Unitary Rooftop Equipment Support for Fast Installation and Even Weathering
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Solution Overview
Problem
Existing rooftop equipment support systems require on-site assembly of multiple components, increasing installation costs and being prone to differential degradation from environmental exposure, leading to premature system failure.
Innovation Solution
A unitary, extruded roof equipment support system with a monolithic body featuring a platform, sidewalls, and strut extensions forming a U-shaped channel, made from a single material to reduce assembly needs and ensure even weathering, along with a roller element for axial movement support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple components are assembled on-site to form rooftop equipment support, then the support system can be customized and adapted to different configurations, but the installation cost increases and the system becomes prone to differential degradation from environmental exposure
Solution Approach 1:
The patent combines multiple separate components (base member, strut member, and equipment support into a single unitary extruded member) that performs all functions. This monolithic structure eliminates the assembly interfaces between components, preventing differential degradation at joints while maintaining the ability to provide various support configurations through the integrated design of the extruded member's geometry.
2Adaptability or versatility
If multiple components are assembled on-site to form rooftop equipment support, then the support system can be customized and adapted to different configurations, but the installation cost increases
Solution Approach 1:
The patent integrates multiple components into a single unitary extruded member, eliminating the need for on-site assembly operations. This reduces installation labor costs and time while the extrusion manufacturing process allows for customization of the member's geometry to meet different configuration requirements, maintaining adaptability without the assembly cost penalty.
3Ease of manufacture
If multiple components are used in the support system, then the system can be assembled from standardized parts, but the system is prone to differential degradation from environmental exposure
Solution Approach 1:
The patent creates a single unitary extruded member that replaces multiple separate components exposed to environmental conditions. By eliminating the interfaces between different materials and components, the design prevents differential degradation, corrosion at joints, and thermal expansion mismatches while maintaining standardized manufacturing through the extrusion process.
4Reliability
If a unitary extruded member is used for rooftop equipment support, then installation costs are reduced and structural strength is enhanced, but the ability to customize configurations may be limited
Solution Approach 1:
The patent uses the extrusion process to create a unitary member with varying cross-sectional geometries along its length, allowing different portions of the member to be optimized for specific functions (support, attachment, equipment mounting) while maintaining structural integrity throughout. The extrusion parameters can be adjusted to produce different profiles that adapt to various configuration needs.
5Ease of operation
If multiple components are assembled on-site, then the support system can be installed flexibly, but the assembly process is time-consuming and prone to error
Solution Approach 1:
The patent integrates multiple components into a single unitary extruded member that can be installed as one piece, dramatically reducing installation time and eliminating assembly errors. The member is designed with integrated features (mounting points, support surfaces, attachment mechanisms) that provide the same installation flexibility as assembled systems but without the time-consuming assembly 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.