INVENTOR(S): Schuyler Milton

FIELD OF THE INVENTION:

The present invention relates to novel substrate devices, and lighting devices with integrated ventilation, and the combination thereof in an apparatus. The devices, apparatuses and methods herein are for growing crops from seed, seedling, clone, plant tissue culture, plant or root stock. The substrate device enables growing crops without the use of fibrous media, using reusable materials. Specifically, the substrate device described herein relates to a device which enables growing from seed, clone, plant tissue culture or root stock using synthetic polymeric non-woven materials which are not consumed in the growing process and which may be cleaned and reused. The substrate device is applicable to a series of apparatus to grow crops in a variety of orientations such as horizontal, vertical and angled in hydroponic or aeroponic systems. Further, the substrate devices in combination with the lighting devices enables previously unattainable planting densities when used separately, by improving existing systems, and even greater densities when used together. The methods described here relate to the use of the devices and integrated apparatuses in growing plants.

BACKGROUND OF THE INVENTION:

Hydroponics encompasses the field of growing crops using nutrient rich water. Hydroponics includes various subsets, specifically, aeroponics, deep water culture (DWC), nutrient film technique (NFT) and flood-drain systems.

Hydroponics relies on the delivery of nutrient rich and oxygen rich water to plant roots. Seeds are typically germinated in a fibrous media such as soil, soil composites with synthetic additives, or in woven or non-woven natural or synthetic fibers such as rockwool, peat, coconut coir, hemp, jute or polyester. The germinated seeds are then inserted or otherwise replanted into the hydroponic system once the seeds have germinated and the roots have infiltrated the fibrous media. The fibrous and porous media serve as structural support for the germinating seeds, further providing structural support as the seedling grows, yielding (being push out of the way) as the plants grow. Importantly, fibrous and porous media serve a primary function of retaining water to ensure proper germination and root development.

Nearly all hydroponics which grow plants from seed to date employ a fibrous or porous media. Limitations of fibrous and porous media are as follows: (1) Fibrous or porous media may be consumed and therefore represent an ongoing economic cost to the process. For example, soils, natural fibers and non-woven fibers such as rockwool are not cleanable or reusable without substantial reprocessing prior to reuse. Porous media such as lightweight expanded clay aggregate (LECA), also known as hydroton, and other mineral media such as gravel or sand, similarly requires extensive cleaning and/or reprocessing when used in sterile or clean environments required in many controlled environment agricultural applications. Such reprocessing steps come at a significant economic cost, and with limited efficacy, due to the vast and protected surface area such media provides, which allow microbial life to survive during cleaning. (2) Synthetic woven and non-woven fibers such as polyester require extensive cleaning to remove plant matter interwoven in the fibers from the prior growing cycle, and suffer the same issue with providing vast protected surface area in which microbial life may endure and repopulate following cleaning cycles. (3) Synthetic fibers such as rockwool and polyester cannot be certified as organic under USDA organic regulations or by parallel regulations in Canada, the European Union or Asia.

High density indoor horticulture and controlled environment agriculture (CEA) are methods of growing plants whereby the practitioner exerts direct control over one or more environmental component, including lighting, ventilation, temperature, CO2 concentration, humidity, irrigation and fertilization. Often, CEA is practiced in tandem with hydroponics, a field of agriculture that encompasses growing crops using nutrient rich water. Hydroponics includes various subsets, specifically, aeroponics, deep water culture (DWC), nutrient film technique (NFT) and flood-drain systems.

Critical components of high density horticulture and CEA addressed by the present invention are lighting and ventilation. Lighting is the means by which plants absorb photosynthetic energy. Ventilation is also critically important for plant growth to ensure delivery of fresh air, CO2, and the control of humidity. Ventilation design for indoor and controlled environment spaces also includes substantial planning and equipment to process excess humidity that enters the space via plant transpiration, evaporation from the substrate, and relatedly, evaporation from irrigation water. High density indoor horticulture and (CEA) both require precise control of the microenvironment to mitigate crop damage that can arise with high concentrations of light, heat and/or humidity. High density indoor horticulture and CEA have come to rely on LEDs for most applications, however in most instances each application inevitably wastes a considerable amount of energy in two ways. First, less than 100% of the photosynthetically active radiation actually falls on the crops, lighting the surrounding area instead, to no economic benefit. Second, high power LEDs placed at a distance greater than two feet from the crops produce a considerable amount of waste heat, which must be removed from the system requiring additional cost in utilities. High power LEDs (with individual chip output greater than or equal to 3 watts) cannot be used close to plants because the heat and high concentration of photons will damage crops. Lower power LEDs can be used closer to crops without causing damage to the crops, but when crops and LEDs are both used at high density both the LEDs and crops can both be damaged without adequate ventilation.

SUMMARY OF THE INVENTION:

The present invention relates to novel devices, apparatus and methods for growing crops from seed, seedling, clone, tissue culture, root stock or other plant form (herein "plants"), including both devices to serve as a substrate for the plant, as well as lighting and ventilation devices to pair with the novel substrate. Together, the novelty of both the substrate and the lighting and ventilation devices provides a more economical method of growing plants, at greater density and with lower operating costs. The substrate device suspends seeds or plants in air such that the shoot system of the plants, that is the portion comprising the stems and leaves, are delineated from the root system. The device can be incorporated into a variety of apparatuses, both by modifying existing systems and/or in newly conceived apparatuses herein, for use in a horizontal plane, vertical plane, slanted plane, or multifaceted or circular column. The method comprises the steps to operate the apparatus including the steps by which seeds, plant clones, tissue cultures or root stock are planted, grown and harvested, and steps by which the apparatus is cleaned and prepared for reuse. The apparatus encompassing the substrate device may be operated in tandem with a lighting and HVAC apparatus. The invention further encompasses an array of hollow bodies on which LEDs are affixed and through which air is circulated. The apparatus may be inserted or removed from the lighting and HVAC array as needed for growing and processing. BRIEF DESCRIPTION OF THE DRAWINGS:

The patent or application file contains at least one drawing and/or photograph executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.

FIG. 1 (A-B) shows two cut-away views with the substrate device used in a horizontal array. A cutaway as viewed from a diagonal is shown (1A) and a cutaway as viewed from an end is shown (IB). Both 1A and IB are of same object as viewed from different angles to show perspective of the delineation formed between the root zone and shoot zone and the role of the protrusions 1 in creating the delineation.

FIG. 2 (A-B) shows two cut-away views with the substrate device used in a horizontal array and with variable topography in the protrusions. The variable topography creates nooks 2 in the device in which seeds or plants of various sizes may be placed during germination and growth, providing greater exposure to water held by capillary action in between the protrusions.

FIG. 3 (A-B) shows two views of the same example of an LED fixture with integrated ventilation. The fixture comprises a hollow body 3, a lighted surface 4 on which LEDs 5 are placed. The surface further comprises a plurality of holes 6 through which air may pass. A fan 7 is integrated into the fixture, which may force air either into the fixture or draw air out of the fixture. The lighted surface of the LED fixture may snap into place via clips 8 attached to the hollow body.

DETAILED DESCRIPTION OF THE INVENTION:

In one embodiment of the invention, the substrate device is comprised of non-woven synthetic polymeric materials such as silicone rubber, polypropylene and/or a combination of the two. The delineation between the shoot system (or shoot zone) and root system (or root zone) created by the device is shown in FIG. 1 and FIG. 2. The shoot zone side of the device is exposed to light and air for the stem and foliage to develop. The root zone side of the device is the side toward which water supplied to either side of the device is directed. The portion of the device forming the delineation between the shoot system and root system may be comprised, for example, of flexible silicone rubber protrusions 1, flexible flaps, or a combination thereof. The protrusions may also be oriented in opposition to each other as demonstrated, for example, with the orientation of the protrusions 1 of FIG. 1 (A-B). This flexible device allows water supplied to the shoot zone as a mist, spray, drip or film, to be held by capillary action, or other means of moisture retention such as surface wetting, by the protrusions. This moisture retention allows newly planted seeds to be kept moist during germination, and similarly provides exposure to water as needed during any other stage of the plant cycle or when propagating from clone, tissue culture, root stock or other form of transplant. The device additionally allows water supplied from the shoot zone side of the device to drain toward the root zone. Seeds are placed on the device on the shoot zone side of the device, resting on the protrusions forming the delineation. When the device is used for growing plant clones, tissue cultures, root stock, seedlings, transplants or other plants, these plant forms may rest on top, or may be inserted through the delineation zone such that the lower portion of the plant is on the root zone side of the device and the stem or foliage of the plant is on the shoot zone side of the device. During insertion into the device, and similarly during plant development, the flexible protrusions, flaps, or combination thereof, yield to the plant. The protrusions are spaced appropriately and comprised of sufficiently rigid material to prevent the seeds, germinated seeds, plant clones, tissue cultures, root stock, seedlings or plants from passing through the delineation zone, formed by the protrusions, under their own weight. Similarly, the protrusions must be comprised of sufficiently flexible material to allow the plants to grow through the delineation zone and to allow insertion of plant clones, root stock, tissue cultures, seedlings or plants without damage to the device or plants. Upon seed germination, the newly germinated root will continue to grow into the root zone where nutrient rich water may be provided and the shoot system will continue to grow into the shoot zone where exposure to light and circulated air may be provided.

The phrase "under their own weight", in the context of the described device, shall mean only the force due to gravity and without external forces such as mechanical pushing or pulling from either side of the device, or, for example, pressure washing from either side of the device. It is intended that external forces above certain threshold, beyond those due to gravity alone, will result in the seeds or plants being forced from rest in the device. Additionally, "under their own weight" shall mean that the device must be able to function without additional support to the plants, such as additional structural or mechanical support to the seeds or plants or roots thereof from below the delineation formed by the device, including additional media, pots, net pots, or buoyant forces exerted on the seeds, plants or device from below the delineation. Additionally, "under their own weight" shall mean that the device must be able to function without additional structural or mechanical support to the seeds or plants or shoot system thereof, from above the delineation.

A distinct advantage of using a non-fibrous and non-porous substrate, as described herein, beyond providing mechanical support to the plants, is that non-fibrous and non-porous substrate provides minimal surface area for evaporation of irrigation water into the environment in which plants are being cultivated. Conversely, fibrous and porous media such as rockwool, soil, LECA, polyester fibers, etc., provide extremely high surface area through which irrigation water can and does evaporate. Evaporation of irrigation water into the controlled environment reduces the watering efficiency of the systems and dramatically increases to capital and operating expense required for mechanical equipment used in dehumidification.

According to an embodiment of the invention, plant clones such as basil cuttings may be grown using the device. The stem of the plant clone can be inserted into the device through the delineation zone such that the cut stem where the root zone is intended to develop is on the watered side of the device and the shoot system is on the shoot zone side.

According to an embodiment of the invention, root stock such as from strawberries may be grown using the device. Protrusions, or a combination of protrusions and flexible flaps, must be appropriately sized such that the delineation zone can accommodate the plant which the device is intended to support. Smaller protrusions would accommodate smaller plants. Larger protrusions, or a combination thereof with flexible flaps, may be implemented to form a larger delineation zone needed to accommodate larger plants. With an appropriately sized substrate device, the root portion of the root stock can be inserted into the device through the delineation zone such that the root system is on the watered side of the device and the shoot system is on the shoot zone side.

According to an embodiment of the invention, the device may be provided water from the shoot zone side, such that the water drains into the device through the delineation zone to reach the root zone. Water may also be provided from the shoot zone side, and will drain toward the root zone size of the device. According to an embodiment of the invention, the device is oriented relative to the ground such that water provided from the shoot zone side will drain into the device passing through the delineation zone into the watered side.

According to an embodiment of the invention, the device is oriented relative to the ground such that water provided from the watered side does not substantially pass through the delineation zone and remains or drains from the watered side of the device.

According to an embodiment of the invention, the device can be incorporated into a horizontal apparatus to enable hydroponic growing via DWC, NFT, flood-drain or aeroponics. Such an embodiment is shown in FIG. 1.

According to an embodiment of the invention, the substrate device can be incorporated into vertical apparatus to enable hydroponic growing via NFT, drip watering, or aeroponics. Implementation of a vertical embodiment of the substrate device may require an internal angle in the substrate device, such that water applied to either side of the device drains substantially toward the root zone side of the device.

According to an embodiment of the invention, the substrate device may be designed to replace neoprene collars used in plant cloning and growing applications. Such an embodiment would require the body of the device to approximate the shape of commonly used neoprene collars, typically circular, with the protrusions angled and sized appropriately to define the delineation between the root zone and the shoot zone.

According to an embodiment of the invention, the substrate device may be design to replace or improve net pots used in germination, cloning, propagation and other plant nursery applications. Such an embodiment would require the body of the device to approximate the shape of commonly used net pots, typically circular, with the protrusions angled and sized appropriately to define the delineation between the root zone and the shoot zone.

According to an embodiment of the invention, the device can be incorporated into angled apparatus to enable hydroponic growing via NFT, drip watering, or aeroponics. According to an embodiment of the invention, the device can be used with hydroponic systems using synthetic, natural, combination or aquaponic nutrient enriched water.

According to an embodiment of the invention, multiple devices can be inserted into a semi-rigid structure to form one or multiple planes on which to grow crops. The planes may be oriented vertically, horizontally, slanted, in towers, multifaceted or circular columns. If oriented horizontally, these assemblies may be stacked to form two or more surfaces on which to grow crops, with appropriate lighting, ventilation and water drainage in between each stacked level.

According to an embodiment of the invention, semi-rigid structures with multiple substrate devices inserted or attached can form multifaceted columns. Such columns are provided water to the interior of the column, typically from the top of the column. The water drains toward the bottom of the column.

According to an embodiment of the invention, semi-rigid structures with multiple substrate devices inserted or attached can form horizontal planes wherein water is provided to the root zone side of the device.

According to an embodiment of the invention, semi-rigid structures with multiple substrate devices inserted or attached may be planted with seeds of varying size, plant clones or cuttings, tissue culture or root stock.

According to an embodiment of the invention, the semi-rigid structures with multiple substrate devices inserted or attached may be planted with seeds wherein seeds are planted directly on top of the delineation zone, on the shoot zone side of the protrusions.

According to an embodiment of the invention, the semi-rigid structures with multiple substrate devices inserted or attached may be planted with plant clones, or cuttings, such as basil stems wherein the stem of the plant is inserted through the delineation zone. According to an embodiment of the invention, the semi-rigid structures with multiple substrate devices inserted or attached may be planted with root stock wherein the root stock is inserted through the delineation zone.

According to an embodiment of the invention, when the plants are ready to harvest a cutting tool may be applied across the foliar portion growing through the front of the semi-rigid structure to cut the grown crops from the remaining portion of the plant body.

According to an embodiment of the invention, after the harvest of the edible portion of the crop the semi-rigid structure and associated substrate device(s) may be washed with high-pressure washing machine to remove all plant material.

According to an embodiment of the invention, the substrate device is inserted into an apparatus comprising a fixture which provides light and ventilation to the plants in the substrate device.

According to an embodiment of the invention, the fixture that provides light and ventilation comprises a hollow body, at least one surface of the hollow body on which one or more LEDs are attached (herein, the "lighted surface"), a source of forced air directed either into the hollow body or drawing air out of the hollow body via a hole in the hollow body, and one or more holes on the lighted surface through which forced air is either expelled from the hollow body in a direction substantially parallel to light from the LEDs, or pulled into the hollow body in a direction substantially parallel to light from the LEDs. For clarity, in the context of this disclosure for forgoing claims, in reference to the direction of light emitted from the LEDs, "parallel" shall be construed to mean both parallel and antiparallel, such that air traveling in a parallel but reverse direction to light emitted from the LEDs is still referred to as parallel. The source of forced air may be reversible, either forcing air into, or drawing air out of, the hollow body.

The combination of LEDs and a ventilation unit solves a critical problem in the horticulture industry, which is the need to use LED lighting efficiently at very high density. Light is an inverse-square phenomenon. Lights at a closer distance achieve equal or greater intensities at lower power than the same lights at a farther distance. Bringing the LED lights closer to the plant canopy increases the lighting efficiency of the system and therefore the economic benefit of the system. Ventilation of high density indoor horticulture systems is a persistent problem since high density invariably means reducing surrounding air volume. Similarly, deploying LEDs close to plants (within two feet) can result in damage to the plants. Further, inadequate ventilation can result in damage to the LEDs and associated hardware due to overheating and high humidity. The present invention solves the problem of higher density applications of LEDs and allows for the use of more efficient use of LEDs in high density indoor horticulture and CEA.

In a preferred embodiment of the invention, the lighting device, FIG. 3, is comprised of a hollow body, the hollow body having an opening connecting to a source of forced air; the hollow body having a plurality of LEDs on at least one outside surface of the hollow body (herein, "lighted surface"); the lighted surface of the hollow body having one or a plurality of holes through which forced air passes either in to out from the hollow body in a direction substantially parallel to the direction of light emitted from the LEDs. The hollow body may have a cross-sectional shape of a circle, oval, triangle, square, rectangle, or other polygon as the application requires. The source of forced air may be a fan directly affixed to the device, or may be connected through ducting to a central source of forced air such as an air handling unit. The source of forced air may either push or pull air through the hollow body. Each of the holes on the lighted surface of the hollow body should have a cross-sectional area smaller than that of the opening connecting to a source of forced air. Light emitting diodes (herein, "LEDs") attached to an outside surface of the hollow body are placed at regular intervals and on the appropriate sides or angles of the hollow body to provide light as required by the specific horticultural application. The plurality of holes serves a dual purpose, the primary function of providing ventilation to the surrounding area, and the additional function of cooling the LEDs attached to the hollow body which prevents the LEDs from damage due to overheating. The lighted surface of the hollow body itself may also serve as a heat sink for the LEDs attached to the hollow body.

According to an embodiment of the invention, the air that is forced through the opening of the hollow body is sufficient to move at least 0.1 cubic feet per minute (CFM), 1 CFM and/or 10 CFM of air as measured at the opening of one or more of the holes in the lighted surface of the hollow body. According to an embodiment of the invention, the air that is forced through the opening is sufficient to move greater than 10 CFM of air as measure at the opening of one or more of the holes in the lighted surface of the device. According to an embodiment of the invention, the individual LEDs each have a power output of less than 0.5 watts, 1 watt and/or 5 watts.

According to an embodiment of the invention the hollow body is made of metal. Metals appropriate for the application include, but are not limited to, galvanized steel, stainless steel, tin and aluminum.

According to an embodiment of the invention, LEDs may be absent on sides of the hollow body that are not facing plants as required by the application. As seen in FIG. 3, the hollow body of the device shown lacks LEDs on the outward facing sides, and have LEDs evenly placed on the crop-facing sides (downward side as viewed in FIG. 3).

According to an embodiment of the invention, LEDs may be present on all sides of the hollow body. According to an embodiment of the invention, the hollow body is elongated with LEDs evenly placed on all sides of elongated hollow body intended to be crop facing sides, with a plurality of holes similarly dispersed on all crop facing sides (all lighted surfaces) of the elongated hollow body.

According to an embodiment of the invention, LEDs are attached in a density sufficient to supply photosynthetically active radiation of at least 200 pmol/m2/s at a distance of 1 inch from a lighted surface of the hollow body, at a distance of 6 inches from a lighted surface of the hollow body, at a distance of 12 inches from a lighted surface of the hollow body, and/or at a distance of 24 inches from a lighted surface of the hollow body.

According to an embodiment of the invention, the LEDs attached to the hollow body are dimmable.

According to an embodiment of the invention, the LEDs attached to the hollow body are dimmed, dimmable, or modulated using commonly available methods, including non-limiting examples such as voltage dimming, pulse width modulation (PWM), or constant current reduction (CCR).

According to an embodiment of the invention, the modulation of the LEDs takes place using a network enabling remote control of the modulation. According to an embodiment of the invention, the LEDs may be attached to the hollow body with adhesives such as glue or tape, or the LEDs may be integrated into a printed circuit board (PCB) on a rigid backing, the rigid backing itself serving as a lighted surface of the hollow body, and the LEDs or PCB to which the LEDs are integrated, may be attached to the hollow body using mechanical means such as brackets, clips or plastic ties. The LEDs may also be attached using a combination of any of the above.

According to an embodiment of the invention, both the substrate device and the lighting device are assembled into an apparatus for growing crops. The assembled apparatus may further comprise multiple similar or identical devices forming an array of both substrate devices and lighting devices.

According to an embodiment of the invention, the devices, or apparatus or array comprising multiple devices, is/are mobile, allowing the devices to be repositioned as needed, either for processing, harvesting, washing, servicing, seeding, planting or repositioning within the array or for any other maintenance activity. The mobility may come from being attached to wheels on the bottom on the bottom of the devices or superstructure to which the devices are attached, or by any other conveyance commonly known in the art. The mobility may also come from being attached to rails, or similar conveyance, suspending the devices which can be adjusted horizontally or vertically as the application requires.

The forgoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.