Dynamic Aeroponics

Abstract

The nutrients are supplied in mist 203 form to the plants 204 via misters 202 from vertical tubes 101. A distributor tubing is connected to a high pressure pump (not shown) via a flexible and extendible tubing 106. The flexible and extendible tubing 106 is collapsed and extended as the boom shaft 109 moves in the direction of the length of the supporting main beam or main tube 105. Hence, as the boom shaft 109 moves, it moves the misters along the length of the aeroponic frame. The boom shaft 109 slides along the main tube via a roller 103 block 104. The sliding motion may be accomplished via a motor inside the block 104 or may be pulled by a wire, and the wire's movement may be motor driven by a motor located at one end of the main tube 105.

Description

[0001] DYNAMIC AEROPONICS

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS: This application is a PCT application that claims priority to and the benefit of the provisional patent application titled “Inserted boom Aeroponics”, with application number 202341057468, filed with the Indian Patent Office on 28 August 2023. This provisional patent application is also the priority of the non-provisional patent application# 202444064765, titled “Dynamic Aeroponics” filed with the indian patent office on 27th August 2O24.The specification of the above referenced patent application is incorporated herein by reference in its entirety.

[0003] BACKGROUND

[0004] 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. A salad green or vegetable that is just harvested from the plant, and that is consumed immediately tastes fresh and delicious. Current agricultural system involve plantations in fields with transport taking time in the order of weeks or days over long distances.

[0005] 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 labour required for farming. 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). For example, in the current 40 ft container farms, the number of plants grown (including seedlings) is about 4000 to 8000. We need to double or triple the number of plants grown to make CEA more economically viable. We need to provide people the ability to grow food indoors within the premises of their house. 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.

[0006] A primary challenge in aeroponic systems is the number of static misters required to cover large root zone areas. A large number of misters increase the probability of failure and the inability to use in large numbers high quality expensive misters.

[0007] In addition, statically positioned misters provide non uniform spray, and different areas within the root zone get different intensities of sprays.

[0008] Moving a truss or other linear structure under the root zone demands high structural strength of the long span suspended plant growing channels or plant receptacles, else the plant support structures will buckle and bend. Long span suspended plant growing structures needed thicker and expensive / unaffordable plant growing trays, channels or support structures.

[0009] A breakdown of an aeroponic system requires fast repair, else the air exposed suspended roots with dry up. If such an event occurs when personnel are not present, the grower may lose the crop. Hence, there is a need to address this issue of managing such system failure risks.

[0010] SUMMARY OF THE INVENTION

[0011] Described herein is an apparatus and system for high density aeroponic vertical farming.

[0012] The apparatus described herein addresses the above unmet needs.

[0013] An overhead travelling boom moves over vertical aeroponic systems and supplies nutrients via mist to the root zone of the aeroponic system through inserted tubing with misters.

[0014] The overhead travelling boom in addition to misting the root zone of the aeroponic system, also cooling the greenhouse by misting or fogging the space above and between the plants.

[0015] Advantageously, the secondary system of misters or foggers located in the top boom applies one or more of the following: foliar nutrient sprays, cooling spray, and plant protection sprays.

[0016] Advantageously, in the dynamic misting systems disclosed herein, substantially fewer misters are needed for root zone misting.

[0017] Advantageously, the uniformity of misting within the root zone is improved, thereby leading to increased water and nutrient savings.

[0018] 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.

[0019] FIG. 1 illustrates an angular view of the inserting boom aeroponic system.

[0020] FIG. 2 illustrates a front view of the inserting boom aeroponic system with A frame aeroponics.

[0021] FIG. 3 illustrates a front view of the inserting boom aeroponic system with fully vertical frame aeroponics.

[0022] FIG. 4A illustrates a side angle view of aeroponic misters on a wheeled trolley guided by a tension mechanism.

[0023] FIG. 4B illustrates a front view of aeroponic misters on a wheeled trolley guided by a tension mechanism.

[0024] FIG. 5 illustrates a side angle view of aeroponic misters on a top guided channel moved by a tension mechanism.

[0025] FIG. 6 illustrates internal frontal view of aeroponic misters on a top guided channel moved by a tension mechanism.

[0026] FIG. 7A illustrates a side angle view of aeroponic misters on a wheeled trolley guided by a tension mechanism wherein a chord drives a nutrient supply tube.

[0027] FIG. 7B illustrates a top view of only pulleys, chords and nutrient supply tube, wherein a chord drives a nutrient supply tube. FIG. 8A illustrates a side angle view of aeroponic misters on a wheeled trolley guided by a tensioned and driven high tension sustaining nutrient supply tube.

[0028] FIG. 8B illustrates a top view of pulleys and a driven high tension sustaining nutrient supply tube.

[0029] FIG. 9A illustrates a side angle view of two redundant parallel systems of aeroponic misters on a wheeled trolley guided by a tensioned and driven high tension sustaining nutrient supply tube.

[0030] FIG. 9B illustrates top view of two redundant parallel systems of aeroponic misters pulleys and a driven high tension sustaining nutrient supply tube.

[0031] FIG. 10A illustrates a side angle view of two redundant parallel systems of aeroponic misters on a wheeled trolley guided by a tensioned and driven high tension sustaining nutrient supply tube, and a top channel guided aeroponic mister line.

[0032] FIG. 10B illustrates top view of two redundant parallel systems of aeroponic misters pulleys and a driven high tension sustaining nutrient supply tube, and a top channel guided aeroponic mister line.

[0033] FIG. 11 illustrates the components of the aeroponic system.

[0034] DETAILED DESCRIPTION OF THE INVENTION

[0035] FIG. 1A illustrates an angular view of the inserting boom aeroponic system for an angled frame system. Nutrients are delivered via an aeroponic misting system. Plants 201 grow on angled surfaces 107, 108 as illustrated in FIG.2 or fully vertical surfaces 301 as illustrated in FIG. 3. A high-pressure nutrient supply line 101, 109 supplies high pressure nutrients to the misters in the cavity 102 between two plant growing surfaces. The supply line 106 may be folded and cascaded to enable movement along the entire aeroponic frame. A roller block 104 with wheels 103 runs on a main overhead supporting pipe or other structure form 105. The overhead misters or foggers 110 are supplied by a separate water line.

[0036] FIG. IB illustrates an angular view of the inserting boom aeroponic system for a flat frame system. Plants may also grow on horizontal beds 112 with hollow root zones for plants to grow. In the cavity between two adjacent horizontal beds, a vertically dropped mister line 111 delivers nutrient mist to both adjacent beds 112.

[0037] Plants 204 are only illustrated in one face of the aeroponic system so as to not clutter the view of the figure.

[0038] The aeroponic system may be located in an indoor controlled environment or it may also be located in a greenhouse.

[0039] In the case of controlled environment agriculture, artificial lighting may also be provided or sunlight may be supplemented with artificial lighting.

[0040] In addition to misting nutrients downwards into the aeroponic cavity or within the aeroponic frame, the boom may also host a separate set of fogging misters that fogs the overhead air above the aeroponic frame for the purpose of cooling the ambient environment. The foggers may direct the fog in the environment around the aeroponic system in any direction fit for cooling.

[0041] For example, nutrient mister nozzles pressured by a 100 psi pump delivers mist nutrients within the aeroponic frame with droplet size of about 50 micron, and fogging nozzles 110 spaced along the length of the boom pressured by a lOOOpsi pump generates fog with a droplet size of 10-20 micron. The supply tube for the fogging nozzles 110 is flexible and extendible (not shown), similar in external appearance to the flexible and extendible tubing 106, but capable of withstanding lOOOpsi pressure.

[0042] The nutrients are supplied in mist 203 form to the plants 201 via misters 202 from vertical tubes 101 connected to a main distributor tubing 201. The distributor tubing 108 is connected to a high pressure pump (not shown) via a flexible and extendible tubing 106. The flexible and extendible tubing 106 is collapsed and extended as the boom shaft 109 moves in the direction of the length of the supporting main beam or main tube 105. Hence, as the boom shaft 109 moves, it moves the misters along the length of the aeroponic frame. The boom shaft 109 slides along the main tube via a roller 103 block 104. The sliding motion may be accomplished via a motor inside the block 104 or may be pulled by a wire, and the wire’s movement may be motor driven by a motor located at one end of the main tube 105.

[0043] For example, 0.4mm misters 202 provide a nutrient mist that is pumped at a pressure of 100 psi from a high pressure pump.

[0044] An enclosed aeroponic cavity bound by plant growing surfaces 107 is herein called a frame. The frame may take an “A” shape as shown in FIG.2 or may take a long rectangular form as shown in FIG. 3, or other forms suitable for the particular variety of plant 204 grown.

[0045] FIG. 2 illustrates a front view of the inserting boom aeroponic system with A frame aeroponics.

[0046] FIG. 3 illustrates a front view of the inserting boom aeroponic system with fully vertical frame aeroponics.

[0047] The insertive movable boom aeroponic system described herein can be applied to both a solid immovable sheet plant growing surface, or it may also be applied to an expansive movable structure plant growing surface. In one embodiment, sidewalls 109 are composed of a hard plastic or stiff foam which house plants. In another embodiment, the sidewalls 109 comprise a front layer of a plastic that supports the plant from seed to harvest, and a rear layer of a thin film cellulosic disposable and biodegradable membrane that holds on to the rear of the front layer by surface tension of a nutrient solution.

[0048] The front layer maybe composed of one or more of a biaxially oriented polyester film or high density polyethylene.

[0049] Even though the figures 2 and 3 represent a vertical growing surface of plants, it is be noted that the inserted boom aeroponics system described herein may also be applied to plant grow surface that are aligned horizontally.

[0050] An example of an expansive structure is a corrugated structure. In other embodiments, the expansive sheet can expand in two dimensions, for example with pyramidal expansive origami type foldings. The expansive structure is two layered, a top structural layer, and a rear membrane layer. 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 paper, for example single ply tissue like paper of 15 to 20 micron thickness. The porous membrane may also comprise a thin plastic, such as very thin PET or LDPE or HDPE, that is made either micro porous or with macro holes allow passage of water and also contains large cavities to allow passage of roots. The top structural layer is a flexible weight bearing layer, for example a thin folded plastic such as PET, BPET, UPVC etc. The expansive sheet expands as the plants grow on the sheet. For example, the space between corrugations is 2 mm on day 1 when the seed is placed on the expansive sheet, on day 10 the space between the corrugations is increased to 10mm to accommodate the space between the plants to allow sufficient light and air to reach the individual plants. And, on day 15 the space between corrugations is increased to 15mm, and on day 18, increased to 25mmm. Finally, the plants, for example baby greens are harvested on day 21. In this expansive technique, the area above the expansive sheet is always covered with either cotyledons or leaves, and when grow light is applied, the light strikes the leaves and is not wasted by missing the leaf and striking the surface below the plant. Hence, this ensures a very high photon capture, thereby providing significant grow light energy savings. In the above described system, the corrugated structure has cutouts for placing seeds between the front sheet and rear film. In another embodiment, cutouts with flaps can advantageously help align the seedling.

[0051] The apparatus described herein advantageously eliminates the need for plant plugs / growing media for seeds. A thin film that is held by water surface tension adheres to the rear of a sheet. The sheet has a cavity wherein a seed is placed between the sheet and the thin film. The thin film has cavities positioned in such a manner that when the seedling germinates the leaves and stem come out of the cavity and reach out to the light between facing sheets, while the roots grow towards gravity downwards and emerge out of the cavity in the thin film, and grow aeroponically into the cavity that is misted. Thin film sheet (for example of thickness 20 to 30 micron) is placed at the rear of, and attached by surface tension of water. The holes in sheet are staggered. The initially get anchored between these sheets and then as the roots emerge out of the hole it reaches into the misting zone and grows aeroponically.

[0052] 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. The sheets supporting the plants are adjustably suspended on trolley rollers on rails. In one embodiment, each of the rollers are motorized. In another embodiment, a moving robot engages with trolley rollers connected to the top of the sheets and moves it to the required position whereby sufficient light and airflow is provided between vertical surfaces of growing plants. Aeroponic misting of roots is accomplished by placing misters between sheets. In another embodiment, the front sheet is continually connected in a circular loop to ropes, wherein at harvest or seeding the sheet is pulled downward by engagement with a robot at the floor level, and after harvesting and seeding, the sheet is rolled back to the original position.

[0053] In FIG. 1A, the vertically oriented aeroponic plant supporting structure is substantially triangular 104. The base of the triangular vertically oriented aeroponic structure is anchored to the ground via spikes (not shown). A rectangular section may also be implemented, however a triangular section provides greater resistance to twisting and torsion.

[0054] The base of the triangular vertically oriented aeroponic structure sits within a nutrient flow channel. The material of the nutrient flow channel is a water proof plastic, such as high density polyethylene (HDPE) pond liner.

[0055] In another embodiment, push fans, i.e. circulation fans, may be located within the root zone 103 and shoot zone 108. The push fans may also be located within the shoot zone 108. Push fans provide added air momentum and positive pressure.

[0056] Described herein is an exemplary illustration of the working of the invention, the dimensions and component numerical specifications are not meant to be limiting. Triangular aeroponic frames are made of coated (water resistant) aluminum tubes. The triangular frames are about 210 cm tall and separated center to center by 210 cm. Insect Mesh no. 50 (capable of blocking white fly pests) defines the interface between one end of the root zone 103 of the aeroponic structure and the external environment. The relative humidity of the external environment is 50%. 900 RPM exhaust fans of blade diameter 18 inches, i.e. low to medium speed high volume fans push air from the shoot zone 108 to the external environment. The exhaust fans 102 are therefore instrumental in also pulling dry air from the external environment through the insect mesh 110 into the wet root zone 103 of the aeroponic frames. The root zone 103 comprises wet cellulosic layer abutting a non permeable plastic front layer. The roots in the root zone 103 are aeroponically misted with misters 205 that deposit water particles of approx. 50 micron size at a pressure of about 100 to 150 psi. As dry air is pulled through wet misted roots and the wet internal cellulose lined walls, evaporative cooling is accomplished. Baby leaf spinach plants are grown on the front layer in the shoot zone. The cooled and humid air drawn through the root zone 103 is then passed through the shoot zone 108 and the humidified cooled air cools the environment around the baby spinach leaves. An effective temperature drop of 5 degree celcius was achieved, achieving a drop in temperature from 30C to 25C. The length of the root zone and the shoot zone are 100ft. The front sheet holding the plants 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 plastic sheet may be fused to a white reflective plant facing plastic sheet.

[0057] The rear layer 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.

[0058] 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.

[0059] 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. The rear cellulosic layer 102 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.

[0060] FIG. 4A illustrates an angular view of a tension driven mister movement system wherein the misters are moved over the ground in the internal cavity of the aeroponic frame system. Misters 101 are located on support structure that is attached to a wheeled base trolley. The trolley is attached to the tensioned high pressure nutrient supply tube. Examples of a tensioned high pressure tube 402 is a high pressure with coaxial metal wire external windings in a polymer or rubber casing. For example, the trolley 403 is attached to the tensioned high pressure nutrient supply tube. Exemplarily, the high pressure nutrient tube 402 is supported on idle rollers 404 and guided through pulley 401. The misters are so positioned that they mist the internal cavity of the aeroponic root cavity. The plant and its roots are supported on the surface of the A frame. Exemplarily, the surface may be a hard foam or a membrane. The aeroponic root 405 cavity may be shaped in the form of an A frame, rectangular frame or any other aeroponic enclosing structure. Multiple pulleys guide a single tensioned high pressure nutrient tube in a closed path, wherein the closed path traverses the root zones of multiple A frame, rectangular frame or any other enclosing structures.

[0061] FIG. 4B illustrates a frontal view of a tension driven mister movement system wherein the misters are moved over the ground in the internal cavity of the aeroponic frame system. Plants 204 are grown on both sides of the aeroponic frame. The roots of the plants grow suspended in a mist environment. The mister support structure is composed of a lightweight material such as aluminum.

[0062] In order to build redundancy, two such tensioned high pressure nutrient tubes may run in parallel within each A frame, rectangular frame or any other aeroponic enclosing structure.

[0063] FIG. 5 illustrates a side angle view of aeroponic misters on a top guided channel moved by a tension mechanism. The nutrient supply structure 101 runs along the length of the aeroponic frame driven by steel chords.

[0064] FIG. 6 illustrates internal frontal view of aeroponic misters on a top guided channel moved by a tension mechanism. Exemplarily, steel chords 607 run over motor driven pulleys to provide the tension and drive characteristics, and drive the roller block 606, and drive the cascading roller joints 604 under the top supporting structure 605, thereby extending the high pressure 601 over the length of the aeroponic frame. Limit switches 602 and 603 define the boundaries.

[0065] FIG. 7A illustrates a side angle view of aeroponic misters on a wheeled trolley guided by a tension mechanism wherein a chord drives a nutrient supply tube. In this system, the risk of tension failure of the nutrient supply line is eliminated as the steel chord 710 primarily takes the tension loading from the drive motor 705. A screw-based tension adjustor 701 enables tightening or loosening of the steel chord 706 running over pulley 702, that pulls along the nutrient pipeline 707 over pulley 703. A collapsible and expandable nutrient supply tube 704 allows extension and withdrawal within the aeroponic frame, the movement defined by limit switches 708, 709.

[0066] FIG. 7B illustrates a top view of only pulleys, chords and nutrient supply tube, wherein a chord drives a nutrient supply tube. A example of a

[0067] FIG. 8A illustrates a side angle view of aeroponic misters on a wheeled trolley guided by a tensioned and driven high tension sustaining nutrient supply tube. An example of a high tension sustaining nutrient tube is a flexible metal braid reinforced rubber hydraulic pipe.

[0068] FIG. 8B illustrates a top view of pulleys and a driven high tension sustaining nutrient supply tube 801.

[0069] FIG 9 A illustrates a second embodiment of redundancy, wherein two adjacently placed floor level implemented tension driven mister movement systems are simultaneously implemented to enable redundancy. FIG. 9B illustrates the top view of only the pulleys and tension chord within the system shown in FIG. 9A.

[0070] FIG. 10A illustrates a first embodiment of redundancy, wherein a top level implemented tension driven nutrient pipe 1001, 1002 movement and a tension driver trolley based mister system are simultaneously implemented to enable redundancy. FIG. 9B illustrates the top view of only the pulleys and tension chord within the system shown in FIG. 9A. Redundancy herein refers to the ability of the system to not catastrophically fail if one of the two mister systems fails. For example, the probability of one mister line system failing in a month could be 2%, whereas the probability of the beforementioned mister line as well as its redundant mister line failing at the same time is less than 0.2 percent. In this exemplary case, consider the case wherein if the first failure can be identified and repaired in 3 hrs. In order for catastrophic failure to occur, the second redundant mister line must also fail within the same beforementioned 3hrs, which is a highly unlikely event and that of a low probability, and therefore very low risk.

[0071] FIG. 10B illustrates a side angle view of two redundant parallel systems of aeroponic misters on a wheeled trolley guided by a tensioned and driven high tension sustaining nutrient supply tube, and a top channel guided aeroponic mister line.

[0072] It is advantageous to incorporate redundancy in controlled environment agriculture. In one embodiment, both a top guided dynamic misting system and a bottom tray driven dynamic misting system installed in an aeroponic system. Even if one system fails, the parallel running system is able to provide sufficient nutrients to keep the roots misted and the plants alive.

[0073] FIG. 10B illustrates top view of two redundant parallel systems of aeroponic misters pulleys and a floor level driven high tension sustaining nutrient supply tube, and a top channel guided aeroponic mister line.

[0074] FIG. 5 illustrates an internal view of the aeroponic cavity in which a tension driven mister movement system wherein the misters are suspended over a wheel supporting guide in the top section of the internal cavity of the aeroponic frame system. Misters 101 are located on support structure that is attached to a wheeled trolley driven on top rails (out of the spray zone). The trolley is pulled by a steel chord. In one embodiment, as illustrated in FIG. 6, the steel chord connect two pulleys in a closed loop at the ends of the aeroponic frame. In a second embodiment as illustrated in FIG. 8 and FIG. 9, the steel chord forms a continuous loop between multiple aeroponic frames. The suspended wheeled trolley is attached to the tensioned high pressure nutrient supply tube. Multiple looped suspensions of the high pressure nutrient supply pipe cascade to form an extensible mister movement system. For example, the trolley is attached to the tensioned high pressure nutrient supply tube. The misters are so positioned that they mist the internal cavity of the aeroponic root cavity. The plant and its roots are supported on the surface of the A frame. Exemplarily, the surface may be a hard foam or a membrane. The aeroponic root cavity may be shaped in the form of an A frame, rectangular frame or any other aeroponic enclosing structure. In one embodiment, multiple pulleys guide a single tensioned high pressure nutrient tube in a closed path, wherein the closed path traverses the root zones of multiple A frame, rectangular frame or any other enclosing structures. In another embodiment a drive steel chord forms a closed loop between two pulleys, one of which is motor driven either directly, or through a rotating common shaft connecting multiple such tension driven mister movement systems.

[0075] Described herein is a top level dynamic aeroponic system, comprising a top linear guide and load supporting suspended structure (105); a roller block (104) guided on the top linear guide and load supporting suspended structure (105); a collapsible and extendible high pressure nutrient pipeline (106) fastened to the roller block (104); a boom structure (109) supporting vertically dropping mister lines (101); a root zone cavity enclosure with plant growing surfaces (107) with a top access cavity (102) in which the vertically dropping mister lines (101) are introduced into a root zone; misters (202) located on the vertically dropped mister lines (101) delivering mist to roots (203); and whereby misters (202) are moved over the length of the aeroponic system to uniformly mist said roots.

[0076] One or more of foggers and misters (202) with a water line supply are attached to the roller block and spray water high over plants and cool the environment over plants (204).

[0077] Redundancy is established by an additional parallelly operating said top level dynamic aeroponic system.

[0078] The top level dynamic aeroponic system further comprises temperature, light and humidity sensors located between aeroponic frames that provide feedback to a processor, wherein based on the feedback, speed of a motor that drives the roller block, and the wait time at the position sensors are defined.

[0079] A ground level dynamic aeroponic system, comprising a ground level high tension nutrient pipeline (402) guided between pulleys (401) to form a continuous closed loop between multiple aeroponic frames; a ground level trolley (403) that supports a mister housing structure (405); a collapsible and extendible high pressure nutrient supply pipeline (704) connected to the ground level high tension nutrient pipeline (402) and fastened to the ground level trolley (403) in one of the aeroponic frames; drive motor (705) driving the pulleys to move along the ground level trolley (403) along a fixed path; position sensors (708, 709) that sense and limit movement of the nutrient pipeline (402) to within length of the aeroponic frames; misters housed on said mister housing structure (405) that uniformly sprays nutrient mist, and moves back and forth within a root zone cavity enclosure defined by plant growing surfaces (107).

[0080] Redundancy is established by an additional parallelly operating ground level dynamic aeroponic system.

[0081] Redundancy is established by an additional parallelly operating top level dynamic aeroponic system. Steel chords (706) pull and guide said nutrient pipeline (402).

[0082] A tension adjustor (701) enables tightening or loosening of a steel chord (706) running over pulley (702), wherein chord pulls a nutrient pipeline (707) over pulleys (703).

[0083] The ground level dynamic aeroponic system further comprises temperature, light and humidity sensors located between aeroponic frames that provide feedback to a processor, wherein based on the feedback, the speed of the motor and the wait time at the position sensors are defined. For example, in the summer, when the ambient temperature is greater than 27 Celcius, the misters move faster between the position sensors and spend less idle time. While in the winter when the temperature is at 18Celcius, the misters may exemplarily move at half before mentioned speed.

[0084] FIG. 11 illustrates an active component level architecture of the underlying aeroponics system. The aeroponic system comprises reservoir / tank 1105, misters 202, filters 1102, control system, pressure tank 1103, solenoids 1104, 1106, pressure sensors, flow sensors, booster pumps 1101 and other sensor modules along with Internet of things (IOT) Connectivity. The misters are 202 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 for example in the range 50 microns The mister module comprising the pipes and connected misters 202 need to serviceable, the misters 202 need to be easily replaceable and the mister 202 functional performance must be easily gauged. Performance parameters of the misters 202 include output flow rate in milliliters per minute, and spray pattern shape consistency. In some cases, a failed mister 202 may not mist, instead drips or linearly jets out nutrients. In addition, the misters 202 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 202 must be easily removed for replacement or cleaning and subsequent refitting. Misters 202 are connected in a fashion that a minimal level of redundancy is established.

[0085] 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.

[0086] Optionally, CO2 can be supplemented to increase plant growth. Exemplarily, Carbon dioxide is preferred in the range of 500 to 800 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.

[0087] 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.

[0088] Filters 1102 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.

[0089] The filtration unit 1102 can have inline filtration components as well as edge filtration modules located at the reservoir. The filtration unit 1102 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.

[0090] The reservoir is communication maybe 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.

[0091] 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.

[0092] 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.

[0093] The reservoir may include a drain that enables reservoir fluid exchange, and the drain may be automated with a motor and associated controls.

[0094] 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.

[0095] 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.

[0096] 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. 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

[0097] 1107, pH down adjustment solution 1109, macronutrients 1107, micronutrients

[0098] 1108, and reverse osmosis filter water 1110.

[0099] 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.

[0100] 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.

[0101] 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.

[0102] Actuators include solenoids, pumps 1101, linear motion actuators, light switches, pH dosing pumps, Macronutrient dosing pumps, micronutrient dosing pumps, cameras, air blowers, mixing pumps, aeration pumps etc. The plant growing 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.

[0103] 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.

[0104] 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.

[0105] The aeroponic system disclosed herein can be used for multiple end grow applications, including but not limited to growing greensbeans, tomato, rice and corn. The systems can be implemented in a conventional farm, vertical farm in a shed, research environments, smaller scaled home and hobby, and in preferably controlled environment agriculture environments.

[0106] The sprayed nutrients that flows over the roots and internal walls are collected in in a sloped floor tray underneath, and the sloped tray feed into a main drain. The sloped floor tray may be composed of a waterproof sheet such as HDPE pond liners. 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.

[0107] The foregoing examples have been provided merely for explanation and are in no way to be construed. While the dynamic aeroponic system 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 dynamic aeroponic system has been described herein with reference to particular means, materials, and embodiments, the dynamic aeroponic system 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 dynamic aeroponic system disclosed herein is capable of modifications and other embodiments may be effected and changes may be made thereto, without departing from the scope of the dynamic aeroponic system disclosed herein.

Claims

CLAIMSI / We claim,1. A top level dynamic aeroponic system, comprising: a top linear guide and load supporting suspended structure (105); a roller block (104) guided on said top linear guide and load supporting suspended structure (105); a collapsible and extendible high pressure nutrient pipeline (106) fastened to said roller block (104); a boom structure (109) supporting vertically dropping mister lines (101); a root zone cavity enclosure with plant growing surfaces (107) with a top access cavity (102) in which said vertically dropping mister lines (101) are introduced into a root zone; misters (202) located on said vertically dropped mister lines (101) delivering mist to roots (203); and whereby misters (202) are moved over the length of said aeroponic system to uniformly mist said roots.

2. The top level dynamic aeroponic system of claim 1 wherein one or more of foggers and misters (202) with a water line supply are attached to said roller block, and spray water high over plants and cool the environment over plants (204).

3. The top level dynamic aeroponic system of claim 1, wherein redundancy is established by an additional parallelly operating said top level dynamic aeroponic system.

4. The top level dynamic aeroponic system of claim 1 , comprising temperature, light and humidity sensors located between aeroponic frames that provide feedback to a processor, wherein based on said feedback, speed of a motor that drives said roller block, and the wait time at said position sensors are defined.

5. A ground level dynamic aeroponic system, comprising: a ground level high tension nutrient pipeline (402) guided between pulleys (401) to form a continuous closed loop between multiple aeroponic frames; a ground level trolley (403) that supports a mister housing structure (405); a collapsible and extendible high pressure nutrient supply pipeline (704) connected to said ground level high tension nutrient pipeline (402) and fastened to said ground level trolley (403) in one of said aeroponic frames; drive motor (705) driving said pulleys to move along said ground level trolley (403) along a fixed path; position sensors (708, 709) that sense and limit movement of said nutrient pipeline (402) to within length of said aeroponic frames; misters housed on said mister housing structure (405) that uniformly sprays nutrient mist, and moves back and forth within a root zone cavity enclosure defined by plant growing surfaces (107).

6. The ground level dynamic aeroponic system of claim 1 , wherein redundancy is established by an additional parallelly operating ground level dynamic aeroponic system.

7. The ground level dynamic aeroponic system of claim 1, wherein redundancy is established by an additional parallelly operating top level dynamic aeroponic system.

8. The ground level dynamic aeroponic system of claim 1, wherein steel chords (706) pull and guide said nutrient pipeline (402).

9. The ground level dynamic aeroponic system of claim 1, comprising a tension adjustor (701) that enables tightening or loosening of a steel chord (706) running over pulley (702), wherein said chord pulls a nutrient pipeline (707) over pulleys (703).

10. The ground level dynamic aeroponic system of claim 1, comprising temperature, light and humidity sensors located between aeroponic frames that provide feedback to a processor, wherein based on said feedback the speed of said motor and the wait time at the position sensors are defined.

Images