Patent Description:
Hydroponics is a method of cultivating plants without natural dirt or soil, by instead using mineral nutrient solutions in a water solvent. Plants may be grown with only their roots exposed to the nutritious liquid, or the roots may be physically supported by a growing medium. As the roots of the plant grow, the roots tend to surround the pieces of the media. This not only anchors the plant but also allows the roots to grow outward and absorb nutrients for the plant. In nature, grow media is usually dirt or soil. Benefits of hydroponic systems include increased growth rate, reduced water usage, and reduced labor.

Known growing mediums include expanded clay aggregate and gravel. Such media have several drawbacks. To maximize the yield from a plant, the nutrients levels of the nutritious liquid in which the plants are grown are closely controlled. A common method for monitoring the nutrient level is measuring the pH of the liquid. As plant roots grasp the expanded clay or gravel, the media breaks down, which can change the overall nutrient composition and pH of the liquid as the chemical makeup of the growing media dissolves, negatively affecting the plant growth.

In addition, the shape of the growing media can be problematic. Expanded clay and gravel tend to be irregular spheroids. Because these growing media are spherical in nature, the expanded clay and gravel can slip pass each other with ease, and do not create a stable foundation for the plant roots. This means the plant root must grow through the expanded clay or gravel and into another substrate, such as a mesh basket, before the plant can remain upright.

Lastly, growing media such as expanded clay and gravel are often porous. Plant roots and bacteria can grow in the pores of the growing media. This makes cleaning the growing media so difficult that it is common for the growing media is used only during one grow cycle and then discarded.

Other known growing mediums include rock wool, growstones made from glass waste, perlite, coconut coir, rice husks, vermiculite, pumice, gravel, and polystyrene packing peanuts. These growing media can also present obstacles with respect to the nutritious liquid, root stability, and recyclability.

Another growing medium is disclosed in document <CIT>.

The aforementioned challenges are overcome by a synthetic growing media of the present invention.

The present invention is defined by the appended independent claims to which reference should now be made. Specific embodiments are defined in the dependent claims. In one arrangement, a synthetic growing media includes a one-piece plastic body comprising a plurality of legs emanating from a common center and pointing in different directions, at least one of the plurality of legs comprising a proximal end which connects to the common center and a distal end which includes a bulbous tip, the bulbous tip having a major dimension greater than a width of the at least one of the plurality of legs.

In another arrangement, a hydroponic growing system including a synthetic growing medium comprising an aggregate of synthetic growing media is provided.

In yet another arrangement, a synthetic growing medium comprising an aggregate of synthetic growing media is provided.

These and other features and advantages of the invention will be more fully understood and appreciated by reference to the entire application including the specification, claims, and drawings.

Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited to the details of operation or to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. In addition, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of "having," "including," and "comprising" and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. Further, enumeration may be used in the description of various embodiments. Unless otherwise expressly stated, the use of enumeration should not be construed as limiting the invention to any specific order or number of components. Nor should the use of enumeration be construed as excluding from the scope of the invention any additional steps or components that might be combined with or into the enumerated steps or components.

Directional terms, such as "vertical," "horizontal," "top," "bottom," "upper," "lower," "inner," "inwardly," "outer" and "outwardly," are used to assist in describing the invention based on the orientation of the embodiments shown in the illustrations. The use of directional terms should not be interpreted to limit the invention to any specific orientation(s).

Referring now to the drawings and to <FIG> in particular, a synthetic growing media <NUM> according to a first embodiment of the invention is shown. The synthetic growing media <NUM> includes multiple protruding parts or legs <NUM> emanating from a common center or nexus <NUM> pointing in different directions. In the embodiment shown, the growing media <NUM> can more specifically have a tetrapod-like shape, i.e. a shape having four protruding parts or legs <NUM> emanating from a nexus <NUM> pointing in four different directions. The shape of the growing media <NUM> allows the individual media to entangle with other media in a confined space, such as a growing tray or a net basket common in hydroponics, without interlocking. This provides a stable foundation for a plant's root system in which to anchor, while providing the gaps necessary for root growth. The synthetic growing media <NUM> can be used with various hydroponic systems, including wick, deep water culture, nutrient film technique, ebb and flow (e.g. flood and drain), and drip systems.

Each leg <NUM> has two ends, a proximal end <NUM> that connects to the nexus <NUM>, and a distal end <NUM> comprising a free end of the leg <NUM>. The nexus <NUM> is the core or center at which the legs <NUM> interconnect. Each of the legs <NUM> extends outwardly from the nexus <NUM> in a different direction, i.e. toward a different point in space. A tip <NUM> is disposed at each of the distal ends <NUM>. One of more of the tips <NUM> has a bulbous shape, as described in detail below.

Referring additionally to <FIG>, the legs <NUM> can have a cylindrical shape. As used herein, the term "cylindrical shape" refers to a columnar shape having a circular cross section (which may be either in the form of a perfect circle or an oval) in a direction perpendicular to an axial direction of the leg <NUM>, i.e. the direction the leg <NUM> extends between the proximal end <NUM> and the distal end <NUM>. The cross-section of the leg <NUM> can remain constant from the proximal end <NUM> to the distal end <NUM>, or may change. In an alternative embodiment, one or more of the legs <NUM> can have a tapered or frustoconical shape, such as being tapered toward the toward the distal end <NUM> of the leg <NUM>. Other columnar shapes for the legs <NUM> are possible, including triangular, quadratic, hexagonal, octagonal, or other prismatic shapes. In the embodiment shown in <FIG>, each leg <NUM> has substantially the same shape. In an alternative embodiment, one or more of the legs <NUM> may have a different shape.

In the embodiment shown in <FIG>, the legs <NUM> have an identical or similar length L measured along an axial direction X of the leg <NUM>, i.e. measured from the proximal end <NUM> and the distal end <NUM>. The legs <NUM> can have a leg length L of <NUM> inches (about <NUM>). In an alternative embodiment, the length of one or more of the legs <NUM> is different than the length of one or more of the other legs <NUM>.

In the embodiment shown in <FIG>, the legs <NUM> have an identical or similar width W measured perpendicular to an axial direction X of the leg <NUM>, i.e. the direction the leg <NUM> extends between the proximal end <NUM> and the distal end <NUM>. The legs <NUM> can have a leg width W of <NUM> inches (about <NUM>). In an alternative embodiment, the width of one or more of the legs <NUM> is different than the width of one or more of the other legs <NUM>.

The tips <NUM> are disposed at the distal end <NUM> of each leg <NUM>. The tips <NUM> can be spherical, and form a ball-shaped body on the distal end <NUM>. The tips <NUM> can have a variety of shapes, and are not limited to the spherical geometries illustrated. For example, the tips <NUM> may be spheroidical, or ellipsoidical, like a ball or an egg, hemispherical, semispherical, or have yet other rounded or bulbous shapes. Still other alternatives are possible. For example, the tip <NUM> of one or more of the leg <NUM> can have a truncated cone shape, which is tapered toward the distal end thereof.

At least one of the tips <NUM> is bulbous, and the bulbous shape defines a major dimension D that is greater than the width W of its associated leg <NUM>, i.e. the leg <NUM> on which the tip <NUM> is disposed. In other words, the thickness of the bulbous tip <NUM> is greater than that of the leg <NUM>. As used herein, the term "major dimension" refers to the largest measurement that can be taken across the tip <NUM> in one direction, and defines the overall size of the tip <NUM>. Depending on the shape of the tip <NUM>, the major dimension D may be a diameter, width, height, or length. For a spherical tip <NUM> as shown in <FIG>, the major dimension is the diameter D of the tip <NUM>. In one embodiment, the diameter D of the tip <NUM> can be on the order of 2x the leg width W. In one embodiment, the tip <NUM> can have a diameter D of <NUM> inches (about <NUM>).

It is noted that the bulbous tip <NUM> is thicker than the leg <NUM> in at least one plane passing through the leg <NUM> and the center of the tip <NUM>, for example, a plane in which the major dimension D is measured as shown in the cross-sectional view of <FIG>. In some embodiments, the tip <NUM> may be equal to or less than the thickness of the leg <NUM> in a different plane passing through the leg <NUM> and the center of the tip <NUM>.

The major dimension D can be greater than the length L of its associated leg <NUM>, i.e. the leg <NUM> on which the tip <NUM> is disposed. In one embodiment, the diameter D of the tip <NUM> can be on the order of <NUM>. 25x the leg length L, alternatively <NUM>. 33x the leg length L, alternatively <NUM>. 5x the leg length L.

The growing media <NUM> is manufactured from a synthetic material, such as plastic. Some non-limiting examples of suitable plastic for the growing media include polypropylene and acrylonitrile butadiene styrene (ABS). This material does not breakdown in the presence of water. Therefore, it will not change the chemical makeup of the nutritious liquid in the hydroponic system.

The growing media <NUM> can more specifically be manufactured from a non-porous plastic material, such as polypropylene or ABS as previously mentioned. As used herein with respect to the growing media, the term "non-porous" refers to materials that air and liquid cannot pass through. If bacteria or other non-desirable organic growths were to grow on the growing media <NUM>, the non-porous material prevents the foreign growths from penetrating the surface of the growing media <NUM>. Such foreign growths can be removed from or killed on the surface of the growing media using standard cleaning techniques since plastic material is insert to most common cleaning products, including hydrogen peroxide and bleach. This allows the synthetic growing media <NUM> to be reused and/or recycled.

In some embodiments, an antibacterial, antimicrobial, or biocide additive can be added to the plastic during the manufacturing process to also aid in the cleanability, and to protect the growing media <NUM> from bacteria, algae, fungi, and/or mold. Such additives can be added during an injection molding process or other manufacturing process. Examples of suitable additives for the plastic growing media <NUM> include, but are not limited to, <NUM>', <NUM>'-oxybisphenox arsine, <NUM>-n-octyl-<NUM>-isothiazolin-<NUM>-one, and dichloro-<NUM>-n-octyl-<NUM>-isothiazolin-<NUM>-one. Biocide products containing tributyl tin, silver, and silver compounds are also effective.

Each growing media <NUM> is a one-piece body manufactured, for example, via injection molding or additive manufacturing, e.g. <NUM>-D printing. In one example, the growing media <NUM> is a plastic injection molded structure. In another example, the growing media <NUM> is a 3D printed structure having multiple layers of plastic material deposited by an additive manufacturing machine.

Referring to <FIG>, in the embodiment shown the growing media <NUM> has four legs <NUM> and is generally in the shape of a cross or "X" when viewed from above (<FIG>) or below (<FIG>). In alternative embodiments, the growing media <NUM> can have more than four legs or less than four legs. For example, the growing media <NUM> can have six legs. In one sixlegged embodiment, the growing media can have four legs <NUM> with spherical tips <NUM>, and two legs <NUM> with pointed tips, similar to a jack. In another embodiment, the growing media <NUM> can have a least two legs <NUM>, alternatively at least three legs <NUM>, emanating from common center <NUM> and pointing in different directions. In any of the aforementioned embodiments, one or more of the legs <NUM> can have a bulbous tip <NUM> and one more of the legs <NUM> can have a non-bulbous tip <NUM>.

As noted above, with the four-legged embodiment shown in the figures, the growing media <NUM> has a tetrapod-like shape. The legs <NUM> are disposed such that less than all of the legs <NUM> contact a relatively flat or planar surface, such as surface S shown in <FIG>, at a time. One or more of the other legs <NUM> is offset from the surface S. The legs <NUM> can alternate to point up and down can so that no matter how the growing media <NUM> is placed on a relatively flat surface, such as surface S shown in <FIG>, two of the legs <NUM>, and more specifically the tips <NUM> of an opposing pair of the legs <NUM>, will form a support and the other opposing pair of legs <NUM> will point upward, away from the surface S. Thus, the two opposing pairs of legs <NUM> are offset in different directions so that they do not contact a common surface S. The opposing legs <NUM> can be diametrically opposing legs having an identical leg length L such that the growing media <NUM> can symmetrically engage a surface S.

Adjacent legs <NUM> are joined together at a joint <NUM>. When viewed from above (<FIG>) or below (<FIG>), the adjacent legs <NUM> enclose an included angle A on the inside of the joint <NUM>. For the cross or X-shaped body shown, the included angle A is approximately <NUM> degrees. This spacing can allow the tip <NUM> of one growing media <NUM> to nest between adjacent legs <NUM> of another growing media <NUM>. For example, the tip <NUM> of one growing media <NUM> can nest in the joint <NUM> of another growing media <NUM>.

When viewed in cross-section (<FIG>), opposing legs <NUM> are joined together at the node <NUM>. The opposing legs <NUM> enclose an included angle B on a first side <NUM> of the node <NUM>, measured at a vertex <NUM> between the legs <NUM> on the first side <NUM>. For the growing media <NUM> shown, the included angle B is less than <NUM> degrees, alternatively an obtuse angle less than <NUM> degrees and greater than <NUM> degrees.

The first included angle A is in a first plane, and the second included angle B is taken in a second plane orthogonal to the first plane. The second plane is defined by the cross-section of <FIG>, both of which are orthogonal to the first plane and to the top and bottom views of <FIG>.

The legs <NUM> can be curved, and can form a concave contour on a first side thereof and a convex contour on second side thereof. The first side <NUM> of the node <NUM> can form a concave contour, with the legs <NUM> extending from the node <NUM> on the first side <NUM> continuing the concave contour. On an opposing second side <NUM> of the node <NUM>, which can be a side opposing the first side, the growing media <NUM> forms a convex contour, with the legs <NUM> extending from the node <NUM> on the second side <NUM> continuing the convex contour. The curved legs <NUM> can minimize stress concentration at the distal ends <NUM> or tips <NUM> of the legs. In an alternative embodiment, the opposing legs <NUM> can form an angle on one or both of the opposing sides <NUM>, <NUM>, rather than a curve, in the region of the node <NUM>.

When viewed from the side (<FIG>) or in cross-section (<FIG>), the tip <NUM> can at least partially overlap each other, which makes the overall shape of the growing media more compact, with a low profile. For example, the major dimension D, e.g. diameter in the embodiment shown in <FIG>, of opposing tips can partially overlap that of the adjacent tips.

In the embodiment shown in <FIG>, a center C of the spherical tips <NUM> can be equidistant from the node <NUM>. In an alternative embodiment, the center C of one or more of the tips <NUM> can be closer to or further from the node <NUM> than the center of at least one other tip <NUM>.

<FIG> is a view of an aggregate growing medium <NUM> comprising a plurality of the synthetic growing media <NUM> of <FIG>. When grouped, the aggregate growing medium forms a stable foundation having a porous structure configured for cultivating plants. The porous structure is comprised of the irregularly arranged growing media <NUM> and the spaces therebetween that form interconnected pores. The growing media <NUM> can be randomly arranged in irregular and/or offset orientations, for example with one growing media <NUM> being rotated in orientation with respect to adjacent growing media <NUM>, and growing media <NUM> in one layer being offset with respect to growing media <NUM> in layers above or below.

The shape of the growing media <NUM> allows the individual media <NUM> to entangle with other media <NUM> in a confined space, such as a growing tray or a net basket (not shown) without interlocking. Various entanglements are possible. For example, the tip <NUM> of one growing media <NUM> can nest between adjacent legs <NUM> of another growing media <NUM> or more specifically in the joint <NUM> of another growing media <NUM>. In another example, the tip <NUM> of one growing media <NUM> can rest atop the nexus <NUM> of another growing media <NUM>.

An exemplary appearance of the aggregate growing medium <NUM> is shown in <FIG>. It is understood that the number, orientation, and layering of the growing media <NUM> for the aggregate growing medium <NUM> may be formed in various ways depending on the conditions.

The present disclosure also provides a hydroponic system for plant cultivation including the synthetic growing media <NUM> described herein. The hydroponic system is not particularly limited as long as it includes the synthetic growing media <NUM> described herein, and can include the structure of a conventionally known hydroponic system including a wick, deep water culture, nutrient film technique, ebb and flow (e.g. flood and drain), or drip system.

<FIG> is a schematic view of one embodiment of a hydroponic system <NUM> comprising a plurality of the synthetic grow media <NUM> of <FIG> as the aggregate growing medium <NUM>. The hydroponic system <NUM> includes a growing container <NUM> holding the aggregate growing medium <NUM>. The growing container <NUM> may be a tray, net basket, pot, or any other suitable container for holding the growing media <NUM> and supporting the growth of plants <NUM>.

Plants <NUM> are supported in the container <NUM> above a reservoir <NUM> of nutritious liquid <NUM>, with only the roots <NUM> of the plants <NUM>, or the tips of the roots <NUM>, extending into the nutritious liquid <NUM>. An air pump <NUM> can bubble air through the nutritious liquid <NUM> to provide oxygen to the roots <NUM>. Optionally, the hydroponic system <NUM> can include a recirculation system for delivering liquid from the reservoir <NUM> to multiple containers <NUM> using pumps (not shown). One example of a suitable recirculation system is disclosed in <CIT>.

There are several advantages of the present disclosure arising from the various aspects or features of the apparatus, systems, and methods described herein. For example, aspects described above provide an improved artificial growing media for plant cultivation. The non-spherical shape of the growing media <NUM> allows the individual media to entangle with other media and provides a stable foundation for plant root systems, while providing the gaps necessary for root growth.

Another advantage of aspects of the disclosure relates to the recyclability/reusability of the growing media. The synthetic growing media can comprise a non-porous plastic material that can be easily cleaned using standard cleaning techniques, allowing the growing media to be reused for multiple growing cycles.

Yet another advantage of aspects of the disclosure is that the synthetic growing media does not breakdown in the presence of water. Plant roots can grasp the legs and tips of the growing media without breaking down the growing media. The growing media remains intact and does not affect the pH of the nutritious liquid, making it easier to optimize plant growth.

Still another advantage of aspects of the disclosure is that a hydroponic system comprising a plurality of the synthetic grow media with the aforementioned advantages is provided.

The above description is that of current embodiments of the invention. Various alterations and changes can be made without departing from the broader aspects of the invention as defined in the appended claims. This disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the invention or to limit the scope of the claims to the specific elements illustrated or described in connection with these embodiments. Any reference to claim elements in the singular, for example, using the articles "a," "an," "the" or "said," is not to be construed as limiting the element to the singular.

Further, any ranges and subranges relied upon in describing various embodiments of the present invention independently and collectively fall within the scope of the appended claims, and are understood to describe and contemplate all ranges including whole and/or fractional values therein, even if such values are not expressly written herein. One of skill in the art readily recognizes that the enumerated ranges and subranges sufficiently describe and enable various embodiments of the present invention, and such ranges and subranges may be further delineated into relevant halves, thirds, quarters, fifths, and so on. As just one example, a range "of from <NUM> to <NUM>" may be further delineated into a lower third, i.e., from <NUM> to <NUM>, a middle third, i.e., from <NUM> to <NUM>, and an upper third, i.e., from <NUM> to <NUM>, which individually and collectively are within the scope of the appended claims, and may be relied upon individually and/or collectively and provide adequate support for specific embodiments within the scope of the appended claims. In addition, with respect to the language that defines or modifies a range, such as "at least," "greater than," "less than," "no more than," and the like, it is to be understood that such language includes subranges and/or an upper or lower limit. As another example, a range of "at least <NUM>" inherently includes a subrange of from at least <NUM> to <NUM>, a subrange of from at least <NUM> to <NUM>, a subrange of from <NUM> to <NUM>, and so on, and each subrange may be relied upon individually and/or collectively and provides adequate support for specific embodiments within the scope of the appended claims. Finally, an individual number within a disclosed range may be relied upon and provides adequate support for specific embodiments within the scope of the appended claims. For example, a range "of from <NUM> to <NUM>" includes various individual integers, such as <NUM>, as well as individual numbers including a decimal point (or fraction), such as <NUM>, which may be relied upon and provide adequate support for specific embodiments within the scope of the appended claims.

Terms like "preferably," "commonly," and "typically," when utilized herein, are not utilized to limit the scope of the claimed invention or to imply that certain features are critical, essential, or even important to the structure or function of the claimed invention. Rather, these terms are merely intended to identify particular aspects of an embodiment of the present disclosure or to emphasize alternative or additional features that may or may not be utilized in a particular embodiment of the present disclosure.

For the purposes of describing and defining the present invention it is noted that the terms "substantially," "about," and "approximately" are utilized herein to represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. The terms "substantially," "about," and "approximately" are also utilized herein to represent the degree by which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue.

Claim 1:
A synthetic growing media (<NUM>) for plant cultivation comprising a one-piece plastic body,
characterized in that the one-piece plastic body comprises a plurality of legs (<NUM>) emanating from a common center (<NUM>) and pointing in different directions, at least one of the plurality of legs (<NUM>) comprising a proximal end (<NUM>) which connects to the common center (<NUM>) and a distal end (<NUM>) which includes a bulbous tip (<NUM>), the bulbous tip (<NUM>) having a major dimension greater than a width of the at least one of the plurality of legs (<NUM>), wherein:
the one-piece plastic body is X-shaped and the plurality of legs (<NUM>) are spaced approximately <NUM> degrees from each other in a first plane; and
an opposing pair of the plurality of legs (<NUM>) are spaced less than <NUM> degrees from each other in a second plane that is orthogonal to the first plane.