Roof Rack Mount Structure for Hidden Fastener Hole Access
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Solution Overview
Problem
Conventional roof racking systems face challenges in alignment and secure attachment due to unevenly spaced studs and obstructed fastener holes, leading to potential safety hazards and installation delays, especially with small, loose components.
Innovation Solution
A mount with a unitary design featuring a base portion, connecting portion, and mounting portion, including multiple holes for adjustable alignment and a tapering configuration to access hidden holes, allowing secure attachment to roofing structures without requiring additional fasteners or tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fastener holes are located below the mounting area on the mount, then the mount structure can support the roof racking system, but the user cannot accurately align the fastener holes with the roofing structure
Solution Approach 1:
The mount extends the fastener holes vertically upward from the base portion to the mounting portion, adding a vertical dimension to hole accessibility. This allows fastener holes to be reached from above the roof surface rather than from below, enabling accurate alignment while maintaining structural support capability.
2Adaptability or versatility
If studs are spaced or located irregularly on the roof structure, then the mounting can accommodate various roof configurations, but the installation process becomes complicated
Solution Approach 1:
The mount incorporates adjustable positioning features that allow the mounting portion to be shifted and repositioned along the base portion. This dynamic adjustability enables the mount to accommodate irregular stud spacing and various roof configurations while maintaining a straightforward installation process.
3Ease of manufacture
If small loose components like nuts and bolts are used in the roof racking system, then the system can be assembled, but unnecessary delays and safety hazards occur when components are misplaced
Solution Approach 1:
The mount integrates the fastener holes directly into the mounting structure itself, combining the mounting function and fastening function into a single component. This eliminates the need for separate nuts and bolts, preventing component loss and installation delays while maintaining assembly capability.
4Strength
If the raised portion of the mount overhangs the fastener holes, then the mount can support the roof racking system, but direct access to tighten fasteners is blocked
Solution Approach 1:
The fastener holes are positioned to extend vertically through the mount structure, allowing access from the top surface rather than from the side. This dimensional change in access path enables workers to tighten fasteners directly from above, eliminating obstruction by the overhanging mounting portion while maintaining structural support.
Data Source
AI summary
A mount including a base portion having a first side and a second side. A plurality of holes are distributed along a lengthwise direction of the base portion and from the first side of the base portion to the second side. A connecting portion extends from the base portion in a direction transverse to a direction of extension of the base portion. A mounting portion extends from the connecting portion. The mounting portion extends in a direction transverse to the direction of extension of the connecting portion such that a portion of the mounting portion is disposed vertically above the base portion. The mounting portion has at least one hole.