Roof Mount Base Plate Sealing Without Flashing for Solar Panels
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Solution Overview
Problem
Mounting equipment on metal roofs, particularly solar photovoltaic panels, faces challenges such as high installation costs, complexity, and the risk of water leakage due to premature aging of elastomeric seals exposed to air, sunlight, and moisture.
Innovation Solution
A mounting apparatus with a base plate and inwardly threaded cover portion that minimizes seal exposure using compressible annular seals, where the fastener compresses the second annular seal for direct contact with the roof surface, creating a water-resistant seal, and optionally incorporates an L-bracket or standoff for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If elastomeric seals are exposed to air, sunlight, and moisture for sealing purposes, then sealing effectiveness is improved, but the seals age prematurely and increase the possibility of roof leakage
Solution Approach 1:
The patent introduces an intermediary mechanism where the seal is compressed between the base plate and the equipment flange, creating a sealed environment that protects the elastomeric seal from direct exposure to air, sunlight, and moisture while maintaining sealing effectiveness against the roof surface
Solution Approach 2:
The elastomeric seal is contained within a protective structure formed by the base plate and equipment flange, effectively creating a protective shell that shields the flexible seal material from degrading environmental factors while allowing it to perform its sealing function
2Reliability
If complex mounting apparatus with multiple components is used to ensure secure mounting and water resistance, then mounting reliability is improved, but installation cost and complexity increase
Solution Approach 1:
The patent combines multiple functions into integrated components: the base plate simultaneously provides mounting attachment points, creates a sealed environment for the seal, and protects internal components from environmental exposure, eliminating the need for separate protective housings and reducing installation complexity
Solution Approach 2:
The base plate serves multiple functions including structural support, seal compression, fastener attachment, and environmental protection, making the mounting apparatus more efficient and reducing the total number of components needed for reliable mounting
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
Simplifies installation, reduces costs, and minimizes the risk of water leakage by protecting seals from environmental exposure, ensuring a secure and durable mounting system for solar photovoltaic panels and other equipment on various roof structures.
Implementation Method 1
The fastener compresses the second annular seal and secures a portion of the base plate bottom surface in direct contact with the roof surface
Implementation Method 2
The bottom of the cover portion compresses the first annular seal either directly or against the intermediary surface. This combination creates a water resistant seal over the fastener
Data Source
AI summary
Disclosed is an apparatus for mounting equipment or solar photovoltaic structures to roofs where the apparatus base plate engages the roof surface directly, creating a water resistant seal, without the need for flashing. The base plate upper surface includes an upwardly projected portion that is circumscribed by a groove. The base plate lower surface includes a counterbore. Both the counterbore and the groove are disposed to receive annular seals. A threaded fastener is received and seated the upwardly projected portion top surface and feeds through the counterbore, securing the base plate to the roof structure and creates a water resistant seal by compressing the lower annular seal and by creating surface-to-surface contact with the roof and portion of the base plate. An inwardly threaded cover portion engages the upwardly projected portion either directly or through an intermediary, creating a water resistant seal over the fastener.