Patent Publication Number: US-2021161091-A1

Title: Hydroponic grow assembly

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     The present application claims priority to U.S. Provisional application Ser. No. 62/942,571 filed Dec. 2, 2019 and entitled HYDROPONIC GROW ASSEMLY, the content of which is hereby incorporated by reference into the present application. 
    
    
     BACKGROUND 
     Hydroponic gardening or farming is becoming more popular. Hydroponics can be used to extend the growing season. The increased popularity of hydroponics has increased demand for flexible hydroponic growth assemblies that are easy to use and maintain. The present application addresses these and other issues or objectives. 
     SUMMARY 
     The present application relates to a hydroponic grow assembly including a base and at least one plant structure removably connectable to the base to form a plant wall for growing plants. The plant structure includes a plurality of plant wells opened to a root chamber and the base includes a bottom structure enclosed by a perimeter wall to form an inner cavity of a reservoir tank to supply water to the root chamber of the plant structure. The bottom structure of the base includes a support feature within the inner cavity of the reservoir tank to support the at least one plant structure in an upright position to form the plant wall. 
     In illustrated embodiments, the support feature is a raised support block formed on the bottom structure having a length and width sized to insert into an opened bottom end of the plant structure so that the plant structure fits over the raised support block to connect the plant structure to the base in the upright position. As shown, in illustrative embodiments the plant structure is formed of a U-shaped frame having an opened front side and at least one plant panel coupled to the opened front side to form the enclosed root chamber. The at least one plant panel includes a plurality of plant wells opened to the root chamber. In illustrative embodiments, the plant structure includes a plurality of plant panels slideably connected to the U-shaped frame through tongue and groove features to enclose the root chamber. As described, water flow is provided to the root chamber through an input at a top of the plant structure and is discharged through an opening at a bottom of the plant structure. 
     For use, in illustrative embodiments, the plant structure is inserted into the reservoir tank to engage the support feature to retain the plant structure in the upright position to form the plant wall. As described, in illustrative embodiments, the plant structure is formed of the U-shaped frame and at least one plant panel coupled to the U-shaped frame to form the plant structure. The U-shaped frame is inserted through a cover opening into the reservoir tank to engage the support feature and one or more plant panels are slideably connected to the U-shaped frame to form the enclosure for the root chamber. In particular, the U-shaped frame is fitted over a raised support block to retain the plant structure in the upright position. 
     The present application also discloses a hydroponic growth assembly include a clam shell structure formed of a plurality of base structures or reservoir tanks moveable between an opened position and a closed position. Plant structures are connected to the base structures to form the plant wall. In particular, the plant structures are connected to an outer perimeter of the base structure to form a perimeter grow wall enclosing a light fixture. In the illustrative embodiments, the base structures are pivotally connected to form a clam shell structure and multiple plant structures are connected to the bases to form the grow wall. The present application includes these and other features as described and shown in illustrative embodiments herein. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1A  is a perspective illustration of an embodiment of a hydroponic grow assembly shown in an opened position. 
         FIG. 1B  is a perspective illustration of an embodiment of a hydroponic grow assembly shown in a closed position. 
         FIG. 1C  is another perspective illustration of an embodiment of the hydroponic grow assembly shown in  FIGS. 1A-1B  having plants growing on a plant wall of the assembly. 
         FIG. 1D  is a perspective illustration of an embodiment of the hydroponic assembly shown in  FIGS. 1A-1B  with a light fixture shown in the opened position. 
         FIG. 1E  illustrates an embodiment of the light fixture for the grow assembly shown in  FIGS. 1A-1D . 
         FIG. 2A  illustrates an embodiment of base structures pivotally connected to form a clam shell construction having an opened position and closed position for a grow assembly of the present application. 
         FIG. 2B  illustrates an embodiment of reservoir tanks of base structures of the clam shell assembly shown in  FIG. 2A . 
         FIG. 2C  illustrates an embodiment of a cover configured to close the reservoir tanks of the base structures. 
         FIG. 2D  illustrates a back side of the reservoir tanks of  FIG. 2B . 
         FIG. 2E  is a top view of the base structures of the present application shown in the opened position with an access cover exploded. 
         FIG. 2F  illustrates another embodiment of the base structures for a hydroponic grow assembly of the present application. 
         FIGS. 3A-3B  illustrate an embodiment of a caster assembly for the base structures shown in a collapsed position in  FIG. 3A  and an expanded position in  FIG. 3B . 
         FIG. 3C  is a bottom view of the reservoir tank illustrating recessed tracks to interface with rails of the caster assembly shown in  FIGS. 3A-3B . 
         FIG. 3D  is a cross-sectional view as generally taken along line  3 D- 3 D of  FIG. 3C . 
         FIG. 3E  is a cross-sectional view as generally taken along line  3 E- 3 E of  FIG. 3C . 
         FIG. 4A  is a cut-away perspective illustration of the base structure illustrating a bottom structure of the reservoir tank. 
         FIG. 4B  is a top view of the reservoir tank illustrating the inner tank cavity and support feature. 
         FIG. 4C  illustrates a U-shaped frame of a plant structure of the present application. 
         FIG. 4D  is a cross-sectional view of the plant structure formed of the U-shaped frame of the present application. 
         FIG. 4E  illustrates an embodiment of a plant panel for the plant structure of  FIG. 4D . 
         FIG. 4F  is a side view of the plant panel show in  FIG. 4E . 
         FIG. 5A  is a cut-away perspective illustration of a reservoir tank showing a U-shaped frame of a plant structure supported on a raised support block or support feature on the bottom structure of the reservoir tank. 
         FIG. 5B  illustrates the plant structure fitted over the support block of  FIG. 5A . 
         FIG. 5C  is a cross-sectional view as taken generally along line  5 C of  FIG. 5A . 
         FIG. 5D  is a detailed view of a portion of an opening in the cover of the reservoir tanks for the plant structures. 
         FIG. 6A  is an exploded view illustrating a top portion of the frame, drip line and top cap of an illustrated embodiment of the plant structures and assembly of the present application. 
         FIG. 6B  is a perspective illustration of the plant structure shown in  FIG. 6A  with the top cap attached. 
         FIG. 6C  is a cross-sectional view of an embodiment of the plant structure shown with the top cap and drip line exploded. 
         FIG. 7  is a flow chart illustrating method steps of an embodiment of the present application. 
         FIGS. 8A-8B  illustrate another embodiment of a hydroponic grow assembly of the present application shown in an opened position in  FIG. 8A  and a closed position in  FIG. 8B . 
         FIG. 8C  illustrates an embodiment of a plant structure having connection interface to connect to base structures of the assembly shown in  FIGS. 8A-8B . 
         FIG. 8D  illustrates an embodiment of a drip line assembly for supplying water to root chambers of the plant structures shown in  FIG. 8C . 
         FIG. 8E  illustrates another embodiment of a plant structure of the present application. 
     
    
    
     DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS 
     The present application relates to a hydroponic grow assembly  100 , an embodiment of which is shown in  FIGS. 1A-1D . As shown, in  FIGS. 1A-1D , the assembly  100  includes a plurality of plant structures  102  coupled to base structures  104   a  and  104   b  to form a plant wall having a plurality of plant wells  108  for growing plants. The plurality of plant structures  102  include a front side  110  and a back side  112  spaced outwardly from the front side  110  to form inner and outer surfaces of the grow assembly  100 . The front sides  110  of the plurality of plant structures  102  include the plant wells  108  to form the plant wall for growing plants as shown in  FIG. 1C . As shown, a plurality of caster or roller wheels  115  are operably coupled to base structures  104   a ,  104   b  to move the base structures  104   a ,  104   b  between an opened position shown in  FIG. 1A  for planting and maintenance and a closed position as shown in  FIG. 1B  for growing plants. As shown in  FIG. 1B , in the closed position, the plant wall surrounds light fixture  120  which supplies light to the growing plants. 
     As shown in  FIG. 1D , the base structures  104   a ,  104   b  are connected through hinge  122  to form a clam shell structure movable between the opened position and the closed position and the plant structures  102  are connected to the base structures  104   a ,  104   b  to form the perimeter plant wall generally surrounding the light fixture  120 . As shown in  FIG. 1E , the light fixture  120  includes a plurality of lighting elements  124  to provide 360 degree lighting to the perimeter plant wall surrounding the light fixture  120 . As shown in detail in  FIG. 1E , the light fixture  120  includes a base  125 , and an upright post  126 . The plurality of lighting elements  124  are spaced about the upright post  126  for 360 degree lighting. Illustrative lighting elements  124  include incandescent bulbs, LED (light emitting diodes), metal halide, fluorescent bulbs, high pressure sodium vapor light elements as well as other lighting elements. Various control elements including a digital timer, temperature and humidity sensors, pump analytics and water level sensing devices can be incorporated into the light fixture  120 . As shown, each of the base portions  104   a ,  104   b  include a donut hole  128  to accommodate the light fixture  120  when the base portions  104   a ,  104   b  of the clam shell structure are closed for use and plant growth. 
     Water is supplied to the plurality of plant structures  102  via an irrigation line  130  as visible in  FIG. 1D  connected to drip lines  132  through a branch connection  134 .  FIGS. 2A-2E  illustrate an embodiment of base structures  104   a ,  104   b  which as shown include a bottom structure  142  and perimeter wall  144  enclosing a tank cavity  146  forming the reservoir tanks of the base structures  104   a ,  104   b . The tank cavity  146  is closed by cover  148  which fits over the perimeter wall  144  of the reservoir tank as shown in  FIGS. 2A-2C . In the embodiment shown, the cover  148  includes plant structure openings  150  spaced about an outer perimeter of the base structure  104   a ,  104   b  or reservoir tank for removably connecting the plant structures  102  to the base structures  104   a ,  104   b.    
     In the embodiment shown, the cover  148  includes four plant structure openings  150  for connection of four plant structures  102 , however, application is not limited to a particular number of plant structures  102 . The cover  148  also includes a plurality of access openings for access to the inner tank cavity  146  ( FIG. 2B ) of reservoir tanks. In the illustrated embodiment the access openings include an oval shaped opening  152  to accommodate a pump or other device as shown in  FIGS. 2A and 2C . The reservoir tanks can be filled with water through access openings or when the cover  148  is removed. The cover also includes an opening  154  for the irrigation line  130  and power cord to operate the pump (not shown). 
     The oval shaped access openings  152  are closed via port covers  156  to seal the reservoir tanks for use as shown in  FIG. 2E . In the embodiment shown, both the cover and reservoir tank include a concave indent  128   a ,  128   b  to form the donut hole  128  to accommodate the light fixture. As shown in  FIG. 2B , the reservoir tanks of the base structures  104   a ,  104   b  are fluidly connected via hose  160  to equalize the fluid in each reservoir tank as shown in  FIGS. 2D-2F . In particular, hose  160  is connected to the inner tank cavity  144  of base structures  104   a ,  104   b  using a fluid tight seal to allow water flow between tanks. Water flow between tanks is controlled via valve  162  along hose  160 . Use of the hose  160  allows for the use of one pump to pump water from both tanks through the irrigation line  130  via gravity feed. In alternate embodiment, water is pumped from each reservoir tank to the drip lines  132  through separate pumps in the separate reservoir tanks. While  FIG. 2A  shows oval access openings  150  for a pump or other device application not limited to a particular shape and the cover  148  can include different shaped access openings as shown in  FIG. 2F . 
     As previously described, the base structures  104   a ,  104   b  include caster wheels  115  to move the base structures  104   a ,  104   b  between the opened and closed positions. In an illustrated embodiment, the caster wheels  115  are coupled to the base structures  104 ,  104   b  through a caster assembly  170 . As shown, the caster assembly  170  includes a plurality of lengthwise rails  172  and crosswise rails  174 . Caster wheels  115  are coupled to opposed ends of the lengthwise rails  172  and coupled to an extended end of crosswise rails  174 . As shown, lengthwise rails  172  are pivotally connected via the hinge connection  122  coupled to the lengthwise rails  172  via brackets  175 . 
     The crosswise rails  174  are connected to the lengthwise rails  170  via a hinge connection  176  proximate to a midlength of the lengthwise rails  170  to provide a lateral or cross support for the reservoir tanks. As comparatively shown in  FIGS. 3A and 3B , the crosswise rails  174  pivot about the hinge connection  176  to collapse the caster assembly  170  for transport. As shown in  FIGS. 3C-3E , the base structures include lengthwise and crosswise tracks  180 ,  182  along the bottom structure  142  of the reservoir tanks sized for placement of the lengthwise and crosswise rails  170 ,  172  to support the reservoir tanks on the caster assembly  170  to open and close the base structures  104   a ,  104   b  of the clam shell assembly for use as comparatively shown in  FIGS. 1A-1B . As shown in  FIGS. 3A and 4A , the rails  172 ,  174  are formed of a hollow square beam structure to support the caster wheels  115  of the caster assembly  170 . The reservoir of the assembly of the present application includes the plurality of plant structure support features along the bottom structure  142  of the reservoir tank as shown in  FIG. 4A . 
     In the embodiment shown in  FIGS. 4A-4B , the support features on the bottom structure  142  include a plurality of raised support blocks  190  spaced about a perimeter of the tank cavity to support the plant structures  102  extending through openings  150  on the cover  148  to form the grow wall. As shown, the bottom structure  142  includes a raised ledge  192  and the blocks  190  are formed thereon In the illustrated embodiments shown in  FIGS. 3C, 4A, 4B , lengthwise and crosswise tracks  180 ,  182  and raised support blocks  190  are blow molded features on the bottom structure  146  of the reservoir tanks. 
     In an illustrative embodiment shown in  FIGS. 4C-4D , the plant structures  102  are formed of a U-shaped frame  200  having back and side walls  202 ,  204  and front plant panel  205  including the plant wells  108 . As shown in  FIG. 4D , the plant panels  205  are removably coupled to the U-shaped frame  200  to form the enclosed root chamber  206 . The plant panel  205  is connected to the U-shaped frame  200  through a tongue and groove connection. The plant wells  108  are formed on the plant panel  205  and have a well channel opened to the root chamber  206 . Water from the drip line  132  flows through the root chambers  206  to provide water flow to plant roots for plant growth. In the illustrated embodiment, the groove features are provided by elongate grooves  208  formed along sides  204  of the U-shaped frame  200  and the tongue feature is formed via sides of the panel  205 . In the illustrated embodiment, the height of the U-shaped frame  200  is sized to accommodate a plurality of plant panels  205  for the plant wall. 
     As shown in  FIG. 4E-4F , the panels  205  include stepped top and bottom edges  210 ,  212  to provide a fluid tight interface for multiple stack panels  205  connected to the U-shaped frames  200 . The plant panels  205  include the plant wells  108  opened to the root chamber  206  and trellis feature  214 . The plant wells  108  are sized to accommodate planting or custom clone collars. The plant panels also include a contact feature  218  that extends from a front surface of the panel  205  to retain alignment of the panels  205 . The features and plant structure can be formed of a molded plastic material and application is not limited to a particular fabrication process, method or construction. As described, the U-shaped frame  200  and plant panels  205  described provide a flexible modular design which can be stacked for shipping and storage. 
     As shown in  FIG. 5A , the U-shaped frame  200  extends through the plant structure openings  150  on the cover  148  and are supported relative to the raised support block  190  or support feature as described. In particular, as shown in  FIG. 5A , the support feature includes support blocks  190  formed on a perimeter ledge  192  of the bottom structure  142 . The blocks  190  have a length and width sized so that an opened bottom end of the U-shaped frame  200  fits over the support block  190  to connect the plant structures  102  to the base structures  104   a ,  104   b  or reservoir tank. As shown in  FIG. 8A , the support block  190  is spaced from the perimeter  144  of the base structure  104   a ,  104   b  to form a slot  220  for the back side or wall  202  of the U-shaped frame  200 . For use the U-shaped frame  200  is supported on the support block  190  and the contact feature  218  of the bottom plant panel  205  abuts cover  148  to retain the plant panel  205  above the reservoir tank. Water from the root chamber  206  is discharged from the bottom of the plant structure  102  into the reservoir tank and is recycled. In particular, as shown in  FIG. 5A , a length of the U-shaped frame  200  of the plant structures  102  extends below the cover  148  and is supported on block  190 . Support blocks  190  are sized and dimensioned to abut the back and side walls  202 ,  204  of the U-shaped frame  200  to retain and limit movement of the plant structure as shown in  FIG. 5B-5C . As shown in detail in  FIG. 5D  the plant structure openings  150  through cover include notched side portions  224  to accommodate the shape of the side walls of U-shaped frames and opposes grooves  208  formed therealong. 
     As previously described, water is supplied to the top of the root chamber  206  through irrigation line  130  and drip lines  132 . Water flows from the top of the root chamber  206  for discharge at the bottom of the root chamber  206 . As shown, the U-shaped frame  200  of the plant structures  102  includes a “cut-out”  230  forming a cradle for the drip line. The drip line is supported in the “cut-outs along the top of the plant structures and water drips into the root chambers through a plurality of drip openings in the drip line  132 . A top cap  232  with cut-outs  234  fits over the drip line  132  to cover the top of the root chamber  206  as shown in  FIGS. 6A-6C . A valve  239  at an end of the drip line allows for drainage following use. In the embodiment shown in  FIG. 6B , a back side of the panels  205  include a plurality of flow features to enhance fluid flow through the root chamber  206 . 
       FIG. 7  is a flow chart illustrating method steps of an embodiment of the present application. As shown in step  240 , U-shaped frames  200  of the plant structures  102  are inserted into tank cavity through openings  150  and an opened bottom end is placed over the support block  190  to connect the plant structure  102  (or U-shaped frame  200 ) to the support feature as shown in step  242 . Steps  240 ,  242  are repeated for each of the plant structures  102  as shown in step  244 . As shown in step  246 , plant panels  205  are connected to the U-shaped frames  200 . The panels are connected by sliding the sides through the grooves  208  along the sides of the U-shaped frames  200 . Step  246  is repeated to insert a plurality of plant panels  205  into each of the U-shaped frames  200  to form the plant wall as shown in step  248 . In step  250 , the drip line  132  is connected to the irrigation line and the drip line is installed over the top of the root chambers of the plant structures  102  to provide water flow to the root chambers  206 . In step  252 , top caps  232  are fitted over the opened top of the root chambers  206  and drip line to close the root chambers  206 . The tongue and groove and support features (or block  190 ) allow for assembly of the plant structures  102  to the base structures  104   a ,  104   b  or reservoir tanks without various fasteners or other devices to retain the plant structures  102  in the upright position for use. 
       FIGS. 8A-8B  illustrates another embodiment of a grow assembly  100  including plant structures connectable to base structures  104   a ,  104   b . As shown in  FIG. 8A-8C , the plant structures include front, back and side walls  270 ,  272 ,  274  enclosing root chambers of the plant structures  102  similar, to the previous embodiment. The front wall  270  forms the front  110  of the plant structures  102  and includes the plant wells  108  spaced between the top and bottom of the plant structure  102 . The plant wells  108  as shown extend through the front wall  200  and are opened to the root chamber. Water flows through the root chamber  206  and is discharged into the the reservoir tank formed in the base structures  104   a ,  104   b . In the illustrated embodiment the irrigation line  130  is coupled to a drip line assembly including top caps  232  with an integrated drip line that snap fits onto tops of the plant structures  102  as shown in  FIG. 8D . 
     Water from the drip line is discharged back into the reservoir tank to provide a closed water system as previously described. As shown, the light fixture  120  includes a base  125  and a plurality of lighting stages  280  coupled to the base  125  at different height elevations. Lighting elements  124  are coupled to the stages  260  to provide light at the different height elevations. In the embodiment shown in  FIG. 8A , the light fixture  120  includes three stages  280  to provide light to the plants on the perimeter plant wall formed via the plant structures  102 . 
     The plant structures  102  are connected to the base structures  104   a ,  104   b  via a connection interface or interface structure  284  at the bottom of the plant structures  102  as shown in  FIG. 8C  which snap fits into openings  150  on the cover for example openings  150  shown in the  FIG. 2F . As shown in  FIG. 8A  various fasteners, such as an L shaped bracket  264  can be used to secure the plant structures  102  to the cover  148  or base structures  104   a ,  104   b  for use or a hinged connection is used to connect adjacent plant structures  102  to one another. Multiple plant structures  102  can be stacked depending upon the desired plant wall height via interface structures  284  inserted into opened top ends of the plant structures as shown in  FIGS. 8A-8B .  FIG. 8E  illustrates another embodiment of a plant structure  102  including an interface structure  254  to connect to the base structure. As shown, the plant structure of  FIG. 8E  incorporates a U-shaped frame  200  and plurality of plant panels  205  similar, to embodiments previously described and a top end is covered via cap  232 . As will be appreciated by those skilled in art, alternate embodiment can incorporate one or more of the features or structures described. 
     While the present application discloses illustrative embodiments, application is not limited to the specific embodiments disclosed and changes and modifications can be made as will be appreciated by those skilled in the art.