Gutter Cover Manufacturing Apparatus

Abstract

Methods and apparatus for fabricating articles having apertures from a flat feedstock, such as gutter covers, are provided herein. In some embodiments, an apparatus for fabricating articles having apertures from a flat feedstock includes an uncoiler for receiving and metering out a desired quantity of a flat feedstock in roll form; a feeder/straightener for receiving the feedstock from the uncoiler; a first press for receiving the feedstock from the feeder/straightener, the first press housing a tool and die that forms one or more apertures in the feedstock; a second press for receiving the feedstock from the first press, the second press housing a tool and die that cuts the feedstock into a finished length; and a roll former for receiving the feedstock from the second press, the roll former comprising a plurality of rollers that create a desired profile along the width of the feedstock.

1 . An apparatus for fabricating articles having apertures from a flat feedstock, comprising:
 an uncoiler for supplying a flat feedstock in roll form;   a feeder/straightener for receiving the feedstock from the uncoiler;   a first press for receiving the feedstock from the feeder/straightener, the first press housing a tool and die that forms one or more apertures in the feedstock;   a second press for receiving the feedstock from the first press, the second press housing a tool and die that cuts the feedstock into a finished length; and   a roll former for receiving the feedstock from the second press, the roll former comprising a plurality of rollers that create a desired profile along the width of the feedstock.   
   
   
       2 . The apparatus of  claim 1 , wherein the first and second presses are about two-ton presses or smaller. 
   
   
       3 . The apparatus of  claim 1 , wherein the second press is configured to form one or more apertures in the feedstock. 
   
   
       4 . The apparatus of  claim 1 , wherein the second press is configured to form one or more notches along an edge of the feedstock. 
   
   
       5 . The apparatus of  claim 1 , wherein the second press is configured to form one or more apertures and one or more notches in the feedstock while cutting the feedstock into a finished length. 
   
   
       6 . The apparatus of  claim 1 , wherein the roll former further comprises a set of feed rollers configured to pull the finished length feedstock into the roll former. 
   
   
       7 . The apparatus of  claim 1 , further comprising:
 a collection table disposed proximate an exit side of the roll former, such that the finished length feedstock can be dropped into the collection table as it exits the roll former during operation.   
   
   
       8 . The apparatus of  claim 1 , further comprising:
 a control module configured to control the one or more of the uncoiler, the feeder/straightener, the first press, the second press, or the roll former.   
   
   
       9 . The apparatus of  claim 8 , wherein the controller counts each part manufactured. 
   
   
       10 . The apparatus of  claim 8 , wherein the controller further includes a computer readable medium containing instructions that, when executed, cause the apparatus to fabricate sections of a rain gutter cover having a plurality of apertures and that overlap and may be fastened together proximate cut edges of the feedstock to form a gutter cover having a desired length. 
   
   
       11 . An apparatus for fabricating articles having apertures from a flat feedstock, comprising:
 an uncoiler for supplying a flat feedstock in roll form;   a feeder/straightener for receiving the feedstock from the uncoiler;   a press for receiving the feedstock from the feeder/straightener, the press configured to form one or more apertures in the feedstock and to cut the feedstock into a finished length; and   a roll former for receiving the feedstock from the press, the roll former comprising a plurality of rollers that create a desired profile along the width of the feedstock.   
   
   
       12 . The apparatus of  claim 11 , wherein the press has a size of up to about  10  tons. 
   
   
       13 . The apparatus of  claim 11 , wherein the press further comprises:
 a first tool and die configured to form from one or more apertures with each stroke of the press; and   a retractable second tool and die comprising one or more independent sections configured to cut the feedstock into a finished length and to make at least one of one or more apertures or one or more notches proximate cut edges of the feedstock.   
   
   
       14 . The apparatus of  claim 13 , wherein the retractable second tool and die is configured to create both one or more apertures and one or more notches proximate cut edges of the feedstock simultaneously in the part of the feedstock being cut into a finished length and the remaining portion of the feedstock. 
   
   
       15 . The apparatus of  claim 11 , further comprising:
 a collection table disposed proximate an exit side of the roll former, such that the finished length feedstock can be dropped into the collection table as it exits the roll former during operation.   
   
   
       16 . The apparatus of  claim 11 , further comprising:
 a control module configured to control the one or more of the uncoiler, the feeder/straightener, the press, or the roll former.   
   
   
       17 . The apparatus of  claim 16 , wherein the controller further includes a computer readable medium containing instructions that, when executed, cause the apparatus to fabricate sections of a rain gutter cover having a plurality of apertures and that overlap and may be fastened together proximate cut edges of the feedstock to form a gutter cover having a desired length. 
   
   
       18 . A method of fabricating articles having apertures from a flat feedstock, comprising:
 providing, in alignment, an uncoiler for supplying a flat feedstock in roll form, a feeder/straightener for receiving the feedstock from the uncoiler, a first press for receiving the feedstock from the feeder/straightener, and a roll former for receiving the feedstock from the press;   metering out a desired quantity of a flat feedstock in roll form from the uncoiler to the feeder/straightener;   forming one or more apertures in the straightened feedstock using the first press;   cutting the feedstock into a finished length; and   creating a desired profile along the width of the feedstock using the roll former.   
   
   
       19 . The method of  claim 18 , wherein the feedstock is cut into a finished length using the first press. 
   
   
       20 . The method of  claim 18 , wherein a second press is provided between the first press and the roll former and wherein the feedstock is cut into a finished length using the second press.