WO2022026780A1 - Hydroponic system for bulb and sprout horticulture - Google Patents

Abstract

A hydroponic growing system configured for growing plants from bulbs. In various embodiments including features configured for accommodating bulbs of various sizes and/or types.

Description

Hydroponic System for Bulb and Sprout Horticulture CROSS REFERENCE TO RELATED APPLICATIONS [01] This application claims priority and benefit of U.S. patent application 17/134, 157 filed on December 24, 2020 and also claims priority and benefit of U.S. provisional patent applications: 63/223,665 filed on July 20, 2021;

63/164,147 filed on March 22, 2021;

63/082,460 filed September 23, 2020; and 63/058,601 filed July 30, 2020.

The disclosures of all of these patent applications are hereby incorporated herein by reference.

BACKGROUND

[02] Field of the invention:

[03] Various embodiments of the invention are in the fields of hydroponics and horticulture. [04] Related Art:

[05] Hydroponic systems are efficient ways of growing plants. See for example, US patent applications 16/152,369 and 16/283,723, which describe unique systems that can be used by professional or hobby growers. While these systems have become popular for plants such as cannabis and leafy vegetables, there is a need for systems better configured for the growing of bulbs.

[06] In the context of this disclosure, a “bulb” is structurally a short stem with fleshy leaves or leaf bases that function as food storage organs during dormancy. As used herein the term “bulb” is meant to further include other plants that grow from underground storage organs, such as ornamental bulbous plants, tubers and corms (bulbo-tuber). Examples include: Amaryllis, Crinum, Flippeastrum, Narcissus, several other members of the amaryllis family Amaryllidaceae. This includes onion, garlic, leeks, shallots, and/or other alliums, members of the Amaryllid subfamily Allioideae, lily, tulip, and many other members of the lily family Liliaceae, and other plants or roots such as beets, fennel, carrots, celery, cabbage, ginger, turmeric, wasabi, yucca, and lettuces that can be regrown after an initial harvest, etc.

[07] For the purposes of this application, garlic refers to Allium sativum, but this does not limit the scope of the inventions or systems described herein to just Allium sativum. Garlic greens, grown from a garlic clove planted in soil or placed in water also taste like garlic and can be used for a variety of culinary purposes - this presents an attractive option to people who want to grow their own food at home.

[08] When placed root down in water, garlic cloves will start to grow dense, sturdy roots down and greens up out of the top. These greens are also referred to as shoots or leaves. If grown long enough, the greens can reach over a foot in length. If the root side is submerged in or in contact with water, garlic cloves will start to sprout roots. But being in contact with water increases the likelihood of plant disease or microbial growing, both undesirable to a user. Garlic cloves can measure from 0.5”- 1.5” tall with a variety of cross-sectional profiles depending on the variety. Some garlic varieties have larger cloves, some have smaller cloves.

SUMMARY

[09] A system for growing bulbs comprises a hydroponic tray and lid configured to accommodate multiple bulb types. The combination of tray and lid provide a preferential environment for germination and growth of bulbs. For example, the tray may be configured to provide variable amounts of water to the bulb at different growth stages. The lid may support the bulb in a stable (e.g., upright) position and also serve to control the amount of light received by the bulb.

[010] Various embodiments of the invention include a bulb growing system comprising: a semi-absorbent sheet having upper and lower sides separated by a thickness; a tray including one or more risers, the tray being configured to hold water, the risers being configured to support the semi-absorbent sheet and create a water reservoir below the semi-absorbent sheet; and a tray lid including a plurality of openings, sides of the tray being configured to support the tray lid such that a plurality of bulbs fit between the semi-absorbent sheet and the openings, wherein the openings are configured to hold the bulbs upright within an enclosure formed by the tray and tray lid.

[Oil] Various embodiments of the invention include a bulb growing kit comprising: a semi absorbent sheet having upper and lower sides separated by a thickness, each of the sheets optionally having a different thickness; a tray including one or more risers, the tray being configured to hold water, the risers being configured to support the semi-absorbent sheet and to create a water reservoir below the semi-absorbent sheet; and a first tray lid including a plurality of openings, sides of the tray being configured to support the tray lid such that a plurality of bulbs fit between the semi-absorbent sheet and the openings, wherein the openings are configured to hold the bulbs upright within an enclosure formed by the tray and the first tray lid. [012] Either the bulb growing system or bulb growing kit optionally include means for controlling a height of the openings above the semi-absorbent sheets. These means may include semi-absorbent sheets of different thicknesses, a spacer configured to be disposed between the tray and the tray lid, a tapered edge of the tray or tray lid, a width of the tray lid, a lid having openings at various heights, risers of varying heights, and/or the like.

[013] The present invention also provides systems and kits for the growth of plant materials such as garlic cloves. An exemplary system comprises a tray capable of holding water, the tray including one or more risers, where a tops of the risers are positioned at a level below that of a lip of the tray. When filled with water, the tray further includes a water reservoir filled to below the lip. The system also comprises an insert sized to fit within the tray and to be supported within the tray on or above the one or more risers. The insert includes a plurality of channels disposed therethrough, each channel including a first aperture facing a bottom of the tray, and a second aperture opposite the first opening. In these embodiments each channel has a width approximately the same as a width of the plant material to be grown. In various embodiments the system optionally further comprising a semi-absorbent sheet disposed between the insert and the one or more riser.

[014] In various embodiments each of the plurality of channels includes a porous cap across the aperture, for example, the porous cap can include holes defined through it in order to provide the porosity. In further embodiments, each of the plurality of channels includes a protrusion extending into the respective channel. In some embodiments the insert comprises a lid that is supported within the tray by resting on the lip of the tray. In still other embodiments, the insert, when situated in the tray, has a top surface that sits at a level that is recessed below a level of the lip of the tray. In some of these latter embodiments, the system further comprising a lid including a plurality of channels disposed therethrough, each channel of the lid including a first aperture facing the insert, and a second aperture opposite the first aperture, each channel of the lid aligned with a corresponding channel of the insert.

BRIEF DESCRIPTION OF THE DRAWINGS [015] FIG. 1 includes a cross-sectional view of a bulb growing system 100, according to various embodiments of the invention. [016] FIGs. 2A and 2B include cross-sectional views of two exemplary bulb growing systems, according to various embodiments of the invention.

[017] FIG. 3 includes cross-sectional views of bulb growing systems, a) and b), having different lid shapes, according to various embodiments of the invention.

[018] FIG. 4 includes a cross-sectional view of a bulb growing system having a lid of various heights, according to various embodiments of the invention.

[019] FIGs. 5A and 5B include, respectively, a cross-sectional view of a bulb growing system including a spacer, and an isometric view of a lid component of bulb growing system, according to various embodiments of the invention.

[020] FIG. 6 includes a cross-sectional view of a bulb growing system including opening spacers, according to various embodiments of the invention.

[021] FIG. 7 includes a front view of a lid component of a bulb growing system, according to various embodiments of the invention.

[022] FIG. 8 includes a top view of a lid component of the bulb growing system of FIG. 7, according to various embodiments of the invention.

[023] FIG. 9 includes a top view of a component of a bulb growing system including openings of various sizes, according to various embodiments of the invention.

[024] FIG. 10 includes a top view of a lid component of bulb or net cup growing system having a grid structure, according to various embodiments of the invention.

[025] FIG. 11 includes a top view of a lid component of a bulb or net cup growing system, according to various embodiments of the invention.

[026] FIG. 12 includes a bottom isometric view of a lid component of a bulb growing system, according to various embodiments of the invention.

[027] FIG. 13 includes a front isometric view of a bulb growing system, according to various embodiments of the invention.

[028] FIG. 14 includes a cross-sectional view of a bulb growing system, according to various embodiments of the invention.

[029] FIG. 15 includes a cross-sectional view of a net-cup growing system, according to various embodiments of the invention.

[030] FIG. 16 includes a cross-sectional view of an alternate net-cup growing system, according to various embodiments of the invention. [031] FIG. 17 includes a cross-sectional view of a net-cup growing system, according to various embodiments of the invention.

[032] FIG. 18 includes a cross-sectional view of a net-cup growing system including plants, according to various embodiments of the invention.

[033] FIG. 19 includes a cross-sectional view of a net-cup growing system including plants, according to various embodiments of the invention.

[034] FIGs. 20A and 20B include, respectively, a top isometric view of a component of a net- cup growing system, and a cross-sectional view of the same included in a net-cup growing system, according to various embodiments of the invention.

[035] FIG. 21 includes a cross-sectional view of a bulb or net-cup growing system having lids of various sizes, according to various embodiments of the invention.

[036] FIGs. 22A and 22B includes cross-sectional views of two exemplary growing systems, according to various embodiments of the invention.

[037] FIG. 23 includes a top perspective view of another exemplary growing system, according to various embodiments of the invention.

[038] FIG. 24 includes a cross-sectional view of another exemplary growing system, according to various embodiments of the invention.

[039] FIG. 25 includes a cross-sectional view of another exemplary growing system, according to various embodiments of the invention.

[040] FIG. 26 includes a cross-sectional view of another exemplary growing system, according to various embodiments of the invention.

[041] FIGs. 27A and 27B include top perspective and top views, respectively, of an exemplary channel insert for a growing system, according to various embodiments of the invention.

[042] FIG. 28 includes a cross-sectional view of a growing system, including the channel insert of FIGs. 27A and 27B, according to various embodiments of the invention.

[043] FIG. 29 includes cross-sectional views of five different exemplary arrangements of protrusions within a channel, according to various embodiments of the invention.

[044] FIG. 30A includes a cross-sectional view of one of the arrangements of FIG. 29 as implemented in an exemplary channel insert, according to various embodiments of the invention. [045] FIG. 30B includes a cross-sectional view of fins extending into respective channels, according to various embodiments of the invention. [046] FIG. 31 includes cross-sectional views of the five different exemplary arrangements of protrusions within a channel shown in FIG. 29, relative to a bottom of a tray properly filled with water, according to various embodiments of the invention.

[047] FIG. 32 includes a cross-sectional view of an exemplary growing system including the channel insert of FIG. 30, according to various embodiments of the invention.

DETAILED DESCRIPTION

[048] Bulbs can be grown hydroponically if held in at least a semi -upright position and provided with an appropriate amount of water. In various embodiments, the bulb growing systems disclosed herein are configured to both provide one or more bulbs an appropriate amount of water while also holding them in a stable position. The bulb growing systems include a least a tray and a lid therefor.

[049] Too much water will drown a bulb while too little water will stunt growth. Water supply to a bulb is optionally controlled using both a semi-absorbent sheet and a set of risers disposed to create a water reservoir below the semi-absorbent sheet. In early stages of growth, water is transported to roots of the bulb at least in part by the semi-absorbent sheet. At later stages of growth, developed roots have grown through the semi-absorbent sheet to the water reservoir.

This configuration provides control over the amounts of water the bulb receives at different times in its growth.

[050] In various embodiments, the bulb growing systems disclosed herein include a lid which has openings configured to help hold the bulbs upright. The lid may also be configured to help control an amount of light received by the bulb and/or to control evaporation of the water. Optionally, a position of the lid relative to the semi-absorbent sheet can be controlled so as to accommodate bulbs of various sizes.

[051] Bulb vegetables such as scallions or leeks can be regrown after an initial harvest of the section of the plant above the bulb. This section is usually edible but can also be used for flavoring purposes without being consumed. By placing the bulb or root side in water, the shoots and/or leaves will start to regrow and yield additional harvests. Regrowing bulb vegetables can be an efficient way to produce desirable plants such as flowers or foodstuffs. Bulbous plants that can be regrown include garlic, onion, shallot, celery, lemongrass, fennel, various vegetables, or the like, or many of the other plants discussed herein. [052] The most common method of regrowing bulb vegetables is by placing the bulb into a cup of water with the cut leafy section above water. This leafy section will begin to grow and be ready to harvest again after a few days. This “leafy section” will refer to the section above the bulb which may or may not be leafy as in the case of fennel or less leafy and more shoot-like as is the case for green onion or scallion. This method of regrowing, though simple and the most popular has several pitfalls.

[053] Various embodiments of the bulb growing system discussed herein solve problems found in hydroponic bulb cultivation. For example: Airflow: Completely submerging the bulb and roots can lead to problems related to air flow. Without proper airflow, the base of the plant can become waterlogged, start rotting and microbes can start growing in the water or on the plant. This can also result in a smelly or bug-ridden crop. The semi-absorbent sheet and risers are configured to assure proper airflow around bulbs. The semi-absorbent sheet optionally comprises a mesh of density for root support. Water saturation: Filling a cup with water and letting a bulb just sit in it can lead to over watering and rotting of the bulb. Further, because the water is not aerated, it can become stagnant and unsanitary for growing food. It is desirable to provide different amounts of water during different growth phases of the bulb, while also minimizing labor involved in changing water and/or water levels.

[054] As disclosed herein, solutions to these problems include a tray, semi-absorbent sheet and tray lid.

[055] In its simplest form the tray lid is a flat piece with an array of holes through it. The tray lid may comprise plastic, polymer, cardboard, glass, metal, and/or other suitable material. The tray lid is optionally planer, although more complex geometries are disclosed herein. These geometries can include, for example, posts or tubes to support tall plants, lids with bends and turns, etc. Optionally, the bottom of a tray lid includes an embossed feature or other registration or locking method to allow it to reference and/or lock within the growing tray and not slide off the tray. In its simplest version, the lid sits on the top surface of the grow tray but it can also be nested within the inner perimeter of the tray top or sit above the tray top. The lid can be glazed or unglazed, finished or unfinished, sealed or unsealed, textured or smooth, plastic, silicone, wood or ceramic (or other water-resistant, rigid or semi-rigid food safe material). Holes within the tray lid (referred to herein as “openings”) are configured for the growing plant and/or upper part of a bulb to pass. The openings optionally hold the bulb in place and semi-upright. The openings can be round or other shapes depending on desired functionality.

[056] The arrangement of holes, thickness of the lid, height of the lid above the base of the tray (via standoffs, lid geometry and/or the like), and how the lid references within the tray all depend on the type of bulb vegetable being grown. For example, a garlic clove standing upright may be ~ 1” tall while a chopped green onion bulb may be ~2-3” tall. The lid height can be adjustable or designed for the plant specifically such that it supports the openings at the proper height.

Various features for adjusting the height of the tray lid are discussed herein. The height may be adjusted above the tray and/or the semi-absorbent sheet.

[057] Planting: To plant, a user simply has to take their tray, fill it up to a fill line, place a sheet of semi-absorbent sheet (e.g., coconut fiber) inside and let the sheet soak up water. Then they place the lid on top of the tray and place bulbs through the lid openings and set them on the coconut fiber. Then they can place their tray on a shelf or countertop and let it grow. The bulbs might also be inserted from the other direction, through the bottom of the lid. The plants might be transplanted into this system either before or after having been cut already. Additional hardware can be built into or attached to the lid including but not limited to support posts for the plants, a humidity dome, lighting system, water level indicator etc.

[058] Harvesting: The growing plants are optionally continuously harvested with knives or scissors from the tray system. Alternatively , the growing plant may be harvested using an automated system configured to cut new growth at a specific height above the tray lids. The users might get many cuttings before having to either refill the water and/or plant new base crops. The orientation of the holes can be designed to facilitate easier harvesting by the user or robotic harvester.

[059] FIG. 1 includes a cross-sectional view of a bulb growing system 100, according to various embodiments of the invention. Shown are grow tray (4), tray lid (3), a semi -absorbent sheet (e.g., a coconut fiber sheet) (7) and bulbs (16). Water (21) is filled to an optional water level (6), and top surface of semi-absorbent sheet (7) is at the water level (6). The bulb portion (5) of the plant is in contact with the semi-absorbent sheet (7) and the leaf portion (1) (if grown) or top of the bulb of the plant extends through the lid opening (2) and protrudes above the tray lid (3). The bulb (16) grows existing and/or new roots (8) into the semi-absorbent sheet (7) and is watered by wicking action of the semi- absorbent sheet (7) and root (8) uptake from the reservoir of water (21) created by risers (9). Risers (9) are configured to create reservoir of water (21) below the semi -absorbent sheet (7).

[060] Semi-absorbent sheet (7) can include any of the materials disclosed in commonly owned U.S. Patent Application Ser. No. 16/152,369, the disclosure of which is incorporated herein by reference.

[061] FIG. 1 is a cross sectional view of the grow tray (4) including growing bulbs disposed between the semi-absorbent sheet (7) and the bulb lid (3). The tray has a sheet of coconut fiber (previously described) placed over the risers. The water fill level is approximately at the level of the upper face of the coconut fiber sheet. Over time the water level drops as the plants use the water such that the base of the crops are no longer submerged in water. The reservoir risers ensure there is enough water for several days or weeks of the bulb vegetables’ growth. The vegetable roots will start to grow into the coconut fiber and water below eventually pulling water directly from the reservoir of water below the coconut fiber sheet between the risers and leaving the base of the plant in air only. In FIG. 14, the water is represented by the light grey shaded area in the lower half of the grow tray (4). The roots in the coconut fiber differentiate into air roots (to pull oxygen from the air) and the roots in the water differentiate into water roots (to pull oxygen from the water and provide water to the plants). These root differences have been previously described and are important in maintaining the overall health of the plant. The use of the semi-absorbent sheet (7) allows this change in water supply and root exposure to take place without intervention. It occurs as the water evaporates and the roots grow. The thickness of the semi-absorbent sheet (7) is optionally selected to optimize these processes. The coconut fiber ensures good airflow to the roots and minimizes the likelihood of mold, bacteria or other microbes and pests from growing. The openings in the lid provide a support for the vegetable as it grows, keeping it upright to allow the roots to take hold and grow into the coconut fiber. The leaf portion of the plant is above the lid and can be harvested when it is ready. In some embodiments, grow tray (4) includes an overflow port configured to limit water height.

[062] FIGs. 2A and 2B include, respectively, a cross-sectional view of a first bulb growing system and a cross-sectional view of second bulb growing system, according to various embodiments of the invention. FIGs. 2A and 2B show bulbs of different sizes and quantity. A tray lid (3) can include openings for 1, 2, 3, 4 or more bulbs. The grow tray (4) of FIG 2A is made taller compared to the grow tray (4) of FIG. 2B to accommodate the larger bulbs (16). [063] FIGs. 3 A and 3B include cross-sectional views of bulb growing systems having different lid shapes, according to various embodiments of the invention. FIG. 3A shows a cross-sectional view of a bulb growing system growing larger bulbs (16) and FIG. 3B shows a cross sectional view of a bulb growing system growing smaller bulbs (16). The tray (4) portion of the system stays the same while the tray lid is configured to be more convex above the tray (4) to accommodate larger bulbs (16) or more concave to accommodate the smaller bulbs (16). This is another way to account for height differences in bulbs (16). The embodiments illustrated in FIG 2B accomplish this by modifying the grow tray (4), while the embodiments in FIGs. 3A and 3B accomplish this by modifying the tray lid (3) shape.

[064] FIG. 4 includes a cross-sectional view of a bulb growing system having a lid of various heights, according to various embodiments of the invention. FIG. 4 shows a across-sectional view of bulb growing system growing larger and smaller bulbs (16) by using a multi-level “topographic” version of tray lid (3) that is taller on one side to accommodate the taller bulbs (16) and shorter on one side to accommodate the shorter bulbs (16). This version has lid openings (2) at different heights above semi-absorbent sheet (7).

[065] FIGs. 5A and 5B include, respectively, a cross-sectional view of a bulb growing system including a spacer, and an isometric view of a lid component of bulb growing system, according to various embodiments of the invention. FIG. 5A shows a cross sectional view of the bulb growing system growing larger bulbs (16) and FIG. 5B shows a front isometric view of a possible spacer (17) for a rectangular grow tray (4). Rather than make the tray lid (3) convex above the grow tray (4), a spacer (17) is utilized to lift the lid-bulb version (3) sufficiently above the grow tray (4) to accommodate the larger bulbs (16). Some embodiments comprise a kit including spacers (17) of different heights.

[066] FIG. 6 includes a cross-sectional view of a bulb growing system including opening spacers, according to various embodiments of the invention. FIG. 6 shows a cross sectional view of bulb growing system utilizing grommets (18) to fill the space between the leaf portion (1) of the bulb (16) and the side of the lid openings (2). The grommets (18) could be made of compliant material or come in a range of predetermined sizes such that the lid openings (2) could be standardized (thus simplifying manufacturing) and the grommets (18) could allow for different diameters of bulbs ( 16) to grow. Depending on the compliance of the grommet, the growing bulb can maintain constant contact with the grommet even as the diameter of the growing bulb increases by compressing the grommet. Fertilizer in the grommets can be dispensed by the action of the growing plant pushing and compressing the grommet. Grommets may be made of rubber, foam, plastic, polymer, any material of the semi-absorbent sheet, paper, plant extract, Styrofoam, wood, fertilizer, and/or the like. The grommets may be moisture, temperature, or microbe responsive via color change or similar and serve to alert a user to the plant’s health. The grommets may have active functionality and serve to fertilize, moisturize, or desiccate depending on the needs of the plant. The plant could be inserted into the grommet through force where the plant is forced through a smaller aperture, or the grommet could be slitted, have an X pattern or similar that expands when the user pinches the grommet or the plant is inserted.

[067] FIG. 7 includes a front view of a lid component of a bulb growing system, according to various embodiments of the invention. In FIG. 7 a front view of bulb lid (3) shows the lid openings (2) and lid ledge (15) designed to keep the bulb lid (3) nestled inside the grow tray (4 not pictured).

[068] FIG. 8 includes a top view of a lid component of the bulb growing system of FIG. 7, according to various embodiments of the invention. FIG. 8 shows a top view of the bulb lid (3) of FIG 7. Showing a possible arrangement of lid openings (2). This particular pattern was designed for a specific bulb (16) where other bulb (16) types could have different arrangements depending on the bulb (16) diameter, height, optimal planting density, ease of harvest or any number of other factors not listed.

[069] FIG. 8 shows a top view of the lid showing a possible hole arrangement. The holes in this version are 0.75” in diameter to accommodate larger diameter bulb scallions but they could easily be made larger diameter to accommodate thicker vegetables such as leeks. The number of holes and orientation is determined based on optimal growing space for the vegetable (factoring in leaf canopy space needs, airflow, microbe or pest mitigation, optimal planting density, visual aesthetics, and similar) and optimal space to allow a user to access and harvest the growing vegetables. The example imagery is one of many possible hole arrangements. Hole distribution doesn’t need to be regular or follow a grid of some kind, the distribution can be more organic or randomized. Additionally, a single lid could contain different diameter or shaped holes for supporting multiple types of bulb plants at once as shown in FIG. 9. The hole distribution could be algorithmically determined based on the various needs of bulb or plant to be grown. [070] FIG. 9 includes a top view of a component of a bulb growing system including openings of various sizes, according to various embodiments of the invention. FIG. 9 shows a top view of a possible embodiment of bulb lid (3) designed to accommodate multiple lid opening (2) diameters, shapes, and arrangements. This design could be for growing multiple bulb (16) types at once for functional purposes or aesthetic. The pattern of lid openings (2) could create patterns, designs, or other aesthetic features when the bulbs (16) are just planted and/or fully grown.

[071] FIG. 10 includes a top view of a lid component of bulb or net cup growing system having a grid structure, according to various embodiments of the invention. FIG. 10 shows a top view of a possible embodiment of tray lid (3), or a possible embodiment of a lid- net cup version (10) design, where the lid is made of a mesh, grid or other similar construction designed to let varying amounts of light, air, moisture, humidity etc. through to the bulbs (16) or plants (14) below. One reason would be if the bulb (16) or plant (14) grows above ground and needs more light, vs a bulb (16) or plant (14) that needs more darkness to grow.

[072] FIG. 11 includes a top view of a lid component of a bulb growing system, according to various embodiments of the invention. FIG. 11 includes a top view of an embodiment of tray lid (3) or an embodiment of tray lid (10) and includes features to provide a better user experience to the end user. A finger tab (19) is configured for lifting the lid-bulb version (3) off the grow tray (4 not pictured) and a watering hatch (20) could be opened to refill the water (21) in the grow tray (4) without the user lifting the entire tray lid (3).

[073] FIG. 12 includes a bottom isometric view of a lid component of a bulb growing system, according to various embodiments of the invention. FIG. 12 includes a bottom isometric view of the tray lid (3) of FIGs 7 and 8 showing the lid ledge (15) feature.

[074] FIG. 13 includes a front isometric view of a bulb growing system, according to various embodiments of the invention. FIG. 13 shows a view of the tray lid (3) sitting on top of a grow tray (4) made by Hamama, Inc. The lid ledge (15, not visible) prevents the tray lid (3) from sliding off the tray (4).

[075] FIG. 14 includes a cross-sectional view of a bulb growing system, according to various embodiments of the invention. FIG. 14 shows a cross sectional view of the tray lid (3) and grow tray (4). The 8 risers (9) protruding from the base of the grow tray (4) create the water reservoir. The risers can be seen at the bottom and the lid openings (2) can be seen at the top. The optional fill line (22) is visible at the back. Embodiments of grow tray (4) can include at least 1, 2, 3, 4,

6, 8, 10 or more risers (9), or any number therebetween.

[076] FIG. 15 includes a cross-sectional view of a net-cup growing system, according to various embodiments of the invention. FIG. 15 cross sectional view of a net cup growing system showing the lid - net cup version (10) above the grow tray (4). The risers (9) are visible at the bottom of the grow tray (4) and net cup portion of lid ( 11 ) visible on the lid - net cup version

(10). This grow method could be used with semi-absorbent sheet (7) or without depending on a growing media plug (see FIG. 17) inserted into the net cup portion of the lid (10).

[077] FIG. 16 includes a cross-sectional view of an alternate net-cup growing system, according to various embodiments of the invention. FIG. 16 shows a cross sectional view of a net cup growing system showing the lid - net cup version (10) above the grow tray (4). This design utilizes removable net cup portions of the lid (11) that are seen passing through the lid-net cup version (10) through lid openings (2). This way individual net cup portions of the lid (11) could be removed or different materials than the lid-net cup version (10) could be utilized depending on what is growing.

[078] FIG. 17 includes a cross-sectional view of an alternate net-cup growing system, according to various embodiments of the invention. FIG. 17 shows a cross sectional view demonstrating grow media plugs (12) with seeds inside (13) about to be placed in the net cup growing system. The lid - net cup version (10) has been lowered into the grow tray (4) and the net cup portion of the lid (11) is partially submerged in the water).

[079] FIG. 18 includes a cross-sectional view of a net-cup growing system including plants, according to various embodiments of the invention. FIG. 18 shows a cross sectional view demonstrating grow media plugs (12) with plants (14) about to be placed in the net cup growing system. The tray lid version (10) has been lowered into the grow tray (4) and the net cup portion

(11) of the tray lid (10) is partially submerged in the water.

[080] FIG. 19 includes a cross-sectional view of a net-cup growing system including plants, according to various embodiments of the invention. FIG. 19 shows a Cross sectional view demonstrating the net cup growing system with grow media plugs (12) with plants (14) sitting in the grow tray (4). The grow media plugs (12) provide support to the plants (14) and the net cup portion of the lid (11) holds the grow media plugs (12) and is submerged such that the grow media plugs get water which has been filled in the grow tray up to the water level (6). The plants may be grown elsewhere and transplanted into the net-cup growing system for continued growth or life support or the plants could have been grown from seed in the system.

[081] FIGs. 20A and 20B include, respectively, a top isometric view of a component of a net- cup growing system, and a cross-sectional view of a net-cup growing system including the component, according to various embodiments of the invention. FIG. 20A is a top isometric view of a pressed media/cup lid combination (23) and FIG. 20B is a cross sectional view demonstrating use of a pressed media/cup lid combination (23). The pressed media/cup lid combination could be formed in a similar process to stamping, where sheet of material such as semi-absorbent sheet (7) is pressed to impose cups and a lid such that this single piece can be placed in a grow tray (4) and accommodate grow media plugs (12). A separate lid-net cup version (10) might not even be needed, nor would a semi-absorbent sheet (7) in some embodiments of the invention, because the pressed media/cup lid combination (23) would itself serve as the growing substrate and provide that structure.

[082] FIG. 21 includes a cross-sectional view of a bulb or net-cup growing system having multiple lids of various sizes, according to various embodiments of the invention. This system is optionally provided in the form of a kit configured to grow bulbs of different sizes. FIG. 21 shows a cross sectional view demonstrating another way to adjust the height of the tray lid (3). By varying the dimensions of the lid, it can be configured to sit either higher or lower in a grow tray (4). In a circular grow tray (4) for example, a smaller diameter lid would sit lower while a larger diameter lid would sit higher. Some embodiments include a kit comprising multiple tray lids (3) having different dimensions, spacers (16) of different heights, tray lids (3) of different shapes, and/or the like.

[083] References to a net cup or net cup portion of the lid, may include any of the slotted hydroponic cups, used in industry, that allow roots to grow out and water to get to the peat, coconut coir, rock wool or other media plug in the cup.

[084] In the removable cup design pictured in FIG 16, the cups are optionally made of different plastics, metal, silicone, or compostable or natural materials including but not limited to coconut fiber, wood, bamboo, straw, twine or other rope, hemp, jute etc. Further, the net cups can be lined with substrate or have a cup-shaped liner like pressed coco that serves as a substrate or intermediary for a growing plant. [085] The various embodiments described herein can be applied to the bulb and net cup growing systems for bulbs or vegetable plants respectively, the growing system is not limited to these organisms. Organisms including but not limited to fungi, non-edible plants, ornamental bulbs, flowers etc. could also be grown in either system depending on the specific organism’s needs.

[086] While the disclosed embodiments may be designed and implemented systems for growing microgreens, and/or for other plants including but not limited to green onions, garlic, celery, fennel, etc.

[087] While the disclosure describes versions of the bulb growing system and net cup growing systems where the tray is made taller or the lid is made taller or shorter to accommodate different sized plants, other components of the tray including the riser height, fill line, or even net cup depth, hole density, grow plug composition could all be tailored to provide optimal growing conditions for the plant.

[088] As illustrated in FIGs. 20A and 20B, instead of net cups, there could also just be a pressed/formed semi-absorbent sheet inserted into the grow tray below the lid that has the cups pre-pressed into them. Then you just put the lid over it and insert the plant directly into the semi absorbent layer through the lid. The tray lid may be optional.

[089] For the convex and concave lids of FIGs. 3A and 3B the height of the semi-absorbent sheet, height of the water, or both could be adjusted to further accommodate the differently sized bulbs. For example in the concave version of FIG. 3B, a thinner semi-absorbent sheet and lower water level could suffice for a smaller bulb, while in a convex version of FIG. 3 A, a thicker semi-absorbent sheet and higher water level could work because the bulb is larger and may need more water/structure.

[090] For the “topographic” lid design of FIG. 4 or any other lid design could be 3D printed, molded, CNCd, or otherwise shaped to appear as a relief of a real location. For example, taking the topographic map of a mountainous area or cityscape, and 3D printing a lid that has the relief in miniature.

[091] Though the tray lids shown in the various figures are pictured as angular in nature does not preclude them from being rounded, curved or contoured or a combination.

[092] Still further embodiments of the present invention are directed to systems and kits for sprouting garlic greens, and the like, which may have different growing requirements to the bulbs previously described. More specifically, these embodiments allow cloves to be grown that need to be broken apart from a greater bulb, such as garlic. While the specification describes these embodiments with reference to garlic, this does not limit the scope of the invention to only garlic as other bulbs, cloves, or plant material can also be grown using the systems described herein.

[093] Systems of the present invention are designed to keep garlic cloves and other plant materials upright during growth such that the root portion is in contact with water, while providing ample water and substrate to support the roots over a growing period. References below to cloves will be understood to apply equally to other plant materials that can fit into the system. In some embodiments, just the root portion of the garlic clove is submerged while the upper portion of the clove is out of the water. In some embodiments, vertical channels are provided along the length of the garlic cloves that project down from a lid and terminate at or above the substrate. Channels can also be supported by the tray and extend down, or the channels can sit on the substrate and extend upward, depending on the application. All clove heights can thus be accommodated, and the channels can be dimensioned or shaped to fit the most common clove dimensions, or a range of channel dimensions can support both wider and thinner cloves.

[094] The present invention also provides inserts that fit into the tray and that include channels disposed therethrough. Two types of inserts are further described, “channel inserts” that when situated in a tray have a top surface that sits at a level that is recessed below the level of the lip of the tray, and also “channel lids” that are tray lids that include channels. Some embodiments employ both a channel lid and channel insert. Either can be fabricated of various materials such as wood, bamboo, plastic, ceramic, or metal depending on the use case. For example, wood or plastic can be more desirable for consumer uses while stainless steel can be more desirable for industrial use. A non-exhaustive list of fabrication methods for the channel insert or channel lid includes 3D printing, injection molding, CNC or manual machining, and thermoforming, for example.

[095] FIGs. 22A and 22B are schematic cross-sectional representations of two channel lid designs. As shown in both illustrations, a system 2200 comprises a tray 2210 with risers 2220 and a semi-absorbent sheet 2230 disposed on the risers 2220. In both illustrations the system 2200 further comprises a lid 2240 including a plurality of channels 2250 defined in the lid 2240. Each channel 2250 consists of a vertical wall 2260 enclosing a volume 2270 that is attached to the lid 2240. Where a channel 2250 intersects the lid 2240, the lid 2240 includes an aperture 2280 so that the channel 2250 has an open end at the lid 2240. Similarly, the bottom of each channel 2250 also includes an aperture 2290 to provide an open end facing, and proximate to, the semi-absorbent sheet 2230.

[096] In FIG. 22A the channels 2250 represented in cross-section extend into and out of the plane of the drawing, for example, to have a depth slightly less than the depth of the lid 2240.

The channels 2250 vary in their width, as can be seen, to accommodate cloves of different widths. Thus, a wider channel 2250 can be planted with wider cloves while a thinner channel 2250 can be planted with thinner cloves. In some embodiments, the depth of each channel 2250 is less than half the depth of the lid 2240 such that two channels 2250 align in a row perpendicular to the plane of the drawing. Three or more channels 2250 can be aligned along their longitudinal axes in the depth dimension. For example, two aligned channels 2250 can be created by dividing one channel 2250 with a divider, three aligned channels 2250 can be created by dividing one channel 2250 with two dividers, and so forth.

[097] In FIG. 22B the concept is extended to channels 2250 that are wider than any single clove, in order to accommodate several cloves across a width thereof. As in the embodiment of FIG. 22A, the channels 2250 extend into and out of the plane of the drawing, and two or more channels 2250 can be aligned along their longitudinal axes in the depth dimension. FIG. 22B further illustrates that some embodiments can mix channels 2250 that are only wide enough for individual cloves, with extra-wide channels 2250 meant to accommodate several cloves across. [098] FIG. 23 shows a perspective view of an embodiment of a channel insert 2300. A channel lid can be created from the channel insert 2300 by adding a lip around the perimeter to rest on the edge of the tray. In these embodiments, each channel 2310 can only accommodate a single garlic clove. Thus, the channels 2310 in these embodiments are arranged in an array and one garlic clove is generally inserted into each channel 2310. As in the prior embodiments, the channels 2310 can have varying depth and width dimensions, though in the illustrated example each channel 2310 has the same dimensions as the other channels 2310.

[099] FIG. 24 is a schematic cross-sectional representation of an exemplary channel insert 2400. In this example the channel insert 2400 is supported on the sloped inside surface of the tray 2210, but in other embodiments the channel insert 2400 rests directly on the semi -absorbent sheet 2230.

[0100] FIG. 25 illustrates still another exemplary embodiment of a system 2500 comprising a tray 2210 with risers 2220 and a semi-absorbent sheet 2230. In these embodiments cloves are held by both a channel insert 2510 and a channel lid 2520. In these embodiments the channel insert 2510 is supported on the sloped inside surface of the tray 2210, or rests directly on the semi-absorbent sheet 2230, and the channel lid 2520 is disposed above of the channel insert 2510 and can be supported on the rim of the tray 2210 or its inner edge. Respective channels 2250 of both have the same depth and width dimensions and are aligned. The channel insert 2510 and channel lid 2520, in some embodiments, contact each other, while in other embodiments they are separated by a gap, as shown. The channel insert 2510 and channel lid 2520 can be made of the same material, or different materials, and in one exemplary embodiment the channel insert 2510 is made of a plastic while the channel lid 2520 is made of a hard wood for a more aesthetic appearance. While the channel lid 2520 here has channels 2250 that project downwards, in some embodiments the channel lid 2520 is simply a planar sheet and the channels 2250 are just apertures disposed through that sheet. The channel lid 2520 can be anything from a sheet with holes to the embodiment illustrated to a lid with channels 2250 that extend all the way to the channel insert 2510.

[0101] The relative thicknesses of the channel insert 2510 and the channel lid 2520 can also vary from a tall channel insert 2510 paired with a short channel lid 2520 to a short channel insert 2510 paired with a tall channel lid 2520. FIG. 26 illustrates how a shorter channel insert 2510 makes positioning cloves easier.

[0102] The semi-absorbent sheet 2230 can pose an impediment to growing certain cloves, such as garlic, because the roots are thick and dense and rather than penetrate the semi-absorbent sheet 2230 they push against it, lifting up the clove out of the channel 2250. One alternative is to replace the semi-absorbent sheet 2230 with soil or a soil analogue, a loose mesh, rock or gravel, or another material with sufficiently low density to encourage rooting. Alternatively, the semi absorbent sheet 2230 is not required. The following embodiments illustrate designs that do not employ the semi-absorbent sheet 2230.

[0103] FIGs. 27A and 27B show perspective and top views, respectively, of an exemplary channel insert 2700. The channels 2710 of the channel insert 2700 include a cap 2720 across the aperture 2290, where the cap 2720 is porous. In the illustrated embodiment the cap 2720 is a flat sheet and is made porous by virtue of a plurality of holes defined therethrough. In other embodiments the cap 2720 can be a latticework, mesh, or weave with appropriately sized openings therethrough. The cap 2720 is shown in the context of a channel insert 2700 but can also be applied to a channel lid.

[0104] FIG. 28 shows a cross-sectional view of a system 2800 in which a channel insert 2700 is set inside a tray 2810. The channel insert 2700, in this embodiment, rests upon risers 2820. The system 2800 does not include the semi-absorbent sheet 2230 found in other embodiments, but the present invention does not exclude the combination of channel insert 2700 and the semi absorbent sheet 2230 where the semi-absorbent sheet 2230 is disposed between the risers 2820 and the channel insert 2700.

[0105] Another alternative embodiment is shown in FIG. 29 which illustrates five different arrangements of protrusions within a channel 2250. These arrangements can be implemented in either a channel lid or channel insert. A channel lid or channel insert can include more than one of these arrangements. These arrangements are meant to support a clove in an upright orientation while providing an unobstructed path for roots from the cloves to reach the water beneath them in the tray. These embodiments allow for easier cleaning because the roots do not grow into a substrate. Additionally, the cloves and roots can be pulled out of the channel 2250 with ease.

[0106] In each arrangement there is a protrusion 2900 extending from one vertical wall 2260 into the channel 2250. In some embodiments there is only one protrusion 2900 while other embodiments include a second protrusion 2910 extending from the vertical wall 2260 into the channel 2250. As illustrated, protrusions 2900, 2910 can be straight or curved, and curved ones can curve up or curve down. In various embodiments having both protrusions 2900 and 2910 the protrusions 2900, 2910 are mirror images while in other embodiments they are not mirror images and instead terminate at different heights relative to the bottom of the channel 2250.

[0107] FIG. 30A shows a perspective cross-sectional view of another exemplary channel insert 3000. The exemplary channel insert 3000 comprises a suitable shape for fabrication by injection molding. In various embodiments, the protrusions 2900 can be made of a pliable or a rigid material. While injection molded embodiments will be integrally formed of one material, other embodiments can be formed of different materials for the protrusions 2900 and the remainder of the channel lid or channel insert. As another example, thin tabs that flex to grip the garlic and hold it in position can be added, while the surrounding insert not contacting the garlic can be rigid. Additional embodiments can have flexures or compliant mechanisms molded into the channel insert 3000 to hold or support the garlic.

[0108] It will be appreciated from FIG. 30A that the vertical wall 2260 is optional. As shown in FIG. 30B, instead of a vertical wall 2260 with protrusions 2900 on either side thereof, the portion of the vertical wall 2260 between adjacent channels 2250, and the protrusions 2900, are replaced by two fins 3010. These fins form parts of walls, analogous to vertical wall 2260, but where the fins are not vertical but angled and/or curved.

[0109] FIG. 31 shows a schematic representation of a cross-section through the several channels 2250 of FIG. 29 in use in a tray (only the bottom of the tray is shown). A thin horizontal line represents the level of the tops of the risers 2220. When a user fills the tray to the fill line, the level of the water will be high enough to enter the channels 2250, enough touch the root area and initiate root growth. In some embodiments the water enters the bottom 0.75 to 0.875 inches of the channel 2250. At this water level the root ends of the cloves are completely submerged and the roots are then able to grown down into the water.

[0110] FIG. 32 is a cross-sectional view of another exemplary system 3200 including a tray 3210, a channel insert 3220, and a lid 3230. In these embodiments the lid 3230 is provided primarily for aesthetics and can be fabricated from a hardwood, for instance. The lid 3230 includes an aperture disposed therethrough to allow air and light to reach the growing cloves. In various embodiments, edges 3240 of the aperture align with the outer edges of the outermost channels 2250. It will be appreciated that channel insert 3220 is not limited to the illustrated example and can be any of the channel inserts previously described. FIG. 32 also serves to illustrate how lid 3230 and channel lids in general, can be supported by a lip 3250 of the tray 3210.

[0111] Several embodiments are specifically illustrated and/or described herein. However, it will be appreciated that modifications and variations are covered by the above teachings and within the scope of the appended claims without departing from the spirit and intended scope thereof. For example, while the examples disclosed herein are directed primarily at an enclosed growing tray. In alternative embodiments the improvements taught can be applied to a flowthrough system in which a flow of water travels through an extended tray or trough. Such systems can include pumps, automated harvesting, light sources, and/or other standard elements of hydroponic or aquaponic systems. For example, fish or other beneficial organisms may be added to trays or other containers with an aquaponic system. In some embodiments, the systems disclosed herein are configured to be used as a fish tank lid, optionally allowing roots (8) to enter water of the fish tank. Embodiments of tray lid (3) optionally include lights, e.g., waterproof LED lights. These systems, in some embodiments, can float on top of the water such that a specific height of water is maintained through the whole growing cycle. Further, while the examples provided herein are directed primarily at “bulbs” the improvements taught can be applied to other plants or fungi, which can be regrown after having an upper part cut away, such as green onions, garlic or leeks. These other plants, or cloves thereof, can optionally be pinned upright and in place using pin flower holders, or the like, where a pin pierces the plant material, though care needs to be given to avoid harming the pre-grown plant. Garlic cloves could come pre-sorted to customers such that the optimally-sized clove is always provided with a certain channel profile.

[0112] Systems of the present invention can include cloves or other plant material already pre inserted into the channels so that a user only needs to add water for a first grow. Cloves or other plant material can also be connected together in the proper orientation with a paper tape or similar - in the manner that nails for a nail gun are connected. This way a user does not have to individually place the garlic cloves, they would just need to insert the line of cloves connected by the paper. The paper optionally can be compostable and can be designed to either break down or stay connected throughout the growing process. The tape can also be made of other materials as well, depending on the application or requirements of the system. The connecting material can contain fertilizer, beneficial microbes or similar, to aid growth.

[0113] If cloves or other plant material are not included in a kit with the system already pre separated, a tool to break apart garlic bulbs can be included with a garlic growing kit, for example. The tool allows the user to easily break apart the bulbs. Whole garlic bulbs or cloves can be included with kits, or can be sent to the user separately on a subscription or repeating basis.

[0114] A garlic kit subscription could include the growing kit and garlic cloves to get the user started. Then more cloves could be sent once the user has grown and harvested the previous batch. Specifically designed profile channels could be applied to other plant types, not just bulbs or cloves. The channel architecture could be used to support other plants during their growth or regrow cycles. Profile channels could be designed to enforce a certain behavior from the plants they are growing such as redirecting roots, angling the plant for optimal light, or positioning the plant for easier user interaction. Profile channels can also be used to grow bulbs described in the previous inventions and even support growing media plugs or strips with seeds or partially grown plants.

[0115] The embodiments discussed herein are illustrative of the present invention. As these embodiments of the present invention are described with reference to illustrations, various modifications or adaptations of the methods and or specific structures described may become apparent to those skilled in the art. All such modifications, adaptations, or variations that rely upon the teachings of the present invention, and through which these teachings have advanced the art, are considered to be within the spirit and scope of the present invention. Hence, these descriptions and drawings should not be considered in a limiting sense, as it is understood that the present invention is in no way limited to only the embodiments illustrated.

Claims

CLAIMS We claim:

1. A bulb growing system comprising: a semi-absorbent sheet having upper and lower sides separated by a thickness; a tray including one or more risers, the tray being configured to hold water, the risers being configured to support the semi-absorbent sheet and create a water reservoir below the semi-absorbent sheet; and a tray lid including a plurality of openings, sides of the tray being configured to support the tray lid such that a plurality of bulbs fit between the semi-absorbent sheet and the openings, wherein the openings are configured to hold the bulbs upright within an enclosure formed by the tray and tray lid.

2. The system of claim 1 , wherein the tray lid is configured to reduce water evaporation from within the tray or light reaching the bulb.

3. The system of claim 1 or 2, wherein edges of the tray or tray lid are tapered such that tray lids of different dimensions rest at different heights in the tray.

4. The system of claim 1, 2, or 3, wherein the semi-absorbent sheet includes coconut fiber.

5. The system of claims 1-3 or 4, further comprising a spacer configured to hold the tray lid above the tray.

6. The system of claims 1-4 or 5, further comprising a pump configured to flow water through the tray.

7. A bulb growing kit comprising: a semi-absorbent sheet having upper and lower sides separated by a thickness, each of the sheets having a different thickness; a tray including one or more risers, the tray being configured to hold water, the risers being configured to support the semi-absorbent sheet and to create a water reservoir below the semi-absorbent sheet; a first tray lid including a plurality of openings, sides of the tray being configured to support the tray lid such that a plurality of bulbs fit between the semi-absorbent sheet and the openings, wherein the openings are configured to hold the bulbs upright within an enclosure formed by the tray and the first tray lid; and means for controlling a height of the openings above the semi-absorbent sheets, the means including tray lids of different shapes, semi-absorbent sheets of different thicknesses, a spacer configured to be disposed between the tray and the tray lid, a tapered edge of the tray or tray lid, or a thickness of the tray lid.

8. The kit of claim 7, further comprising a second tray lid having openings of different size relative to the openings of the first tray lid.

9. The kit of claim 7 or 8, wherein the thicknesses of the semi-absorbent sheets are configured to fit bulbs of different sizes between the tray and the tray lid.

10. The kit of claim 7, 8, or 9, further comprising a second tray lid having dimensions relative to the first tray lid.

11. A system for the growth of a plant material, the system comprising: a tray capable of holding water, the tray including a riser, a top of the riser being positioned at a level below that of a lip of the tray, whereby, when filled with water, the tray further includes a water reservoir filled to below the lip; and an insert sized to fit within the tray and to be supported within the tray on or above the riser, the insert including a plurality of channels disposed therethrough, each channel including a first aperture facing a bottom of the tray, and a second aperture opposite the first opening, each channel having a width approximately the same as a width of the plant material to be grown.

12. The system of claim 11, wherein the plant material is garlic cloves and the width of the plant material to be grown is the width of a garlic clove.

13. The system of claim 11 or 12, wherein each of the plurality of channels includes a porous cap across the aperture.

14. The system of claim 13, wherein the porous cap includes holes defined therethrough to provide porosity.

15. The system of claim 11 or 12, wherein each of the plurality of channels includes a protrusion extending into the respective channel.

16. The system of claims 11-14 or 15, wherein the insert comprises a lid that is supported within the tray by resting on the lip of the tray.

17. The system of claims 11-14 or 15, wherein the insert, when situated in the tray, has a top surface that sits at a level that is recessed below a level of the lip of the tray.

18. The system of claim 17, further comprising a lid including a plurality of channels disposed therethrough, each channel of the lid including a first aperture facing the insert, and a second aperture opposite the first aperture, each channel of the lid aligned with a corresponding channel of the insert.

19. The system of claims 11-17 or 18, further comprising a semi-absorbent sheet disposed between the insert and the riser.