Unitary Rooftop Equipment Support for Fast, Reliable Installation
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Solution Overview
Problem
Existing rooftop equipment support systems require on-site assembly of components made from different materials, increasing installation costs and vulnerability to environmental degradation, which can lead to premature system failure.
Innovation Solution
A unitary, extruded roof equipment support system with a monolithic body, featuring a platform, sidewalls, a top wall, and strut extensions formed from the same material, which defines a U-shaped channel for supporting equipment and allows for easy customization of length without altering the cross-sectional profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If components are assembled on-site from different materials, then installation flexibility is improved, but installation costs increase and system reliability deteriorates
Solution Approach 1:
The patent merges multiple separate components (base member, strut member, piping support elements) into a single unitary extruded structure. This monolithic design eliminates on-site assembly requirements, ensuring consistent material properties throughout the support system while maintaining installation flexibility through customizable lengths and configurations.
Solution Approach 2:
The unitary support structure performs multiple functions simultaneously: it provides structural support, houses piping within integrated lumens, offers mounting surfaces for equipment, and enables thermal expansion accommodation. This multi-functionality is achieved through a single extruded component that replaces several separate parts.
2Adaptability or versatility
If components are made from different materials, then functional versatility is improved, but manufacturing complexity increases and system durability worsens
Solution Approach 1:
The patent achieves functional versatility by varying geometric parameters within a single material. Different sections of the extruded support have different cross-sectional shapes, wall thicknesses, and lumen configurations to accommodate various piping sizes and equipment mounting requirements, all while maintaining uniform material composition for simplified manufacturing and enhanced durability.
3Adaptability or versatility
If multiple components are assembled together, then structural adaptability is improved, but assembly time increases and installation costs rise
Solution Approach 1:
The support structure is manufactured as a complete, integrated unit with all structural elements, lumens, and mounting features pre-formed during the extrusion process. This preliminary action eliminates the need for on-site assembly of multiple components, significantly reducing installation time and costs while maintaining structural adaptability through design variations.
4Reliability
If uniform material is used throughout, then system reliability is improved, but material usage efficiency may worsen
Solution Approach 1:
The patent applies local quality by varying the cross-sectional geometry and wall thickness at different locations along the extruded support. Areas requiring higher strength have thicker walls or reinforced structures, while areas with lower load requirements have thinner walls, optimizing material distribution while maintaining uniform material composition throughout for reliability.
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 solution reduces installation costs by eliminating the need for on-site assembly, enhances structural strength through uniform material usage, and ensures even wear from environmental factors, thereby extending the system's lifespan.
Implementation Method 1
the platform, the pair of sidewalls, the top wall, and the pair of strut extensions are formed from the same material in an extrusion process
Data Source
AI summary
A roof equipment support includes a platform, a pair of sidewalls extending from the platform, and a top wall extending between the pair of sidewalls and offset from the platform. The platform, the pair of sidewalls, and the top wall define an interior cavity that extends a length of the support from a first end to a second end. A pair of strut extensions extend above the top wall, and each of the pair of strut extension include a hook at a distal end. The pair of strut extensions and the top wall define a substantially U-shaped channel that extends at least a portion of the length of the support, and the platform, the pair of sidewalls, the top wall, and the pair of strut extensions are unitarily formed.