Two-Part Tile Replacement Flashing for Stronger Solar Tile Hook Mounting
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Solution Overview
Problem
Existing tile hook systems for solar photovoltaic installations on tile roofs face challenges with varying tile shapes and thicknesses, leading to issues with securing the rafter, deflection under force, and inability to withstand high uplift or compression forces, requiring multiple hook varieties and complex installation processes.
Innovation Solution
A height-adjustable tile hook system with two-part tile replacement flashings, allowing for alignment and securement with locking pins, accommodating different tile profiles and rafter locations, and enabling the tile hook to fit snugly through a notch, enhancing stability and versatility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a tile hook is installed at the lowest location of the tile curve (valley) to accommodate various tile shapes, then the tile hook can fit with surrounding tiles, but the rafter may be several inches away from the valley requiring an extension base that cannot withstand high uplift or compression force
Solution Approach 1:
The tile replacement flashing is divided into two separate parts: a top flashing and a bottom flashing. This segmentation allows the bottom flashing to be positioned at the valley for tile compatibility while the top flashing can be positioned closer to the rafter for structural strength, eliminating the need for a weak extension base.
Solution Approach 2:
The two-part flashing system acts as an intermediary between the tile hook and the surrounding tiles. The bottom flashing provides the valley positioning needed for tile compatibility, while the top flashing provides the rafter-proximity positioning needed for structural strength, mediating between these two conflicting requirements.
2Strength
If tile hooks are made with stainless steel to provide strength, then they can withstand force, but they deflect under compression force and may cause underlying tiles to crack
Solution Approach 1:
By segmenting the flashing into two parts, the system distributes the mechanical loads more evenly. The bottom flashing at the valley absorbs some compression forces, reducing the deflection and tile contact pressure on underlying tiles, while maintaining overall structural strength.
3Ease of operation
If tile replacement flashing uses a pre-drilled hole in the center to accommodate the tile hook, then installation is simplified, but the hole location may not align with the rafter requiring an extension plate that reduces strength
Solution Approach 1:
The two-part flashing design allows the bottom flashing to have a centered pre-drilled hole for easy tile hook installation, while the top flashing can be positioned to align with the rafter location, eliminating the need for extension plates and maintaining structural strength.
4Adaptability or versatility
If tile hooks are designed to fit different tile heights and shapes with large height adjustment range, then versatility is improved, but many varieties of tile hooks must be produced and stocked
Solution Approach 1:
The two-part flashing system is designed as a universal solution that can accommodate various tile profiles, heights, and shapes through a single standardized design. The flashings can be positioned at different heights and configurations to fit different tile types, eliminating the need for multiple specialized hook varieties.
Solution Approach 2:
The flashing system provides dynamic adaptability through adjustable positioning rather than requiring multiple fixed designs. Installers can adjust the height and position of the flashings to match different tile configurations, making the system flexible and versatile without increasing product variety.
Data Source
AI summary
A tile replacement flashing is used with a tile hook. A bottom tile replacement flashing is shaped for placement on a lower portion of a location where a tile is removed from a roof. A top tile replacement flashing is shaped for placement on an upper portion of a location where the tile is removed from the roof. The top tile replacement flashing includes an elevated region at a lower portion of the top tile replacement flashing, the elevated region. The bottom tile replacement flashing is shaped so that after attachment of the bottom tile replacement flashing on the roof, the tile hook can be attached to a rafter of the roof, the attached tile hook extending over an upper portion of the bottom tile replacement flashing and having a portion that, past the upper portion of the bottom tile replacement flashing, extends upwards. The top tile replacement flashing is shaped so that after attachment of the top tile replacement flashing on the roof, at least part of the elevated region of the top tile replacement flashing extends over the bottom tile replacement flashing. A height of the elevated region is sufficient to allow room for the tile hook to extend over the bottom tile replacement flashing and under the elevated region of top tile replacement flashing.