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Patent Searching and Data


Title:
SEALED GUTTER CONNECTORS
Document Type and Number:
WIPO Patent Application WO/2018/042184
Kind Code:
A2
Abstract:
A gutter connection system comprises a connector (2) shaped to match the internal profile of a gutter part (4), whereby the connector and the gutter part can be overlapped. An exterior mating surface (6) of the connector (2) defines a channel (26) that faces an interior mating surface (8) of the gutter part (4). An aperture (30) extends through the connector (2) from the channel (26) to a coupling (28) on an opposite surface, to which a sealant injector (32) or an adaptor (60) for the nozzle of a sealant gun can be attached. The sealant injector (32) preferably contains a volume of sealant to match the volume of the channel (26). The connector (2) is concealed within the gutter so as to be hidden when the gutter is viewed from below.

Inventors:
DANN STEPHEN (GB)
FORD PETER (GB)
TERRIS DAVID (GB)
Application Number:
PCT/GB2017/052544
Publication Date:
March 08, 2018
Filing Date:
September 01, 2017
Export Citation:
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Assignee:
ALUMINIUM ROOFLINE PRODUCTS LTD (GB)
Attorney, Agent or Firm:
SMITH, Peter James (GB)
Download PDF:
Claims:
CLAIMS

1. A gutter connection system, comprising:

a first gutter part having a gutter profile; and

a connector shaped to match the gutter profile, whereby the connector and the first gutter part can be arranged in an overlapping configuration such that an interior mating surface of the first gutter part faces an exterior mating surface of the connector; wherein the mating surface of the connector defines a channel facing the mating surface of the first gutter part, the channel extending around the gutter profile; and the connector further comprises at least one aperture that extends through the connector from the channel to an interior surface of the connector.

2. A gutter connection system according to claim 1 , wherein the channel is defined by a pair of resilient strips attached to the mating surface of the connector.

3. A gutter connection system according to claim 1 or claim 2, wherein, at a first extremity of the gutter profile, the first gutter part comprises a retaining feature that engages the connector to prevent separation between the gutter part and the connector.

4. A gutter connection system according to claim 3, wherein the retaining feature is a hook that engages an upstand of the connector.

5. A gutter connection system according to claim 4, wherein, at a second extremity of the gutter profile, the connector comprises a hook that engages an upstand of the first gutter part.

6. A gutter connection system according to any preceding claim, wherein the interior surface of the connector comprises a coupling for releasably attaching an injection attachment to the aperture.

7. A gutter connection system according to claim 6, wherein the coupling for attaching the injection attachment is a bayonet coupling.

8. A gutter connection system according to claim 6 or claim 7, further including a sealant injector as the injection attachment, the sealant injector comprising:

means for engaging the coupling of the connector;

a sealant chamber; and

a plunger that can be moved into the chamber to expel sealant towards the aperture when the injector is coupled to the connector.

9. A gutter connection system according to claim 8, wherein the plunger can be moved into the sealant chamber by turning the plunger to follow a screw thread.

10. A gutter connection system according to claim 8 or claim 9, wherein the chamber contains sealant, and wherein the volume of sealant expelled when the piston is moved fully into the chamber matches a volume of the channel.

11. A gutter connection system according to claim 6 or claim 7, further including an adaptor as the injection attachment, the adaptor comprising:

means for engaging the coupling of the connector; and

means for receiving a nozzle of a sealant gun and for conducting sealant from the nozzle to the aperture of the connector.

12. A gutter connection system according to any of claims 6 to 11, further including a cap that for engagement with the coupling of the connector to close the aperture.

13. A gutter connection system according to any of claims 1 to 12, further comprising a valve to prevent backflow of sealant from the aperture.

14. A gutter connection system according to any preceding claim, further comprising a clip for temporarily holding the first gutter part and the connector together while sealant is injected.

15. A gutter connection system according to any preceding claim, wherein the connector further comprises a second exterior mating surface that is aligned with the first mating surface and that defines a second channel, whereby the connector can be arranged in an overlapping configuration with both the first gutter part and a second gutter part when the first and second gutter parts are aligned end-to-end.

16. A gutter connection system according to claim 15, wherein the connector can be arranged in an overlapping configuration with the first and second gutter parts when they are aligned end-to-end and respective ends of the first and second gutter parts are touching one other.

17. A method of connecting a first gutter part that has a gutter profile to a connector that is shaped to match the gutter profile, the method comprising the following steps: arranging the connector in an overlapping configuration with the first gutter part, such that an interior mating surface of the first gutter part and an exterior mating surface of the connector face one another, and such that the mating surface of the connector defines a channel that faces the mating surface of the first gutter part and extends around the gutter profile;

injecting sealant through an aperture that extends from an interior surface of the connector through the connector to the channel, thereby to form a seal between the first gutter part and the connector.

Description:
TITLE

Sealed gutter connectors

DESCRIPTION

Technical field

The invention relates to the field of gutters for collecting and channelling water that drains from the edge of a roof. In particular, it relates to apparatus and methods for connecting lengths of gutter arranged end-to-end, while sealing the junction against the loss of water. It is applicable to gutters of both metal and plastics materials and to a wide range of gutter profiles.

Background of the invention

For the convenience of manufacture, transport and installation, guttering is supplied in discrete lengths. The lengths of gutter are typically formed by extrusion and they have a uniform cross-sectional profile along their length. Where a run of guttering is longer than the lengths of gutter supplied, there is a requirement for the lengths to be connected end-to-end. There is also a requirement for lengths of gutter to be connected to other specially shaped parts, such as corner pieces, end caps and downpipes. Each such connection between gutter parts needs to be sealed to prevent water escaping through the junction.

One known solution to the problem of connecting gutter parts is disclosed in patent application GB 2194266 A. A connector has a generally H-shaped cross-section so as to provide two oppositely facing channels. The connector follows the profile of the gutter parts so that an end of each gutter part can be pushed into a respective channel. Resilient blades close the mouth of the channel and form a seal between the connector and the gutter part. A further seal can then be provided by injecting sealant compound into each channel behind the blades. The outer portion of the connector forms a thick rib that runs around the exterior profile of the gutter. It would be preferable if the connector could be substantially hidden when viewed from the exterior so as not to interrupt the smooth appearance of the run of the guttering. Summary of the invention

The invention provides a gutter connection system as defined in claim 1.

The invention further provides a method of connecting a first gutter part to a connector as defined in claim 12.

Preferred but non-essential features of the invention are defined in the dependent claims.

In this specification, the terms "interior" and "exterior" are defined in relation to the gutter as a whole so that an interior surface faces towards the channel of the gutter and an exterior surface faces away from the channel of the gutter, whether or not those surfaces are exposed or are overlapped by another component.

The drawings

Figure 1 is a perspective view from above, front and left of a connector with a sealant injector, in accordance with a first embodiment of the present invention.

Figure 2 is an end view in cross-section of the connector and sealant injector of Fig. 1.

Figure 3 is a perspective view from below, front and left of the connector of Fig. 1. Figure 4 is a perspective view from above, front and left of the connector of Fig. 1 when used to join two gutter parts end-to-end.

Figure 5 is a perspective view from below, rear and left of the connector of Fig. 1 with a single gutter part and a temporary clip.

Figure 6 is an end view in cross-section of a connector with a sealant injector, in accordance with a second embodiment of the present invention.

Figure 7 is a perspective view from above, front and left of the connector of Figure 6 with a sealant cap.

Figure 8 is a perspective view from above, front and left of a connector with a sealant injector, in accordance with a third embodiment of the present invention.

The drawings shows a connector 2 in accordance with the invention. The profile of the connector 2 is seen in Figure 2, which shows a cross-section on a plane perpendicular to the length of the gutter. The profile of the connector 2 matches that of the lengths of gutter 4 with which it is to be used, as best seen in Figure 4. More specifically, the connector 2 comprises a pair of exterior mating surfaces 6. Each mating surface 6 has a profile which matches that of a corresponding interior mating surface 8 of the associated gutter part 4 so that the connector 2 can be nested inside the gutter part 4. Each gutter part 4 has a uniform cross-section along its length so in practice the mating surface 8 of a gutter part is just an end portion of its interior surface that overlaps the connector 2.

In this example, the profile has a flat rear wall 10, a flat base 12 and an ogee-type front wall 14. However, the invention may be used with a wide range of gutter profiles comprising straight or curved segments. The lip of the front wall of the gutter parts 4 is recurved to form a hook portion 16, which engages a short upstand 18 at the lip of the front wall 14 of the connector 2. The lip of the rear wall 10 of the connector 2 is also provided with a hook portion 20, which engages an upstanding edge 22 of the rear wall of the gutter parts 4. Thus the connector 2 can be mated with the gutter parts 4 by first engaging the connector upstand 18 beneath the gutter hook portion 16, then lowering the connector 2 to bring the respective mating surfaces 6,8 into contact and to engage the gutter rear wall 22 with the hook 20 of the connector 2.

The hook portion 16 of the gutter part 4 engages the upstand of 18 the connector 2 in a way that the connector cannot simply be lifted to separate it from the gutter part. For this purpose the downward-pointing element of the hook 16 is not strictly necessary: the horizontal element overlapping the edge of the upstand would serve to retain the connector 2 in place provided that the gutter part is stiff enough to prevent deformation of the front wall. It would be possible to provide alternative forms of retaining feature by which the gutter part engages the connector to prevent it being lifted and separated from the gutter part. One example (not illustrated) would be a longitudinal rib on the connector, which projects into a longitudinal recess in the gutter profile.

As seen in Figure 3, each mating surface 6 on the connector 2 is provided with a pair of strips 24 that extend around the profile and define a channel 26 between them. The strips 24 are preferably formed from a resilient but impermeable material such as soft rubber or a closed-cell foam, which is adhered to the mating surface 6. The channel 26 faces the gutter part 4 such that the mouth of the channel 26 opens towards the mating surface 8 of the gutter part 4. The resilient strips 24 can conform to the contours of the gutter part 4 to seal against the mating surface 8 and thereby close the mouth of the channel 26.

The base 12 of the connector 2 comprises a pair of couplings 28 on its interior surface, which are aligned with the respective channels 26 on the exterior, mating surface 6. Each coupling 28 is associated with at least one aperture 30, which extends through the thickness of the connector 2 to emerge in the associated channel 26 below. In the illustrated embodiment, the coupling 28 defines a generally circular area, within the perimeter of which there are two such apertures 30. The two apertures 30 are inclined in opposite directions relative to the length of the channel 26 in order to direct sealant towards opposite ends of the channel 26, as will be described below.

The apparatus according to one embodiment of the invention further comprises a sealant injector 32 that is designed to engage with the couplings 28 of the connector 2. The injector 32 has radially projecting flanges 34 that can be engaged below suitably positioned lugs 36 of the couplings 28 in a push-and-turn or bayonet action. Alternative fixings such a clip or a screw thread (not illustrated) can easily be envisaged. The fixing should be such that it is possible to engage the injector 32 securely with one of the couplings 28 so that it seals against the base 12 of the connector 2; and then to release and remove the injector 32 after its sealant has been injected.

The sealant injector 32 comprises a generally cylindrical sealant chamber 38 and a piston 40 that can be moved into or out of the chamber 38. In this example, the piston 40 is connected to the chamber 38 via a screw thread 42 so that turning the piston 40 causes it to move up or down along the thread 42. The piston is provided with an enlarged head 43 to make it easier to grip and to turn. The bottom of the chamber 38 may be completely open or may comprise a wall perforated by openings that align with the apertures 30. As the piston 40 moves into the chamber 38, it displaces sealant from the chamber and forces it to flow through the apertures 30, into and along the associated channel 26. The sealant prevents water in the gutter parts 4 from travelling between the mating surfaces 6,8 to reach the junction between the ends of the gutter parts, so the water is prevented from leaking out of the gutter.

Preferably the volume of sealant displaced from the chamber 38 equals the volume of the channel 26 so that the sealant fills the channel 26 without emerging from its ends. It is an advantage of this embodiment of the invention that a measured quantity of sealant can be easily applied in this way, without mess or wastage. The injector 32 may be disposable after use or it can be designed to be refilled with sealant. For ease of refilling, the sealant may be provided in capsules or other packages of a measured volume and a suitable shape to fit within the chamber 38 of the injector 32.

When sealant is injected into the channels 26 between the respective mating surfaces 6,8 of the connector 2 and the gutter part 4, it tends to force the connector and the gutter part away from one another. This is prevented at the front of the profile by the hook 16 of the gutter, which retains the upstanding edge 18 of the connector 2. At the back of the profile, a clip 44 may be applied to the assembly temporarily during the course of injection. As seen in Figures 4 and 5, the clip 44 extends over the hook 20 of the connector 2, down the rear wall of the gutter part 4 and partially beneath the base of the gutter part 4, to prevent the connector 2 lifting away from the gutter part 4. The clip 44 can be removed after the sealant has cured.

It will be noted that, with the exception of the hook 20 at its upper, rear extremity, the connector 2 lies completely within the gutter. The two gutter parts 4 can be aligned with their ends touching so that no part of the connector 2 protrudes or is visible at the junction between the ends. When the guttering is mounted on the eaves of a building and is viewed from the ground below, the connector 2 will be entirely hidden and the guttering will present an essentially smooth, continuous profile along its length. A second embodiment of the invention is illustrated in Figures 6 and 7. It is substantially similar to the first embodiment so like parts have been given like reference numerals and will not be described again.

As seen in Fig. 2, the threaded portion 42 of the piston 40 in the first embodiment is of smaller diameter than the chamber 38 so it does not displace the entire volume of sealant in the chamber. In the second embodiment, the piston 40 terminates in a disclike plunger 46 of substantially the same diameter as the chamber 38, which displaces sealant from the entire volume of the chamber and avoids wastage. As illustrated, the plunger 46 is clipped to the piston 40 but a similar result could alternatively be achieved by pushing a separate disc (not illustrated) ahead of the piston.

In this second embodiment, longitudinal ribs 48 project from the convex corners of the exterior mating surface 6 of the connector 2. They urge the resilient strips 24 into making good contact with the corresponding concave corners of the interior mating surface 8 of the gutter part 4, which would otherwise be points of weakness at which sealant might escape from the channel 26 as it is injected under pressure. The ribs 48 may be formed integrally with the connector 2 or, as illustrated, may be formed as part of separately moulded inserts 50 that are subsequently clipped onto the connector 2.

Figures 6 and 7 illustrate small indicator holes 52,53, which extend through the thickness of the rear and front walls 10,14 of the connector 2 to emerge in each channel 26 near its respective ends. When the sealant being injected has travelled almost to the ends of the channel 26, it will be visible through the indicator holes 52,53, or will emerge in small quantities from them, as a confirmation that the channel 26 is full of sealant and the injection process can be stopped.

Figures 6 and 7 also show that instead of the clip 44 of the first embodiment, a screw hole 54 may be provided near the top of the rear wall 10 of the connector 2. A screw inserted through the hole 54 can hold the connector 2 and gutter part 4 together during the injection of sealant and can be left in place afterwards without interfering with the mounting of the gutter or with the flow of water along it. The screw holes 54 should preferably be located high enough on the rear wall 10 to be above the expected water level when the gutter is full. However, if they are aligned with the channel 26 as shown, the injection of sealant into the channel 26 to surround the screw holes 54 can prevent leakage of water through them.

It is found that the sealant used with the present invention needs to be of relatively low viscosity in order that it can be pushed to the ends of the channel 26 without the need to apply excessive pressure at the apertures 30. Such elevated pressure could cause the sealant to escape from the channel by distorting the resilient strips 24 that form its side walls. After the injection of sealant is complete, the injector 32 must be removed from the coupling 28 so that it does not present an obstruction to the flow of water along the gutter. However, if it is removed before the sealant in the channels 26 has cured there is a risk that the low viscosity sealant may re-emerge from the apertures 30. One solution is to provide the apertures with one-way valves (not illustrated) to prevent the backflow of sealant through them. Another is to replace the injector 32, following its removal, with a cap 56 that fits to the coupling 28 in a similar manner but presents a lower profile to the flow of water so that it can be left in place during the use of the gutter. One such cap 56 is illustrated in Figure 7. It includes a grip 58 to make the cap easy to rotate into position by hand.

A third embodiment of the invention is illustrated in Figure 8. It is the same as the second embodiment except for the injector. In this embodiment, a special form of injector 32 is not used; instead the sealant is injected from a standard sealant gun (not shown), which holds a large volume of sealant and comprises an in-built piston and nozzle. Instead of the coupling 28, the mouth of the apertures 30 may be adapted to match the shape of a standard nozzle. Alternatively, and as illustrated in Figure 8, the coupling 28 may be retained and used to engage an adaptor 60. The adaptor 60 has the basic form of a pipe 62 for delivering sealant from the gun to the apertures 30. At one end the pipe 62 has a mouth 64 of a suitable size and shape to snugly receive the nozzle of a standard sealant gun. At the other end the pipe 62 has radially projecting flanges 66 that can be engaged below the lugs 36 of the couplings 28 in a push-and-turn action similar to that of the injector 32 previously described. In the illustrated embodiment the pipe 62 of the adaptor comprises a bend between its two ends so that the mouth 64 is presented at a convenient angle and position to receive the nozzle of a sealant gun. (It should be remembered that when the gutter is installed on the eaves of a roof, the edge of the roof tiles will typically project over the rear wall 10 and part way across the gutter.) The pipe 62 may take different forms to achieve this purpose or may be made of a flexible material at the bend 68 or along its whole length in order to adapt to different surroundings.

An alternative adaptor (not illustrated) may be much shorter and may have a low enough profile that it does not need to be removed after the injection is complete. In that case, the adaptor can be provided with means for addressing the problem of backflow of low viscosity sealant, discussed above. For example, the adaptor can include a valve element, which is displaced by the insertion of the nozzle to permit the flow of sealant but which closes when the nozzle is removed. Alternatively the adaptor can be turned, relative to the coupling 28, to a different rotary position in which it blocks the apertures 30 in a similar manner to the cap 56 of Figure 7.