Abstract:
A semi-automated crop production system, the system comprising a growing module which has an opening access for insertion of a grid with a plurality of cells, wherein the growing module further has a self-contained lighting system and fan unit, wherein the growing module can slidably be inserted into a shell.

Description:
CROSS REFERENCE 
       [0001]    The present application is a non-provisional application claiming priority to U.S. Provisional Patent Application Ser. No. 61/316,777, filed Mar. 23, 2010, the disclosure of which is incorporated in its entirety herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention is directed to agriculture systems, more particularly to a self-contained semi automated production facility capable of culturing plants and other organisms in a controlled environment. The present invention is in no way limited to the examples disclosed herein. 
       BACKGROUND OF THE INVENTION 
       [0003]    As population continues to grow, more land is required for habitation and more food is required for consumption. To accommodate growing urbanization and the decrease of arable land area, agricultural systems are centralizing to hotspots within the U.S. and other countries. However, these large-scale production systems may use inefficient methods, and some systems may select fruits and vegetables for their ability to be harvested early and transport for extended periods of time as opposed to being selected for good nutritional content. The increase use of transplants is needed to support the increase in farming for the rising population. Some consumers may wish to engage in supporting or growing locally produced foods for increased quality, nutrition and lower price. However, many cities lack the zoning laws to address small-scale agricultural operations. The present invention features a self-contained semi-automated production facility capable of culturing plants and other organisms in a controlled environment. The system of the present invention provides optimal environmental conditions, regardless of the external conditions, to allow for production of such plants and organisms. The system of the present invention helps to use better technologies to produce food, rather than the traditional methods. The present invention is in no way limited to the examples disclosed herein. 
         [0004]    Any feature or combination of features described herein are included within the scope of the present invention provided that the features included in any such combination are not mutually inconsistent as will be apparent from the context, this specification, and the knowledge of one of ordinary skill in the art. Additional advantages and aspects of the present invention are apparent in the following detailed description. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0005]      FIG. 1  is a perspective view of an outer shell embodiment of the system of the present invention. 
           [0006]      FIG. 2  is a top view of an outer shell embodiment of the system. 
           [0007]      FIG. 3  is a front view of the system of  FIG. 1 . User access points and alternative energy-generating components (e.g., Photovoltaic panels) are shown. Communication components are shown, which allow for communication of information to and from the device. The weather station shown communicates external environmental information to and from the device for control. 
           [0008]      FIG. 4  is another perspective view of an embodiment of the system. 
           [0009]      FIG. 5  is an exploded view of the interior shell of the system of the present invention, which slides into the exterior shell. The interior shell can help provide insulation, a chemical-resistant barrier, and beams for securing internal structural components, equipment, wiring, other devices, and the like. The chemical-resistant liner may allow for sterilization of the device without damaging the exterior shell. 
           [0010]      FIG. 6  is a front exploded perspective view of the interior shell of the system. 
           [0011]      FIG. 7  is a side exploded view of the interior shell system, 
           [0012]      FIG. 8  is a top exploded view of the interior shell system. 
           [0013]      FIG. 9  is a perspective internal view of the shell where the growing modules are inserted into the internal shell. 
           [0014]      FIG. 10  is another perspective internal view of the shell where the growing modules are inserted into the internal shell. 
           [0015]      FIG. 11  is another perspective internal view of the shell where the growing modules are inserted into the internal shell. 
           [0016]      FIG. 12  is a front perspective internal view of the shell where the growing modules are inserted into the internal shell. 
           [0017]      FIG. 13  is a top internal view of the shell where the growing modules are inserted into the internal shell. 
           [0018]      FIG. 14  is a top perspective view of the components of the growing module. 
           [0019]      FIG. 15  is a first perspective view of a growing module. The growing module may comprise a lighting component and a cultivation component, and the housing that surrounds it which holds the fans and part of the sliding mechanism. The removable and stackable modules are independently controlled and maintained in the system. 
           [0020]      FIG. 16  is a second perspective view of the growing module of  FIG. 16 . User access points, cultivation components, and ducting are shown. 
           [0021]      FIG. 17  is a front perspective view of the growing module. 
           [0022]      FIG. 18  is a top perspective view of the growing module. 
           [0023]      FIG. 19  is another perspective view of the growing module. 
           [0024]      FIG. 20  is another perspective view of the growing module. 
           [0025]      FIG. 21  is a perspective view of the growing modules with alternate access doors/openings to the module. 
           [0026]      FIG. 22  is another perspective view of the growing modules with alternate access doors/openings to the module. 
           [0027]      FIG. 23  is a perspective view showing a growing module with front and back access doors. 
           [0028]      FIG. 24  is a perspective view showing a growing module with a front only access door. 
           [0029]      FIG. 25  is a perspective view showing a growing module with a side access door. 
           [0030]      FIG. 26  is a perspective view showing a growing module with a top access door. 
           [0031]      FIG. 27  is another perspective view showing a growing module with a top access door. 
           [0032]      FIG. 28  is a perspective view of a growing plane in its structure. 
           [0033]      FIG. 29  is a perspective view of a lighting and air flow unit with a growing plane. 
           [0034]      FIG. 30  is another perspective view of a lighting and air flow unit with a growing plane. 
           [0035]      FIG. 31  is a perspective view of a set of growing modules in a support frame. 
           [0036]      FIG. 32  is another perspective view of a lighting and airflow unit with a growing plane. 
           [0037]      FIG. 33  is an exploded perspective view of a lighting and airflow fixture of the light and airflow unit of the growing module. This lighting and airflow fixture can be used as the lighting unit within the growing module by itself or in combination with other lighting units. 
           [0038]      FIG. 34  is another exploded view of a lighting and airflow fixture of the light and airflow unit of the growing module. 
           [0039]      FIG. 35  is two exploded perspective views of a lighting and airflow fixture of the light and airflow unit of the growing module. 
           [0040]      FIG. 36  is another exploded perspective view of a lighting and airflow fixture of the light and airflow unit of the growing module. 
           [0041]      FIG. 37  is a perspective internal view of an alternate embodiment of the shell where the growing modules are inserted into the internal shell. 
           [0042]      FIG. 38  is a perspective and internal view of an equipment module of the system of the present invention. The equipment module may support and contain hardware needed to operate the system. The equipment module may house lighting components, environmental control components, irrigation components, and the like. 
           [0043]      FIG. 39  is another perspective and internal view of an equipment module of the system. 
           [0044]      FIG. 40  is a front perspective and internal view of an equipment module of the system. 
           [0045]      FIG. 41  is another front perspective view of an equipment module of the system. 
           [0046]      FIG. 42  is a top view of an equipment module of the system. 
       
    
    
     DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0047]    The following is a listing of numbers corresponding to a particular element referred to herein. The present invention is not limited to the described examples components and configurations: 
         [0048]    1. Growing plane(s)/flood tray(s) (pre-plumbed) (e.g., supporting aluminum structure) 
         [0049]    2. Fitted tray cover for growing plane 
         [0050]    3. Misting/aeroponic manifold (s) 
         [0051]    4. Sensor Array(s) inside growing area/volume (e.g., wireless, air T, RH, VPD, PAR, EC, pH, TDS, DO) 
         [0052]    5. Orifice for seedling/media placement 
         [0053]    6. Light Source(s) module(s) (T-8, T-12, T-5 Fluorescent; LED; HID; Incandescent; MV), LED-associated drivers 
         [0054]    7. Light Diffusing Panel(s) or colored lenses (plastic, glass, metal, composite, synthetic, etc.) with orifices or fixtures for airflow 
         [0055]    8. Air circulation fan(s) for lighting and airflow module(s) 
         [0056]    9. Growing Module (with light and airflow unit) 
         [0057]    10. Air circulation fans for growing area/volume 
         [0058]    11. Automatic/Controlled Louvre(s) (e.g., air ducting) 
         [0059]    12. Growing module container/box/skin 
         [0060]    13. Drawer/Shelving hardware to open and close and support growing plane/flood tray w/ products. 
         [0061]    14. Drawer/Shelving hardware to open, close, and support growing module. 
         [0062]    15. Handles to access growing module 
         [0063]    16. Handles to access contents of module 
         [0064]    17. Handles to extract products 
         [0065]    18. Environmental/A/C manifold to growing area 
         [0066]    19. Irrigation nutrient manifold to growing area 
         [0067]    20. HVAC Ducting 
         [0068]    21. Air ducting for A/C in 
         [0069]    22. Air ducting for A/C return 
         [0070]    23. Quick connect to irrigation in 
         [0071]    24. Quick connect to irrigation out/subsequent level 
         [0072]    25. Electrical plug to fans/light/sensors/electrical 
         [0073]    26. User Access Panel 
         [0074]    27. Cooling unit(s) (e.g. A/C)—ductless, split ductless, etc 
         [0075]    28. Waste heat fan for introduction into system for heating 
         [0076]    29. Exhaust system from equipment area (ballasts) (e.g., exhaust fan from electrical area×2) 
         [0077]    30. CO2 injection system (e.g., CO2 cylinder, regulator/actuator, comms, sensor) 
         [0078]    31. Air compressor(s) 
         [0079]    32. UV Sterilizing module(s) (e.g., sterilized unit that uses technologies such as UV, Ozone, chemicals, etc.) 
         [0080]    33. Injector Board(s) (e.g., injector(s), particulate filter(s), pressure gauge(s), inline sensor(s)—EC, pH—misc. fittings) 
         [0081]    34. Mixing tank(s) 
         [0082]    35. Stock Nutrient tank(s) 
         [0083]    36. Particulate filter(s) 
         [0084]    37. Inline sensor arrays (e.g., pH, EC, DO, T, TDS) 
         [0085]    38. Solenoids (e.g., fresh water, nutrient solution) 
         [0086]    39. Chiller(s) (e.g., inline, coil, flow thru) 
         [0087]    40. Heat Pump (e.g., coil, inline, drop in, flow thru) 
         [0088]    41. Fresh H2O riser 
         [0089]    42. Ballast(s) (e.g., fluorescent, HID, Or, power sources for LED) 
         [0090]    43. Interior cover/door (like a virus screen or pre entry—if box opened, contents still not exposed) 
         [0091]    44. Slide in chassis for support modules and equipment 
         [0092]    45. Support beams for anchoring 
         [0093]    46. Chemical resistant lining (e.g., Rhino Liner) 
         [0094]    47. Interior shell (insulation) 
         [0095]    48. Insulating paint 
         [0096]    49. Exterior shell 
         [0097]    50. Exterior Access Panel(s) or door 
         [0098]    51. Viewing window (glass, 2 way mirror, composite, plastic) 
         [0099]    52. Weather Station 
         [0100]    53. GPS Tracking and Communications components 
         [0101]    55. Controller/Computer control system (e.g., multiplexer, etc.) 
         [0102]    56. Photovoltaic System (e.g., wind turbine) 
         [0103]    56. Semi-automatic Crop Production System 
         [0104]    57. Visual detection system (camera, track, lenses (e.g., IR, UV, etc.) 
         [0105]    Referring now to  FIG. 1-42 , the present invention features a self-contained semi-automated production system  100  for culturing plants and other organisms in a controlled environment. The system  100  may be used in a variety of environments including but not limited to farms, yards, fields, warehouses or buildings, and the like. The system  100  can be easily transported from one location to another (e.g., because of the size of the system  100  and exterior shell  49 ). A user can engage in activities such as seeding and harvesting, and the system  100  of the present invention performs the necessary tasks for cultivating the plants or organisms. For example, the system  100  can control conditions including but not limited to light, temperature, relative humidity, carbon dioxide concentration, irrigation, and the like, via internal algorithms and programs. Without wishing to limit the present invention to any theory or mechanism, it is believed that the system  100  of the present invention is advantageous because little agricultural knowledge and experience is required of a user to grow plants and organisms with this system  100 . Also, since the system  100  is contained, production of plants, crops, and other organisms can occur continuously, independent of the external climate and conditions. 
         [0106]    The system  100  of the present invention comprises an outer shell  49 . In some embodiments, the exterior shell  49  is similar to a shipping container, which is well known to one of ordinary skill in the art, however the exterior shell  49  is not limited to a shipping container. The exterior shell  49  may be constructed in a variety of sizes, for example sizes appropriate for small and large-scale use. An interior shell is disposed (e.g., slidably disposed) in the exterior shell  49 . As shown in  FIG. 1  through  FIG. 4 , the system  100  may comprise one or more power sources. The power source, for example, may comprise an alternative energy-generating component to create an off-grid or grid-tied system such as one or more photovoltaic panels  55 . One or more access points (e.g., doors  50 ) are disposed in the exterior shell  49 . The shell  49  may further comprise a variety of other components, for example for providing strength and/or insulation (e.g., for helping to control the internal environmental conditions accurately). As shown in  FIG. 1  through  FIG. 4 , insulating paint  48  may be coated on the exterior shell  49 . In some embodiments, the system  100  further comprises a weather station  52 , a GFS tracking and communications component  53 , and/or a computer control system  54 . 
         [0107]    Referring now to  FIG. 5 , the system  100  may comprise an interior shell  47 . The interior shell  47  may provide additional insulation for the system  100  (e.g., resistance to entry/exit or heating or cooling) and/or provide additional strength to the system  100 . A chemical-resistant liner  46  may be disposed in the interior shell  47 , allowing the unit to be effectively cleaned and sterilized in preparation for use or modification of the system without damaging the exterior shell  49 . Various attachment or fitting components  44  may be disposed on the outside of the interior shell  47 , allowing the interior shell  47  to be slid or mounted into the exterior shell  49 . 
         [0108]    The interior shell  47  provides a means of mounting growing modules and other materials needed for the system  100 . For example, mounting components  45  may be disposed on the inner walls of the interior shell  47  for mounting growing modules, irrigation components, light components, and the like. 
         [0109]    The present invention is not limited to a configuration with an exterior shell and an interior shell. For example, in some embodiments, the system  100  comprises a single shell, and in some embodiments, the system  100  comprises a plurality of shells. 
         [0110]    The system  100  of the present invention comprises a plurality of growing modules, which are small isolated containment units. The system  100  creates micro-climates (e.g., with specific environmental parameters) inside the various growing modules (e.g., see  FIG. 16  through  FIG. 18 ) installed in the system  100 , and each growing module can be used to grow a specific plant or organism (or certain groups of plants or organisms), allowing the specific grown requirements of those plants or organisms to be met. The artificial micro-climates created allows for growth of these plants and organisms in non-traditional environments such as buildings and other urban settings. The growing modules allow for efficient control of parameters such as temperature, light, humidity, carbon dioxide concentration, and the like, because the growing modules have a small volume of space. The environmental parameters are also monitored via sensors  4  for feedback control. 
         [0111]    The system  100  may also be designed to provide the user information about the plant or organism as it progresses, either for educational purposes or to help the user to make decisions, e.g., to modify conditions or to harvest, etc. 
         [0112]    The ability to instantaneously adjust environmental settings based on what is occurring inside the growing area and regulates the immediate conditions of the aerial cultivation environment surrounding the organism, e.g., using components  10 ,  27 , and  30 , allows for almost complete control of its culture and manipulation, modification, and/or response. Through the use of external weather stations (e.g., components  52  and  53 ), the system  100  may opt to utilize external conditions for heating and cooling the device, as well as using data for acclimatizing plants to external conditions where and when appropriate. Usage of passive cooling and heating will increase the efficiency of the device and lower its power requirements. 
         [0113]    Using lighting sources in the growing module (e.g., component  9 ) such as, but not limited to solar collectors, LEDs, and fluorescent lights (e.g., components  6 ,  7 ,  8 ,  42 ), the culture and manipulation of plants and other organisms is made possible without use of sunlight. And, such light sources allow the system  100  to manipulate the light conditions as desired (e.g., alternative light cycles, etc.). Light diffusing panels  7  may be used to achieve uniform lighting throughout the growing module, while able to provide cooling and additional airflow (possibly directed) to the aerial portion of the growing environment. Additional heat generated by the light source may be separated by the diffusing panel and then ventilated away from the growing environment (e.g., via component  8 ). Removing excess heat reduces the load on the air conditioning units, creating a more efficient system. 
         [0114]    Controlling the light output reaching the organism allows precise and accurate control of the plant&#39;s/organism&#39;s development through exposure to specific wavelengths of light emitted including but not limited to UV, PAR, and IR spectrum. Since the amount of light needed varies per plant/organism, the system  100  of the present invention integrates algorithms contained within the computer control systems  54 . These algorithms and programs communicate with sensors  4  inside the growing modules to control light intensity, duration, color, quality, and other factors to yield the desired type of growth. This combination of automatic environmental control and sensing allows users to operate the device without prior knowledge of the plant&#39;s/organism&#39;s optimal conditions. 
         [0115]    Computer control systems  54  coupled with sensors  4  (e.g., see components  30 ,  33 ,  37 ,  52 ,  53 ,  55 ,  57 , etc.) monitor real-time parameters including but not limited  10 : air temperature (AT), solution temperature, RH (%), PAR (umol m-2 s-1), CO2, dissolved oxygen, and other parameters, in addition to visual monitoring through camera and other imaging techniques. Communications between sensors and the computer control systems  54  allow for automated control of the conditions required for growth of the selected organism based on pre-programmed set points so the user requires no prior experience or knowledge. Alternatively, a user may enter alternate parameters or set points. Integrating visual monitoring allows for pre-programmed decision software to completely control plant growth and reduces the user&#39;s interaction. The computer and other control systems allow remote monitoring, access, and control to be accomplished through terminals, computers, laptops, PDA&#39;s, and other communication devices. Remote access allows user interaction and troubleshooting to occur in a non-contact manner, helping to eliminate disturbing of the production process. 
         [0116]    The system  100  of the present invention integrates hydroponic methods on a controlled recirculating system and allows for high-efficiency usage of inputs such as water and fertilizer. Some examples of hydroponic methods (e.g., “deep-flow hydroponics”) have demonstrated reductions in water usage, for example by over about 50 fold. Recirculating methods increase the efficiency of water use by re-using treated water and preventing it from running out of the system and into the ground. Using an internal irrigation system (e.g., see components  19 ,  23 ,  31 ,  33 - 40 ), water may be re-circulated continuously throughout the system. By treating with sterilizing lamps or anti-microbial lights and/or ozone-generating systems (e.g., see component  32 ), nutrient solution and water may be recirculated without introduction of pests, pathogens, and other organisms that may develop or be introduced otherwise. Other treatments (e.g., chemical additives) may be used with the system  100  of the present invention. The recirculation of nutrient solution and its sterilization using the system  100  may provide for optimal water usages and higher efficiency of usage for fertilizer as well. 
         [0117]    The following the disclosures of the following U.S. patents are incorporated in their entirety by reference herein: U.S. Pat. No. 2008/10295400. 
         [0118]    Various modifications of the invention, in addition to those described herein, will be apparent to those skilled in the art from the foregoing description. Such modifications are also intended to fall within the scope of the appended claims. Each reference cited in the present application is incorporated herein by reference in its entirety. 
         [0119]    Although there has been shown and described the preferred embodiment of the present invention, it will be readily apparent to those skilled in the art that modifications may be made thereto which do not exceed the scope of the invention. 
       EXAMPLES 
       [0120]    The examples provided below are merely examples to further clarify the present invention, and do not limit the scope of the invention in any way. 
       Example 1 
     Transplant Growing Protocol 
     Transplant Growing Protocol: 
       [0121]    1. Seed 
         [0122]    2. Germinate 
         [0123]    3. Preparation 
         [0124]    4. Transplant 
         [0125]    5. Monitor 
         [0126]    6. Harvest 
         [0127]    7. Adjust
       1. Obtain clean materials needed for germination: Seed, substrate, tray &amp; cover.
           a. Use 98/200 cell Rockwool slabs and place inside black plastic germination tray.
               i. (Optional) Rinse Rockwool substrate with water for 1 minute.   ii. Use Jiffy preformed media and place in tray   
               b. Obtain the seed from the Seed Refrigerator.   
           2. Pour out the seed desired, and then seal the package and place back inside the refrigerator.
           a. Be sure to place the seeds back into the refrigerator.
               i. Thermal dormancy—High temperatures, above 18 C (optimal germination T) may have an adverse effect on lettuce seed germination. This can be reversed, however the cost and time to do so may be prohibitive. Instead, good seed management practices can prevent thermodormancy.   
               
           3. Pace seed in substrate.
           a. Pelleted—Place 1 seed per cell in pre-stamped hole   b. Naked—place 2-3 seeds in pre-stamped hole.   c. (Optional) Smear one handful of vermiculite over the slab filling each hole lightly. Use more if necessary.   
           4. Place seeded trays in propagation area
           a. If un-irrigated, place clear cover over tray.   b. If irrigated, check irrigation settings and function   
           5. Check each day for germination and record %&#39;s.
           a. Ensure that the slab stay wet, but not soaking.   b. Ensure no fungal growth or other   
           6. Begin irrigating with full strength nutrient solution 3 days after germination of at least 90% of the seeds.   7. 12 days after sowing, select plants that are uniform in size, shape, and leaf number as best as possible.   8. Check DFHS system settings to ensure set points are correct for crop.
           a. EC˜2.0 mS/m; pH 5.90-6.10; DO˜6.9 ppm; H2O Temp˜21.0 C   
           9. Check tanks daily for EC/pH/DO and monitor accordingly.   10. Harvest plants
           a. Remove dead leaves or unsightly parts of the product   b. Store in humid, cool area out of direct sunlight   
           11. - - -   12. Weigh
           a. A—Market acceptable; 150 g   b. B—Not market acceptable, but still usable; 75 g-150 g   c. C—Not usable, feed, compost or trash; &lt;75 g   
           13. Grade
           a. A—Market acceptable   b. B—Not market acceptable, but still usable   c. C—Not usable, feed, compost or trash   
           14. Sort   15. (Optional) Sterilize   16. Pack/Label   17. Storage       
 
         [0000]    
       
         
               
               
               
               
               
             
               
               
               
               
               
             
           
               
                   
                   
               
               
                   
                 Germ 
                 Cult 
                 Storage 
                 Acclimatization 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                 EC 
                 Amb-&lt;0.5 
                 1.5 
                 0 
                 Ambient 
               
               
                 pH 
                 5.5-6.5 
                 6   
                 0 
                 Ambient 
               
               
                 Air T 
                     29 C. 
                 20-30 
                 0-10  
                 Ambient 
               
               
                 Water T 
                   20-30 C. 
                 20-30 
                 0 
                 Ambient 
               
               
                 RH 
                  50-99% 
                    10-99% 
                 10-99%     
                 Ambient 
               
               
                 VPD 
                   
                   
                   
                 Ambient 
               
               
                 PAR 
                   0-250 
                  250-1000 
                 0-250 
                 Ambient 
               
               
                 CO2 
                 300-1000 ppm 
                  300-2000 
                 0-500 
                 Ambient 
               
               
                 Air 
                    0-.5 m/s 
                 0-5 m/s 
                 0-5  
                 Ambient 
               
               
                 Speed