MODULAR HEXAGONAL ENCLOSURE AND COUPLING APPARATUS THEREFOR

What is disclosed is a modular hydroponic enclosure comprising a hexagonally shaped base; a set of pillars attached to the hexagonally shaped base and to a hexagonally shaped roof, wherein the set of pillars support the roof. A method for a modular hydroponic enclosure comprising providing a hexagonally shaped base; providing a set of pillars attached to the hexagonally shaped base; and providing a hexagonally shaped roof attached to the set of pillars, and wherein the set of pillars support the roof.

FIELD OF THE INVENTION

This invention relates to hydroponic enclosures.

BACKGROUND

Enclosures for hydroponic crop growth have become increasingly important. Using hydroponic enclosures means that land which may have been unsuitable for agriculture due to, for example, infertility, can now be used to produce food crops.

Hydroponic enclosures can also be used to produce food crops in remote and inaccessible areas, so as to enable communities to be self-sustaining and reduce reliance on food which would have to be brought in from elsewhere.

Hydroponic enclosures have been detailed in other works of prior art. For example, U.S. Pat. No. 5,073,401 on “Automated hydroponic growing system”, filed Jun. 15, 1989 to Mohr details an enclosure for hydroponic growing with temperature control, drainage, artificial lighting and reflector sections and growing areas. Similarly, U.S. Pat. No. 6,578,319 on “Hydroponic growing enclosure and method for the fabrication of animal feed grass from seed”, filed Dec. 4, 2001 to Cole et al describes a self-contained hydroponic growing enclosure designed to produce grasses free from impurities with low maintenance and minimum operational manpower. Patent Cooperation Treaty (PCT) Application WO2010/102405 on “Modular hydroponic growing unit” filed 11 Mar. 2010 to Rochefort also describes a cylindrical hydroponic growing unit to grow plants and crops therein.

These prior art solutions described different types of enclosures, but did not consider how to optimize coverage of a fixed land area in terms of materials required using identical regular shaped enclosures. This is an important problem when setting up modular hydroponic enclosures in areas in remote or difficult to access locations, as reducing the amount of materials required means reduced transportation cost and/or reduced difficulties in transporting materials to such remote or difficult to access locations. Furthermore, using regular shaped modular enclosures leads to reduced cost of manufacture and assembly, further lowering the price to the end user. It may also mean easier operation.

As is known to those of skill in the art, a regular tessellation is where identical regular shapes, each having identical regular corners or vertices which have the same angle between adjacent edges, can be arranged to fill a plane without any gaps. There are only three shapes that can form such regular tessellations: the equilateral triangle, square, and regular hexagon.

It is known to those of skill in the art, that using regular hexagons to fill a fixed area minimizes the total perimeter. This principle is known as the honeycomb conjecture and was proven in Hales, Thomas C. “The honeycomb conjecture.” Discrete & Computational Geometry 25, no. 1 (2001): 1-22.

Applying the honeycomb conjecture to hydroponic enclosures, it is clear that: Since using hexagonally shaped enclosures to cover an area minimizes the total perimeter, consequently the amount of materials needed to construct the enclosures to cover a fixed area is also minimized. This reduces the transportation requirements and costs of building hydroponic enclosures to cover an area. Therefore not only is it cheaper to cover an area, it reduces the difficulty of transporting materials to areas in remote and inaccessible locations. This makes such a product attractive to an end user.

Hexagonal structures for hydroponic applications have been considered before. For example, US Patent Application 2016/0059938 on “Smart floating platforms” filed Aug. 26, 2015 to Momayez et al details hexagonal modular floating platforms which can be joined together to cover surfaces of natural and artificial bodies of water and other liquids. These hexagonal modular floating platforms can be used to accommodate hydroponic planters. U.S. Pat. No. 5,599,136 on “Structure for topography stabilization and runoff control” filed Apr. 7, 1993 to Wilke details hexagonal pods to provide soil stabilization of a sloped topography. The pods can accommodate hydroponic plants.

While these works of prior art consider using hexagonal structures for hydroponic plants, these works neither disclose nor contemplate a fully functioning hydroponic enclosure designed for hydroponic crops. Furthermore, these works of prior art do not contemplate modular products for assembly in remote and inaccessible locations.

SUMMARY

A modular hydroponic enclosure comprising: a hexagonally shaped base; and a set of pillars attached to the hexagonally shaped base and to a hexagonally shaped roof, wherein the set of pillars support the roof.

A method for a modular hydroponic enclosure comprising: providing a hexagonally shaped base; providing a set of pillars attached to the hexagonally shaped base; and providing a hexagonally shaped roof attached to the set of pillars, and wherein the set of pillars support the roof.

A method to assemble a modular hexagonal enclosure comprising: assembling a hexagonal base; inserting a set of pillars and a set of panels into the assembled base; assembling a hexagonal roof; and attaching the assembled roof to the set of pillars.

An apparatus to couple a first and a second modular hexagonal enclosures together comprising: a first side section and a second side section coupled to each other, wherein the first side section comprises: a first plurality of horizontal fastening members to attach the first side section to a lower roof support shell member and a lower floor support shell member belonging to the first modular hexagonal enclosure, a first plurality of vertical fastening members to attach the first side section to a first pillar and a second pillar belonging to the first modular hexagonal enclosure, a first attachment member for insertion into: a first groove located on a first pillar belonging to the first modular hexagonal enclosure, a second groove located on a second pillar belonging to the first modular hexagonal enclosure, a panel insertion space located on a lower floor support shell member coupled to the first and second pillars belonging to the first modular hexagonal enclosure, and a panel insertion space located on a lower roof support shell member coupled to the first and second pillars belonging to the first modular hexagonal enclosure, and the second side section comprises: a second plurality of horizontal fastening members to attach the second side section to the lower roof support shell member and the lower floor support shell member belonging to the second modular hexagonal enclosure, a second plurality of vertical fastening members to attach the second side section to a first pillar and a second pillar belonging to the second modular hexagonal enclosure, and a second attachment member for insertion into a groove located on a first pillar belonging to the second modular hexagonal enclosure, a groove located on a second pillar belonging to the second modular hexagonal enclosure, a panel insertion space located on a lower floor support shell member coupled to the first and second pillars belonging to the second modular hexagonal enclosure, and a panel insertion space located on a lower roof support shell member coupled to the first and second pillars belonging to the second modular hexagonal enclosure; and an opening extending through the first side section and the second side section.

DETAILED DESCRIPTION

The foregoing and additional aspects and embodiments of the present disclosure will be apparent to those of ordinary skill in the art in view of the detailed description of various embodiments and/or aspects, which is made with reference to the drawings, a brief description of which is provided next.

The following details a system and method for a modular regular hexagonal hydroponic enclosure which overcomes the shortcomings posed by the prior art solutions discussed above.

FIG. 1shows two example embodiments of a regular hexagonal enclosure100which is the subject of this description. One or more users105are associated with the hexagonal enclosure100. The one or more users105use the hexagonal enclosure100to produce hydroponic crops such as fruit, vegetables, herbs, flowers or any type of crop suitable for growth in such an enclosure. The one or more users105are, for example, farmers, agricultural workers, settlers, gardeners, homeowners and restaurateurs. As shown inFIG. 1, enclosure100is attached to a surface104. Enclosure100is attached to the surface104using techniques known to those of skill in the art. Surface104is, for example, the ground, a cement surface, a wooden surface or any surface suitable for attachment of enclosure100. An alternative embodiment of enclosure100with airlock600is also shown inFIG. 1. The individual components of enclosure100will now be described:

Referring toFIG. 1, enclosure100comprises a base101, roof110, set of panels114and set of pillars120. The base101and roof110are hexagonally shaped. The set of pillars120and set of panels114are attached to the base101and roof110. The set of pillars120support the roof110.

FIG. 2Ashows a detailed illustration of an embodiment of base101. Base101comprises floor102, lower floor support shell109, a set of lower floor support beams111comprising a set of lower floor inner beams113and a set of lower floor outer support beams115. The set of lower floor outer support beams115comprises outer support beams116-1to116-6.

FIG. 2Bshows a top view of floor102of base101. Floor102is shaped as a regular hexagon, with sides103-1to103-6. Then, the angle between each side of floor102and an adjacent side is 120°. In some embodiments, each of sides103-1to103-6are between 2 to 8 feet or 0.6 to 2.4 metres in length. In further embodiments, floor102can be made using, for example, plastic or other polymeric materials, wood, metal, or any material suitable for construction. In some embodiments, each of sides103-1to103-6comprises one or more floor connection members. For example, with reference toFIG. 2B, the floor connection members of side103-1are connection points103-1-1to103-1-10. These enable floor102to attach to side103-1, as will be described below.

As shown inFIG. 2B, floor102comprises two separate panels105-1and105-2. To form floor102, these separate panels are connected at connection point104.FIG. 2Cshows top isometric, bottom isometric and side views of floor102with panels105-1and105-2.

In additional embodiments, floor102comprises cut-out spaces to accommodate a set of lower floor inner beams, which will be described below. For example, with reference toFIG. 2B, panel105-1comprises cut out spaces107-2and107-3; and panel105-2comprises cut out spaces107-1and107-4. In other embodiments, connection point104comprises a space to accommodate at least one inner beam, which will also be described below.

As explained previously, base101ofFIG. 2Acomprises a lower floor support shell109. Lower floor support shell109is a regularly shaped hexagon so as to support floor102. As shown inFIG. 2A, lower floor support shell109further comprises six (6) lower floor support shell members117-1to117-6arranged in a hexagonal shape, so as to conform to the shape of floor102. In some embodiments, each lower floor support shell member encases one of the set of outer support beams. For example, as shown inFIG. 2A, lower floor support shell member117-1encases outer support beam116-1, lower floor support shell member117-2encases outer support beam116-2, and so on.

Each outer support beam is adjacent to two (2) other outer support beams, one at each end. Each outer support beam is configured for coupling to one or more columns and one or more inner beams, as will be discussed further below.

FIG. 3Ashows top, side and isometric views of an embodiment of lower floor support shell member117-1. InFIG. 3Athe lower floor support shell member117-1has ends3C-01and3C-02. End3C-01has edge3C-03, and end3C-02has edge3C-05. Member117-1has outer side3C-11and inner side3C-12. Member117-1also has top surface3C-09. In order to form a regular shaped hexagonal lower floor support shell109, the angle3C-37between outer side3C-11and edge3C-05is 60°, and the angle3C-35between outer side3C-11and edge3C-03is 120°.

To enable insertion of pillars, pillar insertion receiving members are used to form pillar connection members. An example is shown inFIG. 3A. End3C-01comprises extrusion3C-04with pillar insertion receiving member3C-08. Member3C-08comprises an opening with a space, the purpose of which will be detailed below. End3C-02comprises extrusion3C-06, and pillar insertion receiving member3C-10. Pillar insertion receiving member3C-10comprises an opening with a space, the purpose of which will be detailed below. Extrusions3C-04and3C-06are equilateral triangles.

As can be seen in the side view shown inFIG. 3A, extrusion3C-06is positioned higher relative to extrusion3C-04. To enable insertion of pillars, an extrusion from an end of the lower floor support shell member117-1is positioned either above or below the corresponding extrusion from an end of the shell member to be coupled to, so that the openings belonging to the pillar insertion receiving members are in vertical alignment to form a pillar connection member. Since the extrusions are equilateral triangles, the angle formed between the lower floor support shell members after coupling is 120°.

Additionally, each lower floor support shell member comprises one or more floor connection members to enable coupling to a floor. In some embodiments, one or more floor fastening members are used together with the one or more floor connection members to enable coupling to a floor. As shown inFIG. 3A, inner side3C-12comprises floor connection members3C-20to3C-29which in turn comprise one or more openings and spaces for a side of the floor to couple to the lower floor support shell member117-1. For example, with reference toFIG. 2B, if lower floor support shell member117-1is to be coupled to side103-1, then, openings103-1-1to103-1-10on side103-1are vertically aligned with these openings in members3C-20to3C-29respectively, and one or more floor fastening members are inserted into these aligned openings to enable a strong coupling between the side103-1and the lower floor support shell member117-1. To couple floor102to lower floor support shell109, then the same operation is performed for the remaining members117-2to117-6and the other sides103-2to103-6.

Referring toFIG. 3A, member117-1comprises space3C-18for insertion of outer support beam116-1.FIG. 3Billustrate top and isometric views of lower floor support shell member117-1with outer support beam116-1inserted into space3C-18.

The lower floor support shell member also comprises one or more pillar connection members to enable coupling to one or more pillars. In some embodiments, one or more pillar fastening members are used with the one or more pillar connection members to enable coupling to one or more pillars. A specific embodiment is shown inFIG. 3A. InFIG. 3Athe pillar connection member3C-17in lower floor support shell member117-1comprises an opening and a space for a fastening member. Additionally, pillar insertion receiving members3C-08and3C-10also form part of pillar connection members. An example of a pillar fastening member is a dowel. An example which utilizes a dowel attached to a pillar will be described later.

The lower floor support shell member also comprises one or more column connection members to enable coupling of the outer beams to one or more columns. In some embodiments, the one or more columns comprise one or more column fastening members which are used with the column connection members to enable coupling to one or more columns. In further embodiments, the column fastening members work together with the previously discussed column receiving members on each of the outer beams to enable coupling of the outer beams to the one or more columns A specific embodiment is shown inFIG. 3A. InFIG. 3Athe lower floor support shell member117-1comprises column connection members3C-13and3C-15. Each of these members comprises an opening and a space for a column to couple to. The openings and spaces which are part of members3C-13and3C-15extend through to space3C-18to enable a column to couple to outer beam116-1when inserted in space3C-18.

The lower floor support shell member also comprises one or more inner beam connection members to enable coupling of each of the outer beams to one or more inner beams. A specific embodiment is shown inFIG. 3A. InFIG. 3A, the lower floor support shell member117-1comprises an inner beam connection member3C-31in the form of an opening for an inner beam to enter. Inner beam connection member3C-31extends through to space3C-18to enable coupling between an inner beam and outer beam116-1. Then, an inner beam is inserted into the opening3C-31, and coupled to the outer beam116-1. The coupling of the inner beam to the outer beam is achieved using techniques known to those of skill in the art, such as screws.

The lower floor support shell member also comprises a panel insertion space to enable insertion of a panel. A specific embodiment is shown inFIG. 3A, where lower floor support shell member117-1comprises panel insertion space3C-33.

Pillars and Panels

As previously explained with reference toFIG. 1, enclosure100comprises set of pillars120, which are used to attach the base101to the roof110of the enclosure. These pillars support the roof of the enclosure. In some embodiments a pillar encases one or more columns to further support the roof.

FIG. 4Ashow top, bottom and side views of an embodiment of a pillar401which encases two (2) columns, without columns inserted.FIG. 4Bshows bottom and side views of pillar401, with columns inserted. With reference toFIG. 4A, pillar401comprises a top surface403; a bottom surface405; inner surfaces407and409; outer surfaces411and413; and side surfaces415and417.

Bottom side405comprises pillar fastening members in the form of dowels419and421. Both these dowels419and421are used to attach pillar401to two lower floor support shell members.

There is a 120° angle between inner surfaces407and409, and outer surfaces411and413. WhileFIG. 4Ashows one particular shape used for pillar401, one of skill in the art would recognize that a variety of shapes are possible for pillar401.

Grooves431and433are cut into side surfaces415and417respectively. Groove431is connected to opening427on the bottom surface405and opening439on top surface403. Groove433is connected to opening429on the bottom surface405and opening441on top surface403. These grooves are designed to hold panels.

Openings423and425in bottom surface405allow columns to be inserted into spaces435and437respectively. Spaces435and437extend from the bottom surface405to the top surface403, and are connected to openings443and445respectively on the top surface403. This allows columns to be inserted into spaces435and437respectively.

FIG. 4Ashows a top view of pillar401and top surface403. Top side403comprises pillar fastening members in the form of dowels447and449. Both these dowels447and449are used to attach pillar401to two lower roof support shell members. Additionally, one of these dowels447and449are used to join two lower floor support shell members together depending on the location of the connection. As explained previously, there is a 120° angle between inner surfaces407and409, and outer surfaces411and413.

When column451is inserted, it protrudes from opening423on the bottom surface405, and from opening443on top surface403. When column453is inserted, it protrudes from opening425on bottom surface405, and from opening445on top surface403.

As previously explained with reference toFIG. 1, enclosure100further comprises a set of panels114. These panels attach to the pillars, the lower floor support shell members and lower roof support shell members, as will be explained later. The set of panels114separate the interior of enclosure100from an exterior.FIG. 4Cis a detailed illustration of top, side and front views of a single panel115-1. As shown inFIG. 4C, panel115-1comprises two (2) horizontal sides115-1-1and115-1-3; and two (2) vertical sides115-1-2and115-1-4. Then the vertical sides115-1-2and115-1-4are attached to the pillars using the previously described pre-cut grooves in the pillars. The horizontal sides115-1-1and115-1-3attach to the lower roof support shell member and lower floor support shell member respectively using the panel insertion spaces in these members.

The materials used to construct set of panels114may depend on the temperature exterior to the enclosure. In some embodiments, when temperatures exterior to the enclosure fall within a certain range, then set of panels114are windows. In some embodiments, this range is from 0° C. to 50° C. (32° F. to 122° F.). In some of the embodiments where set of panels114are windows, set of panels114are rectangular shaped polycarbonate windows. In some of these embodiments where set of panels114are windows, one of the set of panels has a hole for an external water supply tubing to fit through. In other embodiments, when it is likely for temperatures exterior to the enclosure to fall below a certain threshold temperature, for example below 0° C. (32° F.), then set of panels114comprise solid, opaque, heat retaining walls. In yet other embodiments, when it is likely for temperatures exterior to the enclosure to rise above a certain threshold temperature, for example above 50° C. (122° F.), then set of panels114comprises shade curtains to prevent overheating and block out certain spectrums of sunlight. In some embodiments, the set of panels114are made of reflective surfaces so as to ensure that light generated within the enclosure is reflected within the enclosure.

In some embodiments, the enclosure100is insulated. In some of the embodiments where enclosure100is insulated, at least some of the set of panels114comprise phase change materials for regulation of temperature interior to the enclosure. In some of the embodiments where phase change materials are used, the number of panels using the phase change materials will depend on one or more of:The temperature exterior to the enclosure, andFluctuations in the temperature exterior to the enclosure.

Lower roof support shell503is detailed further inFIG. 5B. Lower roof support shell503comprises a set of support beams511, further comprising a set of lower roof inner beams513, and a set of lower roof outer beams515. As is shown inFIG. 5B, lower roof support shell503is shaped as a regular hexagon so as to conform to the shape of enclosure100. InFIG. 5B, lower roof support shell503further comprises six (6) lower roof support shell members504-1to504-6. Then, the angle between each lower roof support shell member and an adjoining member is 120°. In some embodiments, each of the members504-1to504-6are between 2 to 8 feet or 0.6 to 2.4 metres in length. In further embodiments, lower roof support shell503can be made using, for example, plastic or other polymeric materials, or other materials suitable for construction.

The set of lower roof outer support beams515comprises lower roof outer support beams505-1to505-6. In some embodiments, each lower roof support shell member encases one of the set of lower roof outer support beams515. For example, as shown inFIG. 5B, lower roof support shell member504-1encases lower roof outer support beam505-1, lower roof support shell member504-2encases lower roof outer support beam505-2, and so on. In some embodiments, these lower roof outer support beams are inserted into the lower floor support shell members via openings, as will be detailed later.

FIG. 5Cshows detailed diagrams of the top and bottom of lower roof support shell member504-1. Referring to the view of the top: Lower roof support shell member504-1has an outer side504-1-11and an inner side504-1-12. In some embodiments, each of the members504-1to504-6comprises one or more upper roof support shell connection members to enable connection to an upper roof support shell member. For example, with reference toFIG. 5C, the upper roof support shell connection members of member504-1are upper roof support shell connection points504-1-20to504-1-27; and upper roof support shell connection grooves504-1-09and504-1-10.

Referring to the diagram of the bottom shown inFIG. 5C, the lower roof support shell member504-1has ends504-1-01and504-1-02. Each end has an edge. End504-1-01has edge504-1-03, and end504-1-02has edge504-1-05. As explained previously, member504-1has outer side504-1-11and inner side504-1-12. In order to form a regular shaped hexagonal lower roof support shell, the angle between outer side504-1-11and edge504-1-05is 60°, and the angle between outer side504-1-11and edge504-1-03is 120°, similar to that shown for angles3C-35and3C-37for lower floor support shell member117-1inFIG. 3A.

As with the lower floor support shell members, the lower roof support shell member also comprises one or more pillar connection members to enable insertion of one or more pillars using pillar fastening members. An example embodiment is shown inFIGS. 5C and 5D.FIG. 5Dshows front, isometric and side views of lower roof support shell member504-1. InFIGS. 5C and 5Dthe pillar connection member504-1-17in lower roof support shell member504-1comprises an opening and a space for a pillar fastening member.

Similar to the lower floor support shell members, pillar insertion receiving members are used to form pillar connection members. Referring toFIGS. 5C and 5D, end504-1-01comprises extrusion504-1-04with pillar insertion receiving member504-1-08, which in turn comprises an opening with a space. End504-1-02comprises extrusion504-1-06with pillar insertion receiving member504-1-19, which comprises an opening with a space. As can be seen, extrusions504-1-04and504-1-06are equilateral triangles. As can be seen in the front view inFIG. 5D, extrusion504-1-04is positioned higher relative to extrusion504-1-06. To enable insertion of pillars, an extrusion from an end of the lower roof support shell member504-1is positioned either above or below the corresponding extrusion from an end of the shell member to be coupled to, so that the openings belonging to the pillar insertion receiving members are in vertical alignment to form a pillar connection member. Since the extrusions are equilateral triangles, the angle formed between the lower roof support shell members after coupling is 120°. An example of a pillar fastening member is a dowel. An example which utilizes a dowel attached to a pillar will be described later.

In some embodiments, each lower roof support shell member comprises one or more auxiliary connection members. As shown in the bottom view inFIG. 5C, inner side504-1-12comprises auxiliary connection members504-1-30to504-1-39. These may be used to couple other components or structures as necessary.

With reference toFIG. 5B, each of the outer beams505-1to505-6also couples to one of the set of inner beams513. This is achieved in the following way: Each lower roof support shell member comprises one or more inner beam connection members to enable coupling of each of the outer beams to one or more inner beams. For example, with reference toFIG. 5D, lower roof support shell member504-1comprises inner beam connection member504-1-40in the form of an opening and a space to enable insertion of an inner beam. The coupling of the inner beam to the outer beam is achieved using techniques known to those of skill in the art, such as screws.

Referring to the front view of member504-1shown inFIG. 5D, member504-1comprises panel insertion space504-1-41for insertion of a panel such as panel115-1shown inFIG. 4C.

Referring to the view of the top surface of member504-1shown inFIG. 5C; and isometric and side views of member504-1shown inFIG. 5D, member504-1comprises space504-1-18for insertion of outer support beam505-1. Referring to the side view shown inFIG. 5D, space504-1-18has opening504-1-18A for insertion of the outer support beam.

The lower roof support shell member also comprises one or more column connection members to enable coupling of the outer beams to one or more columns. In some embodiments, the one or more columns comprise one or more column fastening members which are used with the column connection members to enable coupling to one or more columns. In further embodiments, the column fastening members work together with the previously discussed column receiving members on each of the outer beams to enable coupling of the outer beams to the one or more columns A specific embodiment is shown inFIGS. 5C and 5D. InFIG. 5Cthe lower roof support shell member504-1comprises column connection members504-1-13and504-1-15. Each of these members comprises an opening and a space for a column to couple to. The openings and spaces which are part of members504-1-13and504-1-15extend through to space504-1-18to enable a column to couple to an outer beam inserted in space504-1-18.

FIG. 5Eshows top and side views of upper roof support shell505, which is designed to couple to lower roof support shell503and accommodate roof panels507-1and507-2. Upper roof support shell505is constructed using upper roof support shell members524-1to524-6. As can be seen, each upper roof support shell member has two adjoining upper roof support shell members. For example, upper roof support shell member524-1is adjoined by members524-2and524-6. Then these adjoining members are at an angle of 120° to member524-1, so as to enable the upper roof support shell to be hexagonal shaped. In some embodiments, upper roof support shell member505is designed to allow a slant in roof panels507-1and507-2. This is slant is, for example, in the range of 0.1 to 5°. This enables water to be drained away from the roof in case of rain or melting snow. For example, inFIG. 5Ethere is a water drainage outlet5H-07at this low point of upper roof support shell505. In some embodiments, the water that is drained away is collected into a receptacle such as a rainwater barrel, and can then be used to irrigate the crops within the enclosure100.

The side view shown inFIG. 5Eillustrates the slant. Upper roof support shell505has top surface506-1and bottom surface506-2, right surface506-3and left surface506-4. Top surface506-1has a slanted section518located between right edge506-3and the left edge506-4. The lower end of the slanted section518is closer to left edge506-4while the higher end of the slanted section518is closer to right edge506-3. Upper roof support shell505is divided into two portions, first portion517-1and second portion517-2. With reference to the top and side views, the three upper roof support shell members524-1,524-2and524-6form the first portion517-1of the upper roof support shell505. Members524-2and524-6comprise slots which slant away from member524-1. The slot on member524-1is also slanted so as to enable roof panel507-1to be inserted at the same slant. When the roof panel507-1is inserted into the slots in each of these upper roof support shell members, the panel will slant away from member524-1. The three upper roof support shell members524-3,524-4and524-5form the second portion517-2of the upper roof support shell505. Members524-3and524-5comprise slots which slant towards member524-4. Member524-4comprises a groove which is slanted to receive roof panel507-2. Then, the low point of this slant is within the groove in upper roof support shell member524-4.

A detailed description of upper roof support shell member524-1to524-6are given below. For upper roof support shell member524-1, a detailed description is given below and with reference toFIG. 5F.FIG. 5Fshows views from the bottom surface524-1-17, front surface524-1-04, and side surface524-1-14of upper roof support shell member524-1. Side524-1-04is the shorter side and side524-4-05is the longer side. Then side524-1-05makes 60° angles with sides524-1-14and524-1-15; and side524-1-04makes 120° angles with side524-1-14and524-1-15, to facilitate a hexagonal shaped roof as seen inFIG. 5F. Each upper roof support shell member comprises lower roof support shell connection members to enable coupling to the corresponding lower roof support shell member. For example, for shell member524-1, the lower roof support shell connection members comprise lower roof support shell connection fastening members524-1-06to524-1-13and lower roof support shell connection tabs524-1-02and524-1-03. These connect into the corresponding connection points and connection grooves on lower roof support shell member504-1, as will be explained later. Then, groove524-1-16is positioned to receive roof panel507-2. As explained above, roof panel507-1slants away from upper roof support shell member524-1. As shown inFIG. 5F, groove524-1-16is angled to maintain roof panel507-1in this slanted orientation.

For upper roof support shell member524-6, a detailed description is given below and with reference toFIGS. 5E and 5G. One of skill in the art would note that lower roof support shell member524-2shown inFIG. 5Eis constructed in a similar fashion.FIG. 5Gshows views looking at the bottom surface524-6-18and at inner surface524-6-04. Surface524-6-04is shorter compared to surface524-6-05. Then side524-6-05makes 60° angles with sides524-6-14and524-6-15; and side524-6-04makes 120° angles with side524-6-14and524-6-15, to facilitate a hexagonal shaped roof. Upper roof support shell member524-6also comprises lower roof support shell connection members to enable coupling to corresponding lower roof support shell member504-6. These connection members comprise connection fastening members524-6-06to524-6-13and lower roof support shell connection tabs524-6-02and524-6-03, which connect into the corresponding connection points and connection grooves on lower roof support shell member504-6. Groove524-6-16is designed to hold panel507-1at the same angle as groove524-1-16. Referring to the view of inner surface524-6-04, it can be seen that top surface524-6-17of upper roof support shell member524-6comprises two sections524-6-17-1and524-6-17-2. Section524-6-17-1is slanted at the same angle as groove524-1-16. Section524-6-17-2is coplanar with the top surface of upper roof support shell member524-1.

A detailed description of upper roof support shell member524-5is given below and with reference toFIGS. 5E and 5H. One of skill in the art would note that upper roof support shell member524-3is constructed in a similar fashion.FIG. 5Hshow views looking at bottom surface524-5-18, and from side524-5-04of upper roof support shell member524-5. Side524-5-04is the shorter side and side524-5-05is the longer side. Then side524-5-05makes 60° angles with sides524-5-14and524-5-15; and side524-5-04makes 120° angles with side524-5-14and524-5-15, to facilitate a hexagonal shaped roof. Upper roof support shell member524-5also comprises lower roof support shell connection members to enable coupling to corresponding lower roof support shell member504-5. These connection members comprise connection fastening members524-5-06to524-5-13and lower roof support shell connection tabs524-5-02and524-5-03, which connect into the corresponding connection points and connection grooves on lower roof support shell member504-5.

Looking from front side524-5-04, groove524-5-21is positioned to receive roof panel507-2. As explained above, roof panel507-2slants towards upper roof support shell member524-4. As shown inFIG. 5H, groove524-5-21is angled to maintain roof panel507-2in this slanted orientation, and ensure that the slant matches that of roof panel507-1. Top surface524-5-17comprises two sections524-5-17-1and524-5-17-2. The slant in section524-5-17-2matches the slant in section524-6-17-1, so as to ensure that sections524-5-17-2and524-6-17-1are coplanar. Section524-5-17-1has a different slant to section524-5-17-2to ensure that the junction of upper roof support shell member524-4with side524-5-14is coplanar with the top surface of upper roof support shell member524-4.

A detailed description of upper roof support shell member524-4is given below and with reference toFIG. 5I.FIG. 5Ishow views looking at the bottom surface524-4-18, from side524-4-04, and from side524-04-14of upper roof support shell member524-4. Side524-4-04is the longer side, and side524-4-05is the shorter side. Then sides524-4-14and524-4-15make 60° angles with side524-4-04and 120° angles with side524-4-05, so as to facilitate a hexagonal roof. For upper roof shell member524-4, the lower roof support shell connection members comprise lower roof support shell connection fastening members524-4-06to524-4-13and lower roof support shell connection tabs524-4-02and524-4-03. These connect into the corresponding connection points and connection grooves on lower roof support shell member504-4. As shown inFIG. 5I, water drainage outlet5H-07is located on top surface524-4-17and extends from side524-4-04to side524-4-05to enable water to be drained away. In some embodiments, water drainage outlet5H-07slants from side524-4-05to side524-4-04.

Looking at the front view of side524-4-05, slot524-4-16is positioned to receive roof panel507-2. As shown inFIG. 5I, slot524-4-16is angled to maintain roof panel507-2in a slanted orientation and therefore enable water to be drained into drainage outlet5H-07.

One of skill in the art would understand that there are a variety of ways to realize upper roof support shell members524-1to524-6. For example, in some embodiments, one or more of the upper roof support shell members comprise sloping sections in their top surfaces to ensure that water is drained into the roof panels and into water drainage outlet5H-07.

As shown in the alternative embodiment inFIG. 1, the door to the enclosure100is constructed using an airlock such as airlock600. This serves the following purposes:When control of the temperature of the interior of the enclosure is vital for the growth of the crops inside the enclosure, the airlock helps reduce heat loss to, or heat gain from the exterior of the enclosure.So as to avoid users bringing in contaminants from the exterior of the enclosure, the airlock will be sufficiently large to, for example, allow users to change footwear or wear appropriate protective clothing to avoid or reduce contamination from the exterior of the enclosure.

Side and isometric views of an exemplary embodiment of the airlock is shown inFIG. 6. InFIG. 6, referring to the side view of airlock600, it can be seen that airlock600comprises outer side621, inner chamber605, and inner side625. Outer side621comprises outer door601attached to the outer door frame607via outer hinges609. Inner side625comprises inner door603attached to the inner door frame611via inner hinges613. As would be known to one of skill in the art, when outer door601opens, inner door603remains closed and vice versa. The temperature and/or pressure the inner chamber of the airlock605is controlled to enable the airlock to function. The inner side625is attached to lower roof support shell member504-1, the pillars coupled to lower roof support shell member504-1and the lower floor support shell member coupled to these pillars. In this way, the airlock600is connected to the side of the enclosure100where the highest point of the roof panel107-1is located.

One of skill in the art would know that different types of airlocks to the one shown inFIG. 6are also possible. In some embodiments, to avoid contamination from the exterior of the enclosure, the interior of the enclosure can be maintained at a higher air pressure compared to the exterior of the enclosure. Then the airlock can serve to ensure maintenance of this pressure differential using techniques known to those of skill in the art.

Subsystems

One or more subsystems used to facilitate the operation of enclosure100are detailed inFIG. 7. InFIG. 7, HVAC subsystem702comprises heating, ventilation and air conditioning components. The heating component704comprises heating devices and systems to heat the interior of the enclosure to a suitable ambient temperature. Examples of heating devices include, for example, a ceramic heater, space heating, gas-fired, propane and geothermal heating devices. In some embodiments, heating component704comprises heating systems which use excess heating produced by other buildings nearby. HVAC subsystem702enables homogenization and equal distribution of air flow to all the plants within the enclosure.

The ventilation component706comprises ventilation devices and systems to maintain the desired composition of air in the interior of the enclosure, and additionally assist in cooling as necessary. In some embodiments, the ventilation component706comprises a plurality of bee-wax piston-controlled vents are used to allow for passive venting. In some of the embodiments where the bee-wax piston-controlled vents are used, these bee-wax piston controlled vents are placed on opposite walls at different heights. In additional embodiments, the ventilation component706comprises an oscillating fan for active ventilation. In yet other embodiments, the ventilation component706comprises mechanical venting for cases where the enclosure exterior temperature is below a threshold temperature, for example 0° C. (32° F.). In yet other embodiments, the ventilation component606comprises oxygen and carbon recycling subsystems.

The cooling component708comprises cooling devices and systems to cool the interior of the enclosure to a suitable ambient temperature. The cooling component708includes, for example, air-conditioning (AC) devices and systems and fans. As explained above, the ventilation component706may additionally assist with cooling.

Water distribution subsystem710plays the role of ensuring that an appropriate amount of water is supplied to enclosure100to enable proper crop growth, and that wastewater is appropriately drained or removed from enclosure100. Water distribution subsystem710comprises, for example, pipes, valves, tubes, pumps, taps, water purification units and other devices and systems necessary to ensure proper supply of water and removal of wastewater.

FIGS. 8A, 8B and 8Cshow detailed illustrations of an embodiment of a lower water return distribution subsystem710comprising a lower water return distribution subsystem810and an upper water return distribution subsystem820. As shown inFIGS. 8A and 8B, the lower water return distribution subsystem810comprises a water tank804having a sump pump to distribute water through a pipe803that runs vertical to upper water return distribution subsystem820. The water tank804has, for example, a capacity of 15-30 gallons (56.7 to 113.6 litres). Then as shown inFIG. 8Bthe bottoms of the towers are connected to the return water pipe806via connections such as outlet808. The return water pipe806comprising segments807-1to807-5is configured to conform to the shape of the enclosure, that is, the segments are coupled to each other to form a hexagon shape, and have angles of 120° with each other. For example, as shown inFIG. 8A, return water pipes807-3and807-4have an angle of 120° with each other. In some embodiments, the return water pipes have a unidirectional flow control system. For example, as shown inFIG. 8A, unidirectional flow control system805maintains unidirectional flow of water into central tank804. In some embodiments, as shown inFIG. 8B, the unidirectional flow control system805comprises a ball valve811-1followed by a check valve811-2followed by a ball valve811-3which connects back to the water tank804. The water tank804will have a connector for tubing to connect to an external water source to fill up the tank without having to enter enclosure100. An example of an external water source is, for example, an external water supply or the receptacle used to collect the water drained away via water drainage outlet5H-07inFIG. 5E.

An exemplary embodiment of the upper water return distribution subsystem820is shown inFIG. 8C. Water from pipe803is fed into pipe823and subsequently into upper distribution pipe821. While upper distribution pipe821is shown to be circular, one of skill in the art would know that pipe821can take any shape to allow for distribution of water to the towers within the enclosure100. A plurality of water feed subsystems are attached to pipe821. A detailed view of a water feed subsystem830to feed water into tower6F-01is shown inFIG. 8C. Water feed subsystem830comprises inlets833and841to enable coupling to upper distribution pipe821and water to enter feed subsystem830. Water then enters upper T-pipe connection831which is connected to flexible hose835at end839. The other end of flexible hose835is coupled to ball valve837. Ball valve837enables water flow into tower6F-01while in an ON state and disables water flow into tower6F-01while in an OFF state. While in an ON state, water is directed to tower6F-01from ball valve837via flexible hose843. The water exits a tower such as tower6F-01via an outlet such as outlet808.

Lighting subsystem712comprises devices and systems necessary to provide sufficient illumination to ensure proper crop growth and also for one or more users105to work within the enclosure100. In some embodiments, lighting subsystem612comprises light emitting diodes (LED) spectrum lighting of 4 to 6 feet (1.21 to 1.83 m) in length.FIG. 9illustrates a detailed embodiment of an LED901in enclosure100. In some embodiments, LEDs are suspended from either set of inner beams511or roof panels507-1and507-2. As shown inFIG. 9, LED901is attached to roof panel507-1via attachment903.

Communication subsystem714enables the subsystems and components of enclosure100to communicate with devices, systems and networks external to enclosure100. Communications subsystem714allows for reception and transmission of communications via at least one of wired and wireless communications technologies using systems and methods known to those of skill in the art. This includes communications using various available network technologies including, for example, Campus Area Network (CAN), Local Area Network (LAN), BLUETOOTH®, Wi-Fi, Near Field Communications (NFC), Radio Frequency Identification (RFID), 3G, Long Term Evolution (LTE), 5G, Universal Serial Bus (USB) and other protocols known to those of skill in the art.

Sensors716are responsible for detecting environmental conditions both inside and outside the enclosure100. Examples of sensors716include:pH sensors,electrical conductivity sensors to perform water tests and determine nutrient concentrations,enclosure interior temperature sensors,enclosure exterior temperature sensors,humidity sensors,water level and flow rate sensors,nutrient level and rates of change sensors,lighting level sensors,carbon dioxide (CO2) level sensors,door open/closed sensors,power consumption sensors,solar condition sensors,wind condition sensors,battery level sensors, andgenerator fuel level sensors.

Security subsystem718is utilized to help secure enclosure100against unwanted intruders such as thieves or animals. Security subsystem718comprises one or more security devices and subsystems such as cameras, alarms, motion sensors, intruder detection subsystems, electrified fences, door locking systems.

Growth subsystem719concerns the equipment necessary to ensure proper growth of the hydroponic crops within enclosure100. This may include, for example, nutrient delivery systems and the towers. The towers have been previously described above. In some embodiments, these are optimized for the hexagonal shape of the enclosure.

As previously explained, enclosure100has a plurality of towers. In some embodiments, at least one of this plurality of towers is shaped cylindrically. In other embodiments, at least one of this plurality of towers is shaped hexagonally.

FIG. 10Ashows a detailed illustration of the top, the front, bottom of tower6F-01, and a single pod6G-02-01. As can be seen fromFIG. 10A, tower6F-01is shaped hexagonally and comprises six (6) surfaces6G-01to6G-06. The surfaces are arranged such that each surface is at a 120° angle to the adjoining surfaces, thereby providing a hexagonal shape to tower6F-01. For example, surface6G-01is at a 120° angle to adjoining surfaces6G-02and6G-06.

As is shown inFIG. 10A, tower6F-01comprises a plurality of pods such as pods6G-02-01and6G-06-01. Individual plants are placed into each of the plurality of pods. As is further shown inFIG. 10A, in some embodiments, the plurality of pods is divided into groups, and each group of pods is arranged on the outside of one of the surfaces. For example, inFIG. 11A, surface6G-01comprises pods6G-01-01to6G-01-08. In other embodiments, the pods are oriented at an angle to the surface that they are located on. A detailed example is shown using pod6G-02-01. For example, pod6G-02-01is oriented at an angle671to surface6G-02. In some embodiments, angle671falls within an optimal range, that is, between a minimum value and a maximum value. If angle671exceeds the maximum value, then the pod6G-02-01is not supported correctly. If angle671is less than the minimum value, this reduces the amount of pods that can be placed on the surface.

The bottom6F-01-01of tower6F-01is also shown inFIG. 10A. With reference toFIG. 8AandFIG. 10A, 6F-01-01is coupled to outlet808of pipe806via cone connection6F-01-02and threaded connection6F-01-03. The tower is sufficiently light to enable it to be screwed into outlet808.

In some embodiments, the tower is comprised of a plurality of sections. Then, prior to use, the tower must be assembled. An example embodiment is shown inFIG. 10B. InFIG. 10B, tower1001is comprised of a plurality of sections comprising sections10B-01,10B-02and10B-03.10B-01is the lowest section of the tower, and it must be attached to the lower return water pipe by being screwed in as previously described. Then next section10B-02is connected to section10B-01, section10B-03is connected to section10B-02until the tower assembly is complete.

FIG. 10Cshows a combination of towers and lighting in enclosure100. In some embodiments, each tower is associated with an LED. For example, inFIG. 10C, LED901is associated with tower6F-01. Then LED901provides sufficient light for the plants in the pods in tower6F-01to grow. Also inFIG. 10C, a plurality of towers10C-01together with a plurality of LEDs10C-03, wherein each LED is proximate to one of the plurality of towers, is shown.

Interconnections720electrically couples the subsystems and components of enclosure100. Interconnections720allows for signals other than power to be transmitted between the subsystems as necessary.

Enclosure100is powered using the power supplied by power supply722. Power supply722powers the other subsystems of enclosure100including HVAC subsystem702, water distribution subsystem710, lighting subsystem712, communication subsystem714, sensors716and security subsystem718. In some embodiments, the power supply722comprises at least one renewable power source such as solar, wind or geothermal power. In some of the embodiments where the power supply comprises power drawn from solar energy, power is drawn from solar panels placed on the roof110. In some of the embodiments where the power supply722comprises power drawn from wind energy, the power is drawn from wind turbines. In some other embodiments, the power supply722comprises at least one non-renewable power source such as a diesel power generator. In further embodiments, the power supply722comprises a connection to a power grid to draw power from a power grid. In yet other embodiments, the power supply722comprises at least one primary and at least one secondary source. Then, if the at least one primary source supplies insufficient power, power is drawn from the at least one secondary source. In yet other embodiments, the power supply722comprises at least one battery. In some of these embodiments, the at least one battery is rechargeable to allow storage of surplus power. This is useful in, for example, environments where the power source is intermittent. For example, if the enclosure100is supplied using solar power, then during times when more solar power than necessary for the operation of the enclosure is generated, the at least one battery is charged using the surplus power. Then if insufficient solar power is generated, power can be drawn from the at least one battery to supply the enclosure. A similar arrangement can be used for other power sources such as wind power.

Assembly of Enclosure

The enclosure100is designed to be modular, meaning that the individual components described above can be transported to and then assembled in a location as necessary.FIG. 11shows a flowchart for assembling enclosure100.

In step1101, base101is assembled and attached to surface104. Assembly of the base101is demonstrated with reference toFIG. 12andFIGS. 1, 2A, 2B2C,3A,3B and13.

With reference toFIG. 12, the assembly of lower floor support shell109comprises steps12-01to12-03. In step12-01ofFIG. 12, referring back toFIG. 2A, each of the set of outer support beams115is inserted into the lower floor support shell member that will encase it. For example, outer support beam116-1is inserted into lower floor support shell member117-1, outer support beam116-2is inserted into lower floor support shell member117-2, and so on.

In step12-02ofFIG. 12, referring back toFIG. 2A, each of the set of lower floor inner beams113is coupled to each of the set of outer beams via insertion into an inner beam connection member. For example, with reference toFIGS. 2A and 3A. one of set of lower floor inner beams113is inserted into opening3C-31of lower floor support shell member117-1and coupled to outer support beam116-1.

In step12-03ofFIG. 12each of the lower floor support shell members is aligned with an adjacent lower floor support shell member. This is performed by positioning an extrusion either above or below the corresponding extrusion from an end of the shell member to be coupled to. In this way, the openings belonging to the pillar insertion receiving members are in vertical alignment to form a pillar connection member. An example is demonstrated with reference toFIG. 13. InFIG. 13shell member117-2has end4E-01. End4E-01comprises extrusion4E-02with pillar insertion receiving member4E-03. End4E-01also comprises edge4E-05. Pillar insertion receiving member4E-03comprises an opening and a space for insertion of a pillar fastening member. Edge4E-05of shell member117-2is aligned with edge3C-05of shell member117-1. Since extrusion4E-02is lower relative to extrusion3C-06, it is positioned below extrusion3C-06, thereby allowing the opening belonging to pillar insertion receiving member3C-10to be vertically aligned with the corresponding opening belonging to pillar insertion receiving member4E-03to form a pillar connection member. This is performed for all the shell members, to partially assemble lower floor support shell109.

In step12-04, floor102is attached to the partially completed lower floor support shell109. This is explained with reference toFIGS. 2A, 2B2C, and3A. Floor panels105-1and105-2are connected at connection point104, and each of the set of inner beams113are accommodated within the cut-out spaces107-1to107-4and connection point104. Then, each side103-1to103-6of floor102is attached to the lower floor support shell members117-1to117-6of lower floor support shell109respectively. As previously explained, with reference toFIGS. 2B and 3Aif, for example lower floor support shell member117-1is to be coupled to side103-1, then:The floor connection members on side103-1, that is, connection points103-1-1to103-1-10are vertically aligned with floor connection members3C-20to3C-29;Floor fastening members are inserted into these aligned connection points and connection members to enable a strong coupling between side103-1and lower floor support shell member117-1.The same operation is performed for the remaining members117-2to117-6and the other sides103-2to103-6to complete the coupling of floor102to the lower floor support shell109.

In step12-05, with reference toFIG. 1, base101is attached to surface104.

In step1102, with reference toFIG. 1, the set of pillars120and panels114are inserted. Pillar and panel insertion is demonstrated with reference toFIG. 14; andFIGS. 2A, 3A, 4A, 4B, 4C and 15, for the case where a pillar is to be placed at the coupling of shell members117-1and117-2.

In step14-01ofFIG. 14, referring toFIG. 4B, columns451and453are inserted into pillar401. For column451, this comprises inserting column451into space435via either opening443or423, so that it protrudes from top surface403and bottom surface405. Similarly, for column453, this comprises inserting column453via either opening445or425into space437so that it protrudes from top surface403and bottom surface405.

In step14-02ofFIG. 14, the pillar fastening members and columns are inserted into lower floor support shell members117-1and117-2. This comprises inserting the pillar fastening members into the corresponding pillar connection members, and the columns into the corresponding column connection members, belonging to shell members117-1and117-2. Referring toFIG. 15, the inserting of the pillar fastening members comprises inserting dowel421of pillar401into the opening which is part of pillar connection member3C-17, so that dowel421occupies the space which is part of member3C-17. Similarly, dowel419is inserted into the pillar connection member formed by the aligned openings belonging to members3C-10and4E-03. The inserting of the columns comprises inserting columns451and453into column connection members3C-15and4E-04of shell members117-1and117-2respectively, to enable coupling to the corresponding outer support beams. As explained at the end of step14-01, the column451will be protruding from opening423. Then, this column451is inserted into column connection member3C-15of shell member117-1, so as to enable column451to contact outer support beam116-1for coupling. Similarly, column453is inserted to occupy the space belonging to column connection member4E-04and enable contact with outer support beam116-2for coupling.

Step14-03ofFIG. 14comprises securing the pillar to the lower floor support shell members. This comprises:Coupling the two columns451and453with outer support beams116-1and116-2using techniques known to those of skill in the art, such as screws; andAs shown inFIG. 15, a securing member such as base plate1503is used to secure the pillar401to the lower floor support shell members117-1and117-2; and couple lower floor support shell members117-1and117-2together.

In step14-04ofFIG. 14, panels are inserted into the base. An example is shown with reference to panel115-1ofFIG. 4C, pillar401as shown inFIG. 4A, and the lower floor support shell member117-1as shown inFIG. 3A. Side115-1-2of panel115-1ofFIG. 4Cis inserted into groove431via opening439on top surface403, and is slid through opening427on bottom surface405, such that side115-1-3is inserted into the panel insertion space3C-33on member117-1. Similarly, another panel is inserted into groove433via opening441on top surface403and is slid through opening429on bottom surface405into the panel insertion space corresponding to member117-2.

In step14-05ofFIG. 14, steps14-01to14-04are repeated for alternating coupling locations of lower support shell members. For example, with reference toFIG. 2A, steps14-01to14-04are repeated at:the coupling location of lower support shell members117-3and117-4; andthe coupling location of lower support shell members117-5and117-6.

In step14-06ofFIG. 14, pillars are inserted at the coupling locations which do not have pillars. For example, with reference toFIG. 2A, the coupling locations of lower support shell members which do not have pillars are:117-2and117-3,117-4and117-5, and117-6and117-1.

Step14-06ofFIG. 14entails repeating step14-01, then sliding the pillars such that the panels are inserted into the grooves of the pillars, then finally repeating steps14-02and14-03to couple the pillars to the lower support shell members.

In step1103, the lower roof support shell503, upper roof support shell505and roof110is assembled. Assembly of the lower roof support shell503, upper roof support shell505and roof110is demonstrated with reference toFIGS. 5A-5I and 16.

In step16-01, a lower roof shell outer beam is inserted into each lower roof support shell member. For example, with reference toFIGS. 5B, 5C and 5D, lower roof outer support beam505-1is inserted into lower roof support shell member504-1via opening504-1-18A to occupy space504-1-18. This is repeated for all lower roof support shell members504-1to504-6and each of the set of outer beams515.

In step16-02, each of the upper roof support shell members is coupled to a corresponding one of the lower roof support shell members. This is performed using the lower roof support shell connection members of each lower roof support shell member. For example, with reference toFIGS. 5C, 5D and 5F, upper roof support shell member524-1is coupled to lower roof support shell member504-1by:Coupling524-1-06to524-1-13to lower roof support shell connection points504-1-20to504-1-27; andInserting tabs524-1-02and524-1-03into lower roof support shell connection grooves504-1-9and504-1-10.

Similarly, upper roof support shell member524-2is coupled to lower roof support shell member504-2, upper roof support shell member524-3is coupled to lower roof support shell member504-3, and so on.

In step16-03, referring toFIG. 5B, some of the set of inner beams511are coupled to the outer beams related to the first portion of the upper roof support shell517-1. The first portion of the upper roof support shell517-1comprises upper roof support shell members524-1,524-2and524-6. Then, the corresponding lower roof shell support members are members504-1,504-2and504-6, which encase outer beams505-1,505-2and505-6. Then, these outer beams are related to first portion517-1. The inner beams are inserted into inner beam connection members such as member504-1-40, then coupled to the outer beams.

In step16-05, referring toFIG. 5E, the lower roof shell members which are coupled to the first portion of the upper roof support shell517-1are aligned. Then, lower roof shell support member504-1is aligned with member504-2, and member504-6is aligned with member504-1. Alignment is demonstrated with reference toFIG. 17for members504-1and504-2. Edge504-2-05of shell member504-2is aligned with edge504-1-05of shell member504-1-1. Since extrusion504-2-02is higher relative to extrusion504-1-06, it is positioned above extrusion504-1-06. Then the opening belonging to lower support connection member504-1-10is aligned with the corresponding opening belonging to connection member504-2-03.

In step16-06, referring toFIGS. 5A and 5E, roof panel507-1is inserted into the grooves of the upper roof shell support members524-1,524-2and524-6comprising the first portion517-1of the upper roof support shell505. As explained previously, this ensures that the roof panels are slanted.

In step16-07, referring toFIGS. 5B and 5E, roof panel507-2is inserted into the grooves of the upper roof shell support members524-3,524-4and524-5which are part of the second portion517-2of the upper roof support shell505.

In step16-08, similar to step16-03, the remaining uncoupled inner beams are coupled to the outer beams related to the second portion517-2. That is, the remaining uncoupled inner beams are coupled to outer beams505-3,505-4and505-5corresponding to lower roof support shell members504-3,504-4and504-5respectively.

In step16-09, referring toFIG. 5E, the lower roof shell members which are coupled to the second portion of the upper roof support shell517-2are aligned with each other in a similar fashion to that described in step16-05. Then, lower roof shell support member504-3is aligned with member504-4, and member504-4is aligned with member504-5. As part of this process, lower roof shell members at the boundary of the first portion517-1and second portion517-2are aligned with each other. For example, lower roof shell member524-6is aligned with lower roof shell member524-5, and lower roof shell member524-3is aligned with lower roof shell member524-2.

One of skill in the art would know that there are a variety of ways of carrying out the process demonstrated inFIG. 16. For example, in some embodiments, steps16-01,16-02and16-04are performed first.

In step1104, roof110is coupled to the set of pillars120. This entails coupling each individual pillar to two adjacent lower roof support shell members. An example process for coupling a pillar401to adjacent lower roof support shell members504-1and504-2is demonstrated inFIG. 18andFIGS. 4B, 4C, 5C and 19.

In step18-01ofFIG. 18, the pillar fastening members and the columns from the set of pillars which were coupled to the base101, are inserted into lower roof support shell members. With reference toFIGS. 4B and 19, this comprises the following:For pillar401, pillar fastening members in the form of dowels449and447are inserted into their corresponding openings in lower roof support shell members504-1and504-2. Dowel449is placed into the opening belonging to pillar connection member504-1-17, and occupies the space which is part of member504-1-17. Dowel447is inserted into the pillar connection member formed by the aligned pillar insertion receiving members504-1-10and504-2-03.Column451which is protruding from opening443is inserted into the space belonging to column connection member504-1-15, so as to contact outer support beam505-1. Similarly, column453protruding from opening445is inserted to occupy the space belonging to column connection member504-2-04and enable coupling to outer support beam505-2.

In step18-02, pillar401is secured to the lower floor support shell members. This comprises:Coupling the two columns451and453with outer support beam505-1and505-2using techniques known to those of skill in the art, such as screws.As shown inFIG. 19, a securing member such as roof plate1903is used to secure the pillar401to the lower roof support shell members504-1and504-2; and couple lower roof support shell members504-1and504-2together.

In step18-03, the horizontal edge of the panel at the top of the pillar is inserted into the appropriate space on a corresponding lower roof support shell member. For example, with reference toFIGS. 4C and 5C, horizontal edge115-1-1is inserted into panel insertion space504-1-41of lower roof support shell member504-1.

In step18-04, steps18-01to18-03are repeated for all the pillars.

In step1105, the subsystems are installed. This step comprises installation of the water distribution subsystem, lighting and towers and one or more of the other subsystems previously listed and described and shown inFIG. 7. The installation of the water distribution subsystem comprises the installation of the lower water return distribution subsystem810and upper water return distribution subsystem820ofFIGS. 8A, 8B and 8C. Once the water distribution subsystems are installed, the towers are screwed into the outlets such as outlet808shown inFIG. 8A. In embodiments where the tower is comprised of sections, such as tower1001ofFIG. 10B, the lowest section such as section10B-01is screwed into an outlet. Then the next section, for example section10B-02, is connected to this lowest section and so on, until the tower assembly is complete as explained previously. The vertical LEDs such as LED901ofFIG. 9are also installed. In the embodiments where LEDs are associated with towers, the LEDs are appropriately placed so as to result in the configuration shown in, for example,FIG. 10C.

In step1106, the airlock door600is installed on the side of the enclosure100which has the highest point of the roof panel107-1, as explained previously.

Coupling a Plurality of Enclosures Together

The benefit of the hexagonal shape of the enclosure is fully realized when more than one enclosure is coupled together.FIG. 20Ashows side and isometric views of a connection apparatus2000to couple two enclosures2002and2004together.

With reference to the side view of apparatus2000shown inFIG. 20A: Apparatus2000comprises three (3) sections: side sections2017and2015, and middle section2011. Side section2017comprises a plurality of vertical fastening members2013for attachment to lower roof and lower floor support shell members. Side section2017also comprises a plurality of horizontal fastening members2001for attachment to pillars. Furthermore, side section2017comprises attachment member2009for attachment to pillars, lower roof and lower floor support shell members. Side section2019comprises a plurality of vertical fastening members2003for attachment to lower roof and lower floor support shell members. Side section2019also comprises a plurality of horizontal fastening members2005for attachment to pillars. Furthermore, side section2015comprises attachment member2007for attachment to pillars, lower roof and lower floor support shell members. Middle section2011serves to separate side sections2017and2015to enable coupling of connection apparatus2000to enclosures, as will be described below.

With reference to the isometric view of apparatus2000and enclosures2002and2004shown inFIG. 20A: InFIG. 20A, pillars2105and2119, lower roof support shell member2123and lower floor support shell member2115belong to enclosure2002. Pillar2107and2117, lower floor support shell member2111and lower roof support shell member2103belong to enclosure2004. Opening2006extends through side sections2017and2019and middle section2011of apparatus2000.

A process to connect the two enclosures together is shown inFIG. 20B. In step20B-01, the attachment member2009is inserted into appropriate spaces for the enclosures:grooves belonging to the pillars such as groove2121of pillar2119, andpanel insertion spaces belonging to the lower roof support shell member2123and lower floor support shell members2115, such as panel insertion space2125of lower roof support shell member2123.
Similar operations are carried out for side section2015with regard to enclosure2004, and using attachment member2007.

In step20B-02, the horizontal fastening members and vertical fastening members are used to securely attach the side sections to the respective enclosures. For example, the plurality of vertical fastening members2013are used to securely attach side section2017to lower roof support shell member2123and lower floor support shell member2115of enclosure2002. The plurality of horizontal fastening members2001are used to securely attach side section2017to pillars2105and2119. Similar operations are carried out for side section2015using plurality of vertical fastening members2003and plurality of horizontal fastening members2005with regard to pillars2107and2117, lower floor support shell member2111and lower roof support shell member2103.

Once this is completed, users can move between enclosures2002and2004using opening2006.

In some embodiments, the plurality of enclosures comprises a cluster of enclosures. In some of these embodiments, the cluster comprises a central enclosure with one or more surrounding enclosures. Then the central enclosure is a control center, and the surrounding enclosures are grow units, that is, units where growth of hydroponic crops takes place.FIG. 21shows an example of a cluster2150comprising seven (7) enclosures arranged in a “flower” configuration. Cluster2150has central enclosure2151and surrounding enclosures2152-2157. In some of these embodiments, central enclosure2151is a control center, and surrounding enclosures2152-2157are grow units. Then, in some of these embodiments, at least some part of the subsystems necessary for the operation of surrounding enclosures are located at the central enclosure. With reference toFIG. 7, examples of this are:HVAC subsystem702,Water distribution system710,Lighting subsystem712,Communication subsystem714,Security subsystem718,Growth subsystem719,Interconnections720, andPower supply722.

Configurations other than the honeycomb configuration are also possible depending on the shape of the space which is to be occupied by the cluster. For example, enclosures can be connected in a V-shape or in a line.

In additional embodiments, central enclosure2151comprises a storage unit to store equipment.

In some embodiments, the enclosure or plurality of enclosures are monitored and operated using an enclosure monitoring application or “app” running on a user device. An example is shown in system2200ofFIG. 22. InFIG. 22, user device2201is associated with one or more users105. User device2201is coupled to enclosure100and processing and control subsystem2203via network2202. Networks2202can be implemented using a variety of networking and communications technologies. In some embodiments, networks2202are implemented using wired technologies such as Firewire, Universal Serial Bus (USB), Ethernet and optical networks. In some embodiments, networks1202are implemented using wireless technologies such as WiFi, BLUETOOTH®, NFC, 3G, 5G, satellite, radio frequency (RF) technologies, and LTE. In some embodiments, networks2202comprise at least one public network. In some embodiments, networks2202comprise at least one private network. In some embodiments, networks2202comprise one or more subnetworks.

User device2201is, for example a smartwatch, smartphone, tablet, laptop, or any appropriate computing and network-enabled device. An embodiment of user device2201is shown inFIG. 23. Processor2301-1performs processing functions and operations necessary for the operation of user device2301, using data and programs stored in storage2301-2. An example of such programs are enclosure monitoring application2301-4which will be discussed in more detail below, and browser2301-8. Display2301-3performs the function of displaying data and information for user101. Input devices2301-5allow user101to enter information. This includes, for example, devices such as a touch screen, mouse, keypad, keyboard, microphone, camera, video camera and so on. In one embodiment, display2301-3is a touchscreen which means it is also part of input devices2301-5. Communications module2301-6allows user device2201to communicate with devices and networks external to user device1201. This includes, for example, communications via BLUETOOTH®, Wi-Fi, Near Field Communications (NFC), Radio Frequency Identification (RFID), 3G, Long Term Evolution (LTE), Universal Serial Bus (USB) and other protocols known to those of skill in the art. The components of user device2201are coupled to each other as shown inFIG. 23.

Enclosure monitoring application2301-4allows user device2201to interact with processing and control subsystem2203and enclosure100over networks2202to perform various functions and operations.

In some embodiments, the enclosure monitoring application2301-4comprises sensor interface functionality to allow user device2201to interact either directly or indirectly with sensors716. In one embodiment this interaction is performed using, for example, processing and control subsystem2203. This functionality allows, for example, a user to monitor the previously described growth conditions or parameters using user device2201remotely. As explained previously, examples of growth parameters which are tracked and recorded include:pH,electrical conductivity,enclosure interior temperature,humidity,water levels and flow rates,nutrient levels and rates of change,lighting levels,CO2levels,door open/closed,power consumption,solar conditions, wind conditions,water temperature,battery level, andgenerator fuel level.

In addition to the sensor interface functionality, the enclosure monitoring application2301-4enables the user to monitor and operate subsystems. Examples of subsystems which can be monitored and operated include:HVAC subsystem702: The enclosure monitoring application enables monitoring and operation of the devices and systems which are part of HVAC subsystem702. For example, using the app, heaters and AC units can be controlled to set the temperature accordingly. Vents can be opened or closed to change, for example, the CO2levels.Water distribution subsystem710: The app allows monitoring and operation of the devices and systems which form part of water distribution subsystem710. For example, water pumps can be turned on and offLighting subsystem712: The app allows monitoring and operation of the devices and systems which form part of lighting subsystem612. For example, using the app, lights can be turned on and off or brightened and dimmed in different areas.Security subsystem718: The app allows for monitoring and operation of the devices and systems which are part of security subsystem718. For example, users can use security cameras to view the interior and exterior of the enclosure.Growth subsystem719: The app allows for monitoring and operations of the devices and systems which are part of growth subsystem719. For example, users can control the rate at which a conveyor belt operates.Power supply722: The app allows for monitoring and operation of the devices and systems which are part of power supply722.

In addition, the enclosure monitoring application2301-4comprises a user interface to perform the sensor interface and subsystem operation and monitoring functionalities. In one embodiment, the user interface is displayed on display2301-3of user device2201. Then, a user can enter commands for the user interface via input devices2301-5of user device2201, such as via a mobile device touchscreen, or a mouse, or a keyboard, or a microphone.

Browser2301-8is used to interface with the World Wide Web. As will be discussed below, in some embodiments, browser2301-8communicates with a website interface to processing and control subsystem2203.

In other embodiments, users are able to share data with each other. Each user is able to input what each tower in is growing and through the sharing portion, other users will be able to see what other habitats are growing and for what cost.

Processing and control subsystem2203performs several different functions such ascollecting data from sensors716,receiving commands from user device2201and supplying data collected from sensors716in response to commands received, andprocessing data collected from sensors716.

Processing and control subsystem2203is described in more detail inFIG. 24. InFIG. 24, communications subsystem2401is coupled to networks2202. Communication subsystem2401receives information from, and transmits information to networks2202.

Database2402stores information and data for use by processing and control subsystem2203. This includes, for example:data collected from sensors716,one or more algorithms and programs necessary to perform processing of received data, andother data as needed, such as intermediate and final results from carrying out processing operations.

In some embodiments, database2402further comprises a database server. The database server receives one or more commands from, for example, hydroponic processing subsystem2403-1to2403-N and communications subsystem2401and translates these commands into appropriate database language commands to retrieve and store data into database1302. In some embodiments, database2402is implemented using one or more database languages known to those of skill in the art, including, for example, Structured Query Language (SQL). In a further embodiment, database2402stores data for a plurality of users. Then, there may be a need to keep the set of data related to each user separate from the data relating to the other users. In some embodiments, database2402is partitioned so that data related to each user is separate from the other users. In some embodiments, each user has an account with a login and a password or other appropriate security measures to ensure that they are only able to access their data, and unauthorized access of their data is prohibited. In further embodiments, when data is entered into database2402, associated metadata is added so as to make it more easily searchable. In a further embodiment, the associated metadata comprises one or more tags. In yet another embodiment, database2402presents an interface to enable the entering of search queries. In some embodiments, the data stored within database2402is encrypted for security reasons. In further embodiments, other privacy-enhancing data security techniques are employed to protect database2402.

Hydroponic processing subsystems2403-1to2403-N perform processing, analysis and control within processing and control subsystem2203using one or more algorithms and programs residing on database2402. These algorithms and programs are stored in, for example,database2402as explained above, orwithin hydroponic processing subsystems2403-1to2403-N.

Examples of processing performed by hydroponic processing subsystems2403-1to2403-N include:Implementations of algorithms used in processing of the data received from sensors716,Performing analytics based on crops grown within enclosure100to provide one or more users with feedback, andProviding data to one or more users105to enable one or more users to visualize results on, for example, user device2201.

In some embodiments, hydroponic processing subsystems2403-1to2403-N implement artificial intelligence (AI), machine learning (ML) and deep learning algorithms to facilitate optimization of growth parameters, energy consumption, water consumption, and improve overall growth of hydroponic crops. This data allows for users such as farmers to learn how to better utilize the enclosure or plurality of enclosures to improve on current practices. In further embodiments, hydroponic processing subsystems2403-1to2403-N implement big data processing techniques and statistical processing techniques.

Interconnection2404connects the various components of processing and control subsystem2203to each other. In one embodiment, interconnection2404is implemented using, for example, network technologies known to those in the art. These include, for example, wireless networks, wired networks, Ethernet networks, local area networks, metropolitan area networks and optical networks. In one embodiment, interconnection2404comprises one or more subnetworks. In another embodiment, interconnection2404comprises other technologies to connect multiple components to each other including, for example, buses, coaxial cables, USB connections and so on.

Various implementations are possible for processing and control subsystem2203and its components. In some embodiments, processing and control subsystem2203is implemented using a cloud-based approach. In other embodiments, processing and control subsystem2203is implemented across one or more facilities, where each of the components are located in different facilities and interconnection2404is then a network-based connection. In further embodiments, processing and control subsystem2203is implemented using one or more servers or computers. In other embodiments, processing and control subsystem2203is implemented in software. In other embodiments, processing and control subsystem2203is implemented using a combination of software and hardware. In further embodiments, processing and control subsystem2203is implemented via a third party hosting operation. In some of the embodiments described above where the plurality of enclosures comprises a cluster of enclosures with a central enclosure being a control center and surrounding enclosures being grow units, at least some part of processing and control subsystem2203is implemented within the central enclosure.

In other embodiments, a website is used to interact with the enclosure100and processing and control subsystem2203. One or more users105can interact with website using, for example, browser program2301-8running on user device2201.

In additional embodiments, a digital marketplace to allow users to sell produce that they produce via each enclosure or each plurality of enclosures is created. Such a marketplace would provide a sustainable solution that also allows for community bonding and social enterprise/digital farmer's market. The digital marketplace allows users to buy, sell and trade their harvest via the enclosure monitoring application2301-4or by using the website in conjunction with browser program2301-8. In some embodiments, growers are able to post their production details, and time of harvest online. Then buyers will be able to view this information and place orders for the amount they want to purchase. At harvest time the app will notify the buyer that their purchase is either ready for pick up, or delivery via existing methods. Buyers also comprise, for example, local grocery stores.

While the above describes the use of the enclosure for hydroponics, one of skill in the art would know that there are other possible uses for such an enclosure. For example, it could be used for temporary housing, quarantining, storage and other purposes as necessary.

It would also be understood by one of skill in the art that, the modular nature of the enclosure detailed above means that it can be provided or sold as a kit for assembly by either one or more users105or a third party such as a contractor. The connection apparatus detailed above and inFIG. 20Acan also be provided or sold for use by either one or more users105or a third party such as a contractor.

Although the processes described above including those with reference to the foregoing flow charts have been described separately, one of skill in the art would understand that any two or more of the processes disclosed herein can be combined in any combination.

Any of the methods, algorithms, implementations, or procedures described herein can include machine-readable instructions for execution by: (a) a processor, (b) a controller, and/or (c) any other suitable processing device.