Abstract:
A system, method and structure are presented to allow water from a fish tank to be pumped upward to an aquaponic trough on the top floor in a multi-floor greenhouse structure, from which the water will have a gravity-fed and unpumped flow to lower troughs. Furthermore, the application describes a plumbing system to control the feed of pumped and gravity fed water through the various aquaponic troughs and back to the fish tank at predetermined intervals.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a utility application claiming priority to U.S. provisional application No. 62/059,564, which was filed on Oct. 3, 2014 and is incorporated in its entirety herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present application relates to a closed loop eco-system food product facility using aquaponic principles. More particularly, the described embodiments relate to the growing of fish in fish tanks while using fish waste to fertilize plants in a four leveled greenhouse structure wherein the levels of the greenhouse are exposed to a controlled flood and drain cycle of water exposure. 
       SUMMARY 
       [0003]    One embodiment of the present invention provides for a multi-level greenhouse structure with one or more growing troughs on each level. Water from one or more fish tanks is pumped to the trough(s) on the highest level of the greenhouse structure. The troughs are filled and emptied on a ¼-time fill, ¼-drain, ½-time sit empty schedule as determined by a computer-controlled system of valves. In one embodiment, each level or story has four, or a multiple of four, troughs. At any given time, one-fourth of the troughs are being filled, one-fourth are being emptied, and one-half are sitting empty with the plant roots exposed. This allows the water to be constantly pumped to the highest level. If the total cycle time is one hour, the water would be switched to a new upper-level trough every fifteen minutes. 
         [0004]    The troughs on the lower levels are watered through the drainage of the troughs on the upper levels. If each trough drains to a trough directly below it, the lower trough would be one fifteen-minute cycle segment behind the trough above it. By making the greenhouse four stories, each trough would empty its water to the trough below it, with the bottom troughs emptying back into the fish tanks. 
         [0005]    The greenhouse can be constructed with steel grating or other material which allows air and heat to rise up from the lower levels (or floors) to the upper levels. Plants grown on the upper levels can be selected from among those plants that grow best in warm, humid conditions. Curtain walls or other structures can be used to isolate troughs, with conditioned air being pumped into each trough compartment to create ideal growing conditions for the plants in each trough. 
         [0006]    Water draining from an upper trough to a lower trough can pass through a hanging lattice of conduit in which plants are supported and grown. The lattice includes water pass-through pipes, with the hanging plants having roots that contact the water passing through the pass-through pipes. Water would then splash into the lower tank in a manner to increase the oxygen levels in the water. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    Aspects and embodiments of the present invention are shown in the following figures: 
           [0008]      FIG. 1  is a cross-sectional frontal view of a housing and a representative arrangement of growing troughs and their arrangement within the housing. 
           [0009]      FIG. 2  is a cross-sectional side view of the housing and trough arrangement shown in  FIG. 1 . 
           [0010]      FIG. 3  is an exterior front view of the housing shown in  FIG. 1 . 
           [0011]      FIG. 4  is an exterior side view of the housing shown in  FIGS. 1-3 . 
           [0012]      FIG. 5  is an exterior rear view of the housing shown in  FIGS. 1-4 . 
           [0013]      FIG. 6  is an exterior side view of the opposite side of the housing shown in  FIG. 4 . 
           [0014]      FIG. 7  is a more detailed interior view of the greenhouse portion of the housing shown in  FIGS. 1-6 . 
           [0015]      FIG. 8  shows an embodiment of a plumbing or pipe assembly for controlling water flow to and through the troughs shown in  FIG. 1 . 
           [0016]      FIGS. 9-13  are a sequence of illustrations depicting the flood and drain cycle of water to the troughs as provided by the pipe assembly of  FIG. 8  and shown at 15 minute increments. 
           [0017]      FIG. 14  is a detailed view of a growing trough and isolation system for creating a micro climate around a given trough within the greenhouse. 
       
    
    
     DETAILED DESCRIPTION 
       [0018]    Inventive aspects of the aquaponics system and housing  10  shown in the various  FIGS. 1-14  start with the structure of the greenhouse portion  12 . Capable of vertical, multi-level design, the greenhouse portion  12  of the structure  10  can consist of many levels with its only limitations in overall height being the zoning regulations or the strength capacity of building materials. In the embodiment shown herein the greenhouse  12  consists of four levels: a ground or first level  20 , a second level  22  directly above the first level  20 , a third level  24  directly above the second level  22 , and a top or fourth level  26  directly above the third level  24 . 
         [0019]    Typically, the structure  10  is a steel column and beam building divided into levels  20 ,  22 ,  24  and  26  through the use of steel grating or similar material, which has the strength necessary to support the aquaponic growing troughs  30  present on each level. The heights of each level  20 ,  22 ,  24  and  26  can vary or they can all be the same depending on the product to be cultivated on a specific level and the lighting requirements for that product. In at least one embodiment, steel grating is used in constructing the level partitions (floors/ceilings)  28  to allow air and heat to freely pass between levels and thus permit highly economical air flow throughout the facility. Other materials of sufficient strength and durability, and which also allow free transfer of air and heat therethrough may alternatively be used to construct the level partitions  28 . The universal air flow, both horizontally and vertically, is very important to the growth of plants for pollination and by creating a consistent environment for humidity and temperature. The floor/ceiling material permits hot, humid air to rise naturally. This provides for individualized placement of specific plants species on a level-by-level basis defined by their requirements for humidity and temperature. 
         [0020]    The ability to integrate multi-level design/construction also enables the facility to provide greater energy savings. By controlling heat loss vertically rather than horizontally like your typical greenhouse, the facility  10  provides economic and environmental benefits to the user. 
         [0021]    As is depicted in the various  FIGS. 1-2  and  7 - 13  the multi-level design provides for the vertical stacking of the troughs  30  “one on top of another”. As is best shown in FIGS.  7  and  9 - 13 , this provides for the flow of the nutrient rich water  32  from the trough(s)  30  on the top level  26  to the trough(s)  30  on the ground level  20  through the use of gravity, which reduces both capital and operating expenditures while enhancing product growth. A computerized control system (not shown) can be used to activate valves  42  (water entry valve  42 ) and  44  (drain valve  44 ) of a plumbing system  40  (see  FIGS. 8-13 ) to open and close, thereby directing the gravitational flow of the nutrient water  32  through the levels  20 ,  22 ,  24 ,  26  and troughs  30  thereon. The system  10  shown ensures that the only pumping of water necessary is in the initial filling of the first trough  30  on the fourth level  26 . 
         [0022]    As depicted in  FIG. 2 , it can be seen that water flow through the troughs  30  begins with the vertical pumping of the nutrient water  32  from at least one fish tank  34  located in the fish growing portion  14  of the housing  10 , via the conduit  46  and valves  42 ,  44  of the plumbing system  40 . It should be noted, that while multiple valves  42  and  44  may be used, as in the manner shown, in at least one embodiment the use of only a single entrance valve  42  is necessary and each trough  30  is provided with a single drain  44 . A detailed view of an example plumbing system  40 , including lattice  47  (discussed in greater detail below) is shown in  FIG. 8 . 
         [0023]    The fish growing portion  14  of the housing  10  can be constructed and arranged in a variety of ways. The structure of the fish growing portion  14  may be of any conventional construction materials, and may be immediately adjacent to the greenhouse portion  12  (as shown in the various figures) or separate therefrom. The fish growing portion  14  must however contain at least one fish tank  34  suitable for containing fish and a sufficient reservoir of water to fill the troughs  30  in the manner mentioned above and described in greater detail below. The at least one fish tank  34  must also be in communication with the plumbing system  40 . 
         [0024]    An example of the pumping and dispersion of nutrient water  32  into and through the troughs  30  is illustrated in  FIGS. 9-13 . As shown therein, nutrient water  32  is pumped from the fish tank(s)  34  of the fish growing area  14  (shown in  FIG. 2  and represented in  FIGS. 9-13  by arrow  34 ) to the trough or troughs  30  located on the fourth level  26  of the greenhouse  12 . 
         [0025]    As depicted in  FIG. 8  the plumbing system  40  brings the nutrient water  32  a vertical distance of approximately 25-30 feet (from the bottom of the at least one fish tank  34  to the truss bearing height of the greenhouse&#39;s fourth level  26 ) where the nutrient water  32  can be distributed horizontally through the trough or troughs  30  located on the fourth level  26 . From there the water  32  will free fall vertically into each trough  30 , though a branch pipe or conduit  46 , of the progressively lower levels  24 ,  22 , and  20 . By selectively opening and closing the valves  42 , 44  troughs  30  on each level  26 ,  24 ,  22 ,  20  are flooded or filed for 15 minutes and then subsequently allowed to drain for 45 minutes; at which point the cycle is repeated as shown in  FIGS. 9-13 . 
         [0026]    After the flooding of the trough(s)  30  on the fourth level  26  for the desired 15 minute period, the nutrient water  32  will drain from the fourth level trough at a location diagonally located from the entry point. This will ensure even flow and distribution of the nutrients within the trough volume. The water will essentially free fall, contained in a pipe from the fourth level  26  trough  30  to the third level  24  trough  30  located directly under it. Again the flooding of the troughs will occur for a period of 15 minutes and then will be subsequently drained for a period of 45 minutes. 
         [0027]    The process is repeated in order to transfer the nutrient water from the third level  24  trough  30  to the second level  22  trough  30  located directly under it, including the diagonal flow of nutrient water across the trough, from entry point to draining point. The second level  22  trough  30  will also fill for 15 minutes and then drain for 45 minutes. 
         [0028]    The filling of the first level (ground floor)  20  trough  30  happens in the same manner as the troughs  30  on the second  22  and third level  24  with the free fall, in a pipe or conduit  46 , of nutrient water  32  into it from the trough above. Nutrient water in the first level  20  trough  30  is oxygenated and then pumped into the fish tank  34 . 
         [0029]    As best shown in  FIG. 8  but also depicted in  FIGS. 9-13  an alternative or in addition to containing the flow of water in conduit  46  for “free fall” between the troughs  30  of each level, the plumbing system  40  may also include conduit lattice  47  above one or more troughs  30  to provide additional surface area for hanging plants to grow (see  FIG. 7  for illustration of hanging plant). The lattice  47  may have a plurality of openings into which the plant is secured directly. This allows the plant&#39;s roots to be exposed directly to the water flowing through the lattice  47 , thereby allowing the plant to gain nutrients from the flowing water and further oxygenating it. In effect using the plumbing system  40  as a mechanism to increase the productivity of the system  10 . 
         [0030]    Though the system  10  of the present disclosure is idealized using the aforementioned flood and drain water cycle of 1 hour duration, in a greenhouse portion  12  having four levels  20 ,  22 ,  24 ,  26 , the number of troughs  30  on each level is limited only by the size of the faculty build to contain them. For example, in the embodiment shown in  FIGS. 1 and 8  a system  10  having four similarly sized troughs  30  on each level  20 ,  22 ,  24 ,  26  of the greenhouse portion  14  is shown. Thus forming a grid of sixteen troughs in four horizontal rows (each level) and four vertical columns. 
         [0031]    For ease of discussion each column of troughs  30  is labeled alphabetically A, B, C and D, and numbered according to their corresponding level of 1, 2, 3 and 4. In such an arrangement, the plumbing system  40 , is utilized via manipulation of valves  42  and  44  to start the water circulation cycle depicted in  FIGS. 9-13  at 15 minute intervals for each column. 
         [0032]    For example: when the troughs  30  of column A are at time zero of the water cycle (shown in  FIG. 9 ) the adjacent troughs of column B are 15 minutes ahead in the cycle (as shown in  FIG. 10 ), and the adjacent troughs  30  of column C are at time 30 minutes (as shown in  FIG. 11 ), and the adjacent troughs  30  of column D are at time 45 minutes (as shown in  FIG. 12 ). This pattern of off set timing may be varied or altered by columns in any manner desired by manipulation of valves  42  and  44  in adjacent columns. In addition, it should be noted that in a similar manner the plumbing system  40  is capable of bypassing water flow to individual troughs  30  or the entire column of troughs so as to allow for cleaning, maintenance, harvesting of plants or for any reason. 
         [0033]    The troughs  30  present on each level  20 ,  22 ,  24 ,  26  may be of similar or different construction and/or arrangement. Troughs may be of different dimensions but to better control and regulate water flow, ideally they should be similar. In at least one embodiment all of the troughs  30  have an interior dimension of approximately 20 feet×48 feet×2 feet. 
         [0034]    In the embodiment shown and described herein, though the troughs  30  are all of similar dimension they do have some distinctions. For example, in the embodiment shown in  FIG. 7  the trough  30  of the first level  20  is contains two distinct reservoirs  60  and  62  for containing two distinct forms of water. Reservoir  60  is a reservoir for collecting and containing rain water run off that is diverted from the guttering  70  of the housing  10  and/or from other storm water collection sources. Reservoir  62  is positioned above the rain water reservoir  60  and contains nutrient water  32  to a level of approximately 18 inches during the “flood” part of the first level water cycle (see discussion above). During the “drain” portion of the cycle, the level of nutrient water  32  contained in the reservoir  62  may drop up to 12 inches. In the embodiment shown, reservoir  62  is used to raise algae and duckweed to aid in cleaning and oxygenating the water before it is returned to the fish tank(s)  30 ; as such reservoir  62  is never allowed to become fully dry. 
         [0035]    The rain water reservoir  60  is separate from the nutrient water reservoir  62 , but the water contained therein may be accessed via the plumbing system  40 . Water from reservoir  60  may be added to the nutrient water  32  when necessary in order to compensate for water lost from evaporation, splashing, spills, etc. 
         [0036]    The troughs  30  shown on the second level  22  and third level  24  include a floating mat  80  of porous material such as rigid insulation, etc. The mat  80  acts as a substrate upon which crops such as lettuce and microgreens may be grown. The root structure of the crops passes through the mat  80  and into the nutrient water reservoir  62  below. 
         [0037]    The depth of reservoir  62  in the troughs  30  of level two and three  22 ,  24  is between about 6 and 14 inches. In embodiments where the depth of the reservoir  62  is less than 12 inches the reservoir  62  may be completely drained of nutrient water  32  during the “drain” phase of the watering cycle. 
         [0038]    As mentioned, the second level  22  and third level  24  troughs  30  will use the floating raft method of aquaponic growth and will employ a flood and drain cycle that may drain approximately half (or more) the water volume contained in each trough  30 . In such embodiments each trough  30  can contain a level of 12 inches of nutrient water  32  at the completion of the flood period. Whereas at the completion of the draining period, the nutrient water level will be 6 inches. That 6 inch level will be maintained during the two—15 minute breathing periods (between flood and drain) as well. Draining half the nutrient water enables the roots of the lettuce plants to become exposed to oxygen which will enhance and promote plant growth. 
         [0039]    A reason for maintaining the 6 inches of nutrient water in the reservoir  62  is to permit any nutrient sediment to settle out of the nutrient water to a false bottom  82  of the trough  30  (see  FIG. 9 ). The false bottom  82  will be placed 1″ to 2″ inches above the actual bottom of the trough to facilitate trough drainage. The false bottom  82  is placed in the trough  30  to capture and hold the nutrient sediment. This provides for more refined breakdown of the sediment. 
         [0040]    Returning now to the illustrative example of the system  10  shown in  FIG. 7  and back up the to the trough(s)  30  of the fourth level  26 , each trough  30  will contain a growing media  84  that may include expanded clay pellets, such as for example hydroton expanded clay media. The depth of the media may be approximately 16 inches. 
         [0041]    Due to the natural tendency for heat to rise, the fourth level environment is going to be very warm, 80 degrees and warmer, and very humid, 60% and greater, almost a tropical environment. The primary plants to be grown on the fourth floor will be: Tomatoes, Basil, Green Peppers, and/or other crops where a warm and wet environment is desirable for their growth. 
         [0042]    As already mentioned, the fourth level  26  troughs  30  will be the first of the troughs  30  to receive the nutrient rich water  32 . Additionally, they will also receive a greater amount of un-dissolved solids from fish waste or leftover food. The use of inert growing media  84  to capture and in essence “provide a home” for this un-dissolved nutrient matter is a key component of the water flow system. The un-dissolved matter settles within the expanded clay pellets, advancing further nutrient breakdown and dissolving. The growing media also provides an undisturbed structure for the root system of plants that require such structure for long term growth and production. The plants roots will also be able to seek out and collect the nutrients that have collected on the clay pellets which also help break down the solids. 
         [0043]    To aid in the breakdown of the un-dissolved solids, earthworms may also be placed in the growing media  84 . The worms will eat and digest the solids, leaving behind their waste castings which are an excellent form of nutrient for the plants. The worms will also construct passage ways within the clay pellet media  84  that will promote nutrient water  32  flow during the time the trough  30  is flooded. When the trough is drained, these passage ways will permit oxygen to flow through the media which will enhance plant growth and nutrient breakdown. Further breakdown of the nutrients permits the nutrients to become dissolvable and easier for the plants consume. The worms can then be harvested from time to time to be fed to the fish, reducing the expense of organic fish food and thereby reducing the cost of all the products produced in the facility. 
         [0044]    After passing through the fourth level  26  through second level  2 , 2  as described above the nutrient water  32  drains to the first floor  20  troughs  30  which are used primarily to grow algae and duck weed. 
         [0045]    Obviously it is not always appropriately sunny, nor can sufficient environmental conditions for plant growth be guaranteed in any greenhouse year round. As such, the present system  10  employs lighting and atmospheric (HVAC) systems to ensure and enhance growing conditions as necessary. 
         [0046]    For example, as depicted in  FIG. 7  each level  20 ,  22 ,  24 ,  26  includes lighting fixtures  72  affixed to and/or suspended from the level partition  28 . There may be any number or type of lighting fixture provided to a given trough  30 . Lighting may be customized to provide specific spectrums and/or intensity. In at least one embodiment the fixtures are LED lights which require minimal power to provide sufficient growing illumination and thus increase the overall efficiency of the system  10 . 
         [0047]    Air flow, temperature and humidity may similarly be enhance or controlled by the use of inflow and outflow vents  74  that may be used to regulate and control air flow within an entire level or around a specific trough  30 . 
         [0048]    In some embodiments of the present system  10 , a still greater degree of environmental control of a specific trough&#39;s growing conditions can be provided through the use of isolating curtains  78  which may be drawn around a trough  30  such as in the manner shown in  FIG. 14 . Trough  30  may be partially or fully enclosed by a curtain  78 , whereupon all aspects of the trough&#39;s growing conditions may be customized via manipulation of the valves  42 ,  44  (not shown in  FIG. 14 ) vents  74  and lighting fixtures  72 . 
         [0049]    Curtain  78  may be suspended from level partitions  28  (see also FIGS.  7  and  9 - 13 ). To properly secure a trough  30  from the surrounding environment, the curtain  78  may be secured or sealed to the ledge  31  of the trough to minimize temperature and humidity variations. Various mechanisms such as hook and loop type fasteners (VELCRO®), buttons, hooks, zippers, etc. can be used to secure the curtain  78  and trough ledge  71 . 
         [0050]    The curtains  78  themselves may be of any construction desired. In some embodiments that are flexible plastic sheeting. In some embodiments they may include a plurality of rigid plastic, fiberglass or even glass panels. In at least one embodiment the curtains  78  include a reflective surface or coating on the interior of the curtain  78  so as to reflect lighting from fixtures  72  back onto the growing area of the trough  30 . 
         [0051]    The many features and advantages of the invention are apparent from the above description. Numerous modifications and variations will readily occur to those skilled in the art. Since such modifications are possible, the invention is not to be limited to the exact construction and operation illustrated and described. Rather, the present invention should be limited only by the following claims.