Roof Mounting Adapter Plate for Non-Invasive Load Transfer
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Solution Overview
Problem
Existing roof mounting systems require invasive procedures to secure anchor devices to the underlying structural decking, compromising the roof integrity and necessitating repairs, as they need to penetrate the roof surface and insulation to attach to structural members, which is not feasible with approved manufacturer procedures.
Innovation Solution
A non-invasive roof mounting adapter plate with an anchor plate and elongated fasteners that securely fasten to a support structure below the roof surface, distributing load forces without damaging the insulation or membrane, using counter-bores and threaded fasteners to transfer loads directly to the underlying structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If anchor devices are installed by penetrating the roof surface and insulation to attach directly to structural decking, then secure attachment and support for equipment is achieved, but the integrity of the roof covering and insulation is compromised, necessitating repair work
Solution Approach 1:
The patent introduces an intermediary mounting system consisting of a mounting plate and fasteners that attach to the roof surface without penetrating the insulation layer. The mounting plate distributes loads across multiple attachment points on the roof decking, while the insulation and vapor barrier remain intact. This intermediary approach allows secure equipment mounting while preserving roof integrity.
Solution Approach 2:
The mounting system is segmented into multiple components: a mounting plate with multiple attachment points, separate fasteners, and equipment-specific mounting brackets. This segmentation allows the system to distribute attachment forces across multiple locations on the roof decking, achieving secure attachment without requiring single-point penetration through the entire roof assembly.
2Reliability
If roof membrane and insulation are cut to expose structural decking for anchor installation, then proper structural support is obtained, but difficult-to-flash penetrations are created requiring additional repair work
Solution Approach 1:
The mounting plate is designed with pre-formed attachment features and mounting holes that align with the roof decking structure. Fasteners are pre-configured to attach to the decking through the membrane without requiring cuts. This preliminary preparation of the mounting system eliminates the need for complex field modifications to the roof assembly.
3Force
If existing anchor devices are used that require direct attachment to structural members, then adequate load support is provided, but invasive installation procedures are required that compromise the roof assembly
Solution Approach 1:
The patent replaces the traditional mechanical penetration-based attachment system with a surface-mounted fastening system. Instead of mechanically penetrating through the roof assembly, the system uses fasteners that attach to the roof decking through the membrane material, with the mounting plate distributing loads across multiple attachment points. This substitution maintains load support capacity while eliminating invasive installation.
Data Source
AI summary
A non-invasive roof mounting adapter plate and method for installing same. In one embodiment, a mounting adapter for attaching an object to a generally flat surface includes an anchor plate having an upper surface and a lower surface, and one or more first apertures extending through the upper and lower surfaces, each first aperture including a counter-bore configured to receive a corresponding first elongated fasteners, each elongated fastener having a length sufficient to extend through and securely fasten the anchor plate to a support structure below the generally flat surface; and a second fastener extending normal from the upper surface of the anchor plate and configured to secure the object to the mounting adapter, wherein load forces from the object are directly transferred from the anchor plate to a support structure below the generally flat surface via the first elongated fasteners.