Between-joist gutter and hanger apparatus and method

Abstract

A between-joist gutter and hanger apparatus and method having hangers and pans for enclosing the open spaces between each pair of adjacent joists. Hangers are attached on each side of the joist space and a pan is placed therebetween providing a continuous top over the area below. Some embodiments of the present invention include a two-part hanger with one-part securable to the joist and the second part securable to the pan and the joist. The first hanger part is securable to the joists and supports the pan and second hanger part. The second hanger attached to the pan and supported by the first hanger is securable to the joist, providing further support for the pan. In some embodiments, the first hanger part includes a mechanism for selectively detaching the pan and second hanger parts after installation to allow cleaning and maintenance. Some embodiment include cross bracing for additional strength.

1 . An apparatus comprising:
 a first upper hanger configured to be fastened to a side of a first joist by a first plurality of fasteners, the first upper hanger having an elongated concave groove recess, and below the groove recess, having a pan-receiver-guide portion and a lower edge spaced at a distance from the first joist;   a first drain pan having a lengthwise upper edge and having a lengthwise convex portion next to the upper edge, the upper edge and convex portion configured to be mated into the groove recess of the first upper hanger in a non-latched manner such that the drain pan is readily and non-destructively removable from below, and such that the drain pan is directly held against the first joist by spring pressure from the first upper hanger sufficient to hold a first weight that is at least half a weight of the drain pan; and   a first lower pan support configured to be fastened to the first joist by a second plurality of fasteners, wherein the pan support, once fastened to the first joist by the second plurality of fasteners, cooperates with the first upper hanger to securely support the drain pan in a manner sufficient to hold the drain pan plus a second weight that is greater than the first weight.   
   
   
       2 . The apparatus of  claim 1 , wherein the first lower pan support includes a separate first lower hanger configured to be mated onto the drain pan in a manner such that the first lower hanger is readily removable from the drain pan and when attached to the drain pan, is held by spring pressure sufficient to hold at least a weight of the first lower hanger in position on the drain pan while the drain pan is held by the first upper hanger, wherein fastening of the first lower hanger to the first joist is facilitated by support from the drain pan held by the first upper hanger without having to manually hold the first lower hanger in place, and wherein once the first lower hanger is secured to the first joist by a second plurality of fasteners, the first lower hanger more securely supports the drain pan in a manner sufficient to hold the drain pan plus a second weight that is greater than the first weight. 
   
   
       3 . The apparatus of  claim 1 , wherein the first lower pan support is a contiguous portion of the drain pan configured to vertically extend below an adjacent non-vertical portion of the drain pan and is held by spring pressure against a surface of the first joist when the drain pan is held by the first upper hanger, wherein fastening of the first lower pan support to the first joist is facilitated by support from the first upper hanger without having to manually hold the first lower pan support in place, and wherein once the first lower pan support is secured to the first joist by a second plurality of fasteners, the first lower pan support more securely supports the drain pan in a manner sufficient to hold the drain pan plus a second weight that is greater than the first weight. 
   
   
       4 . The apparatus of  claim 1 , wherein the drain pan is constructed of sheet metal. 
   
   
       5 . The apparatus of  claim 2 , wherein the first upper hanger and the first lower hanger are constructed of extruded materials. 
   
   
       6 . The apparatus of  claim 2 , wherein the first upper hanger and the first lower hanger are constructed of metal. 
   
   
       7 . The apparatus of  claim 1 , wherein the drain pan includes hand-width-spaced finger-port grooves running lengthwise along sloping walls in the drain pan to facilitate single-handed manual compression of a portion of the drain pan to aid in installation and removal of the drain pan. 
   
   
       8 . The apparatus of  claim 1 , wherein the drain pan includes at least one lengthwise narrow score-guide groove configured to facilitate knife-edge scoring, and wherein, along each of two sides of the score-guide groove, the drain pan includes one of two respective upper finger-port grooves that facilitate subsequent bending of the drain pan for breaking and separating the drain pan into a first narrower portion and a second narrower portion, each having a new edge, and wherein the upper finger-port groove along the new edge of the first narrower portion of the drain pan forms a convex portion pre-configured for mating with into the first upper hanger. 
   
   
       9 . The apparatus of  claim 1 , wherein the first upper hanger has a top engaging edge, the engaging edge extending lengthwise and configured to engage into the joist when the first upper hanger is fastened to the joist by the first plurality of fasteners, to help direct water from going between the joist and the first upper hanger and to provide an edge for caulking. 
   
   
       10 . The apparatus of  claim 9 , wherein top engaging edge of the first upper hanger also includes a lengthwise portion configured to extend away from the joist to provide a drip edge extending over the first plurality of fasteners. 
   
   
       11 . The apparatus of  claim 9 , wherein the first upper hanger includes a double-stick foam strip having two adhesive-covered faces, one of which is adhered to the first upper hanger below the top engaging edge and the other of which is placed against the joist to provide a moisture barrier and to temporarily hold the first upper hanger to the joist until first upper hanger is secured to the first joist by the first plurality of fasteners. 
   
   
       12 . A method comprising:
 providing a supply of sheet metal;   forming a piece of the sheet metal into a first upper hanger having an elongated concave groove recess, and below the groove recess, having a pan-receiver portion and a lower edge spaced to be at a distance from a first joist when the first upper hanger is attached to the first joist;   forming a piece of the sheet metal into a first drain pan having a lengthwise upper edge and having a lengthwise convex portion next to the upper edge, wherein the first drain pan is configured to be mated such that the upper edge and convex portion of the first drain pan fit into the groove recess of the first upper hanger in a non-latched manner when the first upper hanger is attached to the joist, wherein the drain pan is readily and non-destructively removable from below when the first upper hanger is attached to the joist and the drain pan is inserted under the first upper hanger, and wherein the drain pan is directly held against the joist by spring pressure from the first upper hanger sufficient to hold a first weight that is at least half a weight of the drain pan; and   forming a piece of the sheet metal into a first lower pan support that is configured to be fastened to the joist by a second plurality of fasteners, wherein the first lower pan support, once fastened to the joist by the second plurality of fasteners, cooperates with the first upper hanger to securely support the drain pan in a manner sufficient to hold the drain pan plus a second weight that is greater than the first weight.   
   
   
       13 . The method of  claim 12 , wherein the supply of sheet metal is in roll form to facilitate fabrication of arbitrary lengths with reduced scrap waste, and wherein the forming into the first upper hanger, the forming into the first drain pan, and the forming into the first lower pan support are done by roller-forming techniques. 
   
   
       14 . The method of  claim 12 , further comprising performing the method from a vehicle. 
   
   
       15 . The method of  claim 12 , further comprising;
 forming a piece of the sheet metal, separate from the piece used to form the drain pan, into a first lower hanger that forms the first lower pan support;   mating the first lower hanger onto the drain pan in a manner such that the first lower hanger is readily removable from the drain pan and when attached to the drain pan, is held by spring pressure sufficient to hold at least a weight of the first lower hanger in position on the drain pan while the drain pan is held by the first upper hanger;   fastening the first upper hanger against a side of the first joist using a first plurality of fasteners; and   fastening the first lower hanger to the first joist using a second plurality of fasteners, with the drain pan and first lower hanger temporarily held in place by the first upper hanger, and wherein once the first lower hanger is secured to the first joist by a second plurality of fasteners, the first lower hanger more securely supports the drain pan in a manner sufficient to hold the drain pan plus a second weight that is greater than the first weight.   
   
   
       16 . The method of  claim 12 , wherein the forming of the piece of the sheet metal into the first lower pan support includes forming a contiguous portion of the drain pan configured to vertically extend below an adjacent non-vertical portion of the drain pan, such that when the drain pan is held by the first upper hanger, the vertical portion is held by spring pressure against a surface of the first joist; the method further comprising:
 fastening the first upper hanger against a side of the first joist using a first plurality of fasteners; and   fastening the first lower pan support to the first joist using a second plurality of fasteners, with the drain pan and its first lower pan support are temporarily held in place by the first upper hanger, and wherein once the lower pan support is secured to the first joist by a second plurality of fasteners, the lower pan support more securely supports the drain pan in a manner sufficient to hold the drain pan plus a second weight that is greater than the first weight.   
   
   
       17 . A method comprising:
 providing a first upper hanger having an elongated concave groove, and below the groove recess, having a pan-receiver portion and a lower edge spaced to be at a distance from a first joist when the upper hanger is attached to the first joist;   fastening the first upper hanger against a side of the first joist;   providing a first drain pan having a lengthwise upper edge and having a lengthwise convex portion next to the upper edge;   mating the upper edge and convex portion of the first drain pan into the groove recess of the upper hanger in a non-latched manner, wherein the drain pan is readily and non-destructively removable from below, and wherein the drain pan is directly held against the first joist by spring pressure from the upper hanger sufficient to hold a first weight that is at least half a weight of the drain pan;   fastening a first lower pan support the first joist by a second plurality of fasteners, wherein the pan support, once fastened to the first joist by the second plurality of fasteners, cooperates with the upper hanger to securely support the drain pan in a manner sufficient to hold the drain pan plus a second weight that is greater than the first weight.   
   
   
       18 . The method of  claim 17 , further comprising;
 providing the first lower pan support that includes a first lower hanger;   mating the first lower hanger onto the drain pan in a manner such that the first lower hanger is readily removable from the drain pan and when attached to the drain pan, is held by spring pressure sufficient to hold at least a weight of the first lower hanger in position on the drain pan while the drain pan is held by the upper hanger; and   fastening the first lower hanger to the first joist without having to manually hold the first lower hanger in place, and wherein once the first lower hanger is secured to the first joist by a second plurality of fasteners, the first lower hanger more securely supports the drain pan in a manner sufficient to hold the drain pan plus a second weight that is greater than the first weight.   
   
   
       19 . The method of  claim 17 , further comprising;
 providing a first lower pan support that includes a contiguous portion of the drain pan configured to vertically extend below an adjacent non-vertical portion of the drain pan, and is held by spring pressure against a surface of the first joist when the drain pan is held by the upper hanger; and   fastening the first lower pan support to the first joist without having to manually hold the first lower pan support in place, and wherein once the first lower pan support is secured to the first joist by a second plurality of fasteners, the first lower pan support more securely supports the drain pan in a manner sufficient to hold the drain pan plus a second weight that is greater than the first weight.   
   
   
       20 . The method of  claim 17 , wherein the providing of the drain pan includes constructing the drain pan of sheet aluminum. 
   
   
       21 . The method of  claim 17 , wherein the providing of the drain pan includes forming hand-width-spaced finger-port grooves running lengthwise along sloping walls in the drain pan to facilitate single-handed manual compression of a portion of the drain pan to aid in installation and removal of the drain pan. 
   
   
       22 . The method of  claim 17 , wherein the providing of the drain pan includes
 scoring the drain pan along a lengthwise narrow score-guide groove that was configured to facilitate knife-edge scoring;   bending the scored score-guide groove by squeezing using an upper finger-port groove along each of two sides of the score-guide groove, wherein the bending of the drain pan provides snap breaking the drain pan into a first and a second narrower portion, each having a new edge.   
   
   
       23 . The method of  claim 22 , wherein once the drain pan is separated, the upper finger-port groove along the new edge of the first narrower portion of the snap broken drain pan forms a convex portion for mating with into an upper hanger. 
   
   
       24 . The method of  claim 17 , wherein the providing of the upper hanger includes forming a top engaging edge, the engaging edge configured to engage into the joist when the hanger is fastened to the joist by the first plurality of fasteners, to help direct water from going between the joist and the hanger and to provide an edge for caulking. 
   
   
       25 . The method of  claim 24 , wherein the forming of the upper hanger top engaging edge includes forming the engaging edge to extend both towards the joist and away from the joist to also provide a drip edge over the first plurality of fasteners securing the top hanger to the joist. 
   
   
       26 . The method of  claim 24 , wherein the providing of the upper hanger includes configuring a double-stick foam strip below the top engaging edge to provide a moisture barrier and to temporarily hold the upper hanger to the joist until upper hanger is secured to the first joist by the first plurality of fasteners. 
   
   
       27 . An apparatus comprising:
 a first drain pan having a lengthwise upper edge and having a lengthwise convex portion next to the upper edge;   upper means for temporarily supporting the drain pan to a first joist;   means for mating the upper edge and convex portion of the first drain pan into the means for temporarily supporting in a non-latched manner, wherein the drain pan is readily and non-destructively removable from below, and wherein the drain pan is directly held against the first joist by spring pressure from means for temporarily supporting sufficient to hold a first weight that is at least half a weight of the drain pan;   lower means for supporting the drain pan to the first joist, wherein the lower means for supporting, once fastened to the first joist by a second plurality of fasteners, cooperates with the upper means for temporarily supporting to securely support the drain pan in a manner sufficient to hold the drain pan plus a second weight that is greater than the first weight.