Movable tub system for hydroponic methods for rapid cultivation of vegetable crops and method of using the same

Abstract

A system for hydroponically growing plants, comprising an upper seed tray (100, 1401) configured to sit on a bottom tab (200, 1445). The upper tray includes a plurality of openings for holding soil and germinating seeds in the soil. The plurality of openings have contours that allow the roots of the growing plant to extend into the bottom tab. The tab is configured to hold an aqueous mixture of water and nutrient solution for the growing plant and comprises a lip around the top perimeter and at least one aeration device (240) for causing turbulence in the aqueous mixture that comes into contact with the roots of the growing plant. A method for growing plants using such a container is also disclosed.

Description

Technical Field

[0001] This application claims the benefit of priority of U.S. Provisional Application No. 63 / 500,427, filed May 5, 2023, the entire disclosure of which is incorporated herein by reference.

[0002] (Field of the Invention) The present disclosure is in the field of agriculture. This application relates to a hydroponic method for rapidly growing vegetable crops. More particularly, this application relates to hydroponics, and in particular, to devices, systems, and methods for sterilizing growth trays and other materials used in hydroponics.

Background Art

[0003] Hydroponics and hydroponics, which is a part of it, is a rapidly growing system for growing organisms using an inorganic nutrient solution in water as a solvent. This is typically done inside a greenhouse or similar structure, providing a controlled environment. This can be done anywhere in the country and at any time of the year.

[0004] However, there is still substantial room for improvement in this technology. These improvements include the use of light, the design of the flats for holding the plants, and other improvements for removing harmful pests, bacteria, and fungi that can cause extensive damage in hydroponic operations.

[0005] Over the past 20 years, lettuce and basil production has increasingly shifted indoors from open fields to controlled environment agriculture (CEA) facilities such as greenhouses or warehouse-style vertical farms. The main reason for this trend is that lettuce and basil plants are well-suited to commercial hydroponic systems in today's market, except in terms of their growth habits and susceptibility to certain plant pathogens. Vertical farms, along with greenhouses that utilize sunlight using systems such as nutrient film technology (NFT) and deep water cultivation (DWC) systems, provide a space-efficient growing environment for skilled operators striving to make a margin on these crops in the premium market. Many additional hectares of production have been added in North America using growth systems such as Green Automation, Prim, and American Hydroponics for NFT systems, or Dry Hydroponics for DWC, Hydronov, or Viscon systems, and this trend is accelerating with climate change in the west. Spinach, on the other hand, is consumed in similar quantities in the US, but is hardly produced in CEA facilities. The main reason for this is that spinach is far more susceptible to root pathogens than other leafy green vegetables.

[0006] Once a root pathogen infection begins in a facility, it has the ability to infect all parts of the cultivation facility, including piping, trays, and equipment, and rapidly kill crops. Infection by the oomycete pathogen Pythium is a common cause of "wilt" in spinach and other crops, and this is the plant pathological name for having an early root infection that can hinder growth and even kill the plant shortly after germination. Even if the infection is not fatal to the plant, Pythium can significantly reduce yield and affect the shelf life of the harvested produce.

[0007] Pythium is a genus of oomycetes that has several strains of aggressive root pathogens of spinach, as well as other commonly cultivated hydroponically grown crops including cucumbers, lettuce, arugula, and cannabis. Pythium belongs to the Chromistae kingdom, not to the animals, plants, or fungi. Furthermore, it has a unique life cycle. Pythium is ubiquitous and can be introduced into hydroponic systems by seeds, growing media, pests, plants, and even wind.

[0008] Spinach is relatively susceptible to Pythium in fields, particularly in hydroponic systems, which provide an ideal environment for Pythium to proliferate if left unchecked. The vulnerability of spinach to Pythium in hydroponics is partly attributed to its production of particularly large amounts of root exudate, which can function as a chemotactic signal to swimming Pythium zoospores.

[0009] Significant research has been conducted on Pythium in hydroponic production, including spinach. Numerous solutions have been tested, and today there are countless products on the market claiming to reduce Pythium infection. Some of these solutions include supersaturation of nutrient solutions (NS) with nanobubbles or ozone, water filtration, and various methods of water disinfection, including ozone, oxidizing chemicals, and UV light. In field production, it is common to use systemic fungicides in irrigation water or as seed coatings. These fungicides are not labeled for hydroponic production. Other solutions tested include, to name a few, crop isolation to prevent pathogen backflow, beneficial microbial inoculants, aerial cultivation, and sonication / pasteurization of NS.

[0010] The disclosed tabs, systems, and methods for more effectively sterilizing trays are intended to overcome one or more of the problems described above and / or other problems of the prior art. [Overview of the project] [Means for solving the problem]

[0011] In accordance with the present disclosure, seed trays configured to contain and germinate plants are described. In some embodiments, the seed tray is configured to sit and float on an aqueous solution contained in a tub. The seed tray typically has a top and a bottom surface and comprises a plurality of openings that penetrate the top and bottom surfaces completely, the plurality of openings configured to hold soil and germinate seeds in the soil. In some embodiments, the plurality of openings comprises at least three regions, namely, an upper region having an upper opening large enough for a germinating plant to grow through the top surface and side walls having a tapered shape toward a narrower transition region; a transition region having side walls that tapered further toward a narrower end region; and an end region having straight side walls with a bottom opening for the plant roots to grow through the bottom surface and come into contact with the aqueous solution contained in the tub.

[0012] In some embodiments, the described seed tray is made of expanded polystyrene (EPS) and is configured to sit and float on an aqueous solution contained in a tub. In some embodiments, the seed tray has a top surface and a bottom surface having 400 to 450 elliptical openings that penetrate the top surface completely and terminate at a circular opening in the bottom surface, the elliptical openings being configured to hold soil and allow seeds to germinate in the soil. As described, the opening may include an upper region having at least three areas, namely an upper elliptical opening having a diameter of 18 to 20 mm as its longest axis, and tapered side walls having a taper angle of 2 to 4 degrees with respect to a vertical plane drawn through the center of the opening, the upper region having a concave bottom that leads to a transition region. The transition region typically has tapered side walls having a taper angle of 26 to 28 degrees with respect to a vertical plane drawn through the center of the opening that leads to a narrower end region. The end region typically has straight side walls with a rounded shape and a bottom opening having a diameter of 8-10 mm, allowing plant roots to extend downward through the bottom and come into contact with the aqueous solution contained in the tub.

[0013] In accordance with the present disclosure, a tab configured to hold an aqueous mixture of water and nutrient solution for growing plants is described. In some embodiments, the tab includes an upper section having a rectangular shape and including a lip around an inner circumference configured to receive a seed tray, and a lower rectangular section having a smaller rectangular shape than the upper section, the lower section comprising at least one mounting mechanism for removably attaching the tab to a frame and an aeration device configured to generate turbulence of the aqueous mixture placed in the tab. In some embodiments, the side walls are tapered from the upper section to the lower section, and the tapered side walls are configured to allow roots hanging down from the seed tray to grow toward the center of the tab.

[0014] In some embodiments, systems for hydroponically growing plants are disclosed, thereby growing plants in isolated batches comprising seed trays and tubs, as described herein. For example, the system comprises a seed tray configured to contain and germinate plants, the seed tray having a top and a bottom surface and a plurality of openings that penetrate the top and bottom surfaces completely. As previously stated, the plurality of openings are configured to hold soil and germinate seeds in the soil, and the plurality of openings include at least three regions, namely, an upper region having an upper opening large enough for germinating plants to grow through the top surface and side walls having a tapered shape toward a narrower transition region, a transition region having side walls that become further tapered toward a narrower end region, and an end region having straight side walls with a bottom opening for plant roots to grow through the bottom surface and come into contact with the aqueous solution contained in the tubs.

[0015] The system further comprises a tub configured to hold an aqueous mixture of water and nutrient solution for growing plants, the tub having a top having a rectangular shape and including a lip around an inner circumference configured to receive a seed tray, and a bottom closure having a smaller rectangular shape than the top, the bottom closure comprising at least one mounting mechanism for removably attaching the tub to a frame and an aeration device configured to generate turbulence of the aqueous mixture placed in the tub, and a side wall tapering from the top to the bottom closure, the tapered side wall configured to allow roots hanging down from the seed tray to grow toward the center of the tub.

[0016] A method for hydroponically growing plants is also described, consistent with the disclosed embodiments. In one embodiment, the method comprises planting a plurality of seeds in a growth medium, which is contained in a plurality of trays configured to float on top of a tub and provide crops with access to a water mixture as they float. As described above, the tub has a lip around its upper outer circumference and contains a mixture of water and nutrient solution. The method further comprises germinating the seeds to produce trays with germinated seeds and transporting the trays with germinated seeds to the top of the tub. The trays then float on top of the tub until the trays are allowed to descend closer to the tub as the water level in the tub decreases. As the water level decreases due to evaporation and is absorbed by the growing plants, the trays descend so that they sit on the lip of the tub, so that some of the roots are exposed to air and some of the roots remain in contact with the water and nutrient solution mixture. The method includes at least one aeration step that causes turbulence in the water mixture to strike the roots of the plants in contact with the water and nutrient solution mixture. [Brief explanation of the drawing]

[0017] The accompanying drawings incorporated herein and constituting part of this specification illustrate several disclosed embodiments and, together with the description, are useful in illustrating the disclosed embodiments. The details shown are, for illustrative purposes, for the illustrative description of embodiments of the present disclosure. The description made in conjunction with the drawings will make it clear to those skilled in the art how embodiments of the present disclosure may be carried out. [Figure 1A] This is a top view of a seed tray having an elliptical opening, consistent with several disclosed embodiments. [Figure 1B] This is a schematic cross-sectional view of the opening (section AA in Figure 1A), consistent with several disclosed embodiments. [Figure 1C] This is an exploded view of section B of Figure 1B, showing an opening, consistent with several disclosed embodiments. [Figure 2A] This is a top view of a tab used in a fully isolated moving tab system, consistent with several disclosed embodiments. [Figure 2B] Figure 2A shows a side view and an end view of the tab, respectively. [Figure 2C] Figure 2A shows a side view and an end view of the tab, respectively. [Figure 3A] These are a top perspective view and a bottom perspective view of the tab, respectively, consistent with several disclosed embodiments. [Figure 3B] These are a top perspective view and a bottom perspective view of the tab, respectively, consistent with several disclosed embodiments. [Figure 4A] A side perspective view of a tab having an inlet section for an air bubbler, highlighted as detail A, consistent with several disclosed embodiments. [Figure 4B] This is an exploded view of detail A in Figure 4A. [Figure 5A] A side perspective view of a tab having at least one upper corner including a structure to prevent the seed tray from floating away from the tab when the tab is filled with an aqueous mixture, consistent with several disclosed embodiments, is highlighted as Detail B. [Figure 5B] This is an exploded view of detail B in Figure 5A. [Figure 6A] An end perspective view of an empty tab with a seed tray seated on the upper lip of the tab, consistent with some of the disclosed embodiments. [Figure 6B] A cross-sectional view (section A-A of FIG. 6A) showing how the seed tray seats on the upper lip of an empty tab. [Figure 7A] An end perspective view of a filled tab with a seed tray seated on the upper lip of the tab, consistent with some of the disclosed embodiments. [Figure 7B] A cross-sectional view (section A-A of FIG. 7A) showing how the seed tray floats above the upper lip of the tab for the aqueous nutrient solution within the filled tab. [Figure 8A] A side perspective view of an empty tab with a seed tray seated on the upper lip of the tab, consistent with some of the disclosed embodiments. [Figure 8B] A side perspective view showing how the seed tray floats above the upper lip of the tab for the aqueous nutrient solution within the filled tab, consistent with some of the disclosed embodiments. [Figure 8C] An exploded view of the upper corner of the tab shown in detail A of FIG. 8B, consistent with some of the disclosed embodiments. [Figure 9A] A schematic diagram showing a top perspective view of a seed tray (FIG. 9A), a side perspective view of the seed tray at the upper part of the tab (FIG. 9B), and a bottom perspective view of the tab (FIG. 9C), all on a rail system, consistent with some of the disclosed embodiments. [Figure 9B] A schematic diagram showing a top perspective view of a seed tray (FIG. 9A), a side perspective view of the seed tray at the upper part of the tab (FIG. 9B), and a bottom perspective view of the tab (FIG. 9C), all on a rail system, consistent with some of the disclosed embodiments. [Figure 9C] A schematic diagram showing a top perspective view of a seed tray (FIG. 9A), a side perspective view of the seed tray at the upper part of the tab (FIG. 9B), and a bottom perspective view of the tab (FIG. 9C), all on a rail system, consistent with some of the disclosed embodiments. [Figure 10A] Figure 10A illustrates a rail system for moving a plurality of fully isolated movable tabs according to one embodiment consistent with the present disclosure. Figure 10B illustrates a side perspective view of one of the fully isolated movable tabs shown in Figure 10A. [Figure 11A] A rail system for moving multiple fully isolated movable tabs according to one embodiment consistent with the present disclosure is illustrated. Figure 10B shows a side perspective view of one fully isolated movable tab shown in Figure 10A. [Figure 11B] No explanation provided. [Figure 11C] No explanation provided. [Figure 12] This is a flowchart of a method for growing plants using fully isolated moving tabs, consistent with several disclosed embodiments. [Figure 13] This is a flowchart of a conventional method for growing plants in a pond system. [Figure 14] Figure 14A shows a tab system according to one embodiment consistent with the present disclosure, with nascent plants and an upper raft floating above the water below. Figure 14B shows a tab according to Figure 14A, where larger plants cause the upper raft to descend to the top lid of the tab. Figure 14C is a side perspective view of Figures 14A and 14B, with a transparent tab to show the root system of plants growing up to the upper water level within the tab. [Modes for carrying out the invention]

[0018] The following disclosure generally describes components, systems, and methods for significantly reducing infection by Pythium and other root pathogens in deepwater cultivation (DWC) spinach production. In one embodiment, a container for hydroponically growing plants is described, comprising a floating upper tray configured to sit on a bottom tub containing water and nutrients. The upper tray described herein comprises a plurality of fully perforated openings for holding soil and germinating seeds and water in the soil, the plurality of openings having contours that allow the roots of the growing plant to extend into the bottom tub when the roots seek water and nutrients. In one embodiment, the tub is configured to hold a mixture of water and nutrient solution for the growing plant, and the tub comprises a lip around the top perimeter and at least one aeration device for causing turbulence in the water mixture that comes into contact with the roots of the growing plant.

[0019] The upper tray and tub are configured to allow the upper tray to float in the water in the tub for several days while the young roots of the germinating seeds need to be fully submerged in water. As the plants and evaporation consume the water, the floating tray sinks into the tub until it sits on the ledge. Once seated on the ledge, the tray is positioned to allow for the commercial harvesting of the plants with a typical cutting system that cuts the plants like a hedge trimmer. As the water level continues to drop, the roots continue to grow in length in search of water and nutrients, exposing the upper layers of the roots to air. The roots in contact with the water are exposed to the very vigorous flow of bubbles generated by the bubbling system. While success has been achieved by maintaining the water level in the tub, this is not essential and does not offer the benefit of allowing the water level to drop and the roots to be exposed to air.

[0020] In particular, the disclosed tabs, systems, and methods, by utilizing a lower water level, allow the roots of growing plants to continue growing in water, which leads to several advantages. These advantages include (a) keeping bursting bubbles and turbulence closer to the root tips as they continue to grow, and (b) introducing voids that allow mature roots to obtain nutrients and water from their tips while still having maximum access to fresh air and oxygen and reduced exposure to pathogens, resulting in less weight to move, less scattering at harvest due to the lower water level, less water to filter after harvesting the trays, and a drier substrate that reduces the growth of pests, plant, and human pathogens near the plant stems.

[0021] In some embodiments, the tubs are relatively small, typically less than 20 square feet, or even less than 15 square feet, and the water and nutrients within the tub are completely isolated from other tubs and water treatment systems to prevent cross-contamination of pathogens. The tubs can be easily and completely sterilized as needed, at the same frequency as each growth cycle. The tubs are designed to be mechanized and mechanically assembled in systems that can be operated efficiently on a large scale, such as a 10-acre greenhouse.

[0022] A method for hydroponically growing plants is also described, consistent with the disclosed embodiments. In one embodiment, the method comprises planting a plurality of seeds in a growth medium, the growth medium containing a plurality of trays configured to float on top of a tub and provide crops with access to a water mixture as they float. As described above, the tub has a lip around its upper outer circumference and contains a mixture of water and nutrient solution. The method further comprises germinating the seeds to produce trays with germinated seeds and transporting the trays with germinated seeds to the top of the tub. The trays then float on top of the tub until the trays are allowed to descend closer to the tub as the water level in the tub decreases. As the water level decreases and is absorbed by growing plants, the trays descend so as to sit on the lip of the tub, so that some of the roots are exposed to air and some of the roots remain in contact with the water and nutrient solution mixture. The method includes at least one aeration step that causes turbulence in the water mixture to strike the roots of the plants in contact with the water and nutrient solution mixture.

[0023] It is described that each tray is seated in an isolated tub of nutrient solution (NS), which is typically less than 20 square feet in size, e.g., 15 square feet, but can be combined with other tubs to make a large greenhouse (e.g., 10 acres) fully mechanized and commercially efficient. In one embodiment, a method is described herein for growing spinach, other leafy green plants, or vegetables (all referred to herein as “plants”) in very small batches, where the water source is isolated from other batches, and as a result, diseases cannot spread from other plants to the roots.

[0024] (1) Isolation prevents water movement between tabs and reduces the movement of plant pathogens. (2) It may provide several other plant health benefits in addition to the advantages of labor saving and food safety, and it keeps the plant roots constantly covered in a rising cascade of foam that washes away exudate and prevents Pythium spore germination, while rapidly agitating the plant roots using a very large aeration device and high airflow capacity.

[0025] In some embodiments, the disclosed tabs, systems, and methods for more effectively sterilizing trays are intended to overcome one or more of the problems described above and / or other problems of the prior art. In particular, the disclosed tabs, systems, and methods, by utilizing a lower water level, allow the roots of growing plants to continue growing in water, which leads to several advantages. In some embodiments, these advantages include (a) keeping bursting bubbles and turbulence closer to the root tips as they continue to grow, and (b) introducing voids that allow mature roots to obtain nutrients and water from their tips while still having maximum access to fresh air and oxygen, resulting in less weight to move, less scattering at harvest due to the lower water level, less water to filter after harvesting the trays, and a drier substrate that reduces the growth of pests, plant and human pathogens near the plant stems.

[0026] This concept of reducing infection by Pythium and other root pathogens through active root bubbling was developed through understanding how Pythium infection occurs at a microbiological level under humid conditions. It has been found that germ spores of Pythium species release infectious zoospores that attack plant roots. These motile zoospores are attracted to the exudate of young plant roots. Spinach produces an unusually large amount of this exudate, which is part of the reason why it is particularly vulnerable to infection. To address this problem, this disclosure provides strong bubbling in the disclosed system. This mechanism helps to wash away root exudate from the root surface, while their constant movement prevents motile Pythium zoospores from attaching to the root tips and germinating. By preventing infection by root pathogens, the vigor and yield of hydroponically grown spinach are substantially increased, enabling significantly higher yields (kg / m2 / year) than those provided by other growth systems with improved consistency.

[0027] In one embodiment, the fully isolated mobile tub spinach system described herein utilizes a very large aeration capacity. For example, in one embodiment of the present disclosure, the spinach system disclosed herein targets an airflow of 25 L / min through an 8-inch diffuser in a 20-gallon reservoir. Various diffusers may be used with the understanding that they have a high capacity for airflow. In some embodiments, the disclosed method includes pressurizing a large amount of dissolved oxygen to froth the nutrient solution specific to the green leafy vegetables being grown.

[0028] In one embodiment, the aeration rate used in the disclosed process is greater than 3 L / min per 20 gallons, and the dissolved oxygen directly affects the roots of each growing plant. This is not possible with current systems that use large growing ponds. In some embodiments, it has been found that bubbling NS in the amounts and locations described herein (immediately near the root surface) induces vigorous aeration and prevents infection by root pathogens. Thus, the disclosed systems and methods have shown increased yields of harvested plants. High-intensity bubbling in the disclosed mobile tub system has been shown to be effective in mitigating and preventing infection by Pythium species and other root pathogens in hydroponically grown plants such as spinach.

[0029] In several embodiments, it has been demonstrated that spinach can grow healthily even when Pythium broodstock is present in the NS, as the disclosed tab spinach system provides vigorous aeration. In one embodiment, it was shown that it is possible to grow several cycles of high-yielding, healthy crops with the same water without draining it, simply by changing the water used by the plants and keeping the reservoir full.

[0030] More generally, in some embodiments, the fully isolated mobile tub system (MTS) and the method of using it according to the present disclosure begin with seeds sown in a described seed tray. The sowing depth, water content of the soilless mixture, germination temperature / duration, and soil compaction are controlled so that (a) more than 95% of the seed coat is removed from the seedlings during germination, (b) uniform emergence of the seedlings, and (c) the roots protrude from the bottom of the tray before being planted in the tub system. This ensures that the root tips, which are the most vulnerable part of the seedlings, are immediately immersed in a bubbling cascade and do not spend time in waterlogged soil that can rapidly infect. The inventors have found that the success of the system begins with the seed tray.

[0031] In some embodiments, seed trays configured to contain and germinate plants are described. The seed trays described herein are further configured to sit on and float on an aqueous solution contained in a tab, and the seed tray has a top surface and a bottom surface, with a plurality of openings that completely penetrate the top surface and the bottom surface. Figure 1A shows the top surface of a seed tray 100 having a plurality of openings 110. In some embodiments, the openings 110 have an elliptical shape.

[0032] In some embodiments, the seed tray has a rectangular shape with a width of 450-550 mm, for example, 475-500 mm. In some embodiments, the seed tray has a length of 700-800 mm, for example, 725-775 mm. In some embodiments, the seed tray has a thickness of 50-60 mm, for example, 52-58 mm. In some embodiments, the seed tray has 400-450 openings, for example, 410-430 openings, or even 415-420 openings, and can grow 500-1200 plants, for example, 600-800 plants.

[0033] In some embodiments, the multiple openings 110 are configured to hold soil and allow seeds to germinate in the soil. In some embodiments, each opening 110 has a volume in the range of 8 to 10 mL, such as 9 mL.

[0034] Referring to Figures 1B and 1C, in some embodiments, the multiple openings 110 include an upper region 120 having at least three areas: an upper opening 118 large enough for germinating plants to grow through the upper surface, and side walls 121 having a tapered shape to a narrower transition region 122. In some embodiments, the side walls of the upper region 121 have a taper angle of 2 to 4 degrees, for example 3 degrees, with respect to a vertical plane drawn through the center of the opening. In some embodiments, the upper region 120 has a concave bottom 123 leading to the transition region.

[0035] The multiple openings 110 further include a second region which is a transition region having side walls that become further tapered toward a narrower end region 122. In some embodiments, the side walls of the transition region have a taper angle of 26 to 28 degrees with respect to a vertical plane drawn through the center of the opening.

[0036] The multiple openings 110 further include a third region which is an end region having a straight side wall with a bottom opening for plant roots to grow through the bottom and come into contact with the aqueous solution contained in the tab 124.

[0037] In some embodiments, the multiple openings have an elliptical shape 118 on the upper surface of the seed tray 100 and a rounded shape on the bottom surface 126. In some embodiments, the elliptical shape on the upper surface 118 of the seed tray 100 has a diameter of 18-20 mm, for example, 18.5-19.5 mm, as its longest axis. In some embodiments, the rounded shape 126 on the bottom surface of the seed tray 100 has a diameter of 8-10 mm.

[0038] In some embodiments, the top surface of the seed tray 100 includes a border around the edge without the opening 105. In some embodiments, the border 105 has a width at least the same as the longest axis of the elliptical opening 118.

[0039] In some embodiments, the top surface of the seed tray 100 includes a plurality of tabs 107 positioned on a boundary 105. The plurality of tabs 107 are configured to allow seed trays to be stacked on top of each other, and the bottom surface of the upper seed tray stacked on top of the plurality of tabs does not come into contact with the top surface of the bottom seed tray.

[0040] In some embodiments, seed trays configured to contain and germinate plants are described. In some embodiments, the seed tray comprises expanded polystyrene (EPS) and is configured to sit and float on an aqueous solution contained in a tub.

[0041] In some embodiments, the seed tray has a top surface and a bottom surface having 400 to 450 elliptical openings that penetrate the top surface completely and terminate at a circular opening in the bottom surface. In some embodiments, the elliptical openings are configured to hold soil and allow seeds to germinate in the soil and comprise at least three regions, namely an upper region, a transitional region, and a bottom region.

[0042] In some embodiments, the upper region has an elliptical opening at the top having a diameter of 18-20 mm along its longest axis, and tapered side walls having a taper angle of 2-4 degrees with respect to a vertical plane drawn through the center of the opening, and the upper region has a concave bottom that connects to the transition region.

[0043] In some embodiments, the transition region has tapered sidewalls with a taper angle of 26 to 28 degrees with respect to a vertical plane drawn through the center of the opening that leads to a narrower end region.

[0044] In some embodiments, the end region has straight side walls with a rounded shape and a bottom opening having a diameter of 8-10 mm, which allows plant roots to extend downward through the bottom and come into contact with the aqueous solution contained in the tub.

[0045] Referring to Figures 2A-2C and 3A-3B, several embodiments describe a tab 200 configured to hold an aqueous mixture of water and nutrient solution for growing plants, with a seed tray floating above it and seated within it. In some embodiments, the tab includes a top having a rectangular shape similar to or identical to that of the seed tray, and a lip around an inner circumference configured to receive the seed tray 210.

[0046] In some embodiments, the tab includes a bottom closure 220 having a rectangular shape smaller in size than the top 210. The bottom closure 220 may include at least one mounting mechanism 230 for removably attaching the tab 200 to a frame. Referring to Figures 4A and 4B, the tab includes the bottom closure 220 and an aeration device 240 configured to generate turbulence in the aqueous mixture placed inside the tab 200.

[0047] In some embodiments, the aeration device 240 generates more than 3 L / min of aeration per 20 gallons. For example, in some embodiments, the aeration device generates 25 L / min of aeration through an 8-inch aeration device in a 20-gallon reservoir.

[0048] In some embodiments, the side walls of the tab are tapered 225 from the top 210 to the bottom closure 220, and the tapered side walls 225 are configured to allow roots hanging down from the seed tray to grow toward the center of the tab and be influenced by the turbulence of the aqueous mixture placed inside the tab 200. In some embodiments, the majority of the roots hanging down from the seed tray that grow toward the center of the tab come into contact with a large amount of aeration.

[0049] In some embodiments, the lip around the inner circumference of the upper part 210 is configured to receive a seed tray which may have a thickness of 50 to 60 mm.

[0050] In some embodiments, the lip around the inner circumference of the upper part 210 includes a ledge 255 for resting the seed tray when the amount of aqueous mixture in the tub is insufficient to suspend the seed tray.

[0051] Referring to Figures 5A and 5B, in some embodiments, the lip around the top 210 includes a structure 245 at at least one corner of the top for maintaining the seed tray from floating away from the tab when the tab is filled with the aqueous mixture. The structure 245 may further include an opening for removing excess aqueous mixture from the tab.

[0052] Figures 6A and 6B are cross-sectional views of a seed tray 610 seated on the internal lip 615 of an unfilled tab 620 (indicated by a downward arrow 618). Figure 6A is a side perspective view 600, and Figure 6B is a cross-sectional perspective view 601 through the plane AA shown in Figure 6A.

[0053] Figures 6A and 6B, and 7A and 7B show the position of the floating seeds 710 when tab 720 is filled with a nutrient-rich solution, in contrast to the unfilled tab 620. Figure 7A is a side perspective view 700, and Figure 7B is a cross-sectional view 701 (cross-section AA of Figure 7A), showing how the seed tray 710 floats above the top lip of the tab (indicated by an upward arrow 719) due to the aqueous nutrient solution in the filled tab.

[0054] Figures 8A and 8B are similar to Figures 6B and 7B, respectively. In particular, Figure 8A is a cross-sectional view of an unfilled tab 820, with the seed tray 810 seated on the upper lip 815 of the tab 820, similar to Figure 6B. Figure 8B is a side perspective view showing how the seed tray floats above the upper lip of the tab for the aqueous nutrient solution contained in the filled tab, consistent with several disclosed embodiments. In particular, it is a cross-sectional view of a filled tab 820, with the seed tray 810 floating above the upper lip 815 of the tab 820, as indicated by arrow 819, similar to Figure 7B.

[0055] Figure 8C is an exploded view of the upper corner of the tab shown in detail A of Figure 8B, which is described as an overflow feature to allow access to the water and nutrient-rich solution exiting tab 820.

[0056] Referring to Figures 9A, 9B, and 9C, different perspective views of the rail system are shown, consistent with several disclosed embodiments. For example, Figure 9A shows a top perspective view of seed trays 910 arranged side by side. Figure 9B shows a side perspective view with the seed trays 910 on top of the tabs 920. Finally, Figure 9C shows a bottom perspective view of the tabs 920 connected to the rails 930 by at least one mounting mechanism 940.

[0057] Figure 10A shows different perspective views of the rail system shown in Figures 9A–9C for moving a plurality of fully isolated movable tabs according to one embodiment consistent with the present disclosure. For example, Figure 10A shows a tab 1010 detachably attached to a member 1050 perpendicular to a rail member 1060. Figure 10B further illustrates a side perspective view of one of the fully isolated movable tabs shown in Figure 10A.

[0058] Figure 11A illustrates a rail system for moving a plurality of fully isolated movable tabs according to one embodiment consistent with the present disclosure. Figure 11A shows a side perspective view of the rail system for moving a plurality of fully isolated movable tabs 1100 on rail members 1120 and rollers 1130 and 1140, which enable the plurality of fully isolated movable tabs 1100 to be moved in multiple directions. Figure 11B is an exploded view of a connecting member 1150 which detachably secures the tabs 1110 to rail member 1120, which further includes rollers 1130. Figure 11C is an exploded view of roller member 1140. In some embodiments, the combination of rollers 1130 and 1140 enables the tabs to be moved in the X, Y directions, such as 90 degrees from each other.

[0059] A hydroponic system 1200 is described in accordance with this disclosure and with reference to Figure 12. In some embodiments, the hydroponic growth system includes a method of growing plants without soil using a nutrient-rich aqueous solution to deliver essential minerals and nutrients directly to the plant roots.

[0060] In some embodiments, the system is based on a process that typically begins with a clean and sterilized seed tray 1205 used for sowing. In some embodiments, the process of planting seeds or seedlings in step (A) can be automated using a seeder. Non-limiting embodiments of seed trays that can be used in the disclosed system are fully illustrated and described by Figures 1A–1C.

[0061] As described herein, seeds are typically sown in trays, flats, or seedbeds filled with a growing medium such as nutrient-rich soil. In some embodiments, seed trays for hydroponics may be made from durable, food-safe materials such as plastic or Styrofoam®. These materials are lightweight, easy to clean, and resistant to water and nutrient solutions. In some embodiments, seed trays are available in a variety of sizes and shapes, typically rectangular or square.

[0062] In some embodiments, as shown in Figures 1A–1C, the seed tray is divided into multiple compartments or cells, each capable of holding one or more seeds. These compartments help keep the seeds organized and prevent them from becoming tangled or competing for resources as they grow. In some embodiments, the seed tray is made from Styrofoam® or a material that can float on water or liquid used in hydroponic systems. The tray may be made from other materials such as plastics, organic composites, metals, and / or combinations thereof, as long as the material can float on a liquid-filled pond. In some embodiments, the seed tray may be, for example, an expanded polystyrene (EPS) foam plug tray or a flat. In some embodiments, a separate plastic jacket may be first inserted into the cells of the flat or tray, and then filled with a growth medium.

[0063] The size and configuration of a particular tray will vary depending on the type of crop being grown in the tray. For smaller plants, the cells will naturally be closer together, while for larger plants, the cells will be further apart. The following details of tray size are for kale crops or cultivars and are provided for illustrative purposes only. Other crops or cultivars will require different configuration sizes, but such modifications will not deviate from the concept of the invention, so that those skilled in the art will understand the concept of the invention and understand that trays can be adapted to specific crops without departing from the concept of the invention. In the example tray, the vertical axis on the minor or horizontal axis of the tray may be 12 1 / 2 inches to 25 1 / 2 inches and the thickness 2 17 / 64 inches. Each elliptical cell has a major axis at the top of the elliptical cell of 13 / 16 inches and a minor axis at the top of the ellipse of the cell of 11 / 16 inches. The tray can be made from expanded polystyrene or other similar lightweight, moldable, buoyant material. In the prior art, a floating tray was simply a matrix of cells covering the entire tray.

[0064] After sowing, the seeds are germinated in step (B) by placing the seed trays 1210 in the germination chamber. In some embodiments, the seed trays are stacked inside the germination chamber with two or more trays stacked on top of each other. To allow the trays to be stacked without suppressing or damaging the germinated plants, each tray includes at least one projection configured to provide space between the trays when stacked. In some embodiments, each tray includes a plurality of projections arranged around the edges of the seed tray, such as the corners of the tray.

[0065] Also known as a seed germination chamber or seedling incubator, the germination chamber used in process B is a special environment designed to promote seed germination and early seedling growth in hydroponic and traditional agricultural systems. It provides controlled conditions such as temperature, humidity, and sometimes light to optimize the germination process.

[0066] In some embodiments, the germination chamber maintains a consistent, controlled temperature, typically within the optimal range of 70–85°F (21–29°C) for seed germination. This temperature control helps to increase the rate of the germination process and ensure uniformity. The germination chamber may also maintain high humidity to prevent the seeds from drying out. This is often achieved using a misting system or humidifier.

[0067] In some embodiments, the germination chamber may be equipped with an adjustable lighting system to provide a consistent light source for the seedlings. Additionally or alternatively, the germination chamber may be located in a separate growing area with appropriate lighting after germination has occurred.

[0068] Proper air circulation prevents moisture buildup and ensures that the air around the seeds remains fresh and oxygen-rich. This may include a small fan or ventilation system.

[0069] After the germination process (B) is completed and a growth tray containing germinated seedlings is obtained, the tray 1205 is removed from the germination chamber 1215 and floated on the tab 1220. In step (C), according to some embodiments, the tab is cleaned and disinfected and filled with a nutrient-rich solution.

[0070] In some embodiments, the tubs 1220 having germination seedling trays 1215 may be placed on a table (step D). In some embodiments, the table includes one or more ports for receiving compressed air. In some embodiments, one or more ports may be connected directly to the bottom of the tub to ensure turbulence that strikes the roots of growing plants. In some embodiments, one or more ports are connected to a hub that allows compressed air to be distributed to multiple tubs simultaneously.

[0071] In some embodiments, as shown in step D, the table may be movable so as to allow it to be repositioned in or around a greenhouse. For example, in one embodiment, the table may be moved into a greenhouse and, for example, rolled around, and in the greenhouse, the plants grow to maturity in 11-16 days, for example 12-15 days, or 12-14 days, in the case of spinach. Step (D) In ​​some embodiments, the tab itself may be configured to move independently of other tabs.

[0072] To support seedling growth and promote vegetative growth, lighting and environmental conditions can be adjusted, which typically involves more lighting per day. Furthermore, nutrient solutions can be monitored and adjusted to provide essential macronutrients and micronutrients.

[0073] Once the plants have grown to maturity, they are ready for harvest (1225). Process (E). In some embodiments, harvesting is carried out using harvesters. These machines are particularly valuable in large-scale commercial hydroponic operations where efficiency, speed, and precision are important. In some embodiments, the harvester is equipped with a mechanism for handling the harvested crop efficiently and gently. These mechanisms may include a conveyor belt, a robotic arm, or a cutting blade, depending on the crop. One of the main advantages of the harvester is its ability to significantly increase the speed and efficiency of the harvesting process. They allow for the harvesting of large quantities of crop in a short time, reducing labor costs and improving productivity. Another advantage of the disclosed system is its ability to move the entire table through the harvester without the need to remove the plants from the tubs or the tubs from the table, along with the mature plants contained in the disclosed tubs. This makes the harvesting process efficient and economical.

[0074] After harvesting, the harvested plants are moved to a cold storage facility 1230. The seed trays are then removed from the tubs. Step F. The remaining nutrient solution is removed from the tubs. Step J. In some embodiments, the used nutrient solution may be filtered and reused. For example, in some embodiments, the nutrient solution is filtered using basic mechanical filtration, such as using a 5-micron filter to remove spores. In some embodiments, the filtered nutrient solution may then be further purified using one or more methods, including chemical sterilization, ozone treatment, or UV irradiation.

[0075] In some embodiments, both the tabs and seed trays are thoroughly cleaned and sterilized in preparation for the next growth cycle. For example, once the remaining NS is discarded for filtering (step J), the soiled tabs 1235 are cleaned and disinfected, as well as the table and any other elements used during the growth cycle. Step K results in the cleaned and disinfected tabs 1240 being filled with fresh NS and reused. Step L.

[0076] Similarly, after separating the trays from the tabs after harvest (step F), the remaining stems and roots are cut from the growing substrate 1250, leaving the soiled tray 1245, which is washed and disinfected. In some embodiments, the washing step may include washing the tray with water (and / or a desired solution) and washing the tray with a chemical cleaning agent. Step (G) In one embodiment, a washing tray table filled with a chemical cleaning agent is described. The trays may be immersed in the chemical cleaning agent. The trays may be washed first with water (or another solution) before chemical cleaning (i.e., washing the trays with a chemical cleaning agent). After the trays have been used at least once, dirt, debris, film, or other deposits may accumulate on the trays. In this context, “on the tray” means on any part of the tray, including, but not limited to, the top, bottom, sides, and inside and outside of the tray cells. Examples of accumulated material may include excess plant matter, growth medium, algal growth, mucus, residue, or other films or substances that may accumulate on the tray while in use in a hydroponic system. The purpose of this cleaning is to remove any dirt, debris, films, or other material that has accumulated on the tray. This may be done, for example, with water alone or with a water and soap solution. Removing the accumulated material allows for more effective sterilization of the tray in subsequent processes. The tray may be power-washed, rinsed, impregnated, immersed, sprayed, and / or scrubbed. In one embodiment, the tray is power-washed using a high-power sprayer.

[0077] In some embodiments, after rinsing with water, the trays are then cleaned using a chemical cleaner. In this step, the trays are immersed, coated, filled, covered, rinsed, and / or surrounded by the chemical cleaner. The chemical cleaner may be in liquid, semi-liquid, vaporized, or gaseous state. Depending on the type of tray and the substance to be removed from the tray, the chemical cleaner may include, for example, soap, alcohol, detergent, acid, or base. Further examples may include hydrogen peroxide, bleach (sodium hypochlorite), quaternary ammonium solution, low-foaming alkaline detergent, peracetic acid, or a combination thereof. The chemical cleaner may be diluted as necessary to ensure the safety of people, plants, and the trays. For example, the chemical cleaner should not be so corrosive as to dissolve or damage the tray, rendering it unusable in the hydroponic system.

[0078] In some embodiments, low-foaming alkaline detergents such as Master MHW are beneficial because they are formulated to emulsify dirt, oil, and organic substances such as biofilms without generating excess foam from the high agitation of automatic washing machines. Quaternary ammonium compounds such as Kleengrow can also be used to clean trays alone or in combination with Master MHW, as they provide long-lasting and effective broad-spectrum microbial control. The mode of action of quaternary ammonium compounds is membrane disruption by denaturing proteins, which makes the compounds ideal for removing biofilms for long-term microbial control. Positively charged chemicals attack negatively charged pests found on the trays. In contrast to other chemicals, this performance is not impaired by pH changes or exposure to light or temperatures used to maintain plant growth. Quaternary ammonium compounds are very stable, so the use of Kleengrow leaves a residue on all breeding trays for about 30 days. The use of Sanidate 5.0, a hydrogen peroxide and peracetic acid-based disinfectant, can also be used to clean trays and remove biofilms. However, this solution is far less stable compared to the use of quaternary ammonium compound disinfectants, and the cleaning solution deteriorates rapidly.

[0079] In some embodiments, the seed trays are first rinsed with a chemical cleaner and then immersed in a bath of the chemical cleaner. In one example, they are rinsed with a quaternary ammonium disinfectant spray and then immersed in a high-concentration quaternary ammonium solution for less than one minute. The trays may be immersed in a high-concentration quaternary ammonium solution or other chemical cleaner for less than 10 minutes. The length of time depends on the type of cleaner used, the concentration of the cleaner, and the composition of the tray. If the cleaner is particularly gentle on the trays (meaning it does not damage them), the trays may be left in the cleaner for a longer period (e.g., overnight).

[0080] In another embodiment, the trays are cleaned with Master MHW, a low-foaming alkaline detergent, and Kleengrow, a quaternary ammonium compound solution. Master MHW may be diluted to about 1 to 3 ounces per gallon of water. Kleengrow may be diluted to about 0.25 to 0.50 ounces per gallon of water, which corresponds to about 150 to 300 ppm of the quaternary ammonium compound. Preferably, tray washing uses a solution of about 200 ppm of the quaternary ammonium compound. Concentrations higher than about 300 ppm are not considered appropriate for treating trays if the disinfectant solution is not rinsed off before planting. Those higher than 300 ppm may leave excess residue that negatively affects growth. Concentrations below about 150 ppm are not effective in disrupting bacterial biofilms.

[0081] The trays may optionally be rinsed with water after chemical cleaning to ensure that no harmful chemicals affect the growth system and plants. The water may be filtered, sterilized, deuterated, distilled, and / or tap water.

[0082] In some embodiments, the washed trays are completely dried until the moisture content is nearly zero before being reused for the next growth cycle (1255). In some embodiments, the total moisture content may be less than about 5%, e.g., less than 4%, 3%, 2%, or even less than 1%. The moisture content may be determined using a moisture reader, spectroscopy, or by comparing the weight of the trays before and after washing. When determining the moisture content by weight, the trays may be measured individually or in groups. The trays may also be randomly sampled and tested.

[0083] The desired moisture content can also be determined and evaluated by a physical inspection of the tray, such as whether it feels dry to the touch or whether it has water droplets or pools. A tray that feels dry to the touch or has no water droplets or pools has a moisture content that is high enough to kill pathogens in the dielectric process, but low enough to prevent damage to the tray.

[0084] The features and advantages of the tabs, growth methods, and systems used for growth disclosed herein are illustrated by the following examples, which should not be construed as limiting the scope of this disclosure in any way.

[0085] In contrast to the mobile tub system illustrated in Figure 12, which is consistent with some embodiments of the invention, Figure 13 is a flow chart of a pond system 1300 for hydroponic plant growth. The pond system is also based on a process that begins with cleaned and sterilized seed trays 1305 used in a sowing process (A). In some embodiments, a sowing machine can be used to automate the process of planting seeds or seedlings in process (A).

[0086] As described herein, seeds are typically sown in trays, flats, or seedbeds filled with a growing medium such as nutrient-rich soil. In some embodiments, seed trays for hydroponics may be made from durable, food-safe materials such as plastic or Styrofoam®. These materials are lightweight, easy to clean, and resistant to water and nutrient solutions. In some embodiments, seed trays are available in a variety of sizes and shapes, typically rectangular or square.

[0087] After sowing, the seeds are germinated in step (B) by placing the seed tray 1310 in the germination chamber, as described above.

[0088] After the germination process (B) is complete and growth trays containing germinated seedlings are obtained, tray 1315 is removed from the germination chamber and floated in pond 1320 to which water and nutrients have been added. The germinated seedling trays are floated in these ponds for 12 to 30 days, depending on the plant.

[0089] Once the plants have grown to maturity, they are ready for harvesting 1325 and process E. In some embodiments, harvesting is carried out using a harvesting machine. After harvesting 1230, the harvested plants are moved to a cold storage facility 1235. After harvesting, the remaining stems and roots are cut from the growing medium, leaving a soiled tray 1245, which is then washed, disinfected, dried to the desired moisture level 1250, and reused for the next growth cycle.

[0090] Figure 14 shows the case where the upper raft 1401 floats above nutrient-rich water as the plant grows. Typically, during the first few days when the plant 1405 and roots 1410 are young, they need to be submerged in nutrient-rich water. As the water level 1420 drops due to use by the plant and evaporation, the floating raft 1440 settles into a specially designed slot in the tub 1445. From that point onward, the water level 1420 drops below the bottom of the floating raft. The roots 1430 descend with the water level 1420, and the highest parts of the roots 1430 are exposed to the air. The raft 1440 settles into the slot at a level that allows the plant to be commercially harvested through a machine (not shown) that cuts off the top of the plant.

[0091] In one embodiment, the tub has a connecting hose that allows it to be connected to an air source supplying air to a bubbling device attached to the bottom of the tub. The bubbling device is sized to fit a specially designed tub so that the released bubbles create turbulence throughout the root system of the leafy green vegetable. This turbulence is a key part of the disclosed process. While not bound by theory, the turbulence caused by the bubbling device is expected to prevent bacteria and diseases from attaching to the root system. The turbulence caused by the bubbling device is also expected to help remove extruded material released from the roots, which is a food source for bacteria and diseases. For at least these reasons, the bubbling device operates for most of the growth process, and in some embodiments, throughout the entire growth process.

[0092] Other embodiments disclose other growth methods that accelerate the plant's growth cycle and reduce the time it takes for disease to occur. For example, in one embodiment, supplemental lighting is used to accelerate the growth process. Similarly, nutrient levels in the water source are carefully balanced to optimize plant growth. Furthermore, the water and air temperatures above the plant are controlled to achieve optimal growth characteristics.

[0093] After the growing period (which may be as short as 14 days), the plants are harvested and the tubs and rafts are thoroughly disinfected. Using constant bubbling, the plants grown in isolated batches and the complete sanitary conditions after each growing cycle are described herein. In one embodiment, the disclosed tubs are arranged on a special rack that allows two or more tubs to be connected. In one example, there may be 6 to 12 tubs on a single rack. See Figure 6, where it is shown that the tubs 610 described herein are arranged in a rack 675 on wheels 680, and thus the tubs can be moved in an area where they are butted together to form a large field of solid growing plants. The system described herein has a plurality of rollers 685 that allow the rack of tubs to be on wheels rolling on concrete or rails.

[0094] The system described herein allows for the movement of racks throughout the entire lifecycle of plant growth. In one embodiment, multiple tubs, for example, 5 to 15 groups, for example, 6 to 12 or 5 to 12 groups of tubs, are seated on a platform having a common airline and drainage pipe. This platform is called a “row.” The row can be transported across the entire greenhouse on rails using a pneumatic lift. As shown in Figures 6 and 7, a mechanized system is described for moving rows or racks of tubs through the growth system, into the harvesting system, into the cleaning and disinfection system, into the sowing system, and back into the growing area. This system allows large greenhouses, such as a 10-acre greenhouse, to operate efficiently without a large labor pool.

[0095] In some embodiments, the disclosed invention, which features a moving tub system with dispersed air, is best understood by contrasting it with commercially available growth systems. For crops such as leafy greens and herbs, it is ideal to have a centralized area for seedling / germination, as well as for harvesting / packaging and other intercrop cycle activities, which is commonly referred to as a “headhouse.” This means that the plants themselves must be moved from the “headhouse” to a greenhouse where they grow to maturity, and then returned to the “headhouse” for processing.

[0096] When plants enter a greenhouse to grow, they need light, air, and water. The greenhouse structure provides the air and light that plants need. However, there are several different strategies that growers use to supply water to plants. These include (1) overhead drenching with mobile booms and / or stationary sprayers, and (2) drip lines / tubes and / or emitters through which water is delivered to plants at a low flow rate via drip lines via pressure-compensated emitters. This is typically used for plants that remain stationary for long periods, such as cucumbers, strawberries, and tomatoes, as well as cannabis. This method requires considerable effort to set up the drip tubes / emitters and must be frequently flushed to avoid buildup / clogging; (3) an outflow and drainage system, commonly used for longer-cycle ornamental plants when installed on the greenhouse floor; (4) an NFT trough, where water flows intermittently or continuously through a gutter in small amounts through low-flow pipes running throughout the greenhouse; and (5) a deep water cultivation (DWC) pond, a large pond filled with recirculating nutrient solution that transports plants in floating trays and provides them with nutrient water as they grow. These systems are difficult to clean and waterborne root pathogens can move freely throughout the pond, so they are not ideal for sensitive root vegetables. Furthermore, if an outbreak of infection occurs and a complete cleanup is required, shutting down the pond is costly.

[0097] The fully isolated mobile tub systems described herein differ from the aforementioned systems in that they do not rely on the movement of water to irrigate plants throughout the entire crop cycle. Instead of pumping fertilized nutrient solution throughout the greenhouse, systems are described herein for transporting only low-pressure air throughout the greenhouse to deliver turbulence to the nutrient solution within the root zone. In some embodiments, the airlines of the disclosed systems contain a constant, high-velocity flow of warm, dry air, and for this reason, they do not provide a suitable environment for pathogens to grow and thrive. This is in stark contrast to the piping systems of other systems, which are ambient temperature, humid, and contain all the nutrients necessary for the growth of algae and other microorganisms within and adjacent to the irrigation lines.

[0098] In the system of the present invention, once the tubs are filled at the start of the crop cycle, water neither enters nor leaves the tubs, except for evaporation and biomass accumulation. After filling, the tubs, along with other built-in tubs, are mounted on a rolling table and sent to the greenhouse with all the water necessary to reach maturity. This fundamental difference makes it a much more robust method for mitigating the spread of waterborne pathogens. It has also been found that vigorous agitation achieved with a large aeration device and high airflow rate provides additional protection against root infection and promotes vigorous growth. Thus, the disclosed design and configuration achieve significant benefits for growing green leafy vegetables and herbs, particularly for mechanical harvesting.

[0099] The systems described herein include tables that are significantly heavier than conventional horticultural techniques used for growing partitioned plants. The traditional “Dutch rolling table” is a versatile table and rail system common for growing potted plants. Unlike the fully isolated moving tub systems described, the Dutch rolling table used watering systems with dripping or overhead booms, as well as herbs with tidal settings.

[0100] The systems described herein, which feature tables significantly heavier than those used in conventional horticultural techniques, can be vertically altered by using pneumatic cylinders to efficiently move larger loads, such as the described tabs on the large table, down a conveyor belt from the processing area into the greenhouse compartment. In some embodiments, the described tables may be configured to feed grown plants through a harvester.

[0101] In some embodiments, the tables used in this disclosure may be manufactured from aluminum extrusion. In some embodiments, the frame has two aluminum parts, such as a 4 x 2 inch piece, extending the length of the table, connected by transverse members over both the top and bottom of the tray. This edge allows the table to roll on a conveyor and travel perpendicular to the greenhouse compartment.

[0102] In some embodiments, there may be three transverse members on the underside of the table that are structural and also serve as wheel mounting points. In some embodiments, two types of wheels may be present on the bottom of the table: guide wheels and drive wheels. The guide wheels grip the rails from the sides to keep the table moving in a straight line, while the drive wheels simply roll along the rails. The central transverse member has two drive wheels, while each side transverse member has two guide wheels. Thus, in some embodiments, each table may have six wheels (two guides and four drive) on its transverse members. These wheels allow the table to roll along the rails within the greenhouse compartment.

[0103] The top of the table may include two lighter gauge crossbars to support each tab. In some embodiments, these crossbars have holes drilled to match the holes in the tabs, and as a result, the tabs can be bolted to the table crossbars in a watertight connection.

[0104] In some embodiments, the table includes an integrated air manifold pipe. For example, in some embodiments, there is an air manifold positioned between the wheel transverse member and the crossbar. In some embodiments, this manifold may consist of a 3 / 4” Schedule 80 PVC pipe, which runs along the length of the table. A 3 / 4” pipe is tapped into each tab, and hose barbs are inserted. Small diameter (1 / 4” ID) hoses connect the barbs of each tab to the diffuser at the bottom of the tabs.

[0105] In some embodiments, one end of the table manifold has a removable cap that allows the manifold to be cleaned / cleared. The other end of the manifold has a connector for attaching the manifold to the main air pipe.

[0106] In some embodiments, the table includes an integrated air manifold pipe. In some embodiments, the integrated air manifold pipe may be attached to an air main. For example, the air main may be a 2-inch Schedule 80 PVC pipe supplied from a single blower. Using a 3.5 HP blower, air can be supplied to up to 25 tables at a time, and as a result, a single 200-foot greenhouse compartment may have three or more blowers to supply 60-70 tables (600-700 tubs). For each table in the compartment, an air main is tapped, and a longer 3 / 4” hose attaches the table to the air main via a threaded connection. The table with the air manifold is configured to deliver air to the diffuser in each tub. In some embodiments, the manifold is located beneath each table with an airline connection and connects the entire table to an air main with a single connection.

[0107] In some embodiments, the table described above is used in conjunction with the trays and tabs described herein, thereby enabling the tabs to include a large aeration device and the lip portion to hold the tray in place.

[0108] In some embodiments, a system is described in which the disclosed tables are configured to be fed through a harvester without handling the trays. More generally, the system includes one or more tables configured in rows, these tables being made of aluminum on which tabs are bolted. An air manifold is located beneath the tables, supplying air to an aeration device for each tab, which is screwed into the bottom of each tab. As described above, the air manifold can be connected to an air "main pipe" supplying air to each row of tables, i.e., one (non)connection each time the tables are rearranged. In the disclosed system, the tables have two to four sets of wheels underneath so that they can roll down a greenhouse compartment on rails. In some embodiments, at the end of a compartment, conveyor wheels grip the table from underneath to move the table vertically. As a result of the tab design and the end position of the trays within the tabs, at harvest time, the entire row is transported through the harvester together with the trays.

[0109] The features and advantages of the present invention are more fully demonstrated by the following embodiments, which are provided for illustrative purposes only and should not be construed as limiting the invention in any way. [Examples]

[0110] Example 1 The objective of this example was to investigate whether the growth rate and severity of Pythium infection in spinach grown in deep water cultivation are affected by the water source from which the plants were cultivated. This was done to determine the cause of the different growth rates in different independent production reservoirs (ponds), which was thought to be at least part of this variability in plant performance due to differences in the initial concentrations of Pythium spores / other pathogens or potentially symbiotic microorganisms within the reservoirs. The best-performing reservoir and the tub filled with tap water (assumed to be spore-free) were considered to be the most productive (in terms of fresh weight produced) mainly because the plants were less susceptible to Pythium infection due to the lower initial concentration of spores.

[0111] Method: After germination is complete, remove the trays from the stacked cart and place them in their respective tubs. Each tray will be placed in its own tub. At this point, it is also possible to mist the trays from above. The contours of the tubs allow the trays to float when the water level is above the top level of the tub. As the water level drops, the trays will descend until they are seated on the lip of the tub, approximately 3 inches below the maximum water level of the tub.

[0112] Clean and disinfected insulated tubs were filled with water according to the table below. Fresh fertilizer and acid were added to tub 5, which was filled with fresh well water, resulting in a pH and nutrient profile that matched the inventors' production reservoir water. A 9-inch aerator was placed at the bottom of each tub to provide aeration and active turbulence to the water in the tub, which helps to contain infection as the inventors had previously observed. The aerator was supplied by a 3 / 4 HP compressor. The tubs were not actively cooled throughout the growth cycle. Four tubs were grown under HPS (high-pressure sodium) lamps, and the remaining two under LED lighting fixtures. This light was supplementary to the natural light the plants received inside the greenhouse. After setting up the tubs, trays of spinach, sown in new EPS trays and germinated for 5 days, were placed in each tub.

[0113] After planting in the tubs, the plants continued to grow for 14 days. During this time, no fertilizer was added or pH corrected. At maturity, the trays were harvested and their weight was recorded. Photographs of the canopy and roots were taken to observe the health of the plants. The amount of aeration and turbulence in each tub was also recorded, as shown in the "bubbling condition" column.

[0114] [Table 1]

[0115] As a result of this experiment, several important observations were made. Even when compressed air was actively bubbling within the tub, the thermal gain was manageable. This is important because the research in which the inventors designed their system suggests that maintaining the root zone temperature below 20°C is ideal for slowing Pythium growth, increasing the time it needs to reproduce, and helping to mitigate infection. The fact that the warmest tub was only 21°C at the end of the experiment strongly suggests that this thermal gain can be overcome with the inventors' existing water cooling capacity, allowing the inventors' production reservoir to be comfortably maintained within the inventors' ideal range of 18-20°C.

[0116] As noted in the rightmost column of the table, the aeration device in Tab 2 was contaminated (with algae / mineral deposits) throughout the experiment. This resulted in lower levels of aeration and turbulence in this tab, as can be seen in the photograph comparing Tabs 2 and 3 below. Unsurprisingly, Tab 2 is the tab in which the most severe Pythium infection was observed.

[0117] Furthermore, the aeration apparatus of tab 2 was also slightly off-center. As a result, the root morphology on the different sides of the tab was entirely different. This contrast supports the position that active turbulence does indeed affect the course of infection, and that the absence of active bubbling / turbulence leads to faster infection development and more severe symptoms, even in very localized areas, which manifests as shorter, less active roots with more lateral branching.

[0118] While source water appears to have some influence on yield, it did not seem to be the most important factor in terms of plant health or overall productivity. Given that Tab 5, initially filled with fresh water and fertilizer, was in the middle of the pack in terms of yield in this experiment, it is certain that the fresh water tabs did not contain Pythium and / or cast doubt on our assumption that performance in a tab is related to our perceived initial concentration of spores in its water source. And given that Tab 2, which had water from our best-performing reservoir, still became contaminated with low levels of foam, bubbling / turbulence appears to be a more significant variable.

[0119] This suggests that even when filled with fresh water, Pythium can inevitably be present in our reservoirs at certain concentrations. Despite our best efforts, some possible means of introducing Pythium into a clean reservoir include planktonic spores, via reusable EPS trays, or by fungus gnats flying between infected and healthy plants. Even very low initial concentrations of spores introduced inadvertently can rapidly multiply in the right environment within the reservoir, reaching a critical threshold at which they begin to cause damage.

[0120] Furthermore, the root morphology in the freshwater tub closely resembled that of the infected area in tub 2 more than any of the other trays. Roots in the best-performing tray were consistently long and taproot-like. Unhealthy roots were shorter and had more lateral branching, suggesting that root morphology can be used as an indicator of plant health.

[0121] Spinach grown on a high foamy surface can reach harvestable size in as little as 12 days, achieving nearly the same productivity (grams of fresh weight per day) as lettuce varieties.

[0122] At harvest time, the rows are transported to a rail-mounted mechanical harvester that cuts off the marketable leaves. After this point, the remaining root and stem material is removed, and the trays and tubs are prepared for resowing. The trays are washed and then subjected to further disinfection through the use of chemical disinfectants, microwaves, and drying. The remaining water in the tubs is emptied and subjected to filtration. The tubs are washed and disinfected before being refilled with fresh NS or filtered and reused.

[0123] Other embodiments of the present invention will be obvious to those skilled in the art by considering the specifications and practices of the invention disclosed herein. The specification and examples are intended to be considered illustrative only, and the true scope and spirit of the invention are shown by the following claims.

Claims

1. A system for hydroponically growing plants, wherein the plants are grown in isolated batches, and the system is A seed tray configured to contain and germinate plants, A tab configured to hold a sufficient amount of aqueous solution for the germinating plants to reach maturity without the addition of additional aqueous solution, The system comprises a tab mounted on a table to which at least one air manifold is connected, and the at least one air manifold is mounted on an aeration device located at the bottom of the tab.

2. The system according to claim 1, wherein the table includes an integrated air manifold pipe attached to the at least one air manifold.

3. The system according to claim 2, further comprising at least one blower attached to the integrated air manifold pipe.

4. The system according to claim 3, wherein the at least one blower supplies air to a maximum of 25 tables at a time.

5. The system according to claim 3, wherein the attachment mechanism to the inside and outside of the integrated air manifold pipe includes a screw connection.

6. The system according to claim 1, wherein the table is made of a frame comprising at least two elongated members running along the length of the table and a plurality of transverse members running along the width of the table and substantially perpendicular to the elongated members.

7. The system according to claim 6, wherein the frame is made of aluminum or an alloy thereof.

8. The system according to claim 6, wherein the at least two elongated members running along the length of the table are each provided with guide wheels configured to grip the elongated members from the sides in order to keep the table moving linearly in the direction of the elongated members.

9. The system according to claim 8, wherein the plurality of transverse members are provided with drive wheels configured to enable the table to move in the direction of the transverse members and perpendicular to the elongated member.

10. The system according to claim 9, wherein each table has two guide wheels and four drive wheels, and the tables are mechanically moved between growing, harvesting, cleaning, and replanting positions.

11. The system according to claim 6, wherein the plurality of transverse members support each tab and have holes drilled to coincide with holes in the bottom of the tab, the coincident holes allowing the tab to be bolted to the table in a watertight connection.

12. The system according to claim 1, wherein the table is configured to supply grown plants through a harvester without removing the tabs from the table or the plants from the tabs.

13. The seed tray is further configured to sit on and float on an aqueous solution contained in a tab, and the seed tray has a top surface and a bottom surface, with a plurality of openings that completely penetrate the top surface and the bottom surface. The plurality of openings are configured to hold soil and allow seeds to germinate in the soil, and the plurality of openings are configured to have at least three regions, i.e., An upper region having an upper opening sufficient for a germinating plant to grow through the upper surface, and side walls having a tapered shape to a narrower transition region, The transition region has side walls that become further tapered toward a narrower end region, The system according to claim 1, further comprising: an end region having a straight side wall with a bottom opening for plant roots to grow through the bottom surface and come into contact with the aqueous solution contained in the tub.

14. The system according to claim 13, wherein the plurality of openings have an elliptical shape on the upper surface and a round shape on the bottom surface.

15. The system according to claim 14, wherein the elliptical shape on the upper surface has a diameter of 18 to 20 mm as its longest axis.

16. The system according to claim 15, wherein the round shape on the bottom surface has a diameter of 8 to 10 mm.

17. The system according to claim 13, wherein the side wall of the upper region has a taper angle of 2 to 4 degrees with respect to a vertical plane drawn through the center of the opening.

18. The system according to claim 13, wherein the upper region has a concave bottom that connects to the transition region.

19. The system according to claim 13, wherein the side wall of the transition region has a taper angle of 26 to 28 degrees with respect to a vertical plane drawn through the center of the opening.

20. The system according to claim 13, made of expanded polystyrene (EPS).

21. The system according to claim 13, wherein the upper surface includes a boundary without an opening around the edge, and the boundary has a size that is at least the same width as the longest axis of the elliptical opening.

22. The system according to claim 21, wherein the boundary comprises a plurality of tabs configured to allow seed trays to be stacked on top of each other, and the bottom surface of an upper seed tray stacked on top of the plurality of tabs does not come into contact with the top surface of a bottom seed tray.

23. The system according to claim 13, having a rectangular shape with a width of 450 to 550 mm, a length of 700 to 800 mm, and a thickness of 50 to 60 mm.

24. The system according to claim 13, wherein each seed tray includes 400 to 450 openings.

25. The system according to claim 13, wherein each opening has a volume in the range of 8 to 10 mL.

26. The system according to claim 13, wherein each seed tray can grow from 500 to 1200 plants.

27. The aforementioned tab is It has a rectangular shape and an upper part including a lip around an inner circumference configured to receive a seed tray, A bottom closure having a rectangular shape and smaller in size than the upper part, the bottom closure comprising at least one mounting mechanism for removably attaching the tab to the frame, and an aeration device configured to generate turbulence of the aqueous mixture disposed within the tab, The system according to claim 1, comprising: a side wall that is tapered from the upper part to the bottom closing part, wherein the tapered side wall is configured to allow the root hanging down from the seed tray to grow toward the center of the tab.

28. The system according to claim 27, wherein the lip around the inner circumference of the upper part is configured to receive a seed tray having a thickness of 50 to 60 mm.

29. The system according to claim 27, wherein the lip around the upper inner circumference includes a ledge for resting the seed tray when the amount of aqueous mixture in the tab is insufficient to suspend the seed tray.

30. The system according to claim 27, wherein at least one of the upper corners includes a structure for maintaining the seed tray so that it does not float away from the tab when the tab is filled with the aqueous mixture.

31. The system according to claim 30, wherein the structure further includes an opening for removing excess aqueous mixture from the tab.

32. The system according to claim 27, wherein the aeration device generates more than 3 L / min of aeration per 20 gallons.

33. The system according to claim 32, wherein the aeration device generates a flow rate of 25 L / min through an 8-inch aeration device in a 20-gallon reservoir.

34. The system according to claim 27, wherein the majority of the roots hanging down from the seed tray, growing toward the center of the tab, are in contact with the amount of aeration.

35. The system according to claim 27, wherein the tab has a surface area of ​​15 square feet or less.

36. The system according to claim 27, wherein the bottom closing portion comprises four mounting mechanisms for removably attaching the tab to the frame, and an aeration device configured to be positioned in the center of the four mounting mechanisms.

37. The system according to claim 27, wherein the bottom closing portion of the tab comprises four mounting mechanisms for removably attaching the tab to a frame, and an aeration device configured to be positioned in the center of the four mounting mechanisms.

38. The system according to claim 1, wherein the seed tray and tub are configured to allow the seed tray to float in the water in the tub while the water level decreases as the plants develop their initial root systems, and after plant use and evaporation, the tray is allowed to descend with the water level until the tray sits on the lip of the tub.

39. The system according to claim 38, wherein the seed tray and tab are configured such that as the water level continues to fall, the roots follow the water level and as a result a portion of the roots remain exposed to the air and a portion of the roots come into contact with the mixture of water and nutrient solution.

40. The system according to claim 1, wherein the multiple individual tabs are connected within a frame that holds 5 to 20 tabs in a row.

41. The system according to claim 1, wherein the seed tray and tab are configured to be sterilized after each growth cycle.

42. The system according to claim 1, further comprising a filter for purifying any remaining aqueous mixture of water and nutrient solution that remains in the tub after the plants have been harvested.

43. The system according to claim 42, wherein the filter includes a size exclusion filter for removing spores.

44. The system according to claim 43, wherein the size exclusion filter filters out spores larger than 5 microns.

45. The system according to claim 44, further comprising at least one additional method selected from chemical sterilization, ozone treatment, and UV irradiation for purifying the aqueous mixture of water and nutrient solution after filtration.

46. A method for hydroponically growing plants using an isolated growth system, wherein the method is: The method involves planting multiple seeds in a growing medium, wherein the growing medium is contained in multiple trays configured to float above a tab and provide the crops with access to an aqueous mixture of water and nutrient solution as they float. To germinate the aforementioned seeds and produce trays containing germinated seeds, Transferring the tray containing germinated seeds to the top of the tab, The tray is made to float above the tab, The method comprises at least one aeration step of causing turbulence of the aqueous mixture to collide with the roots of the plant in contact with the aqueous mixture.

47. The method according to claim 46, wherein the growth cycle of the plant is modified to reduce the opportunity for the growth of pathogens in the roots.

48. The method according to claim 46, wherein the growth cycle of the plant is modified to accelerate growth by using the aquatic nutrient preparation tailored to the plant being grown, increasing the lighting, controlling the temperature of the water and air, or a combination thereof.

49. The method according to claim 46, wherein the volume of the aqueous mixture of water and nutrient solution in the tab is reduced, allowing the upper tray to sit on the tab.

50. The method according to claim 49, wherein the volume of the aqueous mixture of water and nutrient solution in the tab continues to decrease, allowing a portion of the root to be exposed to air and a portion of the root to come into contact with the aqueous mixture of water and nutrient solution.

51. The method according to claim 46, wherein the at least one aeration step that causes turbulence includes an airflow of at least 5 L / min through an 8-inch diffuser in a 20-gallon reservoir.

52. The method according to claim 51, wherein the at least one aeration step that causes turbulence includes an airflow of at least 15 L / min through an 8-inch diffuser in a 20-gallon reservoir.

53. The method according to claim 51, wherein the at least one aeration step that causes turbulence includes an airflow in the range of 20 to 25 L / min through an 8-inch diffuser in a 20-gallon reservoir.

54. The method according to claim 46, wherein the plant is spinach or kale.

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