Patent Publication Number: US-2019166778-A1

Title: Hydroponic Growing System, Planting Tower and Method

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application does not claim priority from any other application. 
     TECHNICAL FIELD 
     This disclosure pertains to planting containers and techniques for growing plants. More particularly, this disclosure relates to improved systems, apparatus and methods for growing plants by watering and fertilizing the plants, and for stacking, interlocking, and supporting plating tower components. 
     BACKGROUND OF THE DISCLOSURE 
     Techniques are known for growing plants in planting containers stacked vertically and having an irrigation system for delivering water and fertilizer to the plants. However, improvements are needed in the manner and direction in which water and fertilizer are delivered to a stack of growing pods containing plants in a planting tower and in the manner in which such towers are constructed and assembled. Further improvements are needed in the manner in which plating tower components are stacked, interlocked, and supported. 
     While the subject matter of this application was motivated in addressing hydroponic growing systems and methods, it is in no way so limited. The disclosure is only limited by the accompanying claims as literally worded, without interpretative or other limiting reference to the specification, and in accordance with the doctrine of equivalents. 
     Other aspects and implementations are contemplated. 
     SUMMARY OF THE INVENTION 
     A plant growing system and method are provided using vertically nested growing pods that each include a pot and having stacking and interlocking structures and base supports. Such system and method further includes unique water distribution and delivery features for recirculating water and fertilizer in a closed loop system. 
     According to one aspect, a hydroponic growing system is provided having a growing pot and a root distribution plate. The growing pot has a wall portion defining an elevationally-extending concavity. The root distribution plate has an outer periphery configured to be fitted in substantially level conformity within the concavity at a position elevated from a bottommost portion of the concavity and an array of raised root barriers subdividing a top surface of the root distribution plate into a plurality of distinct root beds. 
     According to another aspect, a planting tower is provided having a growing pot, a root distribution plate, and a water distribution plate. The growing pot has a wall portion defining an elevationally-extending concavity; the root distribution plate has an outer periphery configured to be fitted in substantial horizontal conformity within the concavity at a position elevated from a bottommost portion of the concavity and an array of raised root barriers subdividing a top surface of the root distribution plate into a plurality of distinct root beds. The water distribution plate is carried beneath the root distribution plate and has a downwardly sloped radially outwardly extending water distribution surface terminating in a plurality of discharge apertures proximate a net pot containing a rooted plant. 
     According to yet another aspect, a method is provided for growing potted plants. The method includes: providing a planting pot with a vertical cavity, a laterally spaced apart array of adjacent growing pots elevated in the cavity each containing a plant, a root distribution plate substantially level beneath the growing pots having subdivided adjacent pocket regions each beneath one of the growing pots separated by an array of upstanding ribs, and a water distribution plate having a sloped outwardly descending surface spaced below the root distribution plate; supplying water and fertilizer to each growing pot; dropping the water and fertilizer through and down from each growing pot onto the root distribution plate; downwardly withdrawing the fertilizer and water centrally of the root distribution plate downwardly onto the water distribution plate; and accelerating the water and fertilizer outwardly from atop the water distribution plate toward an ejection aperture for delivery to a net pot provided outwardly of the aperture. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Exemplary embodiments of the various disclosures are described below with reference to the following accompanying drawings. The drawings may be considered to represent scale. 
         FIG. 1  is a perspective view from above of a hydroponic growing system in the form of a planting tower containing plants, according to one aspect. 
         FIG. 2  is from above of the planting tower of  FIG. 1  without plants. 
         FIG. 3  is a front view of the planting tower of  FIGS. 1-2 . 
         FIG. 4  is a plan view from above of the planting tower of  FIGS. 1-3 . 
         FIG. 5  is a plan view from below of the planting tower of  FIGS. 1-4 . 
         FIG. 6  is a vertical centerline sectional view of the planting tower of  FIGS. 1-5  taken along line  6 - 6  of  FIG. 4 . 
         FIG. 7  is a partial vertical sectional view taken from within the encircled region  7  of  FIG. 6 . 
         FIG. 8  is a partial vertical sectional view taken from within the encircled region  8  of  FIG. 6 . 
         FIG. 9  is a partial vertical sectional view taken from within the encircled region  9  of  FIG. 6 . 
         FIG. 10  is a partial vertical sectional view taken from within the encircled region  10  of  FIG. 6 . 
         FIG. 11  is a partial vertical sectional view taken from within encircled region  11  of  FIG. 6 . 
         FIG. 12  is a partial vertical sectional view taken from within encircled region  12  of  FIG. 6 . 
         FIG. 13  is a partial vertical sectional view taken from within encircled region  13  of  FIG. 6 . 
         FIG. 14  is a perspective view from above of a cover for a growing pod. 
         FIG. 15  is a perspective view from below of the cover of  FIG. 14 . 
         FIG. 16  is a perspective view from above of a cover for a reservoir tank as shown in the planting tower of  FIGS. 1-3 and 6 . 
         FIG. 17  is perspective view from below of the cover of  FIG. 16 . 
         FIG. 18  is a perspective view from above of a growing pod base as shown in the planting tower of  FIGS. 1-3 and 6 . 
         FIG. 19  is a perspective view from below of a growing pod base as shown in  FIG. 18 . 
         FIG. 20  is a perspective view from above of a root distribution plate used in the planting tower of  FIGS. 1-3 and 6 . 
         FIG. 21  is a plan view from above of the root distribution plate of  FIG. 20 . 
         FIG. 22  is an exploded perspective view from above of reservoir tank and growing pod components for the planting tower of  FIGS. 1-3 and 6 . 
         FIG. 23  is a vertical centerline sectional view taken along the same cutting line as  FIG. 6 . 
         FIG. 24  is a perspective view from above of a hydroponic growing system in the form of a pair, or row of planting towers containing plants, according to another aspect. 
         FIG. 25  is a vertical centerline sectional view taken of the planting tower of  FIG. 24  along line  25 - 25  of  FIG. 24 . 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
     This disclosure is submitted in furtherance of the constitutional purposes of the U.S. Patent Laws “to promote the progress of science and useful arts” (Article 1, Section 8). 
     The terms “a”, “an”, and “the” as used in the claims herein are used in conformance with long-standing claim drafting practice and not in a limiting way. Unless specifically set forth herein, the terms “a”, “an”, and “the” are not limited to one of such elements, but instead mean “at least one”. 
       FIG. 1  illustrates one construction for a hydroponic growing system  10  in the form of a planting tower  12  having a vertical stack of interlocking growing pods, or growing containers  16  affixed atop a reservoir tank  24  holding a closed-loop supply of water and nutrients for irrigating plants  14 . A circumferential array of spaced apart net pots  18  are affixed atop cover  26  and covers  20  for reservoir tank  24  and growing pods  16 , respectively, as shown in  FIGS. 1-4 . A plug of bituminous material and a seed are loaded into each net pot  18 , as shown in  FIG. 1 . Base  28  of reservoir tank  24  contains water and fertilizer which is pumped from tank  24  up through the center of the stack of growing pods  16  to the topmost growing pod  16 , where such water and fertilizer takes a circuitous path via gravity feed downwardly through a base  22  of each growing pod  16 . A cover  32  is received over top opening  30  in the top-most growing pod  16 , as shown in  FIGS. 1 and 2 . 
     As shown in  FIG. 2 , a pair of trapezoidal-shaped access ports  38  and  40  are provided through cover  26  of reservoir tank  24  on planting tower  12  of system  10  to provide access for replenishing water and fertilizer, or doing internal maintenance and cleaning. A pair of complementary snap-fit covers  42  and  44  close off ports  38  and  40  when not in use. Likewise, top cover  32  cooperates with covers  42  and  44  to minimize evaporative loses from inside tower  12  and to prevent intrusion of foreign matter. 
     Planting bases  22  of planting pods  16  for system  10  are locked together in assembly atop cover  26  of reservoir tank  24 , while cover  26  is affixed atop base  28 , as shown in  FIG. 3 . Further details are provided below with reference to  FIGS. 6, 8 and 9 . A resulting circumferential array of net pots  18  are distributed about growing pod  16  along cover  26 , as shown in  FIG. 4 . Base  28  supports the tower along a bottom portion, as shown in  FIG. 5 . 
       FIG. 6 , along with portions depicted in  FIGS. 7-13 , show in cross section the construction details of planting tower  12  for system  10 . A vertical stack of six growing pods  16  are affixed together in interlocking relation atop reservoir tank  24 . Water and fertilizer (not shown) are delivered in a solution from within reservoir tank  24  via a water pump  36  (see  FIG. 23 ) upwardly via a plastic supply tube  34  where it is released beneath a cap, or cover  32  of the topmost growing pod  16 . Pump  36  is omitted to show a cylindrical flat dimple  46  provided in a bottom surface of tank  24 . A complementary male dimple (not shown) is provided on a bottom surface of pump  36  centered within an array of inner surface reinforcing ribs  48  integrally molded in tank  24  to provide lateral stability to the pump and the supply tube. Water and fertilizer moves downwardly through the hydroponic planting tower  12  via gravity to feed each net pot  18  in a very specific cascading pattern, shown below in greater detail with reference to  FIG. 23 . In operation, a timer is placed on the water pump to run the pump for selected, timed periods, after which the root systems of each plant are gravity drained and left free of water and fertilizer so as to mitigate risk of root rot. 
     As shown in  FIG. 7 , supply tube  34  ejects a solution of pumped water and fertilizer beneath cap  32  of topmost growing pod  16 . A water distribution tray  21  is affixed to cover  20  with fingers  57  (see  FIGS. 7 and 22 ) interlocking in assembly with pockets  59  in cover  20  (see  FIGS. 16 and 17 ). Tray  21  provides a recess having a frustoconical, outwardly and downwardly sloped water distribution plate  56  providing a bottom surface encircled by a circumferential sidewall  54  in which fingers  57  are integrally molded. Such construction of snap-fit tray  21  enables use of a single cover  20  throughout planting tower  12 . Tube  34  extends upwardly through a cylindrical aperture  58  and a washer  50  which impedes water transmission between tube  34  and an inner diameter of washer  50  via aperture  58 . A circumferential array of vertical slots, or passages  60  are positioned to deliver water and fertilizer in a radially outwardly extending direction down along a flat and horizontal water distribution plate  56  where the water and fertilizer passes through a circumferential array of slits, or passages  62  in each net pot  18 . Water drips through a bituminous plug containing a plant in net pot  18  and drops vertically onto a root distribution plate  64 . A solution of water and fertilizer is collected atop plate  64  in a subdivided grid pattern of arctuate segments, or sectors  81 ,  83 ,  85 ,  87  and  89  (see  FIGS. 20 and 21 ) and flows radially inwardly through an arcuate drainage slot  100  where it is withdrawn downwardly through a cylindrical aperture  68  (see  FIG. 7 ), as shown below in greater detail with reference to  FIGS. 20 and 21 . Individual sectors  81 ,  83 ,  85 ,  87  and  89  (see  FIGS. 20 and 21 ) on the root plate  64  are defined by upstanding ribs  99  and cylindrical outer rib  98  and include the topmost horizontal surface of the root plate  64  between the upstanding ribs  98  and  99 . Each sector  81 ,  83 ,  85 ,  87  and  89  is positioned directly beneath a respective net pot  18  to define a respective root bed and encourages formation of a segregated root ball between ribs  99  (see  FIGS. 20 and 21 ) on the boundary of each sector  81 ,  83 ,  85 ,  87  and  89 , which facilitates easier removal of an individual plant and net pot  18  when transferring, removing, or rotating plants. 
     A water distribution plate  66  is provided within pot  22  spaced vertically below horizontal root distribution plate  64 . Plate  66  has a topmost conical surface for distributing water and fertilizer in a radially outward direction for delivery through vertical slots, or passages  72  and  74  in base  22  and cover  20 , respectively. Plate  66  has an outwardly downwardly extending slope of from about 10 to about 30 degrees from horizontal. More preferably, plate  66  has an outwardly downwardly extending slope from 14 to about 20 degrees in order to generate sufficient riparian flow energy and speed that ejects water and fertilizer onto and into a respective net pot  18  via aligned slots  72  and  74  (see  FIG. 7 ). Plate  21  (see  FIG. 7 ) is constructed with similar top surface angles as plate  66  detailed above for a similar purpose of generating flow energy for delivery to plants. Tube  34  passes through plate  66  via cylindrical aperture  70 . A plastic washer  50  closes off the top of plate  66  around aperture  70 , restricting flow of water and fertilizer back down aperture  70 . Washer can be a flat washer, or a washer with an integral reduced-diameter plug base portion received in aperture  70 . Plate  66  forms a bottom of base  22 . In assembly, plate  66  locks in rotation within adjacent cover  20 , as described below in greater detail with reference to  FIG. 12 . In such locked configuration, slots  72  and  74  are aligned adjacent to each net pot  18  for delivering water and fertilizer into/onto a root system for a plant within each net pot  18 . 
       FIG. 8  illustrates a circumferential array of integrally formed inner surface reinforcing ribs  48  provided on an inner surface of base  28  of reservoir tank  24 . Ribs  48  are formed within base  28  as a single injection molded plastic piece. A narrowed bottom portion of the base pot  22  (see  FIG. 7 ) of growing pod  16  is fitted coaxially within a cylindrical inner wall  84  of cover  26  with pot  22  being rotated, either clockwise or counterclockwise, to lock pod  16  onto tank  24 . Water and fertilizer drop from each net pot  18  for collection and redelivery from base  28  via a fluid, or water pump (not shown) for delivery to the top of the tree via supply tube  34 . 
     As shown in  FIG. 9 , each net pot  18  has a tapered outer wall that is received in a cylindrical aperture  80  in top  26 . Cover  26  is received over base  28  in snug relationship therebetween. A circumferential array of vertical slots or apertures  62  in the wall of net pot  18  provides for root growth out of pot  18  and for water and fertilizer to drop through into base  28  for recollection and redelivery to the top of the plating tower via the pump. 
       FIG. 10  illustrates the mounting of net pots  18  into cover  20  in a manner similar to that shown in  FIG. 9 . More particularly, a cylindrical aperture  92  in cover  20  includes an arcuate lip, or flange  93  that helps support net pot  18  when received in aperture  20 . Alignment of slots  72  and  74  by rotating relative positions of an interlocking pot  18  and cover  20  enables water and fertilizer to drop onto roots that extend from net pot  18  via slots  62 , as well as to enter net pot  18  via slots  62 . Additionally, a snap-fit attachment for affixing cover  20  atop base  22  is detailed as a radially-inwardly extending bead  78  on cover  20  that snaps in interference fit over a radially-outwardly extending bead  76  on base  22 . Cover  20  and base  22  are each made from injection molded plastic, and elastic yielding of cover  20  enables override of bead  78  about bead  76  during assembly and disassembly. 
       FIG. 11  shows orientation of cover  32  atop cover  20  adjacent to a net pot  18 . Slot  60  is configured adjacent to net pot  18  to provide water and fertilizer to a plant within net pot  18 . 
     As shown in  FIG. 12 , base  66  has a circumferential array of equidistant spaced-apart and radially outwardly extending locking fingers  82  that are locked in rotated relation beneath a bottom edge of flange, or inner wall  94  of cover  20  (see  FIGS. 16 and 17 ). Such fingers are received downwardly in slots  74  and the associated pot is then rotated so that fingers  82  engage under flange  94  (see  FIGS. 16 and 17 ) to lock the pot to the cover of an adjacent pot there below. 
       FIG. 13  illustrates the manner in which root distribution plate  64  is seated on a circumferential shelf provided by base  22  along the top end of slot  75  where base  22  transitions to a smaller dimension, forming a circumferential support shelf  65 , as shown in  FIGS. 18 and 19  by way of surfaces  96  and  97 . Base  22  is affixed atop cover  26  in a locking relationship similar to that used to lock base  22  onto adjacent cover  20  as shown previously with reference to  FIG. 12  using slots  75  and surface  84 , as shown with reference to  FIGS. 14 and 15 . Shelf  65 , along with interlocking features between adjacent parts, such as base  22  and cover  20 , facilitate quick and easy assembly and disassembly when installing, repairing, and/or cleaning large arrays of such systems in a commercial or industrial setting. 
       FIGS. 14 and 15  show construction details of cover  20 . More particularly, slots  75  are provided in an equidistant spaced-apart circumferential array extending through a circumferential inner reinforcing wall  84  (see  FIG. 15 ). In a similar manner, an equidistant spaced-apart circumferential array of apertures, or cylindrical through-holes  80  are provided in cover  20  each for receiving a net pot (not shown). However, at two locations, access ports  38  and  40  are provided in place of a hole  80  to enable internal access and maintenance within the reservoir tank. Snap fit covers  42  and  44  affixed atop each port  38  and  40  to close out the port using small peripheral finger tabs (not shown). A circumferential array of equally spaced-apart and radially extending reinforcing ribs  90  are integrally molded into cover  20 , along with a tapering cylindrical inner wall  84 , circumferential middle wall  86 , and circumferential outer wall  88 . 
       FIGS. 16 and 17  show construction details for cover  20 . More particularly, an equidistant spaced-apart circumferential array of through-slots  74  are provided in a tapering cylindrical wall portion, or inner wall  94 . An equidistant spaced-apart circumferential array of apertures, or cylindrical through-holes  92  are provided outwardly of each slot  74  for supporting a respective net pot (not shown). As shown in  FIG. 17 , each slot  74  has a tapering and chamfered outer bottom edge to facilitate alignment of locking fingers  82  (see  FIGS. 18 and 19 ) when loading and unloading such fingers from slots  74 . Additionally, an arcuate support wall  93  is provided along a bottom of each aperture  92  (see  FIG. 16 ). Furthermore, radially inwardly extending and integrally molded circumferential bead  78  is shown. 
     Construction details of base  22  are shown in  FIGS. 18 and 19 . More particularly, base  22  is constructed as a single plastic injection molded part. As shown in  FIGS. 18 and 19 , base  22  includes an enlarged tapered cylindrical surface, or frustoconical surface  96  and a reduced diameter tapered cylindrical surface, or frustoconical surface  97 . Cylindrical shelf  65  (see  FIG. 13 ) is formed where surfaces  96  and  97  transition. Alternating through-slots, or vertical apertures  72  terminate at a bottom end proximate a locking finger  82  along surface  97 . As shown in  FIG. 19 , locking fingers  82  are integrally formed in the bottom of base  22  extending from a radial array of enforcing ribs joined by a circumferential rib with aperture  70  extending through the bottom of base  22 . 
       FIGS. 20 and 22  illustrate construction details of root distribution plate  64  which is injection molded from a single piece of plastic material. A cylindrical outmost rib, or wall portion  98  extends upwardly about an outer periphery of plate  64 . An equidistant spaced-apart circumferential array of radially extending ribs  99  also extend upwardly along plate  64 . Along a radial innermost cylindrical periphery of aperture  68 , a radial innermost gap  100  is provided between each adjacent pair of radial ribs  99  to enable water and fertilizer to flow in a radial inward direction for passage through aperture  68  in a downward direction onto a slope water distribution plate  66  (see  FIG. 6 ). 
     Component details showing in exploded view the assembly of a selected topmost growing pod  16  and bottommost reservoir tank  24  are depicted in  FIG. 22 . It is understood that additional growing pods  16  may be stacked between uppermost pod  16  and lowermost reservoir tank  24 . Topmost growing pod  16  receives water distribution plate, or tray  21  in snap-fit relation within an inner surface of cover  20  and cap  32  is affixed atop cover  20 . Individual net pots  18  are then carried by cover  20 , as well as by cover  26 . Base  22  then locks via rotation onto an adjacent cover  26  (or  20 ) in assembly. Cover  26  nests atop a topmost edge of base  28 , while supply tube  34  and pump assembly  36  are supported in the bottom of base  28 . 
       FIG. 23  is a vertical centerline sectional view with portions removed corresponding with the view shown in  FIG. 7 , but further showing potted plants (bituminous plug and plant) in each net pot  18  and illustrating the delivery path for water and fertilizer in a closed loop supply system through hydroponic growing system  10 . Pump  36 , such as an aquarium pump, withdraws water and fertilizer  37  from within reservoir tank  24  and delivers it vertically upwardly via supply tube  34  where it is ejected onto plate  56  and dispersed radially outwardly and downwardly with downslope flow velocity to supply net pots  18  along cover  20 . Water and fertilizer then drops from net pots  18  onto root plate  64  where it moves radially inwardly for passage down onto water distribution plate  66 . This process is repeated through each growing pod  16  until finally reaching reservoir tank  24  where the remaining water and fertilizer returns into tank  24 . In this way, plants  14  are irrigated according to a delivery schedule that is coordinated with a timer suppling power to pump  36  for selected durations and at specific intervals to initial watering within system  10 . In addition, the self-contained system significantly reduces evaporative losses, reducing water supply needs. 
       FIGS. 24 and 25  illustrate an alternative construction hydroponic growing system  110  configured for use with an overhead drip irrigation arrangement using drip lines  134  for feeding water and fertilizer into the top of each system  110 . Systems  110  each include a saddle support base  128  in substitution for the reservoir tank  24  used in the prior construction of  FIGS. 1-13 . More particularly, base  128  includes a pair of clearance apertures  131  configured to overlie a water/fertilizer collection line  129  that returns water and fertilizer back to a main pumping tank (not shown) that feeds drip lines  134 . 
       FIG. 25  shows in vertical centerline sectional view system  110 . More particularly, water and fertilizer is fed from drip source  134  onto water distribution plate  56  of tray  21 . A central plug  150  is placed within a bore in plate  56 , as well as in center apertures found in additional water distribution plates in system  110 . Water and fertilizer flows through system  110  in a manner similar to system  10  (of  FIGS. 1-23 ). Water and fertilizer exits centrally from the bottom of the bottommost base  22  into saddle, or support base  124  within a central cavity  125  of base  124 . Cavity  125  terminates in a central down pipe  127  into a transition fitting  128  affixed to a longitudinal collection pipe  129 . 
     As shown above with reference to two versions, structural components are made from plastic or injection molded plastic. However, it is understood that any suitable structural material can be used to make components parts including metal, clay, ceramic, composite, or any other suitable material. 
     In compliance with the statute, the various embodiments have been described in language more or less specific as to structural and methodical features. It is to be understood, however, that the various embodiments are not limited to the specific features shown and described, since the means herein disclosed comprise disclosures of putting the various embodiments into effect. The various embodiments are, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted in accordance with the doctrine of equivalents.