Patent Publication Number: US-2016227721-A1

Title: Hydroponics system

Description:
PRIORITY CLAIM 
     This application claims priority to U.S. Provisional Patent Application No. 62/114,981 filed on Feb. 11, 2015. The foregoing application is herein incorporated by reference in its entirety. 
    
    
     COPYRIGHT NOTICE 
     This disclosure is protected under United States and International Copyright Laws. ©2012-2014 Emerald Ventures, Inc. All Rights Reserved. A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever. 
     FIELD OF THE INVENTION 
     The present invention relates to large scale or commercial horticultural systems and in particular to systems for cultivating plants using soil-less techniques such as hydroponics. 
     BACKGROUND OF THE INVENTION 
     Hydroponics has been defined as one example of the soilless culture in which mineral nutrient solutions are utilized for crop growth. Such systems allow for more controlled utilization of nutrients than traditional soil-based techniques. Environmental factors, such as temperature, evaporation and light affect system efficiencies and plant growth. Accordingly, there is a need for a hydroponics system that provides improved operational efficiency and plant yield. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Preferred and alternative examples of the present invention are described in detail below with reference to the following drawings: 
         FIG. 1  is a schematic diagram of a hydroponics system according to a preferred embodiment of the present invention; 
         FIG. 2  illustrates various aspects of the system of  FIG. 1 ; 
         FIG. 3  illustrates still further aspects of the system of  FIG. 1 ; 
         FIG. 4  depicts a light source suitable for use in the system of  FIG. 1 ; 
         FIG. 5  depicts portions of the plumbing and water system for the system of  FIG. 1 ; 
         FIG. 6  illustrates stadium arrangement of benches for the system of  FIG. 1 ; 
         FIG. 7  illustrates the use of curtains for the system of  FIG. 1 ; and, 
         FIG. 8  illustrates a seed bed according to an alternative embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Hydroponics is a soil-less technique for growing plants. An advantage of hydroponics over conventional soil-based techniques is that the growing environment can be better controlled, including for example, the nutrient levels provided to the growing plants, the water provided to the plants can be readily retained in the system providing significant water savings and/or minimizing the risk of mold development, and the energy expended by the system can be more efficiently utilized. 
     Devices for cultivating plants using hydroponic techniques typically comprise a table and a water pool in which plants are suspended from a rack so that the roots are exposed to a nutrient solution wherein the water is pumped into the pool of water and back out, e.g. using an ebb and flow technique. 
       FIG. 1  illustrates a modular hydroponics system  100  according to a preferred embodiment of the present invention. System  100  preferably includes a frame or framework  101  of one or more cages  102 . For ease of understanding, a single cage  102  is illustrated in  FIG. 1 . It is, however, understood as discussed herein, that system  100  may comprise more than one cage  102 . Cage  102  preferably includes a source of electrical power  104 , water system  106 , at least one, preferably moveable, light source  108  and at least one circulating fan  110 . Plants  112  are arranged on one or more benches  114  in ebb &amp; flow containers  116  in a stadium arrangement (not shown in  FIG. 1 ). Light source  108  preferably moved by mechanism  118  moves along the benches  114  and a reflective hood  120  precisely directs light from a lamp  122  to the plants  112 . The fan  110  circulates air to control the air temperature within a cage  102 . The watering system  106  supplies and collects water to and from the plants. The pH and nutrient levels (not shown in  FIG. 1 ) in water system  106  are monitored and controlled by controller  124 . Controller  124  may also provide various levels of control to other components of system  100 , including the power supply  104 , light source  108 , fan  110  and water system  106 . Controller  124  may, for example, but without limitation, be in the form of a centralized control panel or as various distributed controllers and monitors throughout system  100  offering various degrees of control and automation. 
     The hydroponics system according to the present invention is well suited for large-scale commercial applications and provides improved system efficiencies and plant quality (yield). For example, plant growth is accelerated and the consistency and quality of plants  112  is improved through use of the hydroponics system  100  of the present invention. Further, by way of example, energy, water and nutrients are more efficiently utilized through use of the hydroponics system  100 . 
     As previously discussed and represented in  FIG. 1  and further illustrated in  FIGS. 2-7 , system  100  is preferably modular and may comprise a frame or framework of one or more cages  102 , wherein each cage preferably includes, by way of example, a power supply  104 , 6 benches  114 , 2 light sources  108 , 2 axial fans  110 , water system  106 , 20 plants  112  in 20 ebb and flow containers  116  and controller  124 . Water system  106  includes one or more each of a reservoir  126 , circulating pump  130 , plumbing  132  and manifold  134 . Water system  106  also preferably includes nutrient controllers  128  for monitoring and/or controlling nutrient levels in the water. Nutrient controllers may, for example, be PH/PPM meters. Light source  108 , preferably includes a 1000 watt lamp  122 , a mechanism  118  (such as a motors) for moving the light source  108  and a device  120  for directing the light from lamp  122  ( FIG. 4 ). Light directing device  120  may, for example, be a reflective hood or prismatic lens to aid in efficiently directing the light output to the plants  112 . It is understood that the number and mixture of components of a cage, as exemplarily illustrated above, may be changed, increased or reduced to satisfy user-specific needs. For example, the number of the above-noted components in each cage could be increased for very large scale commercial operations. Similarly, the number of cages could be increased or reduced to meet specific user needs. Similarly, reducing the number of components in a cage, say for example by half, may make a cage suitable for small scale operations such as home or personal use. 
     Cage  102 , according to one embodiment, is constructed from PVC tubing ( FIG. 2 ) and includes reflective curtains  136  ( FIG. 7 ) to improve energy efficiency of the system by redirecting energy to the plants, thereby reducing system energy loss. The reflective curtains  136  may, for example, comprise Mylar® sheets attached to some or all of the sides and ends of the cage(s)  102 . The Mylar® is preferably removably attached to cages with, for example, rubber bands or other nonconductive material that further help in minimizing heat transfer, and thereby further improve system efficiency. The cages  102  along with the reflective curtains  136  form a micro-environment for the plants  112 . 
     As previously discussed and illustrated in  FIG. 1 , each cage  102  preferably incorporates a power source  104 , such as for example, one or more GFI outlets for supplying electricity to light sources  108  and fans  110  within the cage  102 . Individual ebb and flow containers (pots)  116  sit on benches  114  with flow tubes (plumbing)  132  ( FIG. 5 ) going to each container. In accordance with one embodiment, each ebb and flow container  116  contains a plant  112  that is being grown with the hydroponics system of the present invention. A drain  138  on the ebb and flow containers  116  is restricted so the incoming nutrients drain slower than they fill, allowing the water level to reach an overflow  140  at the top of each container  116 . Utilizing gravity, both the drain  138  and/or overflow  140  are discharged into a PVC drain tube  142  under each bench  114 . This in turn, preferably directs the flow of all the containers  116  on a single bench  114  to one drain hole  144  in the top of the reservoir, providing a substantially closed-loop system enhancing overall system efficiency. 
     Each light source moving mechanism  118  shuttles a light source  108  back and forth in line preferably with the center one of three substantially parallel benches  114  located over each reservoir  126 . The light source moving mechanism  118  may be an electric motor or other actuator positioned on a rail or track  146  positioned above the benches  114  and is preferably powered by the power source  104 . The power source  104  may also be nonelectrical, such as for example pneumatic or hydraulic with the motor or actuator powered accordingly. The motion allows the lamp  122  of the light source  108  to be positioned closer to the plants (i.e., closer than if the light source  108  were stationary) without delivering excessive energy to the plant  112 , resulting in a more efficient use of the light source  108  while reducing the risk of burning or otherwise damaging the plants  112 . Reflective hoods  120  in each light source  108  are positioned above the lamp  122  (relative to the plant  112 ) to reflect and direct energy (e.g., light) to the plant, further increasing system efficiency. 
     The axial fans  110  may be connected to the same power source  104  as the light sources  108  in a particular cage  102  and may either be coupled to the rail or track  146  and move with the light source  108  or be stationary within the cage  102  ( FIG. 3 ). The fans  110  are preferably mounted vertically on the cage at substantially the same level as the lamp  122 , blowing cool air around the lamp and heating the air in motion while cooling the lamp  122  and/or reflective hood  120 . According to one embodiment, the lamps  122  are 1000 watt metal halide, but it is understood that other wattages and types of lamps may be used in the system of the invention and that other modifications to various elements and their arrangements within the system may be required in order to provide system efficiencies. 
     As represented in  FIG. 1  and further illustrated in, for example,  FIG. 5 , the reservoirs  126  sit below the benches  114 . Each reservoir  126  preferably includes a pump  130  and/or manifold  134  to deliver water to each ebb and flow container  116 . The manifold  134  is designed to deliver the same flow rate (i.e., the same amount of water at the same time and/or pressure) to each of the ebb and flow containers  116 . The water passes through the containers  116  containing the plants and into a trough  148 . Trough  148  may be positioned within or under each bench  114 . Gravity returns the liquid (e.g., water plus nutrients) back to reservoir  126 . In accordance with a preferred embodiment of the present invention, each reservoir  126  includes an additional circulation pump  150 , which stirs the reservoir  126  when desired and/or during the plant watering process. 
     According to a preferred embodiment of the present invention system efficiencies are enhanced as water evaporation is reduced and more light is allowed to reach each plant  112 , thereby increasing the efficient use of resources and expending the least amount of energy. Preferably, the ebb and flow containers  116  fill and stop automatically when watering, and each individual container  116  can be moved about the bench  114  as needed. As a result water and light are better utilized, through less evaporation and optimizing plant locations relative to the lighting, respectively. 
     In accordance with a preferred embodiment, benches are arranged in groupings of three (3) and are generally parallel to one another in a “stadium” arrangement, whereby the middle bench is lower in elevation than the two outer benches (best depicted in  FIGS. 2, 3, 6 ). The lengths of the benches are generally in line with the movement of the light sources discussed above. This arrangement allows the light fixture associated with a group of three benches to move along their length and efficiently provide light to plants situated on the benches. 
     As previously introduced, each reservoir  126  preferably has an instrument or device for monitoring and/or controlling the chemistry of the fluid in the system (nutrient controller  128 ). For example, each reservoir  126  may have a PH/PPM meter for monitoring PH and nutrient levels of the circulating water. The devices may provide readouts for personnel to monitor or, alternatively, they may provide output signals to controllers  124  in the system  100  that automatically control the PH and nutrient levels. 
     In accordance with further aspect of the present invention, the reflective hoods  120  of the light sources  108  are mounted vertically around the lamps  122  and are designed to direct light and dissipate heat from the lamps  122  ( FIG. 4 ). In accordance with a preferred embodiment, the hoods  120  are designed to accommodate stadium-arranged benches  114 . That is, for example, three (3) rows of plants  112  with four (4) plants  112  in the center row and three (3) plants  112  in each outside row. Preferably, the tallest plants are placed in the outer rows, shortest plants in the center row in order to maximize light use. This diamond pattern placement of plants  112  allows more light from the lamp  122  to strike the plants (i.e., reduces the amount of light hitting the floor) and thereby further enhances system efficiency. 
     In accordance with a further embodiment of the present invention,  FIG. 8  illustrates a seed bed  154  used in system  100 . Seed bed  154  is position above the reservoir  126  and replaces ebb and flow containers  116 . Water and nutrients are pumped from the reservoir into the seed bed  154  via drain fittings placed in the bottom of the seed bed. Water overflow from the seed bed is prevented by overflow drains  156  placed preferably in the center of the seed bed  154 . Further operation and functionality are as set forth and described herein. 
     While the preferred embodiment of the invention has been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of the invention. For example, as previously noted, different light sources may be used and may require modifications to other elements, such as size, location and orientation of fans, reservoirs, manifolds, to name a few. Also, it may be possible to vary the stadium arrangement of the benches to accommodate other modifications to the preferred embodiment, such as, for example, the number of plants and light sources used with each particular group of benches. The cages may be constructed with various materials other than PVC, such as other non-heat conducting materials, or even using conductive materials that are insulated to prevent unintended heat loss or transmission. Further, many of the elements and functions of the system of the present invention, may be controlled manually, automatically, or a combination of both. Accordingly, the scope of the invention is not limited by the disclosure of the preferred embodiment. Instead, the invention should be determined entirely by reference to the claims that follow.