Polymer Rooftop Equipment Support With Metal Fastener Channel
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Solution Overview
Problem
Existing rooftop equipment supports, such as those made from pressure-treated lumber, are prone to rot, rust, and damage, and may rupture the roof membrane, while alternative solutions like polyethylene foam supports do not fully address the need for durable and easy-to-install options that avoid penetrating the roof membrane and accommodate equipment movement.
Innovation Solution
A rooftop equipment support system comprising a polymer material block, typically made of polyurethane foam, combined with a metal fastener support that covers the edges of the block, providing a channel for fasteners and threaded inserts for secure attachment, thereby protecting the block from physical damage and UV exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If pressure-treated lumber is used as rooftop support, then the support structure is strong and durable, but the wood may rot, rust hardware, and rupture the roof membrane
Solution Approach 1:
The invention uses a composite structure combining polyethylene foam (providing buoyancy and protection) with metal fasteners and pressure-treated lumber links (providing structural strength). This composite approach allows each material to contribute its strengths while mitigating weaknesses - the foam protects against rot and rust while the metal components provide durable, non-rotting fastening capability
Solution Approach 2:
The polyethylene foam block serves as an intermediary between the roof membrane and the piping system. It provides a protective buffer that prevents direct contact between rigid support components and the vulnerable roof membrane, while also providing buoyancy to lift pipes clear of obstacles and standing water
2Strength
If pressure-treated lumber is used as rooftop support, then the support provides necessary elevation, but the wood is heavy and difficult to move
Solution Approach 1:
The polyethylene foam block provides buoyant force that counteracts the weight of the piping system and support hardware. This buoyancy effect reduces the effective weight that needs to be supported by the roof membrane and makes the overall assembly easier to position and adjust during installation
3Object-affected harmful factors
If free-floating supports are used, then the roof membrane is not penetrated, but additional tools and hardware are required for installation
Solution Approach 1:
The invention combines multiple functions into integrated components: the polyethylene foam block integrates buoyancy, protection, and positioning functions; the metal fasteners integrate attachment and adjustment functions; the pressure-treated lumber links integrate structural support and elevation functions. This integration reduces the number of separate components and tools needed for installation
Data Source
AI summary
A rooftop equipment support includes a polymer material block and a metal fastener support attached to an upper portion of the block. The fastener support has a fastener portion that is configured to receive one or more fasteners for securing piping or other equipment. According to one embodiment, folded-down lips of the metal fastener portion form a channel configured to accept one or more fasteners, such as pipe clamps. In another embodiment, the metal fastener portion is a plate having one or more threaded inserts. The threaded inserts may be located between a sheet metal part of the fastener portion and a top surface of the polymer material block. The polymer material block may be made of a polyurethane foam material. The metal fastener portion may cover at least part of the edges of a top surface of the polymer material block.