GB2550186A - Vertical tiered growing systems - Google Patents

Abstract

A vertical tier growing system for plants, the system having at least one vertically tiered shelf section each having one or more arms 87 extending upwardly therefrom and mounted to one or more rails 85, 86 located above the growing system, so that the or each section can be moved along the rail(s), each section having means to provide and direct liquid and lighting to plants growing on said section during use. Each arm may have a roller 88 located at or near its distal end that mounts to the rail. The systems may further comprise one or more floor or ground mounted rails (34 Figure 16) onto which a further roller or set of rollers mounted beneath the section locate. The floor rails may be in vertical alignment with the or each rail above the section.

Description

VERTICAL TIERED GROWING SYSTEMS FIELD OF THE INVENTION

The present invention relates to vertical tiered growing systems for inter alia growing plants, micro herbs or edible foliage. More especially, the present invention relates to vertical tiered growing system that is modular in structure with individual tiered sections movable thereby to reduce the footprint of the system to allow it to be accommodated in areas where space is limited.

BACKGROUND TO THE INVENTION

The hydroponics industry is growing year on year. It is becoming increasingly common and indeed necessary for nations of the world to grow fresh produce locally to feed their populations. A common method of growing plants involves an NET (Nutrient Film Technique) system. An NFT system is a recirculating hydroponic system that consists of growing channels or trays over which a nutrient solution is constantly pumped across, creating a nutrient film into which the roots grow. Plants are often started in stone wool cubes and placed on the growing channels. The solution is recirculated from a main tank.

Large scale NFT systems require a considerable amount of land as plants are traditionally laid out in channels along a horizontal plane over a large area. In general, the greater the amount of produce required, the greater the area of the land needed to grow the produce. Consequently, urban areas rely on fresh plants and edible produce to be delivered from the rural, often distant, farming areas. The expanse of farming area required means that fresh produce is generally not grown on a commercial scale within urban areas and cities.

This is particularly the case in built-up cities around the world were open space is limited and at a premium.

Restaurants within cities and urban areas require daily deliveries of fresh produce. Supermarkets also require regular large deliveries requiring vast transport networks and logistics .

Vertical tier NFT systems are known which allow fresh produce to be grown in vertical tiers of shelving. Such systems however have been found to have inflexible structures and have restrictive limitations on the amount of tiers, and hence produce, that can be grown within a given area. Walkways must be provided between each shelf tier to allow access to any plant growing within the assembly. This can easily double the size of the footprint area needed for such systems.

Moreover, should the framework of known systems need to be moved, all lighting and fluid systems required for the system must be disconnected. Consequently, it is not possible to move or re-position any parts of the framework during any plant growing cycle.

Applicant's International Patent Application publication number WO2015140493 describes an improved vertical growing system for growing inter alia plants, which has a flexible modular structure to alleviate the spatial limitations of current systems and which allows sections of tiered shelving structure to be moved along a floor-mounted track and repositioned during, and without interfering with, the growing cycle. The term "growing system" is intended to include any system that provides water or other nutrient fluid and light to plants growing within the system. This includes NFT systems as well as flood and drain systems.

The term "plants" is intended to include edible leaves, such as lettuces and herbs.

SUMMARY OF THE INVENTION A first aspect of the invention provides a vertical tier growing system for plants, the system comprising at least one vertically tiered shelf section each having one or more arms extending upwardly therefrom and mounted to one or more rails located above the growing system, so that the or each section can be moved along the rail(s), the or each section having located thereon means to provide and direct liquid and lighting to plants growing on said section during use.

The or each arm may have a roller located at or near its distal end which in use mounts on top of a rail.

Two or more arms may be provided, each having a roller located at or near its distal end which in use mounts on top of a respective rail.

The or each arm may have a plurality of adjacent rollers at or near its distal end for mounting on top of the rail.

The or each rail may have a slot extending through its vertical plane, through which the or each arm extends, with the distal end of the or each arm projecting through the top of the rail(s) and carrying one or more rollers which mount on top of the rail.

The system may further comprise one or more floor or ground mounted rail(s) onto which a further roller or set of rollers mounted beneath the or each section locate.

The floor or ground mounted rail(s) may be in vertical alignment with the or each rail(s) above the section(s).

The system may further comprise a user-operable friction brake for selectively securing the section to the or each rail(s).

The roller or rollers may be associated with an electric motor which is controllable by means of a remote control unit to cause movement of a section along the rail(s). A second aspect of the invention provides a growing system apparatus comprising: _- an enclosed area having a ceiling and a floor; _- one or more rails or tracks located in or beneath the ceiling, extending linearly from one end of the enclosed area to towards the other; and _- a vertical tier growing system, comprising plural side- by-side sections, the or each section having located thereon means to provide and direct liquid and lighting to plants growing on said section during use, and at least one upwardly extending arm carrying a roller or the like on or near the distal end which locates on the or each rail or track so as to permit movement along the rails or tracks relative to the or each other section.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described by way of example only with reference to the accompanying diagrammatic drawings in which: -

Figure 1 is a perspective view of a vertical tiered section forming part of a vertical growing system constructed in accordance with a first embodiment useful for understanding the present invention;

Figure 2 is a close up view of part of tiered section of figure 1;

Figure 3 is an end view of the tiered section;

Figure 4 is a view of a drainage tank for use with the tiered section;

Figure 5 is a close of the top part of the tiered section;

Figure 6 is a perspective view of a vertical tiered section forming part of a vertical growing system constructed in accordance with another embodiment, which is useful for understanding the invention;

Figure 7 is an end view of the tiered section of figure 6;

Figures 8 (a) to (c) are schematic illustrations of tracks of the system in plan view;

Figures 9(a) and (b) are schematic illustrations of how the sections can be moved to form paths there between;

Figures 10(A) and (B) are schematic illustrations showing the water tank of the system;

Figures 11 to 13 are schematic illustrations showing the use of an air duct sock within the system;

Figure 14 is a perspective view of a growing structure employing rails mounted above the growing sections according to an embodiment of the present invention;

Figures 15(a) to (d) show in plan view different variations of how a section may locate on rails above;

Figure 16 is a perspective view of a growing structure with rails both above and below growing sections according to a further embodiment of the invention; and

Figure 17 is a plan view of one upwardly extending arm, showing an electrical drive system located within the arm for driving the roller on a rail.

DETAILED DESCRIPTION OF THE INVENTION

Embodiments herein first describe use of a vertical tiered growing system as outlined in WQ2015140493, which is useful for understanding the invention to be described later on, as described and shown with reference to Figures 14 to 16.

Figure 1 illustrates a tiered section 1 of a vertical tiered growing system, in this case an NFT system. The overall system would include a plurality of such sections. The section 1 comprises a framework of interconnecting vertical and horizontal beams (2 and 3 respectively). Angled beams 4 are provided at the base to provide strength to the base of the framework. A tiered array of elongate plant trays 5 extend longitudinally along the frame work resting across the horizontal beams 3.

The framework beams 2, 3 are constructed from aluminium or other suitable strong but lightweight material.

As can be seen in figure 2, the horizontal beams 3 are connected to the vertical beams 2 through jointed clamps 6, the height of which can be altered to lower or heighten any tier level within the section 1 without having to deconstruct the entire framework.

Each plant tray 5 is generally made from plastic and has a hollow rectangular form. Apertures 7 are provided uniformly along each tray 5 in which are received plant roots or seedlings which grow into plants such as, for example in the case illustrated in the top tier of figure 5, lettuce. In use, a flow of nutrient is directed into and along each tray 5.

One end of the section (shown in figure 1) has a secondary frame of pipe work 9. Tubing 10 links the end of each tray 5 with the pipe work 9 to provide a closed system through which nutrient can flow between the trays 5 and the pipe work 9 for recirculation across the tiers of trays 5.

Artificial light tubes 11 extend above and generally parallel to each tray 5. The artificial light may be generated from, for example, LEDs. The light tubes 11 are clamped to, and extend downwardly from, the horizontal beams 3 of the framework. As can be seen in figure 2, the electrical connection 12 to each light tube 11, linking the light tube 11 to a power source remote from the section, is flexible such that the power link remains intact and connected when the height of any shelf within the section 1 is adjusted.

In an alternative construction the light tubes may extend across the lateral axis of the framework, perpendicular to the trays 5. Under required circumstances, this may reduce the dimensions of the overall structure making it more compact. It may also reduce the number of lighting units required thereby reducing installation and running costs.

The other end of the tiered section 1 is illustrated in figure 3. Drainage pipe work 13 is connected to this end of the section 1. The drainage pipe work 13 has a plurality of outlet pipes 14 connected in turn to the end of each tray 5.

Once assembled, the trays 5 extend across each tier of the section 1 at a slight angle such that they extend slightly downwardly towards the end of the section with the drainage pipe work 13 (i.e. the end shown in figure 3) . Consequently excess nutrient flows along to the trays 5 into the drainage pipe work 13 to be dispensed into a drainage tank 15. The drainage tank 15 includes a pump 16 to pump nutrient back through tubing 17 and back into the trays 5 for recirculation (see figure 5) .

As can be seen in figure 3, the system further includes a track assembly 18 which is secured to the floor of the building in which the vertical growing system is to be installed. Only part of the track assembly 18 is shown in figure 3. The entire track 18 has a grid like form allowing individual sections to be moved sideways along the grid towards or away from each other.

The track 18 extends across the entire base footprint of the system. In practice a number of tiered sections 1 are located on the track assembly 18 and each section is movable along the track 18 to alter their position relative to each other. This allows a path to be opened between any two sections 1 to allow access the plants in any section 1 where necessary. When access is no longer required to the side of a particular section 1, the neighbouring section can be moved across the track assembly 18 towards and against its neighbour thereby closing the gap whilst at the same time opening up path between another section 1 and its neighbour.

The fact that each section 1 is individually movable along the track assembly 18 means that the overall footprint area of the track for the entire system (including a number of sections) cnly needs to incorporate a single path width thereby significantly increasing the number of the tiered sections 1, and hence the growable area within the system, within any defined location.

Referring to Figure 8 (a) , which is a plan view of a growing room 30 having entrance door 32, in some embodiments the track may comprise first and second parallel rails 34, spaced apart. Each section 1 (not shown in Figure 8) is configured to slide or roll over the rails by respective spaced-apart sets of wheels, casters, rollers or sliders. A handle may be provided on the end of each section 1 to assist the movement. Figure 8 (b) shows that the track may comprise one or more additional rails 36. Figure 8(c) shows a grid-like system 38 of rails, including one or more rails transverse to the longitudinal rails shown in Figures 8 (a) and (b) for stability in terms of preventing the rails moving towards or away from each other.

The rails of the track can be of any form, e.g. cross-sectional profile. Figures 9(a) and (b) show in schematic view how the overall footprint area of the system, in particular a growing room 30, can be minimised, by using the aforementioned track system. In Figure 9(a) the space 40 represents both an access path for the adjacent section 1 (G) , and also a void into which said section (G) can be moved to provide access to the next section (F) . It follows that multiple sections 1 can be moved as required, and Figure 9 (b) shows how movement of multiple sections (C, D, E, F, G) along the track rails creates a new path 42 for access to the adjacent sections (B, C) .

Furthermore, the fact that individual lighting and water assemblies supporting plant growth on each section 1 are carried on that section 1 itself means that the section 1 can be moved sideways along the track 18, e.g. as indicated in Figure 9, during a plant growing cycle without requiring disconnection of the lighting or nutrient systems which would otherwise disrupt and adversely affect growth of the plants. Moreover, each individual lighting and nutrient fluid assemblies are connected to a centralized source with flexible linkages which are able to accommodate an increase or decrease in length as the section 1 is moved towards or further away from the source. The centralised power source and warer/nutrient storage (neither shown) feeding the overall system may, for example be located in within the roof structure of the building within which the system is installed and would be connected to each section 1 through individual flexible linkages extending downwardly from the source for connection to the appropriate section.

In an alternative embodiment (not shown) each section may carry its own power source, such as a battery, and a storage tank for nutrient fluid.

Whilst the drainage tank 15 shown in figure 4 is shown to be width of a single section 1, it envisaged that in some embodiments the tank 15 can be elongated so that its overall length would be sufficient to accommodate sideways movement of the section 1 along the track 18 whilst retaining the ends of the drainage pipes 13 within the confines of the tank walls 19.

In an alternative embodiment the drainage tank takes the form of a single trough like structure that extends along the entire side perimeter of the track such that the drainage pipes 13 of each section remain within the confines of the walls of the trough, even when a section is moved to the extremity of the track. An example of this is described later on.

Figures 6 and 7 illustrate a different tiered section 20 for use in a vertical drainage system, this time working on the flood and drain principle. In flood and drains systems, sometimes known as ebb and flow, the entire root zone is periodically flooded with nutrient solution before it dries out. This is done with a timer on a pump from a main nutrient tank usually located directly below the flood tray. The root zone is flooded for short periods of time (between 10-15 minutes). The interval between floods will depend on plant size and medium used (stonewool or expanded clay pebbles). As with the embodiment previously described, the overall system would include a plurality of such sections. The section 20 comprises a framework of interconnecting vertical and horizontal beams (21 and 22 respectively). The framework beams 21, 22 are constructed from aluminium or other suitable strong but lightweight material.

The horizontal beams 22 are connected to the vertical beams 21 through jointed clamps 23, the height of which can be altered to lower or heighten any tier level within the section 20.

Three elongate supporting arms 24 extending longitudinally through the section 20 at each tier level. The arms 24 provide supports for plant trays 25 which extend perpendicularly across the framework at each tier level.

Each arm 24 is provided with a roller mechanism 26 extending along the entire length of each arm 24 such that the trays 25 can be easily dragged along the longitudinal axis of the section 20 from one end to the other. The trays 26 may be manually moved along the rollers 2 6 or the movement may be automated.

As can be seen best in figure 7, drainage channels 27 extend along the length of one side of the section 20. The drainage channels 27 provide a path for flow of nutrient from the tray 25 after it has been flooded, during the drainage stage.

The end of the drainage channels extend over a drainage tank (not shown).

Like in the first described embodiment, the section 20 is one of several within the system that is secured to a floor track allowing movement of the sections 20 to open and close walkways therebetween as has previously been described.

Like with the first described embodiment, the lighting and nutrient systems for any given section 20 are carried on that section 20 such that any given section 20 can be moved along the track without the need for disconnection of the systems thereby allowing that section to be moved during the growth cycle of the plants.

The vertical tiered sections described above are designed for use in an overall system comprising a number of such sections and a floor track on which each section is mounted. The system would also include means to connect the centralised fluid and electricity supplies to the nutrient and lighting assemblies of each section.

Referring to Figures 10(a) and 10(b), there is now described an example of the above-mentioned elongated tank. The tank 50 has a length, in this case, that extends substantially the length of side-by-side sections 1 in the growing room 30 as well as extending along the gap 40. The drainage pipes 13 of each section 1 (shown in section) are supported overhanging the tank 50 so that fluid exiting the lower ends drains into the tank, and the aforementioned sideways movement of the sections does not result in spillage. Indeed, the overhanging pipes 13 can be level with, or below, the upper perimeter wall of the tank 50 to minimise splashing.

The Figure 10 tank 50 is also different in that it is divided into two distinct liquid-carrying parts, namely a drainage portion 52 and a fresh liquid portion 54 divided by an intermediate lengthwise wall 56. The drainage portion 52 has a sloping floor in order to urge using gravity the collected liquid towards one end where it can be removed from the tank 50, whether permanently, or for processing by a filtering/recycling system. The flow of draining liquid is indicated by the arrows to an exit aperture 60. The fresh liquid portion 54 is covered by a top wall 62; liquid is fed-in from a mains or other source through an inlet pipe 64 and exits as and when required through outlet pipe 66 which is connected to a pump that transmits the liquid to the individual sections 1. The incoming liquid may be fresh water or nutrient-containing liquid. Inspection covers 70 are provided to enable access to the fresh liquid portion 54, whether for checking levels and/or adding chemicals. Thus, both drainage and fresh liquid storage is enabled in a combined, compact and convenient unit within the growing room 30. The tank 50 is relatively lightweight, being preferably made from plastics material, although any suitable material can be used.

Further, in some embodiments, an air sock duct (hereafter "sock") can be provided in the growing room 30. Referring to Figure 11, a sock 72 is shown attached to a wall mounting 74 through which air of a predetermined temperature is delivered from a low-velocity fan delivery system. The sock 72 is formed of fabric (or similar flexible) material which has a length that extends substantially the length of the room 30; it serves to evenly distribute air within the room, with microperforations diffusing the air and preventing draughts. Figure 12 indicates where the sock 72 can be located in the growing room 30, e.g. above the side walkway, with the air delivery system 80 located on the external roof to maintain a compact footprint. The delivery system 80 is connected to the sock 72 by a duct 82, and controlled from a control unit 84 mounted to the side wall. As shown in Figure 11, the perforations in the sock 72 can be arranged along one side to direct air substantially evenly towards the tiered sections, as indicated in Figure 13.

The system would be located within a building specifically designed with strict temperature and climate controls to provide optimum conditions for plant growth. The buildings may be prefabricated units constructed on-site. The individual maneuverability of the tiered sections within the system allow the footprint of the unit to be only a little larger than the combined footprint of the sections with only a little extra width required to form a pathway between selected sections when necessary.

Referring now to Figures 14 to 16, there will now be described embodiments in accordance with the invention, which employ one or more rails located above the sections 1 of the vertical tier growing system.

Referring to Figure 14, in an enclosed growing structure 80 is provided a pair of rails 85, 86 mounted to or just beneath a ceiling 82 of the structure 80. The rails 85, 86 extend along the longitudinal extent of the structure. The above-mentioned sections 1 of the growing system are in this case held beneath the rails 85, 86 (without the need for rollers or casters, and therefore the track) by means of a pair of upwardly extending arms 87 either side of the sections. At the distal end of the arms 87 are provided respective rollers, castors or sliders 88 which locate over the top of respective rails 85, 86 to enable the sections to move therealong in the manner indicated in the previous Figures, and for the same purpose. By obviating the need for ground-mounted tracks and the lower rollers, as in previous Figures, more space is created under each section for access and/or providing other components. In effect, the sections 1 hang from the upper rail(s).

As shown in Figures 15(a) to (d) there are various mechanisms by which the rollers 88 can locate on the rails 85, 86. In Figure 15(a), for example, the arms 87 extend to the same side of each rail 85, 86. In Figure 15(b), the arms 87 extend within each rail 85, 86. In Figure 15 (c), the arms 87 extend outside each rail 85, 86. In Figure 15(d), each rail 85, 86 is slotted down its centre, so that the arms 87 extend through the central slot with the a pair of rollers 94 located either side of the slot. Having pairs of adjacent rollers improves stability.

Referring to Figure 16, in addition to using upper rails 85, 86, the floor-mounted rails or tracks 34 previously described can also be provided, so that the system uses both upper and lower rails for increased stability.

In all embodiments, a friction brake system can be associated with each section 1, i.e. so that the wheels, rollers or castors on each can be braked with respect to the rails to selectively fix its position temporarily.

In all embodiments, a motor can be associated with each set of wheels, rollers or casters, or at least one of which on a given section 1, to permit driving of a section along the rail (whether upper or lower) and which may be selectively controlled using a remote controller to get to the reguired position.

Figure 17 shows one example implementation of a motor driven system. Adjacent the roller 92 is a drive roller 93 which abuts the roller 92 to cause rotation in sympathy with rotation applied by a motor 94 through an interconnecting shaft. The motor 94 is controlled electrically by a control system 95 which may receive user inputs to start/stop the rotation, and control direction of rotation, through a wired or wireless controller. Of course, a drive system of this sort is not essential. Movement of the sections 1 can be done manually by user action._The Figure 17 system can alternatively be representative of a friction brake, whereby element 93 represents a moveable brake pad which moves into contact with roller 92 in response to mechanical or electrical input to element 95, e.g. through a pull cable or lever.

It will be appreciated that the foregoing is merely descriptive of example embodiments of this invention and that modifications can readily be made to these embodiments without departing from the true scope of the invention as set out in the appended claims.

Claims (11)

1. A vertical tier growing system for plants, the system comprising at least one vertically tiered shelf section each having one or more arms extending upwardly therefrom and mounted to one or more rails located above the growing system, so that the or each section can be moved along the rail(s), the or each section having located thereon means to provide and direct liquid and lighting to plants growing on said section during use.

2. A system according to claim 1, wherein the or each arm has a roller located at or near its distal end which in use mounts on top of a rail.

3. A system according to claim 1 or claim 2, wherein two arms are provided, each having a roller located at or near its distal end which in use mounts on top of a respective rail.

4. A system according to claim 2 or claim 3, wherein the or each arm has a plurality of adjacent rollers at or near its distal end for mounting on top of the rail.

5. A system according to any preceding claim, wherein the or each rail has a slot extending through its vertical plane, through which the or each arm extends, with the distal end of the or each arm projecting through the top of the rail(s) and carrying one or more rollers which mount on top of the rail.

6. A system according to any preceding claim, further comprising one or more floor or ground mounted rail(s) onto which a further roller or set of rollers mounted beneath the or each section locate.

7. A system according to claim 6, wherein the floor or ground mounted rail(s) are in vertical alignment with the or each rail(s) above the section(s).

8. A system according to any preceding claim, further comprising a user-operable friction brake for selectively securing the section to the or each rail(s) .

9. A system according to any preceding claim, wherein the roller or rollers is or are associated with an electric motor which is controllable by means of a remote control unit to cause movement of a section along the rail(s).

10. A growing system apparatus comprising: - an enclosed area having a ceiling and a floor; - one or more rails or tracks located in or beneath the ceiling, extending linearly from one end of the enclosed area to towards the other; and - a vertical tier growing system, comprising plural side-by-side sections, the or each section having located thereon means to provide and direct liquid and lighting to plants growing on said section during use, and at least one upwardly extending arm carrying a roller or the like on or near the distal end which locates on the or each rail or track so as to permit movement along the rails or tracks relative to the or each other section.

11. A system as substantially hereinbefore described and referred to in the accompanying figures.