Patent Application
20220110277
The present invention relates to systems and methods for hydroponic agriculture and, more particularly, to improvements in the yield and transportability of tiered hydroponic gardening systems.
Some hydroponic gardening systems having small footprints and high output are known. However, while having some success against intended targets in productivity and reliability for single-family food production, the cost structure of such systems makes them unsuitable for widespread deployment without significant financial subsidies after an initial launch date, or into future markets when funded entirely by the target customer. Typical costs of ownership include transportation, training and setup of a collection of adapted components requiring significant skill, and tooling for proper setup, and such systems may require a difficult maintenance regimen. Despite the importance of food security to users in challenging environments, prior art systems have failed to provide designs that are capable of high yield production and facilitate of use, transportation, and maintenance.
An understanding of embodiments described in this disclosure and many of the related advantages may be readily obtained by reference to the following detailed description when considered with the accompanying drawings, of which:
The present inventive system addresses productivity, reliability, cleanliness, ease of use and cost issues that hamper previous systems, through novel features, advanced manufacturing techniques and use of materials that are heretofore undisclosed in the literature or marketplace. The individual and combined features provide a system with a cost structure that is sustainable in the target market and achieves superior performance in food yield.
In accordance with some embodiments, a hydroponics system is provided that includes one or more of the following features:
In accordance with some embodiments, hydroponics systems are provided that include one or more of the following features:
According to some embodiments, methods of hydroponic gardening are provided utilizing one or more types of circulating hydroponic systems described in this disclosure, wherein circulation is continuous.
According to some embodiments, methods of hydroponic gardening are provided utilizing one or more types of circulating hydroponic systems described in this disclosure, wherein circulation is intermittent.
In some embodiments, the described trough enables a flexible arrangement of plants per unit tier length, effectively enabling a commensurate multiple (2× or more) of the food output per unit length of the tier and unit area of the system.
In accordance with some embodiments, multiple tiers of trough may be combined in an arrangement to comprise a system. The trough structure requires minimal support elements, is designed for manufacture (DFM), ease of maintenance, and for minimal package size, weight, and cost.
A further beneficial result of the disclosed trough design, in accordance with some embodiments, is nested or stacked component shipment, enabling self-contained safe and protected transport of the system in a single package with minimal packing waste, having all tier components shipped inside nested troughs.
In one or more embodiments, an internal weir structural element is provided to enable effective and simplified fluid management within the trough during daily use for fluid containment (passive) and replenishment (active) cycles required for low maintenance plant growth, as well as an anti-clogging function by benefit of the effectively enlarged aperture of the weir top, providing fluid flow over an unconstricted dam (vs. into a constricted pipe).
In accordance with some disclosed embodiments, further benefits may be realized in ease of setup and use, and ease of maintenance (e.g., removable cover plates allow the exposing of all internal elements for ease of cleaning).
Various embodiments of the disclosed hydroponics system provide solutions to deficiencies in the prior art. The Babylon basic system by Levo International (
Additionally, a system based on round PVC pipe is bulky to transport, especially if transportation is between country locations (particularly in development and scale up phases). Round pipes do not stack well, and a great deal of air (bulk) is added to shipping cost. The structural framework of plywood and pine studs of the Babylon basic system incorporates a scalloped pattern for ease of alignment and level, but the wood is not a robust exterior grade material for multi-year lifespan of the system. Accordingly the inventors have recognized that it is desirable to use sheet plastic or rigid plastic for a scalloped framework that can collapse for shipment and build-in-place.
Some example specifications for modeling of the new inventive designed system in accordance with some embodiments are provided below. According to one or more embodiments, the geometry and spacing of a (2′×5′) 4-tier 16-plant concept (also utilized in the Babylon basic system prototype) provides a robust and flexible arrangement, suitable for a wide variety of plants important to the farmer in underdeveloped environments. Although the example layout as described in this disclosure is proposed as a practical set of constraints, it will be obvious to one skilled in the art in light of this disclosure that the inventors have also contemplated extension to larger and/or smaller footprints containing the same features, which may result in significant benefit to the target market(s). The example constraints are for illustration, and the inventive concepts are not intended to be limited to any particular physical size and/or tier arrangement.
The present inventive hydroponics system is comprised of specific departures from the basic system, while maintaining, in accordance with some embodiments, a tiered arrangement and user-friendly instruction set for operation. Some example inventive solutions for hydroponic systems are depicted in
In some example embodiments, the proposed inventive system may utilize an open top trough, plus flat top plates for hole patterns to cover the trough. Top plates will snap on and snap off the trough. When the top plate is snapped off or otherwise removed, the whole trough may be accessible for cleaning in between cycles. The flat plates can be drilled or punched with a hole pattern and swapped for (or reconfigured to) different patterns when needed, without affecting the physical integrity of the trough.
In accordance with some embodiments, pre-punched knock-out discs may be provided that can be re-inserted as needed to block unused portions of the trough (as required for selective harvesting; i.e., removing mature and unproductive, or diseased plants).
As depicted in
In accordance with some embodiments (see, e.g.,
In accordance with one embodiment, the weir may be inserted and welded or otherwise affixed to the trough prior to use. In another embodiment, the weir may be removably securable to the trough (e.g., a snap in—snap out feature) while remaining leak-proof when installed. In some embodiments, the weir is configured to create an effective watertight seal with the trough in which it is installed; in this way, the weir can beneficially contain nutrient fluid upstream of the weir without seepage or leakage under and/or around the sides of the dam for extended periods of time.
In one embodiment, the weir has a fixed height optimal for root growth, containment, and minimal clogging of channel. Alternately, the weir can provide an adjustable height (e.g., from half trough height to full trough height) to accommodate different needs of the root between seedling phase, growth phase, and mature phases of plants.
According to some embodiments, a small collection area beyond the weir may contain a single outlet and the aforementioned downspout (see, e.g., drainage hole 18 and downspout 19 of
In another embodiment, the weir, collection area, downspout and endcap may be formed of a single molded piece that is sealed to the end of the trough prior to use. Preferably, such an arrangement is removable and resealable between plant growing cycles.
As described with respect to some embodiments, it may be beneficial to allow detached (non-sealed) transport within the nested trough(s) during shipping. For this reason, in some embodiments the downspout and weir may be removable parts from the weir-collection-endcap section.
According to some embodiments, the structural framework may be a rigid plastic system, holding troughs at opposite ends in plumb and parallel register. Legs to the registration feature may comprise rigid plastic or galvanized pipe members, preferably in a snap together system with structural safety fastener features (bolt or clip).
As discussed in this disclosure, various aspects of the present invention allow for various combinations and arrangements of components for a desired implementation.
In accordance with some embodiments, a number of weirs (15) may be packed loosely in the top trough of a set of nested troughs for shipping or storage purposes.
This example arrangement creates two chambers within the trough that are divided by the weir 15: the larger upstream containment chamber (20) for maintaining a nutrient liquid level for root nourishment and growth, and the smaller downstream drainage chamber (21) for collection of overflow liquid during circulation. The example configuration of the weir 15 in the trough 12 advantageously confines roots to the upstream containment chamber 20 and excludes roots from the drainage chamber (21) and downspout (19).
According to one example embodiment, the downspout 19 is mechanically sealed to the bottom of the drainage chamber by means of a nominal seal arrangement (22) at the drainage hole (18).
Referring now to
Note that the example hydroponics system of
Referring now to
In
The following paragraphs describe some advantages of the disclosed design solutions in according with some example embodiments.
1—Flexible arrangement of plants per unit pipe (trough). The snap-on top plate provides flexibility in hole patterns. Since the top plate is not tasked with fluid containment, it can be produced from a substantially flat sheet, using a potentially thinner gauge of plastic than the structural trough, and therefore consuming less plastic material and requiring less machining/processing (i.e. a less expensive component). Top plates are replaceable and reconfigurable, depending on the plant mix used on a given trough. As received, plates can be pre-drilled, or provided with knock-outs (partially punched holes that can be individually snapped out or left in place). The knock-outs are provided in a staggered pattern that allows a 50% increase, or with a double track staggered pattern, up to 100%, (double) the number of plants per unit length, or with a triple track staggered pattern, up to a 150% increase (triple) the number of plants per unit length. Higher multiples are possible based on width of the upper portion of trough. The flexibility is provided to enable a higher overall yield, and a more robust plant mix. For example, a higher number of holes per unit length will be more useful for plants that do not require large horizontal spacing in a row; but many important plants are more “vertical’ (certain lettuce, Epinah, jalapeno pepper varietals, etc). Guidance for plant spacing may be provided in training. The knock-outs will serve double duty; they can be retained and replaced over a hole to seal the hole when a root cup is removed mid-season. This will address a system management issue that is currently jury-rigged or ignored in the field. Snap-on and snap-off features (such as indents, bosses or indexed mating patterns can be integrated into either the top plate, the upper surfaces of the trough, or both.
2—Major advantage of the trough systems are ease of transport and system delivery in challenging environments. Four troughs will stack efficiently and rigidly into a single trough. The design will minimize the shipping footprint. Structural framework components will nestle into the top trough, for compactness in shipping. Above the trough, 4 full length flat plates with knockout hole patterns pre-stamped into the plates are stacked together and laid on top. The lowest plate in the stack will snap into the top trough for rigidity during shipping. The top trough will contain the framework components. In this manner, the troughs plus top plate stack will comprise their own shipping container, with a minimal wrap of cling plastic for secure containment of shipped parts. Assembly will be done on-site by the end-use customer, with included parts and visual work instructions.
3—Ease of cleaning. The fluid containment features of the trough system are fully exposed after snapping off the top, for hot water or chemical sanitization, or for vigorous scrubbing with simple soap and scouring pad. Exposure ensures an easy visual confirmation of an effectively cleaned system.
4—Anti-clogging feature: the weir and collection chamber provide protection against root clogging of an orifice.
The following paragraphs describe some examples of inventive features (and example combinations of such features) and systems.
1—The inventive design elements of trough and plate, with staggered plate hole patterns arranged in parallel staggered tracks down the length. In one embodiment, there are two tracks, enabling the opening of as few as 4 through as many as 8 holes per 5-foot section. In a 4-tier system, this would provide (as examples) 4×4, or 4×6, or 4×8 (or any count in-between) plants per system. This provides a flexible arrangement of plants per unit pipe (trough). The snap-on top plate provides the flexible arrangement of hole patterns. Top plates are replaceable and reconfigurable, depending on the plant mix used on a given trough. As received, plates will be pre-drilled, or will be provided with knock-outs (partially punched holes that can be individually snapped out or left in place). In the present embodiment, the knock-outs are provided in the parallel staggered pattern that allows up to 100%, (double) the number of plants per unit length when compared to the basis Babylon basic system. In yet another embodiment, a wider opening at the top of the trough could be designed, which would enable three tracks of staggered plate hole patterns arranged in parallel. This in turn would provide as few as 4 or as many as 12 holes per 5 foot section. The flexibility is provided to enable a more robust plant mix. A higher number of holes per unit length will be more useful for plants that do not require large horizontal spacing in a row; but many important plants are more “vertical’ (certain lettuce, Epinah, jalapeno pepper varietals, etc). Guidance for plant spacing will be provided in operator training. The knock-outs will serve double duty; they can be retained and replaced over a hole to seal the hole when a root cup is removed mid-season. This will address a system management issue that is currently jury-rigged or ignored in the field. The enabling feature of a wide opening at top of trough will ensure that each plant (no matter where placed across the length and width of the top plate) will have equal immersion depth of root cups at all points, equal access to fluid and equal root expansion possibility within a track. Although not wishing to be bound by theory, it is proposed that root expansion space at top is a desirable feature in hydroponics, since the constraints of a circular cross section (as in 4″ PVC pipe) forces the top of the root to conform with restrictions on both sides of the hole, and forces root growth lower into the channel, increasing the possibility of local clogging of channel. Root expansion at the point of entry of the root cup is desirable, creating a surface lawn of substantially less restricted root grown at the high water point, and leaving the lower portion of the the “U” shaped or “V” shaped (or intermediate hybrid shape) channel open for unrestricted flow and nutrient exchange during flow events. These beneficial arrangements in the channel are proposed (in theory) to be enabling to stronger and faster root growth, more rapid upper plant development, and less plant energy expended on root conformation to pipe features.
2—Simplified level control, fluid transport, failsafe containment with Anti-clogging feature: the weir and collection chamber provides protection against root clogging of an orifice. An internal weir structural element is provided to enable effective and simplified fluid management within the trough during daily use for fluid containment (passive) and replenishment (active) cycles required for low maintenance plant growth, as well as an anti-clogging function by benefit of the effectively enlarged aperture of the weir top, providing fluid flow over a unconstricted dam (vs. into a constricted pipe).
3—nutrient sachet using teabag or non woven web containment of locally sourced NPK extracting substances (manure, shell, porous rock or sand, mined micronutrient) may be advantageously used to provide nutrient ion fertilizer in a time release manner, further reducing material and operating costs.
4—A method of source local water analysis for calcium, magnesium, sulfur, potassium and other beneficial ionic elements required for plant grown can be performed, for determination of adequacy of said ions in a hydroponic feedwater, such that a secondary addition of optimized nutrient additive blend may be predetermined and adjusted to exclude the analyzed quantities of hard water elements that are replenished via local water make-up additions; providing additional economy of fertilizer addition for optimal plant growth.
5—A prophylactic oxygen bubbler system for root O2 replenishment in the feedwater for use in tropical environment (high temperature) can be provided to mitigate plant root disease.
In some embodiments, the inventive system and components may be constructed from engineering plastic materials that are robust against the environment, in relatively thin sections. Thin cross sections of support components (for example, the trusses and legs comprised of round, square, or rectangular shaped in cross sections) are expected to provide strength, while being less likely to fail in high wind due to their low surface area. Optimal shape and dimension of any structural component may be determined by routine engineering analysis finding the proper balance between strength, cost, and shape for prevention of blow-down during high wind events. The system may be constructed, alternatively, from formed metals such as coated aluminum, steel, galvanized metals or other form-able construction materials known to those familiar with the art. Plastic or metal forming machines can be advantageously set up and operated in-country, as desired. Plastic raw material (i.e. resin beads or powder) can be globally sourced for cost containment. Suitable plastics include but are not limited to: PVC, High Density Polyethylene, Polypropylene, Polyamide (Nylon) and other materials known in the art. Structural plastics for framing and support members may advantageously contain fillers, UV stabilizers, colorants or molding agents.
Structural plastics for hydroponic fluid contact may be selected to conform to regulatory guidance in country, as required. In the absence of an in-country regulatory system, USDA and NSF regulatory restrictions for potential food contact, for example, may be observed in plastic selection for wetted surfaces.
Various embodiments of the invention have advantages over previously-known hydroponics systems. Traditional soil based gardening is the standard in developing world economies, having the lowest cost of entry and the highest customer acceptance. Productivity of this method is the basis by which new gardening systems are judged. Soil gardening is highly labor intensive in dry climates, requiring frequent watering events that are especially difficult in drought conditions, where sourced water requires foot travel to a local town well, pump station, river, creek or other containment body. Typical transport of water is effected by use of nominally 5-gallon polyethylene or polypropylene buckets repurposed from other uses (food service packaging, paint, industrial liquids, etc.). These buckets are typically balanced and carried on the farmer's head, most typically on women's and children's heads. A 5-gallon load weighs nominally 40 pounds and is carried various distances relative to garden proximity to the source. Distances of 3 to 5 miles over uneven paths are not uncommon. Water waste at point of use in gardening is a factor, where diffusion into the parched ground and away from the plant can significantly reduce the immediate uptake, and the staying power of the water in the vicinity of the root. In times of drought, the plants may require multiple treatments in the course of a day.
The primary advantage of hydroponics is the economy of water use, which is captured and contained in the plumbing and containment vessel; not lost to diffusion into soil. Water savings are significant over the life cycle of the plant, approaching a lox reduction in total water need. This results in collateral savings of time and energy of the individual farmer and family, and is highly desirable.
The size of the hydroponic system is a factor as well. The family farmer in the developing world may not have an abundance of arable land, and a significant percentage of families have not adopted farming at all due to the relatively tiny plots of land under their direct control, on which they can site a garden.
The specific advantages of the present novel system over available hydroponic solutions include system cost and high density yield in a minimal system footprint. The Babylon footprint has been field tested. The market data has verified that the Babylon basic family system is properly sized to gain traction in the 3rd world due to its favorable footprint. The basic Babylon system has provided the basis for entitlement food production, and would be widely accepted in country if the system could be obtained at a sustainable cost, with assurance of achievement of the target entitlement food yield. The present novel system is expected to meet or exceed the entitlement food yield of a Babylon system at a lower cost and with higher reliability.
Competitive systems are nonexistent in the third world due to first-world pricing and non-existent distribution, sales and support models. The LEVO business system and processes described herein are proposed to provide the necessary business model(s).
A prophetic example for a 4-tier novel system as described in the present invention will deliver an output food yield of at least about 20% greater than a basic system, up to at least about 50% greater than a basic system, with at least 90% reliability in the first growing cycle, when operated in accordance to LEVO instructions. Reliability is expected to improve further with training and support, plus continuing experience of the operator.
As previously mentioned, the problem of root clogging in plumbing systems for hydroponic gardening is well known. A closed system having fluid transport between growth chambers (such as the commonly used 4-inch or 6-inch PVC pipe as a growth chamber) relies on smaller diameter piping, for pumping, draining, filling, etc., operations. Especially at the drain ports, closed hydroponic systems of the prior art are highly susceptible to root clogging of the plumbing drain connections between growth chambers, or from growth chamber to fluid containment tanks, where a restriction to a smaller diameter drain exists. Roots from plants in the upstream chambers will typically grow and spread in an unrestricted manner into the downstream plumbing. This results in clogged plumbing systems, reducing or substantially eliminating the replenishment of fresh hydroponic nutrient, which harm the health, viability and productivity of the plants.
A test system of the present invention was built and tested in a two-tier configuration, as described with respect to
In accordance with some embodiments, novel business systems are provided for creative micro-financing, local (in-country) manufacture of components and system assembly, plus local (regional) distribution models and local (kiosk) component and consumable supplies and service, which in turn create new employment and economic opportunities through value-added processes in the target 3rd world economic environment. These business systems in aggregate create a sustainable economic model for the local growth, of low-cost high-yield hydroponic food security systems.
| Number | Date | Country | |
|---|---|---|---|
| 63090948 | Oct 2020 | US |
