Interlocking Green Roof Trays for Gap-Free Modular Coverage

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Solution Overview

Problem

Conventional green roof systems face issues with gaps between modular trays leading to unutilized roof area, soil spillage, and increased installation costs due to the need for screws or bolts for connection.

Innovation Solution

A modular green roof system featuring trays with interlocking U-shaped edges and a double locking mechanism, eliminating gaps and the requirement for screws or bolts, while incorporating drain holes and a secure fastening system for efficient water management and easy installation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If modular trays are used in green roof systems, then storm water management and vegetation support are improved, but gaps between adjacent trays occur leading to unutilized roof area and soil spillage

Engineering Contradiction:

Improvestorm water management capacityVSAvoidroof area utilization

Core Design Contradiction:

Quantity of substanceVSArea of stationary object

Solution Approach 1:

The roof system is divided into modular trays that can be independently manufactured and installed. Each tray is a self-contained unit with integrated edges that interlock with adjacent trays, creating a segmented yet continuous coverage across the roof surface without gaps.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The tray design merges multiple functions into a single integrated component: the tray body contains vegetation support, storm water management, and interlocking edges for structural connection. The edges themselves are integrated into the tray structure rather than being separate elements, eliminating gaps between adjacent trays.

Inventive Principle:

Principle #5Merging (Combining)

2Stability of the object's composition

If screw or bolted connections are used to secure adjacent trays, then tray stability is improved, but installation time and costs increase significantly

Engineering Contradiction:

Improvetray connection stabilityVSAvoidinstallation time

Core Design Contradiction:

Stability of the object's compositionVSLoss of time

Solution Approach 1:

The fastening function is extracted from separate screw or bolt components and integrated directly into the tray edges themselves. The edges are designed with complementary geometries that interlock when trays are joined, eliminating the need for separate fastening hardware and reducing installation steps.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The tray edges are designed to self-connect through their interlocking geometries without requiring external fasteners. The complementary edge designs automatically align and secure adjacent trays together through their own structural features, making the connection system self-sufficient and simplifying installation.

Inventive Principle:

Principle #25Self-service

3Ease of manufacture

If gaps exist between adjacent trays, then tray manufacturing simplicity is maintained, but soil mixture spills out causing water pooling and roof damage

Engineering Contradiction:

Improvetray manufacturing simplicityVSAvoidsoil spillage and water pooling

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The tray edges feature asymmetric interlocking geometries where one edge has a protruding element and the adjacent edge has a corresponding recess. This asymmetric design creates a positive lock that prevents soil spillage while maintaining manufacturing simplicity, as the asymmetry is built into the edge profile rather than requiring complex additional components.

Inventive Principle:

Principle #4Asymmetry

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

The system provides seamless roof coverage, prevents soil spillage, reduces installation time and costs, and enhances water retention and energy efficiency by minimizing temperature fluctuations.

Implementation Method 1

The tray also includes a securing device that penetrates the sidewalls of the tray, thereby providing a double locking system

Methodology Applied

Scientific EffectMechanical Fastening: Mechanical Fastener

Implementation Method 2

reduced storm-water runoff, due to the water-absorbing nature of the vegetation and accompanying soil

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Implementation Method 3

reduced energy costs, due to the insulating effects of the vegetation

Methodology Applied

Scientific EffectThermal Insulation: Thermal Insulation

Data Source

PatentUS7726071B2Vegetation roofing system

Publication Date: 2010.06.01 COLUMBIA GREEN TECH

AI summary

A vegetation roofing tray comprising an interconnecting lip is provided. The interconnecting lip on the sidewall of a tray engages with a sidewall of an adjacent tray, securely interconnecting the adjacent trays side-by-side together. A securing device penetrating the sidewalls of adjacent trays may also be used to secure the adjacent trays together. A vegetation roofing system is also provided. The system includes two or more trays and an irrigation hose disposed across the trays.