US20110154743A1

US20110154743A1 - Unitary Fascia And Gutter

Info

Publication number: US20110154743A1
Application number: US12/943,273
Authority: US
Inventors: Sudhir Railkar
Original assignee: Sudhir Railkar
Current assignee: Building Materials Investment Corp
Priority date: 2009-12-28
Filing date: 2010-11-10
Publication date: 2011-06-30
Also published as: CA2725300A1; MX2010013398A

Abstract

A unitary single piece fascia and gutter is extruded from plastic material or a composite and is formed with a relatively flat fascia portion sized to cover the ends of rafters along an edge of a roof. A gutter portion projects upwardly and outwardly from the fascia portion and the gutter portion and fascia portion together bound and define a gutter trough for receiving rainwater and directing the rainwater to a drainage location. The fascia and gutter is installed along an edge of a roof by being positioned along the edge with the fascia portion covering the edge and the gutter portion projecting outwardly from the edge, and securing the fascia and gutter to the edge of the roof with appropriate fasteners.

Description

TECHNICAL FIELD

This disclosure relates generally to roof structures and more particularly to fascia and gutters of roof structures.

BACKGROUND

A typical residential gable roof structure has roof decks of a predetermined pitch covered with shingles. A common configuration at the bottom edge portion of the roof structure is an overhang forming soffits. A vertical fascia board is usually installed at the end of the overhang to cover ends of roof rafters and to provide a pleasing architectural appearance. It also is common for rain gutters to be installed along the fascia. The shingles of the roof deck overlap the fascia and partially overhang the gutters so that the gutters collect rainwater from the roof and direct it to downspouts that deliver the water to a designated location for drainage. In the past, gutters made of aluminum, copper, plastic, or other material have been fabricated separately, either on site or at an off site facility, and installed with fasteners to the fascia boards of a roof structure. While this is functional, it nevertheless has certain inherent problems. For example, the fabrication of custom gutters from metal is time consuming, expensive, and requires a high degree of specialized skill. The installation of the gutters also requires particular skill. Further, once the gutters are installed, they can leak water, especially after years of use, and these leaks commonly lead to rotting of the fascia boards and underlying wooden structures. This condition usually requires that the gutters and fascia be removed and replaced with new gutters and fascia. A need thus exists for a fascia and rain gutter system that is simple and efficient to install, that requires a lower degree of expertise and skill, that eliminates fascia rotting leaks, and that is economic and architecturally pleasing. It is to the provision of such a gutter system that the present invention is primarily directed.

SUMMARY

Briefly described, a unitary fascia and gutter is extruded from plastic or a composite material in predetermined lengths. The fascia and gutter is profiled to define a substantially flat fascia portion sized to cover the rafter ends along the edge of a roof. A gutter portion of the fascia and gutter is unitarily extruded with the fascia portion and extends outwardly and upwardly therefrom so that the gutter and the fascia together bound and define a gutter trough. The gutter portion preferably has an exterior profile that mimics that of traditional metal gutters, or it may have a unique and different profile if desired. The fascia and gutter is installed along the edge of a roof structure with fasteners that extend through the fascia portion and into the ends of the roof rafters. When so installed, both the fascia of the roof and the gutters are applied simultaneously. Further, the installation requires a significantly lower skill level and significantly less time than prior art separate fascia and gutters. No separate fabrication and installation of gutters is required and the problems associated with leaking gutters and consequent rotting fascia boards is eliminated. At corners, the fascia and gutter can simply be mitered and welded together by, for example, heat welding or sonic welding forming a unitary and leak proof corner. These and other features and advantages of the disclosed fascia and gutter will become more apparent upon review of the detailed description set forth below when taken in conjunction with the accompanying drawing figures, which are briefly described as follows.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a sectional view of the edge portion of a roof structure illustrating an installed fascia and gutter according to the present disclosure.

FIG. 2 is an enlarged cross section of the fascia and gutter of this disclosure illustrating one particular embodiment thereof.

FIG. 3 is a top plan view of the fascia and gutter of this disclosure illustrating two lengths welded together at a corner to form a leak-proof joint.

DETAILED DESCRIPTION

Referring now in more detail to the drawing figures, wherein like numerals refer to like parts throughout the several views, FIG. 1 is a sectional view of a roof structure 11 constructed with a sloped roof 12 having rafters 13, a roof deck 14, and shingles 16 overlying the roof deck. The rafters 13 rest on the top plate of a wall 21 and, in the illustrated structure, ceiling joists 19 define an interior ceiling of the structure. The rafters 13 overhang the wall 21 and extend to rafter ends 18, which are cut at an angle to define aligned substantially vertical ends. The overhanging portion of the rafters and roof 12 define a soffit 22 in a traditional manner. While a traditional gable roof with ceiling joists, an overhang, and a soffit have been illustrated in FIG. 1, it should be understood that this is not a limitation of the invention and that the invention may be used with other and varying types of roofs and roof structures. For example, the invention may be used with a roof structure that does not overhang walls to define soffits but instead is substantially flush with the exterior walls of a building.
A unitary fascia and gutter 23 according to the present disclosure is secured to and extends along and covers the ends 18 of the roof rafters 13. The fascia and gutter 23 comprises a fascia portion 24, which is formed with a substantially flat configuration and has a width corresponding to the width of a traditional fascia board. The thickness of the fascia portion 24 also may be about the same as that of a traditional fascia board, although it also may be thicker or thinner depending upon application dictated requirements. Fasteners 28 are driven through the fascia portion 24 and into the ends 18 of the rafters 13 to secure the fascia and gutter in place as shown. The fasteners may be nails, screws, staples, or any other fastener appropriate for securing the fascia portion to the rafter ends 18. When secured along the ends of the rafters as shown, the fascia portion 24 mimics the appearance of a traditional fascia board that otherwise might be attached to define the fascia of the roof edge.
A gutter portion 26 of the fascia and gutter 23 is formed unitarily with the fascia portion and extends outwardly and upwardly therefrom. More specifically, the gutter portion 26 extends outwardly from near the bottom edge of the fascia portion 24 and then upwardly to a lip 33. The exterior profile of the gutter portion 26 may be shaped to mimic the profile of a traditional metal gutter as illustrated in FIG. 1, or, alternatively, it may be formed with other and distinct shapes as desired or needed. In any event, the gutter portion 26 in conjunction with the fascia portion 24 bounds and defines a gutter trough 27 shaped to contain rainwater and direct it to a drainage location. The shingles 16 of the roof 12 preferably overhang the top edge of the fascia portion 18 as illustrated in FIG. 1 so that rainwater flowing down the roof is directed into the gutter trough 27, where it is contained in the trough 27 by the fascia portion defining the back of the trough and the gutter portion defining the front of the trough. One or more downspouts 29 may be secured to a corresponding opening formed through the bottom of the gutter trough to receive rainwater from within the trough and direct it downwardly to be drained away from the building.
FIG. 2 is a cross sectional view of one possible embodiment of the fascia and gutter of this disclosure. As mentioned above, the unitary fascia and gutter 23 is formed with a fascia portion 24 and a gutter portion 26. More specifically, the fascia and gutter 23 preferably is formed by extrusion of an material appropriate to lend strength, durability, and appearance to the unitary fascia and gutter. Such materials might include, for example, a plastic material such as polyvinylchloride (PVC), a composite material such as a plastic with organic or inorganic fillers, or another appropriate material. In the exemplary embodiment of FIG. 2, the fascia and gutter 23 is extruded of a plastic material with a relatively less dense foamed plastic core 31 surrounded by a relatively more dense plastic skin 32. This configuration is lightweight, makes efficient use of materials, and provides for a durable exterior surface that mimics the look of traditional metal gutters. Further, the fascia and gutter can be extruded of plastics having a variety of colors to match various architectures and decoration schemes, and, unlike metal gutters, the color is indelible and scratch proof.
The unitary fascia and gutter of this disclosure offers additional advantages when two lengths are joined at a corner of the roof, where traditional metal gutters sometimes are joined in an unsightly manner or have a tendency to leak. FIG. 3 illustrates first and second lengths of the fascia and gutter of this disclosure meeting at a right angle and joined together as they would be at a corner of a roof. More specifically, each length is mitered at its end, in this case at forty-five degrees. The mitered ends are then thermally welded together along joint 34 to form a watertight, strong, and unitary connection between the lengths of fascia and gutter. The ends may be welded in any acceptable manner such as, for instance, with a heated welding plate, plastic welding rods, a sonic welder, or the like. In any event, the joint between the two meeting lengths is superior to traditional corner joints where metal gutters are joined because it is stronger and substantially leak proof and the gutter trough 27 extends unobstructed around the corner of the roof.
The invention has been described herein in terms of preferred embodiments and methodologies that represent the best mode known to the inventor of carrying out the invention. However, numerous modifications, additions, and deletions might be made to the illustrated embodiments within the scope of the invention. For example, the particular shape of the gutter portion and/or the fascia portion can be different from that illustrated in the preferred embodiments. Further, the fascia and gutter may be formed by methods other than extrusion and may be fabricated of any material with the appropriate strength and durability to withstand stresses encountered in use. In addition, the fascia and gutter may be fabricated with the gutter portion extending at a slight angle with respect to the fascia portion so that, when installed, water will tend to run toward one end of the gutter portion for draining out through a downspout. In fact, lengths of the fascia and gutter may be formed with gutter portions that slope at opposite angles or that are higher or lower on the fascia portion so that long runs of fascia and gutter can be connected end to end while maintaining the slope of the gutter portion or to provide a slope in either direction. These and other modifications and additions might well be made to the illustrated embodiments without departing from the spirit and scope of the invention as set forth in the claims.

Claims

1. A roof structure comprising:

a roof deck supported by rafters, the rafters extending to substantially vertical ends along an edge of the roof structure;

shingles covering the roof deck;

a fascia spanning the vertical ends of the rafters along the edge of the roof structure; and

a gutter projecting outwardly and upwardly from the fascia to define the front wall of a trough;

the fascia defining a rear wall of the trough such that the gutter and fascia together bound and define the trough and cooperate to collect and direct rainwater to a drainage location.

2. A roof structure as claimed in claim 1 and wherein the fascia and the gutter are formed together as a unitary structure.

3. A roof structure as claimed in claim 1 and wherein both the fascia and the gutter are formed of the same material.

4. A roof structure as claimed in claim 3 and wherein the fascia and the gutter are formed of a plastic material.

5. A roof structure as claimed in claim 4 and wherein the plastic material comprises PVC.

6. A roof structure as claimed in claim 4 and wherein the plastic material comprises a composite material including plastic and a filler.

7. A roof structure as claimed in claim 4 and wherein the plastic material has a relatively less dense plastic core encased in a relatively more dense plastic skin.

8. A roof structure as claimed in claim 4 and wherein the fascia and the gutter are formed as a unitary structure.

9. A unitary molded fascia and gutter comprising a fascia portion sized and shaped to span and cover the ends of rafters along an edge of a roof and a gutter portion projecting outwardly and upwardly from the fascia portion to form a trough sized to receive, contain, and direct rainwater, the trough being bounded and defined by the gutter portion of the fascia and gutter and the fascia portion of the fascia and gutter.

10. The fascia and gutter of claim 9 and wherein the fascia and gutter are molded of a plastic material.

11. The fascia and gutter of claim 10 and wherein the plastic material comprises PVC.

12. The fascia and gutter of claim 11 and wherein the fascia and gutter have a relatively less dense core encased by a relatively more dense skin.

13. The fascia and gutter of claim 9 and wherein the fascia and gutter are molded of a composite material.

14. The fascia and gutter of claim 9 and wherein the fascia and gutter are molded with an extrusion process.

15. The fascia and gutter of claim 9 and wherein the gutter portion extends at a predetermined angle relative to the fascia portion to define a grade for directing rainwater downhill when the fascia and gutter are installed.

16. A method of installing a fascia and gutter along an edge of a roof structure, the method comprising the steps of:

(a) extruding a unitary fascia and gutter comprising a relatively flat fascia portion and a gutter portion projecting outwardly and upwardly from the fascia portion to define, with the fascia portion, a gutter trough;

(b) positioning the unitary fascia and gutter along the edge of the roof structure with the gutter trough at least partially underlying the edges of shingles on the roof structure; and

(c) securing the unitary fascia and gutter to the edge of the roof structure.

17. The method of claim 16 and where in step (a) the fascia and gutter are extruded from a plastic material.

18. The method of claim 17 and wherein the plastic material comprises PVC.

19. The method of claim 16 and wherein in step (a) the fascia and gutter are extruded from a composite material.

20. A unitary structure formed to define a relatively flat fascia portion and a gutter portion projecting outwardly from a face of the fascia portion and wherein the fascia portion and the gutter portion together form a gutter for receiving rainwater and directing the rainwater to a drainage location.