Classifications

• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
  • E04D13/00—Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage ; Sky-lights
  • E04D13/04—Roof drainage; Drainage fittings in flat roofs, balconies or the like
  • E04D13/064—Gutters
  • E04D13/072—Hanging means
  • E04D13/0725—Hanging means situated above or inside the gutter

Definitions

• the present invention relates to roof gutters. More particularly, it relates to a roof gutter fastener and method for the application thereof, that utilizes a threaded shank portion for securing the gutter to the facia panel.
• the developmental procedure leading to the invention of the gutter bolt is as follows. First seven inch metal threaded self tapped coated steel Phillips head 3/16" thick insulation screws were tested. Each was fastened with a #3 Phillips bit/7" lag bolt hex head. The results are as follows. Extensive stripping of the bolt head due to the torque applied to the long steel bolt to screw it into the wood that was meant for metal installation. Even cutting a wider and deeper slotted head into steel screws did not solve the problem. Changing it into a universal
• Phillips or slotted head also failed to solve the problem.
• the force required for holding a drill that need to be applied caused a splitting of facia boards.
• the drill tip would pop out and then accidentally mark or puncture the gutter. Pilot holes thusly had to be drilled.
• the excessive damage and the amount of time required for this procedure did not make those screws commercially applicable in business.
• a head with more points of controlled contact is provided.
• Lag bolts require a pilot hole when fastening into new wood, so that there is no splitting of the facia board. Once again this is a very time consuming procedure. Also the bolt head protruded out from the front of the gutter. Quite often, the lag bolt head projected very far out in front of the gutter. The lag bolts therefore have an unsightly appearance and bring unwanted attention to the fastener for the gutter. Cutting back the heads of the lag bolt is not acceptable, even when the heads are painted to match the color of the gutter. When fastening due to torque of the tool, the fastener paint is removed and chipped away. Touch up painting is required to prevent rusting which starts occurring immediately.
• Rods or coil aluminum was used plus heat treating application followed by specific machining techniques.
• five different types of aluminum were tested with eight heat treatment processes involved with the different aluminum material before using current material.
• Hundreds of tests were made by drilling seven inch bolts into three-quarter inch pine boards. Then there was test drilling into Douglas Fir for the occasional situation wherein the gutter bolt hits the rafter tails that holds up the facia board. Finally an aluminum bolt material was found that had the strength necessary to achieve the desired results.
• the Prior Art U.S. Patent No. 3,909,905 to Giordano discloses gutter installation tools.
• the invention consists of a spacer tool having a U-shaped channel and being positioned between the front and rear panels of the gutter.
• a conventional spike can be driven through the front gutter panel into the U-shaped channel and the rear gutter panel to fasten the gutter to the structure.
• the prior art discloses a novel spike design that adds a notch on the shaft near the head for engaging the front portion of the gutter. The notch enables a more secure coupling between the spike and the gutter.
• This more secure connection eliminates the need for subsequent re-securing of the gutter with the facia panel.
• This more secure connection also eliminates the need for using a pilot hole in the facia board.
• a wood screw or gutter fastener having a head portion for receiving a tool, a first shank portion integrally formed with head portion, and second shank portion integrally formed with the first shank portion.
• the first and second shank portions each a have a specific length, and share a common longitudinal axis.
• the length of the first shank portion is such that the gutter fastener can pass through the front of a gutter and extend across the water collecting opening in the gutter.
• the second shank portion has a length substantially equal to one-half the length of the first shank portion.
• the second shank portion is threaded in a screw-like manner, and has a pointed end for facilitating the engagement of the gutter fastener with the gutter and facia panel. It is therefore a further object of the present invention to provide a wood screw or gutter fastener that utilizes a threaded end to secure the gutter to the facia panel.
• a further object of the invention is to provide a wood screw or gutter fastener that eliminates the need for re- securing the gutter to the facia panel after a period of time.
• the present invention solves this prior art problem.
• the solution for using these bolts without pilot holes resides in cutting the threads to such a degree of pitch, curvature, height, depth, sharpness, so that the threading cuts like a drill bit and the threading holds like a wood screw. After 30 different tests, it was determined to cut eleven threads to the inch at a thread depth of one-third the gutter bolt diameter from top to bottom of thread.
• a steep pitch in the front of the thread is for cutting and lesser curved or shallow pitch behind the thread enables the thread to cut like a drill due to the steepest pitch and hold like a wood screw due to the shallow portion of the thread.
• Threads extended from the smooth portion length and threading includes 2.5 inch cut into the seven inch length bolt. This was researched for use with fasteners of 3 different size gutters (4", 5", 6") and gives the most support to the four inch smooth portion meeting the cut portion. This is due to taking away 1/16" from actual thickness of smooth portion from cutting in threads and for fastening a gutter, example 4" gutter 2 1/4" passes through the 3/4" standard thickness facia board with 1/4" of thread still embedded in back facia. The one-half inch smooth portion is embedded into the facia with the four inch smooth portion supporting the gutter with washer hex head contacting the gutter.
• the gutter bolt of the invention is 7 inch in total length and includes a 2.5 inch wood screw threaded end portion on the one-quarter inch diameter thick gutter bolt.
• the threading is primarily to go through the facia board and the rafter tails if necessary.
• the gutter bolt is of so great a strength that this fastener can hold the entire weight of gutter system without the use of a bracket system as in the prior art.
• a sleeve may be added but only to keep the cavity of gutter from being crushed if pressed towards the facia board. This is in case of force applied to front of gutter and is other than what gutter is designed to support.
• the smooth unthreaded shank portion of the gutter bolt connects into the threaded part of the gutter bolt so as to provide the maximum strength to support the gutters. This is because all the threading is embedded into the wood so that only the smooth shank can be covered by the sleeve to the depth of the 5" cavity of the gutter.
• the gutter bolt can penetrate the pieces of wood close to the edge of the wood without splitting.
• Prior art rolled or lathed wood threading fasteners are known to split the wood without first having a prior pilot hole being drilled into the wood.
• the hexagonal shaped head, or hex head provides six points of fastening contact on the sides of the gutter bolt head.
• the hexagonal shaped head or hex head
• a hex head washer combination attached to the smooth portion of the shank provides a greater holding force at the front of the gutter. Since the washer has a larger diameter than hex head diameter, the washer also prevents the socket wrench used for turning the hex head from touching the front of the gutter and from leaving a ring mark or scratch on the gutter face when securing the bolt to the gutter.
• facets are added to the screw portion of the fastener part for wood screw installation to reduce the required torque.
• Facets are notches cut or rolled in between each thread of the fastener. Facets reduce the torque on the head, rod, threading, tools and reduce the stress on the material being fastened, such as the facia. Facets are shaped multiangle and do not exceed the highest or lowest point of the threading. They are a separate function of the screw portion. Facets are located on the remaining solid portion of the rod and between each of the threads. Facets are recessed at different angle pitches allowing the wood to pass over the highest point of the facet and to reside in the deepest most recessed portion of the notch.
• the present invention is thusly directed to a screw-threaded portion of a wood screw or gutter bolt fastener comprising a shaft having threads thereon, and each thread having a front; said thread having a steep pitch in the front of the thread and having a shallow curved portion behind the thread; and facets comprising notches located in the shallow curved portion behind the thread.
• the angle of the facet reduces stress in the wood. As the wood slides up to the next facet, it gradually builds up torque until it reaches the highest point of the facet. This equals the amount of pressure of a solid rod fastener without facets until it rolls over into the cavity of the next facet. With many facets placed on each thread having multiple threads per inch, stress relief will occur on each individual thread.
• the facets are added to the shallow portion of the thread. This requires slowing down the turning RPM of the cutting blade as it contacts the rod. This permits the cutting blade to reside in one area of the circumference of the bolt for a longer time and to make deeper cuts of random or controlled depths and sizes within the facet. Thus there can be a variable number of facets for each individual thread.
• angles of the facets vary in degrees. This allows screwing the threaded portion into the wood so as to turn the fibers with the threads. Hence the fibers of wood will conform to the low-high angles of the facets.
• Facets provide a gradually sloped portion of the thread when turning the fastener clockwise into the wood. This allows fibers of the wood to travel up the least slope part of the facet to the normal pressure depth of the thread. Fibers of wood then drop off the steep end of the facet allowing expansion of the fibers of wood down into the lowest portion of the facet. This reduces the pressure and the force that are applied to the wood fibers by the solid portion in between the threads .
• the facets permit the wood fibers to have a constant pressure relief at all times per thread, since in one embodiment there are many facets randomly placed at different depths per thread. Wood fibers are not evenly placed on any two facets at one time allowing a multiple action for pressure release all the time. Hence, there are expansion, and contraction, of wood fibers around the threaded portion of the fastener as it penetrates into the wood. There are from 5 to 15 facets, or notches, per thread, preferably from 8 to 10 facets per thread.
• the present invention is a solution to this problem due to the uniqueness of gutter bolts. For example, they fasten three types of gutters with one size of fastener having adequate holding power, and not having to predrill pilot holes for the fastener gutter bolt of the invention.
• the gutter bolts of the invention have several important advantages.
• the gutter bolts have achieved significantly improved sales in spite of the cost of producing the bolt.
• Commercial success has been achieved with very little advertising and is the result of demonstrations of the product by the inventor, installers, homeowners, etc.
• Gutter bolts can be up to five times more expensive than a prior art gutter spike, and are 1.5 times more expensive than prior art bracket systems.
• the savings in using gutter bolts of the invention is due to over the years not having to pay another person to renail the gutter back into position. Also there is avoiding the risk of the repair person falling to the ground in an attempt to nail back the loosened gutters. Also when nails do not grip in the same hole that was made with the original installation, the repair person would move that nail enter to the left or to the right of the existing hole for refastening of the loosened gutter. This causes additional holes in the back of gutter and in the facia board which in turn will permit water seepage to cause damage to the facia board. Also when replacing gutters in the past, it was necessary to replace facia board due to this excessive number of holes, and due to possible splitting of the wood, and water damage .
• the gutter bolts of the invention can solve these problems, due to the unique operational quality of the invention not only for new installations but also for gutter spike replacement as well. It is just necessary to remove the old original gutter spike and to install a new gutter bolt through the front opening and the back opening that had been previously made by the original gutter spike and then to screw the gutter bolt snugly into the facia. If the hole in the facia board is reamed out due to the gutter spike and if the threading does not grab into the wood, one could add a one inch plastic anchor into the reamed out hole. Then install the gutter bolt. For a secure fastening installation to hold that gutter, it is no longer necessary to use the leading prior art bracket system known as the hidden hanger. This prior art bracket system screws through the back of the gutter and only clips onto the front return lip of the gutter.
• FIG. 1 is a perspective view of the gutter fastener according to the invention
• FIG. 2 is a partial cross-sectional view of a gutter secured to a facia panel with the gutter fastener according to the invention
• FIG. 3 is a top view of a first embodiment of the tool receiving end of the gutter fastener according to the invention
• FIG. 4 is a top view of a second embodiment of the tool receiving end of the gutter fastener according to the invention.
• FIG. 5 is a top view of a third embodiment of the tool receiving end of the gutter fastener according to the invention.
• FIG. 6 is a perspective view of another embodiment of the gutter fastener according to the invention having the integrally attached washer at the tool receiving end of the fastener;
• FIG. 7 is a partial cross-sectional view of a gutter secured to a facia panel with the gutter fastener according to the invention, and having the integrally attached washer contacting the gutter;
• FIG. 8 is a top view of a fourth embodiment of the tool receiving end of the gutter fastener according to the invention, also having the integrally attached washer;
• FIG. 9 is a top view of a fifth embodiment of the tool receiving end of the gutter fastener according to the invention, also having the integrally attached washer
• FIG. 10 is a top view of a sixth embodiment of the tool receiving end of the gutter fastener according to the invention, also having the integrally attached washer
• FIG. 11 is an enlarged view of the partial cross-section shown in FIG. 7 showing in detail the second shank portion
• FIG. 12 is a plan view of the manufacturing technique for producing the unique threading of gutter bolt of the invention.
• FIG. 13 is a section view along line 13-13 of FIG. 12 showing facets added to the screw threaded portion of the fastener.
• FIGS. 1 and 2 show the gutter fastener 10 according to the invention.
• Fastener 10 has a first shank portion 14 and a second shank portion 16 integrally formed with one end of the first shank portion.
• a head portion 12 is integrally formed with the opposite end of first shank portion 14.
• First shank portion 14 and second shank portion 16 share a common central or longitudinal axis 30.
• First shank portion 14 has a length Lj and second shank portion 16 has a length L 2 .
• Length L ⁇ is substantially equal to twice the length L 2 . In other words, length L 2 is substantially equal to one-half the length L ⁇ .
• L : and L 2 these are the preferable lengths that enable gutter fastener 10 to operate more efficiently than other gutter fasteners.
• first shank portion 14 The length ⁇ of first shank portion 14 is such that this shank portion can completely pass through ferrule 22 and across water collecting opening 28 in gutter 20 (FIG. 2) .
• the threaded second shank portion 16 is completely secured within facia panel 24 and thereby secures gutter 20 to the facia panel.
• the overall length of fastener 10 is proportional to the diameter D such that an approximate ratio of 24:1 length to diameter is formed. For example, with diameter D equal to 1/4", the overall length of LI and L2 combined would be approximately 6".
• the overall length of fastener 10 can be in the range of 6"- 8" without the head.
• the preferred length of second shank portion 16 is 2 inches to 2.67 inches based upon an overall length of 6 to 8 inches.
• the length of fastener 10 plays an integral part in the design of the fastener. As the length is increased, the torque applied to the head when being forced into facia panel 24 causes an additional torsional stress to occur at the weakest points along fastener 10.
• the weakest points of fastener 10 are the point at which head 12a connects with first shank portion 14, and the transition point between first shank portion 14 and second shank portion 16 (i.e. where the threaded portion meets the non-threaded portion) .
• head 12a can have a thickness in the range of 1/8" - V.
• the total length of the gutter bolt fastener of the invention is such that the same size fastener can support a 4 inch gutter, a 5 inch gutter, or a 6 inch gutter, by itself without the use of any other fastener means.
• Second shank portion 16 has an end 18 that is pointed to facilitate the initial engagement of fastener 10 with gutter 20 and facia panel 24.
• pointed end 18 enables the user to hammer fastener 10 through gutter 20 and into facia panel 24 to further facilitate the initial engagement.
• Fastener 10 has a diameter D that can be, for example,
• Diameter D is chosen such that it is slightly larger that the diameter of a standard gutter nail.
• diameter D of fastener 10 can be different for first shank portion 14 and second shank portion 16.
• the diameter of second shank portion 16 could be slightly larger that of first shank portion 14.
• FIGS. 6 to 10 correspond respectively to FIGS. 1 to 5, except that in FIGS. 6 to 10 the integrally attached washer 40 is shown.
• Washer 40 is integrally attached to the head 12a on the inner surface 42 of head 12a such that washer 40 is located between the head and the first shank portion 14.
• the first shank portion 14, the washer 40 and the head 12a are of a unitary continuous construction having a tandem relationship to each other.
• the screw-like threads 50 (FIG. 11) of second shank portion 16 have sharp edges 15, and a pitch P suitable for engaging wood.
• the sharp edges provide a deeper thread than that of machine threads.
• the thread depth for wood is enlarged to compensate for the low strength of wood in comparison to the strength of steel.
• Pitch P can be in a range of 1/16" - 3/16" (i.e. approximately 5 to 16 threads per inch) .
• pitch P and diameter D have a ratio such that when one increases the other increases, and vice versa.
• the pitch P is chosen such that it is small enough to reduce the torque needed to drive the fastener 10, without effecting the ability to apply the fastener to the wood, or causing the fastener to torsionally break at its weakest point.
• the head 12a washer 40 combination attached to the smooth portion 14 of the shank provides a greater holding force at the front of the gutter. Since the washer 40 is circular in shape and has a larger diameter than head diameter 12a, the washer 40 also prevents the socket wrench used for turning the head 12a from leaving a ring mark or scratch on the gutter face when securing the bolt 10 to the gutter 20.
• a steep pitch in the front of the thread is for the cutting and a lesser curved or shallow pitch portion C behind the thread enables the thread to cut like a drill due to the steepest pitch and hold like a wood screw due to the shallow portion of the thread.
• the height H or the depth d refers to the distance from the edge at the sharpest point of the sharpness S to the surface of the shallow pitch position C of the curvature.
• the shallow portion of the curvature C is concave to such a degree that preferably the radius of curvature is almost infinite and thus the shallow portion C is almost flat.
• the sharpness S of the thread 50 is such that the angle of S relative to C is about 90°, or preferably is a right angle of 90 degrees.
• an oil or a TEFLON® coating e.g. a non-stick polymer lubricant coating
• a paraffin coating can be applied to the screw-like threads of second shank portion 16 to aid in reducing friction between fastener 10 and facia panel 24, thereby reducing the torque required to drive the fastener.
• the screw-like threading on second shank portion 16 provides an extra secure coupling of gutter 20 with facia panel 24.
• FIGS. 3, 4, and 5 show the first, second and third embodiments of head portion respectively.
• head portions 12a, 12b, and 12c are engaged by a manual or automatic tool operated by the user which applies the requisite rotational motion and pressure to secure gutter 20 to facia panel 24.
• Fastener 10 can be made from aluminum, galvanized steel, stainless steel, or any other suitable known material.
• the gutter bolt 10 is made from aluminum.
• pointed end 18 is placed against the gutter and lightly hammered through the front of the gutter and through the back of the gutter, until end 18 engages facia panel 24 under roof 26.
• a ferrule 22 is fit around fastener 10 before the hammer blow that penetrates the back wall of the gutter.
• head portions 12a, 12b, and 12c Upon initial contact with facia panel 24, repeated light hammer blows to head portions 12a, 12b, and 12c will cause pointed end 18 to further penetrate facia panel 24, and the threads on second shank portion 16 will cause fastener 10 to begin to rotate in the thread direction.
• the user may apply a manual or electric power tool to head 12a and further secure fastener 10 into the facia panel.
• the aluminum alloy used for the manufacture of the gutter bolt l ⁇ is alloy number 5356-0 from AlcoTec Wire Company of Traverse City, Michigan, and has the following chemical composition limits in % by weight based upon the total weight:
• this technique of double cutting of the front edge of the thread enables the bolt threads to be able to be drilled into the pieces of wood without splitting the wood.
• the gutter bolt actually drills its own pilot hole for the threads as it penetrates the wood.
• the gutter bolt drills like a drill bit and holds like a screw. Therefore, it takes a double cutting of the front portion of the thread of the gutter bolt to produce the steep slope thread front portion and to provide the shallow almost flat portion behind that front portion. By double cutting it at the front part of the thread, this gives the threads the sharpness needed to cut into wood like a drill bit. Only the front of the thread is cut during the reverse cutting pass 66 through the cutter machine 58.
• FIG. 13 shows the embodiment in which facets 80 are added to the screw portion of fastener threads 50 for wood screw installation to reduce the torque required.
• Facets 80 are notches 82 cut or rolled in between each thread of the fastener. Facets 80 reduce torque on the head, rod, threading, tools and reduce stress on material. Facets 80 are shaped multiangle and do not exceed the highest or lowest point of the threading. They are a separate embodiment of the screw portion. Facets are located on the remaining shallow curved portion behind the thread and in between each of the threads. Facets are recessed at different angle pitches allowing wood to pass over the highest point 84 of the facet into a notched pitched angle. This relieves the stress on the wood as the fastener screws into the wood. The facet gives the wood a chance to expand and contract. With the turning penetration into the wood of the threaded fastener, each individual thread allows this process to happen.
• the angle of the facet reduces stress in the wood. As the wood slides up to the next facet, it gradually builds up torque until it reaches the highest point 84 of the facet. This equals the amount of pressure of a solid rod fastener without facets until it rolls over into the cavity or lowest portion 86 of the facet. With many facets placed randomly or in an exact location on each thread having multiple threads per inch, relief of stress will occur on each individual thread. Between the highest point 84 and the lowest point 86 is the intermediate point 88 of the facet.
• the screw portion of the fastener holds better in wood.
• unscrewing counterclockwise rotation
• the threaded portion from the wood the wood now slides up to the highest point 84 of the facet.
• the wood has to overcome the resistence to removal at the maximum height 84 of the facet.
• FIG. 12 shows 8 facets.
• the angles of the facets vary in degrees.
• the angle « is subtended between points 86-88-84 and ranges between 90° to 120°.
• the angle ⁇ is subtended between points 88-84-86 and ranges between 130° to 160°. This allows screwing the fastener portion into the wood to turn with the threads causing fibers of wood to conform to the low-high angles of the facet.
• the facet has three sections of unequal length, namely the shortest length 90, the longest length 92 and the intermediate length 94.
• the intermediate length 94 connects the shortest length 90 to the longest length 92.
• the angle « is located at the intersection of the shortest length section 90 and the intermediate length section 94.
• the angle ⁇ is located at the intersection of the intermediate length section 94 and the longest length section 92.
• Standard 7" or 8" gutter nails are used for fastening gutters, as shown in the Marulic Patent No. 4,888,920.
• the normal spacing for all gutter fasteners is 2 H to 3 feet apart. Due to weather conditions, gutter nails tend to loosen after a year or two. The nails can even fall out if the weather conditions are severe, causing damage to the gutters and facia board which could allow water to seep into the house or basement.
• gutter nails tend to split the facia board when they are inserted too close to the edge of the wood. Also, the nails will bend when they hit something solid, for example a knot in the wood or the rafter tail. Gutter nails tend to bend when using pressure treated wood.
• Gutter bolts of the invention are a unique improvement. For example, there is full control when installing the gutter bolts. There is no more swinging of a hammer or leaning over the gutter from a ladder to screw in a hidden hanger. Gutter bolts are screwed in with an electric drill or 12 volt cordless drill. There is a reduced chance of an accident happening because of more control when fastening the gutter bolts. It is possible to use aluminum gutter bolts to install aluminum gutters, or to use copper gutter bolts for installing copper gutters. There is no mixing of metals. When fastening gutter bolts, they go right through knots in the wood, rafter tails or extremely hard woods. Gutter bolts do not need pilot holes.
• Gutter bolts do not split the wood even when being installed close to the edge of the wood. It takes about 875 pounds to remove a gutter bolt of the invention from a 3/4" pine board. If there is a 25' gutter and the gutter bolts are spaced 2 W apart, or installing 10 gutter bolts, there would be 8,750 pounds holding up a 25' gutter that weighs 20 pounds. If only 5 gutter bolts were used on a 25' gutter, there would be 4,375 pounds of holding force for a 20 pound gutter. The holding force for the gutter bolt of the invention greatly surpasses all existing prior art gutter fasteners, as can be seen from the prior art test results of 500 to 600 pounds for the prior art fasteners.

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• Engineering & Computer Science (AREA)
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• Structural Engineering (AREA)
• Connection Of Plates (AREA)
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• 1998
  • 1998-10-27 CN CNB988126729A patent/CN1143933C/zh not_active Expired - Lifetime
  • 1998-10-27 CA CA002307587A patent/CA2307587C/fr not_active Expired - Lifetime
  • 1998-10-27 AU AU12819/99A patent/AU736853B2/en not_active Expired
  • 1998-10-27 AT AT98956252T patent/ATE275681T1/de not_active IP Right Cessation
  • 1998-10-27 DE DE69826143T patent/DE69826143D1/de not_active Expired - Lifetime
  • 1998-10-27 RU RU2000113734/11A patent/RU2217631C2/ru active
  • 1998-10-27 EP EP98956252A patent/EP1029139B1/fr not_active Expired - Lifetime
  • 1998-10-27 WO PCT/US1998/022776 patent/WO1999023326A1/fr not_active Ceased

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