Structural attachment sealing system
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Solution Overview
Problem
Existing systems for sealing structural attachments, such as solar panel mounts, often fail to create a reliable watertight seal, leading to leaks and requiring additional components like flashing and nails, which increase installation costs and vulnerability to water ingress.
Innovation Solution
A system utilizing an adhesive sealant injected under pressure through a sealant dispenser gun into an enclosed cavity around penetration points, ensuring a permanent airtight and watertight seal without the need for standard flashing and minimizing roof penetrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standard flashing and assemblies are used for sealing roof penetrations, then the sealing function is provided, but the installation cost increases and additional penetrations are created making the structure more vulnerable to leaks
Solution Approach 1:
The patent combines multiple sealing functions into a single integrated adhesive sealant system. The adhesive sealant simultaneously provides waterproofing, air sealing, and structural bonding functions that previously required separate flashing components, thereby reducing the number of parts while maintaining or improving sealing reliability
Solution Approach 2:
The adhesive sealant serves multiple functions: it acts as a waterproof barrier, an air seal, a structural adhesive for attaching mounting hardware, and a flexible accommodation for thermal movement. This multi-functionality eliminates the need for separate flashing assemblies and reduces overall system complexity
2Manufacturing precision
If adhesive sealant is injected under pressure into enclosed cavity, then complete void filling and air removal is achieved, but the injection process complexity increases
Solution Approach 1:
The patent uses pressure injection (pneumatic principle) to force adhesive sealant into the enclosed cavity through a dispensing system. The pressure differential ensures complete filling of voids and forces air out through the vent hole, achieving precise and complete sealant placement without complex manual intervention
Solution Approach 2:
The vent hole acts as an intermediary element that facilitates the pressure injection process. It provides a controlled escape path for air during sealant injection, enabling complete void filling while simplifying the overall process by allowing passive air removal rather than requiring active evacuation systems
3Reliability
If multiple sealing components and flashing assemblies are used, then comprehensive coverage is achieved, but the installation time and cost increase
Solution Approach 1:
The patent merges multiple sealing operations into a single adhesive sealant application process. Instead of installing separate flashing pieces, fasteners, and sealants in multiple steps, the pressurized adhesive sealant system accomplishes all sealing functions in one continuous operation, significantly improving installation productivity
Solution Approach 2:
The adhesive sealant is pre-formulated with appropriate viscosity and bonding properties, and the pressurized injection system is prepared in advance. This preliminary preparation allows the installer to simply position the mounting hardware and activate the injection, eliminating the need for complex on-site assembly and adjustment procedures
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 system provides a cost-effective, leak-resistant solution by eliminating the need for additional sealing components and reducing the risk of roof damage, while ensuring a secure attachment that withstands water and air pressure.
Implementation Method 1
Sealant is then injected under pressure using, by way of example, a sealant dispenser gun, into an enclosed cavity around the penetration. The force from the sealant dispenser gun increases the pressure inside the enclosed cavity and forces all the air out through a vent hole.
Implementation Method 2
The system utilizes an adhesive sealant to create a permanent watertight seal at any surface penetration.
Data Source
AI summary
A mounting device including a base having an internal cavity and an upper portion above the base. The upper portion extends upward from the base and includes a vertical member defining opposed first and second faces above the base. An aperture is formed through the upper portion and extends through the first and second faces. The base extends outward, beyond each of the first and second faces.