Patent Publication Number: US-2020288646-A1

Title: Pod lighting system for plants

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Patent Application No. 62/817,728 filed Mar. 13, 2019 entitled “LIGHTING AND REFLECTION SYSTEMS FOR PLANTS”, the contents of which are incorporated by reference in their entirety as if set forth in full. 
     This application claims the benefit of U.S. Provisional Patent Application No. 62/884,811 filed Aug. 7, 2019 entitled “POD LIGHTING SYSTEM FOR PLANTS”, the contents of which are incorporated by reference in their entirety as if set forth in full. 
    
    
     TECHNICAL FIELD 
     This disclosure generally relates to light reflectors and apparatuses for plants. 
     BACKGROUND 
     There is a continuing need for horticulture systems that can save energy and increase yields. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG. 1  shows a top perspective of an example embodiment of a modular pod lighting system for plants, wherein the modular pod lighting system for plants is lowered into a normal operating position. 
         FIG. 2  shows a top perspective view of the example embodiment of a modular pod lighting system for plants as shown in  FIG. 1 , wherein the modular pod lighting system for plants is raised above its normal operating position. 
         FIG. 3A  shows a top perspective exploded view of the example embodiment of a modular pod lighting system for plants as shown in  FIG. 1 , wherein the modular pod lighting system for plants does not include plants or tables. 
         FIG. 3B  shows a bottom perspective exploded view of the example embodiment of a modular pod lighting system for plants as shown in  FIG. 1 , wherein the modular pod lighting system for plants does not include plants or table. 
         FIG. 4A  shows a top perspective view of an example embodiment of reflective light panel, and  FIG. 4B  shows a bottom perspective view of the same. 
         FIG. 5A  shows a top perspective exploded view of an example embodiment of reflective light panel with the light emitting side of the reflective light panel showing. 
         FIG. 5B  shows a top perspective exploded view of an example embodiment of reflective light panel with the non-light emitting side of the reflective light panel showing. 
         FIG. 6A  shows a top perspective view of an example embodiment of support box, shown without a top panel. 
         FIG. 6B  shows a bottom perspective view of the example embodiment of support box shown in  FIG. 6A . 
         FIG. 6C  shows a side profile view of both a male and female reflective light panel mounting grooves. 
         FIG. 7A  shows a top perspective view of an example embodiment of reflective light engine, wherein the light emitting side is shown. 
         FIG. 7B  shows a top perspective view of an example embodiment of reflective light engine, wherein the non-light emitting side is shown. 
         FIG. 8A  shows a top perspective view of an example embodiment of a light reflection apparatus for plants, wherein the apparatus is engaged with plants. 
         FIG. 8B  shows a top view of the example embodiment of a light reflection apparatus for plants as shown in  FIG. 8A . 
     
    
    
     DETAILED DESCRIPTION 
     Indoor horticulture such as growing plants buildings etc. has become a prominent growing method for a variety of plants. Indoor growing may be advantageous, for example, the growing conditions such as temperature, humidity, lighting cycles and pest control may be optimally controlled.  Cannabis  is one such crop that may benefit from indoor growing, and in fact, the practice has become widespread. Although various embodiments of the invention may be described with respect to cultivating  cannabis , this is for illustrative purposes only, and should not be construed to limit the scope of possible applications for the various embodiments of the invention. The written descriptions may use examples to disclose certain implementations of the disclosed technology, including the best mode, and may also to enable any person skilled in the art to practice certain implementations of the disclosed technology, including making and using any devices or systems and performing any incorporated methods. The patentable scope of certain implementations of the disclosed technology is defined in the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims. 
     The words “stem” or “shoot” may be used interchangeably. Example embodiments of plant reflectors herein described may fit on any suitable appendage of a plant, and the use of the words “stem” or “shoot” should not be construed to limit this generality. 
     There may be drawbacks of current lighting systems in use for indoor horticulture, both with LED systems and traditional high pressure sodium or metal halide lamp systems. With all systems, the general configuration may be to utilize very high light output fixtures, and hang them at a relatively high height over the plants. This may be done for several reasons:
         1. In order to provide the required light distribution across the desired plant growing area. For example, a 1000 watt HPS light fixture may be hung at many feet above the plants in order to provide a wide enough light cone to cover a average sized row or rows of plants.   2. Higher fixture heights may allow sufficient distance from the plants to eliminate bleaching of the plants due to the considerable heat from the light fixtures as well as light hot spots.   3. Overlapping light cones from adjacent fixtures may be required to give a more uniform light density to the plants.       

     As a result of the higher light fixture mounting heights and the inverse square law of light, extremely high powered lights may be required to provide adequate light levels at the plant height. These high powered lights may create considerable heat, and generally may require ventilation systems vented to the outdoors. This may create extra energy costs on an ongoing basis as well as higher fit-up costs. Extra cooling may be required in the warmer months to offset the heat from the lights. 
     A further drawback may be light loss. With the described light fixture configuration, the entire inside of the growing room may be lit, including wall, floors, space between plants etc. This may create a large light loss, as this light is not being utilized by the plants, except for perhaps some minimal reflections from said surfaces. The cost of lighting energy for indoor  cannabis  cultivation may be one of the largest single expenses in the production of commercial  cannabis.    
     Another drawback may be non-uniformity of the light levels at the plant height. Even with overlapping light from adjacent light fixtures, light non-uniformity may be a relatively large ratio. For  cannabis  crops for example, this may have a direct and significant negative impact on yields. 
     Examples embodiments of modular pod lighting systems that will be presented may overcome the drawbacks of current lighting systems as described. With the very high revenue potential for  cannabis  products, even a small increase in light efficiency and uniformity may significantly increase revenues. A plant lighting system with the following advantages may indeed be novel and increase yields and revenues:
         Low brightness, uniformly lit light fixture apertures that may cover the entire growing footprint of the plants, that may be placed close to, or touching the plants. This would largely mitigate the effects of the inverse square law of light, and allow for significantly lower light levels from the fixture aperture.   Reflective light panels that both emits light towards the plants and also reflects light towards the plants that may come from back-scatter from the light diffusers in front of the light source, or light reflected from other external surfaces.   Side reflector curtains attached to opposing sides of the reflective light panels, wherein the reflective curtains may extend to the base of the plants. This may function to capture and recycle to the plants a large amount of otherwise wasted light.   Bottom reflectors facing upwards toward the reflective light panels wherein incident light from the reflective light panel and light reflected by the side reflector curtains may be reflected back to the plants or up to the reflective light panel, which may in turn recycle this light towards the plants.   A tunnel created by the reflective light panel, side reflector curtains and bottom reflectors may allow one or more relatively small low powered fans to create a wind tunnel effect, thereby providing superior ventilation for the plants contained therein, and with less power used.       

     An example embodiment of a modular pod lighting system (herein referred to as “Pod”) is shown in  FIG. 1  and  FIG. 2 .  FIG. 1  shows a perspective view of the Pod which may have been lowered into a typical position suitable for growing, and  FIG. 2  shows the same Pod but in a raised position, which may be suitable for the inspection and maintenance of the plants. 
     It should be noted that a grow bench  6860  ( FIG. 1 ) and  6960  ( FIG. 2 ) and plants  6805  with pots  6813  ( FIG. 1 ) and  6905  and  6913  ( FIG. 2 ) may not be part of the claimed invention and may be used for illustrative purposes only. Their use or lack of use should not be construed to create any limitations to the example embodiments herein presented. There may be numerous growing methods in use that may use of variety of different growing equipment and configurations. For example, some growers may not use grow tables, and may assemble the plants on the floor. Some growers may not use individual pots, and may use continuous row containers to contain a grow medium. 
     Referring to a top perspective view of an example embodiment of POD as shown in  FIG. 1 , two modular reflective light panels  6840  may be joined together and attached to a support box  6841 . Support box  6841  may enclose wiring, electrical components such as LED drivers and a hoist with cables  6844 . It should be noted that throughout the drawings the cables  6844  may be depicted as shown for illustrative convenience. In practice, the cables may be long enough to reach a ceiling, and the cables may terminate each with an attachment device such as a hook or carbineer clip to attach the cables to a ceiling attachment point. Modular fan assembly  6843  may be attached to either or both ends of the reflective light panels  6840 . Modular fan assembly  6843  may be crucial with respect to proper ventilation of the plants. 
     Side reflector curtains  6801  may be attached to opposing perimeter edges of the reflective light panels  6840 . Plant reflector panels  6842  may lie on the rims of pots  6813 . As shown, the described individual basic elements may form an example embodiment of POD wherein a large majority of light may be contained with the POD and subsequently recycled within the POD, thereby minimizing light loss. The effect may be somewhat analogous to a tanning booth for plants, wherein most of the emitted light may be contained within the tanning booth. Although the example embodiment of POD as shown may have two open ends wherein light may escape therefrom, it should be noted that example embodiments of POD are modular. Growers may typically configure their growing setup with long continuous rows of plants, perhaps as long as the building dimensions will allow. If example embodiments of PODs are configured in length to match the plant row lengths as described, for example forty feet in length, then the projected surface area of the two open ends on an example embodiment of POD may become a negligible proportion of the total inner surface area of the POD, wherein the vast majority of light emitted from the reflective light panels  6840  may be recycled within the POD and potentially useable by the plants therein. 
     A perspective view of the example embodiment of POD from  FIG. 1  in its raised position is shown in  FIG. 2 . Two modular reflective light panels  6940  may be joined together and attached to a support box  6941 . Support box  6941  may enclose wiring, electrical components such as LED drivers and a hoist with cables  6944 . Side reflector curtains  6901  may be attached to opposing perimeter edges of the reflective light panels  6940 . Plant reflector panels  6942  may lay on the rims of pots  6913 . Modular fan assembly  6843  may be attached to either or both ends of the reflective light panels  6840 . 
     In  FIG. 3A , a perspective exploded top view of the example embodiment of POD from  FIG. 1  and  FIG. 2  is shown, and in  FIG. 3B , a perspective exploded bottom view of the example embodiment of POD from  FIG. 1  and  FIG. 2  is shown. Two modular reflective light panels  7040  may be joined together and attached to a support box  7041 . Support box  7041  may enclose wiring, electrical components such as LED drivers and a hoist with cables  7044 . Side reflector curtains  7001  may be attached to opposing perimeter edges of the reflective light panels  7040 . Plant reflector panels  7042  may lay on the rims of pots (not shown). Modular fan assembly  6843  may be attached to either or both ends of the reflective light panels  7040 . Optical film differs panels  7050  may slidingly engage with or otherwise attach to the reflective light panels  7040   
     In an example embodiment as shown in  FIGS. 4A and 4B , a novel reflective light panel is disclosed. A panel that can reflect as well as emit light may have several advantages which may function to increase overall light efficiency and decrease light loss. The light emitting side of reflective light panels  7140  may be covered by optical film diffuser panels  7150 . The diffuser panels may function to diffuse and even our hot spots of the light emitted from LED strips (not shown). As may be inherent with any diffusive refraction medium, a certain amount of light from the light source will be reflected back towards the light source from the back of the diffusive refraction medium (“back-scatter”). In many commercial horticulture light fixtures, single LED strips may be mounted on narrow long metal bases and covered by acrylic diffuser lenses. Accordingly, a large percentage of back-scattered light from the back of the acrylic diffuser lens may be directed to the building ceiling, and away from the plants, and lost. The aperture of other commercial horticulture light fixtures may be completely covered in LED panels or LED strips and covered by one or more diffusers, which may lead to the same type of light loss. Additionally, in other commercial light fixtures, any light reflected back from external surfaces such as white pained floors may be predominantly lost. These disadvantages may be overcome by an example embodiment of novel reflective light as shown in  FIGS. 4A and 4B . 
       FIG. 4A  shows a top perspective view of an example embodiment of reflective light panel, and  FIG. 4B  shows a bottom perspective view of the same. An outer frame may be fabricated from lightweight aluminum square tubing utilizing frame members  7157  and corner connectors  7170 . It may be preferable if the frame members  7157  had an inner ledge fabricated into their profile design such as shown in  FIG. 5B  features  7280 , wherein an inner edge may enable the support of a reflective light engine  7190 . Other suitable outer frame assemblies may be also utilized other than those described. 
     The reflective light engine  7190  may be configured from repeating reflective film pieces  7153  joined to LED heat sinks  7152  with two outer opposing light engine frame pieces  7151 . The reflective film  7553  may comprise any reflection film previously discussed in this application, or related applications. The reflective film pieces  7153  (corresponding to  FIG. 42A   4201 B) may be configured with edge trusses  7575  (corresponding to  FIG. 42A   4202 ) configured from folds  7577  along each of the long edges of the reflector film pieces  7553  (corresponding to  FIG. 42A   4203 ), wherein the edges of the edge trusses  7575  formed on the reflector film pieces  7553  (corresponding to  FIG. 42A   4221 ) may engage with the edge truss retention feature of the light engine frame pieces  7576  and LED heat sink edge truss retention features  7586  (corresponding to  FIG. 42A   4220 ). Any other suitable or practical frame pieces and methods of attachment of the reflector panel to the frame pieces may also be utilized. 
       FIG. 7A  shows a perspective view of the light emitting side of the light engine  7490 , and  FIG. 7B  shows a perspective view of the back side of the light engine  7490 . LED heat sinks  7452  are interconnected with reflection film pieces  7453  and outer light engine frame pieces  7451 , and LED strips  7472  may slide into channels configured into LED heat sinks  7452 . 
       FIG. 5A  shows an exploded perspective view of the top side of an example embodiment of reflective light panel, and  FIG. 5B  shows an exploded perspective view of the light emitting side of the same example embodiment of reflective light panel. Referring  FIG. 5A , diffuser panels  7250  may be fabricated similarly to those described, or may be fabricated in other configurations, such as sheets of diffusive, non-diffusive or prismatic acrylic sheets. Diffuser panels  7250  may slidingly engage inside channels in opposing diffuser attachment guides  7258 . This attachment arrangement may be beneficial wherein easy removal of the diffuser panels for cleaning may save in labor costs. 
     Referring  FIG. 5B , outer frame members  7257  may be connected together with connectors  7220 . Connectors  7220  may comprise locking dowel receiving holes  7259 B which may accept locking dowels  7259 , which may allow reflective light panels to be interconnected. Diffuser panels  7250  may slidingly engage with mating diffuser attachment groves  7258 . Wiring cover panels  7254  may function to hide and contain the wires emanating from the LED strips  7272 , as well as adding additional rigidity to the outer frame members  7257 . 
     Referring to  FIG. 1 , in an example embodiment, the side reflector curtains  6801  may be novel additions to the reflective light panels  6840 . They may be fabricated with a top and bottom frame member, and may be fabricated in a similar way to that shown and described referencing  FIGS. 64A and 65A . A top frame member may enable reliable attachment points to the reflective light panels  6840 , and a bottom frame member may allow the reflector curtains  6801  to remain taught. The reflection material may be any material which may reflect light, however reflection materials described in this application as well as related applications may be preferable. The side reflector curtains  6801  may be comprise other configurations as well. For example, they could be rigid panels of reflection material, or reflection material mounted on outer frames. 
     A notable feature is the mating reflective light panel mounting grooves  7256 B ( FIG. 5B ) which may be attached to wiring cover panels  7254 . Referring to  FIG. 6B , support box  7341  which may enclose wiring, electrical components such as LED drivers and a hoist with cables, may have male light panel mounting grooves  7356 B attached as shown.  FIG. 6C  shows a close-up profile view of the male light panel mounting grooves  7356 B and the female light panel mounting grooves  7356 . The male light panel mounting grooves  7356 B may slidingly engage with female light panel mounting grooves  7356  which may be mounted on wiring cover panels  7254  ( FIG. 5B ). This mounting method may allow for fast installation and removal of the reflective light panels from the support box  7341 . 
     A novel example embodiment of a light reflection apparatus for plants will now be disclosed, and is shown in  FIGS. 8A and 8B . Plant reflector panel  7642  may be fabricated from any reflective film, but preferably reflection films (or variations thereof) described in this or related applications. It may be preferable if the reflection film had very high reflective efficiency, perhaps over 97% for example, very high diffuse Lambertian type reflection over 97%, was UV stable, and was impervious to water or humidity. An optional rigid backing substrate may be required to mount the reflection film on in order to provide the required rigidity for a particular application, wherein the reflector panel may remain sufficiently horizontal with acceptable sag. An example of a backing substrate may be corrugated plastic sheets. 
     Installation slot  7699  may be cut into the reflector panel  7642  using any cost effective means such as steel rule die cutting or flatbed cutting machines for example. The reflection panel  7642  may be installed by sliding plant stems  7698  along the installation slot  7699  until the plant stems  7698  may be disposed within the installation slot  7699  at the desired position. The reflector panels  7644  may be supported on the rims of pots  7613 . The reflector panels  7642  dimensions may be fabricated using any suitable dimension for any particular application. Although not shown, clips, brackets, tape, hook and loop fasteners, screws, pins or any other fasteners may be used to help join or secure adjacent panels to each other, which may help keep the reflector panels  7642  disposed in a more level and orderly fashion. 
     The example embodiment of a light reflection apparatus for plants as shown in  FIGS. 8A and 8B  may have benefits which may function to lower lighting energy costs and increase yields. Since light from light fixtures or sunlight is predominately directed downwards, a horizontal light reflector as described may reflect and recycle a significant amount of light back towards the plants. 
     Another notable feature of an example embodiment of light fixture may be the support box  7341  as shown in  FIG. 6A . The support box  7341  may comprise a lightweight aluminum box which may function to support and slidingly engage the reflective light panels as previously described. An optional cover (not shown) may cover the support box  7341 . The support box may house components such as LED drivers  7397  and hoist  7395 . 
     The hoist  7395  may comprise any suitable electric hoist. However, it may be extremely beneficial that the hoist comprise a lightweight design, can be wirelessly controlled, and self-leveling. Pulleys  7396  may function to redirect the pulley cables  7344  vertically towards the ceiling for subsequent attachment of example embodiments of PODs to the ceiling, and may also lessen the effective pulling force required for the hoist  7395 . 
     As described in example embodiments of modular pod lighting systems, novel advantages have been presented which may increase the light quantity to the plants, thereby increasing yields and revenues. These novel features may comprise
         Low brightness, uniformly lit apertures that may cover the entire growing footprint of the plants, that may be placed close to, or touching the plants. This would largely mitigate the effects of the inverse square law of light, and allow for significantly lower light levels from the fixture aperture.   Reflective light panels that both emits light towards the plants and also reflects light towards the plants that may come from back-scatter from the light diffusers in front of the light source, or light reflected from other external surfaces.   Side reflector curtains attached to opposing sides of the reflective light panels, wherein the reflective curtains may fully, or any portion thereof, extend to the base of the plants. This may function to capture and recycle to the plants a large amount of otherwise wasted light   Bottom reflectors facing upwards toward the reflective light panels wherein incident light from the reflective light panel and light reflected by the side reflector curtains may reflected back to the plants or up to the reflective light panel, which may in turn recycle this light towards the plants.   A tunnel created by the reflective light panel, side reflector curtains and bottom reflectors may allow one or more relatively small low powered fans to create a wind tunnel effect, thereby providing superior ventilation for the plants contained therein, and with less power used.       

     In an example embodiment of the disclosed technology, a modular pod lighting system for plants may comprise a light containment enclosure, which may further comprise a light panel with one side configured to emit light, wherein the light panel may be configured to hang from an above structural element in a relatively horizontal orientation. The modular pod lighting system for plants may further comprise side reflection curtains attached to opposing edges of the light panel, wherein the reflection curtains may extend downwards away from the light panel. The light containment enclosure may be configured to partially enclose plants therein, and wherein light emitted from the light panel may be partially contained and recycled within the light containment enclosure. 
     In an example embodiment, the plants may further comprise pots that they are contained therein, or plant growing medium containment structures. One or more bottom reflectors configured to reflect light may be disposed on or near the rims of the pots or edges of the plant growing medium containment structures such that their light reflection surfaces may reflect incident light from the side reflection curtains and the light panel. 
     In an example embodiment, the addition of bottom reflectors may form a more complete light containment enclosure, wherein light emitted from the light panel may be substantially contained and recycled within the light containment enclosure. 
     In an example embodiment, the light containment enclosure may further comprise a winch system which can raise or lower the light containment enclosure. 
     In an example embodiment, the light containment enclosure may further comprise a fan assembly attached at one or more ends, wherein the space within the light containment enclosure may function as a partial wind tunnel, wherein air movement caused by the fan assembly may be forced through the constricted space within the light containment enclosure, therein possibly creating greater air movement within the light containment enclosure than would otherwise occur in open space. 
     In an example embodiment, the light panel may further comprise a reflective light panel or reflective light engine. 
     In an example embodiment, the side reflector curtains may be rigid or semi rigid reflector panels. 
     In an example embodiment, the side reflector curtains may further comprise an outer frame. 
     In an example embodiment of the disclosed technology, a reflective light engine may comprise a light engine comprising a light emitting side, one or more light sources configured to emit light from the light emitting side, and one or more light reflection surfaces on the light emitting side of the reflective light engine. 
     In an example embodiment, the reflective light engine may further comprise one or more linear elongated heat sinks configured to attach to LED strips, LED strips may be attached to each corresponding one or more linear elongated heat sinks, and reflection material may be attached to one or two sides of the one or more linear elongated heat sinks. 
     In an example embodiment, the one or more linear elongated heat sinks may further comprise a channel on each opposing side, wherein each channel may comprises a first surface, a second surface that opposes the first surface, and an edge truss retention feature. The reflection material may comprise at least two long edges and a first surface, wherein at least one of the long edges may be configured with at least one edge truss, wherein the at least one edge truss may be configured from a corresponding fold in the reflection material that extends along all, or a portion of the corresponding long edge of the reflection material. At least one edge truss may be configured at an angle relative to the first surface of the reflection material, and wherein the outermost edge of the at least one edge truss may comprise an outer perimeter edge. The reflection material may be configured for attachment to the one or more linear elongated heat sinks such that the at least one edge truss of the reflection material may nest inside a corresponding channel of the one or more linear elongated heat sinks, and the perimeter edge of the at least one edge truss may be engaged by the corresponding channel&#39;s edge truss retention feature such that the at least one edge truss may become lodged and secured within the corresponding channel of the one or more linear elongated heat sinks. 
     In an example embodiment, the reflective light engine may comprise multiple light sources which may be interconnected with corresponding multiple strips of the reflection material, therein forming a reflective light engine. 
     In an example embodiment of the disclosed technology, a light reflector for plants comprises a piece of reflective material, a top side that comprises the reflective material, and a bottom side configured to be supported on plant pot rims or edges of plant growing medium containment structures. An optional backing substrate attached to the reflective material may help keep the reflective material relatively level when disposed in a horizontal position. Installation slots may be configured in the light reflector for plants, wherein the installation slots are configured to engage or border on plant stems, shoots or trunks, wherein after installation, the light reflector for plants may be horizontally disposed on plant pot rims or on edges of plant growing medium containment structures, wherein plant stems, shoots or trunks may protrude upwards through the installation slots. 
     In an example embodiment, the light reflector for plants may further comprise adjacent light reflectors that may be joined together utilizing clips, brackets, tape, hook and loop fasteners, screws, pins or any other fasteners.