Non-metallic Pipe Connector for Corrosion-Free Roof Mounting
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Solution Overview
Problem
Current methods for securing pipes to supports on rooftops are inefficient, prone to corrosion, and aesthetically unappealing, with wooden blocks being non-uniform, susceptible to decay, and metal strapping experiencing electrolysis and corrosion when used with solar panels.
Innovation Solution
A pipe support block and connector system made of non-metallic materials like ABS, AES, or nylon, utilizing a dual channel configuration with a locking mechanism involving zip ties or cable ties for secure and efficient installation, avoiding electrolysis and corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wooden blocks and metal strapping are used to secure pipes to supports, then the installation method is simple and materials are readily available, but the blocks are non-uniform in height, susceptible to rot and decay, and metal strapping experiences electrolysis and corrosion when used with solar panels
Solution Approach 1:
The patent removes metal components from the pipe support system entirely. The connector is made of non-metallic material (polymer or plastic) that eliminates metal-to-metal contact, preventing electrolysis and corrosion when solar panels are present. This extraction of harmful metal elements resolves the reliability issue while maintaining ease of installation through the simple snap-fit design.
Solution Approach 2:
The patent employs composite construction by combining a polymer or plastic connector material with a metal block. This composite approach allows the non-metallic connector to prevent corrosion and electrolysis while the metal block provides structural support. The dual-material solution addresses both reliability concerns and installation simplicity.
2Ease of manufacture
If wooden blocks are used as pipe supports, then the initial installation is straightforward, but the blocks rot and decay over time causing stress points and compromising the conduit
Solution Approach 1:
The patent replaces durable but complex metal support systems with a simpler, non-metallic connector designed for ease of installation. While the connector itself is intended to be long-lasting through corrosion resistance, the design philosophy embraces simplicity and replaceability rather than relying on naturally decaying wooden blocks.
Solution Approach 2:
The patent changes the material parameter from organic (wood) or metallic to synthetic polymer/plastic. This material substitution fundamentally alters the durability characteristics, providing resistance to rot, decay, and environmental degradation while maintaining the straightforward installation process.
3Strength
If metal strapping and screws are used to secure pipes to blocks, then the connection is initially strong, but the screws pull free when the wood begins to rot, compromising the connection
Solution Approach 1:
The patent eliminates metal fasteners (screws and strapping) from the connection system. The non-metallic connector uses a snap-fit or friction-based mechanical engagement that does not rely on penetrating fasteners, thereby preventing the issue of screws pulling free as the block deteriorates.
Solution Approach 2:
The patent replaces the screw-and-strapping mechanical fastening system with a integrated snap-fit or friction-based mechanical engagement. This substitution maintains connection strength while eliminating the reliability issue of fastener failure due to block degradation.
4Ease of manufacture
If wooden blocks are used for pipe support, then no special equipment is needed for installation, but cutting blocks to size requires proper saws and the process is time consuming
Solution Approach 1:
The non-metallic connector is manufactured in standardized, pre-cut sizes that eliminate the need for on-site cutting operations. This preliminary preparation of components in the factory setting resolves the productivity issue by removing time-consuming cutting steps while maintaining ease of installation through simple assembly.
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 solution provides a secure, efficient, and corrosion-resistant method for affixing pipes to supports, reducing installation time and maintaining structural integrity while being aesthetically appealing, even in environments with solar panels.
Implementation Method 1
It has recently been discovered that the DC power, combined with outside moisture is causing electrolysis and corrosion to occur at the connection points between the metal channel and the metal struts and the metal is decaying and failing
Data Source
AI summary
A connector for securing a pipe or conduit to a pipe support where the pipe support has at least one channel and two rails that run parallel to the channel and where the connector has an upper pipe connector portion having a platform and a fastening means for securing the pipe to the platform; a middle portion that provides a gap between the upper portion and a lower pipe support connecting portion and where the lower pipe support connecting portion has at least two legs that are integrally formed with the upper pipe connector portion and the two feet at a bottom portion of the legs has two channels formed by the feet and legs whereby the rails of the pipe support are inserted into and secured within the channels.