Abstract:
The present invention relates to a system for growing plants hydroponically on a vertical wall. The system can be used to grow many different species of plants concurrently. The system comprises a specially designed wall together with an integrated and customizable automatic irrigation system for providing nutrients and water, with metered absorption of the nutrients and water by the plants and regulation of excess nutrients and water. The wall may be equipped with an automatic release system which releases the nutrients into the wail&#39;s absorbent covering.

Description:
[0001]    This application claims priority to U.S. provisional application 60/876,213, filed on Dec. 21, 2006. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates generally to hydroponic horticultural systems and, more particularly, to a means for successfully growing plants hydroponically on a vertical wall with limited associated human intervention. 
       BACKGROUND OF THE INVENTION 
       [0003]    Plants have been grown hydroponically for decades. In a hydroponic system, generally, plants are grown using mineral nutrients n an aqueous environment and without the aid of a purely soil base. In such a system, the root system of the plants must remain in a sufficiently aqueous environment in order to survive. In contrast, in traditional geoponic horticulture, the nutrients and water are distributed in soil and the plant uses its root system to extract nutrients and water from the soil. 
         [0004]    Hydroponic horticulture can be appreciably more labor intensive than traditional geoponics in that the plant does not have a base in which nutrients are naturally stored and from which those nutrients may be extracted. For a plant to survive, space must therefore be apportioned for the plant to grow a root system. In addition, nutrients, including water, must be added and maintained at appropriate levels, which generally requires significant human intervention. Further, issues of water and nutrient loss through plant absorbsion, evaporation, and run-off must be addressed. 
         [0005]    Hydroponic horticulture often is carried out indoors. It is therefore advantageous to achieve horizontal space savings by affording a platform for concurrently growing multiple plants along a vertical structure. In addition, because of the indoor use, the hydroponic structure must be compatible with plant growth as well as be aesthetically pleasing. 
         [0006]    In general, prior art hydroponic systems entail plantings elevated above a pond or river-like body of water with root systems extending into the water. The problems with these systems are multi-facetted, but each results in significant human effort and intervention. For example, algae growth can be an issue and can require cleaning of the water. In addition, many plants cannot survive if fully under water, so a supporting structure for the live matter must be constructed and the live matter must be attached to the supporting structure so as to permit growth. As the plants grow, the plants need to have their positions adjusted relative to the supporting structure so that they can continue to grow freely. These types of issues generally are dealt with through various labor intensive ways or mechanisms. 
         [0007]    Accordingly, it would be desirable to provide a hydroponic system which overcomes these disadvantages. 
       SUMMARY OF THE INVENTION 
       [0008]    Generally speaking, in accordance with the present invention, a hydroponic growing system is provided. The present invention overcomes the aforementioned disadvantages and issues related to a system for growing plants hydroponically on a vertical wall. The system can be used to grow many different species of plants concurrently. The system comprises a specially designed wall comprising a plurality of absorbent layers. In addition, the system comprises an integrated and customizable automatic irrigation system for providing nutrients and/or water, with metered absorption of the nutrients and/or water by the plants and regulation of excess nutrients and water. The wall may be equipped with an automatic release system for releasing the nutrients and/or water into the wall&#39;s absorbent layers. In general, the wall, through its absorbent layers, retains the nutrients and/or water until accepted by the plants. The technology is suitable for use in creating small and large vertical gardens. 
         [0009]    The irrigation system of the present invention includes metering and piping. The water pressure from the water flow causes the water to mix with nutrients and mixes nutrients into the water flow. The present invention comprises irrigation lines along the top of the wail. The irrigation lines selectively deliver water and nutrients to the wail for delivery to the plants. The irrigation system of the invention is advantageous in that it works on any size plant wall support. The wall may optionally be configured into zones, with different zones for specific live matter requiring different quantities or flow rates of water or nutrients. 
         [0010]    Multiple manifolds are needed in order to configure the wall for multiple zones. When the wall is configured with multiple zones, each zone is presumed to require different amounts of water or nutrients and the irrigation system releases different amounts to the different zones. Each flow rate may be at a pre-set level, such as constant pre-set flow or pre-set flow based on time-of-day or day-of-week, or may instead be automatically adjusted based on the specific needs of the system. 
         [0011]    The irrigation of the specified watering zones may be controlled by measuring humidity at or near the wall and controlling irrigation by retaining a selected range of humidity. Optionally, a humidity control unit may be included, piloted by a control process unit for control of watering. The humidity control unit sends feedback to the irrigation system in order to control the level of watering on a zone by zone basis. 
         [0012]    Artificial lighting may also be added to further reduce human intervention. These lights will permit installation of a vertical garden indoors in low light areas. 
         [0013]    It is an object of the present invention to provide a hydroponic growing system and apparatus. 
         [0014]    It is yet another object of the present invention to clean and improve the air quality of a room by using special species of plants. 
         [0015]    The invention accordingly comprises the several steps and the relation of one or more such steps with respect to each of the others, the device embodying the features of construction, combination of elements and arrangement of parts which are adapted to affect such steps, and the article which possess these characteristics, properties and relation of elements, all as exemplified in the detailed disclosure hereinafter set forth, and the scope of the invention will be indicated in the claims. 
     
    
     
       DESCRIPTION OF THE FIGURES 
         [0016]    For a fuller understanding of the invention, reference is made to the following description taken in connection with the accompanying drawings, in which: 
           [0017]      FIG. 1  is a schematic view showing a view of the complete inventive system; 
           [0018]      FIG. 2  is a perspective view showing the plant installation in a plurality of absorbent layers; 
           [0019]      FIG. 3  is a perspective view showing the structural components of the wall; 
           [0020]      FIG. 4  is a side elevational view showing the structural components of the wall; 
           [0021]      FIG. 5  is a schematic view showing the recycling system in the context of the overall system; 
           [0022]      FIG. 6  is a perspective view showing the structure of the irrigation pipe; 
           [0023]      FIG. 7  is a schematic view showing the manifold and the irrigation line; 
           [0024]      FIG. 8  is a schematic view showing the irrigation system; and 
           [0025]      FIG. 9  is a schematic view of a multi-zone irrigation system with artificial lighting. 
       
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
       [0026]    Referring first to  FIG. 1 , a preferred embodiment of the present invention, the invention is comprised of a wall  101  and an irrigation system  201 , as shown. Irrigation system  201  is used to supply water and nutrients to live matter growing along wall  101 . Referring to  FIG. 3 , a complete wall with live matter therealong and generally indicated at  101  is shown. In a preferred embodiment, wall  101  of the inventive system is a multi-layer formation. As can be seen in  FIG. 3 , wall  101  includes a first layer comprising a structural mesh frame  102  made from a plurality of rods defined by aluminum squares, such as Aluminum 6063T5 or equivalent, with preferred dimensional cross-sections of two inches by two inches. Rods  1  are preferably hollow aluminum with a thickness in the range of 1.6 mm to 2 mm. Rods  1 , as shown in  FIG. 3 , are generally welded together to form, for example, a mesh frame  102  comprised of two foot by two foot sections. As can be appreciated, multiple such mesh frame sections may be assembled together so as to form larger walls. As also can be appreciated, the sections of mesh frame  102  may vary in size generally from two-foot-by-two-foot to four-foot-by-four-foot. Other materials may also be used, such as galvanized steel studs or even a wood-framed wall with a waterproof membrane disposed there over. 
         [0027]    Wall  101  is provided with a custom made gutter  7  that is equipped with a depending drain pipe  9 , is shown in  FIG. 3  and in  FIG. 4 , while the gutter is attached to structural mesh frame  102  by means of brackets  8 . In a preferred embodiment, brackets  8  are welded to gutter  7  and attached to mesh frame  102  by means of screws  103  which are threaded into pre-drilled screw holes  104 . 
         [0028]    Continuing with  FIG. 3 , wall  101  also includes solid wall element  2  comprised of expanded polyvinyl chloride (PVC) and installed along structural mesh frame  102  and over brackets  8  in order to form a generally vertical surface. Wall element  2  is connected to mesh frame  102  by means of non-rusting screws  103 . Expanded PVC is preferred for element  2  due to its characteristics of smoothness, structural integrity, lack of porousness, and longevity. Element  2  has a typical wall thickness preferably of 10 mm and generally not to exceed 15 mm, and a density preferably of 0.55 g/cm 3  and generally not to exceed 0.70 g/cm 3 . Staples  6  are used to attach additional elements, such as additional absorbent layers  3  and any added covering  4 , to wall element  2 . 
         [0029]    In accordance with the invention, alternative materials and dimensions may be used. These include standard galvanized studs and marine plywood with a waterproof membrane. Depending upon the size of wall element  2 , multiple wall elements may be used and aligned along side one another. Specifically shown in  FIG. 3 , wall elements  2  and  2 A are abuttingly disposed one next to the other. Significantly, the bottom of wall element  2  must extend sufficiently far into gutter  7  in order to avoid backsplash. Further, and in accordance with the inventive system, excess water is collected by gutter  7  and is transported to drain pipe  9  which carries the waste water to a waste line  331  or to an optional recycling system, the latter being shown in  FIG. 5 . 
         [0030]    In a preferred embodiment of the wall of the inventive system and as can be seen in  FIG. 3 , one side of the surface of wall  101  is covered with a plurality of layers  3  of an absorbent material, such as Aquanape Feutre horticole, such as which often is used as carpet padding recycled felt, with a density of 350 g/m 2  within a typical density range of from 250 g/m 2  to 400 g/m 2 . Equivalent materials for providing for absorbency, retention, and the release of liquids may also be used, such as felt. At the upper most portion of wall  101 , two layers  3 A and  3 B made from an absorbent material are sufficiently separated from one another in order to encircle an irrigation line  38 , as best shown in  FIG. 6 . Irrigation line  38  is connected to wall  101  by a pipe clamp  42 , such as a Twin Talon pipe clamp with screw bulk buckets, as can be seen in  FIG. 7 . In addition, in order to improve the finish appearance or shading, a fishnet covering  4 , such as 50% Shade and Windbreak netting which is often used for greenhouse shading, may be attached or otherwise applied over absorbent layer  3 B (see  FIG. 3 ). 
         [0031]    In a preferred embodiment, wall  101  is generally flat. As can be seen in  FIG. 2 , an outer layer  3 B of the plurality of absorbent layers  3  and any additional fishnet covering  4  is sliced, as can be seen in slice  45 . A plant  49  is placed between absorbent layer  3 B and absorbent layer  3 A. Staples  6  are then stapled along the lower circumference of the plant area forming seam  48  so as to provide additional structural integrity to the absorbent layer surrounding plant  49 . These staples, together with the surface tension of absorbent layer  3 B keep plant  49  in place. 
         [0032]    The present invention includes an associated irrigation system (see  FIGS. 1 ,  7  and  8 ), including at least one associated irrigation line  38  (as depicted in  FIG. 7 ). A fresh water supply  10  is used to fill a tank  11 . An anti-flooding solenoid valve  13 , such as WCKRS Watercop Corporal Kit, or equivalent, is used to avoid overflow. Tank  11  is equipped with a floating check valve  14  to stop the water input when the level is too high inside tank  11 . A manual CPVC ball valve  15  is used to drain the fresh water from the tank to permit a cleaning of tank  11  during maintenance operation. Drain pipe  16  is used to continue water flow exiting ball valve  15 . 
         [0033]    Valve  17  is used to isolate the booster pump for maintenance operation and to keep the fresh water in tank  11 . As can be seen in  FIG. 8 , a booster pump  19 , such as Davey Pump Pressure Booster  18  GPM 3/4 HP 115 Volt# HS18-30HT1, may be required for pumping water or a water/nutrient mix from water line  18  to a valve  21 . Booster pump  19  should preferably be installed on a non-rusting and preferably galvanized steel custom made pan  20  to prevent any flood or any leak on the floor. The size of pump  19  is calculated based on maintaining the requisite flow of fluid in irrigation line  38  at the top of wall  101 , which in turn is based on the water needs of the live plant matter disposed there along. Ideally, absorbent material  3  is fully saturated with no run off to gutter  7   
         [0034]    As can be seen in  FIG. 8 , the irrigation system also includes a nutritive tank  25 , which stores a nutritive solution  52 . Nutritive solution  52  may vary based on the vegetation being grown, but may, for example, be made with a dry concentrate nutrient diluted in fresh water, such as MAXIGRO™ Dry Concentrated Nutrient. Alternatively, a liquid nutrient can be used, such as FLORANOVA™ SERIES Liquid Super Concentrated Nutrient. An additional pump  24 , preferably a Dosatron-manufactured DI210 or an alternative with similar metering and dosing capabilities, is included in the system for extracting nutritive solution  52  from inside nutritive tank  25  for subsequent mixing with the water originating from tank  11 . Valves  22 ,  26 , and  29  are used to isolate mesh filter  23  and pump  24  for maintenance operation. If pump  24  fails, the wall may be irrigated manually with only fresh water. 
         [0035]    Accordingly, after passing through mesh filter  23 , water from booster pump  19  flows into and through pump  24 . Pump  24  sucks out a metered quantity of the nutritive solution (approximately 0.1 grams of nutrient per liter of solution but not more than 0.3 grams per liter of nutrients) from nutritive tank  25 , mixes water from filter  23  with nutritive solution  52 , and directs this mixture to manual ball valve  26 . Manual ball valve  26  may be used to stop flow so as to allow for system maintenance. Nutritive tank  25  is also equipped with a manual ball valve  27  and drain  28  to permit maintenance, such as cleaning of tank  25 . The water and the nutritive solution mix is then directed to an irrigation line  30  for eventual delivery to irrigation line  38  (see  FIG. 7 ). 
         [0036]    Continuing with the operation of the inventive system, the water and nutritive solution mix enters a manifold  70  as shown in  FIG. 7 . The purpose of the manifold is to open and close automatically the irrigation flow. The manifold  70  is equipped with an isolation CPVC manual ball valve  31 , two (2) isolation CPVC manual ball valves,  32  and  33 , and a Solenoid valve  34 , such as 100-PEB: one inch (26/34) industrial-strength glass-filled nylon globe valve for commercial applications from Rain Bird corporation, or the equivalent. Solenoid valve  34 , is connected to a Timer/Controller,  35 , such as ESP-LX+ and ESP-LXi+ Series from Rain Bird Corporation or the equivalent. Manifold  70  attaches and delivers water to irrigation line  37 . Irrigation line  37  is preferably made of 0.75 inch diameter, but may be of up to 2 inches in diameter. Irrigation line  37  may not have a diameter larger than that of line  38 . Irrigation line  37  is preferably of PVC, but may be comprised of a material of similar structural integrity, lack of porousness, and longevity, such as another plastic. Irrigation line  37  permits the flow of the mixture to irrigation line  38 . The water and nutritive mix thereby continue to flow through irrigation line  38 , which is installed at the top of wall  101 , as shown in  FIGS. 6 and 9 . Irrigation lines  37  and  38  are joined together by union coupling  39 . The total number of irrigation fines disposed at the top of wall  101  is determined by the total linear length of the wall based upon the maximum length of one irrigation line. Multiple irrigation lines are connected serially by removable plumbing clamp  42 , which attach irrigation line  38  to the wall. At the distal end of the serial irrigation line or lines a union cap  41  is provided in order to preclude water runoff. 
         [0037]    One feature of the inventive system is the unique arrangement of the irrigation lines at the top of wall  101 . In particular, irrigation line  38  is installed at the top of wall  101  between two of the plurality of absorbent layers, as previously described. As can be seen in  FIG. 7 , irrigation line  38  has numerous holes  40 . Holes  40  of irrigation line  38  should be oriented at approximately 45 degrees with respect to the surface of wall  101  so that the water solution will drip uniformly against the wall and within the absorbent layers. The line may be oriented at up to 80 degrees. However, the line should remain in line with the horizontal dimension of the wall. 
         [0038]    Irrigation line  38  is preferably made from PVC tubing of 0.75 inch diameter, although other plastic, non-corrosive materials with similar properties to that of PVC pipe may be used. The irrigation system (see  FIG. 7  and  FIG. 8 ) includes piping  37 , valves isolation valve  31 , ball valves  32  and  33 , Solenoid valve  34 , by-pass valve  36 , a timer/controller  35 , metering pump  24 , and optional booster pump  19 . The function of valve  31  is to isolate the entire manifold  70  for maintenance operation. The function of valves  32  and  33  is to isolate solenoid valve  34  for maintenance operation. Valve  34  is a solenoid valve controlled by timer/controller  35  to start and stop the irrigation cycle. 
         [0039]    In accordance with the invention, a zoning plan of irrigation lines is created in order to cover all linear sizes of a hydroponic wall, as can best be seen in  FIG. 6  by inclusion of irrigation line  38  with orientation of its holes  40 .  FIG. 6  shows the placement of the irrigation line. The irrigation system may connect to a recycling system  300 , as shown in  FIG. 5 . 
         [0040]    Once the inventive system is set up, as shown in  FIG. 1 , living plant matter may be placed along two of the absorbent layers  3  by displacing them inside the protrusion/cavity formations, as shown in  FIG. 2 . 
         [0041]    In accordance with the present invention, live plant matter may be able to grow on both sides of wall  101  concurrently. To create such a double-faced hydroponic surface, the construction details set forth above are repeated along the opposite side of mesh frame  102 . In other words, the other side of wall  101  includes a solid wall element  2  made of expanded PVC, and a plurality of absorbent layers  3  for surrounding irrigation line  38  near the top of wall  101  as well as a plants inserted between two of said absorbent layers through a slice in an outer absorbent layer secured by staples. As can be appreciated, if wall  101  is arranged for live plant matter growth on both sides, two irrigation lines or two sets of irrigation lines may be needed. 
         [0042]    The multi-zone process works with timer controller  35 . Timer controller  35  is able to control up to 24 zones or irrigation line. A special cycle may be pre-set for each zone, within the programmability of timer controller  35 . Each zone will separately irrigate the wall. 
         [0043]    In one embodiment of the present invention, water flow may be adjusted based upon wall humidity. Referring to  FIG. 1 , humidity probe  199  is attached to wall  101 . Humidity probe  199  provides humidity readings to timer/controller  35 . Timer/controller  35  is programmed to turn on or off based upon humidity measurements. 
         [0044]    In another embodiment of the present invention, artificial lighting may supplement or replace natural lighting necessary for plant growth. Referring to  FIG. 9 , track light  198  is installed approximately one foot above the tip of the wall and forward of the growing surface preferably by three feet, but generally from one to three feet forward. 
         [0045]    In another embodiment, the inventive irrigation system delivers waste water to a recycling system, as can be seen in  FIG. 5 . Solenoid valve  348  directs the flow from drain pipe  331 . The recycling system is controlled by a control unit  347 . When the recycling system is activated, the three-way solenoid valve  348  is used to open the waste line  349  instead of the recycling system line. When the recycling system is activated, a fresh water supply  10 , is replaced by water from piping  302 . Water in piping  302  is produced by recycling the water/nutrient mix. Waste water from gutter  7  and drain pipe  9  collects in drain line  331 . Level probe  339  controls pump  338  inside gutter tank  340 . The tank is filled by waste water from drain line  331 . Pump  338  fills recycling tank  344 . Tank  344  is equipped with a manual ball drain valve  343  for maintenance operation and receives the waste water coming from valve  348 . Top level probe  342  is used for triggering the system. When the water level reaches the top level probe, control unit  347  activates valve  345 . This valve allow for the substitution of fresh water supply with recycled water from recycling tank  344  and also causes the shut down of pump  24  for nutritive solution  52 . Water from tank  344  is fed through piping  302  to three-way solenoid valve  346  in order to supply water directly to the irrigation manifold  70 . 
         [0046]      FIG. 9  includes a schematic diagram of the present invention with multiple zones. As can be appreciated from  FIG. 9 , each manifold has a valve  34  which is controlled by timer/controller  35 . For zone  1 , when humidity sensor  199  recognizes that zone  1  has sufficient humidity or water content, timer/controller  35  turns valve  34  off. Similarly for zone  2 , when humidity sensor  199 A recognizes that zone  2  has sufficient humidity or water content, timer/controller  35  turns valve  34 A off. When the humidity is too low in a zone, timer/controller  35  turns the appropriate valve or valves back on. Timer/controller  35  may be programmed for different humidity levels for different zones. 
         [0047]    It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained and, since certain changes may be made in carrying out the above process, in the described product, and in the construction set forth without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrated and not in a limiting sense. 
         [0048]    It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.