Rooftop support system
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Solution Overview
Problem
Existing rooftop mounting systems for conduits and pipes are prone to damage from weight and thermal expansion, require frequent replacement due to moisture exposure, and are cumbersome to install, especially in varying height and slope conditions.
Innovation Solution
A rooftop support system featuring a support block with a U-shaped recess, inclined sidewalls, and an elongate channel with apertures, made from water-resistant and vibration-dampening materials like polymeric materials, which allows for easy transport, installation, and flexible adaptation to different heights and slopes without causing roof damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If wooden planks with metal clamps are used to mount conduits, then the mounting system can be constructed, but significant damage is caused to the roofing material from weight and thermal expansion movement
Solution Approach 1:
The patent changes the material parameter from wood to closed-cell foam, which fundamentally alters the interaction with the roof surface. The foam material provides sufficient structural strength while being gentler on the roofing material, preventing the damage caused by wooden planks during thermal expansion and contraction cycles.
Solution Approach 2:
The mounting system uses a composite structure combining closed-cell foam with integrated metal clamps and brackets. This composite approach provides the strength needed for secure mounting while the foam base protects the roof surface from damage, resolving the contradiction between mounting strength and roof protection.
2Ease of manufacture
If wooden planks are used for mounting, then the system can be built, but the wood rots and metal rusts from moisture exposure requiring frequent replacement
Solution Approach 1:
The patent changes the material parameter from organic materials (wood and unprotected metal) to synthetic materials (closed-cell foam and corrosion-resistant metal components). This material substitution eliminates the rot and rust problems while maintaining ease of construction through integrated design.
Solution Approach 2:
Instead of using inexpensive but short-lived wood and metal components that require frequent replacement, the patent employs durable closed-cell foam and corrosion-resistant metals that provide long-term reliability without increasing manufacturing complexity.
3Adaptability or versatility
If wooden planks are used for mounting, then the system can be constructed, but the planks must be shimmed or cut to accommodate height and slope variations requiring tools and complex installation
Solution Approach 1:
The closed-cell foam mounting system is designed with universal adaptability to accommodate various height and slope conditions without requiring modification tools. The foam material can be easily shaped and the integrated clamps adjust to different conduit configurations, eliminating the need for shimming or cutting operations.
Solution Approach 2:
The mounting system incorporates pre-formed features and integrated components that eliminate the need for on-site modification. The foam blocks are manufactured with predetermined shapes and the metal clamps are pre-configured to accommodate various installation scenarios, allowing direct installation without tools.
4Strength
If conventional mounting systems are used, then conduits can be mounted, but the systems are bulky and difficult to transport to the roof
Solution Approach 1:
The patent changes the material parameter from dense wood and heavy metal assemblies to lightweight closed-cell foam with integrated metal components. This material substitution dramatically reduces the weight of mounting systems while maintaining sufficient strength through the foam's structural properties and strategic metal reinforcement.
Solution Approach 2:
The patent merges the mounting block, clamps, and support structures into an integrated closed-cell foam assembly. This consolidation eliminates the need for separate wooden planks, metal brackets, and fasteners, reducing overall weight and simplifying transport while maintaining full mounting capability.
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, easy-to-install, and adaptable solution for mounting conduits and pipes, reducing damage to the roof and interior structures while simplifying the installation process by using a lightweight, water-resistant, and vibration-dampening design.
Implementation Method 1
made from water-resistant and vibration-dampening materials like polymeric materials
Implementation Method 2
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.