Adjustable Roof Brackets for Non-Penetrating Patio Support
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Solution Overview
Problem
Standard 'L' brackets for attaching patio covers or other structures to buildings are weak, unsightly, require frequent installation, and necessitate removal of rain gutters, while also being difficult to match roof pitches and lacking in load-bearing capacity.
Innovation Solution
The development of brackets with a flat plate and saddle design that can be configured to match specific roof pitches without penetrating the roof substrate, allowing for load-bearing support of structures like patio covers, solar panels, and trellises, with options for adjustable pitches and reduced installation frequency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If standard L brackets are used to attach patio covers to buildings, then the attachment method is simple and widely available, but the brackets are weak, unsightly, and require frequent installation at 24" on center connections
Solution Approach 1:
The bracket is divided into distinct functional segments: a mounting plate for attachment to the building structure, a vertical support element, and a horizontal support element with a saddle for receiving the beam. This segmentation allows each part to be optimized for its specific function while maintaining overall structural strength.
Solution Approach 2:
The bracket transitions from the conventional two-dimensional L-shape to a three-dimensional structure with vertical and horizontal components extending in multiple directions. This adds dimensional complexity but enables the bracket to span greater distances and support heavier loads with fewer units.
2Ease of operation
If standard L brackets are attached to the building's wall or fascia, then attachment is straightforward, but it affects appearance and requires removal of existing rain gutters
Solution Approach 1:
The bracket design extracts the mounting function from the wall/fascia attachment point and relocates it to the roof structure. The mounting plate attaches to the roof deck or trusses, separating the support function from the aesthetic exterior surfaces and eliminating the need to remove gutters.
Solution Approach 2:
The bracket introduces an intermediate mounting plate that attaches to the roof structure rather than directly to the wall or fascia. This intermediary element mediates between the building structure and the patio cover, allowing attachment without interfering with exterior aesthetics or gutter systems.
3Adaptability or versatility
If standard L brackets are used, then they are readily available, but they must be bent to match roof pitch on site and are not load-bearing sufficient
Solution Approach 1:
The bracket incorporates adjustable parameters including the angle between the vertical and horizontal elements to match different roof pitches, and the length of the horizontal element to accommodate various beam positions. These parameter variations allow the same basic design to adapt to different roof configurations while maintaining structural integrity.
Solution Approach 2:
The bracket design allows for dynamic adjustment of the mounting angle and positioning to match different roof pitches. The vertical and horizontal elements can be configured at various angles during installation, enabling the bracket to adapt to different roof slopes while maintaining optimal load-bearing performance.
4Reliability
If more standard L brackets are installed at 24" on center, then coverage is increased, but installation time and complexity increase
Solution Approach 1:
The enhanced structural strength of each individual bracket compensates for reduced quantity. Each bracket is designed with sufficient load-bearing capacity to support the patio cover over longer spans, effectively counterbalancing the reduced number of units installed and maintaining overall attachment reliability.
Data Source
AI summary
Roof brackets for attaching a structure such as a patio cover to a building, and methods for installing the brackets. The brackets have a saddle for receiving a support beam of the structure. The brackets can be attached to the building roof, but do not penetrate the roof substrate, thus preventing leakage and other structural problems. The roof brackets comprise a plate that is installed between the roof substrate and the shingles or tile on the roof. The brackets are available in different configurations compatible with standard roof pitches for easy installation. One roof bracket has a riser so that the saddle is lifted above the roof. Another roof bracket is configured so that when installed the saddle is located beyond the edge of the roof. Other brackets can be attached to the rafters under the roof, are available in different configurations depending on standard roof pitch, and they are configured to extend below and outward from the fascia. Any of these brackets are available in versions which are adjustable by the installer to provide a level saddle even in situations where the roof does not have a standard pitch, whether by design or due to inaccurate installation.