Modular Polypropylene Pallet for Underground Hardscape Support
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Solution Overview
Problem
Traditional wooden pallets are heavy, prone to wear and tear, contribute to deforestation, and cannot be easily connected to form larger units for supporting hardscape and softscape structures, which are also costly and complex to implement.
Innovation Solution
A modular pallet system comprising a honeycomb-like structure made of polypropylene, allowing for interlocking and forming scalable multilayer support structures under the ground, enabling tree root growth, water drainage, and utility storage, with hollow legs for forklift access and void spaces for root growth and utility placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional wooden pallets are used, then they provide sufficient strength and load-bearing capacity, but they are heavy, prone to wear and tear, and contribute to deforestation
Solution Approach 1:
The patent changes the material parameter from wood to polypropylene plastic, which fundamentally alters the weight-to-strength ratio. The plastic pallet maintains adequate load-bearing capacity while being significantly lighter and more durable, eliminating the need for frequent replacement and reducing environmental impact from deforestation
Solution Approach 2:
The patent employs composite material construction within the pallet structure, incorporating reinforcing ribs and hollow chambers that combine different geometric forms to achieve optimal strength-to-weight ratio. The honeycomb-like internal structure provides structural reinforcement while minimizing material usage and overall weight
2Device complexity
If traditional wooden pallets are used, then they are simple in structure, but they cannot be coupled together to form larger units for supporting bigger or more goods
Solution Approach 1:
The pallet is designed as a modular unit with standardized dimensions and interconnection features. Multiple pallets can be coupled together through integrated joining mechanisms to form larger matrices or three-dimensional multilayer structures, enabling scalable support systems for various load sizes and configurations without requiring complex custom designs
Solution Approach 2:
The pallet design incorporates universal coupling features that enable the same basic unit to serve multiple functions - whether used individually or combined with other pallets in various configurations. The standardized interface allows for flexible assembly into different structures (flat matrices, stacked layers, or three-dimensional frameworks) to accommodate diverse supporting needs
3Strength
If large scale support structures are implemented for hardscape/softscape, then they provide adequate support, but they are complex and costly to manufacture and implement
Solution Approach 1:
The support structure is divided into discrete, identical modular pallet units that can be manufactured independently using standardized processes. These modular units are then assembled into larger support configurations beneath hardscape or softscape features, providing the necessary structural support while simplifying both manufacturing and installation compared to traditional monolithic concrete or steel structures
Solution Approach 2:
The patent combines multiple functions into the single pallet structure: load-bearing support, water drainage pathways, and potential utility routing spaces. By integrating these functions into one modular unit rather than requiring separate systems, the overall structure becomes less complex and more cost-effective to manufacture and install
4Strength
If solid support structures are used under ground, then they provide strong support, but they prevent tree roots growth and water drainage
Solution Approach 1:
The pallet structure incorporates a honeycomb-like internal geometry with numerous voids and channels that allow tree roots to penetrate and grow through the structure. These porous pathways also facilitate water drainage and air circulation, enabling the support structure to provide mechanical strength while being permeable to biological and fluid elements in the surrounding environment
Data Source
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AI summary
A modular pallet for use in supporting and transporting goods. The modular pallet comprises a plurality of hollow legs integral to an inner side of the sidewall and a plurality of interlocking means integral to an outer side of the sidewall for coupling other modular pallets laterally, wherein each of the hollow legs comprises a top opening aligned with the top surface of the pallet and a bottom opening further away from the bottom surface of the pallet, and a top groove along a peripheral edge of the top opening and a bottom groove along a circumference of the hollow leg adjacent to the bottom surface. A multilayer support structure comprises at least two layers of the modular pallets separated by a plurality of hollow support columns for being positioned under the ground to support a hardscape/softscape disposed thereon while enable for tree roots growth, water drainage and storage of utilities.