Attachment member for attaching objects to an underlying construction element
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Solution Overview
Problem
Existing mounting solutions for solar panels on roofs, particularly those with insulation, are expensive and not suitable for all applications, and often fail to provide adequate support for heavy structures due to reliance on threaded bolts or nuts.
Innovation Solution
A cost-effective attachment member with a massive connection member and lower attachment elements, such as tapered metal rods, that can be securely screwed into underlying construction elements like rafters or concrete decks, providing a stable and torsionally rigid anchoring system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If threaded bolts or nuts are used to attach mounting brackets to underlying structures, then the attachment can be secured, but the system may not be sufficient to support heavy structures like solar panels adequately
Solution Approach 1:
The attachment member is divided into distinct functional segments: an upper bracket portion for mounting solar panels and a lower anchor portion for securing to the underlying structure. This segmentation allows each part to be optimized for its specific function, with the lower portion designed specifically for high-strength anchoring
Solution Approach 2:
The attachment member combines different material properties within a single integrated component. The upper bracket portion can be made from materials suitable for structural support, while the lower anchor portion incorporates features (such as expanded metal or specialized geometry) optimized for anchoring strength in concrete or masonry, creating a composite structure that exceeds the capabilities of simple threaded bolts
2Ease of manufacture
If existing mounting brackets are used, then solar panels can be mounted, but the production costs are high and the installation process is complex
Solution Approach 1:
The invention merges multiple components into a single integrated attachment member. Instead of requiring separate brackets, anchors, bolts, and nuts, the design combines the mounting bracket and anchor into one piece that can be installed as a single unit, reducing both manufacturing steps and installation complexity
Solution Approach 2:
The lower anchor portion is designed to be self-installing into the underlying structure. The expansion mechanism or anchor geometry allows the lower portion to secure itself into concrete or masonry without requiring additional fasteners, threading operations, or complex assembly steps, making the product install-ready and reducing labor costs
3Ease of operation
If multiple separate components are used for mounting, then attachment can be achieved, but the installation process becomes time-consuming and complicated
Solution Approach 1:
By combining the bracket and anchor into a single pre-assembled unit, the invention eliminates the need for on-site assembly of multiple components. The integrated design allows installers to simply position and secure one component rather than coordinating multiple parts, significantly reducing installation time and complexity
Solution Approach 2:
The attachment member is pre-assembled and pre-configured during manufacturing. The upper bracket and lower anchor are connected before delivery to the installation site, with all necessary alignment features and connection points already in place. This preliminary action transfers complexity from the installation phase to the manufacturing phase, where it can be more efficiently resolved
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
Enables fast, easy, and reliable mounting of solar panels and other objects on insulated roofs, ensuring adequate support and sealing while reducing production costs and simplifying installation processes.
Implementation Method 1
a lower attachment element configured to be mounted in the underlying construction element and attached to the connection member
Implementation Method 2
the lower connection surface is configured to bear against the underlying construction element and hereby provide a stabilising lower connection surface
Data Source
Figure 1a~1d
Figure 2a~2b
Figure 3a~3b
AI summary
An attachment member (2) for attaching one or more objects such as mounting rails for solar panels (86) to an underlying construction element (24) such as a rafter or a concrete deck is disclosed. The attachment member (2) comprises a massive or semi-massive connection member (4) having a longitudinal axis (X) and an upper end and a lower end. The connection member (4) is configured to transfer load from a mount (10), a bracket (10) or a unit (6) for attachment of the mount (10) or bracket (10) to at least one lower attachment element (8), where the connection member (4) comprises a lower connection surface (40) extending perpendicular to the longitudinal axis of the connection member (4), where the lower connection surface (40) is configured to bear against the underlying construction element (24), where the at least one lower attachment element (8) protrudes from the lower connection surface (40) and extends along the longitudinal axis (X) of the connection member (4).