Polymeric Rooftop Support Block to Reduce Moisture and Thermal Damage
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Solution Overview
Problem
Existing rooftop mounting systems for conduits and pipes are prone to damage, require frequent replacement, and are cumbersome to install due to the use of wooden planks and metal clamps, which are not flexible and can be damaged by thermal expansion and moisture exposure.
Innovation Solution
A rooftop support system featuring a support block with a U-shaped recess, inclined sidewalls, and an elongate channel with apertures and coupling features, made from water-resistant and vibration-dampening materials like polymeric materials, allowing for easy transport, installation, and adjustable support for various conduit sizes and weights.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If wooden planks and metal clamps are used to mount conduits on the rooftop, then the mounting system can support the weight of conduits and HVAC equipment, but the system causes significant damage to the roofing material and requires frequent replacement due to rot and rust
Solution Approach 1:
The support block is constructed from a composite material combining wood pulp or cellulose with polymeric material, creating a single integrated component that provides both structural strength and resistance to moisture and thermal damage. This composite structure eliminates the need for separate wooden planks and metal clamps that were prone to rot and rust respectively.
Solution Approach 2:
The material properties are changed by transitioning from traditional wood and metal to a polymeric composite material that maintains mechanical strength while adding resistance to water, moisture, and thermal expansion. This parameter change in material composition directly addresses the durability issues of the previous system.
2Adaptability or versatility
If wooden planks are used to support conduits, then the system can accommodate various conduit sizes, but the planks must be shimmed or cut requiring bulky materials and tools to be transported to the roof
Solution Approach 1:
The support block is designed as a universal component with a standardized elongate channel that can accommodate various conduit sizes and configurations without requiring modification. The block can be used in different orientations and positions, eliminating the need for multiple specialized wooden pieces and installation tools.
Solution Approach 2:
The support block is designed as a modular, pre-fabricated unit that can be easily transported and installed as a single component rather than requiring assembly from multiple wooden pieces on-site. The integrated design with built-in channel and coupling features reduces installation complexity.
3Strength
If unfinished metal clamps are used to attach conduits to wooden planks, then the connection can be secured, but the unprotected metal rusts and requires frequent replacement
Solution Approach 1:
The polymeric composite material inherently provides protection against moisture and corrosion, eliminating the need for separate metal clamps that were vulnerable to rust. The material maintains connection strength while being immune to the harmful effects of water and moisture exposure.
Solution Approach 2:
The invention replaces expensive, short-lived metal components that require maintenance and replacement with a durable, long-lasting polymeric material that does not rust or rot, significantly reducing maintenance needs and replacement frequency.
4Strength
If the mounting system uses heavy wooden planks and metal components, then sufficient strength is provided, but the system is cumbersome to transport and install
Solution Approach 1:
The polymeric composite material provides high strength-to-weight ratio, delivering the necessary mounting strength while being significantly lighter than traditional wooden planks and metal clamps combined. This reduces transportation and installation effort.
Solution Approach 2:
Multiple components (support block, channel, coupling features) are merged into a single integrated polymeric unit, eliminating the weight of multiple separate wooden and metal components while maintaining or improving structural strength.
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 support system provides a durable, flexible, and easy-to-install solution that minimizes damage to the roof and reduces maintenance needs by using a lightweight, water-resistant material that can accommodate different conduit sizes and weights, while being easy to transport and assemble.
Implementation Method 1
made from water-resistant and vibration-dampening materials like polymeric materials
Data Source
AI summary
A rooftop support system including at least one support block. The support block includes a base configured to rest on the rooftop, and the base has a first base section and a second base section separated by a U-shaped recess that defines a first gripping feature. The support block includes first and second sidewalls unitary with the base and extending along a length of the support block, and the first and second sidewalls each define a second gripping feature. The support block also includes third and fourth sidewalls unitary with the base and extending along a width of the support block, and the third and fourth sidewalls each define a third gripping feature. An upper surface of the support block defines an elongate channel, and a pair of apertures are formed in the elongate channel with a coupling feature embedded therein.