Preformed Hinged Foam Sump for Flat Roof Drainage

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Solution Overview

Problem

The existing methods for creating a sump on flat roofs are time-consuming, require skilled labor, and result in significant material waste, as they involve cutting foam insulation panels on-site to form a slope and sump, which are typically large and difficult to recycle.

Innovation Solution

A preformed sump with mirror-imaged sides that fold together via a hinge, composed of isosceles triangle panels bonded with flexible tape, allowing for easy transportation and on-site assembly around the drain, reducing the need for on-site cutting and waste.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If foam insulation panels are cut on-site to form a sump, then the sump can be customized to fit the drain, but the installation time increases and skilled labor is required

Engineering Contradiction:

Improvecustomization to fit drainVSAvoidinstallation time

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The sump is pre-formed at the factory with the correct shape and dimensions to fit standard drains, eliminating the need for on-site cutting and customization. The pre-formed sump includes integrated flashing and is ready for immediate installation, significantly reducing installation time and eliminating the need for skilled cutting operations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention uses a standardized template or pattern for the sump design that can be replicated in manufacturing. This allows the sump to be precisely formed in the factory using molds or templates, ensuring consistent fit for standard drains without requiring on-site measurement and cutting.

Inventive Principle:

Principle #26Copying

2Adaptability or versatility

If foam insulation panels are cut on-site to form a sump, then the sump can be customized to fit the drain, but material waste increases

Engineering Contradiction:

Improvecustomization to fit drainVSAvoidmaterial waste

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention eliminates material waste by forming the sump from a pre-cut piece of foam insulation that is precisely sized in the factory. The remaining foam material from the manufacturing process can be reused or recycled, whereas on-site cutting produces irregular scraps that are difficult to recycle.

Inventive Principle:

Principle #34Discarding and recovering

3Productivity

If a preformed sump is used, then installation time is reduced, but the sump must be transported to the job location in a compact form

Engineering Contradiction:

Improveinstallation timeVSAvoidtransportation requirements

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The sump is designed to fold into a compact configuration that can be nested within itself or alongside other sump components during transportation. The folded sump fits within a standard 4×8 foot shipping container, allowing efficient transport to the job site despite the expanded size when installed.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The sump incorporates flexible hinges that allow it to transition between a compact folded state for transportation and an expanded three-dimensional form for installation. The flexible tape hinge enables the sump to be easily unfolded and shaped at the job site to fit around the drain pipe.

Inventive Principle:

Principle #15Dynamics

4Device complexity

If the sump is made from multiple panels, then the sump can be folded for shipping, but the manufacturing process becomes more complex

Engineering Contradiction:

Improvefoldable structureVSAvoidmanufacturing process

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

The sump is divided into multiple triangular panels that are connected by flexible hinges, allowing the structure to be folded into a compact form for shipping. The segmentation into standard triangular panels also simplifies the manufacturing process, as each panel can be cut from standard 4×8 foot sheets of foam insulation using simple geometric patterns.

Inventive Principle:

Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution significantly reduces installation time, requires less skilled labor, and minimizes material waste, facilitating faster and more cost-effective installation of flat roof membranes while ensuring proper drainage.

Implementation Method 1

The two sides are bonded together with a flexible tape to form a unitary sump

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Data Source

PatentUS8365487B2Roof sump structure

Publication Date: 2013.02.05 HUNTER PANELS LLC

AI summary

A preformed hinged foam sump for use on a flat roof includes two mirror image sides connected along the hinge which folds from an 8×8 structure to a 4×8 structure. Each of the mirror image panels includes a central panel which is a right isosceles triangle which slopes to the 90 degree angle of the right isosceles triangles. Each side includes two side panels which are sloped to the same point as the central panel and are also right isosceles triangles. The panels are bonded together to form each side which is connected by a flexible material or tape along the bottom side to allow the two sides to fold relative to each other to change from an 8×8 structure to a 4×8 structure and open up to an 8×8 structure for use on a roof surface.