Patent Publication Number: US-2021161088-A1

Title: Vertical hydroponic tower array fixture system

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of and priority to U.S. application Ser. No. 15/522,069, filed on Apr. 26, 2017, which claims priority to PCT Application No. PCT/US2015/060085, filed Nov. 11, 2015, which claims priority to U.S. Provisional Application No. 62/081,733 filed Nov. 19, 2014, the entire contents of all of these applications are incorporated herein by reference for all purposes. 
    
    
     BACKGROUND 
     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. 
     SUMMARY 
     An embodiment of the present disclosure comprises a hydroponic tower array fixture system comprising: two or more hollow hydroponic towers, wherein each hollow hydroponic towers has a front, an open first end, and an open second end; a slot formed in the front of each hydroponic tower, the slot having a width equal to only a portion of a width of the front of the hydronic tower; and a media material insertable into each hollow hydroponic tower; an upper bracket, wherein at least two upper bracket openings are formed in the bottom surface of the upper bracket substantially corresponding to shape and width of the two or more hydroponic towers; and a lower bracket, wherein at least two lower bracket openings are formed in the bottom surface of the lower bracket substantially corresponding to shape and width of the two or more hydroponic towers; wherein the first end of at least one of the two or more hollow hydroponic towers is inserted into one of the at least two upper bracket openings of the upper bracket; and wherein the second end of the hollow hydroponic tower is inserted into one of the at least two lower bracket openings of the lower bracket. 
     Another embodiment may comprise a method for producing organisms on a hydroponic tower array fixture system, the method comprising: providing two or more hollow hydroponic towers, wherein said two or more hollow hydroponic towers have a front surface, an open first end, and an open second end; providing a slot formed in the front surface of each hydroponic tower; providing a media material; inserting said media material into each hollow hydroponic tower; providing an upper bracket, wherein at least two upper bracket openings are formed in the bottom surface of the upper bracket substantially corresponding to shape and width of the two or more hydroponic towers; and providing a lower bracket, wherein at least two lower bracket openings are formed in the bottom surface of the lower bracket substantially corresponding to shape and width of the two or more hydroponic towers; inserting the first end of at least one of the two or more hollow hydroponic towers into one of the at least two upper bracket openings of the upper bracket; and inserting the second end of the hollow hydroponic tower into one of the at least two lower bracket openings of the lower bracket; inserting one or more organisms into the medial material through the slot formed in the front surface of each hydroponic tower; and growing one or more organisms on said media material. 
     The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tools and methods, which are meant to be exemplary and illustrative, not limiting in scope. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
       The accompanying figures, which are incorporated herein and form a part of the specification, illustrate some, but not the only or exclusive, example embodiments and/or features. It is intended that the embodiments and figures disclosed herein are to be considered illustrative rather than limiting. 
         FIG. 1  is a perspective view illustrating an example of the front of a hydroponic tower array fixture system. 
         FIG. 2  is a close-up view illustrating an example of a hydroponic tower of the modular hydroponic tower array fixture system. 
         FIG. 3 a    is a perspective view illustrating an example of the lower bracket of the modular hydroponic tower array fixture system. 
         FIG. 3 b    is a perspective view illustrating an example of the cross piece isolated from lower bracket of the modular hydroponic tower array fixture system. 
         FIG. 4  is a perspective view illustrating an example of the upper bracket of the modular hydroponic tower array fixture system. 
         FIG. 5  is a close-up view illustrating an example of the upper bracket in association with a means of irrigation. 
         FIG. 6  is a close-up view illustrating an example of the lower bracket in association with a reservoir. 
         FIG. 7  is a perspective view illustrating an example of the modular hydroponic tower array fixture system coupled to a walled structure. 
         FIG. 8  provides a flow diagram for producing organisms on a modular hydroponic tower array fixture system. 
     
    
    
     DETAILED DESCRIPTION 
     Embodiments of the present disclosure include various apparatus, systems and methods for the germination, growth and/or harvesting of organisms, including but not limited to, various forms of plants (including but not limited to pteridophytes, gymnosperms and angiosperms, such as annual and perennial ornamental plants, vegetables, including leafy greens, brassicas, tomatoes) and fungi (including but not limited to basidiomycetes and ascomycetes) in hydroponic towers modularly coupled in an array to allow for individual hydroponic towers to be removed from the array as necessary. The apparatus and system allows for an array of two or more hydroponic towers to be attached to vertical surfaces, including, but not limited to, internal and external walls of structures such as houses, offices, warehouses and outbuildings. 
     The system described herein allows for hydroponic towers to be placed in the array and easily removed by the user, making this a user friendly means of organizing and attaching towers to structures while simultaneously irrigating and collecting effluent from the towers using integrated irrigation and collection systems. 
       FIG. 1  provides a front perspective view of an example modular hydroponic tower array system of the present disclosure  100 . As shown in  FIG. 1 , the modular hydroponic tower array system comprises two or more hydroponic towers  102 , at least one upper bracket  104 ; at least one lower bracket  106 ; a reservoir  108  and a means of irrigation  110  to transport water and nutrients from the reservoir  108  to the top of the two of more hydroponic towers  102 . 
     As will be discussed and shown in further detail in  FIG. 2 , each hydroponic tower  102  is a hollow, elongated structure with a slot  112  formed lengthwise from the first end  114  of the hydroponic tower  102  to the second end  116  the hydroponic tower  102  along the front of the tower  102 . Each tower  102  may be constructed of metal such as steel or aluminum, or other materials such as but not limited wood, synthetic polymers such as nylon, plastics, such as high density polyethylene ‘HDPE’ or concrete. In the example system  100  shown in  FIG. 1 , eight (8) hydroponic towers  102  are illustrated but any number of two or more hydroponic towers  102  can be used in the system. Therefore, while this descriptive example has eight hydroponic towers  102 , it should be understood that this description is applicable to any such system with other numbers of hydroponic towers, as will be understood by one skilled in the art, once they understand the principles of this system. 
     As further shown in  FIG. 1 , an embodiment of the modular hydroponic tower array  100  consists of an upper bracket  104  and lower bracket  106 . As will be discussed in further detail in relation to  FIG. 4 , the upper bracket  104  is a hollow, elongated structure and comprises openings (not shown in  FIG. 1 ) cut along lower surface of the upper bracket  104 , cut slightly larger than the cross sectional dimensions and shape of the corresponding hydroponic tower  102 , allowing the upper bracket  104  to slip over the top of the hydroponic tower  102 . 
     As will be discussed in further detail in  FIG. 3 a   , the lower bracket  106  also is a hollow, elongated structure and comprises openings, cut along upper surface of the lower bracket  106 , oppositely disposed to the openings of the upper bracket  104  when the two brackets are aligned. In an embodiment, each end of the lower bracket  106  may be fitted with a cap  118 , where a drain fitting (not shown in  FIG. 1 ) is operably coupled to the cap  118  to allow excess effluent, such as water and/or nutrients, to drain away from the lower bracket  106 . The lower bracket  106  functions as a gutter system when a drain fitting is installed, allowing effluent such as water and nutrient solutions to be collected and drained away. 
     As shown in  FIG. 1 , a reservoir  108  is provided to capture and store excess water or nutrients that runs through the hydroponic towers  102  and through the lower bracket  106 . A means of irrigation  110 , such as a pump operably coupled to a pipe, hose or other conduit which is capable of delivering water and nutrient solutions (such as but not limited to solutions containing nitrogen, phosphorus, potassium, iron, magnesium and zinc), is also shown in  FIG. 1  The means of irrigation  110  allows water and/or nutrient solutions to be transported from the reservoir  108  to the first end  114  of the hydroponic towers  102 , by running the means of irrigation  110 , such as a pipe along the top of the hydroponic towers  102 . The water or nutrient solution may be emitted from the means of irrigation  110  to the first end of the hydroponic towers  102  by a variety of emitters, including but not limited to drip emitters, sprinklers and micro-spray emitters. 
     In an embodiment, a pump moves water and/or nutrient solutions through the means of irrigation  110  from the reservoir  108  to the top or first end of the hydroponic towers  102 , distributing a nutrient solution into media material (not shown in  FIG. 1 ) inserted in the grow chamber. The water and/or nutrient solution is allowed to drip down through the media and the roots of the plants or fungi growing in the media. Some of the nutrient solution trickles down the walls of the hydroponic towers  102  and is captured by roots or hyphae in contact with the walls of the towers  102 . Excess nutrient solution drains to the bottom of the hollow grow chamber of the tower  102  where it is drained into the lower bracket  106  and subsequently drains into the reservoir  108 . 
     As will be discussed in  FIG. 5 , the means of irrigation  110  can be easily hidden in the upper bracket  104  by attaching irrigation lines to the top of the upper bracket  104 , with emitters allowing water to drip down onto the tops of the inserted towers  102 . 
     In another embodiment, water or excess solution in the reservoir  108  may be pumped to a storage tank (not shown in  FIG. 1 ). The storage tank may hold/store the water and nutrient solutions for future use in the hydroponic tower array system  100 . 
       FIG. 2  provides a close-up view of a single hydroponic tower  102 . As shown in  FIG. 2 , the hydroponic tower  102  is comprised of a front, with an open top portion and an open bottom portion. The hollow shape of the hydroponic tower  102  creates a grow chamber  202  in the hollow cavity of the hydroponic tower  102  where media material is inserted to provide a stable surface/platform on which an organism such as a plant or mushroom is able to establish roots or rhizomes and grow. While the shape of the elongated hydroponic towers  102  shown in  FIG. 1  and  FIG. 2  are substantially square or rectangular, as will be understood by one skilled in the art, a variety of shapes may be used to create the hydroponic shown and growth chambers described herein, including but not limited to substantially square, rectangular, round, oval, octagon, pentagon and triangular. 
     As further shown in  FIG. 2 , the hydroponic tower  102  has a slot  112  formed lengthwise along the front of the tower  102 . The slot  112  also allows for the easy insertion of organisms such as plants and fungi into the media along the length of the structure and to grow out of media that is inserted into the growth chamber  202 . 
     The media material of the present disclosure maybe be a single piece of media composed of a variety of materials including plastic, such a polyester matrix material cut to a diameter that allows for easy insertion of the material into the grow chamber  202  of each hydroponic tower  102 . In another embodiment, the media material may be coated in a silicone binder. In one embodiment, the single piece of media material may be cut into strips the width of the diameter of the grow chamber  202 . The individual strips of media material may then be folded and pulled into this grow chamber  202  at the top of the grow chamber  202  of each hydroponic tower  102 , with seedlings or fungi sandwiched in the fold between the two halves of the media material and corresponding to the location of the slot  112  running the length of the face of the hydroponic towers  102 . As the media is pulled into the grow chamber  202 , more seedlings are added, and as the media enters the grow chamber  202 , the shoots of the seedlings extend out horizontally and travel down this slot  112 . Multiple media inserts may be added to the grow chamber  202 , until the media encompasses the entire length of the grow chamber  202 . 
     A variety of media material may be used with the system of the present disclosure. Examples of media that may be used in the system of the present disclosure may include but is not limited to, a fibrous, non-woven matrix media material, granular materials, Styrofoam, polyurethane foam, plastic mesh, rock wool, coconut fiber, vermiculite, as well as organic soil such as potting soil. 
     In an embodiment of the present disclosure, the media material of the present disclosure may be altered in several ways to serve a diverse range of functions. The media may 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 grow chamber  202 . This alteration allows compost based hydroponic growth using regular irrigation water, with plant or fungal nutrients supplied by the compost or other additive. Tops, sides, and corners of the media material can also be cut, rounded, or cut at an angle to reduce biosolids accumulation, algal growth, or to enhance water distribution through the media, depending on application. Multiple inserts can also be used in the grow chambers  202  allowing multiple age groups of plants and fungi to incorporate into each grow chamber  202 . Worms are also commonly integrated into the grow chambers and the media is designed to have the correct mesh size to accommodate their movement through the media, although media with a smaller or larger mesh size may be used depending on application. 
     Plants, seedlings or fungal tissue are placed between the two halves of media in each grow chamber  202  of the system, with the upper portions of the plant or organism protruding through the slot  112  of each hydroponic tower  102 . 
     In a further embodiment, the media material is folded in half, a pulling hook with a flat hook attached to a handle allows the media inserts to be pulled into and out of the grow chamber  202  by means of the slot  112 , with the pulling hook handle extending from the slot  112  in the grow chamber  202  of each hydroponic tower  102 . In a further embodiment, the hook can also be attached to a pneumatic or hydraulic device that allows automated “pulling” of the media inserts. 
       FIG. 3 a    provides a perspective view of the lower bracket  106  of the hydroponic array system. As shown in  FIG. 3 a   , the lower bracket  106  is an elongated hollow structure with lower bracket openings  302  cut along the upper surface of the lower bracket  106 , of the same shape and slightly larger than the cross section dimensions of the hydroponic tower  102  where the shape may include but is not limited to, substantially square, rectangular, round, oval, octagon, pentagon and triangular. In embodiment of the present disclosure, inside the lower bracket  106  is placed a cross piece  304  that runs down the length of the lower bracket  106 . 
       FIG. 3 b    provides a perspective view of the cross piece  304 , isolated from the lower bracket  106 . As shown in  FIG. 3 b   , the cross piece  304  typically consists of a section of pipe  306  substantially equal in length to the lower bracket  106 , inserted through support pieces, called bowties  308  that hold the pipe  306  up off of the bottom of the lower bracket  106  at a specific height, where an example elevated height may be three inches. The cross piece  304  may be made of metal such as aluminum or steel as well as plastic or wood and allows each hydroponic tower  102  to rest on the pipe  306  and hold securely on the cross piece  304 , when the hydroponic tower  102  is inserted into a corresponding lower bracket opening  302  in the lower bracket  106 . This allows each hydroponic tower  102  to remain elevated above the bottom of the lower bracket  106 , allowing water and nutrients to easily drain out of each hydroponic tower  102  and into the lower bracket  106  where the water or nutrient solution is able to travel and drain into the reservoir  108 . 
       FIG. 4  provides a perspective view of the upper bracket  104  as isolated from the hydroponic tower array system. As previously discussed in relation to  FIG. 1  and shown in  FIG. 4 , the upper bracket  104  is an elongated hollow structure with upper bracket openings  402  cut along the lower surface of the upper bracket  104 , of the same shape and slightly larger than the cross section dimensions of the hydroponic tower  102  where the shape may include but is not limited to, substantially square, rectangular, round, oval, octagon, pentagon and triangular. 
       FIG. 5  provides a close-up view illustrating an example of the upper bracket  104  in association with a means of irrigation,  500 . As shown in  FIG. 5 , a means of irrigation  110 , which is capable of transporting and delivering water and nutrient solutions, is run from the reservoir  108  to the top of the first end  114  of the hydroponic towers  102 . The means of irrigation  110  may be operably coupled, such as by a hangers or clips (not shown in  FIG. 5 ) to the upper bracket  104  allowing the means of irrigation  110  to remain elevated above the first end  114  of the hydroponic towers  102 . Water or nutrients are pumped through the means of irrigation  110  from the reservoir  108  to the top of the hydroponic towers  102 . The water or nutrient solution may then be emitted from the means of irrigation  110  by a variety of emitters  502 , including drip emitters, sprinklers and micro-spray emitters through the upper bracket openings  402  in the bottom of the upper bracket  104  into media material inserted in the grow chamber  202 . The water and nutrient solution is then allowed to drip down through the media and the roots of the plants growing in the media. 
       FIG. 6  provides a close-up view illustrating an example of the lower bracket in association with a reservoir  600 . As shown in  FIG. 6 , the second end  116  of each hydroponic tower  102  is placed in the lower bracket opening  302  located in the top portion of the lower bracket  106 . Each hydroponic tower  102  rests on the cross piece  304  running the length of the lower bracket  106 , allowing each hydroponic tower  102  to be held securely on the cross piece  304 . 
     As further shown in  FIG. 6 , each hydroponic tower  102  remains elevated above the bottom of the lower bracket  106 , allowing water and nutrients to easily drain out of each hydroponic tower  102  and into the lower bracket  106  where the water or nutrient solution is able to travel and drain into the reservoir  108 . 
       FIG. 7  is a perspective view illustrating an example of the modular hydroponic tower array fixture system coupled to a walled structure,  700 . As shown in  FIG. 7 , in an embodiment the hydroponic tower array fixture system described herein may be mounted or coupled to a walled structure. In this embodiment the lower bracket  106  is operably coupled to the wall of a structure such as an internal wall or an external wall. A variety of methods are available to operably couple the lower bracket  106  to the wall, which are known in the art, including but not limited to, operably coupling each lower bracket  106  to the outer wall by bolting the lower bracket  106  to the wall. The upper bracket  104  may then be operably coupled to the wall or supported against the wall using the same or similar methods that were used to operably couple the lower bracket  106  to the wall. 
     Additional methods for attaching or mounting the system to a structure may include but is not limited to, pins that snapped into place on the structure, clips, including z-clips, and architectural anchors as well as various forms of adhesives depending on the building code and the expected use. 
     Each hydroponic tower  102  is then inserted into the system by inserting the first end  114  of the first hydroponic tower  102  into the opening in the upper bracket  104 . The second end  116  of the hydroponic tower  102  is then swung inward and placed in the corresponding opening in the lower bracket  106 . The bottom of the hydroponic tower  102  comes to rest and is situated on the cross piece running the length of the lower bracket  106 . 
     To remove an individual hydroponic tower  102 , the second end  116  of the hydroponic tower  102  is lifted vertically until the second end  116  is clear of the lower bracket  106 . The second end  116  of the hydroponic tower  102  is then swung outward and lowered, allowing the first end  114  of the hydroponic tower  102  to drop out of and release from the upper bracket  104 . In this way, individual hydroponic towers  102  can be quickly and easily placed in the modular hydroponic array system  100  and removed from the system  100 . 
     The system described herein may also be supported by a variety of other means without the need of coupling the system to a walled structure. These may include various types of stands and braces, which will be understood by one skilled in the art. 
       FIG. 8  provides a flow diagram for producing organisms in a hydroponic tower array fixture system  800 . In step  802 , a single piece or strips of media material is placed or inserted into the hollow grow chamber of each hydroponic tower, where the hydroponic tower is comprised of a surface with a slot running the length of the surface, with an open first end and an open second end. In step  804 , the open first end of the hydroponic tower is inserted into an upper bracket with openings in the bottom surface of the upper bracket substantially corresponding to the diameter and shape of each hydroponic tower. The second end of each hydroponic tower is then inserted into a lower bracket, which also has openings cut into the top surface of the upper bracket substantially corresponding to the width and shape of each hydroponic tower. Each hydroponic tower rests and is secured on top of a cross piece internally running the length of the lower bracket. In step  806 , one or more plants or fungi are inserted into the media material, through the slot running the length of the front surface of each hydroponic tower. In step  808 , the plants or fungi in the media material are then grown and may be harvested as desired. Water and nutrients may be pumped to the top of each hydroponic tower and emitted into the media material and allowed to drip down through the media where the plants may update the nutrients as needed. Any remaining nutrients may then be collected in the lower bracket and then drained into a reservoir located at the base of the hydroponic tower array fixture system, where the nutrients may then be recycled back to the plants or fungi. 
     The hydroponic tower array fixture system offers the ability for users to quickly remove a single hydroponic tower from the system as needed, such a removing mature plants for harvesting or removing dead plants while also allowing the user to quickly and easily identify, isolate and remove pests or disease from the system without damaging other plants located in other hydroponic towers 
     The foregoing description of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and other modifications and variations may be possible in light of the above teachings. The embodiment was chosen and described in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention in various embodiments and various modifications as are suited to the particular use contemplated. It is intended that the appended claims be construed to include other alternative embodiments of the invention except insofar as limited by the prior art.