Method and systems for converting shipping pallets to components for shelter and green infrastructure

Abstract

A method of converting a shipping pallet for use as a building component for a environmentally green super-structure and green infrastructure including a range of building types from tent structures to homes medical facilities, classrooms, small commercial, and small industry. In one example, a hinged pallet frame is attached to an existing pallet to form a construction panel, and multiple panels are assembled and pivoted to form structures. A kit for converting a pallet comprises tubular frame elements, hinge connector elements, and leg frame elements. In other examples, new pallet-like panels are created with foam core, stress skin, and protective frames that facilitate interconnection.

Description

BACKGROUND

Field of Invention

The current invention relates to the use of pallet modules and pallet frames to serve as improved pallets and as construction modules.

SUMMARY

This application describes a redesigned and engineered shipping pallet used in a manner that enables components to serve either as an entirely new shipping pallet or enables use as building components for a environmentally green super-structure and green infrastructure including a range of building types from tent structures to homes medical facilities, classrooms, small commercial, and small industry. Decentralized infrastructure needs including methods of mounting or protecting PV's, towers for wind systems, housing for biomass gasification, battery banks, and provisions for water harvesting, waste water treatment, organic waste treatment, porous paving and bank stabilization. Food is addressed in the form of greenhouses, and animal shelters as well as fish in the form of aquaculture, raised bed gardens, and organic waste to food.

The uniqueness of the approach is its ability to piggyback onto a large international manufacturing, shipping/distribution and inventory system with significant spatial correlation to a wide range of clients from ecotourism, to the military, to disaster and other needs worldwide. As a Blue economy product it offers the pallet industries a new and significant clientele never considered in the form of disaster relief mitigation and prevention, humanitarian issues of immigration homelessness, environmental and war refugees and the DIY industry including tiny houses grow homes, camps, retreat centers; many of these being served by custom non modular, non pre-manufactured interoperable components. Together these and other clients that require user and environmentally friendly building along with accompanying employment opportunities at all levels of the development process is the background and purpose of this patent application. The sPOD pallet designed purposely to be repurposed can address disaster relief shipping depots and harbors, water pollution, food deserts and shortage, lack of sanitation, shelter, as well as other use configurations that develop through a crowd sourcing approach that enables feedback and further evolution in the use of the system and to use human capacity to support, independence, cooperation, resilience and creativity.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is top perspective view of an example pallet.

FIG. 2 is a top perspective exploded view of components of example pallets.

FIG. 3A is a top perspective view of a conventional wood pallet retrofitted with a frame.

FIG. 3B is a top perspective view of a plastic pallet retrofitted with a frame.

FIG. 3C is a top perspective view of a heavy duty pallet retrofitted with a frame.

FIG. 3D is a side perspective view of a protective pallet frame section.

FIG. 3E is a cross section view of the protective pallet frame section showing the storage of various items.

FIG. 3F is a side perspective view of a fabric roll being inserted into a protective pallet frame section.

FIG. 3G shows various materials that may be stored in a frame element.

FIG. 4A is an exploded top perspective view of a protective frame and and hinged leg frames.

FIG. 4B is a top perspective view of a pallet with a stressed skin.

FIGS. 5A-5E show example pallet types.

FIG. 5A shows a medium duty pallet,

FIG. 5B shows a pallet.

FIG. 5C shows a heavy duty pallet.

FIG. 5D shows a box pallet and extended pallet.

FIG. 5E shows a mobile pallet.

FIG. 6A is a top perspective view of a spillage confinement frame.

FIG. 6B is a top perspective view of a light duty pallet.

FIG. 6C is a top perspective view of a retrofit kit for making existing pallets modular.

FIG. 6D is a top perspective view of a medium duty pallet.

FIG. 6E is a top perspective view of a self propelled pallet.

FIG. 6F is a top perspective view of a drum pallet.

FIG. 6G is a top perspective view of a container box pallet.

FIG. 6H is a top perspective view of an extended pallet.

FIG. 7A is a top perspective view of a raised bed frame.

FIG. 7C is a top perspective view of a lounge chair base with hinged back.

FIG. 7B is a top perspective view of stools and a table.

FIG. 7D is a top perspective view of a work station desk.

FIG. 7E is a top perspective view of an example partition.

FIG. 7F is a top perspective view of an open frames combined with cowling insert.

FIG. 7G is a top perspective view of an example shed.

FIG. 7H is a top perspective view of an example cover.

FIG. 7I is a top perspective view of an example carport.

FIG. 7J is a top perspective view of leg cowlings used as packaging for cowlings of or parts.

FIG. 7K is a top perspective view of of leg cowlings laid flat for compartmentalized packaging.

FIG. 8A is a side perspective view comparison of a prior art SIP panel and sPOD components.

FIG. 8B is a side perspective view of example fast deployment fold out panel tents.

FIG. 8C is a side view of the example tents of FIG. 8B.

FIG. 8D is a side perspective view of examples very low cost shelters.

FIG. 8E is a side perspective view of example door frames and window frame.

FIG. 8F shows perspective view and side views of example hollow core utility walls and concrete poured or sand-filled walls.

FIG. 8G is a side view of 12 volt wiring embedded within a stressed skin panel.

FIG. 8H are top perspective views of a plurality of panels folded to structures.

FIG. 8I are top views of example floor plans which can be created by various combinations of single panels and sets of panels.

FIG. 9A shows top perspective views of example porous paving and bank stabilization.

FIG. 9B shows side perspective views of an example living wall and living roof.

FIG. 9C shows top perspective views of example Community Integrated District Utility Spines.

FIG. 9D shows top perspective views of example green machines.

FIG. 10 shows an example manufacturing process for carbonized foam.

FIG. 11 is a side perspective view of an sPOD branding symbol.

FIG. 12 is a front perspective view of a tubular frame set.

FIG. 13 is a front perspective view of an example square tubular frame and an example round tubular frame.

FIG. 14A is a front view of an example square tubular frame holding an unfolded hinge connector and hinge pins.

FIG. 14B is a top view of the unfolded hinge connector of FIG. 14A.

FIG. 14C is a top perspective view of the hinge connector of FIG. 14A in a folded orientation.

FIG. 15A is a front view of square tubular frame holding retrofit brackets, pins, and bolts.

FIG. 15B is a top perspective view of a retrofit bracket of FIG. 15A.

FIG. 16A is a front view of square tubular frame holding leg frames.

FIG. 16B is a side view of an unfolded leg frame.

FIG. 16C is a side view of a folded leg frame.

FIG. 17A is a front view of square tubular frame holding strut rods.

FIG. 17B is a top view of strut grid.

FIG. 17C is a cross section detail showing strut grid formed with rods oriented in the X-direction

and the Y-direction.

FIG. 17D is a top view of a strut rod with a T-sleeve and an elbow sleeve.

FIG. 18A is a front view of square tubular frame holding stress skin hinge plates.

FIG. 18B is a top view of a stressed skin positioned over a foam core.

FIG. 19A is a front view of square tubular frame holding fiber reinforced abrasion protection strips.

FIG. 19B is a top view of applied fiber reinforced abrasion protection strips.

FIG. 20A is a cross section of a foam core construction panel fabricated from kit components.

FIG. 20B is an example foam core construction panel of FIG. 20A with leg frames.

FIG. 21A is an example retrofit pallet.

FIG. 21B is another example retrofit container pallet.

FIG. 22A is a side view of a portion of a stacked pin panel.

FIG. 22B is a side view showing an unfolding sequence of a stacked pin panel.

FIG. 22C is a top view of a multiple fold pinned panel.

FIG. 22D is a side perspective view of a panel box formed on a pallet.

DESCRIPTION

sPOD Green Superstructure and Infrastructure Diagrams

There are four main conditions for a super structure (foundation—6 attributes, wall—4 attributes, floor—6 attributes, roof—4 attributes); and three main conditions for infrastructure (Energy—7 attributes, Water—8 attributes, Food—6 attributes).

Basic Components

In this specification the term tubular means a hollow elongated member. In some examples the cross-section may be a rectangular or circular. FIG. 13 is a front perspective view of an example square tubular frame 220 and an example round tubular frame 221.

In some examples, the frame member may not be tubular, and may be provided as an an elongated flat plate.

Basic components-comprise six separate elements and three retrofits to existing pallet applications making a total of nine conditions that require explanation:

FIG. 1 is top perspective view of an example pallet 100 with a hinged pallet frame 200 and legs 280. In this example, the hinged pallet frame functions as a protector/holder and structural frame for a stressed skin panel and comprises 7 inner features that key into and hold in place the stressed skin panel. This frame also has the necessary slots and holes for holding the struts and hinge pins in place all having a wide variety of other applications. The frame can be released from the panel simply by removing any of the corner hinge pins and can therefore be used also for other purposes when incorporated within the series of pallet types or the home interior and yard, superstructure and infrastructure needs. Structural applications include (including the creation of box columns beams and space frame members. Another attribute of the frame is the fact that it has a series of alternating hinge sleeves top and bottom around the perimeter that are used in various applications from holding legs in place on the bottom of the pallet or as spacers. The legs are also manufactured to be the same leg dimensions and characteristics hinge holes with the struts and hinge pins described below enable connectivity of frame to frame in planner or a perpendicular fashion. An extension connected to the pallet protuberances mentioned earlier enables the frame to also be retrofitted onto existing wood plastic or pharmaceutical pallets so that they can all become modular building components with the same outside dimension once they have an insulation panel placed within the retrofitted frame. In one example, an insulation panel is created by attaching a bladder or stress skin over a foam core, such as a carbonized foam core.

The frame and skin structure facilitates efficient expansion and reconfiguration of structures and the disassembly and reconfiguration of the components.

FIG. 2 is a top perspective exploded view of components of example pallets. A bladder assembly 309 comprises a belly protector 310 and a top cover 320. Hinges 281 are provided for the pallet legs. Caps 284 are provided for leg areas.

Connector Block Hinge Features

A connector block typically has spaced apart hinge pin sleeves that are configured to mate with offset hinge pin sleeves provided on a second connector block.

Connector blocks are typically provided on each end of the frame element, and one or more intermediate connector block as provided between the corner blocks. The use of multiple connector blocks promote stronger hinging and pivoting of construction panels.

A bladder surface protection skin 320 is attachable using snap-on sides 310 that go over the pin of hinge pin on the frame. The pallet is prepped to have leg hole areas removed or remain as an entire plane. When the perforated areas are popped out for the legs, the bladder becomes a protective belly under the pallet panel for purposes of avoiding puncture by the fork lift and for protection of the strut grid. This bladder attribute is used for many other purposes such as quick thin uninsulated field structures and sheds held together with items like long ¼ inch rebar.

Bladders are protective cover coverings for the top or bottom surfaces of a retrofitted panel. In one example, a bladder is a fiber reinforced abrasion resistance surface lot applied over a pallet or a foam core to protect the pallets from forklifts underneath, or to protect the pallet top from abrasive loading.

A grating or strut grid 430 supports pallet legs. In one example, struts in the strut grid and pins comprise approximately ¼ diameter biobased fiber reinforced material the longer struts containing slight bumps on all surfaces to function as thin reinforcing bars for other purposes, the struts being 4 foot pins are counter sunk into the stressed skin panel one more in depth than the other so as to be able to orthogonally cross each other as described below. Since they crisscross each other the counter sink must accommodate ½ inch depth-2 times the ¼ inch strut. There are two types of Pins both made of the same material and diameter as the struts one shorter and straight but the other although of the same diameter is U-shaped for connecting the hinge areas of the frame in varying angles U shaped pins can be stored within one or more the leg cowlings when the leg cowling is not also filled with the stressed skin. Again the U-shaped pin enables a face to face connection or stacked one frame to the frame above when needed.

Leg Frames and Legs

Leg frames typically have the same height as frame elements. A hard fiber reinforced epoxy may be used for the leg frame.

Legs may be added to custom pallets, or may serve as spacers between pallets so that concrete or insulated material may be added between the pallets.

Hinged leg frames 283 are similar to the large frame and are of the same 3″ depth but with approximately 6″×6″ or a 8 inch by 8 inch footprint. These cowlings also have their protruding key on each side to hold a smaller stressed skin leg in position. They also have a hinge on all four corners for removal form stressed skin leg as well as hinge holes on the top and bottom edges just like the large frame so they can also be stacked with the U-Pin or laid out flat. These legs can be connected in plan or stacked or in orthogonal orientation just like the main frame using the struts.

Examples 330 and 340 show alternative stress skin panels. Stressed skin panel 330 has corners and side and potentially the middle free areas and the others all solid. The holes are coordinated to enable the legs to be stored within to be dropped out and pinned when used as a 9 legged pallet. Or a disassembly version with the nine legs can exist when the cowling holders(the struts and hinges are pinned beneath and the legs not able to recede within the pallet frame until pins are removed. It is important to note that the cowlings and therefore the legs can be placed on either side of the pallet to create a configuration of leg panel leg panel sandwich configuration. This means that each side of any panel version (holes or solid) have the crevices for the struts on both sides whether used or not used and whether covered top or bottom with the solid bladder. It is also worth noting that due to the hinges on all frame corners (large and small) that hinged triangular frames can be made into triangulated surfaces that have structural integrity better than the square orthogonal frames and can be become folded plate(when stressed skin panels are inserted or just be an open of folded space frame type beam.

Stressed skin leg inserts or containers 331 are configured to fit within the stress skin panel 340 into the leg protective frames possess and key indentation for the leg frame to hold it in place but most important it is structural and insulative and while adding to the structural capacity of the structural leg frame in order to take heavy loads when used as a pallet.

FIG. 4A is an exploded top perspective view of a protective frame 200 and hinged leg frames 283

FIG. 4B is a top perspective view of a pallet with a stressed skin 341.

FIG. 3A is a top perspective view of a conventional wood pallet 272 retrofitted with a 4 foot×4 foot frame 200. FIG. 3B is a top perspective view of a plastic pallet 274 retrofitted with a frame 200. FIG. 3C is a top perspective view of a heavy duty pallet 276 retrofitted with a frame 200. All retrofitted pallets can be used within the system as dimensionally coordinated. The retrofitted frame comprise solid stressed skins panel, with no accommodation for disappearing legs, for insulation and to increase impact. The frames are retrofitted with special angles that fit into the protuberances of the frame and are bolted into the exiting pallet frame at a point of structural integrity.

The example components include a protective frame assembly 200 cowling addition with frame segment 210 and hinge connector 211. Side extensions 270 provide forklift protection. In this example, the protective frame assembly comprise a square tube with male and female hinge sleeves on all four corners that are coordinated with the frame so it can be attached to the main frame using the hinge holes either on one face of the pallet or the other or on the side of the pallet frame to create in essence a very robust double frame. These cowlings have seven or more uses when they are filled with a variety of inserts that roll out and become covers protectors, insulators and clear uses such as see through covers for merchandise as well as windows when used in building. The seventh cowing use consists of a set of extended wheels with motors GPS sensors, steering mechanism, batteries all enabling the self movement and delivery of pallets with loads on them.

FIG. 3D is a side perspective view of a protective pallet frame section 202.

FIG. 3E is a cross section view of the protective pallet frame section 202 showing the storage of various items including foam, water repellant 217, cargo net 225, camouflage 216, interior or exterior insulation 212, and a motor 228. FIG. 3F is a side perspective view of a fabric roll 204 being inserted into a protective pallet frame section 202. FIG. 3G shows various materials that may be stored.

Biobased Materials

In these examples, there are two major applications for all bio-based fiber reinforced materials in sPOD.

A hard fiber reinforced epoxy is used for the frame guard, the leg guards and the struts and hinge pin materials.

A foamed core for the stressed skin panels.

There are two types of applications for bio-based foam 1) as a straight foam 2) as the basis for a carbonized foam for purpose of having sPOD take extreme heat at it core while retaining insulation and puncture resistance.

These traits can be with either panel type, with holes for disappearing legs or the other solid panel. The most important part is the capacity of the bio-based foam to be carbonized. This means placed into a pyrolysis unit or better into a gasification unit in order to use the escape gas as fuel to operated the system. the special attributes of carbonized bio-based foam is multiple (EMF protecting of occupants—high strength, fire proof, termite proof and floatable or able to be flooded purposely so the structure can become very heavy to adapt to climatic needs)

Family of Products

There are four pallet product categories that sPOD is capable of being adapted to and all of these are simply a reshuffling in the use or delivered components either appearing separately within an inventory system or contained within most any pallet:

FIGS. 5A-5E show example pallet types. In one example a kit is provided for retrofitting existing pallets into the same modular size, a spillage pallet to contain warehouse spill able items, a light duty pallet made up mainly of just cowlings and struts, a retrofit pallet kit for (existing wood plastic and foamed core pallets),

FIG. 5A shows a medium duty pallet 601 that adds the stressed skin panel and stressed skin legs.

FIG. 5B shows a pallet 602.

FIG. 5C shows a heavy duty pallet 603 with double stresses skin and double stacked frames for 55 gallon drum carrying,

FIG. 5D shows a box pallet and extended pallet 604.

FIG. 5E shows a mobile pallet 605 using the cowlings described earlier to hold wheels and axles

Home and Yard Applications Kit Pallet

General conditions comprising inside and out side applications—inside being furniture and spatial partitioning, outside being simple sheds, car ports and PV mounting frames to plant and animal support systems including trellis and raised gardens.

Superstructure General Conditions

In this example, the super structure has several attributes conditions and/or applications;

• • 1) sPOD fits a so far unfilled niche in the building industry—it can be a robust 8×8 (or 6×6) block that is incremental in itself in size and thickness before it is the block to be used (ie 16×16×6 or 12×12×3 etc). It possesses an inter-connecting shroud frame with hinge type connections, and is insulating and light and user friendly unlike concrete CMU which are heavy un-insulating and need mortar to stay together. When it is the size of a 4×4 foot panel frame, it is smaller than the usual 4×8 structural insulated panel and therefore more user friendly but with the same strength.
  • 2) tents;
  • 3) low cost hexagonal structures;
  • 4) window and door configurations;
  • 5) hexagonal structures;
  • 6) fold out structures with the hinged frames and internal stressed skin panels for foundation/floors wall and roofs;
  • 7) Evolutionary plans where buildings comprise a starter unit with first pallets or top framed panels of pallets with or without legs and then configured into various box sizes or box shaped modules from a 4×4×4 to 8×8×8 to 12×12×12 or 16×16×16 feet. Other dimensions are possible but the integrity of the system stems from its modular growth possessing a double shear wall that developed as modules are directly added to each other between module wall that are duplicated.
  • 8) sPOD pallet used as forms for concrete or as open wire and utility chases; and
  • 9) when a series of cowling box tubes are retrofitted they can add various surfaces membranes

Green Infrastructure Utility Housings General Conditions

Green infrastructure emphasizes the use of natural processes (ie minimizing mechanical) to accomplish basic life support this sPOD category includes

• • the use of plants, aggregates, and soils to absorb water on site verses piping drainage water to other locations and in the process to clean air and supply oxygen absorb CO2;
  • the use of horizontal and vertical building surfaces with planting areas to again absorb water, cool surfaces supply oxygen absorb CO2; and
  • to provide a safe spine to protect utilities (water lines sewage lanes electrical and communication between buildings while 1 becoming a pedestrian walkway—all using the sPOD building component to supply the building block to accomplish this form foundation to trellis and housing of various renewable utilities that serve this spine.

Example Pallet Applications

FIG. 6A is a top perspective view of a spillage confinement frame 610

using the frame and bladder alone for the purpose of controlling leaking from various containers on to the warehouse

FIG. 6B is a top perspective view of a light duty pallet 601 using only the larger pallet frame and the leg frames and struts but not stresses skin panel for bags of fibers and other dry organic matter.

FIG. 6C is a top perspective view of a retrofit kit 278 for making existing pallets modular and insulating for enabling any pallet to fit the dimensional standard of sPOD modularity while becoming strong and insulating for buildings which most shipping pallets do not have as their characteristics.

FIG. 6D is a top perspective view of a medium duty pallet 603. This pallet uses all the stressed skin insert sin all the frames so that a normal medium duty pallet can result—from approximately 1200-2500 pound capacity.

FIG. 6F is a top perspective view of a 4/55 gal drum heavy duty pallet 614. By doubling up on the panel surface (including a double frame for holding the extra panel sPOD is enabled to take on extreme weight such as 4 55 gallon drums

FIG. 6G is a top perspective view of a container box pallet 613 for flowable materials and fluids, the container pallet takes advantage of the hinge able panels that enable the sPOD pallet to become a containment box including the lid.

Example—Container Pallet Construction

At step 1000, the contents are removed from a tubular frame set.

At step 1010, hinge cowling end pieces are attached to the tubular frames to form a tubular frame.

At step 1020, intermediate cowlings are attached to the tubular frame elements at positions corresponding to attachment points on an existing pallet.

At step 1030, retrofit brackets are used to attach the cowlings to the pallet.

At step 1040, the retrofit brackets are bolted to the pallet.

At step 1050, bottom strut rods are attached to the hinge cowlings.

At step 1060, container sides are secured to the strut rods.

In the alternative, a single stressed skin panel is placed inside the tubular frame, and the stressed skin panel is secured to the frame with stressed skin hinge plates.

In one example, stress skins are thin layer fiber reinforced abrasive resistant surfaces. Stress skins are typically provided on assembled construction panels rather than on retrofitting existing pallets.

FIG. 6H is a top perspective view of an extended pallet 612 an extended pallet both flat and boxed for other size shipments, this feature can be limited to the pallet itself or enable the user to construct a 4×4×8 foot small container type pallet with the advantage of all walls using the strength of the hinge even on the side.

FIG. 6E is a top perspective view of a self propelled pallet 611 with the wheeled GPS motorized steering capable cowlings described earlier the sPOD pallet can become self propelled and self guided with programed warehouse and inventory capability. In some cases, this pallet may eliminate the need for a fork lift since the pallet can take considerable weight when duplicating the robust qualities of the drum pallet.

Example—Retrofitting an Existing Pallet

In this example, a plurality of frame members are delivered as a stacked as shown in FIG. 12. which is a front perspective view of a tubular frame set 219. In this example, the set includes 4 rectangular frame members 219a which contains hinge cowling plates and retrofit plates; 219b which contains leg frames; 219c which contains strut rods and a stressed skin hinge plate; and 219d which contains fiber reinforced abrasion protection strips. The Frame members service storage for a plurality of rods, connector blocks, leg frames, pins, and other components.

FIG. 14A is a front view of an example square tubular frame 219a holding an unfolded hinge connectors 219a (also referred to as a hinge cowlings 242) and hinge pins 240. FIG. 14B is a top view of the unfolded hinge connector 242 of FIG. 14A. FIG. 14C is a top perspective view of the hinge connector 242 of FIG. 14A in a folded orientation.

FIG. 15A is a front view of square tubular frame 219b holding retrofit brackets 244, pins 241, and bolts 243. FIG. 15B is a top perspective view of a retrofit bracket 244 of FIG. 15A.

FIG. 16A is a front view of square tubular frame 219c holding leg frames 283. FIG. 16B is a side view of an unfolded leg frame 283. FIG. 16C is a side view of a folded leg frame 283.

FIG. 17A is a front view of square tubular frame 219d holding strut rods 429. FIG. 17B is a top view of strut grid 430. FIG. 17C is a cross section detail showing a strut grid formed with rods oriented in the X-direction 429b and the Y-direction 429a. FIG. 17D is a top view of a strut rod with a T-sleeve 432 and an elbow sleeve 431. The rods are removed and assemble to form a strut grid. The strut grid has a lower level spaced apart rods oriented and the X direction, and an upper level spaced apart rods oriented in the Y direction. The ends of each rod are attached to a connector block such as by friction fit, adhesive, or set screw.

FIG. 18A is a front view of square tubular frame 219e holding stress skin hinge plates 245. FIG. 18B is a top view of a stressed skin 330 positioned over a foam core 334. The stressed skin has a structural edge 333, and hinge plates 245 are mounted to a structural edge.

FIG. 19A is a front view of square tubular frame holding fiber reinforced abrasion protection strips 336. FIG. 19B is a top view of applied fiber reinforced abrasion protection strips 336.

FIG. 20A is a cross section of an example foam core construction panel 102 fabricated from kit components. In this example, fiber reinforced stress skin 330 is applied to the top and bottom of a foam core 334. The top surface is protected by fiber reinforced abrasion protection strips 336. A foldable hinge cowling 242 is attached to a hard core edging 247 with a hinge plate 244 and to a rectangular frame element 220. FIG. 20B is an example foam core construction panel 102 of FIG. 20A with leg frames 283.

Leg frames are removed and assembled the form square frames which are then inserted into selected openings between the X and Y rods. These leg frames may serve as spacers when a second pallet is stacked on a first pallet.

A stress skin having a thickness of approximately ⅛ inch is set over the strut grid. The stress skin has shallow spaced apart grooves oriented in the X direction, in deeper spaced apart grooves oriented in the X direction so that the stress can may be placed on the strut grid.

The connector blocks are removed and attest to a shipping pallet, and frame members or slid through the connector blocks and pinned to secure the frame members to the connector blocks and pallet.

Attaching the Connector Blocks to a Shipping Pallet

In one example, several connector blocks are bolted to each side edge of the shipping pallet. Frame members or then inserted through the connector blocks and secured do the connector blocks.

In order to achieve a consistent construction panel dimension such as 4′×4′, it may be necessary to provide additional spacing between the connector blocks and pallet so that the final width between frame elements is 4 feet.

In other examples, the connector blocks may be attached to the frame members before attaching the frame members to the pallet.

FIG. 21A is an example retrofit pallet 103 with a foam core 334 applied over an existing pallet 90.

FIG. 21B is another example retrofit container pallet. In this example, a container pallet 104 is formed by attaching a plurality of leg containers 283 over existing pallet 90.

sPOD Home and Yard Retail Kit

This kit caters to the retail market but is comprised of components similar to all other pallets but my have extra or less parts than normal—in the larger sense this kit is meant to enable people who have lost all their furniture to flood or fire or other disasters to gain a new start with a system that is strong and bacterially robust if such circumstances were to re-occur.

Indoor Furniture

A few examples of furniture are shown in FIGS. 7A-7G.

FIG. 7A is a top perspective view of a raised bed frame 702 with a height of the users choice because the pallet legs are additive.

FIG. 7C is a top perspective view of a lounge chair base 706 with hinged back.

FIG. 7B is a top perspective view of a stool 705 made up of pallet legs attached vertically and horizontally, and a table 704 of varying heights, lengths and widths, for meetings or dining.

FIG. 7D is a top perspective view of a work station desk 708 with leg cowling 6 inch deep shelves using the pallet struts as support frames.

FIG. 7E is a top perspective view of an example partitions 722.

FIG. 7F is a top perspective view of open frames combined with cowling inserts 724 of varying types including light through see through and designer patterns ordered by the roll for use with closets, storage shelves and privacy curtains.

FIG. 7G is a top perspective view of an example shed 742.

FIG. 7H is a top perspective view of an example cover 762.

FIG. 7I is a top perspective view of an example carport 764.

FIG. 7J is a top perspective view of leg cowlings used as packaging for cowlings of or parts.

FIG. 7K is a top perspective view of of leg cowlings laid flat for compartmentalized packaging.

In various examples, the modules may be used to construct outdoor furniture, shade structures, PV mounts, trellises, benches and picnic table with integrated seating 5.4 tool sheds, greenhouses, fish ponds, and poultry/animal sheds.

Green machines are procedures that use simple nature based procedures to accomplish everyday talks like make a cistern to hold water form your roof or to make a tower for a small wind generator or form a grey water holding area that treats that water using plants or a poultry fish plant food system using waste

sPOD Super Structure

FIG. 8A is a side perspective view comparison of a prior art SIP panel 80 and CMU block 81 versus a pallet module 340, and a cowling frame 202.

There are ergonomic comparative benefits of SPOD relative to conventional construction elements as to size, weight, insulation capacity, impact resistance. These features out perform the usual concrete masonry unity or the SIP panel presently used in construction.

There are several types of conditions which may be interconnected using the hinge connectors for 4 ft×4 ft panel and 6 inch×6 inch leg. Some components are filled with stresses skin inserts, and others are not filled. Some example super structure categories are discussed below.

FIG. 8B is a side perspective view of example

fast deployment fold out panel tents including a quick tent 911 an insulating tent 912 a raised tent 913, and a robust tent 914 for high wind or cold weather.

FIG. 8B is a side perspective view of examples very low cost shelters 920 and 930.

FIG. 8E is a side perspective view of example door frames 972 and window frames 970 incorporating built in hinges, open and solid panels using varieties of added cowlings such as clear for windows. In one embodiment, the support key for holding the original pallet stressed skin panels and feet are used as the door and window stops fold out structures

FIG. 8H are top perspective views of a plurality of panels 954 folded to structures 952 and 956. These structures use the hinge capacity of the frames both legs and panels with their associated built-within hinge frames to be foldable foundation. Floors, walls, and roof—some can be used as concrete or sand-filled forms such as the inter-connectable take a part hollow hinged leg frames when they do not have the stressed skin insert.

FIG. 22A is a side view of a portion of a stacked pin panel 921.

FIG. 22B is a side view showing an unfolding sequence of a stacked pin panel 921.

FIG. 22C is a top view of a multiple fold pinned panel 922.

FIG. 22D is a side perspective view of a panel box 923 formed on a pallet 90.

Evolutionary Plan

The 4 foot module enables growth from a tiny dog house size structure to the ability of the sPOD pallet panels to create substantial house plans—the special attribute is that we suggest no hallways but direct entrance from module unit to module unit (some modules can be circulation to multiple rooms if necessary) but by building in modular increments enables the wall of each module to touch the next, thereby creating thicker walls at these wall overlaps. Panels can be added in depth and length to enable robust sheer walls between modules to aid in wind and water pressure. FIG. 8H are top views of example floor plans 958E-958G which can be created by various combinations of single panels 958A, sets of 4 panels 958B, sets of 9 panels 958C, and sets of 25 panels 958D.

FIG. 8F shows perspective view and side views of example hollow core utility walls 941 and concrete poured walls 942 with a 12 volt electrical system.

The ability of sPOD to use legs as panel separators enables floors walls and ceiling to have continuous utility channels so that utility lines (electrical communication, hot and cold water, chilling equipment are all organized and repairable separate from the physical wall and structure—and waffle type concrete foundations floors walls and roofs where the sPOD unit is filled with concrete in order to afford very robust and insulated out side in side or both sides and be connected to a poured column or pedestal foundation in a continuous fashion.

FIG. 8G is a side view of a 12 volt electrical system where the positive 948 and negative 949 wiring is embedded with the criss cross crevices of the stressed skin panel where the struts are located but not are replaced with 12 volt wiring with access to appliances using a plug that connects the two wires.

sPOD Infrastructure

In some embodiments, infrastructure is comprised of variations in the use of frames and stresses skin elements in a similar manner as the super structure above but now provided for infrastructure

FIG. 9A shows top perspective views of example porous paving and bank stabilization, uses protective leg frames and protective panel frames 1010, 1012, 1014, 1015, 1016, and 1017 as gravel or grass confinements and the same as tiered steps 1018 or angled surfaces depending on steepness of back. All frames are inter-locked or pierced into ground using the hinge holes and pin system.

FIG. 9B shows side perspective views of an example living wall 1022 and living roof 1021, which are similar applications to paving and bank stability uses using same interlocking and anchoring systems but on completely horizontal or vertical surfaces. Other support means may be necessary for these frames to function and depending on size of plants and their roots. Varying root depths are accommodated using the vertical and horizontal capacity of both small and large frames to be attached to each other using the hinge type assembly process. In the case of green roofs, this enables both intensive type and extensive type green roof system to be installed.

FIG. 9C shows top perspective views of example Community Integrated District Utility Spines (CIDUS) 1030 and 1031. This open trellis type spine protects people from the sun and wind while also providing protection. A mounting system is provided for a variety of utilities including communications and electricity above with the utility channels provided by the sPOD system and water and sewage below beside or beneath a raised sPOD side walk. In one example of dimensions of the POD unit, the width of the spine can be 4 or 8 feet. The columns for holding up the trellis may use one of two procedures a) the stacked and pin connected hollow leg cowlings connected into a large 4 ft×4 ft frame; and b) all poured together with appropriate concrete mix. The top trellis connection uses the same pin connections but into larger frames filled with the leg frames and braced by the longer struts. Other supply utilities verses the flow utility components described above can also be accommodated including solar PV, wind towers using the same sPOD module and housings for gasification to electricity stations.

FIG. 9D shows top perspective views of example green machines. In various examples, these green machines comprise a series of carefully designed and engineered volumes that enable biologically based processes to do work for humans in the sense of the rapid production of food, plant based waste water treatment, the treatment and storage of water, waste water treatment using plants that become food for chickens whose excrement becomes the direct food for fish. The following is a description of these example green machines;

A first flush and cistern water tank 1041 connects the washing apparatus that separated initial rain from the constant rain, thus letting the roof clean itself before the good water enters the cistern tank In this example, both the first flush module and the cistern are constructed solely of the sPOD components.

A waste water wetland 1042 comprises a trough using the sPOD panel and frame to hold a gravel infill that function as the growing medium for scirpus type reed plants to treat the water. the system is comprised of a settling chamber similar to a sceptic tank before the water enters the trough.

An organic waste to vegetables and fish green machine 1043 uses two biological processes. Soldier flies break down the organic waste in a vessel that let the flies breed larvae which find there way up a ledge and drop into the fish pond. This fish pond, in turn, has a circulating pump that takes the fish waste water and places it within a hydroponic vegetable bed that both uses the fish waste as fertilizer and lets that now treated water back into the fish tank thus creating a symbiotic process between the plants, fish fish and human need for protein and fiber while ridding the kitchen form organic waste.

A waste water to poultry and fish system 1044 uses waste water to feed poultry using the food from the plants in a waste water wetland. The system comprises two circular shallow tanks put together like a donut. The center tank and the outer tank create a trough that is planted like a waste water wetland with the same gravel growing medium and plants that poultry like but whose roots are protected so that only the top young leaves are used as food that pokes through a wire mesh. The chickens then go up to their perching and egg laying area that is situated above the center pond. The defecation from the chickens falls into fish pond, and the fish use it as food since chicken dung is mostly under processed and can be used as fish food.

A wind generator tower 1045 is constructed from sPOD panels and frames. The structure can be held down with water as a cistern at the bottom if the wind system is pumping water, as a housing for a pressure tank if the wind system is a compressor, or as a battery storage area if it is a wind electric system.

Multifunctional support pedestals 1046 are provided in order to raise buildings with columns that are robust and will not be swept way with the flood. The sPOD system enables a robust vertical 8 foot tall by 4×4 foot base to be constructed that serves this purpose while at the same time holding key green utility type components within. These components include but are not limited to protected regulating and charging equipment with batteries, spiral stairs, waste water pretreatment before entering wetlands, garden tool storage, auxiliary power supply.

Green Manufacturing

FIG. 10 shows an example manufacturing process for carbonized foam.

The foam core material may be manufactured as carbonized foam through what is referred to as a gasifier. Unlike pyrolysis that uses external fuel to create the the necessary pressure and temperature, gasification is a self firing system using the fumes that result from baking an organic substance in the absence of oxygen as the fuel to run the system itself and to fuel items like internal combustion engines. The resulting fuel is carbon monoxide and hydrogen both being partially cycled back into the system as new material enters the combustion area through a series of air locks. The heat generated is used at step 10 to prebake a premixed batter that has been mixed in a process similar to making cake or bread dough and then placed into a mold. The substance possesses a certain lightness depending on yeast and rising time, and a shape such as an sPOD foamed core panel or foamed core feet.

A high temperature capable mold with ingredients intact enters the gasification chamber at step 12. Once gasified, the material exits the chamber and is then extracted from the mold as the carbonized foam core product. The usual charred material usually referred to as charcoal or biochar now becomes a more valuable “ waste” product than before.

One uniqueness of the SPOD system is in the recognition that the resulting charred material is not only light weight and insulating, strong and fire proof but can retain the shape of the original input molded material albeit slightly reduced in size due to shrinkage. This phenomenon therefore produces a useful object. Applicant expects that this shape and shrinking can be controlled. The bubbles within the cake or bread can also be controlled by the amount of yeast and the dough type and consistency and the length of the moldering time for the yeast to rise. The importance of using the gasifier also enhances other processes such as use of the waste heat for baking the bread or the fuel to operate other manufacturing processes such as running a generator that operates machinery, molding 3D printing, lights etc.

One goal is to have a self contained off-the-shelf manufacturing process that is inclusive of the troughs for growing of the plants that produce the flour to make the “bread” and to incubate and refrigerate the yeast. The fact that this facility is core to how a neighborhood operates and becomes to varying degrees self contained processes and become one of the processes within CIDUS (the community integrated district utility system) As discussed above, a next layer of integration would include such processes as using part or all of the waste water generated by people or animals to feed the flour/fiber producing crops that feed the basic materials for the manufacturing of components.

Material Options

Bio-based material use is in keeping with global protocols for reduction of petroleum plastics and thus the reduction of fossil fuel use. Bio-based options include but are not limited to agricultural-based (castor seed, sugar cane, mushroom, flours from wheat, rye, soy—to name a few), and sea based materials (including fishing shell extracts, algae, sea weed to name a few). It also recognizes forestry products (resins, tree based foaming agents, foams, fibers,) and reed-based materials such as kenaf, bamboo, typha, and carrizo, hemp and bamboo. All these have been proven either scientifically and/ or commercially by others to be viable options for some if not all the aspects of the sPOD family of requirements to meet or exceed structural, manufacturing and regional economic development goals. When these materials singularly or in combination satisfy structural, environmental, human use and manufacturing criteria for health and safety any are considered viable.

Symbol Embedded Multipurpose Communication Fork Lift Sensor and Communication System

FIG. 11 is a side perspective view of an sPOD branding symbol 1100 embossed and sealed within each part of the sPOD system. The branding symbol is functional in that it identifies that seed or component in the pod and enables the user to connect to a a crowd/image based training system like Image Net to learn the possible uses of that seed component both in super structure and infrastructure terms. The crowd sourced learning and exchange also enable the system to receive feedback and creates the basis for system improvement over time. The symbol also has three other functions 1) a location device and 2) an inventory organizer 3) a sensor for the fork lift operator to know when the forks are in the right position so as to not destroy the pallet.

Claims

1. A modified shipping pallet comprising a shipping pallet comprising a top surface,a bottom surface,a detachable rectangular hinged pallet frame comprising four pallet frame segments, each segment forming a side of the palletframe and configured to be attached to a side of the shipping pallet,each pallet frame segment comprising a top surface,a first end portion, anda second end portion; anda plurality of hinge connector blocks including a corner hinge connector block positioned in proximity to each corner of the pallet frame, andand at least one hinge connector block positioned between the first end portion and the second end portion of each pallet frame segment, such that each connector block includes upwardly-oriented, downwardly-oriented, and outwardly-oriented hinge sleeves.

2. The pallet of claim 1 further comprising a first stressed skin panel configured to attach to the or bottom top surface of the pallet.

3. The pallet of claim 2 wherein the first stressed skin panel has an open middle solid top surface.

4. The pallet of claim 1 further comprising a plurality of hinged leg frames.

5. The pallet of claim 1 further comprising a strut grid.

6. The pallet of claim 1 wherein the pallet frame further comprises a storage compartment in each of the frame segments.

7. A kit for modifying a shipping pallet, the kit comprising a set of four tubular frame elements, each frame element comprising . . . a top surface,a first end portion,a second end portion;a plurality of hinge connector blocks, each of the plurality of hinge connector blocks comprising upwardly-oriented, downwardly-oriented, and outwardly-oriented hinge sleeves;a plurality of hinge pins; anda plurality of leg frames.

8. The kit of claim 7 wherein the plurality of hinge connector blocks, the plurality of hinge pins, and the plurality of leg frames are shipped in the tubular frame elements.

9. The kit of claim 7 further comprising a stressed skin.

10. The kit of claim 7 further comprising a plurality of strut rods.

11. The kit of claim 7 further comprising a plurality of retrofit brackets.

12. The kit of claim 7 wherein the tubular frame elements are provided in bio-based materials.

13. The kit of claim 12 wherein the bio-based material further comprises agricultural-based materials selected from the group consisting of castor seed, sugar cane, mushroom, flours from wheat, rye, or soy; orsea-based materials selected from the group consisting of fishing shell extracts, algae, or sea weed; orforestry products selected from the group consisting of resins, tree based foaming agents, foams, fibers, and reed-based materials including kenaf, bamboo, typha, and carrizo, hemp and bamboo.

14. The kit of claim 7 wherein the bio-based material further comprises a carbonized foam.

15. The kit of claim 7 further comprising an sPOD branding symbol comprising a location element, and inventory organizer,and a position sensor.

16. A method for converting a plurality of shipping pallets to structural panels and configuring the structural components, the method comprising providing a plurality of shipping pallets, each pallet comprising a top surface, a bottom surface, and four side surfaces;providing a plurality of tubular pallet frame elements, each frame element having a first end and a second end, anda plurality of hinge connector blocks, each hinge connector block having at least one of an upwardly-oriented, downwardly-oriented, and outwardly-oriented hinge pin sleeve;creating a plurality of structural panels by attaching hinge connector blocks in proximity to the first end and second end of each frame element, andattaching a frame element to each side of each of the plurality of shipping pallets;connecting a first structural panel to a second structure panel by attaching a frame element of the first structural panel to the frame of the second structural panel by attaching a side of the first structural panel frame to a side of the second structural panel by nesting adjacent hinge connector block pin sleeves, andinserting a hinge pin in the nested pin sleeves;orienting the first and structural panels, if necessary, by pivoting one of the structural panels along the connected side; andadding structural panels to the connected first structural panel or the second structure panel by creating additional structural panels by attaching frames to shipping pallets,attaching one or more of the additional structural panels to one or more sides of the first structural panel or the second structure panel, and pivoting panels as necessary to achieve a desired configuration.

17. The method of claim 16 further comprising assembling the structural panels to a fold out structure.

18. The method of claim 16 wherein assembling the structural panels to provide a shelter.

19. The method of claim 16 further comprising enlarging the shelter by adding structural panels.

20. The method of claim 16 further comprising reconfiguring the structural panels.