SYSTEM AND METHOD OF VERTICAL FARMING FRAME MOUNT FIELD ARCHITECTURE FOR MULTIPLE CROP CLASSES

Abstract

A scalable precision distribution aeroponic system, including a modular frame mount constructed of a lightweight, rigid material, the frame mount including a pair of generally vertically oriented support members and at least one generally horizontally oriented crossmember positioned between the vertically oriented support members, the pair of generally vertically oriented support members operably coupled to the generally horizontally oriented crossmember via couplings, the couplings including a generally horizontally oriented support configured to extend substantially orthogonal to the horizontally oriented crossmember, and an interchangeable growth media operably coupled to the modular frame mount, the interchangeable growth media comprising a nourishment layer and a surface film, the nourishment layer defining one or more channels into which the generally horizontally oriented supports of the couplings are positioned for support of the interchangeable growth media.

Claims

1. A modular frame mount for a precision distribution aeroponic system, comprising: a pair of generally vertically oriented support members; at least one generally horizontally oriented crossmember positioned between the vertically oriented support members; and one or more couplings, wherein the pair of generally vertically oriented support members are operably coupled to the generally horizontally oriented crossmember via the one or more couplings, the couplings comprising a generally horizontally oriented support extending substantially orthogonal to the horizontally oriented crossmember and configured to support an interchangeable growth media selectively coupleable to the modular frame.

2. The modular frame mount of claim 1, wherein the frame mount further comprises one or more bearing wheels configured to enable the modular frame mount to be hung in a generally vertical orientation

3. The modular frame mount of claim 1, wherein the couplings include at least one of a three-way T-shaped coupling, a three-way corner coupling, or a four-way coupling.

4. The modular frame mount of claim 1, wherein the pair of generally vertically oriented support members are constructed of an extruded aluminum tubing.

5. The modular frame mount of claim 1, wherein one or more components of the modular frame mount are operably coupled together via a pin coupling.

6. The modular frame mount of claim 1, wherein at least one of a trellis or other plant supporting structure is selectively coupleable to the generally horizontally oriented supports of the modular frame mount.

7. A scalable precision distribution aeroponic system, comprising: a modular frame mount constructed of a lightweight, rigid material; and an interchangeable growth media operably coupled to the modular frame mount, the interchangeable growth media comprising a nourishment layer having a first thickness, and a surface film having a second thickness, the nourishment layer defining one or more channels into which a portion of the modular frame, thereby coupling the interchangeable growth media to the modular frame mount.

8. The scalable precision distribution aeroponic system of claim 7, wherein the nourishment layer of the interchangeable growth media is constructed of a reticulated foam material.

9. The scalable precision distribution aeroponic system of claim 8, wherein the reticulated foam material includes a plurality of a pores with a spacing of between about 5 and about 15 pores per square inch.

10. The scalable precision distribution aeroponic system of claim 7, wherein the surface film of the interchangeable growth media is constructed of a biaxially-oriented polyethylene terephthalate material.

11. The scalable precision distribution aeroponic system of claim 10, wherein the surface film is constructed of at least one of a corona treated mylar or reflective polyester film.

12. The scalable precision distribution aeroponic system of claim 7, wherein the nourishment layer and the surface film are operably coupled to one another via an adhesive.

13. The scalable precision distribution aeroponic system of claim 12, wherein the adhesive has a melting point configured to enable separation of the nourishment layer from the surface film for recycling of at least one of the nourishment layer or surface film upon completion of a growth cycle.

14. A scalable precision distribution aeroponic system, comprising: a modular frame mount constructed of a lightweight, rigid material, the frame mount comprising a pair of generally vertically oriented support members and at least one generally horizontally oriented crossmember positioned between the vertically oriented support members, the pair of generally vertically oriented support members operably coupled to the generally horizontally oriented crossmember via couplings, the couplings including a generally horizontally oriented support configured to extend substantially orthogonal to the horizontally oriented crossmember; and an interchangeable growth media operably coupled to the modular frame mount, the interchangeable growth media comprising a nourishment layer and a surface film, the nourishment layer defining one or more channels into which the generally horizontally oriented supports of the couplings are positioned for support of the interchangeable growth media.

15. The scalable precision distribution aeroponic system of claim 14, wherein the interchangeable growth media defines one or more channels configured to enable efficient distribution of an atomized nutrient rich water solution.

16. The scalable precision distribution aeroponic system of claim 15, wherein the one or more channels have a width of between about 1 inch and about 6 inches and a depth between about of an inch and about 3 inches.

17. The scalable precision distribution aeroponic system of claim 15, wherein the one or more channels can define one or more atomized nutrient rich water solution congregation points.

18. The scalable precision distribution aeroponic system of claim 17, wherein the interchangeable growth media includes one or more plant apertures co-positioned at the one or more atomized nutrient rich water solution congregation points.

19. The scalable precision distribution aeroponic system of claim 15, further comprising a distribution nozzle positioned within the one or more channels, the distribution nozzle configured to introduce an atomized nutrient rich water solution into the one or more channels for distribution throughout at least a portion of the interchangeable growth media.

20. The scalable precision distribution aeroponic system of claim 15, further comprising at least one of a blower or vacuum mechanism configured to promote a flow of gas through the one or more channels, wherein the flow of gas is configured to at least one of promote an increase in distribution of the atomized nutrient rich water solution, aid in heat dissipation, enable temperature and/or humidity control of the root zone environment, or a combination thereof.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The disclosure can be more completely understood in consideration of the following detailed description of various embodiments of the disclosure, in connection with the accompanying drawings, in which:

[0023] FIG. 1 is a perspective view depicting a frame mount, in accordance with an embodiment of the disclosure.

[0024] FIG. 2A is a plan view depicting the frame mount of FIG. 1.

[0025] FIG. 2B is a profile view depicting the frame mount of FIG. 2A.

[0026] FIG. 2C is a detailed view of a portion of the frame mount of FIG. 2B.

[0027] FIG. 3 is a perspective view of a frame mounted pin coupling, in accordance with an embodiment of the disclosure.

[0028] FIG. 4 is a perspective view depicting an aeroponic system, in accordance with an embodiment of the disclosure.

[0029] FIG. 5A is a back plan view depicting the aeroponic system of FIG. 4.

[0030] FIG. 5B is a profile view depicting the aeroponic system of FIG. 5A.

[0031] FIG. 5C is a detailed view of a portion of the aeroponic system of FIG. 5B.

[0032] FIG. 6A is a front plan view depicting the depicting the aeroponic system of FIG. 4.

[0033] FIG. 6B is a detailed view of a portion of the vertical field assembly of FIG. 6A.

[0034] FIG. 7A is a rear profile view depicting an aeroponic system, in accordance with an embodiment of the disclosure.

[0035] FIG. 7B is a side view depicting the aeroponic system of FIG. 7A.

[0036] FIG. 7C is a front profile view depicting t the aeroponic system of FIG. 7A.

[0037] FIG. 8 is a perspective view depicting an aeroponic system, in accordance with an embodiment of the disclosure.

[0038] FIG. 9 is a perspective view depicting a plant supporting structure, in accordance with an embodiment of the disclosure.

[0039] FIG. 10 is a perspective view depicting an aeroponic enclosure, in accordance with an embodiment of the disclosure.

[0040] FIG. 11 is a perspective view depicting an aeroponic enclosure, in accordance with another embodiment of the disclosure.

[0041] FIG. 12 is a flow diagram depicting a series of aeroponic enclosures positioned along a projected growth cycle, in accordance with another embodiment of the disclosure.

[0042] While embodiments of the disclosure are amenable to various modifications and alternative forms, specifics thereof shown by way of example in the drawings will be described in detail. It should be understood, however, that the intention is not to limit the disclosure to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the subject matter as defined by the claims.

DETAILED DESCRIPTION

[0043] Referring to FIGS. 1 and 2A-C, a modular frame mount 102 (alternatively referred herein to as a universal frame mount or field frame assembly), is depicted in accordance with an embodiment of the disclosure. In some embodiments, the frame mount 102 can be constructed of a high strength, lightweight, rigid material. For example, in one embodiment, the frame mount 102 can be constructed of extruded aluminum tubing, wherein one or more components of the frame mount 102 are operably coupled together via one or more couplings are connectors, thereby enabling rapid assembly and disassembly of the frame mount 102.

[0044] As depicted in FIGS. 2A-B, in one embodiment, the frame mount 102 can include first rigid members 104A, 104B and 104C, second rigid members 106A1, 106A2, 106B1, and 106B2, and third rigid members 108A1, 108A2, 108B1, and 108B2. In some embodiments, the first, second and third rigid members 104, 106 and 108 can be of different respective lengths. For example, in one embodiment, the first rigid members 104 can have a length of about 20 inches, the second rigid members 106 can have a length of about 14 inches, and the third rigid members 108 can have a length of about 26 inches; although other lengths are also contemplated. In some embodiments, the second rigid members 106 and third rigid members 108 can be configured as generally vertically oriented support members, with respect to a gravitational frame of reference, while the first rigid members 104 can be configured as generally horizontally oriented support members with respect to the gravitational frame of reference, wherein the at least one first rigid member 104 is positioned between corresponding pairs of the second or third rigid members 106, 108. In some embodiments, the first rigid members 104 can be positioned substantially orthogonal to the second and third rigid members 106, 108 within a given plane; although other angles and configurations are also contemplated.

[0045] The various first, second and third rigid members 104, 106 and 108 can be operably coupled to one another via first connectors 110A1, 110A2, 110B1, and 110B2, second connectors 112A1, 112A2, 112B1, and 112B2, and third connectors 114A and 114B. In one embodiment, the first connectors 110 can be configured as a three-way, T-shaped coupling, the second connectors 112 can be configured as a four-way coupling, and the third connectors 114 can be configured as a three-way corner coupling; although other types of couplings are also contemplated. In embodiments, the couplings 110, 112, 114 can each include a support 120 (as depicted in FIG. 2C) configured to be generally horizontally oriented with respect to a gravitational frame of reference, to extend away from the plane of the first second and third rigid members 104, 106, 108. For example, in one embodiment, each of the supports 120 can be positioned substantially orthogonal to the horizontally oriented first rigid members; although other angles and configurations are also contemplated.

[0046] As depicted in FIG. 2C, in one embodiment, one or more bearing wheels 116 can be operably coupled to the connectors 112A1, 112A2, for example via shoulder screw 118, thereby enabling the frame mount 102 to be operably coupled to an overhead railing or other transport mechanism. In other embodiments, frame mount 102 can include one or more brackets (not depicted) configured to enable the frame mount 102 to be hung in a generally vertical orientation with respect to a gravitational frame of reference, such as that disclosed in Patent Cooperation Treaty App Ser. No. PCT/US2018/062035 (filed Nov. 20, 2018), the contents of which are incorporated by reference herein.

[0047] In some embodiments, the various connectors 110, 112, 114 can be configured to enable rapid assembly and disassembly of the frame mount 102. For example, in one embodiment, the various connectors 110, 112, 114 can include quick connect/disconnect buttons or other type of pin coupling 122 (as depicted in FIG. 3), thereby enabling the various components of the frame mount 102 to selectively and rapidly lock into place relative to one another, thereby contributing to the overall modularity of the frame mount 102 design. In some embodiments, one or more edges of the frame mount 102, supports 120 and/or pin couplings 122 can be rounded to inhibit wear and tear on softer materials that may be coupled to the modular frame mount 102, thus preserving the integrity of the soft materials.

[0048] Referring to FIGS. 4, 5A-C and 6A-B a scalable precision distribution aeroponic system 100 is depicted in accordance with an embodiment of the disclosure. In some embodiments, the aeroponic system 100 can include a modular frame mount 102 (such as that depicted in FIGS. 1 & 2A-C) and an interchangeable growth media 202. For example, in some embodiments, the growth media 202 can be selectively coupled to the frame mount 102 via the generally horizontally oriented supports 120. In particular, in some embodiments, the growth media 202 can define one or more channels 204 into which at least a portion of the frame mount 102 can be positioned, thereby operably coupling the growth media 202 to the frame mount 102.

[0049] In some embodiments, a portion of the frame mount 102 (e.g., ends of the respective supports 120) can penetrate entirely through the growth media 202 (as depicted in FIG. 6A), thereby enabling various types of tooling (e.g., trellises, supports, lighting, moisture distribution and drainage mechanisms, airflow mechanisms, etc.) to be readily coupled to the aeroponic system 100 as desired. Other methods of coupling the growth media 202 to the frame mount 102 are also contemplated. For example, in some embodiments, additional clips and/or reusable adhesives can be used to operably couple the growth media 202 to the frame mount 102. In other embodiments, the frame mount 102 can be used to sandwich the growth media 202 between the aluminum frame and a rigid exterior surface.

[0050] In some embodiments, the growth media 202 can be a multilayer assembly, which in some embodiments can include one or more nourishment layers 206 having a first thickness, and at least one surface layer 208 having a second thickness (as depicted in FIG. 5C). In some embodiments, first thickness of the one or more nourishment layers 206 can be larger than the second thickness of the at least one surface layer 208.

[0051] In some embodiments, the nourishment layer 206 can be constructed of a reticulated foam material. In some embodiments, the reticulated foam material can define a plurality of pores having a poor spacing of between about 5 pores and about 15 pores per square inch (PPI); with a nominal PPI of about 10 pores per square inch; although the use of other materials with other pore spacing is also contemplated.

[0052] In some embodiments, the at least one surface layer 208 can be a thin-film adhered to an outer surface of the nourishment layer 206. In some embodiments, the at least one surface layer 208 can be constructed of a biaxially-oriented polyethylene terephthalate (BoPet) material. For example, in one embodiment, the surface layer or film 208 can be a corona treated mylar, or other highly reflective, polyester film made from stretched polyethylene terephthalate. In some embodiments, the at least one surface layer 208 can be adhered to the nourishment layer 206 via an adhesive. For example, in one embodiment, the adhesive can be hot glue or other type of adhesive having a melting point configured to enable separation of the surface layer 208 from the nourishment layer, for recycling of at least one of the nourishment layer 206 or surface layer 208 upon completion of the growth cycle. At the end of the service life of a growth media 202, the growth media 202 can be rapidly disassembled. For example, in one embodiment, the hot glue can be reheated to enable disassembly of the various components, and the expensive components can be recycled in a later growth media 202, thereby minimizing waste.

[0053] In some embodiments, the nourishment layer 206 can define one or more channels or apertures 210 or other congregation points where a nutrient rich water solution introduced into the growth media 202 can generally congregate. In some embodiments, the nourishment layer 206 can define one or more plant apertures 212 (e.g., in the form of a cross slit) into which seeds, a seedling or other plant can be positioned for growth. In embodiments, the one or more plant apertures 212 can be co-positioned at the one or more apertures 210 or other points where nutrient rich water solution tends to congregate.

[0054] Referring to FIGS. 7A-C, another embodiment of a precision distribution aeroponic system 100, is depicted in accordance with an embodiment of the disclosure. Various embodiments are described in detail with reference to the drawings, wherein like reference numerals represent like parts and assemblies throughout the several views. In some embodiments, the one or more apertures 210 or other points where a nutrient rich water solution tends to congregate can be positioned within one or more channels through which and atomized spray of a nutrient rich water solution can be distributed.

[0055] For example, in some embodiments, the growth media 202 can define one or more vertical channels 214A-D and/or one or more horizontal channels 216A-B configured to enable an efficient distribution of atomized nutrients and moisture (occasionally referred to herein as a fog). In some embodiments, the one or more channels 214, 216 can have a width of between about 1 inch and about 6 inches, and a depth of between about of an inch and about 3 inches.

[0056] For example, in one embodiment, the vertical channels 214A-D can have a width of about 3 inches and a depth of about 0.75 inches, and the horizontal channels 216A-B can have a width of about 1 inch and a depth of about 0.75 inches. Other dimensions of the channels are also contemplated.

[0057] In some embodiments, the one or more apertures 210 or other points for nutrients rich water solution tends to congregate can be located within the channels 214, 216. Additionally, one or more plant apertures 212 into which seeds, a seedling or other plant can be positioned for growth, can be co-located with the one or more apertures 210, thereby creating an optimal root zone environment for plant roots in proximity to the one or more plant apertures 212. In embodiments, individual plants can be positioned within each of the plant apertures 212, such that roots of plants positioned within the plant apertures to into naturally extend into the channels 114, 116 for increased exposure to the nutrient rich fog.

[0058] In some embodiments, the aeroponic system 100 can include a distribution nozzle 218A/B positioned within at least one of the channels 214/216, wherein the distribution nozzle 218 AB is configured to introduce an atomized nutrient rich water solution into the one or more channels 214/216 for distribution throughout at least a portion of the growth media 202. Further, in some embodiments, the aeroponic system 100 can include other ductwork and/or fan such as a blower or vacuum mechanism 222 configured to promote a flow of gas through the one or more channels 214, 216, wherein the flow of gas configured to at least one of promote an increase in distribution of the atomized nutrient rich water solution, aid in heat dissipation (e.g., dissipate heat generated by the grow lights absorbed by the growth media 202) enable precise control of temperature and/or humidity within the root zone environment, or a combination thereof.

[0059] Referring to FIG. 8, a precision distribution aeroponic system 100 is depicted in accordance with another embodiment of the disclosure. In some embodiments, the aeroponic system 100 can include a single vertical channel 214 in which a plurality of apertures 210 or other points where a nutrient rich water solution tends to congregate can be defined. In some embodiments, the aeroponic system 100 can include a single distribution nozzle 218 configured to introduce an atomized nutrient rich water solution into the one or more channels 214/216 for distribution throughout at least a portion of the growth media 202. One or more bearing wheels 116A/B can be coupled to the aeroponic system 100, thereby enabling the aeroponic system 100 to be suspended and move along an overhanging track. For additional details regarding the aeroponic system 100 design, see U.S. Design Patent Application Ser. No. 29/753,449 (filed Sep. 30, 2020), the contents of which are hereby incorporated by reference herein.

[0060] Ductwork and/or one or more blower or vacuum mechanism 222A/B configured to promote a flow of gas through the one or more channels 214, 216A/B. For example, in one embodiment, a blower 222A can be positioned on one end of the aeroponic system 100 and vacuum source can be positioned on another end of the aeroponic system 100; although other configurations of ductwork and/or one or more blower or vacuum mechanisms 222 is also contemplated. Accordingly nutrient rich fog introduced by the distribution nozzle 218 can be guided by air currents within the horizontal and vertical channels 214, 216A/B, which can be controlled to optimize circulation of the atomized nutrients and moisture within the root zone environment, thereby minimizing the need to recycle nutrient fluids, particularly in comparison to aeroponic systems of the prior art. Circulation of fluids within the horizontal and vertical channels can further aid in heat dissipation and removal (e.g., from the light source), and improved control of temperature and humidity within the root zone environment.

[0061] In some embodiments, additional tooling such as additional roller assemblies, and additional structures (e.g., trellises, screens, netting, supports, lighting, moisture distribution and drainage mechanisms, airflow mechanisms, etc.) can be operably coupled to the ends of the supports 120, which in some embodiments penetrate entirely through the growth media 202 (as depicted in FIG. 5B, 6A & 7A). One example of a plant supporting structure 300 is depicted in FIG. 9. In one embodiment, the plant supporting structure 300 can include a plurality of legs 302A-D selectively coupleable to the supports 120. The plurality of legs 302A-D can support a frame structure 304 or other structure configured to support a plant canopy. Although a relatively simple trellis is depicted in FIG. 9, other, potentially more complicated plant supporting systems operably coupleable to supports 120 are also contemplated. For additional details regarding the plant supporting structures 300, see Patent Cooperation Treaty App Ser. No. PCT/US2020/032337 (filed May 11, 2020), the contents of which are hereby incorporated by reference herein.

[0062] With reference to FIGS. 10-11, an aeroponic enclosure 400 configured to at least partially house one or more aeroponic systems 100 is depicted in accordance with an embodiment of the disclosure. In some embodiments, the aeroponic enclosure 400 can include one or more rails 402A/402B upon which bearing wheels 116 of the one or more aeroponic systems 100 can be positioned, thereby enabling the one or more aeroponic systems 100 to be suspended within the aeroponic enclosure 400, while enabling ease in lateral movement of the aeroponic systems 100 from one position to another (e.g., during different growth cycles). In some embodiments, the aeroponic enclosure 400 can include one or more sides 404A/B, which can be configured with a variety of lights and/or ductwork to provide optimal growth conditions to plants contained within the aeroponic enclosure 400. In some embodiments the one or more sides 404A/B can be configured to slide along the one or more rails 402A/402B between an open and a closed position. For additional details regarding the aeroponic enclosure 400 design, see U.S. Design Patent Application Ser. No. 29/739,358 (filed Jun. 24, 2020), the contents of which are hereby incorporated by reference herein.

[0063] With additional reference to FIG. 12, in some embodiments, a plurality of aeroponic enclosures 400A-E can be positioned in series to create optimum growth conditions for a plant as it matures from a seed or seedling to a mature/ready to be harvested plant. For example, in some embodiments, individual aeroponic systems 100 positioned within the aeroponic enclosures 400 can move from one end of the plurality of aeroponic enclosures (e.g., enclosure 400A) to the other end of the plurality of aeroponic enclosures (enclosures 400E); although other combinations and configurations of pluralities of aeroponic enclosures are also contemplated.

[0064] Although the disclosure primarily discusses use of the systems 100 in terms of aeroponic growth systems, the systems and methods disclosed herein may equally be applicable to hydroponic growth systems. Accordingly, such a manufactured enclosure 400 architecture (including one or more vertical field architecture system 100) streamlines manufacturing, reduces the processes of seeding, growing and harvesting to the efficiencies of assembly processes thus establishing the efficiency gains necessary for scaling aero- and hydroponic indoor commercial agriculture.

[0065] Accordingly, embodiments of the present disclosure provide a simple and robust vertical field architecture that is efficient to manufacture with a standardized system architecture across multiple crop classes and farm types. Moreover, the systems and methods as disclosed herein are configured to enable an assembly line approach to efficient vertical field manufacturing across multiple crop classes. In situ, mechanized and automated seeding of seeds, seedlings and clones directly into manufactured vertical field apertures can be completed in a rapid manner.

[0066] Various embodiments of systems, devices, and methods have been described herein. These embodiments are given only by way of example and are not intended to limit the scope of the claimed inventions. It should be appreciated, moreover, that the various features of the embodiments that have been described may be combined in various ways to produce numerous additional embodiments. Moreover, while various materials, dimensions, shapes, configurations and locations, etc. have been described for use with disclosed embodiments, others besides those disclosed may be utilized without exceeding the scope of the claimed inventions.

[0067] Persons of ordinary skill in the relevant arts will recognize that the subject matter hereof may comprise fewer features than illustrated in any individual embodiment described above. The embodiments described herein are not meant to be an exhaustive presentation of the ways in which the various features of the subject matter hereof may be combined. Accordingly, the embodiments are not mutually exclusive combinations of features; rather, the various embodiments can comprise a combination of different individual features selected from different individual embodiments, as understood by persons of ordinary skill in the art. Moreover, elements described with respect to one embodiment can be implemented in other embodiments even when not described in such embodiments unless otherwise noted.

[0068] Although a dependent claim may refer in the claims to a specific combination with one or more other claims, other embodiments can also include a combination of the dependent claim with the subject matter of each other dependent claim or a combination of one or more features with other dependent or independent claims. Such combinations are proposed herein unless it is stated that a specific combination is not intended.

[0069] Any incorporation by reference of documents above is limited such that no subject matter is incorporated that is contrary to the explicit disclosure herein. Any incorporation by reference of documents above is further limited such that no claims included in the documents are incorporated by reference herein. Any incorporation by reference of documents above is yet further limited such that any definitions provided in the documents are not incorporated by reference herein unless expressly included herein.

[0070] For purposes of interpreting the claims, it is expressly intended that the provisions of 35 U.S.C. 112(f) are not to be invoked unless the specific terms means for or step for are recited in a claim.