Patent Publication Number: US-2023148486-A1

Title: Structures for growing plants

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. application Ser. No. 17/436,275 filed Sep. 3, 2021 which is a 371 of International Application No. PCT/CA2020/050302 filed Mar. 6, 2020 which claims the benefit of and priority to U.S. Provisional Application No. 62/815,131 filed Mar. 7, 2019 the contents of which are hereby incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     The present disclosure relates to structures for growing plants. 
     BACKGROUND 
     Existing greenhouses can be useful for growing plants, but can also have various drawbacks. Greenhouses lack insulation, which makes them extremely expensive to heat in cold conditions. 
     For example, greenhouses use vertical posts and trusses to support the roof system. This can be problematic in that growing operations must be designed around the vertical posts, and the trusses and posts cause shade, which reduces the amount of natural sunlight. 
     For example, greenhouses use either polyethylene or glass, which do not allow the full light spectrum of natural sunlight to penetrate the greenhouse. As a result, structures that use polyethylene or glass do not allow ultraviolet (UV) light to enhance plant growth. 
     SUMMARY 
     Embodiments described herein provide improved structures for growing plants. The improved structures generate micro-environment conditions. An aspect of the present disclosure provides a structure for growing plants comprising: a foundation having a first end closer to the equator and a second end farther from the equator; a main support comprising two vertical members extending upwardly from opposed lateral sides of the foundation and a horizontal member extending laterally across the foundation in an east-west direction between the two vertical members; a plurality of vertical supports extending upwardly from the foundation and spaced around a perimeter of the foundation; a perimeter frame connected to top portions of the vertical support members; an outer shell comprising an outer roof comprising an outer cable net supported by the outer perimeter frame and a plurality of transmissive panels coupled to the outer cable net, and an outer wall on each of the east and west lateral sides and the first end, each outer wall comprising outer wall cables extending vertically to the outer perimeter frame and a plurality of transmissive panels coupled to the outer wall cables; and, an inner shell comprising an inner roof comprising an inner cable net supported by the inner perimeter frame and a plurality of transmissive panels coupled to the inner cable net, and an inner wall on each of the east and west lateral sides and the first end, each inner wall comprising inner wall cables extending vertically to the inner perimeter frame and a plurality of transmissive panels coupled to the inner wall cables. 
     Further aspects and details of example embodiments are set forth below. 
    
    
     
       DRAWINGS 
       The following figures set forth embodiments in which like reference numerals denote like parts. Embodiments are illustrated by way of example and not by way of limitation in the accompanying figures. 
         FIG.  1    shows structural elements of an example plant growing structure according to one embodiment of the present disclosure. 
         FIG.  2    shows another view of the structure of  FIG.  1   . 
         FIG.  3    shows a side view of an outer wall of the structure of  FIG.  1   . 
         FIG.  4    shows a side view of an inner wall of the structure of  FIG.  1   . 
         FIG.  5    is a sectional view taken along the line A-A of  FIG.  1   . 
         FIG.  6    is a sectional view taken along the line B-B of  FIG.  1   . 
         FIG.  7    is a sectional view taken along the line C-C of  FIG.  1   . 
         FIG.  8    shows a top plan view of the roof of the structure of  FIG.  1   . 
         FIG.  9    shows the structure of  FIG.  1    with transmissive panels attached. 
         FIG.  10    shows outer and inner cables holding transmissive panels of the structure of  FIG.  1   . 
         FIG.  11    is a sectional view through the horizontal member of the main support of the structure of  FIG.  1   . 
         FIG.  12    is a sectional view through the intersection between a vertical support and the perimeter frame of the structure of  FIG.  1   . 
         FIG.  13    shows an example plant growing structure adjacent to a headhouse according to one embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     The following describes example structures for growing plants. 
     For simplicity and clarity of illustration, reference numerals may be repeated among the figures to indicate corresponding or analogous elements. Numerous details are set forth to provide an understanding of the examples described herein. The examples may be practiced without these details. In other instances, well-known methods, procedures and components are not described in detail to avoid obscuring the examples described. The description is not to be considered as limited to the scope of the examples described herein. 
       FIG.  1    shows an example plant growing structure  100  according to one embodiment of the present disclosure. The structure  100  has a foundation  101  at its base, with a stem wall  102  extending upwardly a short distance (for example about  3  feet) around the perimeter of the foundation  101 . The structure has opposed lateral sides. The structure has ends that can be positioned relative to the equator. The structure  100  has a main support  104  with two vertical members  103  on either side of the foundation, extending upwardly from the foundation and a horizontal member  105  extending laterally across the foundation in an east-west direction between the two vertical members  103 . The sides of the foundation can be generally positioned east and west so that the horizontal member  105  extends laterally across the foundation in an east-west direction between the two vertical members  103 . The two vertical members  103  are on either side of the foundation and so can also be generally positioned east and west. In some embodiments, the foundation can be in a position proximate true north (e.g. within a range of 15 degrees off true north) to retain optimal solar exposure. 
     The horizontal member  105  can connect with top portions of the two vertical members  103  and extend laterally across the foundation. In an example, a height of the structure can be 40′ at the ridge of the structure. The vertical members  103  extend upwardly along the opposed later sides of the structure  100 . 
     The main support  104  and two vertical members  103  provide a tri-chord configuration to support the structure  100 . The horizontal member  105  can connect with top portions of the two vertical members  103  using connectors. The location of the connections can vary depending on the ridge height of the structure  100 . 
     The structure  100  has a plurality of vertical supports  106  extending upwardly from the stem wall  102  along the sides  108  of the structure  100  and along a first end  110  of the structure  100 , and a perimeter frame  124  around the upper edges of the structure atop the vertical supports  106 . The structure  100  has vertical supports  106  extending upwardly from the stem wall  102  along the sides  108  of the structure  100 , and the structure  100  has vertical members  103  that also extend upwardly from the stem wall  102  along the sides  108  of the structure  100 . The vertical supports  106  and the vertical members  103  can extend from the same region of the stem wall  102  along the sides  108  of the structure  100 . The vertical supports  106  and the vertical members  103  can be implement using metal and cable components, for example, and reside within and provide the envelope or walls of the structure  100 . The perimeter frame  124  may have an inner perimeter frame  132  and a larger outer perimeter frame  134  each connected to the vertical supports  106 , as shown in  FIG.  12   . The inner and outer perimeter frames  132  and  134  can be structural steel nodes, for example. The inner and outer perimeter frames  132  and  134  can be at the juncture between the vertical walls and the sloped roof of the structure  100 . The inner perimeter frame  132  connects to a vertical support  106  and lower secondary cables  122 . The outer perimeter frame  134  connects to a vertical support  106  and upper secondary cables  118 . The upper secondary cables  118  form part of an outer cable net  800  ( FIG.  8   ).  FIG.  12    shows closure panels that generate an air tight building envelope and sealed air volume or barrier. In this example, tie back cables  126  are attached to the outer perimeter frame  134 . 
     The support for the structure  100  may further comprise horizontal supports  112  connected between the vertical supports  106  along the lateral sides  108  of the structure  100 . A second end  114  of structure  100  may be supported by a building or with additional rigid support. For example, in some embodiments, the second end  114  of the structure  100  may be supported by a wall of a headhouse  200 , as shown in  FIG.  13   . In some embodiments, the structure  100  may further comprise additional support elements. This additional support can be from interior columns, for example. 
     When the structure  100  is configured for use in the northern hemisphere, the first end  110  is located closer to the equator than the second end  114  (i.e. the first end is on the south and the second end  114  is on the north), so as to maximize the sunlight incident on the growing area within the structure  100 . Conversely, the structure  100  may be configured for use in the southern hemisphere such that the first end is north of the second end, so as to maximize the sunlight incident on the growing area. 
     In some embodiments, vertical and horizontal members  103  and  105  of the main support  104  may each comprise a tri-chord truss, with three outer members, as shown in  FIGS.  1  and  2   . In some embodiments, the vertical supports  106  and horizontal supports  112  may comprise bi-chord trusses, as shown in  FIGS.  1  and  2   . In some embodiments, the perimeter frame  124  may also be constructed from bi-chord trusses, with the inner and outer perimeter frames  132  and  134  being formed by the two chords of the trusses. 
     The structure  100  further comprises a roof upper primary cables  116  and lower primary cables  120  running north-south and upper secondary cables  118  and lower secondary cables  122  running east-west. In some embodiments the upper secondary cables  118  and lower secondary cables  122  may be comprised of short lengths of cable, spanning the space between the upper primary cables  116  and lower primary cables  120  rather than long cables, spanning the whole width of the structure  100 . 
     In some embodiments, structure  100  may be further supported by tie back cables  126  attached to the outer perimeter frame  134  and anchored to the ground outside the structure  100 . In some embodiments, the tie back cables  126  may each be at an angle of approximately 30 degrees from horizontal. 
     In some embodiments, the structure  100  further comprises a post  130  (which may be referred to as a “flying mast”) extending downwardly from the horizontal member  105  of the main support  104  and held under tension by a cable  128  connected at or near the ends of the horizontal member  105  of the main support  104 . The post  130  helps prevent sagging of the horizontal member  105 . 
     Hydraulic and mechanical cable tensioners can used in the installation sequencing to tension the cables. When all cables are tensioned as engineered the cables are stayed by fittings or turnbuckles to fix and retain the proper setting. 
     The bottoms of the walls are formed by the stem wall  102 . In some embodiments, the stem wall  102  incorporates one or more drains for collecting foam residue, as discussed below. 
     The structure  100  has lateral sides. A lateral side has an outer side and an inner side. 
       FIG.  3    shows the outer side  300  of the structure  100  shown in  FIG.  1   . The outer side  300  further comprises outer wall cables  302  extending vertically downward from the outer perimeter frame  134  to the stem wall  102 . 
       FIG.  4    shows the inner side  400  of the structure  100  shown in  FIG.  1   . The inner side  400  further comprises inner wall cables  402  extending vertically downward from the inner perimeter frame  132  to the stem wall  102 . 
     The outer side  300  and the inner side  400  create a sealed air volume or barrier. The outer side  300  has a different height than the inner side  400 . 
       FIG.  5    shows a cross-sectional view of the structure  100  of  FIG.  1    taken along the line A-A. As shown, there can be a linkage  1004  at various points between the upper and lower primary cables  116  and  120  for structural support between outer side  300  and the inner side  400 . 
       FIG.  6    shows a cross-sectional view of the structure  100  of  FIG.  1    taken along the line B-B.  FIG.  6    shows the foils that provide the sealed air volume for the structure  100 . The structure  100  has spaces that contain dynamic foam insulation. 
     Lower secondary cables  122  and upper secondary cables  118  can be connected by linkage  1004 . 
       FIG.  7    shows a cross-sectional view of the structure  100  of  FIG.  1    taken along the line C-C.  FIG.  7    shows the primary singular tensile structure support tri-chord columns and truss. The structure  100  can have tie back cables  126  and cables  128  for the main support  104 . 
     As shown in  FIG.  8   , upper primary cables  116  and upper secondary cables  118  form an outer cable net  800 . Similarly, lower primary cables  120  and lower secondary cables  122  form an inner cable net (not shown) below the outer cable net. 
     Primary cables can be long span heavy gauge cables that support the secondary cables. The secondary cables can be smaller gauge perpendicular cables that thread through pockets and support the transmissive panels. 
     As shown in  FIG.  9   , the outer cable net  800  provides a structure to hold transmissive panels to form an outer roof  900 . Outer wall cables  302  provide a structure to hold transmissive panels along the sides  108  and the first end  110  forming an outer wall  902 . Similarly, the inner cable net holds transmissive panels, forming an inner roof and inner wall cables  402  provide a structure to hold transmissive panels forming an inner wall. 
     The structure  100  can have parallel strips of matching transmissive panel material that can be welded to opposing sides of the outside and inside transmissive panels. This creates linear pockets within which the secondary cables are positioned, supporting the complete material structure. 
       FIG.  10    shows upper and lower primary cables  116  and  120  respectively connected to upper secondary cables  118  and lower secondary cables  122  by an upper connection assembly  117  and a lower connection assembly  121 . The connections can be mechanical connections held in stasis through compressive and tensile forces. The upper secondary cables  118  and lower secondary cables  122  hold transmissive panels  1002  of the structure  100  of  FIG.  1   , which are also secured to the upper and lower connection assemblies  117  and  121 . They can be secured by mechanical connections held in stasis through compressive and tensile forces. 
     In some embodiments, upper secondary cables  118  and lower secondary cables  122  may be held within pockets  1003  formed on the transmissive panels  1002 . The pockets  1003  of the transmissive panels  1002  on the outer and inner roofs may, for example, be formed by attaching a strip of panel material to either side of each transmissive panel. In some embodiments, the transmissive panels  1002  of the outer and inner roofs run laterally (east-west) across the structure, parallel to the secondary cables  118  and  122 . Similarly, transmissive panels  1002  on the sides  108  and first end  110  may have pockets for receiving the inner wall cables  402  and outer wall cables  302 , and may run vertically, parallel to the inner and outer wall cables  302  and  402 . In some embodiments, a linkage  1004  may be provided at various points between the upper and lower primary cables  116  and  120  to maintain structural integrity of the outer and inner roofs and the spacing therebetween. In some embodiments, a bird deterrent assembly  1006  may be provided above some or all of the upper primary cables  116 . For the pockets  1003 , parallel strips of matching material is welded to opposing sides of the outside and inside transmissive panels to create linear pockets within which the secondary cables are positioned, supporting the complete material structure. 
     As used herein, the term “transmissive” in relation to panels means panels which are either transparent or translucent, and which allow a high proportion of light with wavelengths in the solar spectrum to pass therethrough. In some embodiments, the transmissive panels  1002  allow UV light to pass therethrough. The transmissive panels  1002  may, for example, comprise panels of a stretchable, high-strength material. Examples of suitable materials for the transparent panels include transparent and translucent petroleum and non-petroleum based plastics and materials. Another example material is glass. In some embodiments, the transmissive panels of the outer roof and outer walls are translucent, with a matte finish, to diffuse light, and the transmissive panels of the inner roof and inner walls are transparent. The transmissive panels can have different finishes and thickness. In some embodiments, the transmissive panels of the outer roof have a thickness of about 350μ, the transmissive panels of the outer walls have a thickness of about 300μ, and the transmissive panels of the inner roof and inner walls have a thickness of about 150μ. 
       FIG.  11    shows a cross sectional view of the horizontal member  105  of the main support  104  of the structure  100  of  FIG.  1   . The horizontal member  105  of the illustrated example is a tri-chord truss (as are the vertical members  103 ). Therefore, at the top of the structure  100  there is a space within horizontal member  105  for a platform  1102 . The platform  1102  may be located lower than shown in some embodiments (for example centered on the lower chords of the horizontal member  105 ). The platform  1102  may be of sufficient size to permit a person to pass along it, for example for maintenance. In some embodiments, the structure comprises dynamic foam generators  1104  situated in proximity to the horizontal member  105  so that a person on platform  1102  can access them for maintenance or repair. The foam generators  1104  may be placed between the outer roof  900  and the inner roof  1106  such that the space between the outer roof  900  and inner roof  1106  fills with dynamic foam solution when the foam generators  1104  are in operation. 
     Foam generators  1104  generate foam from a dynamic foam solution. In some embodiments, the foam generators  1104  are operable to generate a dynamic foam that provides an insulating value of R1 per inch. Thus in an example structure with a 36″ cavity between the outer skin and the inner skin, the dynamic foam may provide insulation values of up to R36. In some embodiments, the dynamic foam may also be used to providing shading and/or reduce UV transmission. In some embodiments, the solution used to generate the foam comprises approximately 99.2% water and approximately 0.8% coconut oil soap and/or other components. Once used, the dynamic foam breaks down to a liquid solution that may be captured in drains between the outer walls and inner walls along the foundation of structure  100  for later recycling. 
     The structure  100  has a foundation with ends and opposed lateral sides. The structure has a main support  104  with two vertical members  103  extending upwardly from the opposed lateral sides  108  of the foundation and a horizontal member  105  extending laterally across the foundation between top portions of the two vertical members  103 . 
     The structure  100  has a plurality of vertical supports  106  extending upwardly from the foundation and spaced around a perimeter of the foundation. The structure  100  has a perimeter frame  124  connected to top portions of the vertical supports  106 . The perimeter frame  124  has an outer perimeter frame  134  and an inner perimeter frame  132 . 
     The structure  100  has an outer shell and an inner shell. The outer shell has an outer roof with an outer cable net supported by the outer perimeter frame  134  and a plurality of outer roof transmissive panels coupled to the outer cable net. The outer shell connects with welded metal connections, mechanical connections, compression, tension, and so on. The outer cable net is supported by stasis or equilibrium, compression and tension, as this is a tensile structure. 
     The outer shell has an outer wall on each of the opposed lateral sides and the first end. Each outer wall has outer wall cables extending vertically to the outer perimeter frame and a plurality of outer wall transmissive panels coupled to the outer wall cables. This can involve mechanical connectors, held in place through tension. 
     The inner shell has an inner roof with an inner cable net supported by the inner perimeter frame  132  and a plurality of inner roof transmissive panels coupled to the inner cable net. The inner shell has an inner wall on each of the opposed lateral sides and the first end. Each inner wall has inner wall cables extending vertically to the inner perimeter frame  132  and a plurality of inner wall transmissive panels coupled to the inner wall cables. The support can be provided by mechanical connections that secure metal struts between the transmissive panels, held in stasis through compressive and tensile forces. 
     The structure  100  can have a post extending downwardly from the horizontal member  105 . The post can have a first end connected to the horizontal member  105  and a second end held under tension by cables connected to the main support  104 . Hydraulic and mechanical cable tensioners can be used to tension the cables. When all cables are tensioned as engineered the cables are “stayed” by fittings or turnbuckles to fix and retain the proper setting. 
     In some embodiments, each of the two vertical members  103  and the horizontal member  105  of the main support  104  comprises a tri-chord truss. 
     In some embodiments, the vertical supports  106  are bi-chord trusses. 
     In some embodiments, the perimeter frame  124  is bi-chord trusses. 
     In some embodiments, there can be a plurality of foam generators located between the outer shell and the inner shell. In some embodiments, the foam generators are located alongside the platform. 
     In some embodiments, the horizontal member  105  further comprises a platform for accommodating a person between the outer shell and the inner shell. 
     In some embodiments, the structure can have drainage collection members at bottom portions of outer sidewalls and a first end of an outer endwall. 
     In some embodiments, the drainage collection members are provided in a stem wall extending upwardly from the foundation on the east and west lateral sides and the first end of the structure  100 . 
     In some embodiments, the structure  100  can have tie-back cables, each tie-back cable having a first end attached to perimeter frame above one of the vertical supports, and a second end anchored outside the structure  100 . 
     In some embodiments, the structure  100  can have horizontal supports  112  connected between the vertical supports  106 . 
     The structure  100  can contain and integrate with different automated systems for growing plants. The structure  100  provides a flexible, sealed volume so that the structure  100  can accommodate different physical configurations for different automated systems. The automated systems can include production lines with conveyors and channels for plants and related matter. For example, the structure can integrate with the automated growing system as described in U.S. provisional patent application No. 62/891,562 the entire contents of which is hereby incorporated by reference. 
     The structure  100  can integrate with different automated systems including mechanical systems, fertigation systems, and control systems. 
     The structure  100  can integrate with different configurations of mechanical systems to actuate and control components of the growing systems. Mechanical systems can involve different mechanical and electrical devices such as Internet of Things (loT) devices to collect data within the structure and actuate based on control commands. The mechanical systems interface with other facility and operational systems and practices. 
     The structure  100  can integrate with different configurations of fertigation systems to actuate and control fertigation components of the growing systems. Fertigation systems can include fertigation delivery lines and loT devices that interface with other facility and operational systems and practices. The fertigation systems provide optimized fertigation nutrient mixes. 
     The structure  100  can integrate with different configurations of control systems and exchange of control commands for different components of the growing systems, including the mechanical systems and fertigation systems. Control systems can interface and integrate through loT devices, components of the structure, operational systems, and practices. 
     The structure  100  supports automated grow systems, which create the environmental (micro-climate) conditions and horticultural environment components that optimize the growing environment. The structure  100  supports the facility HVAC systems, which create the environmental (micro-climate) conditions and positive air pressure that optimized the growing environment. 
     The structure can help implement standard operational practices (SOPs). The SOPs can involve program code or instructions to direct or control complex operations within the structure  100 . The SOPs can provide performance criteria that together with the structure can generate a microclimate for different growing systems. SOPs can achieve efficiency, quality output and uniformity of performance, while reducing miscommunication and compliance failures. The SOPs can interface and integrate through loT devices, operational systems, and practices. 
     The structure  100  can be used for specialized methods of cultivation. 
     The structure  100  can be used for different plants. The structure  100 , automated growing systems, and SOP are configured for different agriculture crops, and nutraceutical or pharmaceutical plants. 
     It will be appreciated that numerous specific details are set forth in order to provide a thorough understanding of the exemplary embodiments described herein. However, it will be understood by those of ordinary skill in the art that the embodiments described herein may be practiced without these specific details. In other instances, well-known methods, procedures and components have not been described in detail so as not to obscure the embodiments described herein. Furthermore, this description is not to be considered as limiting the scope of the embodiments described herein in any way, but rather as merely describing implementation of the various example embodiments described herein. 
     The description provides many example embodiments of the inventive subject matter. Although each embodiment represents a single combination of inventive elements, the inventive subject matter is considered to include all possible combinations of the disclosed elements. Thus, if one embodiment comprises elements A, B and C, and a second embodiment comprises elements B and D, then the inventive subject matter is also considered to include other remaining combinations of A, B, C or D, even if not explicitly disclosed. 
     Although the embodiments have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As can be understood, the examples described above and illustrated are intended to be exemplary only. 
     As will be apparent to those skilled in the art in light of the foregoing disclosure, many alterations and modifications are possible to the methods and systems described herein. While a number of exemplary aspects and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions and sub-combinations thereof. It is therefore intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions and sub-combinations as may reasonably be inferred by one skilled in the art. The scope of the claims should not be limited by the embodiments set forth in the examples, but should be given the broadest interpretation consistent with the foregoing disclosure. 
     The present disclosure may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive.