Fillable Equipment Pad for Lightweight Shipping and Stable Elevation
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Solution Overview
Problem
Existing methods for elevating equipment units, such as air conditioning condenser units, face challenges including delays and increased costs due to the need for concrete pads, which can be heavy and expensive to ship and install, and may be prohibited in areas with high winds, necessitating the development of lightweight alternatives that still provide stable support.
Innovation Solution
A fillable pad system that includes a support surface with a cavity for receiving fill material, allowing the equipment unit to be elevated above the ground, with the fill material solidifying to maintain the pad in place, reducing shipping and installation costs while providing stability comparable to concrete pads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pre-fabricated concrete pad is used, then the equipment unit can be elevated above ground level, but the weight of the pad makes shipping prohibitively expensive and increases labor costs
Solution Approach 1:
The pad is divided into two functional components: a lightweight support structure (plastic or foam) and a fill material (concrete or gravel). The support structure is shipped lightweight, then filled onsite with the heavy material, separating the shipping weight from the final stabilizing weight.
Solution Approach 2:
The support structure is pre-fabricated offsite in a lightweight form, allowing for easy shipping and handling. The heavy fill material is then added onsite before the equipment unit is installed, preparing the pad in advance to provide concrete-level stability without the shipping burden.
2Weight of moving object
If a lightweight pad is used, then shipping and installation costs are reduced, but the pad may shift and requires a separate anchoring system
Solution Approach 1:
The pad is prepared in advance by filling the cavity with heavy material before the equipment unit is installed. This preliminary weighting action ensures the pad is stable and resistant to shifting from the moment the equipment is placed on it, eliminating the need for separate anchoring systems.
Solution Approach 2:
The pad combines a lightweight structural material (plastic or foam) with a heavy fill material (concrete or gravel) to create a composite structure that is both easy to ship and stable in use. The composite design leverages the advantages of both materials: the structural integrity and lightness of the outer shell, and the weight and stability of the inner fill.
3Ease of operation
If unanchored lightweight pads are used in hurricane-prone areas, then installation is simpler, but they are prohibited by law due to inability to resist high winds
Solution Approach 1:
The pad is pre-weighted with heavy fill material before installation, creating a stable base that can resist high winds without requiring complex anchoring systems. This preliminary preparation allows the pad to meet code requirements in hurricane-prone areas while maintaining simple installation procedures.
Solution Approach 2:
The combination of lightweight structural material and heavy fill material creates a pad that is both easy to install and capable of withstanding hurricane-force winds. The outer shell provides structural integrity and ease of handling, while the inner fill provides the weight necessary for wind resistance.
4Weight of moving object
If concrete is mixed and poured onsite, then no shipping costs are incurred, but multiple trips to the job site over several days are required
Solution Approach 1:
The pad manufacturing process is segmented into two stages: fabrication of the lightweight support structure (done offsite in one operation) and filling with heavy material (done onsite in one operation). This eliminates the need for multiple site visits required for traditional concrete pouring while avoiding shipping of heavy materials.
Solution Approach 2:
The support structure is pre-fabricated offsite, completing the complex manufacturing step before shipping. This allows the onsite installation to be completed in a single visit by simply adding the fill material, eliminating the need for multiple trips required for mixing and pouring concrete.
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 fillable pad system allows for quick and cost-effective installation of equipment units, providing stability and compliance with regulatory requirements by using a lightweight, fillable design that anchors to the ground, reducing the need for multiple site visits and heavy materials.
Implementation Method 1
allowing the workable fill material to solidify and cure
Implementation Method 2
allowing the workable fill material to solidify and cure
Data Source
AI summary
A system may support an equipment unit above a ground surface. The system generally includes a support and a cavity. The support may elevate the equipment unit off of the ground surface. The cavity may be adapted for receiving a fill material to maintain the fillable pad on the ground surface.