Modular Tray Assemblies for Indoor Farming
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Solution Overview
Problem
Existing tray systems for indoor farming with soilless growth media are limited by non-expandable modular designs, high manufacturing costs due to multiple mold requirements, and inefficiencies in seed germination and plant harvesting processes.
Innovation Solution
Modular tray assemblies composed of flat, interchangeable tray modules with stand-off features for secure stacking and easy cleaning, connected via accessible features that allow for the formation of larger assemblies without the need for center support structures, reducing waste and inventory complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If modular tray systems use separate locking structures and multiple mold designs to secure modules, then the structural stability is improved, but the manufacturing cost increases and inventory complexity increases
Solution Approach 1:
The patent integrates the locking mechanism directly into the tray module structure itself, merging the support and securing functions into a single integrated component. The tray modules include built-in locking features that engage with corresponding features on adjacent modules, eliminating the need for separate locking structures and reducing the number of parts required.
Solution Approach 2:
The patent designs universal tray modules that can be used in multiple configurations and positions within the tray assembly. The modules are designed with standardized interfaces that allow them to function identically regardless of their position, enabling a single mold design to produce all modules needed for assemblies of various sizes.
2Adaptability or versatility
If modular tray systems use multiple mold designs for different tray sections, then the adaptability to different configurations is improved, but the inventory complexity and manufacturing cost increase
Solution Approach 1:
The patent divides the tray system into standardized modular sections that can be combined in various configurations. Each module is designed with uniform dimensions and interfaces, allowing them to be segmented and reconfigured independently while maintaining compatibility with other modules of the same type.
Solution Approach 2:
The patent creates universal tray modules that can serve multiple functions and positions within the assembly. The modules are designed to be interchangeable and can be used in edge positions, corner positions, or intermediate positions depending on the assembly configuration, eliminating the need for different mold designs for different positions.
3Stability of the object's composition
If tray assemblies include center support structures, then the structural stability is improved, but the access to nutrients for young roots is reduced
Solution Approach 1:
The patent replaces solid center support structures with segmented or lattice-like support elements that provide structural stability while creating openings and gaps. These segmented supports allow nutrient solutions to flow through to the roots while still providing the necessary structural reinforcement for the tray assembly.
Solution Approach 2:
The patent employs porous or permeable support structures that allow fluid passage while maintaining structural integrity. The support elements are designed with porosity or open cellular structures that enable nutrient solution to reach the root zone through the support framework without requiring large solid barriers.
4Ease of manufacture
If tray modules are designed as integrated single-piece structures, then the manufacturing cost is reduced, but the ease of repair and replacement is worsened
Solution Approach 1:
The patent designs tray modules as standardized interchangeable units that can be independently replaced. Each module is a complete functional unit with integrated features, allowing damaged modules to be removed and replaced without affecting other modules, facilitating easy maintenance while maintaining manufacturing efficiency.
Data Source
AI summary
Embodiments of the disclosure relate to tray modules and tray assemblies made from interconnected tray modules. The modular tray assemblies can be used in indoor farming with a soilless growth medium to germinate seeds, develop plants from the germinated seeds, and harvest the developed plants. The tray modules making up a tray assembly are interchangeable and can be made from the same mold design. This can reduce production costs for making tray modules and can reduce the inventory of replacement parts needed to repair tray assemblies.