet I a. The free edge 2 of the sheet 1 a is being pulled, driven or other-wise translated in the direction A Mounted above the sheet 1 a, are means 4 arranged to coat the surface 3 io thereof The means 4 comprise pre-treatment means 5 and coating means 6.

The pre-treatment means 5 primes the surface 3 of the sheet I a and the coating means 6 coats the surface 3 and the longitudinal edges of the sheet la with a protective coating 7.

The protective coating 7 may comprise a powder coating, as is known in the coating art, and which can be afforded a hard-wearing, corrosion resistant finish.

Referring now to Figure 2, there is shown a length of sheet 10 which has been cut to the required dimensions from the sheet la, provided with the protective coating 7. The action of cutting the sheet la, exposes longitudinal 11 and transverse 12 edges of the length of sheet 10, which obviously are not coated.

The length of sheet 10 is pulled, driven or otherwise translated in the direction B such that its entirety passes by coating means 4', which comprises pre-treatment means 5' and coating means 6'.

The pre-treatment means 5' primes the surface of the sheet 10 such that the coating means 6' can apply a further protective, for example, corrosion resistant coating 7' to the sheet 10. The coating means 6' applies said further Protective coating 7' such that the exposed edges 11, 12 are also coated, thereby providing a finished sheet 10 which is coated in its entirety.

Figure 3) shows an example of a finished length of guttering 20, which has been roll-formed from the sheet 10, and which comprises a length of material of semi-circular cross-section 15 provided with a protective coating 7-, To install lengths of guttering 20, brackets may be used to affix each length to a wall, or other substrate, and snap-fit Joints can be used to connect two lengths 20 together. Suitable snap-fit Joints have previously been disclosed in, and are the subject of, our co-pending British Patent Application No. 9716802.5 (GB 2327955). The use of such snap-fit joints ensures that the gutter lengths 20 and, more specifically, the coating 7-- - thereon, is not damaged during installation and consequently a point of corrosive attack is not provided.

Indeed, Figure 4 shows a length of guttering 20', with the Ogee profile or cross-section, in position with a snap-fit clip 30. The clip 30 is provided with a compressable gasket 3 1, which is interposed between the clip 30 and the adjacent portion 25 of the length of guttering 20'. The Joint between clip 30 and guttering 20' is further sealed by the provision of a silicone sealant which, in use, covers at least the end 26 of the length of guttering 20', thereby preventing corrosion of the exposed metal surface. The gutter system may be affixed to a wall or other substrate by screws 32, provided in countersunk holes in the clip 30, and concealed by the gutter 20'.

---1 It Is clear that a gutter length may, be formed with any suitable crosssection, the powder coating being flexible enough to be so-stretched once it has been applied. Obviously, by coating the entirety of each length 20, 20, no point of attack is provided thereon However, once a gutter length is cut to the required length an edge 26 is exposed, this edge 26 Is always encapsulated into the sealant filled gutter joint 30 and is not exposed to corrosion, although any portion of the gutter 20, 20' which is damaged and the metal surface exposed may be "touched-up" with the appropriate repair paint, in contrast with prior art guttering in which entire edges have to be re-painted, or have their protective coating re-applied, which is a time-consuming and arduous task. Moreover, with the provision of snap-fit unions 30 the lengths of guttering 20, 20' do not have to be drilled, riveted or welded to form a common gutter system, as was previously the case, and which, as discussed above, exposes io further points of attack.

Whilst the specific description indicates that the pre-coating 5, 5' and coating means 6, 6' operate upon the sheet I a, 10 as it is conveyed passed them, this is not necessarily the case. For example, the precoating means 5, 5' may be separated from the coating means 6, 6' such that the sheet la, 10 is allowed to "rest" between these stages. In certain circumstances each stage may be completed in a coating booth as is known and established in the powder coating arts.

Furthermore, lengths of gutter 20, 20' can be provided in standard sizes and sold in wholesale or retail outlets, the purchaser simply cutting the gutter 20, 20' to the required length and painting or coating the exposed end with a proprietary protective coating, Therefore, it is clearly understood from this description that the method of coating the gutter sections, and the gutter lengths 20, 20' so- formed ensure the provision of a corrosion resistant guttering system.

Claims

CLAIMS A method of providing guttering comprising applying a protective coating to one side of a sheet, cutting the sheet to the required length and width, applying a further protective coating to the other side of the sheet and forming the further coated sheet into a length of guttering.

1

2. A method according to claim 1, wherein application of the further protective coatine, ensures that all exposed edges of the sheet are covered therewith.

protective coating A method according to claim 1 or 2, wherein the comprises a powder coating.

4. A method according to claim 1, 2 or 3, wherein each side of the sheet is primed prior to the application of the protective coating thereto.

5. A method according to any preceding claim, wherein the sheet comprises a metal.

6. A method according to claim 5, wherein the metal is aluminium or steel.

7. A method according to any preceding claim, wherein the forming of 25 the sheet into a length of guttering comprises roll forming.

8. A method according to any preceding claim, wherein the protective coatings are flexible, such that forming of the sheet into guttering does not cause mechanical damage thereto.

9. A method according to any preceding claim, wherein the guttering is formed into lengths with substantially semi-circular or substantially rectangular cross section, or with the ogee profile as hereinbefore defined.

10. A method of providing guttering substantially as hereinbefore described.

11. A length of guttering the entirety of which is covered with a protective coating and which has been roll-formed from a sheet subsequent to the 10 application of the protective coating.

12. A gutter system comprising a plurality of lengths of guttering the entirety of each of which is covered with a protective coating and each of which has been roll-formed from a sheet subsequent to the application of the 15 protective coating, and at least one snap-fit clip which is arranged to join two or more lengths of guttering to form a gutter channel.

13. A gutter length or gutter system according to claim 11 or 12, wherein the protective coating comprises a powder coating. 20

14. A gutter length or gutter system according to claim 11, 12 or 13, wherein each side of the sheet has been primed prior to the application of the protective coating thereto. 25

15. A gutter length or gutter system as claimed in any of claims 11 to 14, wherein the sheet comprises a metal.

16. A gutter length or gutter system according to claim 15, wherein the metal is aluminium or steel. 30

17. A gutter length or gutter system according to any of claims 11 to 16, wherein the or each length of guittening is formed with a substantially semicircular or substantially rectangular cross section, or with the ogee profile as hereinbefore defined.

18. A gutter length or gutter system according to any of claims 11 to 17, wherein the snap-fit clip comprises a spacer element which comprises a resiliently compressible material, a resiliently deformable material or an elastomeric material and which, in use, is interposed between the clip and one 10 end of an abutting length of guttering, to provide a water- tight seal therebetween.

19. A length of guttering substantially as hereinbefore described with reference to the accompanying drawings.

20. A gutter system substantially as hereinbefore described with reference to the accompanying drawings-