Abstract:
A vertical hydroponic plant production apparatus for allowing vertical hydroponic greenhouse crop production is provided. The apparatus comprises a hollow grow tube having a front face, a back face, an open first end, and an open second end. A slot is formed in the front face of the grow tube with the slot having a width equal to only a portion of a width of the front face. A media material is insertable into the grow tube. The slot allows the front face to expand outward during insertion of the media material and biased inward against the media material once the media material is inserted. The grow tube is positionable in either a horizontal position, vertical position, or any position between the horizontal position and the vertical position allowing inclined, multi-angled crop production and multi-storied conveyor style crop production.

Description:
The present application is a continuation-in-part of U.S. Pat. No. 8,327,582, issued on Dec. 11, 2012, entitled Vertical Hydroponic Plant Production Apparatus, which claims benefit of priority of provisional patent application Ser. No.: 61/273,317, filed on Aug. 3, 2009. entitled “Vertical Hydroponic Plant Production Apparatus”. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates generally to a vertical hydroponic plant production apparatus and, more particularly, the invention relates to a vertical hydroponic plant production apparatus allowing for vertical hydroponic greenhouse crop production in a fraction of the space necessary for traditional plant production techniques and allowing utilization of vertical surfaces for plant production. 
     2. Description of the Prior Art 
     Traditional hydroponics has focused primarily on horizontal production techniques and has been subject to major space constraints. Vertical hydroponic applications have either been impractical, expensive to operate, or inefficient. Often these applications utilize some type of growth medium that is heavy when saturated, causing clogging when filled with plant roots, and/or requiring a great deal of maintenance. In addition, conventional technology makes it difficult to allow in-store display of live, growing vegetables and is not conducive to “you-pick” vegetable and herb sales to customers. Little technology exists that allows vertical plant displays that are highly scalable. 
     SUMMARY 
     The present invention is a vertical hydroponic plant production apparatus for allowing vertical hydroponic greenhouse crop production. The apparatus comprises a hollow grow tube having a front face, a back face, an open first end, and an open second end. A slot is formed in the front face of the grow tube with the slot having a width equal to only a portion of a width of the front face. A media material is insertable into the grow tube. The slot allows the front face to expand outward during insertion of the media material and biased inward against the media material once the media material is inserted. The grow tube is positionable in either a horizontal position, vertical position, or any position between the horizontal position and the vertical position allowing inclined, multi-angled crop production and multi-storied conveyor style crop production. 
     In addition, the present invention includes a method for allowing vertical hydroponic greenhouse crop production. The method comprises providing a hollow grow tube having a front face, a back face, a first end, and a second end, forming a slot in the front face of the grow tube with the slot having a width equal to only a portion of a width of the front face, inserting a media material into the grow tube, expanding the front face outward during insertion, biasing the front face inward against the media material, and positioning the grow tube in either a horizontal position, vertical position, or any position between the horizontal position and the vertical position allowing inclined, multi-angled crop production and multi-storied conveyor style crop production. 
     The present invention further includes a vertical hydroponic plant production apparatus for allowing vertical hydroponic greenhouse crop production. The apparatus comprises a hollow grow tube having a front face, a back face, a first end, and a second end. A slot is formed in the front face of the grow tube with the slot having a width equal to only a portion of a width of the front face. A media material is insertable into the grow tube with the media material being composed of two halves of material split down the middle with a bolt spanning the width of the two halves for joining the two halves. A pulling hook is provided having a flat portion for grasping the bolt for inserting and removing the media material from the grow tube. An “H” bracket having a receiving portion and an anchoring portion, the “H” bracket is mounted to the rear face of the grow tube. A “Z” bracket having a vertical, upward facing tongue portion receivable within the receiving portion of the “H” bracket is provided with the “Z” bracket mounted in a predetermined location. An aperture is formed in the “Z” bracket for receiving a fastening mechanism. The grow tube is positionable in either a horizontal position, vertical position, or any position between the horizontal position and the vertical position allowing inclined, multi-angled crop production and multi-storied conveyor style crop production. The slot allows the front face to expand outward during insertion of the media material and biased inward against the media material once the media material is inserted. As weight is applied to the tongue portion of the “Z” bracket through the placement of a grow tube, downward torque is applied across the “Z” bracket causing a clutch action to affix the “Z” bracket tightly to the predetermined location. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front perspective view illustrating a grow tube of a vertical hydroponic plant production apparatus, constructed in accordance with the present invention; 
         FIG. 2  is a rear perspective view illustrating the grow tube of the vertical hydroponic plant production apparatus of  FIG. 1 , constructed in accordance with the present invention; 
         FIG. 3  is a front perspective view illustrating another embodiment of the grow tube of the vertical hydroponic plant production apparatus, constructed in accordance with the present invention; 
         FIG. 4  is a rear perspective view illustrating the grow tube of the vertical hydroponic plant production apparatus of  FIG. 3 , constructed in accordance with the present invention; 
         FIG. 5  is a front perspective view illustrating a media column of the vertical hydroponic plant production apparatus, constructed in accordance with the present invention; 
         FIG. 6  is a rear perspective view illustrating the media column of the vertical hydroponic plant production apparatus of  FIG. 5 , constructed in accordance with the present invention; 
         FIG. 7  is a perspective view illustrating a Z bracket of the vertical hydroponic plant production apparatus, constructed in accordance with the present invention; 
         FIG. 8  is a perspective view illustrating a pulling hook of the vertical hydroponic plant production apparatus, constructed in accordance with the present invention; 
         FIG. 9  is a perspective view illustrating the vertical hydroponic plant production apparatus, constructed in accordance with the present invention, with the slot formed to a point below the first end of the grow tube; 
         FIGS. 10-12  is a perspective view illustrating the vertical hydroponic plant production apparatus, constructed in accordance with the present invention, with the media material being composed of two halves of material split down the middle with a bolt spanning the width of the two halves; 
         FIG. 13  is a perspective view illustrating the vertical hydroponic plant production apparatus, constructed in accordance with the present invention, with the media material having a thickness substantially half an internal width/diameter of the grow tube such that the media material is folded in the middle so that the thickness both halves together roughly equal the inside dimensions of the grow tube; 
         FIG. 14  is a perspective view illustrating the vertical hydroponic plant production apparatus, constructed in accordance with the present invention, with a cap and tubing extending through the cap; 
         FIG. 15  is a perspective view illustrating the vertical hydroponic plant production apparatus, constructed in accordance with the present invention, with a nutrient solution reservoir; and 
         FIG. 16  is a perspective view illustrating the vertical hydroponic plant production apparatus, constructed in accordance with the present invention, with a pump. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     As illustrated in  FIGS. 1-16 , the present invention is a vertical hydroponic plant production apparatus, indicated generally at  10 , allowing vertical hydroponic greenhouse crop production in a fraction of the space necessary for traditional plant production techniques and allows utilization of vertical surfaces for plant production. 
     The vertical hydroponic plant production apparatus  10  of the present invention includes a grow tube  12  useable in a horizontal position, vertical position, or any position between the horizontal position and the vertical position. The grow tube  12  is highly portable, being light, making it easy to move the grow tube  12  from area to area for transplant, grow out, and harvest. The grow tube  12  further allows inclined, multi-angled crop production and multi-storied conveyor style crop production. The grow tube  12  of the vertical hydroponic plant production apparatus  10  of the present invention also functions as aquacultural biofiltration/nutrient stripping devices for plant-based, high-efficiency waste nutrient removal and as sites nitrification processes, having massive surface area/volume thereby reducing the costs of single pass aquaculture and improving the efficiency of recirculating aquaculture. 
     The grow tube or tower  12  of the vertical hydroponic plant production apparatus  10  of the present invention also functions as in-store or at market display devices allowing the display of fresh, live produce for you-pick vegetable sales at market places and allowing the sale of produce that is more fresh than traditionally harvested vegetable products. Designed for easy affixation to the walls and/or roofs of buildings, the grow tube  12  reduces heating and cooling costs through shading and plant evapotranspiration and performs a decorative function. The grow tube  12  applied in such a manner can also reduce rooftop and hard surface water runoff depending on application and plumbing system. 
     Basically, the vertical hydroponic plant production apparatus  10  of the present invention allows for decorative landscape designs as well as vertical plant production displays indoors for a variety of purposes. The grow tubes or towers  12  can house aromatic and decorative species of herbs that may be used for aromatherapy type interactive hallways, lobby displays, kitchen, and cafeteria displays as well as common industrial plant displays in offices and workspaces. 
     The grow tube  12  of the vertical hydroponic plant production apparatus  10  of the present invention has a first end  14  and a second end  16  and is preferably a square, triangular, or angular tubing containing a non-woven matrix media  18  composed of any number of plastic materials, suspended vertically from the ceiling, supported by a framework, and/or standing upright on the floor using a support pole or frame. Preferably, the grow tube  12  is constructed of a PVC plastic material with side walls having a width of approximately four (4″) inches to six (6″) inches although constructing the grow tube from a different material with different widths is within the scope of the present invention. 
     The grow tube  12  of the vertical hydroponic plant production apparatus  10  of the present invention has a slot  20  formed lengthwise through the grow tube  12 . The slot  20  can be formed along the entire face of the grow tube  12  from the first end  14  to the second end  16  or the slot  20  can be formed to a point approximately four (4″) inches to approximately six (6″) inches from the first end  14  of the grow tube  12 . In the case of the slot  20  formed along the entire face of the grow tube  12 , the slot  20  can have angled portions  22  at the first end  14  of the grow tube  12  allowing for easy insertion and removal of the media, as will be described further below. Preferably, the slot  20  has a width of approximately one-half (½″) inch to approximately one and one-half (1½″) inches although constructing the slot  20  with different widths is within the scope of the present invention. 
     As mentioned briefly above, the vertical hydroponic plant production apparatus  10  of the present invention has a media material  18  preferably constructed from a polyester matrix material approximately two (2″) inches thick, cut to the internal width/diameter of the grow tube, and folded in the middle so that both halves together roughly equal the inside dimensions of the grow tube or tower housing  12 . The media material  18  can also be composed of two halves of approximately two (2″) inch thick media or one piece of four (4″) inch thick media split down the middle to within approximately four (4″) inches to approximately six (6″) inches of the top of the media material where a bolt spans its width. In the bolt embodiment of the present invention, this bolt not only spans the width of the media insert  18 , joining the two halves, and/or lending structural integrity to the media insert, but also anchors a handle or receiver to the media  18 , allowing either the handle to be grasped for the purposes of inserting and removing the media  18  insert from the grow tube  12 , or allowing a forked or hooked handle to be inserted into the receiver for the same purpose. 
     In the embodiment of the vertical hydroponic plant production apparatus  10  of the present invention where the media material  18  is folded in half, a pulling hook  24  with a flat hook  26  attached to a handle  28  allows the media inserts  18  to be pulled into and out of the grow tube  12 , with the pulling hook handle  28  extending from the slot  20  in the grow tube  12 . The hook  24  preferably consists of a piece of round bar metal bent to form a broad, flat, “L” shaped hook, roughly the width of the folded media  18  with a handle  28  affixed to the end. The hook  26  can also be attached to a pneumatic or hydraulic device that allows automated “pulling” of the media inserts  18 . 
     For planting, seedlings are placed between the two halves of media  18  of the vertical hydroponic plant production apparatus  10  of the present invention, with the upper portions out, and are “zipped” into the grow tubes  12  with the upper portions of the plant protruding through the gap in the tower housing  12 . The top of the grow tube  12  can be capped with a removable cap having holes of variable sizes drilled in the center, or may not be capped at all. If capped, a mister or irrigation tubing is inserted through the hole in the cap hole. The bottom of the grow tube  12  is either submerged in nutrient solution, rests in a drain or trough for recirculating nutrient solution, or fits into a lower pipe. A pump moves nutrient solution from a nutrient solution reservoir to the mister or irrigation pipe at the top of the grow tube  12 , where the nutrient solution is emitted and allowed to drip down through the media  18  and plant roots. Some of the nutrient solution trickles down the walls of the pipe  12  and is captured by roots in contact with the pipe wall. Excess nutrient solution drains to the bottom of the pipe  12  where it is drained back to the nutrient solution reservoir. High humidity is maintained within the grow tube due to the constant trickling/misting of nutrient solution. The height of the plant grow tube  12  is variable dependent on greenhouse height, and the spacing for plants is variable dependent on plant type and desired spacing. It is possible to stack grow tubes  12  on top of each other to vary height, by fitting the bottoms of the grow tubes  12  with coupling caps, to utilize conveyor production techniques. 
     The grow tubes  12  of the vertical hydroponic plant production apparatus  10  of the present invention can be fixed in place using hangers, rope, or strap and metal hooks that loop over a support beam or bracket and secure to the grow tube  12  or tower through holes  30  drilled at the first end of the grow tube  12 . The holes  30  can be of variable size and placement depending on application, although in the most common embodiment, there are four holes  30 , one pair centered on either side of the housing upper, and one pair forward (towards the front of the grow tube  12 ) of the centered pair allowing slight inclination of the hanging tower  12  if inclined growing is desired. The grow tubes  12  can also be fixed in place using a series of holes or a gap cut in the grow tube  12  allowing the grow tube to be fixed to a pole having a bracket or pressure or spring action hanging system attached to it. The grow tube  12  can also be inclined on said pole or hanging system for the purpose of inclined production. 
     The grow tube  12  of the vertical hydroponic plant production apparatus  10  of the present invention can also be secured to a support pole utilizing a system of metal brackets whereas one bracket type is female and is designated as an “H” bracket  32  and the other bracket type is male and is designated as a “Z” bracket  34 . The female “H” bracket  32  has a receiving portion and an anchoring portion to bolt to the back or side of the tower  12 . The male “Z” bracket  34  consists of a vertical, upward facing tongue portion that fits into the receiving portion of the female bracket  32 , and has a hole  36  through the middle, angled portion of the bracket  34  which fits over a support pole. The rear, downward facing vertical portion of the bracket  34  has a hole  38  drilled midway across the bottom of the bracket  34  and is threaded to receive a bolt. As weight is applied to the tongue portion of the bracket  34  through the placement of a bracketed tower, downward torque is applied across the “Z” bracket  34  causing a clutch action to affix the bracket tightly to the support pole. The torque attachment of this “Z” bracket  34  can be enhanced by tightening the bolt threaded into the rear of the bracket  34  against the support pole, applying even more pressure for bracket attachment. 
     The media insert  18  of the vertical hydroponic plant production apparatus  10  of the present invention can also be altered in several ways to serve a diverse range of functions. The media  18  can be cut at a taper from the unfastened or unfolded end to the fastened or folded end, reserving a tapered space at the rear of the insert to allow compost, alternate plant media, fertilizing substance or some type of soil amendment or additive to be held in the space between the tapered media insert and the rear and sidewalls of the tower housing  12 . This alteration allows compost based hydroponic plant production using regular irrigation water, with plant nutrients supplied by the compost or other additive. Tops, sides, and corners of the media insert  18  can also be cut, rounded, or cut at an angle to reduce biosolids accumulation, algal growth, or to enhance water distribution through the media  18 , depending on application. Multiple inserts  18  can also be used in towers  12  allowing multiple age groups of plants to incorporated into each grow tube  12 . Worms are also commonly integrated into the grow tubes  12  and the media is designed to have the correct mesh size to accommodate their movement through the media  18 , although media  18  with a smaller or larger mesh size may be used depending on application. 
     The vertical hydroponic plant production apparatus  10  of the present invention is comparatively lightweight, inexpensive to manufacture (being based on common PVC extrusion techniques) and existing polyethylene matrix material production, will not clog with nutrient solution, and requires much less labor to operate. The present invention can also be converted to more traditional horizontal production techniques if desired, eliminating the risk inherent in changing production techniques for commercial producers. 
     In addition, traditional nitrogen and phosphorus removal techniques in aquaculture are very poor compared to removal using plant uptake for phytoremediation. Plants are able to remove N and P to levels an order of magnitude lower than any mechanical/chemical/microbial technique currently in use. The present invention phytoremediates water allowing for prolonged water use/recirculation and water conservation. 
     The vertical hydroponic plant production apparatus  10  of the present invention is an improvement on traditional harvesting and sales models where production systems are physically removed from the sales systems and shipping and handling results in a large percentage of producer losses, both financially as wasted or expired produce. By selling live plants, there is no spoilage and shipping and handling is done partially by producers moving towers to market places, but primarily by consumers who are interested in fresh produce and the experience of picking and harvesting vegetables, herbs and greens for their own use. The grow tubes are easily transported and easy to stack, lift, and slide onto shelves. They essentially operate as a packaging system as well as a plant production system. Further, by utilizing individual towers, landscape designers and home users can scale their display or production system exactly to their specifications. 
     The vertical hydroponic plant production apparatus  10  of the present invention reduces necessary growing space tremendously. Typical reductions in growing space utilizing a vertical aeroponic technique have varied between 60% and 85% compared to conventional growth methods. Greenhouse growing space is very expensive, so the ability to increase crop size without increasing greenhouse space could prove very profitable. The present invention is also very affordable to manufacture, building on existing PVC pipe production infrastructure. Implementation of the present invention will also be simple, building on current hydroponic production technology. 
     The increased water recirculation time achieved with the vertical hydroponic plant production apparatus  10  of the present invention can eliminate one of the high costs and reduce the negative environmental effects of aquaculture, resulting in increased profits and a better industry image for aquacultural producers. Using the present invention can also allow aquacultural producers to diversify their product base and/or grow supplementary feed products (depending on the dietary needs of the fish). 
     The vertical hydroponic plant production apparatus  10  of the present invention has the potential to open up an entirely new system of production, transportation, shipping, handling, and display to vegetable producers, retailers, and consumers. This can result in fresher produce, a more pleasant customer shopping experience, reduced waste, reduced handling and packaging costs, fewer food miles, less plastic and packaging material consumption, and longer shelf life of purchased produce. 
     The vertical hydroponic plant production apparatus  10  of the present invention can be used by industrial institutions for phytoremediation of waste waters, using the towers as trickling, plant integrated filters for the removal of waste materials, and the remediation of waste waters for discharge. 
     The foregoing exemplary descriptions and the illustrative preferred embodiments of the present invention have been explained in the drawings and described in detail, with varying modifications and alternative embodiments being taught. While the invention has been so shown, described and illustrated, it should be understood by those skilled in the art that equivalent changes in form and detail may be made therein without departing from the true spirit and scope of the invention, and that the scope of the present invention is to be limited only to the claims except as precluded by the prior art. Moreover, the invention as disclosed herein may be suitably practiced in the absence of the specific elements which are disclosed herein.