Patent Publication Number: US-2022232786-A1

Title: Improved Automated Horticulture System

Description:
BACKGROUND 
     Hydroponic gardening is the growing of plants in nutrient solutions with or without an inert medium to provide mechanical support for the plant. When grown hydroponically, plants flourish in a manner superior to the way they are grown in a normal soil medium. This is because the plants do not have to push through soil to develop their expansive root systems to absorb necessary nutrients. These nutrients are also more bio-available to the plants when not in dirt. With hydroponic growing techniques, plants begin growth very quickly and grow faster than they would in a soil medium causing them to ripen earlier. There are many types of systems that fall under hydroponic growing. One technique termed Aeroponics has been developed in which the plant roots, instead of being suspended in a nutrient solution, are suspended in air while a fine mist of nutrient solution is sprayed onto them. Another technique called Nutrient Film Technique (“NFT”) is a hydroponic technique that uses a very shallow stream of water, containing all the dissolved nutrients required for plant growth, and re-circulates the water past the bare roots of plants in a watertight gully, also known as a channel. Drip Irrigation is a form of hydroponics that drips water to the roots maximizing air flow in chambers while allowing the roots to receive a consistent supply of water and nutrients. Until the system described herein was developed, no one has been able to effectively combine these hydroponic techniques into one system. 
     SUMMARY 
     What is presented is a horticulture system that comprises a reservoir containing water and a growing array that comprises a plurality of modular growing chambers arranged in sequence in at least one row. A sprayer system comprising at least one sprayer head delivers water from the reservoir to each growing chamber. A drip system comprising at least one drip nozzle delivers water from the reservoir to each said growing chamber. Each growing chamber further comprises a suspension chamber with an opening to receive a plant and an attachment member above the opening for the mounting of one of the drip nozzles from the drip system. A growth channel is located beneath the suspension chamber having a first end connected to an endcap or an upstream growing chamber, at least one opening for the insertion of one of the sprayer heads from the sprayer system, a cavity for the containment of plant roots, and a second end connected to a drain or a downstream growing chamber. There is a negative slope from the first end to the second end for the discharge of runoff water from the drip system and the sprayer system. Adjustable support racks could be used set the slope of the growing chambers of the growing array. The drain returns the runoff water from said drip system and said sprayer system to said reservoir. The sprayer heads create a mist of water within the growth channel. The horticulture system could comprise more than one growing array connected to the water reservoir. 
     An access door may be located on the growth chamber to access the cavity. The number of openings for the insertion of sprayer heads from the sprayer system can also be varied. In some embodiments, the growth channel having at least two openings for the insertion of sprayer heads from the sprayer system. Some crops would require a flush tank to be connected to the growing array. A supplemental energy source could also be connected to the horticulture system. The plant container could have a growing medium for the growth of contained plants. 
     The horticulture system may include a treatment system connected to the reservoir. In such embodiments, the drain returns the runoff water from the drip system and the sprayer system to the treatment system before it is returned to the reservoir. The treatment system could be an ozone treatment system, a UV treatment system, a filtration system, or other water treatment system. 
     Oxygen could be added to the water in the horticulture system by one of sprayers, oxygen stones, oxygen tanks, a pump adding ambient air to said reservoir, or other means. A nutrient injector could be connected to the reservoir for the addition of nutrients to the water. A blower may be connected to the endcap for the provision of additional airflow through the growing array. Each row of the growing array could have a pressure regulator for independent control of the sprayer system and a pressure regulator for independent control of the drip system. Each said sprayer head and each drip nozzle could also be equipped with a shutoff valve. A return pump could be located downstream of the growing array to return runoff water to the reservoir. Sensors could be incorporated at various locations in the horticulture system to monitor the chemical and/or environmental conditions of the water and the growing chambers. 
     Those skilled in the art will realize that this invention is capable of embodiments that are different from those shown and that details of the devices and methods can be changed in various manners without departing from the scope of this invention. Accordingly, the drawings and descriptions are to be regarded as including such equivalent embodiments as do not depart from the spirit and scope of this invention. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       For a more complete understanding and appreciation of this invention, and its many advantages, reference will be made to the following detailed description taken in conjunction with the accompanying drawings. 
         FIG. 1  is a schematic of a horticulture system disclosed herein; 
         FIG. 2  is a variation of a horticulture system having several growing arrays and controlled by a network of sensors; 
         FIG. 3  is perspective view of a modular growth chamber; 
         FIG. 4  is an exploded view of a modular growth chamber of  FIG. 3  installed in a growth array; 
         FIG. 5  is another exploded view of a modular growth chamber of  FIG. 4 ; 
         FIG. 6  is a perspective view of a row of modular growth chambers of  FIG. 3 ; 
         FIG. 7  is a top view of a horticulture system comprising a growing array of modular growth chambers of  FIG. 3 ; 
         FIG. 8  is a perspective view of the horticulture system of  FIG. 8 ; and 
         FIG. 9  is a perspective view of another horticulture system having a different growing array of modular growth chambers. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to the drawings, some of the reference numerals are used to designate the same or corresponding parts through several of the embodiments and figures shown and described. Corresponding parts are denoted in different embodiments with the addition of lowercase letters. Variations of corresponding parts in form or function that are depicted in the figures are described. It will be understood that variations in the embodiments can generally be interchanged without deviating from the invention. 
     The embodiments disclosed herein overcome the shortcomings of prior art horticulture systems and apparatuses by combining the strengths of Aeroponic, NFT, and drip irrigation systems. It is a fully automated farming system designed to maximize efficiency and consistency in personal and commercial settings. 
     The system presented has various systems and sub-systems that work in unison to produce quality plants consistently and efficiently. Within the various systems there are alterations, adaptations, and advancements of previous technologies and devices. 
       FIG. 1  shows a schematic of the horticulture system  10  presented herein. Water is added to the horticulture system  10  from water source  12 . This water may be treated or filtered outside the horticulture system  10  system as needed. This could be by one or more of reverse osmosis, ultraviolet (“UV”) light, sand or other filters, or by any other means. Whether or not the water is so treated, it is fed to a treatment system  14  before it is fed to a reservoir  16 . This ensures that the water in the horticulture system  10  is as free of contaminants as possible. 
     The treatment system  14  is preferably an ozone system, however, any system that purifies the water of algae, bacteria, or other pathogens would be acceptable. Ozone systems are preferred as they also oxygenate the water. The treatment system  14  essentially refreshes the water thus allowing the horticulture system  10  to continue cycling the water longer before replacing it if that is even necessary. 
     After treatment, the water is transferred into the reservoir  16 . In the reservoir  16  the nutrients, pH, oxygen, conductivity, and any other parameters of the water can be adjusted and monitored by sensors (not shown). While in the reservoir  16  a pump continuously pumps the water through a sand filter. Also, while in the reservoir  16  the water can be oxygenated by sprayers, oxygen stone, or other methods. This oxygen can be provided by an oxygen machine or a pump using ambient air. The preferred method would be an oxygen machine. This supplement oxygen could also be used as an oxygen source for the treatment system  14 —this is particularly useful if the treatment system  14  is an ozone system. Nutrients can also be added to the water in the reservoir  16 . An agitator which could be a mixer or an aerator (not shown) located in the reservoir  16  keeps nutrients evenly mixed as well as further oxygenating the water. This is important to keep the water fresh and consistent throughout the horticulture system  10 . Water in the reservoir  16  may be periodically diverted to the treatment system  14  as needed to control algae, bacteria, or other pathogens and then returned to the reservoir  16 . 
     Pumps  18  in or connected to the reservoir  16  direct water to a growing array  20  that is the primary plant growth system. These pumps  18  pump water from the reservoir  16  to a sprayer system (example: high pressure pump for misters/foggers) and a drip irrigation system (“DIS”) which are associated with the growing array  20  and will be discussed in further detail below. The growing array  20  is located in a grow room or a greenhouse. The growing array  20  and the reservoir  16  and treatment system  14  may be located in different rooms or may be in the same room. The pumps  18  in the system would be sized appropriately for the pressure conditions required for the operation of the horticulture system  10 . 
     The environment in the grow room is not part of the horticulture system  10  disclosed since the horticulture system  10  can be placed in an outdoor setting or an indoor setting, but the environment does directly impact the quality and quantity of whatever is grown in the horticulture system  10 . Certain aspects, such as the plant&#39;s ability to absorb CO 2 , may be amplified using this system as well. 
     The grow room may have supplemental lighting that includes height adjustable lights suspended above the growing array  14 . Various types of lighting may be used based on types of plants, plant growth stage and preference. Different types of lighting may require slight modifications in system set-ups. 
     The grow room may also require duct work for heating and/or cooling. Air would be circulated by intake and exhaust systems which would also filter the fresh air coming in. Supplemental CO 2  may be added by CO 2  systems. Ozone for air purification can be added by an Ozone system or from the water treatment  14  system if that includes an ozone system. 
     As described in further detail below, the growing array  20  comprises a plurality of growing chambers  22  arranged in sequence in at least one row  24 .  FIG. 1  shows a growing array  20  of five rows  24  and only shows two growing chambers  22  in each row  24 , but it will be understood that the number of growing chambers  22  may be varied by the application. Water from the reservoir  16  is directed to each row  24  of growing chambers  22  in the growing array  20 . 
     Each row  24  ends in a drain  26  from which excess water either flows by gravity or is pumped back to the reservoir  16 . The water from the drain  26  can be returned to a holding tank (not shown), the treatment system  14 , or directly to the reservoir  16 , as needed. The purpose of a holding tank, if used, would be monitored and treat the water quality before returning it to the reservoir  16 . The water can be rerouted to the treatment system  14  instead of the reservoir  16  at any time via switching valve  27  to treat and purify the water. Water may also be sent between the reservoir  16  the treatment system  14  via the treatment fluid passage  15  and the reservoir fluid passage  17 . The ozone gas produced from the ozonized water can be vented to the grow room to kill airborne bacteria/pathogens or it can be vented outdoors where it is naturally occurring.  FIG. 1  also shows the presence of a flush tank  28 . Some plants require flushing prior to harvesting to improve product quality. In such instances, valves  30  may be incorporated to direct water flow back to the flush tank  28 . 
     Each row  24  of the growing array  22  may be individually controlled and/or turned on or off or rerouted as needed. This would allow plants to be grown at different stages in the same room creating a perpetual growth and harvest cycle and easier management during harvest. For example, if a first row  24  would be ready to harvest in the tenth week, the second row  24  would be ready the following week, and so on. When a row  24  is harvested, a new crop of plants would replace the harvested crop thereby restarting the cycle. 
     All nutrient water pumped through the horticulture system  10  should at some point go through a chilling system (not shown) which could be a water chiller, an underground system, or an underwater system. This would help prevent any harmful bacteria/pathogens from growing. This also makes the nutrient solution more bioavailable to the plants roots and keeps the pumps cool which helps them last longer. 
     Various filters may be placed throughout the horticulture system  10  to prevent clogs and keep the water clean (examples: sand filters, whole house water filters, etc.). When the water goes through the horticulture system  10  it is returned to the reservoir  16  (example: by gravity flow, by pumps, etc.). As discussed, water may be returned to multiple locations, such as a holding tank (not shown), the treatment system  14 , or directly to the reservoir  16 , as needed. Automatic or manual shut-off valves can be incorporated throughout the horticulture system  10  to re-route water as desired. 
     The entire horticulture system  10  can be run manually but is meant to be run by a computer that monitors and controls every aspect from start to harvest.  FIG. 2  shows an application of the horticulture system  10   a  in which the components that handle and process the water in the horticulture system  10   a , collectively indicated as the water system  32   a , serve three separate growing arrays  20   a , each in different rooms for different stages of plant life. Water flow throughout the horticulture system  10   a  can be controlled by inline automated solenoids. Sensors and monitors can be placed throughout the horticulture system  10  to measure temperature, humidity, CO 2  and O 2  levels, ventilation, and the operation of various components. In addition, water quality sensors can measure nutrients, pH, oxygen, conductivity, and any other parameters of the water. All of the readings from these sensors and monitors and controllers can be routed to a microcontroller  34   a  that could be as simple as an Arduino device. The micro controller  34   a  routes the readings to a microprocessor  36   a  which could be a simple Raspberry Pi or a personal computer or other device. Readings from the microprocessor  36   a  are routed to a client control interface  38   a  where a user can review the readings from the monitors and sensor and provide instructions to control each of the elements of the horticulture system  10   a.    
     Climate (Ventilation, CO2, Temperature, &amp; Humidity) is controlled by automated greenhouse monitor/controllers. The water treatment systems would be controlled by their own monitor and control systems. Photoperiods are automatically controlled as well as light levels. Electricity can be generated by solar panels, bought, or both. Each growing array  20   a  can be monitored or controlled for parameters such as water output, clogs in sprayer and drip systems, oxygen levels, or even bacteria or pathogens levels and nutrients levels in the water. Individualizing the nutrient ratio per plant site through injectors or some other method will also be controllable through the software. The software can track the life of the entire system and its parts to inform the user when something needs replaced or maintenance needs performed. 
       FIG. 3  shows an individual growing chamber  22   b  and its components and  FIGS. 4 and 5  show an exploded views of the growing chamber  22   b  installed in a row  24   b  of a growing array  20   b . As best understood by comparing  FIGS. 3, 4, and 5 , the growing chamber  22   b  comprises a suspension chamber  32   b  with an opening  34   b  to receive a plant container  36   b  that holds a plant to be grown in the growing chamber  22   b . The plant container  36   b  may have a growing medium designed for the growth of contained plants. An attachment member  38   b  is located above the opening  34   b  for mounting a drip nozzle  40   b  from a drip system  42   b  (discussed in more detail later). 
     A growth channel  44   b  located beneath the suspension chamber  32   b  has a first end  46   b  connected to either an endcap  48   b  or an upstream growing chamber. At least one opening  50   b  is provided for the insertion of sprayer heads  52   b  from a sprayer system  54   b  (discussed in more detail later). In the embodiment shown in the figures, the growth chamber  22   b  has three openings  50   b  that each receive a sprayer head  52   b . A cavity  56   b  extends through the growth channel  44   b  for the containment of plant roots. The growth channel  44   b  has a second end  58   b  that is connected to a drain (as discussed earlier) or a downstream growing chamber. When the growing chamber  22   b  is installed in a growing array  20   b  there is a negative slope from the first end  46   b  to the second end  58   b  that allows for runoff water from the drip system  42   b  and the sprayer system  54   b  to flow through the growing chamber  22   b  and be discharged to the drain or the next growing chamber in the growing array  20   b .  FIG. 6  shows an example of how three modular growing chambers  22   b  connected in series with an endcap  48   b  at the first end  46   b  of the first growing chamber  22   b  and the second growing chamber  22   b  connected to the second end  58   b . A blower (not shown) could be connected to the endcap  48   b  to provide airflow to the roots of the plants growing in the row  24   b.    
     In the embodiment shown, an access door  60   b  is installed in the growth channel  44   b  to access the cavity  56   b . As best shown in  FIG. 5 , this access door  60   b  allows a user to access the cavity  56   b  and to inspect and replace the sprayer heads  52   b  and to also inspect the roots of the plants that would grow into the cavity as the plant grows in the growing chamber  22   b.    
     The drip nozzle  40   b  connected to the drip system  42   b  is arranged to drip nutrient water into the plant container  36   b , usually at the base of the plant above the root zone. The drip nozzle  40   b  is held in place with the attachment member  38   b . The roots are sprayed with nutrient water from all angles by the one or more sprayer heads  52   b  within the growing chamber  22   b  from the sprayer system  54   b . This creates a mist of water within the growth channel  44   b . The number and location of the sprayer heads  52   b  may vary by whatever configuration is determined to be effective for the plant to be grown. The type of sprayer head  52   b  is interchangeable depending on the user preference or plant needs. Pressure regulators  62   b  are used throughout the system as required to adjust the water pressure to the sprayer heads  52   b  and drip nozzles  40   b  as needed. Shutoff valves  64   b  could be incorporated at the beginning of the drip system  42   b  and sprayer system  54   b  to selectively use one or both of the systems. Additional shutoff valves (not shown) could be incorporated at each sprayer head  52   b  and drip nozzle  40   b  to provide additional control to the water provided at each growing chamber  22   b.    
     As the plant grows, so do its roots. The roots will expand down through the suspension chamber  32   b  and into the cavity  56   b  and eventually will lay in the nutrient water as it flows down the connected growing chambers  22   b . The use of both the sprayer system  54   b  and the drip system  42   b  constantly will keep humidity at 100% in the chambers but constant use is not required. This configuration of the sprayer system  54   b , the drip system  42   b , and the cavity  56   b  that allows the roots to lay in the nutrient water flow combines aeroponics with drip irrigation and NFT in a single modular system. 
     The plant&#39;s roots are suspended in the growing chamber  22   b . Multiple chambers can be combined into as many rows  24   b  as needed to fill the available space to create larger systems. The size and spacing of the growing chambers  22   b  are determined by the size of the plant that will be growing in it. For example, a head of lettuce might use an opening  34   b  that only has a 2-inch diameter with each opening  34   b  that is spaced 4-inches apart while tomatoes might use 6-inch diameter openings  34   b  spaced 24-inches apart. 
       FIGS. 7 and 8  show views of a small horticulture system  10   b  that has a growing array  20   b  comprising two rows  24   b  having two growing chambers  22   b  each. A treatment system  14   b  is connected to the reservoir  16   b . The sprayer system  54   b  and the drip system  42   b  are served by a pump  18   b  that is connected to the reservoir  16   b . The growing chambers  22   b  are on a grade that allows the nutrient water to flow to the end of the rows  24   b  where they connect to the drain  26   b  where the water will be pumped or drained back to the reservoir  16   b  to be reused. The drain  26   b  is fitted with a switching valve  27   b  to allow the runoff water to be routed to the treatment system  14   b  rather than the reservoir  16   b  either periodically or as needed. 
     Conduit for the sprayer system  54   b  and the drip system  42   b  run alongside the interconnected growing chambers  22   b  with feeder lines branching to each individual growing chamber  22   b . Adjustable support racks  66   b  or stands are installed under interconnected growing chambers  22   b  to set the sloping grade and hold the growing chambers  22   b  in place for water to gravity flow to the drain at the end of the row. Supplemental energy sources could be incorporated into the horticulture system  10   b  in case of power failures to prevent loss of crops. 
     To prevent roots clogging the growing chambers  22   b , a channel may be incorporated to keep the water flowing. Viewports could also be incorporated to view the roots growing through the growing chambers  22   b.    
       FIG. 9  is a variation of the horticulture system  10   c  showing a growing array  20   c  that comprises four rows  24   c  of two growing chambers  22   c  each. This illustrates the flexibility of the modular growing chambers  22   c  in custom growing arrays. 
     This invention has been described with reference to several preferred embodiments. Many modifications and alterations will occur to others upon reading and understanding the preceding specification. It is intended that the invention be construed as including all such alterations and modifications in so far as they come within the scope of the appended claims or the equivalents of these claims.