EP3993603A1

EP3993603A1 - Growing tray

Info

Publication number: EP3993603A1
Application number: EP20737361.4A
Authority: EP
Inventors: Stuart Green
Original assignee: Hydrogarden Ltd
Current assignee: Hydrogarden Ltd
Priority date: 2019-06-10
Filing date: 2020-06-05
Publication date: 2022-05-11
Also published as: WO2020249481A1; GB2584741B; GB201908269D0; GB201917900D0; GB2584741A

Abstract

A tray assembly, shelving and rack for growing plants within a hydroponic assembly, the tray assembly comprising a base tray, a tray insert and a cover 5with apertures to retain a net pot within the assembly. The tray insert comprises a base with upstanding side walls and having a fluid inlet channel extending widthwise across one end, a fluid outlet channel extending widthwise across the other end, longitudinally extending ridges extending between said inlet and outlet channels forming a gully therebetween and means to direct fluid from the 0inlet channel through the or each gully and into the outlet channel.

Description

Growing tray

Field of invention

The present invention relates to a hydroponics growing tray. More especially the invention relates to a growing tray designed and constructed to be suitable for use within Nutrient Film Technique (NFT) and/or Flood and Drain hydroponic growing systems.

Background to the invention

NFT is a technique used in the hydroponic growing of plants and involves passing a thin layer of film or fluid containing dissolved nutrients needed for the plants growth along a channel so that it comes into contact with the roots of the plants being grown.

There are several factors that can alter the effectiveness of NFT systems and one of these is the ability to supply a regular even film across the width of the channel such that an even distribution of nutrient solution is received by all the plants.

Other problems are associated with obtaining a reliable and regular flow rate along longer lengths of growing area in stacked shelf assemblies.

Another major issue with current NFT systems is the power consumption, mainly due to the growing trays remaining static within the system during the growth cycle.

Presently, in order ensure optimum flow rates NFT systems require substantial, expensive and often complex irrigation assemblies within the system. Each fluid channel requires separate fluid pipes and pressure modulators to control the rate of fluid along the channels.

One such example of a NFT system with irrigation is disclosed in the Applicant’s earlier patent application no. EP3119184.

The present invention seeks to provide a growing tray for use with NFT systems incorporating design features to regulate flow nutrient within the system thereby removing the need for separate complex irrigation assemblies. A major issue with NFT systems of the type described is that of power consumption. In current NFT systems the plants trays remain static within the system during the plant growing cycles. As a consequence it is difficult to the vary and modulate the power consumption across the system.

The present invention also seeks to provide a means of locating the trays within the NFT shelf assembly in a way that the trays are movable along the system.

Another alternative technique used in hydroponic growing of plants is Flood and Drain. This technique involves flooding a nutrient solution over the growing bed for a short period of time before subsequently allowing the nutrient solution to drain away.

As NFT and Flood and Drain systems work on similar but different principles, they are generally require separate systems. The present invention though seeks to provide a tray assembly that is suitable for use in NFT or Flood and Drain systems to allow the consumer to use the same hydroponic apparatus but to selectively choose to use it as a Flood and Drain or an NFT growing system.

Statements of Invention

According to a first aspect there is provided a tray assembly for growing plants within a hydroponic assembly, the tray assembly comprising a base tray, a tray insert and a cover with apertures to retain a net pot within the assembly.

Preferable the tray insert comprises a base with upstanding side walls and having: a fluid inlet channel extending widthwise across one end;

a fluid outlet channel extending widthwise across the other end;

longitudinally extending ridges extending between said inlet and outlet channels forming a gully therebetween; and

means to direct fluid from the inlet channel through the or each gully and into the outlet channel.

Preferably the directing means comprising a wall with a recess having sloped walls at the entrance to each gully.

Preferably the or each recess is generally V-shaped with a flattened base. Preferably the fluid inlet channel has a central divider.

Preferably the base has longitudinal ridges forming at least one gully either side of the divider.

Preferably the central divider is higher than the recessed wall.

Preferably the tray assembly is provided with means to direct fluid into the inlet channel either side of the divider.

Preferably the fluid outlet channel includes at least one cut through slot to drain fluid from the tray insert.

Preferably the tray assembly includes a cover extending over the fluid inlet channel, the cover having an aperture at or near to each end to receive fluid and direct it into the channel either side of the divider.

Preferably the base tray has a widthwise extending fluid inlet channel directly under the slots to receive fluid draining from the tray insert.

Preferably the tray insert sits within the base tray in such a way that the outlet channel of the tray insert overlies the inlet channel of the base tray.

Preferably the base tray has a longitudinally extending central gully leading to a widthwise extending fluid outlet channel.

Preferably the floor of the fluid inlet channel of the base tray is sloped for either end towards the center to direct flow of fluid into and down the gully. Preferably the fluid outlet channel includes a sump at one end.

Preferably the floor of the outlet channel is sloped towards the sump.

According to a further aspect of the invention there is provided a shelving assembly for carrying a tray assembly according to the first aspect, the shelving assembly having a shelf frame that is slidable in a lateral direction from the shelving assembly, the shelving assembly further comprising drainage pipe extending widthwise across the assembly and aligned underneath the outlet channel of the base tray of the tray assembly.

Preferably the drainage pipe has an elongate slot cut along its length so to receive fluid drained from the base tray whilst the tray is slid out of the shelving assembly for loading or unloading.

According to a third aspect there is provided a rack assembly for use with a tray assembly according to the first aspect, the rack assembly including a fluid pipe extending along the length of the assembly and having one or more flexible outlet pipes extending from the fluid pipe and into the fluid channel of the tray insert.

Preferably the or each outlet pipe is biased downwardly to extend into an aperture of the end cover of the tray assembly and to lift from said aperture as the tray assembly moves through the assembly and subsequently extend into the aperture of an end cover of another tray assembly as that tray assembly moves underneath the outlet pipe.

Brief description of the drawings

One embodiment of the invention will now be described by way of example only, with reference to the accompanying figures in which:

Figure 1 is an exploded view of the a tray assembly constructed in accordance with the invention;

Figure 2 is a perspective view of the tray assembly in assembled form;

Figure 3 is a side view of the tray assembly of figure 2;

Figure 4 is a perspective view of a row section of a net pot cover of the tray assembly;

Figure 5 is a side view of the net pot cover of figure 4; Figure 6 is a perspective view of a tray insert of assembly;

Figure 7 is a plan view of the tray insert of figure 6;

Figure 8 is an end view of the tray insert of figure 6 from the fluid outlet channel end;

Figure 9 is an end view of the tray insert of figure 6 from the fluid inlet channel end;

Figure 10 is a perspective view of an end cover of the tray assembly;

Figure 11 is a plan view of the end cover of figure 10;

Figure 12 is a side view of the end cover of figure 10;

Figure 13 is a perspective view of a base tray of the tray assembly;

Figure 14 is a plan view of the base tray of figure 13;

Figure 15 is a side view of the base tray of figure 13;

Figure 16 is a perspective of a base tray including growing mats;

Figure 17 is a plan view of the base tray of figure 13;

Figure 18 is a side view of the base tray of figure 13;

Figure 19 is a side cross section view of one end of the base tray of figure 18;

Figure 20 is an exploded view of the a tray assembly constructed in accordance with a second embodiment of the invention; Figure 21 is an exploded view showing further elements of the tray assembly of figure 20;

Figure 22 is a perspective view of the assembled tray assembly of figure 20;

Figure 23 is a perspective view of the assembled tray assembly of figure 21 ;

Figure 24 illustrates the nutrient fluid delivery mechanism for use with a tray assembly constructed in accordance with the invention;

Figure 25 illustrates the fluid delivery mechanism whilst the tray assembly moves through the system;

Figure 26 is a view of a tray assembly constructed in accordance with the invention used in a rack system;

Figure 27 shows the tray assembly within the rack system;

Figures 28 to 30 show the sliding mechanism of the tray assembly within the rack system; and

Figure 31 shows the sliding mechanism of a fluid tank within the racking system.

Detailed description of preferred embodiments

The present invention provides a tray assembly for use in a vertical tier shelf system, such as that disclosed in the Applicant’s earlier application EP3119184, many of the features of which are incorporated herein by reference. The use of the tray assembly within the system will be described later.

Referring first to figure 1 , the tray assembly comprises a base tray 2, a tray insert 4, a net pot cover 6 in which net pots 8 can sit, and end covers 10. The net pot cover 6 can be formed in sections of varying size, for example figure shows 1 a net pot cover 6 consisting of three rows, and also a single row section cover.

Figures 2 and 3 show the tray assembly in a fully assembled state.

Each section of the assembly will now be described.

A (single section) net pot cover 6 can be seen best in figures 4 and 5. The cover 6 has a ridged top surface 12 with downwardly extending side walls 14. Each raised ridge has a flattened face 16 with at least one aperture 18. The apertures 18 are spread unfirmly across the net pot cover 6. As can be seen in the figure, the number of apertures 18 in the top surface 12 alternates between one and two apertures on each flattened ridge. Different numbers and patterns of apertures may be used depending on the size and purpose of the trays.

The apertures 18, in use, receive net pots 8 for plants to be grown within the tray assembly and the system. The net pots 8 have a tapered structure and fit and rest within the boundary of the apertures 18 and extend downwardly from the cover 6 into the tray insert 4 below, as can be seen in figures 3 and 4.

The tray insert 4 will now be described with reference to figures 6 to 9. The tray insert 4 has a base 20 with upstanding side walls 22. The base 20 is formed with raised longitudinally extending ridges 24 that form gullies 26 either side. The gullies 26 extend across the longitudinal length of the base 20.

The ridges 24 in the base 20 of the tray insert 4 do not extend to end walls of the base 20 so that fluid channels are provided along the width at both ends of the tray insert 4. One end 28 of the tray insert 4 provides a fluid inlet channel 30. The other end 32 provides a fluid outlet channel 34.

The fluid inlet channel 30 has a central divider 36 separating the channel 30 into two halves. The end of each ridge 24 is formed with a raised wall 38 where the ridge 24 meets the inlet channel 30. The wall 38 has a generally V-shaped recess 40 with a flattened base, at the entrance to each gully 26. In use, fluid entering the inlet channel 30 flows along the channel 30 and into the gullies 26. The sloped walls 42 of the recess 40 forming the entrance to the gully 26 allow the fluid to build up within the channel 30 to a point where the fluid naturally flows into each gully 26. The shaped recesses 40 provide a continuous flow of fluid and accelerate its flow through and into the gully 26 to prevent algae from building up.

The divider 36 is higher than the wall 38 which allows fluid to build up within one side of the channel 30 to cause flow into the gullies 26 in that side. The divider 36 prevents the fluid from simply flowing passed the gullies 26 to the other side of the channel 30 leaving little or no fluid to flow down the gullies 26.

As will now be explained, an elongate end cover 10 is provided over the end of tray assembly 4 that is the inlet channel 30 through which fluid is fed into the channel 30 at points either side of the divider 36 to ensure that both sides of the divider 36 have a fluid build-up within the channel 10 to cause flow into the gullies 26 of each section.

As can be seen in figure 10, the end cover 10 is of similar construction to the net pot cover 6 in that it has a top surface 44 with downwardly extending side walls 46. The top surface 44 has two punched or drilled apertures 48 at or near to either end. As will be explained later, in use the apertures 48 receive fluid pipes of the NFT system to transfer fluid into the inlet channel 30 of the tray insert 4 and down the gullies 26.

When the end cover 10 and net pot cover 6 are in place over the tray insert 4 the apertures 48 are located above the fluid inlet channel 30 either side of the divider 36 and the base of the net pots 8 extend into the fluid gullies 26 so that the nutrient fluid flows over the plant roots (see figure 3).

Returning to figure 7, it can be seen that the other end 32 of the tray insert 4 provides for a fluid outlet channel 34 extending across the width of the tray insert 4. Fluid leaving the gullies 26 flows into the outlet channel 34. The outlet channel 34 has elongate cut slots 50 in the base 20, one either side of the center, through which fluid in that side of the channel 34 is drained into the base tray 2 below it.

Figures 13 to 15 show the base tray 2 of the assembly in detail. The base tray 2 has a base 52 with raised flattened platforms 54 which form a fluid inlet channel 56 extending widthwise across one end 58, a fluid outlet channel 60 extending widthwise along the opposing end 62 and a central longitudinal gully 64 linking the inlet and outlet channels 56, 60 to allow nutrient fluid drained from the tray insert 4 above to fall through gravity into the inlet channel 56, down the gully 64 and into the outlet channel 60. The floor of the base 52 is sloped towards the outlet channel 60. The floor of each end of the inlet channel 56 is sloped towards the center such that fluid entering each side of channel 56 through the slots 50 is directed towards the center of the channel 56 and into the gully 64. The fluid travels down the gully 64 and into the outlet channel 60 at the other end. One end of the outlet channel 60 is provided with a sump 66 which is drilled to drain the fluid out of the base tray 2. The floor of the outlet channel 60 is sloped towards the sump 66 to ensure that the fluid is directed towards the sump 66.

The base tray 2 is suitable for flood and drain systems by using it separately without the tray insert 4 or net pot cover 10. In such a case, and end cover 10 is located over the inlet channel 56 to feed fluid from the system directly into the inlet channel 56 of the tray 2.

Figures 16 to 19 show the base tray 2 used for flood and drain. Four tray inserts are located in the tray, each being overlaid by a grow mat 68. As can be seen in figure 19, the raised platforms 54 on the base 52 provide adjacent voids or air gaps 70 underneath the grow mats 68.

During the initial growing stages the flood and drain level is set to a level that floods the grow mats 68 within the tray 2.

As the plants grow, their roots penetrate the grow mats 68 and extend downwardly into voids 70 within the tray 2. The voids 70 capture and retain moist, humid air to provide an atmosphere conducive to root growth. Once the roots extend into the voids 70 the flood level can be reduced to only flood the voids 70. Not only does this allow the grow mats 68 to dry, thereby stopping algae growth, reduced water consumption provides a considerable cost saving, together with a saving of energy used for the temperature control and a reduced power use for the system. Figures 20 and 22 illustrates and tray assembly of a further embodiment of the invention. The tray assembly is largely the same as that of the previously described embodiment with several design changes which will now be described.

The cover 90 is wider and includes finger grips 92 at various places along its edge to allow for easier removal.

Each end cover 94 has a recessed groove 96 extending along approximately half its length. This is to ensure that drips from the fluid source are captured during movement of the trays within the assembly.

The fluid inlet channel 98 of the tray insert 100 does not have a central divider.

The main design changes relate the base tray 102. Rather than having flattened platforms the each raised section 104 of the tray 102 is formed with X-shaped recesses 106 which compliment a ridged design of the an over-tray 108 (seen in figure 21) which overlies the base tray 102, replacing the tray insert 100 in this instance used for a flood and drain technique.

Top covers 110 are then placed over the over-tray 108, as an alternative to covers 90. The top covers 110 have a top surface on which branding can be applied.

Figures 24 and 25 show how nutrient fluid is fed into the tray assembly whilst the tray assembly is located within a vertical tier NFT system, such as one described in the Applicant’s earlier patent application.

The tiered rack system includes nutrient fluid pipework 72 extending along at least one side of the rack to deliver nutrient fluid from a storage tank to the tray assemblies for the fluid to pass through the tray assemblies as previously described.

Flexible outlet pipes 74 extent outwardly from the pipework 72 at intervals along tis length. The flexible pipes 74 are made from a flexible material such as silicon rubber and are extend into the racks over the inlet channel 30 of the tray insert 4. The figures show the tray insert 4 with the end cover 10 and net pot cover 6 removed. In practice however the outlet pipes 74 extend onto the end cover 10. The outlet pipes are biased downwardly so that they extend into or over the closet aperture 48 of the end cover 10 to deliver fluid into the inlet channel 30 below. The flexible fluid delivery system allows the tray assemblies to be moved along the rack system as sideways movement of the tray assembly causes the end of the outlet pipe 74 to lift out of the aperture 48 for subsequent the engagement with and into the aperture 48 of the neighboring tray assembly or tray assembly section as that assembly or section is passed underneath it.

The nutrient delivery system described allows for an infinitely more versatile NFT system. Movement of the tray assemblies through the system allows the system to have static lights and have at the start of growth for example, lower powered lighting thereby saving power. Movement of the tray assemblies also allows variation of the light spectrums across the system allowing, for example, for increased UV spectrum at the end of the growth cycle to bring out the red coloration in leaves if desirable. A versatile NFT system has a significant increase in crop growth while providing a significant reduction in power consumption.

The static lights may be connected to the rack frame using a quick release mechanism to allow the height of the lights to be easily adjusted.

The tray assemblies may be movable through the system by any known means, for example by using a roller system as described in the Applicant’s earlier application EP18150790.6 in relation to the flood and drain system disclosed therein (but not the NFT embodiment).

Figures 26 to 31 illustrate the loading mechanism for tray assemblies on the rack system.

Figure 26 illustrates tiered rack to hold the tray assemblies. The tray assemblies are placed on framed shelves within the rack. Each shelve can be pulled outwardly from the rack in a similar way to a draw, to allow the tray assemblies to be placed on the shelf frame 76. A drainage pipe 78 extends widthwise along the end of the rack underneath and in alignment with the outlet channel 60 of the base tray 2. It will be appreciated that the channel visible in figure 24 is the inlet channel 30 of the tray insert 4 which overlies the outlet channel 60 of the base tray 2.

The drainage pipe 78 has an elongate longitudinal slot 80 cut in its top surface to allow fluid exiting the sump 66 to fall into the drainage pipe 78 to exit the system. The slot 80 extends along the length of the pipe so that the fluid released from the sump 66 will continue drain into the drainage pipe 78 as the shelf is pulled out of the rack for loading or unloading. The drainage pipe 78 is angled downwardly to an outlet 82 allow drainage of fluid from the system by gravity into a tank (not shown) located in the base of the frame.

The tank is located on the base shelf which is also slidable out of the rack. To accommodate the heavy weight of the tank, the sliding mechanism comprises a cut pipe section 84 which is slidable along the bottom frame 86 of the rack via a nylon bush 88.

The described drainage of the fluid through and out of the system allows suitability for NFT and flood and drain allowing the two techniques to be alternated as and when desired using the same system structure.

Claims

1. A tray assembly for growing plants within a hydroponic assembly, the tray assembly comprising a base tray, a tray insert and a cover with apertures to retain a net pot within the assembly.

2. A tray assembly according to claim 1 , wherein the tray insert comprises a base with upstanding side walls and having:

a fluid inlet channel extending widthwise across one end; a fluid outlet channel extending widthwise across the other end;

3. A tray assembly according to claim 2, wherein the fluid directing means comprising a wall with a recess having sloped walls at the entrance to each gully.

4. A tray assembly according to claim 3, wherein the or each recess is generally V-shaped with a flattened base.

5. A tray assembly according to any one of claims 2 to 4, wherein the fluid outlet channel includes at least one cut through slot to drain fluid from the tray insert.

6. A tray assembly according to any one of claims 2 to 6, wherein the tray assembly includes an end cover extending over the fluid inlet channel, the cover having an aperture at or near to each end to receive fluid and direct it into either end of channel.

7. A tray assembly according to claim 6, wherein one or each aperture is located within a recessed groove in the end cover.

8. A tray assembly according to any one of claims 5 to 7, wherein the base tray has a widthwise extending fluid inlet channel directly under the slots to receive fluid draining from the tray insert.

9. A tray assembly according to claim 8, wherein the tray insert sits within the base tray in such a way that the outlet channel of the tray insert overlies the inlet channel of the base tray.

10. A tray assembly according to claim 9, wherein the base tray has a longitudinally extending central gully leading to a widthwise extending fluid outlet channel.

11. A tray assembly according to claim 10, wherein a floor of the fluid inlet channel of the base tray is sloped for either end towards the center to direct flow of fluid into and down the gully.

12. A tray assembly according to claim 11 , wherein the fluid outlet channel includes a sump at one end.

13. A tray assembly according to claim 12, wherein the floor of the outlet channel is sloped towards the sump.

14. A shelving assembly for carrying a tray assembly according to any preceding claim, the shelving assembly having a shelf frame that is slidable in a lateral direction from the shelving assembly, the shelving assembly further comprising drainage pipe extending widthwise across the assembly and aligned underneath the outlet channel of the base tray of the tray assembly.

15. A shelving assembly according to claim 14, wherein the drainage pipe has an elongate slot cut along its length so to receive fluid drained from the base tray whilst the tray is slid out of the shelving assembly for loading or unloading.

16. A rack assembly for use with a tray assembly according to any one of claims 1 to 13, the rack assembly including a fluid pipe extending along the length of the assembly and having one or more flexible outlet pipes extending from the fluid pipe and into the fluid channel of the tray insert.

17. A rack assembly according to claim 16, wherein the or each outlet pipe is biased downwardly to extend into an aperture of the end cover of the tray assembly and to lift from said aperture as the tray assembly moves through the assembly and subsequently extend into the aperture of an end cover of another tray assembly as that tray assembly moves underneath the outlet pipe.