Thermally controlled greenhouse system
20220201943 · 2022-06-30
Inventors
Cpc classification
Y02A40/25
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
Abstract
Greenhouses designed for optimized thermal control are provided, incorporating various elements for controlling the temperature and air quality in the greenhouse. The greenhouses are configured with structural insulation in the roof, walls, and floor of the greenhouse which use particular materials, such as concrete, glass or polycarbonate, and design implementations for thermal control of the greenhouse. The airflow and environment in the greenhouse is also managed by providing air circulation systems controlling the fresh air flow and temperature and humidity of the air in the greenhouse.
Claims
1. A greenhouse system comprising: flooring comprised of a first material; outer walls comprised of a second material; a roof comprised of a third material; and a thermally controlled air circulation system.
2. The greenhouse system according to claim 1, wherein the first material comprises concrete.
3. The greenhouse system according to claim 2, wherein the first material further comprises one or more of melamine formaldehyde or polypropylene.
4. The greenhouse system according to claim 1, wherein the second material comprises concrete.
5. The greenhouse system according to claim 4, wherein the second material further comprises one or more of melamine formaldehyde or polypropylene.
6-7. (canceled)
8. The greenhouse system according to claim 1, wherein the outer walls comprise one or more sheets of polycarbonate.
9. The greenhouse system according to claim 1, wherein the outer walls further comprise glass.
10. The greenhouse system according to claim 1, wherein the third material comprises concrete.
11. The greenhouse system according to claim 10, wherein the third material further comprises one or more of melamine formaldehyde or polypropylene.
12.-13. (canceled)
14. The greenhouse system according to claim 1, wherein the roof comprises one or more sheets of polycarbonate, and at least one of the one or more sheets comprises a plurality of hexagonal rows running in parallel.
15. The greenhouse system according to claim 14, wherein the roof or the outer wall further comprises one or more retractable shades inside the greenhouse having a black or a reflective material.
16. The greenhouse system according to claim 1, wherein the thermally controlled air circulation system comprises one or more cooling units configured to provide a supply of cold air and one or more heating units configured to provide a supply of heated air.
17.-21. (canceled)
22. The greenhouse system according to claim 16, wherein the thermally controlled air circulation system further comprises one or more interstitial passages comprising an open vent arranged near the roof to intake warmed air that has risen towards the roof of the greenhouse and one or more openings beneath the roof configured to output the warmed air.
23. The greenhouse system according to claim 22, wherein the one or more interstitial passages comprise one or more additional polycarbonate sheets or panels across a length of the roof and walls of the greenhouse arranged on an interior or exterior of the greenhouse.
24. The greenhouse system according to claim 16, wherein the thermally controlled air circulation system further comprises an air exchange unit configured to eject air from inside the greenhouse and intake external air from outside the greenhouse; and wherein the air exchange unit is configured in communication with at least one of the one or more openings of the one or more interstitial passages and comprises at least one venting fan configured to create a negative pressure that causes the intake of the warmed air at the open vent of the interstitial passage.
25. (canceled)
26. The greenhouse system according to claim 24, wherein the air exchange unit is configured to manage a level of CO.sub.2 in the greenhouse.
27. (canceled)
28. The greenhouse system according to claim 24, wherein air exchange unit further comprises a desiccant wheel system configured to control humidity of air entering the greenhouse.
29. The greenhouse system according to claim 1, wherein the flooring comprises: a base comprising the first material; a plurality of support pegs projecting a distance above the base; and a sheet of polycarbonate material placed atop the support pegs; wherein an air gap is formed between the base and the sheet of polycarbonate material.
30. The greenhouse system according to claim 29, wherein an upper surface of the sheet of polycarbonate comprises one or more polyethylene sheets.
31. The greenhouse system according to claim 29, wherein the air gap is ventilated to increase the flow of air comprising heat dissipated by the base to another location to decrease the amount of heat conducted from the base to the greenhouse.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0022]
[0023]
[0024]
[0025]
[0026]
[0027]
[0028]
[0029]
[0030]
[0031]
[0032]
[0033]
[0034]
[0035]
[0036]
[0037]
[0038]
DETAILED DESCRIPTION OF THE INVENTION
[0039] The present application will now be described with reference made to
[0040] Depending on climate or crop requirements, as well as other considerations such as limited sunlight and the prevalence of extreme weather conditions (e.g., hurricanes), thermally controlled greenhouse roof, floor and walls may be made of concrete.
[0041]
[0042] Cool air 44a rises from the floor 41 of the greenhouse 40 through the grow zone where the plants are arranged. Warmer air 44b rises towards the concrete roof 46 of the greenhouse 40, and is drawn down interstitial passages 44c of the greenhouse 40, towards air exchange points 45 at floor level. The air exchanges 45 control the amount of incoming air to the cooling units 42, and the temperature of the incoming air can be controlled through a heat exchanger and desiccant system 110, shown and described in
[0043]
[0044] Heated air 54a rises from the floor 51 of the greenhouse 50 through the grow zone where the plants are arranged. The heated air 54b rises towards the concrete roof 56 of the greenhouse 50, and is drawn down interstitial passages 54c of the greenhouse 50, towards air exchange points 55 at floor level. The air exchanges 55 control the amount of incoming air to the heating units 52, and the temperature of the incoming air can be controlled through a heat exchanger and desiccant system 110, shown and described in
[0045] Insulation capabilities of concrete may be enhanced through the use of polymers such as melamine-formaldehyde or waste thermoset plastics, including polypropylene. Additives will also make the concrete lighter. Structural capabilities of the concrete may be enhanced through the use of steel or basalt reinforcement. Additives, such as melamine-formaldehyde, will also increase structural strength.
[0046] Thermally controlled concrete structures can be used in both hot and cold climates, made to be hurricane resistant, made using modular sections for cost saving and rapid construction, stacked in multiple levels where ground space is limited, and include insulated polycarbonate windows and skylights to permit some natural light.
[0047] Transparent materials such as polycarbonate or glass may be used to construct thermally controlled greenhouses when abundant sunlight is available or the cost of electric power for permanent indoor lighting (as required by concrete or warehouse structures) is prohibitive. Exemplary embodiments of such greenhouses are shown in
[0048]
[0049] Cool air 64a rises from the floor 61 of the greenhouse 60 through the grow zone where the plants are arranged. Warmer air 64b rises towards the concrete roof 66 of the greenhouse 60, and is drawn down interstitial passages 64c of the greenhouse 60, towards air exchange points 65 at floor level. The air exchanges 65 control the amount of incoming air to the cooling units 62, and the temperature of the incoming air can be controlled through a heat exchanger and desiccant system 110, shown and described in
[0050]
[0051] Heated air 74a rises from the floor 71 of the greenhouse 70 through the grow zone where the plants are arranged. The heated air 74b rises towards the concrete roof 76 of the greenhouse 70, and is drawn down interstitial passages 74c of the greenhouse 70, towards air exchange points 75 at floor level. The air exchanges 75 control the amount of incoming air to the heating units 72, and the temperature of the incoming air can be controlled through a heat exchanger and desiccant system 110, shown and described in
[0052] Polycarbonate can be used for thermally controlled greenhouses and offers many significant advantages over glass, including: it is lighter in weight, which enables multi-layered roofs to be supported by structural supports that are not substantial in size and therefore do not interfere with light; it is less costly to transport; it can be fabricated less expensively and efficiently into complex shapes to facilitate insulation and structural strength; (See, e.g.,
[0053] Polycarbonate roof materials can be square, rectangular or hexagonal honeycomb sheets running either in parallel (
[0054] Polycarbonate roof greenhouse wall materials may be composed of flat sheets of polycarbonate or include clear polycarbonate or glass blocks, which may or may not be load bearing, as shown in
[0055] For polycarbonate greenhouses, in order to provide extra insulation at night for cold climates and to shade high levels of insolation during the hottest parts of the day in hot climates, black or reflective roll-out shades may integrated into greenhouse design (
[0056] Generally, little consideration is given to floor construction in non-thermally controlled greenhouses. The floors can be dirt, gravel, sand or concrete, based upon cost and basic operational requirements.
[0057] The thermally controlled greenhouse requires that floor design and construction be an integral part to the building's structure and thermal operating performance. In both polycarbonate and concrete structures, as described above and shown for example in
[0058] An example embodiment of flooring 101 including a concrete slab 102 with conduits 103 formed therethrough is shown in
[0059] In accordance with the present application, thermal management of the airflow in the greenhouse is also provided. The basis for cooling air includes that cooled air is delivered directly to the growing area through conduits in the floor and disseminated through floor vents or vents in the raised daises where plants are grown (e.g., platforms 43, 63 in
[0060] The basis for heating air can be similar to that described above. Heated air is delivered directly to the growing area through conduits in the floor and disseminated through floor vents or vents in the raised daises where plants are grown (e.g., platforms 53, 73 in
[0061] Stored solar energy in the floor system can also be used to level thermal load variation for over twenty-four hours.
[0062] The airflow can also be managed in a thermally controlled greenhouse according to the present application. Airflow management in a thermally controlled greenhouse includes the option to perform any of the following as appropriate for the specific greenhouse thermal environment: (1) Channeling collected room air to: outside vents, interstitial passageways in the greenhouse structure, and/or insulated conduits to recirculation/treated venting plenum; (2) Managing air exchange with outside air by: supplying replenishment of fresh air to maintain required CO.sub.2 levels, pre-cooling/pre-warming refresh air with venting air as appropriate, direct venting of interstitially heated vent air, recirculation of room air for thermal treatment and/or gusting for plant stimulation; (3) Managing the use of solar insolation stored in the flooring system; and/or (4) Regenerating the desiccant drying system, using either: roof level collected room air or interstitially warmed air.
[0063] When beneficial to thermal control, the flow path of air is controlled so that ceiling collected air 44b, 54b, 64b, 74b is directed along the boundary of greenhouse 44c, 54c, 64c, 74c. This could be in the inner wall of the greenhouse 40, 50, 60, 70, the outer wall of the greenhouse 40, 50, 60, 70, or an intermediary distance between the inner and outer layer of the of the greenhouse wall. This interstitial flow of air at the boundary of the greenhouse 40, 50, 60, 70 (i.e., the roof 46, 56, 66, 76 and walls 47, 57, 67, 77) is subject to the direct conductive thermal effect of the outside environment, even though this effect is limited by the thermal insulation provided by the greenhouse construction.
[0064] In order to achieve a continuous flow of air along either the inner or outer boundary, an interstitial passage 44c, 54c, 64c, 74c can be created by the addition of flat polycarbonate sheets or panels across the panels of the roof 46, 56, 66, 76 and uninterrupted down the side of the walls 47, 57, 67, 77. The sheets or panels can be between 0.5 and 1.0 cm thick. A mid-line interstitial flow can be created by sandwiching an air flow path between two layers of the boundary material.
[0065] Air is drawn into the interstitial passage 44c, 54c, 64c, 74c via open vents at the roof 46, 56, 66, 76 and pulled through the passage 44c, 54c, 64c, 74c by the negative pressure effect created by the venting fans of the air exchange units 45, 55, 65, 75. The interstitial passage 44c, 54c, 64c, 74c and the additional polycarbonate panel, while serving to manage air flow, also provide further insulation to the boundary layer of the greenhouse 40, 50, 60, 70. The air flow exiting the interstitial path 44c, 54c, 64c, 74c will have been heated to a higher temperature than the source ceiling air 44b, 54b, 64b, 74b. This will further lower the relative humidity of the exiting air increasing its utility in regenerating the desiccant system 110.
[0066] Since the airflow of the thermally controlled greenhouse 40, 50, 60, 70 is designed to be controlled and non-turbulent, gusting fans 48, 58, 68, 78 can be employed, such as 3-4 times per day, to move the foliage of mature plants to promote optimal growth.
[0067] The air exchange with outside air can also be managed for replenishment of fresh air and maintenance of required CO.sub.2 levels. One or more vents 45, 55, 65, 75 are placed at the base of the walls 47, 57, 67, 77 of the greenhouse 40, 50, 60, 70, and air is drawn from either the interstitial flow path 44c, 54c, 64c, 74c or the insulated conduits prior to venting. Control software can be configured to determine how much air needs to be re-circulated and how much needs to be vented for replacement based upon CO.sub.2 levels in the greenhouse 40, 50, 60, 70. It is beneficial that only minimum replacement levels for optimum cost efficient growth occur since incoming air will require thermal conditioning and/or moisture level management.
[0068] The energy efficient, thermally controlled greenhouse 40, 50, 60, 70 can manage the venting process so that, when thermally advantageous, the incoming air will be pre-conditioned prior to heating or cooling by passing it through an efficient air heat exchange manifold using vented air.
[0069] As described above, the floor 41, 51, 61, 71 of the greenhouse 40, 50, 60, 70 can act as both a reflector and a thermal trap for the direct solar insolation that strikes it, depending on the thermal load characteristics of the specific greenhouse and the level of utilization for trapped thermal energy.
[0070] In greenhouses with no use for stored heat overnight, such as in a pure tropical environment, the floor base can be silver or reflective to maximize the amount of solar insolation reflected back to the atmosphere, as long as the specific plants can tolerate underside reflected sunlight. The gap area is then circulated with either ambient air (or water) that is directly vented. This will keep the base surface cool and virtually eliminate re-radiation to the greenhouse. If plants cannot tolerate reflection, a black floor base can be used and the level of vented air (or water) flow increased.
[0071] In greenhouses with a large requirement for night heating, a black floor base can be used to maximize thermal storage during the day. Floor venting flow is limited to control maximal storage without excessive floor temperature and re-radiation. Air flow is recirculated overnight to transfer stored heat to the greenhouse.
[0072] In greenhouses with moderate overnight heating requirements, a black or silver floor base can be provided with controlled daytime venting and controlled night time recirculation. In greenhouses with constant heating requirements, a black floor base can be provided with constant recirculation to the room and turbulent mixing of room air to minimize floor to ceiling gradient.
[0073] The energy efficient, thermally controlled greenhouse will manage the venting process so that the incoming air will be pre-conditioned prior to heating or cooling by passing it through an efficient air heat exchange manifold using vented air when thermally advantageous. This will reduce the energy required for heating or cooling air to the desired levels. An exception to this is if the vented air is either hotter (for a cooled greenhouse) or colder (for a heated greenhouse) than the ambient air being drawn in from outside of the greenhouse by virtue of its circulation around the boundary layer of the greenhouse itself or absorption of solar insolation. In this case, control software can ensure that air is vented bypassing the heat exchange manifold.
[0074] Any air that is ultimately vented will always be heated to near ambient by either interstitial flow or in a vent air out/fresh air in heat exchanger.
[0075] For humidity control a rotating desiccant wheel system 110 will be installed following the thermal treatment section. Humidity control is usually needed in hot, moist environments where moisture needs to be removed from the treated air if the treated temperature reduction is not sufficient to lower the humidity level in the green house to the 70% level ideal for plant health. The desiccant wheel 110 includes a motor 111 and rotor 112, and its operation is shown in
[0076] Additional exemplary greenhouse configurations are illustrated in
[0077]
[0078]
[0079]
[0080] It should be understood that, unless stated otherwise herein, any of the features, characteristics, alternatives or modifications described regarding a particular embodiment herein may also be applied, used, or incorporated with any other embodiment described herein. Also, the drawing herein is not drawn to scale.
[0081] While there have been shown and described and pointed out fundamental novel features of the invention as applied to preferred embodiments thereof, it will be understood that various omissions and substitutions and changes in the form and details of the devices and methods described may be made by those skilled in the art without departing from the spirit of the invention. For example, it is expressly intended that all combinations of those elements and/or method steps which perform substantially the same function in substantially the same way to achieve the same results are within the scope of the invention. Moreover, it should be recognized that structures and/or elements and/or method steps shown and/or described in connection with any disclosed form or embodiment of the invention may be incorporated in any other disclosed or described or suggested form or embodiment as a general matter of design choice.