This invention relates generally to a sterile synthetic medium for the propagation and growth of plants. More specifically, the synthetic growth medium components are formed in particular shapes and sizes of an open cell polymer foam to optimize the several stages of a plant's propagation and growth and minimize scrap material disposal problems. A method for utilizing these components in conjunction with trays in a standard glass house environment is also disclosed.
Plants and flowers are currently grown in synthetic mediums in greenhouses utilizing several different substrate materials. For a long time the synthetic medium of choice was a mat made from Rockwool or other mineral fibers such as glass wool, or slag wool. These mineral fiber compounds are typically held together with a chemical binder such as a furan. These also use a standard surfactant to assist in water retention. Although these compounds have advantages over soil as a growth medium in their freedom from disease and pests, they also have several significant disadvantages. The disposal of these materials after use has become very problematic. They are no longer accepted in many land fills because of the chemicals that could leach into the surrounding ground water. They can not be pyrolized as they do not burn. Some suppliers are being forced to store their scrap materials on site. Rock wools tend to have a water retention memory such that if a rock wool substrate is under dosed as far as water absorption is concerned, it will never accept more water than the first dosage. Other synthetic materials in use today are open cell polyurethane foams with several different additives. Disposal of these polyurethane foams can also present problems. Although polyurethane foams can be subjected to a pyrolisis process, expensive filtering of pyrolization exhausts and residues can be required depending on the nutrient residues and the amount of nitrogen entrapped in the cellular structure.
The present invention provides a set of components made from a polymer foam that crushes to powder form with up to an 80% volume reduction over the foamed material, dramatically simplifying the disposal of used foam materials and reusable trays made from recyclable thermoplastics.
It also provides a soilless method of growing plants optimized for the various stages of development which dramatically reduces disease growth.
It provides a set of components that work efficiently together with standard glass house irrigation and nutrient feeding systems.
It provides a method of growth encouragement with improved oxygen to media ratios with the air gaps and structural support for the plants at various growth stages.
Still further objects and advantages will become apparent from a consideration of the ensuing description and accompanying drawings. In the description, reference is made to the accompanying drawings which form a part thereof, and in which are shown, by way of illustration, a specific embodiment in which the invention may be practiced. This embodiment will be described in sufficient detail to enable those skilled in the art to practice this invention, and be understood that other embodiments may be utilized and that structural changes may be made without departing from the scope of the invention. In the accompanying drawings, like reference characters designate the same or similar parts throughout the several views.
In order that the invention may be more fully understood it will now be described by way of example, with reference to the accompanying exemplary drawings in which:
The same reference numbers are used to refer to the same or similar parts in the various views.
Propagation and growth system 12 is comprised of starter plug strips 20, growth blocks 24 and growth slabs 26 shown in
Starter plug strips 20 are separated into individual starter plugs 22 at the appropriate point in the growth process as shown in
In
Multi-cavity trays 36 and growth slab trays 48 and growth slab tray lids 50 are produced preferably from a thin wall thermoplastic material such as polyethylene with a vacuum forming process as shown in
It will be understood that propagation and growth system 12 is intended to provide a sterile soilless medium for plant development that is comprised of components that are made from a crushable polymer foam each optimally sized for a particular stage of development of a particular plant 18. The foam is developed such that plant root structures can mature easily through the foam and it is combined with sufficient surfactants as to absorb and hold moisture adjacent to that developing root structure as to optimize plant 18's growth and yield potential.
The method of utilization of the above described components is illustrated in the following specification. An exemplary process begins with placing starter plug strips 20 into multi-cavity trays 36. Seeds 14 or small seedlings 16 are placed into plant starter openings 34 in starter plug top surface 30 and multi-cavity trays 36 with seeds or seedlings are suspended by their support ledges 74 in racks 76 (not part of this invention) as shown in
When the root structure of seedlings 16 approaches starter plug bottom surface 32, starter plug side walls 62, lead walls 58 and trail walls 60, starter plug strips 20 are removed from multi-cavity trays 36 and broken into individual starter plugs 22 carefully minimizing damage to growing root structures as shown in
Individual starter plugs 22 with plant roots approaching the exterior walls are transplanted into growth block starter pockets 40 in growth blocks 24. Growth blocks 24 are placed over an irrigation bar that fits into growth block notch 72 in a typical glass house environment and allowed to grow. Growth blocks 24 can have one or more than one groove or notch 72 running across the bottom to improve the oxygen ratio critical to optimize plant growth. The roots breakthrough the exterior walls of starter plug 22 and grow quickly into the air gap between starter plug lead wall 58 of starter plug 22 and growth block starter pocket lead wall 66 and then continue to expand through growth block 24 until the roots reach growth block side walls 46 and growth block bottom surface 44. The air pocket created with the diverging lead walls between starter plugs 22 and growth block starter pocket lead wall 58 also significantly improves the oxygen ratio for the early stage of development.
Growth slabs 26 are then placed into growth slab trays 48 and growth slab tray lids 50 are installed on tray 48. Growth tray lids 50 have openings 52 through which growth blocks 24 with plant roots extending close to the exterior surfaces of growth block 24 are transplanted onto growth slabs 26. Growth blocks slab tray lid openings 52 are spaced along growth slab tray lid 50 with sufficient spacing to optimize the root growth of various plant types.
As plants 18 continue to grow and perhaps bear fruit, specific plant support frames 54 are utilized for the several plant types depending on their individual growth or climbing habit. An example of one such support frame 54 is shown in
When plants 18 have matured to point of sale level or to the end of their useful life, plants and roots are cut from the polymer foam and the used foam components can be crushed, reducing their volume by up to 80%, dramatically reducing the scope of the disposal problem. The residual powder can be land-filled, recycled as soil additive, or incinerated without environmental impact. Trays 36 and 48 and tray lids 50 made from thermoplastic materials can also be recycled or reused.
While this invention has been described with reference to illustrative embodiments, it will be understood that this description is not limiting as to size or scale of the components. Persons skilled in these arts can size the various components to optimize the growth experience for various plants with different root system patterns, mature heights and fruit loading. Rather, the scope of this invention is defined by the following claims.