Rotomolded Chassis for Scalable Vertical Farming
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Solution Overview
Problem
Current vertical farming systems are labor-intensive, difficult to scale, and lack a cost-effective, easy-to-assemble solution for supporting multiple layers of plants and efficient nutrient delivery and drainage, particularly in large-scale operations.
Innovation Solution
A rotomolded chassis system with dual walls, stacking elements, and integrated plumbing for liquid delivery and drainage, along with features for supporting plants and electric lights, designed for easy assembly, transportation, and cleaning, using materials like HDPE and PP.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional PVC pipes and aluminum gutters are used to fabricate grow system chassis, then the system can support plant growth and nutrient flow, but the construction process becomes extremely labor intensive and difficult to scale
Solution Approach 1:
The grow system is divided into modular chassis units that can be independently manufactured and then assembled. Each chassis is a self-contained module with integrated features, allowing parallel production and easy deployment at scale without requiring complex on-site construction
Solution Approach 2:
The rotomolded chassis integrates multiple functions into a single component: structural support, nutrient solution containment, plant positioning features, and drainage integration. This multi-functionality eliminates the need for separate PVC pipes, gutters, and mounting hardware, dramatically reducing assembly complexity and labor requirements
2Manufacturing precision
If each opening for plants is crafted individually in conventional systems, then precise plant positioning is achieved, but the assembly time and labor requirements increase tremendously
Solution Approach 1:
All plant openings, drainage features, and structural elements are pre-formed during the rotomolding manufacturing process. The chassis arrives at the installation site with precisely positioned plant openings already integrated, eliminating the need for individual crafting or drilling of openings during assembly
Solution Approach 2:
The manufacturing of plant openings is merged with the chassis fabrication process itself. The rotomolding process creates the entire chassis including all openings and features in a single manufacturing step, rather than requiring separate operations for each opening
3Strength
If a large pond construction is used for large scale operations, then structural support for nutrient solution is provided, but the system becomes difficult to transport and reconfigure
Solution Approach 1:
The large-scale grow system is segmented into multiple transportable chassis modules. Each module maintains full structural integrity and can be independently transported, then assembled into larger configurations as needed, providing both the structural support of large systems and the mobility of modular units
Solution Approach 2:
The chassis are designed to nest within each other during transportation and storage, maximizing space efficiency. When deployed, they can be stacked or arranged in various configurations, providing structural support comparable to large permanent installations while maintaining ease of transport and reconfiguration
Data Source
AI summary
A growing system is provided that includes a rotomolded chassis that defines (i) an “interior” where plants are/may be located, and (ii) an “exterior” that at least partially defines a perimeter around the interior. The chassis generally includes stacking elements which allow one chassis to be stacked one upon the other. The disclosed growing system also generally includes (i) means for delivering liquid into the chassis, (ii) means for draining liquid from the chassis, and (iii) means for supporting plants that is conducive to their growing within the chassis.