Lightweight Composite Roofing Support for Steep-Roof Stability
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Solution Overview
Problem
Existing roofing support systems for steeply pitched roofs are heavy, require time-consuming repositioning, and often damage the roof with fasteners, while polymer blocks are unstable and prone to sliding.
Innovation Solution
A lightweight composite roofing support system with a dual-wedge design and a resilient cover layer that adheres to the roof without fasteners, providing a stable, non-skid platform for workers and materials, adaptable to various roof pitches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional jack stands and jack boards are used to provide a support platform, then a stable working surface is achieved, but the system becomes heavy and requires substantial time and effort for repositioning
Solution Approach 1:
The patent changes the material parameters from traditional heavy wood and metal to lightweight closed-cell foam with density of 0.02-0.08 g/cm³, while maintaining structural integrity through geometric design (wedge shape with specific angles) and surface treatments (adhesive layers, textured surfaces)
Solution Approach 2:
The patent uses composite construction combining closed-cell foam core material with adhesive layers and textured surface treatments to achieve both lightweight properties and stable, non-skid working surface characteristics
2Ease of operation
If jack stands and jack boards are used to create a support platform, then workers can work on pitched roofs, but the system requires anchoring with nails or screws that damage the roof and create leakage paths
Solution Approach 1:
The patent removes the fastening elements (nails, screws, anchors) from the support system design, replacing them with a friction-based retention mechanism that relies on the wedge shape and adhesive layers to hold the platform in place without penetrating or damaging the roof surface
Solution Approach 2:
The patent introduces adhesive layers as an intermediary between the foam support structure and the roof surface, providing attachment without penetration, and textured surfaces as an intermediary to enhance friction and prevent sliding without mechanical fasteners
3Weight of moving object
If polymer roof blocks are used to provide support on pitched roofs, then the system is lightweight, but the blocks are too rigid and unstable, tending to slide downward on steep roofs
Solution Approach 1:
The patent applies curved or rounded surface treatments to the foam blocks, creating textured surfaces that increase friction and prevent sliding, replacing the flat rigid polymer surfaces that caused instability
Solution Approach 2:
The patent uses asymmetric wedge shapes with specific angles (e.g., 30-60 degree angles) that provide mechanical interlocking with the roof surface and prevent downward sliding, replacing the symmetric rigid blocks that tended to slide
4Adaptability or versatility
If traditional support systems are used on steeply pitched roofs, then workers can access the roof surface, but repositioning the support structures is time-consuming and labor-intensive
Solution Approach 1:
The patent divides the support system into individual modular foam blocks that can be independently positioned and adjusted, allowing workers to quickly reconfigure the platform as needed without moving heavy interconnected structures
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 offers a stable, level working surface on steeply pitched roofs without damaging the roof, allowing easy movement and secure placement of workers and materials, reducing installation time and material costs.
Implementation Method 1
a longitudinally-extending resiliently compressible cover layer comprising a resiliently compressible cover material disposed on the first roof contact side
Data Source
AI summary
A lightweight composite roofing support system comprises a longitudinally-extending core member comprising a longitudinally-extending first roof contact side comprising a first edge and opposed second edge, a longitudinally-extending second side comprising a second side working surface having a second width and a second length that is greater than the second width, the second side tapering toward the first edge at a first predetermined acute angle, and a longitudinally-extending third side comprising a third side working surface having a third width and a third length that is greater than the third width, the third side tapering toward the second edge at a second predetermined acute angle that is different than the first predetermined acute angle, a first end comprising an integral first recess defining a first handle, and an opposed second end comprising an integral second recess defining a second handle, the core member comprising a wedge-shaped lateral cross-section.