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.

What is claimed is: 
     
         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 pallet 
 frame and configured to be attached to a side of the shipping pallet, 
 each pallet frame segment comprising
 a top surface, 
 a first end portion, and 
 a second end portion; and 
 
   a plurality of hinge connector blocks including
 a corner hinge connector block positioned in proximity to each corner of the pallet frame, and 
 and 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; and   a 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; or 
 sea-based materials selected from the group consisting of fishing shell extracts, algae, or sea weed; or 
 forestry 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, and 
 a 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, and 
 attaching 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, and 
 inserting 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; and   adding 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.