Gutter cover

Abstract

A gutter cover according to the present invention is an extruded plastic component having a cover segment sized to extend generally across an eavestrough and merge with a rounded transition edge, said rounded transition edge joining with an undercut angled section extending rearwardly and positioned partially below the cover segment. The undercut angled section joins with a perforated pass through allowing water to pass through said cover segment at a position below and inwardly of the rounded transition edge, perforated pass through merges with an integral resilient clip having a securing cavity sized for resiliently engaging an upper outer edge of an eavestrough or for engaging a securing flange of an eavestrough hook. The gutter cover can be used with many existing vinyl or metal eavestrough systems. A particular method for producing the gutter cover is also disclosed.

1 . A gutter cover comprising an extruded plastic component having a cover segment sized to extend generally across an eavestrough and merge with a rounded transition edge, said rounded transition edge joining with an undercut angled section extending rearwardly and positioned partially below said cover segment; said undercut angled section joining with a perforated pass through allowing water to pass through said cover segment; said perforated pass through merging with an integral resilient clip having a securing cavity, said securing cavity being sized for resiliently engaging an upper edge of an eavestrough or for engaging a securing flange of an eavestrough hook. 
     
     
         2 . A gutter cover as claimed in  claim 1  wherein said securing cavity is sized to receive therein a folded or rolled metal edge of an eavestrough. 
     
     
         3 . A gutter cover as claimed in  claim 2  wherein said resilient clip includes an upper arm and a lower arm connected adjacent said perforated pass through, said arms defining an elongate split line at a forward end of said gutter cover with said arms resiliently separating at said split to effect securement of said gutter cover. 
     
     
         4 . A gutter cover as claimed in  claim 4  wherein said lower arm intermediate its length includes a notched portion forming an integral biased hinge allowing said lower arm to hinge downwardly during securement of said gutter cover. 
     
     
         5 . A gutter cover as claimed in  claim 3  including a ramp segment on said upper arm angled upwardly and outwardly. 
     
     
         6 . A gutter cover as claimed in  claim 5  wherein said cover segment includes a textured upper surface to slow and spread rivulets of water passing over said cover segment. 
     
     
         7 . A gutter cover as claimed in  claim 6  wherein said textured upper surface is produced by embossing. 
     
     
         8 . A gutter cover as claimed in  claim 6  wherein said textured upper surface is generally consistent across said cover segment. 
     
     
         9 . A gutter cover as claimed in  claim 8  wherein said resilient clip is positioned below and aligned with said rounded transition. 
     
     
         10 . A method of manufacturing a gutter cover comprising extruding a semi circular like sheet substrate with a securing clip at one edge thereof; cooling said securing clip using a cooling fluid to extract heat therefrom, passing said sheet substrate through a first performer cooling structure to partially flatten the semi circular like sheet substrate, embossing a top surface of said gutter cover to one side of said clip to provide a textured upper surface across said gutter cover and further flattening said sheet substrate; passing said sheet substrate through a second performer to provide an angled segment displacing said clip downwardly while maintaining said textured upper surface; passing said sheet substrate through a calibrator to produce a rounded transition merging with said angled segment extending downwardly and rearwardly with said clip positioned below said rounded transition; said caliper discharging said gutter cover to cooling tank for further removal of heat and setting of said gutter cover; said set gutter cover including a tapered channel opening outwardly between said rounded transition and said securing clip and punching said channel to provide a perforated pass through portion at the pass of said channel. 
     
     
         11 . A method as claimed in  claim 10  including punching said channel to produce alternating trapezoidal ports with angled walls therebetween. 
     
     
         12 . A method as claimed in  claim 10  wherein said calibrator includes a vacuum source engaging a lower surface of said gutter cover and a water seal is provide on an upper surface of said gutter cover to maintain said textured surface. 
     
     
         13 . A method as claimed in claim in  claim 12  including forming said securing clip to have an upper arm and a lower arm defining a securing cavity therebetween, said lower arm including an integral hinge intermediate the length of said lower arm for resilient displacement of said arm about said integral hinge to access said securing cavity. 
     
     
         14 . A method as claimed in  claim 13  including liquid cooling of each performer to cool said sheet substrate during passage through said performers. 
     
     
         15 . A method as claimed in  claim 14  wherein said calibrator is connected to said cooling tank that includes cooling water at a level above a discharge level of said substrate to allow weepage of water along said gutter cover within said calibrator to form said water seal. 
     
     
         16 . A method as claimed in  claim 10  including providing a cooling tube aligned with said securing clip and positioned therein immediately downstream of an extrusion die, said cooling tube removing heat from said clip sufficient to maintain the extruded shape of said clip. 
     
     
         17 . A method as claimed in  claim 16  wherein said cooling tube is open ended and discharges air along a length of said securing clip downstream of said extrusion die.