Tile Roof Solar Mounting With Oblique Fasteners and Waterproof Sealing
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Solution Overview
Problem
Existing solar panel roof mounting assemblies designed for asphalt shingle roofs are not suitable for tile roofs, as they can cause cracked tiles, and existing tile roof assemblies require tile removal for installation, which is inconvenient and may not provide adequate waterproofing and wind resistance.
Innovation Solution
A roof mounting assembly for tile roofs that secures a stanchion to the roof deck through a hole drilled in the tile, using a double-sided threaded fastener and obliquely positioned threaded fasteners, combined with polyurethane foam and waterproof adhesive sealant, along with optional roof-flashing and butyl rubber for enhanced waterproofing and wind resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a roof mounting assembly designed for asphalt shingle roofs is used on a tile roof, then the assembly can be installed without removing tiles, but the rigid tiles will crack due to compression from the fasteners
Solution Approach 1:
The patent changes the fundamental installation parameter from compression-based fastening (suitable for asphalt shingles) to penetration-based fastening through drilled holes (suitable for rigid tiles). This parameter change allows the same mounting assembly to be adapted for tile roofs without causing tile damage.
Solution Approach 2:
The installation process is segmented into distinct steps: first drilling holes in the tiles, then inserting and securing the mounting assembly. This segmentation separates the tile penetration function from the compression function, allowing each to be optimized for its specific material type.
2Reliability
If roof tiles are removed to install a tile roof mounting assembly, then the assembly can be securely attached to the underlayment, but the installation process becomes complex and time-consuming
Solution Approach 1:
Holes are drilled in the tiles before installing the mounting assembly. This preliminary action creates pre-prepared access points that simplify the subsequent installation process while maintaining secure attachment to the underlayment through the drilled holes rather than requiring tile removal.
Solution Approach 2:
The patent extracts the underlayment attachment function from the tile itself, allowing the mounting assembly to secure to the underlayment through holes in the tiles without requiring the tiles to be removed. This separation maintains attachment security while simplifying installation.
3Reliability
If traditional tile roof mounting assemblies are used without additional waterproofing layers, then the installation process is simpler, but the system lacks adequate protection against water infiltration and wind damage
Solution Approach 1:
Polyurethane foam is applied to the roof deck before installing the mounting assembly. This foam layer serves as a cushioning and sealing layer that prevents water infiltration and provides additional bonding surface, enhancing waterproofing performance before the mounting assembly is installed.
Solution Approach 2:
The patent combines multiple materials with different properties: polyurethane foam for cushioning and sealing, waterproof adhesive sealant for bonding and waterproofing, and butyl rubber for additional sealing. This composite material system provides superior waterproofing and wind resistance compared to single-material solutions.
4Reliability
If fasteners are extended vertically through the stanchion, then the installation process is simpler, but the system provides inadequate resistance to extreme wind events
Solution Approach 1:
The patent uses asymmetric fastener positioning with oblique angles rather than vertical alignment. This asymmetric configuration provides superior wind resistance by creating a more stable geometric arrangement that better resists uplift forces from extreme wind events, though it requires more complex installation.
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 secure attachment of solar panels to tile roofs without removing tiles, providing superior waterproofing and wind resistance, meeting stringent building codes for extreme weather conditions like hurricanes.
Implementation Method 1
The waterproof adhesive sealant bonds to the roof underlayment and creates a waterproof seal between the fasteners and the roof deck
Implementation Method 2
The butyl rubber forms a tight wind-resistant and waterproof bond between the flashing and the roof tile
Data Source
AI summary
Disclosed are methods and devices for securing a solar panel racking system to a tile roof, without removing roof tiles. The devices and method in combination may operate under severe weather conditions such as hurricanes, typhoons, and other tropical cyclones. An installer positions a stanchion through a hole in one of the roof tiles in the tile roof and onto a layer of polyurethane foam positioned over a layer of waterproof roof adhesive sealant. The installer extends the threaded fasteners obliquely through the stanchion, the layer of polyurethane foam, and the layer of waterproof roof adhesive sealant into the roof deck. The waterproof adhesive sealant bonds to the roof underlayment and creates a waterproof seal between the threaded fasteners and the roof deck.