Roof Mounting Bracket Using Opposing Set Points to Reduce Seam Damage
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Solution Overview
Problem
Existing roof mounting systems require high torque to secure brackets to panel seam roofs, which can damage the paint finish or pierce the metal, and often necessitate creating dimples or dents in the seam, complicating the installation process.
Innovation Solution
A roof mounting bracket that uses opposing set points to create deformations in the panel seam, securing the bracket without the need for high torque or damaging the metal, by inserting screws through threaded fasteners to create a 'wave'-like deformation, allowing secure attachment with less user force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high torque is applied to secure the bracket to the panel seam, then the attachment strength is improved, but the paint finish is damaged or the metal is pierced
Solution Approach 1:
The patent changes the attachment mechanism from high-torque friction-based connection to low-torque deformation-based connection. By using opposing set points that create controlled deformations in the panel seam, the system achieves secure attachment without requiring high torque that would damage the paint finish or metal.
Solution Approach 2:
The patent converts the potentially harmful effect of metal deformation into a beneficial attachment mechanism. By deliberately creating controlled deformations at opposing set points, the system transforms what would normally be considered damage into the very mechanism that secures the bracket to the panel seam.
2Reliability
If a single set screw is used to create a dimple in the panel seam, then the bracket is secured to the seam, but the installation process is complicated and requires creating dimples or dents
Solution Approach 1:
The patent divides the attachment function into multiple opposing set points distributed along the bracket arms. Instead of relying on a single dimple creation point, the system uses multiple distributed contact points that collectively secure the bracket, simplifying the installation process while maintaining reliable attachment.
Solution Approach 2:
The patent inverts the traditional approach of creating a dimple to secure the bracket. Rather than using a single set screw that pushes metal in between two other set screws, the system uses opposing set points that create deformations that work together to prevent sliding, reversing the conventional dimple-creation methodology.
3Reliability
If multiple set screws are used to create compression or friction-type attachment, then the bracket is secured to the seam, but high torques are required that can damage the panel
Solution Approach 1:
The patent fundamentally changes the attachment parameter from torque-based friction connection to deformation-based mechanical interlocking. By using opposing set points that create controlled deformations in the panel seam, the system achieves secure attachment without requiring high torques that would damage the panel.
Solution Approach 2:
The patent converts the potentially harmful effect of metal deformation into a beneficial attachment mechanism. By deliberately creating controlled deformations at opposing set points, the system transforms what would normally be considered damage into the very mechanism that secures the bracket, eliminating the need for high torques.
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 bracket provides a secure attachment to the roof panel seam with reduced torque requirements, preventing damage to the paint finish or metal, and simplifying the installation process by deforming the metal using opposing set points instead of a single set screw.
Implementation Method 1
creates a deformation or distortion in the panel seam using opposing set points to secure the bracket to the panel seam
Data Source
AI summary
A roof mounting bracket is disclosed which creates a deformation in a roof panel seam using opposing set points. In a preferred embodiment, a generally U-shaped bracket includes two or more threaded fasteners in a first arm of the bracket and one or more opposing threaded fasteners in the second arm. Void in bracket is placed over the panel seam, with the first arm on a first side of the seam and the second arm on the opposite side of the seam. First screws inserted into the fasteners in first arm pass through the first arm and the first screw heads contact the first side of the seam, slightly engaging the seam and creating first deformations in the seam as the set screws are tightened. Second screws inserted into the fasteners in the second arm pass through the second arm and the second screw heads contact the second side of the seam in the spaces between the first deformations on the opposite side of the seam, engaging the seam and creating second deformations in the seam as the second screws are tightened. The opposing contact points create a “wave” deformation in the seam, securing the bracket to the seam. The opposing set points of the present invention allow secure attachment of the bracket to the seam without having to “dimple” or dent the panel seam using a single set screw, requiring less force by the user. Bracket can include varying numbers of opposing fasteners in first and second arms for varying numbers of opposing set points. In an alternative embodiment, bracket can further comprise divots into which first deformations are recesses to create a deeper “wave” the seam for stronger attachment to seam.