Patent Publication Number: US-2015082696-A1

Title: Horticultural grow gutter

Description:
BACKGROUND OF THE INVENTION 
     The present invention generally relates to a horticultural grow gutter, also referred to as a growing gutter, providing a draining system which allows cultivation of a garden, orchard, or nursery having flowers, fruits, vegetables, or other ornamental plants, and a method for constructing such grow gutters. 
     SUMMARY OF THE INVENTION 
     One aspect of the present invention includes a horticultural system having a horticultural grow gutter produced from a single sheet of material, typical steel or sheet metal, and including an upper bridge section having an upper nutrition mat receiving top surface. The horticultural grow gutter also has a length, a bottom surface, and two side edges. Two upwardly facing upper channel sections are each individually integral with one of the two side edges along at least substantially all of the length of the upper bridge section. The upwardly facing channel sections have a top edge extending above the upper nutrition mat receiving top surface and a channel bottom having a plurality of apertures positioned in the bottom of the upwardly facing upper channel section and configured to allow a liquid to pass through the apertures by gravity. Two side panels are each individually integral with one of the top edges and extend downward from the top edge. An inwardly bent and upwardly facing lower channel section is integral with each side panel and the upwardly facing lower channel section is sized and positioned to receive the liquid passing through the apertures disposed below the upper channel section. 
     One aspect of the present invention includes a horticultural grow gutter which includes an upper bridge section having an upper nutrition mat receiving member, a bottom surface, and at least two side edges. Moreover, the horticultural grow gutter includes an upwardly facing upper channel section which is integral with at least one of the at least two side edges. The upwardly facing upper channel section also includes a top edge. At least one side panel extends downward from the top edge of the upwardly facing upper channel section which is integral with at least one of the at least two side edges. The upwardly facing upper channel section also includes a top edge. At least one side panel extends downward from the top edge of the upwardly facing upper channel section and forms an inwardly bent, and upwardly facing lower channel section which is disposed below the upper channel section. The lower channel section is configured to receive water or other liquid from the upper channel section. 
     Another aspect of the present invention includes a horticultural grow gutter which includes an upper bridge section having an upper nutrition mat receiving member, a downwardly concave bottom surface, and at least two side edges which extend an entire length of the upper bridge section. Moreover, at least one generally U-shaped, upwardly facing, upper channel section is integral with at least one of the at least two side edges. The upwardly facing upper channel section includes a top edge which extends the entire length of the upper bridge section. Additionally, at least one downwardly extending side panel extends from the top edge and forms an inwardly bent, and upwardly facing, lower channel section. The lower channel section is configured to receive water or other liquid from the upper channel section. Moreover, the bottom surface of the upper bridge section is permanently visible throughout the entire length of the bridge section. 
     Yet another aspect of the present invention includes a method of producing a grow gutter including the following steps. First, providing a single, non-pre-punched sheet of material (a sheet of material that is free of any punched sections forming one or more perforated apertures in the sheet of material) into a upper bridge section having an upper nutrition mat receiving member, a bottom surface, and at least two side edges. The machine also forms an upwardly facing upper channel section which is adjacent to at least one of the at least two side edges and includes a top edge. Moreover, the machine forms at least one side panel which extends downward from the top edge and forms an inwardly bent and upwardly facing lower channel section. Next, the water or other liquid is drained from the upper nutrition mat receiving member into the upper channel section. Finally, the water or other liquid is received into the lower channel section through a plurality of pass through apertures which are disposed on the upper channel section. 
     These and other features, advantages, and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a partial top perspective view of the horticultural grow gutter apparatus according to an aspect of the present invention; 
         FIG. 2A  is a partial bottom right perspective view of the horticultural grow gutter apparatus according to an aspect of the present invention; 
         FIG. 2B  is a partial bottom left perspective view of the horticultural grow gutter apparatus according to an aspect of the present invention; 
         FIG. 3A  is a partial top plan view of the horticultural grow gutter apparatus according to an aspect of the present invention; 
         FIG. 3B  is a partial bottom plan view of the horticultural grow gutter apparatus according to an aspect of the present invention; 
         FIG. 4  is a top plan view of the horticultural grow gutter apparatus according to an aspect of the present invention; 
         FIG. 5  is a cross-sectional view of the horticultural grow gutter apparatus according to an aspect of the present invention; 
         FIG. 5A  is an enlarged partial cross-sectional view of the horticultural grow gutter apparatus according to an aspect of the present invention; 
         FIG. 6  is a top perspective view of the horticultural grow gutter apparatus installed according to an aspect of the present invention; and 
         FIG. 7  is a front perspective view of a machine used to form the horticultural grow gutter apparatus according to an aspect of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENT 
     For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in  FIG. 1 . However, it is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. 
     Where a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limit of that range, and any other stated or intervening value in that stated range, is encompassed within the invention. The upper and lower limits of these small ranges may independently be included in the smaller ranges, and are also encompassed within the invention, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the invention. In this specification and the appended claims, the singular forms “a,” “an” and “the” include plural reference unless the context clearly dictates otherwise. 
       FIGS. 1-5  generally show a horticultural grow gutter  10 . The horticultural grow gutter  10  of the present invention is typically formed from a single piece of metal or plastic and includes an upper bridge section  12 , two upwardly facing upper channel sections  13  disposed along at least substantially all, and more typically along the entire length of the grow gutter, and upwardly facing lower channel section  14  positioned beneath the upwardly facing upper channel sections and running at least substantially the length of the grow gutter or the entire length of the grow gutter. 
     The upper bridge section  12  of the horticultural grow gutter  10  includes a top surface  82  and a bottom surface  84 , and at least two side edges  18 . A nutrition mat  20  is typically place don the top surface of the bridge section  12 . The side edges  18  are disposed on either side of the upper bridge section  12  and extend an entire length  24  or at least substantially all of the entire length of the horticultural grow gutter. The side edges  18  form a generally rectangular surface with a front edge  26  and a rear edge  28 . The upper bridge section  12  between the edges  18  and the front edge  26  and rear edge  28  may be a generally flat, aperture free and recess free, rectangular surface. The upper bridge section  12  may be slightly concave down in order to allow drainage from the top surface  82  and a nutrition mat  20  down toward the at least two side edges  18  by gravity when the grow gutter  10  is mounted. The nutrition mat is typically a pre-formed plant nutrient providing material configured to germinate and/or grow one or more plants of various plant varieties. The nutrition mat may be soil, a composite of soil and fertilizer and/or a synthetic man-made growing/nutrient providing material. Typically, the nutrition mat is positioned along the entire length or substantially all of the entire length  24  of the grow gutter  10 ; however, a plurality of nutrition mats may be positioned along only portions, substantially all or all of the top surface of the upper bridge member. There conceivably may be space or gaps between nutrition mats or they may physically abut one another. 
     The upper bridge section  12  has a width  30  of from approximately 200 to approximately 250 centimeters and most typically approximately 220 centimeters. The bottom surface  84  may correspondingly be slightly concaved down or a generally flat surface. Moreover, typically, the bottom surface  84  is visible throughout the entire length of the upper bridge section  12  when viewed from a bottom perspective, as shown in  FIGS. 2A-2B . There is typically no other portion of the grow gutter other than the upper bridge section  12  that interconnects the upwardly facing upper channel sections  13  and the upwardly facing lower channel sections  14 . 
     The upwardly facing upper channel section  13  is formed integral with each of the side edges  18 , forming two upwardly facing upper channel sections  13  disposed on opposing sides of the upper bridge section  12 . Water or other liquid received on the top surface  82  and the nutrition mat  20  collects via gravity in the upwardly facing upper channel section  13 . The upwardly facing upper channel section  13  is typically generally a U-shaped channel that typically extends along the entire length  24  of the upper bridge section  12 . The upwardly facing upper channel section  13  may be completely level with the ground or may be slightly slanted along the length of the grow gutter in order to prevent standing water or other liquid by allowing gravity to move liquid within the channel along the length of the channel. 
     The upwardly facing upper channel section  13  further includes a plurality of pass-through apertures, or holes  40 . The holes  40  are typically disposed in a bottom  42  of the upper channel section  13  and are typically linearly spaced apart throughout an entire length  24  of the upper channel section  13 . The holes  40  or apertures are typically oval-shaped or capsule-shaped (rectangular center section with arch-shaped ends), but may also be circular, triangular, square, star-shaped, heart-shaped, or any other shape as known by one of ordinary skill in the art. The holes  40  typically have a length  46  of approximately 10 to 20 centimeters, most typically approximately 15 centimeters. The holes  40  also have a width  48  of approximately 5 to 10 centimeters and most typically approximately 8 centimeters. The holes  40  typically have arch-shaped ends. The holes  40  in the upwardly facing upper channel section  13  are specifically designed such that the opening of the holes  40  is minimized to prevent blockage and to allow only water or other liquid to fall through the holes  40  of the upwardly facing upper channel section  13 . The holes  40  are typically mechanically punched completely through the upper channel section  13  and are typically disposed approximately 250-750 mm apart and specifically approximately 500 mm apart. The holes  40  are typically punched on-site and can be made to any desired shape or configuration as desired by individual customers. 
     The upper channel section  13  also typically has a radius  50  of from approximately 6 to approximately 10 centimeters and most typically about or exactly 7.5 centimeters. Moreover, the upper channel section  13  from the side edges  18  of the upper bridge section  12  to the deepest portion of the upper channel section  13  is approximately 10 centimeters deep. On the opposite side of the upper channel section  13  from the side edge  18  is a top edge  54  of the upper channel section. The top edge  54  of the upper channel section  13  extends upward approximately 10 to 20 centimeters, and most typically approximately 15 centimeters above the side edge  18  (see length B in  FIG. 5A ). 
     A side panel  60  is integral with and extends downward from each of the top edges  54  of the upwardly facing upper channel sections  13 . The side panel  60  extends downward from the top edge  54  from approximately 100 to 150 centimeters and most typically approximately 121 centimeters and to a point sufficiently below the upper channel section  13  to allow the upwardly facing lower section  14  to be formed under the upper channel sections  13 . The top edge  54  of the upwardly facing upper channel section  13  and the side panel  60  form a small semi-circle or looped portion  62 . The looped portion  62  may also be linear or flattened. However, the looped portion  62  is typically semi-circle or looped in order to provide strength to the horticultural grow gutter  10 . The looped portion  62  between the upwardly facing upper channel section  13  and the side panel  60  improves the rigidity and strength of the horticultural grow gutter  10 . The portion of the upper channel section  13  that extends upward to the top edge  54  and the side panel extending down from the top edge  54  typically are proximate one another or physically engage one another to provide strength. 
     The side panel  60  also includes an outwardly projecting section  64 . The outwardly projecting section  64  has a length C (see  FIG. 5A ) of from approximately 8 to 12 centimeters and typically approximately 10 centimeters, and projects outward away from the upper bridge section approximately 2 to 7 centimeters and most typically approximately 5 centimeters. The outwardly projecting section  64  of the side panel  60  also allows stacking or nesting of the horticultural grow gutter  10  on top of each other during manufacturing and shipping. The outwardly projecting section  64  of the side panel  60  is configured to provide the lower channel section  14  with a larger radius  68  than the radius  50  of the upper channel section  13  such that all of the water or other liquid falling through the holes  40  in the upper channel section  13  to the lower channel section  14  is received into the lower channel section  14 . The outwardly projecting section  64  may also be configured to provide a capillary effect to the water or other liquid which is dripping from the holes  40  from the upper channel section  13  into the lower channel section  14  such that when a droplet of water or other liquid falls from the holes  40  in the upper channel section  13 , the water is then disposed onto an inside surface  70  of the side panel  60  and follows along the outwardly projecting section  64  into the lower channel section  14 . 
     The side panel  60  continues to extend downward from the outwardly projecting section  64  and is upwardly and inwardly bent in order to form the upwardly facing upper channel section  13 . The upwardly facing lower channel section  14  has a diameter D (see  FIG. 5A ) or width of from approximately 30 to about 40 centimeters, and most typically approximately 35 centimeters and is disposed directly below the upwardly facing upper channel section  13 . The lower channel section  14  is a generally U-shaped channel. The lower channel section  14  further includes an inward edge  74  and has a height of from approximately 40 to approximately 50 centimeters and most typically approximately 45 centimeters from the bottom of the upwardly facing upper channel section. 
     The upwardly facing lower channel section  14  is inwardly facing so as to prevent contamination from root growth. In prior art plant breeding gutters, protruding plant roots emerging from the nutrition mats lay in drain water of outwardly oriented channels. When the roots lay in drain water there is a chance of undesired virus or bacterial or fungi contamination from one plant to another if the drain water becomes contaminated because plant diseases are transferred via water in which the roots are placed. The horticultural grow gutter  10  of the present invention eliminates such chances of virus or other contamination. 
     In operation, the horticulture will grow from the nutrition mat  20 . Once long enough, the roots of the horticulture will reach the top edge  54  of the upper channel section  13  and then fall downward onto an outside surface  80  of the side panel  60 . Because the upwardly facing lower channel section  14  faces inward, the roots do not come into contact with the lower channel section  14  so as to prevent decontamination of the plants. Also having the lower channel section  14  facing inward allows no dirt, algae or leaves falling from the plant to fall directly into the lower channel section  14 , resulting in less contamination to the water or other liquid in the lower channel section  14 . Furthermore, because the two opposing upwardly facing lower sections are not interconnected using a planar material covering the bottom surface of the upper bridge section, one can visually inspect the upwardly facing lower sections of the present grow gutters. The lower channel section  14  is only connected to the side panel  60  and is not connected to any other portion of the horticultural grow gutter  10 . The open orientation of the lower channel section  14  allows a user to clean the lower channel section  14  without deconstructing the horticultural grow gutter  10 . As mentioned, the inwardly facing lower channel section  14  also allows a user to see if dirt, algae or other contaminates fall into the lower channel section  14  through the holes  40  of the upper channel section  13 . The open air construction of the upwardly facing lower channel section  14  allows ventilation to the lower channel section  14  which helps prevent diseases or other contamination inside of the grow gutter. This configuration also allows for no fruit contamination with drain water. 
     The horticultural grow gutter  10  is typically comprised of a strong sturdy material, such as steel, but could conceivably be made of plastic. The steel may be brushed steel, painted steel, or stainless steel as would be used by one of ordinary skill in the art. Moreover, the horticultural grow gutter  10  may also be comprised of any sturdy material which provides the desired strength and rigidity desired to produce the horticultural grow gutter. Most typically, the horticultural grow gutter  10  is comprised of three quarter inch galvanized steel. The material is typically painted with a food safe primer and then coated with a food safe coating. The food safe primer and the food safe coating are both typically a polyester paint which coats the horticultural grow gutter  10  in order to provide a food safe barrier between plants grown on the surface of the horticultural grow gutter  10  and the steel material. Typically both top surface  82  and bottom surface  84  of the horticultural grow gutter  10  include the food safe primer and the food safe coating; however, it is contemplated that only one surface or only a portion of one surface or portions of both surfaces may include the food safe coating and the food safe primer. 
     The horticultural grow gutter  10  of the present invention is typically hung from a ceiling in a greenhouse or other grow house by steel or plastic rods. Typically the horticultural grow gutter  10  is hung from approximately 0.5 meter to about 3 meters from the ceiling and most typically approximately 1 meter from the ceiling. This height gives optimal growing room for the plants and also allows the roots of the plants to hang below the grow gutter. The horticultural grow gutter  10  of the present invention typically has a length  24  of from approximately 3.5 to approximately 6 meters, and most typically approximately 5 meters. In operation, the horticultural grow gutter  10  is hung from the ceiling, as described above, and attachment mechanisms from the ceiling to the horticultural grow gutter  10  may be a great length apart, typically approximately 3 to 8 meters and most typically approximately 5 meters. In order to support the nutrition mat  20  and horticulture, the horticultural grow gutter  10  must be a rigid member and capable of supporting the weight of the nutrition mat  20  and any horticulture desired by a consumer. 
     An advantage of the present invention is that the horticultural grow gutter  10  can be made from a single sheet of flat (unshaped) steel. The single sheet of steel has no pre-punched holes, and can be purchased from any steel supplier in the United States and abroad. The pre-punched steel used in prior art applications typically comes from Europe and has a higher cost than non-pre-punched steel due to processing costs. Using single sheeted, non-pre-punched steel of the present invention allows the horticultural grow gutter  10  to be less expensive than traditional grow gutters using pre-punched steel. 
     The description above is describing a single portion of the horticultural grow gutter  10  and the complete horticultural grow gutter  10  will include a single upper bridge section  12  with one upwardly facing upper channel section  13  integral with each side edge  18  of the upper bridge section  12 . The downwardly extending side panel  60  extends from each of the upwardly facing upper channel sections  13  and are bent to form the upwardly extending lower channel sections  14 . The horticultural grow gutter  10  is generally symmetrical and typically has a maximum width  92  of from approximately 250 to approximately 275 centimeters and most typically approximately 266 centimeters. 
     The present invention also relates to methods for the production of the novel horticultural grow gutter  10  for greenhouse farming from rolls of flat material, usually steel, typically continuously and over large lengths that may be cut with a material (steel) cutter as the grow gutter is being produced. As shown in  FIG. 6 , typically a roll forming machine  100  for continuous production of the gutter  10  is used. The horticultural grow gutter  10  is formed from a single piece of non-pre-punched steel and typically begins in a roll of steel  102 . The roll of steel  102  is unrolled by the roll forming machine  100  while the roll forming machine  100  bends the single piece of non-punched steel into the horticultural grow gutter  10  of the present invention. The roll forming machine  100  employs several sets of rollers  104  which operate to form the upper bridge section  12 , the upwardly facing upper channel section  13 , and the downwardly extending side panel  60 , which is inwardly bent in order to form the upwardly facing lower channel section  14 . 
     Specifically, the method begins by providing the single, non-pre-punched sheet of material which is typically steel. Next, the roll forming machine  100 , which is typically portable such that the grow gutters may be made to length needed for an individual greenhouse on-site, is used to form from the single non-pre-punched sheet of material the upper bridge section  12 , and the at least two side edges  18 . The roll forming machine  100  forms the upwardly facing upper channel section  13  adjacent to the at least two side edges  18  and having a top edge  54 . Moreover, the roll forming machine  100  forms at least one side panel  60  extending downward from the top edge  54  and inwardly bends and forms the upwardly facing lower channel section  14 . 
     The grow gutter typically is installed proximate the top of greenhouse usually be suspending the grow gutter segments from the ceiling or other support structure of the building typically using steel rods  200  having a hook end  202  that matingly receives the bottom of the upwardly facing lower channel section  14 . The nutrition mat may be engaged with the top surface  82  either before or optionally after the grow gutter is mounted proximate the ceiling of the greenhouse structure. Plant seeds or plants to be grown are typically added to the nutrition mat. 
     In operation water or other liquid applied to the plant, plant seed and/or nutrition mat and excess water or other liquid is drained from the top surface  82  of the upper bridge section  12  into the upper channel section  13 . Finally the water or other liquid is received into the lower channel section  14  through a plurality of pass through holes  40  which are disposed on the upper channel section  13 . 
     The roll forming machine  100  is transportable and capable of being brought to any commercial greenhouse site in order to produce the horticultural grow gutter  10  in the same location as it will be used. Having a roll forming machine  100  which produces the grow gutter on site also allows for specific widths  92  and lengths  24  of the horticultural grow gutter  10  in order to optimize horticultural growth for each desired consumer. The depth A,  76  of the upper channel section  13  and the lower channel section  14  can be varied according to plant breed specifications, provided that sufficient profile strength is still evident. Other potential requirements and wishes of a consumer can also be incorporated in the horticultural grow gutter  10  design by means of changing the constructive specifications of the rollers  104  in the roll forming machine  100 . 
     Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments of the invention described herein. Such equivalents are intended to be encompassed by the following claims.