Conduit Tile Hook for No-Penetration Roof Installation
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Solution Overview
Problem
The existing method for installing solar PV system conduits on tilted rooftops is inefficient, requiring the use of glued wood pieces which are not readily available in electrical warehouses, slowing down installation and not aesthetically pleasing, while also causing overheating due to inadequate spacing from the roof surface.
Innovation Solution
The Conduit Tile Hook, made from durable materials like aluminum 6063 alloy, is designed to be easily installed on Spanish or flat tile roofs without glue, providing a 1.5″ gap to reduce overheating, using a hook mechanism that slides under existing tiles without penetrating the roof, thus eliminating the need for wood pieces and reducing installation time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wood pieces are glued to the tile to support the conduit, then the conduit can be mounted without penetrating the roof, but the installation process becomes slower and more complex due to additional steps (transport, cut, glue, dry time)
Solution Approach 1:
The patent extracts the wood piece intermediary and replaces it with a metal bracket that directly attaches to the tile. The bracket has a hook portion that engages with the tile's undersurface, eliminating the need for glue and wood pieces while maintaining conduit support functionality.
Solution Approach 2:
Instead of attaching support pieces to the top of the tile and then mounting the conduit, the patent inverts the approach by having the bracket hook engage with the undersurface of the tile from below, providing support without requiring adhesive or additional fastening steps.
2Manufacturing precision
If wood pieces are used to provide spacing between the roof and conduit, then the conduit is positioned at the required 1.5" distance, but the process requires multiple steps and materials not readily available in electrical warehouses
Solution Approach 1:
The patent merges the spacing function and mounting function into a single integrated metal bracket. The bracket's geometry inherently provides the required 1.5" spacing while simultaneously serving as the mounting mechanism, eliminating the need for separate wood pieces and glue.
Solution Approach 2:
The metal bracket performs multiple functions: it attaches to the tile, positions the conduit at the correct distance, and provides structural support. This multi-functional component replaces the multi-step process of attaching wood pieces and mounting the conduit separately.
3Device complexity
If the conduit is mounted close to the roof surface, then the installation is simpler, but the heat effects from sun exposure increase significantly
Solution Approach 1:
The bracket is designed with built-in spacing geometry that automatically positions the conduit at the thermally optimal 1.5" distance from the roof surface during installation, eliminating the need for separate spacing components and ensuring thermal performance is built into the installation process.
Data Source
AI summary
A Conduit Tile Hook is disclosed for supporting a conduit above a roof. The Conduit Tile Hook simply slides under an existing roof tile, without cut-outs or removing any nails, and allows the conduit to sit 1.5″ off of the roof surface to decrease the effects of heating caused by solar irradiance.