Sliding plant growing system

Abstract

Described herein is a bellowed plant growing structure consisting of alternating plant supporting section and sets of ribs. The bellowed plant growing structure slides over a container. The plant growing surface comprises plant receptacles that selectively allow roots to pass through. The stem of the plant is above the level of the plant receptacle. Sectional members support a plurality of said plant receptacles. The space between the sectional members is increased over time to optimize light reception on the plant. Ribbed surfaces join successive sectional members. The expansive ribs expand in a direction normal to the length of the section.

Description

[0001] SLIDING PLANT GROWING SYSTEM

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS: This application is a PCT application that claims priority to and the benefit of the Non-provisional patent application titled “Sliding Plant Growing System”, application number 202344084219, filed in the Indian Patent Office on 11 December 2023 which claims priority from its corresponding provisional patent application titled “Two axis sliding aeroponic rack”, application number 202341015379, filed in the Indian Patent Office on 07 March 2023. The specification of the above referenced patent application is incorporated herein by reference in its entirety.

[0003] BACKGROUND

[0004] This invention in general relates to agricultural equipment, and specifically refers to a plant growing system.

[0005] The Covid pandemic has exposed the vulnerability of the food system, and has reinforced the need to grow food locally. In order to grow food locally, at the point of consumption or near the point of consumption, and to be economically comparable to regular agriculture field production, the productivity of locally grown food must be high, planting density must be extremely high and the energy consumption must be low. There is an unmet need to increase the density of planting in orders of magnitude more than the productivity of existing agricultural and the currently available controlled environmental agriculture systems. Current agricultural system involve plantations in fields with transport taking time in the order of weeks or days over long distances.

[0006] With the given agricultural productivity per acre of land, by 2050 we will run out of agricultural land to feed the growing population. There is an urgent need to develop growing systems with increased productivity. In addition to the lack of sufficient arable land by 2050, we may run short on energy for agricultural activities. In parallel, there is a need to reduce the labor required for farming. There is an urgent need to bring in automation even in developing countries. We are running out of fresh water for farming operations, and we need to find a way to grow food even in desert like conditions through a highly productive version of controlled environment agriculture (CEA). We need to significantly increase the density of plants grown to make CEA economically viable. We need to reduce pollution and waste as a result of fertilizer application. Currently, wasted fertilizer runoff in fields equates to almost 40 to 60%. This runoff causes water pollution in rivers downstream. We need to reduce or eliminate pesticide application.

[0007] Light energy is one of the highest input cost components in lighted indoor controlled environment agriculture. And land is one of the highest cost components in greenhouse based controlled environment agriculture without lighting.

[0008] There is a need for a plant growing system that saves both light energy and land area requirement. In current hydroponic and aeroponic systems, some form of plug is used to germinate the seed and anchor it to the wall of the hydroponic or aeroponic system. Examples of plugs include cocopeat in a plastic holder, rockwool in a plastic holder, Polyurethane foam, plastic foam, rubber foam, sponges etc. The growing medium in these plugs are typically of one time use, and add to production costs. If they are to be reused, they need to be sterilizied with chemicals, costly and environmentally unfriendly process. In addition, these media are a source of contamination in an otherwise sterile hydroponic or aeroponic system. In addition, a separate germination unit is required using these plugs, and these plugs are then transplanted onto the main growing station. This separate germination unit and the added process of transplanting seedlings is a significant cost factor in existing controlled environment agriculture plant growing systems. Hence, there is an unmet need to eliminate growing media. A significant part of the LED lighting applied at the seedling stage does not contribute to plant growth. Most of the photons miss the sprouting cotyledons or initial leaves, and lost in the gaps between the leaves, and wasted / absorbed onto the media surface, such as the surface of cocopeat or other growing media. Hence, there is an unmet need to ensure that most of the light emitted from the LED (such as at least 70%) strikes a leaf or plant surface and directly contributes to photosynthesis.

[0009] In current systems, there is an unmet need to save energy by ensuring that the photons emitted from the artificial light source hits a leaf, and is not wasted on striking the underlying surface between below the plants.

[0010] SUMMARY OF THE INVENTION

[0011] Described herein is an apparatus and system for growing plants wherein the space between plants increase as the plants grow.

[0012] Described herein is a bellowed plant growing structure consisting of alternating plant supporting section and sets of ribs. The bellowed plant growing structure slides over a container. The plant growing surface comprises plant receptacles that selectively allow roots to pass through. The stem of the plant is above the level of the plant receptacle. Sectional members support a plurality of plant receptacles. The space between the sectional members is increased over time to optimize light reception on the plant. Ribbed surfaces join successive sectional members. The expansive ribs expand in a direction normal to the length of the section.

[0013] BRIEF DESCRIPTION OF THE DRAWINGS The foregoing summary, as well as the following detailed description of the invention, is better understood when read in conjunction with the appended drawing. For illustrating the invention, exemplary constructions of the invention are shown in the drawing. However, the invention is not limited to the specific components disclosed herein. The description of a component referenced by a numeral in a drawing is applicable to the description of that component shown by that same numeral in any subsequent drawing herein.

[0014] FIG. 1A illustrates a compressed bellowed plant growing structure with plants growing at the seedling stage.

[0015] FIG. IB illustrates a partially expanded bellowed plant growing structure with plants growing at the mid stage of the crop cycle.

[0016] FIG 1C illustrates a fully expanded bellowed plant growing structure with plants growing at the final stage of the crop cycles.

[0017] FIG. 2 illustrates a horizontally aligned sliding plant growing system enabling increase in spacing between the plants as the plants mature.

[0018] FIG.3 illustrates the moving misters in a bellowed aeroponic system.

[0019] FIG. 4 illustrates a suspended feed tube technique of deploying moving misters in the aeroponic system.

[0020] FIG. 5 illustrates a positive tension driven technique of using tension ropes for moving misters in the aeroponic system.

[0021] FIG. 6A illustrates a front view of a sliding aeroponic system enabling increase in spacing between plants as plants grow.

[0022] FIG. 6B illustrates an angled view of a sliding aeroponic system enabling increase in spacing between plants as plants grow.

[0023] FIG. 7 illustrates a multilayered plant supporting section.

[0024] FIG. 8 illustrates a guide to expand the spacing between plants as they grow.

[0025] FIG. 9A illustrates an aeroponic system displaying an aeroponic rack. FIG. 9B illustrates an aeroponic system displaying a pulled out rack.

[0026] FIG. 9C illustrates an aeroponic system displaying a pulled out rack stacked with plants.

[0027] FIG. 10A illustrates a side view of the aeroponic rack.

[0028] FIG. 10B illustrates a front view of the aeroponic rack.

[0029] FIG. IOC illustrates an angular view of the aeroponic rack.

[0030] FIG. 11 A illustrates a side view of the aeroponic rack with plants loaded.

[0031] FIG. 1 IB illustrates a front view of the aeroponic rack with plants loaded.

[0032] FIG. 12A illustrates an angular view of the aeroponic planar plant holder with two compartments.

[0033] FIG. 12B illustrates the side view frame of the aeroponic planar plant holder with two compartments.

[0034] FIG. 13A illustrates an angular view of the aeroponic planar plant holder with one compartment.

[0035] FIG. 13B illustrates the side view frame of the aeroponic planar plant holder with one compartment.

[0036] FIG. 14 illustrates the frame of the aeroponic planar plant holder compartment installed on the aeroponic rack.

[0037] FIG. 15 illustrates the frame of the aeroponic planar plant holder compartment installed on the aeroponic rack sliding out in the Y axis.

[0038] FIG. 16 illustrates an active component level architecture of an aeroponics system.

[0039] DETAILED DESCRIPTION OF THE INVENTION

[0040] FIG. 1A illustrates a compressed bellowed plant growing structure with plants growing at the seedling stage.

[0041] FIG. IB illustrates a partially expanded bellowed plant growing structure with plants growing at the mid stage of the crop cycle. FIG 1C illustrates a fully expanded bellowed plant growing structure with plants growing at the final stage of the crop cycles.

[0042] Described herein is an apparatus for growing plants. A plant growing surface comprises plant receptacles 106 that selectively allow roots to pass through. The stem of the plant 103 is above the level of the plant receptacle 106. Sectional multidimensional members 101 support a plurality of plant receptacles 106. The space between the sectional multidimensional members 101 is adjusted over time. Expansive surfaces 102 join successive sectional multidimensional members. The expansive surface 102 increases spaces between plants as they grow. The expansion of the surfaces increases the spacing between the multidimensional members 101. The plant supporting structure, including the multidimensional members 101 and the expansive surface 102, is expanded at the stage when plants 103 overgrow and their canopy or leaves begin to over shade each other. Successive sectional multidimensional members 102 are joined by bellowed expansive surfaces 101.

[0043] The plant receptacle 106 is a cutout in the plastic with a rear membrane. In another embodiment, the receptacle 106 is a “net cup” normally used in the hydroponic systems.

[0044] Exemplarily, a vertically aligned plant supporting structure is compressed at the level wherein atleast 95% of light from said artificial lighting strikes a plant 103 part rather than the surface of the front layer of parts 101, 102.

[0045] A nutrient solution collecting container 104 is positioned under the bellowed plant growing structure. A section of the container 104, the multidimensional member 101 and expansive surface 102, form a closed rootzone cavity. The aeroponic misters 302 positioned in the rootzone cavity apply nutrient mist to roots in the root zone. In another embodiment, instead of ribbed expansive structures, the expansive surface comprises a plurality of overlapping flaps that slide over each other to increase spacing between successive linear members 101.

[0046] The plant growing structure during expansion is directed using channels or walls during expansion. In FIG. 3, the walls of the reservoir 104 serve as the means of direction.

[0047] Misters dynamically move along the Y direction, i.e. along the length of the plant growing system. A slider system 105 that carries and moves suspended misters is positioned above the root zone. For example, every seven minutes the misters are moved back and forth over a 50 ft long bellowed structure.

[0048] In order to automate the expansion of the bellow, sprockets with tooth engage with the ribs of the corrugation of the front layer. The rotating sprockets teeth engages with the ribs of the bellow and drives the movement of the vertically aligned plant supporting expansive structure.

[0049] FIG. 2A illustrates a horizontally aligned sliding aeroponic plant growing system enabling increase in spacing between the plants as the plants mature.

[0050] Described herein is horizontally aligned sliding aeroponic system. In this case, the plant growing surface structure placed is substantially horizontal. Plant receptacles 106 selectively allow roots to pass through. The stem of the plant is above the level of said plant receptacle. Linear members 101 support a plurality of plant receptacles 106. The linearity of the members 102 is along the X direction. The expansive surfaces 102 join a plurality of linear members 101 wherein the expansive surface 102 enables expansion in the Y direction. A container 104 for nutrient solution collection is positioned below the plant growing surface structure. The roots from the plants positioned in the plant receptacles are suspended in air. Misters are positioned in the root zone to supply nutrient solution. The misters are dynamically moved using assembly 105, described in detail in FIG.3, FIG.4 and FIG. 5.

[0051] FIG. 2B illustrates a horizontally aligned sliding hydroponic system enabling increase in spacing between the plants as the plants mature. Described herein is horizontally aligned sliding hydroponic system. In this case, the plant growing surface structure placed is substantially horizontal. Plant receptacles 106 selectively allow roots to pass through. The stem of the plant is above the level of the plant receptacle 106. Linear members 101 support a plant receptacle(s) 106. The linearity of the members 101 is along the X direction. The expansive surfaces 102 join a plurality of linear members 101 wherein the expansive surface 102 enables expansion in the Y direction. A container 104 for nutrient solution collection is positioned below the plant growing surface structure. The roots from the plants 103 positioned in the plant receptacles 103 are partially or fully immersed in the nutrient solution 202. The nutrient solution 202 is flowing in the container, similar to the solution flow in NFT (Nutrient flow technique) channels, supplied through nutrient input tube 201. In this case the container 104 is an NFT channel.

[0052] In another embodiment, the nutrient solution is static within the container, such as in deep water culture hydroponic systems. In this case the plant growing structure is either directly floating on the nutrient solution in a large tank or is preferably supported on a lightweight floating frame.

[0053] FIG.3 illustrates the moving misters in a bellowed aeroponic system. The mister movement system 105 with pulleys 404 at one or more ends, comprises aeroponic supply mister tube 301 pressurized by a high-pressure pump 303, pressurizing misters 302 to spray within the aeroponic zone.

[0054] FIG. 4 illustrates a suspended feed tube 301 technique of deploying moving misters in the aeroponic system. The mister movement system 105 with motor driven pulleys 404 at one or more ends, comprises aeroponic supply mister tube 301 pressurized by a high-pressure pump 303, pressurizing misters 302 to spray within the aeroponic zone. The directing structure 401 with internal wheels is above the aeroponic misting area.

[0055] FIG. 5 illustrates a positive tension driven technique of using tension ropes 503 for moving misters in the aeroponic system. Both the misting tube 301 and tension ropes 503 are wound a drum and both engage with the top and bottom of the driven 403 rope. The mister movement system 105 with motor driven pulleys 404 at one or more ends, comprises aeroponic supply mister tube 301 pressurized by a high- pressure pump 303, pressurizing misters 302 to spray within the aeroponic zone. The directing structure 401 with internal wheels 402 is above the aeroponic misting area.

[0056] FIG. 6A illustrates a front view of a sliding aeroponic system enabling increase in spacing between plants as plants grow.

[0057] FIG. 6B illustrates an angled view of a sliding aeroponic system enabling increase in spacing between plants as plants grow.

[0058] In this case, the plant growing structure is substantially vertically oriented. The roots of multiple plants supported on said linear members 101 interlock with one another to form an interlocked grid. The interlocked grid of roots support the weight of the plants. Light emitting diodes positioned in proximity to said plant growing surface. In another embodiment, the width of each of said linear members 101 may also be expansive.

[0059] The spacing between successive linear members 101 may be increased by applying motorized rotary grippers. The expansion of the plant growing surface may be automated by gripping one end and pulling the gripped end. In another embodiment, the rotating teeth from motorized sprockets engages with the ribs of the plant growing surfaces and pulls and extends the plant growing surface.

[0060] FIG. 7 illustrates a multilayered plant supporting section. The expansive surface is a multi-layered structure with a frontal plastic surface 701 and a rear membrane 702. The roots 703 of multiple plants 103 supported on said linear members interlock with one another to form an interlocked grid, whereby said interlocked grid of roots support the weight of the plants. The rear layer maybe pre-imbibed with one or more of slow release fertilizers, humic acid, activated carbon or charcoal. A rear membrane 702mallows page of roots. Examples of the rear 702 membrane include a cellulosic membrane or a non-woven membrane. Exemplarily, the non-woven membrane may be composed of polyester.

[0061] FIG. 8 illustrates a guide to expand the spacing between plants as they grow. Rod guides 801 are positioned in cavities within said expansive surface to controllably align the expansion of the expansive surface structure in the Y direction along the length of the rod 801. Exemplarily, the rods may be made of stainless steel or fiberglass.

[0062] FIG. 9A, FIG. 9B and FIG. 9C illustrates the overall aeroponic system displaying an aeroponic rack that can be maneuvered in both x and y directions. FIG. 9A illustrates an aeroponic system displaying an aeroponic rack. FIG. 9B illustrates an aeroponic system displaying a pulled out rack. FIG. 9C illustrates an aeroponic system displaying a pulled out rack stacked with plants.

[0063] The vertically aligned plant supporting structure comprises a front layer of a plastic with a first set of cutouts that supports the plant from seed to harvest. A rear membrane allows page of roots. Examples of the rear membrane include a cellulosic membrane or a non-woven membrane. Exemplarily, the non-woven membrane may be composed of polyester.

[0064] In another embodiment, a rear layer of a plastic membrane with a second set of cutouts is positioned behind the first layer. The rear thin plastic holds on to the rear of the front layer by surface tension of a nutrient solution. The first set of cutouts and set second set of cutouts are offset and do not overlap, whereby the roots slip in the cutouts between the front and rear layer and reach the aeroponic misting zone. Artificial plant grow lighting 904 illuminate plants on the front layer.

[0065] Aeroponic misters positioned behind said second layer. Two vertically aligned plant supporting expansive structures with their respective rear layers face misters and create an enclosed aeroponic misting space.

[0066] FIG. 10A illustrates a side view of the aeroponic rack. Rollers 1002 allow movement in Y direction and racks 1001 allow movement in the X direction.

[0067] FIG. 10B illustrates a front view of the aeroponic rack.

[0068] FIG. 10C illustrates an angular view of the aeroponic rack.

[0069] FIG. 11A and 11B illustrate a vertically oriented plant support structure wherein plants are grown aeroponically. The root zone is in the cavity between two vertical plant growing structures.

[0070] FIG. 11 A illustrates a side view of the aeroponic rack with plants loaded.

[0071] FIG. 1 IB illustrates a front view of the aeroponic rack with plants loaded.

[0072] FIG. 12A illustrates an angular view of the aeroponic planar plant holder with two compartments.

[0073] FIG. 12B illustrates the side view frame of the aeroponic planar plant holder with two compartments. The aeroponic racks are therefore easily accessible, and they can be slotted in and out of the apparatus. This ergonomic feature allows easy access to the plant and enables easy inspection during the growth phase.

[0074] FIG. 13 A illustrates an angular view of the aeroponic planar plant holder with one compartment.

[0075] FIG. 13B illustrates the side view frame of the aeroponic planar plant holder with one compartment.

[0076] FIG. 14 illustrates the frame of the aeroponic planar plant holder compartment installed on the aeroponic rack.

[0077] FIG. 15 illustrates the frame of the aeroponic planar plant holder compartment installed on the aeroponic rack sliding out in the Y axis.

[0078] A ribbed plant supporting surface is composed of a substance with an elastic memory. Certain plastics with elastic memory have the ability to return to its original folded shape after unfolding and holding in the unfolded position for a period of time. The return to the original folded position may be substantial or partial, preferably returning to atleast 30 to 50% of its previously folded position. More specifically, elastic memory herein refers to the folded plastic being able to return to its original folded shape after being held in a flexed position for a period of time. Hence, only a few materials such as solid thin sheet forms of polyethylene terephthalate (PET), biaxially oriented polyester film (BOPET), high density polyethylene (HDPE), thin fiberglass composite sheets etc. are suitable. Forms of cloth are not suitable as they do not have elastic memory to come back partially or fully to the original thermally set folded state. FIG. 13 A illustrates a compressed plant expansive structure. The ribbed structure when expanded and released, comes to its natural compressed state due its elastic memory.

[0079] A disposable thin membrane rear membrane may be used. The membrane may be composed of a porous material that allows roots to penetrate to the rear aeroponically misted cavity. The rear membrane layer is a porous material, with either micro or macro pores to allow for passage of water and fine roots of the germinating seed. Example of the porous membrane include soft tissue paper, for example single ply tissue like paper of 15 to 20 micron thickness. Preferably, the disposable membrane 702 is a biodegradable material such as of cellulosic material. Once, the plants are harvested, the rear disposable membrane 702 along with the roots are rotary wiped cleaned. Dirt or plant residue does not adhere to the smooth, thin and non porous material of the frontal layer 701. Hence, the cleaning process post harvest is convenient given the advantages of a smooth frontal layer 701 and easily wipe removable and disposable rear layer 702. The plant expansive structure has two distinct layers that are separate and not adhesively or stitch attached. The rear layer 702 merely clings to the front layer 701 by surface tension of the aqueous nutrient solution. The rear layer 702 is preferably a disposable layer and a frontal specific plastic layer 701 is reused. The frontal layer 701 has cutout holes for the deposition of seeds, and the continuous rear layer 702 seals the holes. The seeds are positioned in the holes, and lie over the supporting rear layer 702.

[0080] The plant growing structure that house the plants increase photon capture efficiency and therefore provide significant energy savings. For example, in the first four days post germination, the rows of seeds are adjacent to each other with little or no discernible gap along the direction of the row. The photons from the LED are not wasted at this stage by striking the surface underneath, and instead make contact with the sprouted seedling. The plant expansive structure is compressed in this early stage to 17% of the final expanded stage. Exemplarily, in the subsequent four days, i.e. in the exemplary second stage, the plant expansive structure is expanded to 33% of its final expanded stage. Exemplarily, in the subsequent four days, i.e. in the exemplary third stage, the plant expansive structure is expanded to 50% of its final expanded stage. Exemplarily, in the subsequent four days, i.e. in the exemplary final fourth stage, the plant expansive structure is expanded to 100% of its final expanded stage. In all these stages, as the plant grows, the spacing between the plants increase, and therefore light is not wasted by striking the underlying surface.

[0081] After germination, the roots 703 of plant 103 moves down and interlocks with the roots of plant underneath. Surprisingly, it is found that even a thin 20 micron thin cellulosic rear layer 702 does not tear by the plant weight because the interlocking roots of vertically adjacent plants create a rear structural grid of roots that takes the entire load, and transfers it to the front layer 701. Surprisingly, the wet and weak 20 micron cellulosic rear layer 702 maintains structural integrity, it does not break or allow cavities, and does not allow the mist from entering the plant leaf zone from the misted root zone.

[0082] Seeds deposited are deposited on the cellulosic membrane exposed in the cutouts. The folded plant expansive structures with seeds are preferably stored in a dark humid zone for germination. However, in the case of lettuce, it is preferable to expose the seeds to light from the second day onwards to avoid stem stretching and subsequent weakening of the lettuce seedlings.

[0083] A teethed sprocket may drive the controlled movement of the plant expansive structure. The teethed sprocket’s teeth interlock with the folds of the plant expansive structure and drives the movement of the plant expansive structure. For example, when expansion and movement is to be achieved in a more compressed state of the plant expansive structure, i.e. in the early stages of plant growth, a sprocket with a greater number of teeth are utilized. For example, if a 6 cm diameter sprocket with 20 teeth drives a continuous plant expansive structure with two revolutions, a 6cm diameter sprocket with 10 teeth will rotate only once to maintain sheet tension when the same plant expansive structure is passed continuously over both the before mentioned sprockets.

[0084] For given sprocket diameter, sprockets with decreasing number of tooth are utilized to drive the plant expansive structure as the plant grows from one stage to the next.

[0085] Sprockets engage or rotary grippers engage with and drive the plant expansive structures along a continuous path. After harvest in the final stage, a new plant expansive structure with seeds, or a plant expansive structure with seeds that have just germinated is affixed to the front section of plant expansive structures already present in the aeroponic plant growth system. The plants 103 in the plant expansive structures at the end of the loop are harvested, and that end section of the harvested plant expansive structures are taken out of the system for cleaning. In another embodiment, the plant is cleaned in proximity of the system while the plant expansive structure to be harvested is still attached to the preceding plant expansive structure.

[0086] The ribbed sheet 102 with plant supporting sections is manufactured by thermally forming sheets or by injection molding. In the corrugation machine, the sheet is heated and softened by heaters that heat the plastic sheet close to, or at its softening point. A measure of softening point is Vicat hardness. Vicat hardness reflects the softening point for plastics. The Vicat softening temperature (VSP) test is a standard test (ASTM DI 525 and ISO 306) which determines the temperature at which the plastic sheet is penetrated to a depth of 1 mm by a flat-ended needle with a 1 mm2 circular or square cross-section.

[0087] Alternatively, the material of the front layer 701 may be composed of shape memory polymers. Shape memory polymers ‘remember’ their original shape and return to that shape provided a stimulus, such as light or heat, irradiation with infrared light, immersion in water, and application of electric or magnetic fields.

[0088] In other embodiments, the plant expansive structure can expand in two dimensions, for example with pyramidal expansive origami type foldings.

[0089] The top structural layer 701 is a flexible weight bearing layer, for example a thin folded plastic such as biaxially oriented polyester film, BOPET or PET. Other forms of plastic such as high density polyethylene (HDPE) may also be used.

[0090] PET refers to Polyethylene terephthalate (PET), an aliphatic polyester. PET has a semi-crystalline form when stable, and is recylable. PET sheets composed of a thermoplastic polyester resin is thermoformable and ideally suited for the folded plastic sheet application. It’s smooth surface is resistant to scratches and does not allow dust and dirt to adhere easily to its surface. Such dirt can be relatively easily removed from the surface by the rotary swiping action of an automated brush or through reciprocating wipers.

[0091] The front sheet 701 can be light blocking as well as reflective by one of three techniques. The plastic sheet may be composed of a white opaque pigment that is reflective in the direction of the plants. Alternatively, a metallized PET sheet will both reflect light towards the plant side and as well as block out light in the root zone. An example of a metallized PET sheet is a Aluminum coated sheet. Alternatively, the rear of the plastic sheet facing the roots may be painted with a light blocking paint. Alternatively, a secondary dark colored ing plastic sheet may be fused to a white reflective plant facing plastic sheet.

[0092] The front layer 701 is thermally crease pleated with a memory to partially fold back.

[0093] The rear layer 702 is preferably a porous surface that allows roots to easily penetrate. Exemplarily, it is a cellulosic layer that is composed of loosely held cellulosic fibers. The loose hold of cellulosic fiber is accomplished by one or more of the following techniques: use of adhesives within the cellulosic layer with lower fiber bonding strength, addition of fiber lubricants, additives that reduces the bond between fibers etc. Exemplarily, the rear layer is a single ply or two ply sheet of softened bonded cellulosic fibers.

[0094] In another embodiment, the rear cellulosic layer may be selectively punched and made porous in the region of the cut hole to allow easy passage of the roots.

[0095] The rear cellulosic layer may additionally contain a controlled release fertilizer (CEF). Exemplarily, the relative proportion of Nitrogen Phosphorous Potassium (NPK) in the controlled release fertilizer may be customized based on crop type. Exemplarily, the rear cellulosic layer may be infused with humic acid prior to seeding. It has been observed that seedlings develop higher chlorophyll content in their cotylydons and first set of true leaves when the rear cellulosic layer 102 has been pre imbibed with nutrients or other growth enhancing materials.

[0096] The rear cellulosic layer 702 may also contain carbon particulates in the form of powdered charcoal or activated carbon, with the ability to absorb non desirable growth inhibitory organics from the nutrient mix, such as root exudates.

[0097] Described herein is a technique and apparatus to fold a fully expanded or semi expanded plant expansive structure back to a fully folded state. After the plant expansive structure is fully expanded in the final growing phase of the plant, it may not fully recover to its folded state. However, atleast a 30% folded state is sufficient for the plant expansive structure to be recompacted to a fully folded state, enabled by the elastic memory of the specific plastic used in the plant expansive structure. If the plastic has poor memory, then it would extend completely and it will not be feasible to refold the plant expansive structure into a compacted state for reuse. The elastic property is essential because on release for expansion, the folds push out and uniformly expands. This uniform expansion through pull or push is feasible through the elastic strain energy stored in the compressed plant expansive structure. Microfleece cloths are inelastic and cannot be used in the disclosed plant growing system. The full folding apparatus feeds the partially expanded plant expansive structure between a top and lower guide that holds the plant expansive structure in a planar state. Rotary soft brush rollers push and compact the folds to a fully folded state after over extension of the plant expansive structures.

[0098] FIG. 16 illustrates an active component level architecture of the underlying aeroponics system. The aeroponic system comprises reservoir / tank 1603, misters, filters 1602, control system, pressure tank 1605, solenoids 1604, 1606, pressure sensors, flow sensors, booster pumps 1601 and other sensor modules along with Internet of things (IOT) Connectivity. The misters are positioned on pipes. Examples of pipe material includes high tensile pressure bearing plastics or stainless steel. The misters preferably provide fine mist, with droplet sizes preferably in the range 50 microns. Very small droplet sizes, such as 20 micron droplets tend to “evaporate” and are not effective at providing a substantial nutrient film layer on the roots. Excess atomization of the droplets introduces excessive root hair, and the plants grow a greater portion of roots instead of the desired marketable higher shoot. The mister module comprising the pipes and connected misters need to serviceable, the misters need to be easily replaceable and the mister functional performance must be easily gauged. Performance parameters of the misters include output flow rate in milliliters per minute, and spray pattern shape consistency. In some cases, a failed mister may not mist, instead drips or linearly jets out nutrients. In addition, the misters at a pressure of about 100 psi will preferably create droplets in the range of 50 microns. Mist droplets larger than 100 microns may not provide the aeroponic growth advantage. The misters must be easily removed for replacement or cleaning and subsequent refitting. Misters are connected in a fashion that a minimal level of redundancy is established.

[0099] Carbon dioxide in exemplarily set in the range of 500 to 2400 ppm. The effectiveness of raising the CO2 concentration dependent on a number of plant growth factors, such as the lighting intensity, type of crop, temperature, ventilation type and external air exchange magnitude and frequency. Stale air and the boundary layer around the leaf needs to refreshed with C02 enriched air movement.

[0100] Exemplarily, CO2 is supplied in the form of liquid carbon dioxide. Compared to other sources of CO2, liquid CO2 is purer, with no related additional heat or moisture, providing the ability to effectively control CO2 levels and the ability to guide CO2 in the midst of the crop. Exemplarily, the consumption of CO2 is estimated to be about 0.12-0.20 kg / hr / (100 m2 of growing surface).

[0101] The light sources are preferably linear light sources such as LEDs (light emitting diode). The linear light sources may be in the form of batten lights, LED strip lights or LED rope lights. The LED can be full spectrum (380nm-730nm), or one or more of a combination of red, blue, green, white, infrared, far red and UV. Certain LED wavelengths are suitable for specific stages of plant growth. For example, LEDs with a higher concentration in the blue wavelength keep the plants compact, increases pigmentation and does not dry out the cotyledons that have just emerged from the seeds. Red light enables plant extension, and stimulates flowering and fruiting. Far red LEDs create plant leaf surface and stem length elongation by initiating shade responses. Green light penetrates a canopy deeper than other light wavelengths, providing the lower and older leaves to photosynthesize and maintain freshness. In high density farming, it is essential to maintain a minimum level of photosynthesis in the lower leaves, and reduce the rate of lower leaf senescence.

[0102] Filters 1402 filter the recirculating nutrient media to remove particulate matter that may clog the fine misting nozzles. The filtration system comprises of both coarse filters and fine filters. Coarse filters filter out seed shells, decayed vegetation, pieces of roots etc. Examples of filters include particle strainers and basket filters. The fine filters, for example filtration pores in the range of 50 microns removes fine particulate matter, both organic and inorganic. Examples of organic matter include algae remnants, decayed matter etc. and inorganic includes fine rust particles, chemical deposits, nutrient deposits etc. In some cases, the filters may support colonization of beneficial bacteria and fungi that enhance plant growth and health.

[0103] The filtration unit can have inline filtration components as well as edge filtration modules located at the reservoir. The filtration unit may also be columnar with multiple layers of filtration starting from coarse to fine. There may be an activated carbon filtration layer that removes organic toxins, such as root exudates that may inhibit plant growth.

[0104] The reservoir is communication coupled to a nutrient dosing system. The nutrient dosing system comprises one or more of Macronutrient part A concentrate, Micronutrient part B concentrate, water with low total dissolved solids and other additives. Examples of inorganic fertilizers include Calcium nitrate, calcium Ammonium nitrate, Potassium nitrate, chelated Iron, Potassium phosphate, Magnesium sulfate, Borax, Sodium molybdate, Zinc sulfate, Copper sulfate, and Manganese sulfate.

[0105] The reservoir may also include UV-C lighting (short-wavelength, typically, 200 to 280 nanometers of the ultraviolet spectrum) to sterilize the nutrients. The UV-C lighting is preferably located at point where there is turbulent movement of the nutrients within the reservoir tank. UV-C reduces the chance of Algae outbreaks. Some UV-C systems come with inbuilt flow modules. Inline UV-C clairifiers may be used in the return line into the tank.

[0106] The reservoir may be temperature controlled using a chiller or heater. Exemplarily, electric resistance heaters or forced hot air heaters may be utilized for heating. Higher oxygenation levels are achieved at lower temperatures. The reservoir is aerated using air pumps, thereby avoiding staleness and maintaining high oxygen levels.

[0107] The reservoir may include a drain that enables reservoir fluid exchange, and the drain may be automated with a motor and associated controls.

[0108] The control system that controls and monitors all input parameters and output performance, comprises multiple modules such as Processing modules, Sensing modules, Communication modules and Actuation modules. Client user interfaces may be provided in one or more of the following: User Interface (UI) displays at site, mobile phone applications, or web apps accessible for personal computers.

[0109] Examples of processing modules comprises robust programmable logic controllers (PLC), and versatile Arduino, Raspberry Pi etc. In another embodiment, data is collected from the farm via sensors, and transmitted via transmission modules. Communication modules, i.e the transmission and receiver modules may comprise Ethernet based connections from the farm to the internet cloud or central server, or Wi-Fi based connections to the cloud or central server. The Wi-Fi system may comprise access points, transceivers, routers and gateways. In another embodiment, the communication modules may transmit data and receive instructions from distributed computing device networks.

[0110] Sensors include one or more of temperature sensors, humidity sensors, pressure sensors, flow sensors, carbon dioxide sensors, dissolved oxygen sensors, pH sensors, electrolytic conductivity sensors, light intensity sensors, light wavelength sensors, photosynthetically active radiation (PAR) sensors, imaging sensors, wind anemometers, level sensors. Discrete reservoirs supply pH up adjustment solution

[0111] 1607, pH down adjustment solution 1609, macronutrients 1607, micronutrients

[0112] 1608, and reverse osmosis filter water 1609.

[0113] For the purpose of conserving water, water condensate from the dehumidifier, air condi tioner / H VAC system may be collected and fed into the water supply tank post filtering or sterilization.

[0114] The software intelligence modules actuates and modulates the actuators. Intelligence and controls are applied for regular operations of various components as well as predictive maintenance of the components.

[0115] Alarms are controlled by the intelligence modules or at a local component level. For example, if the CO2 level exceeds 1500mm, the alarm is actuated by the input from a localized sensor at a local decision level, or is actuated by a central processing module. The alarm may be in the form of an online electronic message to the farm operator through SMS, MMS, Social Media Group message, etc. The alarm may also be in the form of one or more of lighted LEDs, flashing lights, warning audio announcements and sirens.

[0116] Actuators include solenoids, pumps 1401, linear motion actuators, light switches, pH dosing pumps, Macronutrient dosing pumps, micronutrient dosing pumps, cameras, air blowers, mixing pumps, aeration pumps etc.

[0117] The plant growing plant expansive structures can be tagged to enable Produce Traceability Initiative (PTI) label-compliant with electronic produce traceability. The PTI system allows tracing the source of the produce, and identifies the path of the system from production to shipping. Contamination risk and allergen tracking can also be accomplished using PTI.

[0118] The software intelligence optimally recommends seeding schedule for a given target harvest. It suggests the number of seeds to be planted, type of plant to be planted (if not already defined), setting the DAS (days after seeding for the harvest) etc. The software intelligence optimally manages the harvest queue.

[0119] The plant expansive structures may be RFID tagged or may be tagged with other types of electronic signatures. As the plant expansive structure moves across over time, a camera captures plant properties and inferences from image analytics may be tagged to the RFID and such information is stored either locally or in the cloud. Examples of image analytics include size of crop, chlorophyll pigmentation level, coloration, nutrient deficiency signalling coloration and patterns.

[0120] The aeroponic system disclosed herein can be used for multiple end grow applications, including but not limited to growing greens, baby greens, microgreens, strawberries, and even larger crops such as rice and corn. The systems can be implemented in a conventional greenhouse, vertical farm in a shed, research environments, home and hobby, and in preferably controlled environment agriculture environments.

[0121] The sprayed nutrients that flows over the roots and internal walls of the plant expansive structures are collected in rack drains, and the rack drains further feed into a main drain. The drains may be designed with a small sloping gradient, for example 1 cm every meter to facilitate water flow. The section of the rack drains may have a central U portion to facilitate water aggregation and faster drain through concentrated central flow. The nutrient solution from the main drain is either gravitationally fed to the reservoir tank, if the reservoir tank is at a lower level, or the nutrient solution in pumped upto a larger reservoir.

[0122] The apparatus described herein advantageously ensures that as plants grow, the spacing between the plants is adjustably increased to accommodate light focus and induce airflow circulation.

[0123] The foregoing examples have been provided merely for explanation and are in no way to be construed. While the vertical farm module has been described with reference to particular embodiments, it is understood that the words, which have been used herein, are words of description and illustration, rather than words of limitation. Furthermore, although the vertical farm module has been described herein with reference to particular means, materials, and embodiments, the vertical farm module is not intended to be limited to the particulars disclosed herein; rather, the design and functionality extends to all functionally equivalent structures and uses, such as are within the scope of the appended claims. While particular embodiments are disclosed, it will be understood by those skilled in the art, having the benefit of the teachings of this specification, that the vertical farm module disclosed herein is capable of modifications and other embodiments may be effected and changes may be made thereto, without departing from the scope and spirit of the vertical farm module disclosed herein.

Claims

CLAIMS1. An apparatus for plant cultivation, comprising: a plant growing structure, further comprising: plant receptacles that selectively allow roots to pass through, and wherein stem of the plant is above the level of said plant receptacle; linear members that support a plurality of said plant receptacles, wherein linearity of said members is along theX direction and the space between said linear members is increased over time in the Y direction; and expansive surface structures that join successive linear members, wherein said expansive surfaces enable expansion in said Y direction, and expansion of said surfaces increases the spacing between the linear members; two of said plant growing surfaces enclosing a rootzone; and aeroponic misters positioned in said rootzone to apply nutrient mist to said roots in the root zone.

2. The apparatus of claim 1 , wherein spacing between plants in the plant receptacles in neighbouring linear members is increased by expanding said expansive surface over time.

3. The apparatus of claim 1, wherein said expansive surface structures are guided through channels during expansion.

4. The apparatus of claim 1 , wherein rod guides are positioned in cavities within said expansive surface to controllably align the expansion of the expansive surface structure in the Y direction along the length of said rod.

5. The apparatus of claim 1, wherein the expansive surface is a multi-layered structure with a frontal plastic surface and a rear membrane.

6. The apparatus of claim 1 , wherein said expansive surface comprises a plurality of overlapping flaps that slide over each other to increase spacing between successive linear members.

7. The apparatus of claim 1, wherein said misters dynamically move along the Y direction.

8. The apparatus of claim 1, wherein said plant growing structure is substantially vertically oriented.

9. The apparatus of claim 1, wherein roots of multiple plants supported on said linear members interlock with one another to form an interlocked grid, whereby said interlocked grid of roots support the weight of the plants.

10. The apparatus of claim 1, further comprising light emitting diodes positioned in proximity to said plant growing surface.

11. The apparatus of claim 1 , wherein width of each of said linear members is expansive.

12. The apparatus of claim 1, wherein spacing between successive linear member is increased by applying motorized rotary grippers.

13. The apparatus of claim 1, wherein said receptacle is a membrane underneath a cutout in the linear member.

14. The apparatus of claim 1, wherein a plant receptacle is a net cup.

15. An apparatus for plant cultivation, comprising: a plant growing surface structure placed substantially horizontal further comprising: plant receptacles that selectively allow roots to pass through, and wherein stem of the plant is above the level of said plant receptacle; linear members that support a plurality of said plant receptacles, wherein linearity of said members is along theX direction; and expansive surfaces that joint a plurality of said linear members wherein said expansive surface enables expansion in the Y direction;container for nutrient solution positioned below said plant growing surface structure, wherein said container allows a substantial portion of said roots to be immersed in the nutrient solution.

16. The apparatus of claim 15, wherein said nutrient solution is flowing in said container.

17. The apparatus of claim 15, wherein said nutrient solution is substantially static within said container.

18. The apparatus of claim 15, wherein said plant growing surface is supported on a frame and wherein said frame floats over said nutrient solution.

19. An apparatus for growing plants, comprising: a plant growing surface further comprising: plant receptacles that selectively allow roots to pass through, and wherein stem of the plant is above the level of said plant receptacle; sectional multidimensional members that support a plurality of said plant receptacles, wherein space between said sectional multidimensional members is adjusted over time; and expansive surfaces that joint successive sectional multidimensional members, wherein said expansive surface enables expansion in a direction normal to the section, and expansion of said surfaces increases the spacing between the linear members;a lower nutrient solution collecting container, wherein a section of said container and said multidimensional member form a closed rootzone cavity; and aeroponic misters positioned in said rootzone cavity to apply nutrient mist to roots in the root zone.

20. The apparatus of claim 19, wherein successive sectional multidimensional members are joined by bellowed expansive surfaces.

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