U.S. patent application number 17/473757 was filed with the patent office on 2022-01-13 for stacked shallow water culture (sswc) growing systems, apparatus and methods.
This patent application is currently assigned to Upward Enterprises Inc.. The applicant listed for this patent is Upward Enterprises Inc.. Invention is credited to Aftab Alam, Jason Green, Nico Hawley-Weld, Rachael Klepner, Matt Larosa, Ben Silverman, Dan Volpe.
Application Number | 20220007603 17/473757 |
Document ID | / |
Family ID | 1000005869298 |
Filed Date | 2022-01-13 |
United States Patent
Application |
20220007603 |
Kind Code |
A1 |
Volpe; Dan ; et al. |
January 13, 2022 |
STACKED SHALLOW WATER CULTURE (SSWC) GROWING SYSTEMS, APPARATUS AND
METHODS
Abstract
A vertically-stacked growing system includes vertical beams and
horizontal shelves respectively arranged on different vertical
levels. Each horizontal shelf has a length and a width, and
includes horizontal structural supports coupled to at least some of
the vertical beams, decking coupled to the horizontal structural
supports, and multiple walls to form a shallow pond when the
horizontal shelf contains a plant nutrient water culture, thereby
constituting a growing layer of the growing system. The walls
include two side walls along the length and two end walls along the
width. Each horizontal shelf further includes a loading and/or
unloading apparatus to facilitate loading and/or unloading of a
plurality of rafts into and/or out of the shallow pond, via the two
end walls, wherein respective rafts of the plurality of rafts
include a plurality of germinated plants. At least a first
horizontal shelf further comprises a raft conveyance system to move
at least a first raft of the plurality of rafts through a first
shallow pond contained in the first horizontal shelf.
Inventors: |
Volpe; Dan; (Brooklyn,
NY) ; Hawley-Weld; Nico; (Ridgewood, NY) ;
Larosa; Matt; (Brooklyn, NY) ; Klepner; Rachael;
(Brooklyn, NY) ; Alam; Aftab; (Brooklyn, NY)
; Silverman; Ben; (Brooklyn, NY) ; Green;
Jason; (Brookyln, NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Upward Enterprises Inc. |
Brookyln |
NY |
US |
|
|
Assignee: |
Upward Enterprises Inc.
Brooklyn
NY
|
Family ID: |
1000005869298 |
Appl. No.: |
17/473757 |
Filed: |
September 13, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15689035 |
Aug 29, 2017 |
11116156 |
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17473757 |
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PCT/US2017/028999 |
Apr 21, 2017 |
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15689035 |
|
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62325957 |
Apr 21, 2016 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A01G 31/02 20130101;
Y02P 60/21 20151101; A01G 31/06 20130101; A01G 31/00 20130101; A01G
7/045 20130101; A01G 31/04 20130101; A01G 31/042 20130101; A01K
63/045 20130101 |
International
Class: |
A01G 31/06 20060101
A01G031/06; A01G 31/02 20060101 A01G031/02; A01G 31/00 20060101
A01G031/00; A01G 31/04 20060101 A01G031/04; A01G 7/04 20060101
A01G007/04; A01K 63/04 20060101 A01K063/04 |
Claims
1. A vertically-stacked growing system, comprising: a plurality of
vertical beams; and a plurality of horizontal shelves mechanically
coupled to the plurality of vertical beams and respectively
arranged on different vertical levels of the growing system, each
horizontal shelf of the plurality of horizontal shelves having a
length and a width and comprising: a plurality of horizontal
structural supports coupled to at least some of the plurality of
vertical beams; decking, coupled to the plurality of horizontal
structural supports; a plurality of walls to form a shallow pond
when the horizontal shelf contains a plant nutrient water culture,
thereby constituting a growing layer of the growing system, the
plurality of walls comprising: two side walls along the length of
the horizontal shelf; and two end walls along the width of the
horizontal shelf, and a loading and/or unloading apparatus to
facilitate loading and/or unloading of a plurality of rafts into
and/or out of the shallow pond, via the two end walls, when the
horizontal shelf contains the plant nutrient water culture, wherein
respective rafts of the plurality of rafts include a plurality of
germinated plants, wherein: at least a first horizontal shelf of
the plurality of horizontal shelves further comprises a raft
conveyance system to move at least a first raft of the plurality of
rafts through a first shallow pond contained in the first
horizontal shelf when the first shallow pond and the first raft are
present in the growing system; and the loading and/or unloading
apparatus comprises at least one ramp, disposed proximate to at
least one end wall of the two end walls and above the decking.
2. The growing system of claim 1, wherein: each horizontal shelf
contains the plant nutrient water culture to form the shallow pond
constituting the growing layer of the growing system; and the
growing system further comprises the plurality of rafts in the
shallow pond of at least some of the horizontal shelves of the
plurality of horizontal shelves.
3. The growing system of claim 1, wherein the at least one ramp
comprises a plurality of rails.
4. The growing system of claim 1, wherein the at least one ramp
comprises a second ramp disposed proximate to a second end wall of
the two end walls and above the decking, to facilitate unloading of
the respective rafts out of the shallow pond when the horizontal
shelf contains the plant nutrient water culture.
5. The growing system of claim 1, wherein the at least one ramp
comprises a first ramp disposed proximate to a first end wall of
the two end walls and above the decking, to facilitate loading of
respective rafts of the plurality of rafts into the shallow pond
when the horizontal shelf contains the plant nutrient water
culture.
6. The growing system of claim 5, wherein at least the first ramp
includes a plurality of first underwater rails inside an inner edge
of the first end wall to prevent tops of the respective rafts from
dipping under the plant nutrient water culture during the loading
of the respective rafts into the shallow pond.
7. The growing system of claim 6, wherein at least some of the
plurality of first underwater rails include an angled portion to
facilitate loading of the respective raft into the shallow
pond.
8. The growing system of claim 7, wherein respective ends of the at
least some of the plurality of first underwater rails are above the
plant nutrient water culture proximate to the first end wall.
9. The growing system of claim 5, wherein the at least one ramp
comprises a second ramp disposed proximate to a second end wall of
the two end walls and above the decking, to facilitate unloading of
the respective rafts out of the shallow pond when the horizontal
shelf contains the plant nutrient water culture.
10. The growing system of claim 9, wherein the second ramp includes
a plurality of second underwater rails inside an inner edge of the
second end wall to prevent tops of the respective rafts from
dipping under the plant nutrient water culture during the unloading
of the respective rafts out of the shallow pond.
11. The growing system of claim 10, wherein at least some of the
plurality of second underwater rails include an angled portion to
facilitate unloading of the respective rafts out of the shallow
pond.
12. The growing system of claim 11, wherein respective ends of the
at least some of the plurality of second underwater rails are above
the plant nutrient water culture proximate to the second end
wall.
13. The growing system of claim 1, wherein the at least one ramp
comprises: a first ramp disposed proximate to a first end wall of
the two end walls and above the decking, to facilitate loading of
respective rafts of the plurality of rafts into the shallow pond
when the horizontal shelf contains the plant nutrient water
culture, the first ramp comprising a plurality of first underwater
rails inside an inner edge of the first end wall to prevent tops of
the respective rafts from dipping under the plant nutrient water
culture during the loading of the respective rafts into the shallow
pond, wherein at least some of the plurality of first underwater
rails include a first angled portion to facilitate loading of the
respective rafts into the shallow pond; and a second ramp disposed
proximate to a second end wall of the two end walls and above the
decking, to facilitate unloading of the respective rafts out of the
shallow pond when the horizontal shelf contains the plant nutrient
water culture, the second ramp comprising a plurality of second
underwater rails inside an inner edge of the second end wall to
prevent the tops of the respective rafts from dipping under the
plant nutrient water culture during the unloading of the respective
rafts out of the shallow pond, wherein at least some of the
plurality of second underwater rails include a second angled
portion to facilitate unloading of the respective rafts out of the
shallow pond.
14. The growing system of claim 13, wherein the side walls of the
horizontal shelf are higher than at least one end wall of the two
end walls of the horizontal shelf.
15. A method for handling a plurality of rafts of germinated plants
in a vertically-stacked growing system, the vertically-stacked
growing system including a plurality of elongated shallow ponds of
plant nutrient water culture respectively arranged on different
vertical levels of the vertically-stacked growing system, wherein
at least a first elongated shallow pond of the plurality of
elongated shallow ponds has a length and a width smaller than the
length and comprises: two side walls along the length of the
elongated shallow pond; and two end walls along the width of the
elongated shallow pond, the method comprising: A) loading and/or
unloading the plurality of rafts into and/or out of at least the
first elongated shallow pond from the two end walls of the first
elongated shallow pond and not the two side walls of the first
elongated shallow pond; and B) moving at least a first raft of the
plurality of rafts through at least the first elongated shallow
pond of the plurality of elongated shallow ponds, wherein the first
elongated shallow pond includes at least one ramp, disposed
proximate to at least one end wall of the two end walls, to
facilitate loading and/or unloading of the plurality of rafts into
and/or out of the first elongated shallow pond, and wherein A)
comprises: sliding the respective rafts of the plurality of rafts
into and/or out of the first elongated shallow pond via the at
least one ramp.
16. The method of claim 15, wherein the at least one ramp includes
a plurality of first underwater rails inside an inner edge of the
at least one end wall of the two end walls to prevent tops of
respective rafts of the plurality of rafts from dipping under the
plant nutrient water culture during A), and wherein A) comprises:
sliding the respective rafts of the plurality of rafts into and/or
out of the first elongated shallow pond via the plurality of first
underwater rails.
17. The method of claim 16, wherein at least some of the plurality
of first underwater rails include an angled portion to facilitate
the sliding of the respective rafts into and/or out of the first
elongated shallow pond.
18. The method of claim 15, wherein: at least one ramp includes a
first ramp disposed proximate to a first end wall of the two end
walls of the first elongated shallow pond; a second end wall of the
two end walls includes a catchment area constituting a weir for the
first elongated shallow pond, wherein the plant nutrient water
culture flows freely over a top of the weir and into the catchment
area; and A) comprises: A1) loading respective rafts of the
plurality of rafts into the first elongated shallow pond via the
first ramp; and A2) unloading the respective rafts out of the first
elongated shallow pond via the weir.
19. A vertically-stacked growing system, comprising: a plurality of
vertical beams; and a plurality of horizontal shelves mechanically
coupled to the plurality of vertical beams and respectively
arranged on different vertical levels of the growing system, each
horizontal shelf of the plurality of horizontal shelves having a
length and a width and comprising: a plurality of horizontal
structural supports coupled to at least some of the plurality of
vertical beams; decking, coupled to the plurality of horizontal
structural supports; a plurality of walls to form a shallow pond
when the horizontal shelf contains a plant nutrient water culture,
thereby constituting a growing layer of the growing system, the
plurality of walls comprising: two side walls along the length of
the horizontal shelf; and two end walls along the width of the
horizontal shelf, and at least one ramp (106), disposed proximate
to at least one end wall of the two end walls and above the
decking, to facilitate loading and/or unloading of a plurality of
rafts (500) into and/or out of the shallow pond when the horizontal
shelf contains the plant nutrient water culture, wherein respective
rafts of the plurality of rafts include a plurality of germinated
plants.
20. The growing system of claim 19, wherein: each horizontal shelf
contains the plant nutrient water culture to form the shallow pond
constituting the growing layer of the growing system; and the
growing system further comprises the plurality of rafts in the
shallow pond of at least some of the horizontal shelves of the
plurality of horizontal shelves.
21. The growing system of claim 19, wherein the at least one ramp
comprises a first ramp disposed proximate to a first end wall of
the two end walls and above the decking, to facilitate loading of
respective rafts of the plurality of rafts into the shallow pond
when the horizontal shelf contains the plant nutrient water
culture.
22. The growing system of claim 21, wherein at least the first ramp
includes a plurality of first underwater rails inside an inner edge
of the first end wall to prevent tops of the respective rafts from
dipping under the plant nutrient water culture during the loading
of the respective rafts into the shallow pond.
23. The growing system of claim 22, wherein at least some of the
plurality of first underwater rails include an angled portion to
facilitate loading of the respective raft into the shallow
pond.
24. The growing system of claim 23, wherein respective ends of the
at least some of the plurality of first underwater rails are above
the plant nutrient water culture proximate to the first end
wall.
25. The growing system of claim 21, wherein the at least one ramp
comprises a second ramp disposed proximate to a second end wall of
the two end walls and above the decking, to facilitate unloading of
the respective rafts out of the shallow pond when the horizontal
shelf contains the plant nutrient water culture.
26. The growing system of claim 25, wherein the second ramp
includes a plurality of second underwater rails inside an inner
edge of the second end wall to prevent tops of the respective rafts
from dipping under the plant nutrient water culture during the
unloading of the respective rafts out of the shallow pond.
27. The growing system of claim 26, wherein at least some of the
plurality of second underwater rails include an angled portion to
facilitate unloading of the respective rafts out of the shallow
pond.
28. The growing system of claim 27, wherein respective ends of the
at least some of the plurality of second underwater rails are above
the plant nutrient water culture proximate to the second end
wall.
29. The growing system of claim 19, wherein the at least one ramp
comprises: a first ramp disposed proximate to a first end wall of
the two end walls and above the decking, to facilitate loading of
respective rafts of the plurality of rafts into the shallow pond
when the horizontal shelf contains the plant nutrient water
culture, the first ramp comprising a plurality of first underwater
rails inside an inner edge of the first end wall to prevent tops of
the respective rafts from dipping under the plant nutrient water
culture during the loading of the respective rafts into the shallow
pond, wherein at least some of the plurality of first underwater
rails include a first angled portion to facilitate loading of the
respective rafts into the shallow pond; and a second ramp disposed
proximate to a second end wall of the two end walls and above the
decking, to facilitate unloading of the respective rafts out of the
shallow pond when the horizontal shelf contains the plant nutrient
water culture, the second ramp comprising a plurality of second
underwater rails inside an inner edge of the second end wall to
prevent the tops of the respective rafts from dipping under the
plant nutrient water culture during the unloading of the respective
rafts out of the shallow pond, wherein at least some of the
plurality of second underwater rails include a second angled
portion to facilitate unloading of the respective rafts out of the
shallow pond.
30. The growing system of claim 29, wherein the side walls of the
horizontal shelf are higher than at least one end wall of the two
end walls of the horizontal shelf.
Description
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a continuation application of U.S.
application Ser. No. 15/689,035, filed on Aug. 29, 2017, entitled
"STACKED SHALLOW WATER CULTURE (SSWC) GROWING SYSTEMS, APPARATUS
AND METHODS," which is a continuation application of International
Application No. PCT/US2017/028999, filed on Apr. 21, 2017, entitled
"STACKED SHALLOW WATER CULTURE (SSWC) GROWING SYSTEMS, APPARATUS
AND METHODS," which claims priority to U.S. Application No.
62/325,957, filed Apr. 21, 2016, entitled "APPARATUSES, METHODS AND
SYSTEMS FOR STACKED, SHALLOW WATER CULTURE CONVEYANCE, INTEGRATED
FERTIGATION, AND MATERIAL HANDLING." Each of the foregoing
references is hereby incorporated herein by reference in its
entirety.
BACKGROUND
[0002] Agriculture is unique among manufacturing arts in that the
finished product, being at one stage a living organism, can
self-assemble from raw materials under the right growing
conditions. Accordingly, the agricultural arts in general focus on
delivering these right growing conditions, as well as storage,
handling, and conveyance (collectively referred to as "material
handling") of the organism (the "work in process" or "crop") and
any associated containers or materials across time and space in the
production chain.
[0003] For indoor agriculture, efficient material handling is
desired for several reasons. First, efficient material handling can
increase space efficiency, which is usually the major justification
of the cost of an enclosing structure, such as a greenhouse,
warehouse, or other container. Second, production throughput
velocities are often extremely high, due to optimized growth and
lower cycle times characteristic of the younger, higher value,
non-commodity crops suitable for indoor production. Third,
efficient material handling can clear from the growing area
agricultural residues after each crop cycle so as to rapidly create
space for the next crop and also prevent the propagation of
disease. Both result in a higher profit margin for indoor
agriculture. Fourth, a substantial number of unit operations are
often involved in indoor farming, such as seeding, transplanting,
harvesting, washing, drying, mixing, and packaging. Each of these
unit operation is typically implemented onsite, especially when the
finished product is a consumer packaged product as opposed to a
commodity that is sold to processors. Automation of these
operations can reduce the cost of labor. However, even if each unit
operation is fully automated, the storage, handling, and conveying
of material between unit operations still comprises about 80% of
the remaining labor.
SUMMARY
[0004] Embodiments of the present disclosure relate to controlled
environment and/or indoor agriculture. More particularly, the
present disclosure relates to storage, handling, and conveyance
systems (also known as "material handling systems") utilized in the
hydroponic or aquaponics production of organisms such as plants and
fungi. In one example, a vertically-stacked growing system includes
a plurality of vertical beams and a plurality of horizontal shelves
mechanically coupled to the plurality of vertical beams and
respectively arranged on different vertical levels of the growing
system. Each horizontal shelf of the plurality of horizontal
shelves has a length and a width. Each horizontal shelf includes a
plurality of horizontal structural supports coupled to at least
some of the plurality of vertical beams and decking coupled to the
plurality of horizontal structural supports. Each horizontal shelf
also includes a plurality of walls to form a shallow pond when the
horizontal shelf contains a plant nutrient water culture, thereby
constituting a growing layer of the growing system. The plurality
of walls includes two side walls along the length of the horizontal
shelf and two end walls along the width of the horizontal shelf.
Each horizontal shelf further includes at least one ramp, disposed
proximate to at least one end wall of the two end walls and above
the decking, to facilitate loading and/or unloading of a plurality
of rafts into and/or out of the shallow pond when the horizontal
shelf contains the plant nutrient water culture. Respective rafts
of the plurality of rafts include a plurality of germinated
plants.
[0005] In another example, a vertically-stacked growing system
includes a plurality of vertical beams and a plurality of
horizontal shelves mechanically coupled to the plurality of
vertical beams and respectively arranged on different vertical
levels of the growing system. Each horizontal shelf of the
plurality of horizontal shelves has a length and a width and
includes a plurality of horizontal structural supports coupled to
at least some of the plurality of vertical beams. Each horizontal
shelf also includes decking, coupled to the plurality of horizontal
structural supports, and a plurality of walls to form a shallow
pond when the horizontal shelf contains a plant nutrient water
culture, thereby constituting a growing layer of the growing
system. The plurality of walls includes two side walls along the
length of the horizontal shelf; and two end walls along the width
of the horizontal shelf. Each horizontal shelf further includes at
least one ramp, disposed proximate to at least one end wall of the
two end walls and above the decking, to facilitate loading and/or
unloading of a plurality of rafts into and/or out of the shallow
pond when the horizontal shelf contains the plant nutrient water
culture. Respective rafts of the plurality of rafts include a
plurality of germinated plants. The vertically-stacked growing
system also includes a mechanical ventilation system having a
plurality of fans or duct openings disposed along the length of
each horizontal shelf. At least a first horizontal shelf of the
plurality of horizontal shelves further includes a raft conveyance
system to move at least a first raft of the plurality of rafts
through a first shallow pond contained in the first horizontal
shelf when the first shallow pond and the first raft are present in
the growing system. The raft conveyance system includes a
mechanical pusher to move the first raft through the first shallow
pond. At least some of the horizontal shelves further includes a
plurality of lights embedded between at least some of the plurality
of horizontal structural supports
[0006] In yet another example, a vertically-stacked growing system
includes a plurality of vertical beams and a plurality of
horizontal shelves mechanically coupled to the plurality of
vertical beams and respectively arranged on different vertical
levels of the growing system. Each horizontal shelf of the
plurality of horizontal shelves has a length and a width and
includes a plurality of horizontal structural supports coupled to
at least some of the plurality of vertical beams and decking,
coupled to the plurality of horizontal structural supports. Each
horizontal shelf also includes a plurality of walls to form a
shallow pond when the horizontal shelf contains a plant nutrient
water culture, thereby constituting a growing layer of the growing
system. The vertically-stacked growing system also includes a
mechanical ventilation system having a plurality of fans or duct
openings disposed along the length of each horizontal shelf and a
plurality of lights embedded between at least some of the plurality
of horizontal structural supports of each horizontal shelf.
[0007] In yet another example, a vertically-stacked growing system
includes a plurality of vertical beams and a plurality of
horizontal shelves mechanically coupled to the plurality of
vertical beams and respectively arranged on different vertical
levels of the growing system. Each horizontal shelf of the
plurality of horizontal shelves has a length and a width and
includes a plurality of horizontal structural supports coupled to
at least some of the plurality of vertical beams. Each horizontal
shelf also includes decking coupled to the plurality of horizontal
structural supports and a plurality of walls to form a shallow pond
when the horizontal shelf contains a plant nutrient water culture,
thereby constituting a growing layer of the growing system. The
plurality of walls includes two side walls along the length of the
horizontal shelf and two end walls along the width of the
horizontal shelf. Each horizontal shelf also includes a loading
and/or unloading apparatus to facilitate loading and/or unloading
of a plurality of rafts into and/or out of the shallow pond when
the horizontal shelf contains the plant nutrient water culture.
Respective rafts of the plurality of rafts include a plurality of
germinated plants. At least a first horizontal shelf of the
plurality of horizontal shelves further includes a raft conveyance
system to move at least a first raft of the plurality of rafts
through a first shallow pond contained in the first horizontal
shelf when the first shallow pond and the first raft are present in
the growing system. The raft conveyance system comprises a
mechanical pusher to move the first raft through the first shallow
pond.
[0008] In yet another example, a vertically-stacked growing system
includes a plurality of vertical beams and a plurality of
horizontal shelves mechanically coupled to the plurality of
vertical beams and respectively arranged on different vertical
levels of the growing system. Each horizontal shelf of the
plurality of horizontal shelves having a length and a width and
includes a plurality of horizontal structural supports coupled to
at least some of the plurality of vertical beams. Each horizontal
shelf also includes decking coupled to the plurality of horizontal
structural supports and a plurality of walls to form a shallow pond
when the horizontal shelf contains a plant nutrient water culture,
thereby constituting a growing layer of the growing system. The
plurality of walls includes two side walls along the length of the
horizontal shelf and two end walls along the width of the
horizontal shelf. For at least a first horizontal shelf of the
plurality of horizontal shelves, one end wall of the two end walls
constitutes a weir for a first shallow pond when the first
horizontal shelf contains the plant nutrient water culture. The
first horizontal shelf further comprises a catchment area proximate
to the weir to collect and divert the plant nutrient water culture
flowing freely over a top of the weir.
[0009] In yet another example, a vertically-stacked growing system
includes a plurality of vertical beams and a plurality of
horizontal shelves mechanically coupled to the plurality of
vertical beams and respectively arranged on different vertical
levels of the growing system. Each horizontal shelf of the
plurality of horizontal shelves has a length and a width and
includes a plurality of horizontal structural supports coupled to
at least some of the plurality of vertical beams and decking,
coupled to the plurality of horizontal structural supports. Each
horizontal shelf also includes a plurality of walls to form a
shallow pond when the horizontal shelf contains a plant nutrient
water culture, thereby constituting a growing layer of the growing
system. The plurality of walls includes two side walls along the
length of the horizontal shelf and two end walls along the width of
the horizontal shelf. Each horizontal shelf also includes at least
one robotic arm, disposed proximate to at least one end wall of the
two end walls and above the decking, to facilitate loading and/or
unloading of a plurality of rafts into and/or out of the shallow
pond when the horizontal shelf contains the plant nutrient water
culture. Respective rafts of the plurality of rafts include a
plurality of germinated plants.
[0010] In yet another example, a method for handling a plurality of
rafts of germinated plants in a vertically-stacked growing system
is disclosed. The vertically-stacked growing system includes a
plurality of elongated shallow ponds of plant nutrient water
culture respectively arranged on different vertical levels of the
vertically-stacked growing system. At least a first elongated
shallow pond of the plurality of elongated shallow ponds has a
length and a width smaller than the length. The first elongated
shallow pond also includes two side walls along the length of the
elongated shallow pond and two end walls along the width of the
elongated shallow pond. The first shallow pond further includes at
least one ramp, disposed proximate to at least one end wall of the
two end walls, to facilitate loading and/or unloading of the
plurality of rafts into and/or out of the first elongated shallow
pond. The method includes loading and/or unloading the plurality of
rafts into and/or out of at least the first elongated shallow pond,
via the at least one ramp, from the two end walls of the first
elongated shallow pond and not the two side walls of the first
elongated shallow pond.
[0011] In yet another example, a method for handling a plurality of
rafts of germinated plants in a vertically-stacked growing system
is disclosed. The vertically-stacked growing system includes a
plurality of elongated shallow ponds of plant nutrient water
culture respectively arranged on different vertical levels of the
vertically-stacked growing system. At least a first elongated
shallow pond of the plurality of elongated shallow ponds has a
length and a width smaller than the length. The first elongated
shallow pond includes two side walls along the length of the
elongated shallow pond, two end walls along the width of the
elongated shallow pond, and at least one ramp, disposed proximate
to at least one end wall of the two end walls, to facilitate
loading and/or unloading of the plurality of rafts into and/or out
of the elongated shallow pond. The method includes A) loading
and/or unloading the plurality of rafts into and/or out of at least
the first elongated shallow pond, via the at least one ramp, from
the two end walls of the first elongated shallow pond and not the
two side walls of the first elongated shallow pond. The method also
includes B) moving at least a first raft of the plurality of rafts
through at least the first elongated shallow pond of the plurality
of elongated shallow ponds. Step B) also includes using a
mechanical pusher to move at least the first raft through the first
elongated shallow pond. The method further includes C) ventilating
the germinated plants in the respective rafts of the plurality of
rafts in at least the first elongated shallow pond via a plurality
of fans or duct openings disposed along the length of the first
elongated shallow pond.
[0012] It should be appreciated that all combinations of the
foregoing concepts and additional concepts discussed in greater
detail below (provided such concepts are not mutually inconsistent)
are contemplated as being part of the inventive subject matter
disclosed herein. In particular, all combinations of claimed
subject matter appearing at the end of this disclosure are
contemplated as being part of the inventive subject matter
disclosed herein. It should also be appreciated that terminology
explicitly employed herein that also may appear in any disclosure
incorporated by reference should be accorded a meaning most
consistent with the particular concepts disclosed herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The skilled artisan will understand that the drawings
primarily are for illustrative purposes and are not intended to
limit the scope of the inventive subject matter described herein.
The drawings are not necessarily to scale; in some instances,
various aspects of the inventive subject matter disclosed herein
may be shown exaggerated or enlarged in the drawings to facilitate
an understanding of different features. In the drawings, like
reference characters generally refer to like features (e.g.,
functionally similar and/or structurally similar elements).
[0014] FIG. 1 shows a schematic of a vertically-stacked growing
system using shallow water ponds for conveyance of plants.
[0015] FIG. 2 shows a schematic of vertical and horizontal
supporting structures that can be used in a vertically-stacked
growing system.
[0016] FIG. 3 shows a perspective view of a system including
decking disposed on supporting structures that can be used in a
vertically-stacked growing system.
[0017] FIG. 4 shows a side view of a system including decking
disposed on supporting structures that can be used in a
vertically-stacked growing system.
[0018] FIG. 5A shows a side view of a horizontal structural support
disposed on a vertical beam that can be used in a
vertically-stacked growing system.
[0019] FIGS. 5B and 5C show a side view and a perspective view,
respectively, of a horizontal structural support that can be used
in a vertically-stacked growing system.
[0020] FIG. 6 shows a side view of a lighting system that can be
used in a vertically-stacked growing system.
[0021] FIGS. 7A and 7B show a perspective view and a side view,
respectively, of a decking that can be used in a vertically-stacked
growing system.
[0022] FIG. 8 shows a schematic of a ramp disposed in a growing
shelf that can be used in a vertically-stacked growing system.
[0023] FIGS. 9A and 9B show a perspective view and a side view,
respectively, of a ramp that can be used in a vertically-stacked
growing system.
[0024] FIGS. 10A and 10B show a schematic of a vertically-stacked
growing system including horizontal ventilation to achieve desired
temperature, humidity, and CO.sub.2 levels between stacked
layers.
[0025] FIG. 11 shows a top view of the second growing shelf shown
with only the support structure and decking in FIG. 10A.
[0026] FIG. 12 shows a top view of the third growing shelf shown
with a pond liner to contain the plant nutrient solution in FIG.
10A.
[0027] FIG. 13 shows a top view of the fourth growing shelf shown
filled with rafts in FIG. 10A.
[0028] FIGS. 14A and 14B illustrate the ventilation system in the
vertically-stacked growing system shown in FIGS. 10A and 10B.
[0029] FIGS. 15A and 15B show a side view and a perspective view,
respectively, of a free standing vertical conveyance system to load
rafts into growing shelves and/or to collect rafts from the growing
shelves.
[0030] FIG. 16 shows a schematic of an indoor farming system
including a vertically-stacked growing system.
[0031] FIG. 17 illustrates a method of indoor farming using a
vertically-stacked growing system.
[0032] FIG. 18 illustrates a stack of rafts in germination that can
be used in the method illustrated in FIG. 17.
[0033] FIGS. 19A and 19B illustrate schematic of a vertical
conveyor attached to the growing system to load rafts into growing
shelves and/or to collect rafts from the growing shelves and rafts
onto a growing shelf including shallow water ponds.
[0034] FIG. 20 shows a schematic of a system including a pond
filled with rafts loaded from one end of the pond and unloaded from
the other end of the pond.
[0035] FIG. 21 is a photo of a mature tray of baby greens with
roots hanging through the raft.
[0036] FIG. 22 is a photo of a tray of micro greens being removed
from one end of a pond with a portion of the top of the raft and
plants dipping into the plant nutrient solution to illustrate the
risk of food contamination.
[0037] FIG. 23 shows a schematic of a growing shelf including a
weir structure to unload rafts from a growing pond in the growing
shelf.
[0038] FIGS. 24A and 24B illustrate a schematic of a growing system
using a flume for raft conveyance.
DETAILED DESCRIPTION
[0039] Overview
[0040] Material handing in indoor agriculture can benefit from
several techniques. In one example, material handling can use
vertical stacking, in which plants are grown in vertically stacked
layers. Each stacked layer can be either partially or fully
illuminated by artificially controlled light. The vertical layers
are fertigated (i.e., fertilized and irrigated) to provide
nutrients and water to the roots of the plants. Advantages of
vertical stacking include efficient use of three-dimensional space,
the ability to confer lighting and environmental conditions
differentially and precisely, and the ability to employ different
crop cycle lengths for each layer, thereby optimizing both nutrient
production and yields. However, it might be difficult to visually
inspect plants and maintain higher and lower than waist height
growing areas in vertical stacking. In addition, conveying plants
to and from the vertically stacked layers may also pose a challenge
in large-scale indoor farming. It may also be difficult to
ventilate the tightly confined air volume above each growing
layer.
[0041] In another example, material handling can use a flow-through
approach. Typically, the time duration for the growing stage is
about one or two orders of magnitude longer than the time for pre-
and post-grow processing stages in crop production. Therefore,
there is usually an acute need for storing and conveying the crop,
or work in process, during the growing stage, in a manner that is
efficient both in time and space. Because production is generally
strictly a feedforward process (i.e. harvesting always follows
seeding), growing systems can be designed such that the work in
process "flows through" the growing area, both conceptually and
physically, on its way from an earlier to a later stage processing
area. For crops with long cycles (e.g., longer than 5 weeks), it
can be economical to use physical agents such as human workers or
powered vehicles to convey the crop across the growing area,
typically in batches. For crops with short cycles, it can be more
advantageous to autonomously convey the crop across the growing
area, without the means of physical agents shuttling back and
forth.
[0042] Examples of the flow-through approach include, for example,
a mobile gully system, in which the entire channels (i.e.,
"gullies") of crops are moved by robotic conveyors spanning the
entire length and width of a growing facility. Alternatively or
additionally, the flow-through approach can use a powered flow
rack, in which trays ("flats") containing plants are mechanically
moved along rails and irrigated from above or below. A deep flow
system can also be used for implementing the flow-through approach.
In this case, plants are grown on floating rafts placed atop a long
rectangular pond, allowing the water to act as a near frictionless
conveyor belt for the rafts to move from one end of the pond to the
other.
[0043] Deep flow systems eliminate rails, belts, and rollers, and
therefore can significantly reduce the cost of conveyance.
Typically, deep flow ponds are 12 to 16 inches deep, 12 to 30 feet
wide, and up to several hundreds of feet long. The ponds are used
not just to hold the rafts, but also for irrigation and nutrient
delivery. To accomplish this, plants are typically seeded within
media filled slots, holes, or containers built into the raft.
Alternatively, plants can also be seeded into the structural matrix
of porous rafts.
[0044] In deep flow systems, there is usually a substantial mass of
water within the growing facility. A larger mass water can make the
deep flow system less vulnerable to fluctuations in ambient
temperature, nutrient level, dissolved oxygen level, water
hardness, and pH value. In other words, the mass of water can
function as a buffer against unwanted environmental
fluctuations.
[0045] However, deep flow systems also have limitations. For
example, the depth of the water increases the overall height of
each shelf, thereby limiting the number of deep flow systems (or
deep flow layers) that can be stacked within a given space.
Additionally, the weight of the water requires larger structural
supports, which can further increase the height of each shelf. Yet
another example of a limitation of deep flow systems is the high
volumetric flow rate used in circulating water, which in turns
involves large expensive pumps and high electricity use. A further
disadvantage is the high nutrient load in absolute terms in order
to achieve the required concentrations of those nutrients. Another
example of a limitation is the need to raise the rafts up over the
lip of pond (which is necessarily higher than the water level) in
order to remove the raft from the pond. This requires additional
space between shelves in order to prevent plants from the plants
from hitting the bottom of the next shelf and becoming damaged.
[0046] In many mobile gully systems and some deep flow systems, one
material handling feature is the progressive adjustment of
plant-to-plant spacing as the plant grows in size, in order to
minimize empty space between plants in a responsive manner. This
can be done in a single or multiple discrete steps via, for
example, transplanting. Alternatively, spacing adjustment can be
carried out gradually and continuously. Gullies can easily be
positioned progressively wider from one another over time. However,
due to the high aspect ratio and the underlying conveyance systems
often already in place, this positioning system usually includes a
substantial number of additional equipment, such as a device to
move plants into a new raft with lower planting density, in order
to be implemented in a deep flow system.
[0047] To further improve the material handling process for indoor
agriculture, systems and methods disclosed herein effectively take
advantage of the vertical stacking, flow-through, and water
conveyance approaches described above with improvements made to
each approach. For example, a material handling architecture for an
indoor hydroponic farm includes multiple growing shelves vertically
stacked along a supporting structure. Adjacent growing shelves are
disposed close together vertically (e.g., with spacing less than 18
inches) to fully exploit the indoor space. Horizontal ventilation
(i.e. perpendicular to the long side of the shelf) can be employed
to improve heat dissipation in the growing space between shelves.
The growing shelves use culture ponds to provide nutrients to
plants disposed in rafts floating in the culture ponds, as well as
to convey the rafts during growth. The depth of the culture ponds
is usually less than 6 inches to facilitate vertical stacking. A
ramp and or weir is included in each growing shelf to facilitate
loading rafts on and off the growing shelves. The ramp can also
prevent the plants on the rafts from being dipped into the growing
culture, thereby preventing accidental contamination to the
plants.
[0048] Systems and methods based on the above approach have several
benefits. For example, the shallow culture ponds leads to reduced
resource consumption. The ramp can decrease the probability of food
contamination due to preventing rafts from dipping into water upon
exit of ponds. The close spacing between growing shelves makes
efficient use of both vertical and horizontal space.
[0049] Vertically-Stacked Growing Systems
[0050] FIG. 1 shows a schematic of a vertically-stacked growing
system 1000 using vertical stacking, flow-through, and water
conveyance approaches. The system 1000 includes an array of
vertical beams 50, each of which holds multiple horizontal shelves
100 (also referred to as growing shelves) disposed into multiple
layers vertically along the vertical beam 50. The horizontal shelf
100 has a length 60 and a width 62. Each horizontal shelf 100 is
supported by multiple horizontal structural supports 70
mechanically coupled to a corresponding vertical beam 50 (see more
details in FIG. 2).
[0051] The horizontal shelf 100 includes decking 75, which is
coupled to the multiple horizontal structural supports 70 and
functions as a base or bottom for the shelf 100. The horizontal
shelf 100 also includes at least two side walls 102 along the
length 60 of the horizontal shelf 100 and at least two end walls
104 along the wide 62 of the horizontal shelf 100. The side walls
102 and the end walls 104 form a shallow pond when the horizontal
shelf 100 contains a plant nutrient water culture (also referred to
as a culture), thereby constituting a growing layer of the growing
system. Multiple rafts 500 are used to support plants (e.g.,
germinated plants) that are grown in the system 1000. The rafts 500
can float the plants above the culture, while at the same time
allowing the roots of the plants to acquire nutrients from the
culture underneath of the rafts 500.
[0052] Each horizontal shelf 100 also includes at least one ramp
106 (underneath the two rafts 500 angled up and moving out of the
system) to facilitate loading and/or unloading of the rafts 500
into and/or out of the shallow pond including the culture. In one
example, each horizontal shelf 100 includes a ramp 106 at the
beginning of the shelf 100 to facilitate loading of the rafts 500.
In another example, each horizontal shelf 100 includes a ramp 106
at the end of the shelf 100 to facilitate unloading of the rafts
500. In yet another example, each horizontal shelf 100 can include
one ramp 106 at the beginning and another ramp 106 at the end.
[0053] The length 60 of the shelf 100 can depend on factors such as
the available space in the farm. In some examples, the length 60 of
the shelf 100 can be about 5 feet to hundreds of feet (e.g., about
5 feet, about 10 feet, about 20 feet, about 50 feet, about 100
feet, about 200 feet, about 300 feet, or about 500 feet, including
any values and sub ranges in between). Multiple vertical beams 50
can be used to construct a long shelf 100. The spacing between
adjacent vertical beams 50 can be about 5 feet to about 20 feet
(e.g., about 5 feet, about 10 feet, about 15 feet, or about 20
feet, including any values and sub ranges in between).
[0054] The width 62 of the shelf 100 can be about 3 feet to about 6
feet (e.g., about 3 feet, about 3.5 feet, about 4 feet, about 4.5
feet, about 5 feet, about 5.5 feet, or about 6 feet, including any
values and sub ranges in between). In one example, the width 62 of
the shelf 100 can hold only one raft 500, in which case the width
of the raft 500 is substantially similar to the width 62 of the
shelf 100. In another example, the width 62 of the shelf 100 can
hold more than one raft 500 (e.g., two rafts, three rafts, or
more).
[0055] The depth of the shallow pond in the shelf 100 can be
substantially equal to or less than 6 inches (e.g., about 6 inches,
about 5.5 inches, about 5 inches, or less, including any values and
sub ranges in between). The shallow pond can reduce the amount of
water used in each shelf 100, thereby facilitating the construction
of multiple shelves 100 within each system 1000. In some examples,
the system 1000 can include four or more shelves 100 (e.g., 4
shelves, 5 shelves, 6 shelves, 7 shelves, 8 shelves, 9 shelves, 10
shelves, or more).
[0056] The spacing between adjacent shelves 100 can be
substantially equal to or less than 18 inches (e.g., about 18
inches, about 16 inches, about 14 inches, about 12 inches, about 10
inches, or less, including any values and sub ranges in between).
In one example, the multiple shelves 100 are disposed vertically in
a periodic manner, i.e. the spacing between adjacent shelves is
fixed. In another example, the multiple shelves 100 can have more
than one spacing between adjacent shelves 100. For example, the
first two shelves can have a first spacing and the next two shelves
can have another spacing. This multi-spacing configuration can
accommodate, for example, growth of different plants on different
levels in the system 1000.
[0057] The rafts 500 as used in the system 1000 can be made of
foam, plastics, or any other material that can float on water. The
thickness of the rafts 500 can be substantially equal to or less
than 4 inches (e.g., about 4 inches, about 3.5 inches, about 3
inches, or less, including any values and sub ranges in between).
The rafts 500 can have a rectangular shape to maximize the use of
the space in the shelves 100. The length of each raft 500 can be,
for example, about 10 inches to about 50 inches (e.g., about 10
inches, about 20 inches, about 30 inches, about 40 inches, or about
50 inches, including any values and sub ranges in between). The
width of each raft 500 can be, for example, about 5 inches to about
48 inches or the full width of the pond (e.g., about 5 inches,
about 10 inches, about 20 inches, about 30 inches, about 40 inches,
or about 48 inches, including any values and sub ranges in
between).
[0058] In one example, the side walls 102 can be part of the
decking 75 (see, e.g., FIGS. 7A and 7B). In this case, each shelf
100 can include multiple decking 75 disposed and aligned along the
length 60. In another example, the decking 75 can include only the
bottom of the shelf 100 and the side walls 102 can be assembled
separately. The material of the decking 75 can include, for
example, metal (e.g., aluminum or steel), plastic, or glass.
[0059] FIG. 2 shows a schematic of vertical and horizontal
supporting structures that can be used in the system shown in a
vertically-stacked growing system. The illustration shows three
vertical beams 50a, 50b, and 50c. Two arrays of horizontal
structural support 70a(1) and 70a(2) are mechanically coupled to
the two sides of the vertical beam 50a. Similarly, horizontal
structural supports 70b(1) and 70b(2) are coupled to the vertical
beam 50b, and horizontal structural supports 70c(1) and 70c(2) are
coupled to the vertical beam 50c. Each beam 50a/b/c also includes
two base support structures 72a/b/c(1) and 72a/b/c(2) (collectively
referred to as base support structures 72). The base support
structures 72 can include "I" shape beams to secure the vertical
beams 50 (as well as components disposed directly or indirectly on
the vertical beams 50) to the floor.
[0060] FIG. 3 shows a perspective view of a system including
decking disposed on supporting structures that can be used in the
system in a vertically-stacked growing system. The first shelf
100(1) does not include any decking to illustrate the underlying
supporting structures, including the horizontal structural support
70. The second shelf 100(2) includes three decking 75a, 75b, and
75c, aligned along the length of the shelf. Each decking 75a/b/c
has its own side walls 102 and adjacent side walls 102 define a gap
103. A liner can be used to cover the decking 75 so as to form a
water-proof container to hold the shallow pond (see, e.g., FIG.
10A). The piecewise configuration of the shelf 100 allows
convenient construction of shelves 100 having an arbitrary length
by increasing or decreasing the number of decking 75.
[0061] FIG. 4 shows a side view of a system including decking
disposed on supporting structures that can be used in a
vertically-stacked growing system. FIG. 4 illustrates two vertical
beams 50a and 50b. On each level, a corresponding decking 75 is
disposed between the two vertical beams 50a and 50b, and the
decking 75 is supported by the two horizontal structural supports
70a and 70b coupled to the vertical beams 50a and 50b,
respectively.
[0062] FIG. 5A shows a side view of a horizontal structural support
70 disposed on a vertical beam 50 that can be used in a
vertically-stacked growing system. FIGS. 5B and 5C show a side view
and a perspective view, respectively, of a stand-alone horizontal
structural support 70 that can be used in a vertically-stacked
growing system. Each horizontal structural support 70 includes a
plate 710 to couple the horizontal structural support 70 to the
vertical beam 50 via two sets of screws 715a and 715b. The
horizontal structural support 70 also includes a horizontal arm 720
(also referred to as horizontal beam 720) and two U channels 730
coupled to the two sides of the horizontal arm 720. In some cases,
the plate 710 can be coupled to the horizontal arm 720 via welding.
In some cases, the U channels 730 can be coupled to the horizontal
arm 720 via welding. As shown in FIG. 5A, the decking 75 is
disposed on the two U channels 730 so that the horizontal portion
of the decking 7075 is flush with the top of the horizontal arm
720. And the gap 103 defined by adjacent side walls 102 has the
same width as of the horizontal arm 720. This configuration allows
convenient alignment of multiple decking 75.
[0063] FIG. 6 shows a side view of a lighting system 6000 that can
be used in a vertically-stacked growing system. The system 6000
includes a vertical beam 6050 and two horizontal structural
supports 6700a and 6700b disposed on the vertical beam 6050. A
decking 6075 is disposed on the second horizontal structural
support 6700b. A first horizontal support structure 6800a for light
strips on a first level is mechanically coupled to the first
horizontal structural support 6700a and a second horizontal support
structure 6800b for light strips on a second level is mechanically
coupled to the second horizontal structural support 6700b. In one
example, the ends of the light strip horizontal support structures
6800a and 6800b can be disposed in the U channels 6730a and 6730b
in the horizontal structural supports 6700a and 6700b,
respectively, to acquire mechanical support. The supported light
strips 10071 are shown in FIG. 10A.
[0064] The light strips 10071 can include light emitting diodes
(LEDs) to provide artificial light for the plants. In one example,
the light strips 10071 can include broadband light sources. In
another example, the light strips 10071 can include single-color
light sources, such as LEDs emitting a single color (e.g., pink
LED, green LED, etc.).
[0065] FIGS. 7A and 7B show a perspective view and a side view,
respectively, of a decking 7000 that can be used in a
vertically-stacked growing system. The side view in FIG. 7B is
along the AA' line indicated in FIG. 7A. The decking 7000 includes
two side walls 7102 defining a bottom section in between. The
bottom section includes flat portions 7075 and corrugated portions
7078 (also referred to as ridges). In operation, the corrugated
portion 7078 can be disposed on horizontal structural supports
(e.g., 730 in FIG. 5A). This corrugated configuration can provide
improved mechanical strength to the decking 7000, especially when
water culture is contained in the resulting growth system. In some
examples, the height of the corrugations in the corrugated portion
7078 can be substantially equal to the distance between the top of
730 and the top of 720 shown in FIG. 5A. In this case, a continuous
horizontal surface without gaps (e.g., gaps 103 in FIG. 3) in the
side wall.
[0066] For each decking 7000, the corrugated portion 7078 can
include 5 or more corrugations (e.g., 5 corrugations, 7
corrugations, 10 corrugations, 15 corrugations, or more, including
any values and sub ranges in between). The area ratio of the
corrugated portion 7078 width to the flat portion 7075 can be about
5% to about 50% (e.g., about 5%, about 10%, about 15%, about 20%,
about 25%, about 30%, about 35%, about 40%, about 45%, or about
50%, including any values and sub ranges in between). As used
herein, the area of the corrugated portion 7078 means the
horizontal area without taking into account the area of the
vertical walls in the corrugations.
[0067] FIG. 8 shows a schematic of a ramp 8600 disposed in a
growing shelf that can be used in a vertically-stacked growing
system 8000. FIGS. 9A and 9B show a perspective view and a side
view, respectively, of the ramp 8600. The system 8000 includes a
vertical beam 8050 and horizontal structure support 8070 to support
a growing shelf 8100. The ramp 8600 is disposed in the growing
shelf 8100 and includes three supporting spacers 8610a, 8610b, and
8610c disposed on the floor of the growing shelf 8100 to support an
array of rails 8635. The rails 8635 includes a flat region 8620
(also referred to as a horizontal region 8620) and an angled region
8630 (also referred to as a ramped region 8630). The third
supporting spacer 8610c is higher than the other two supporting
spacers 8610a and 8610b so as to create the angled region 8630. In
some cases the third supporting spacer 8610c can be variable in
height in order to allow the angled region 8630 to lowered to a
horizontal position when not in use.
[0068] In one example, the flat region 8620 and the angled region
8630 use a continuous rail. In another example, the flat region
8620 includes a first piece of rail and the angled region 8630
includes a second piece of rail. The two pieces of rails can be
mechanically coupled together or separated. The ramp 8600 can
include 2 or more rails 8635 so as to support rafts (e.g., 2 rails,
3 rails, 4 rails, 5 rails, 6 rails, 7 rails, 8 rails, or more).
[0069] In operation, the rails 8635 can be underneath the surface
of the shallow pond. The angled region 8630 can facilitate loading
or unloading the rafts, while the flat region 8620 can support the
rafts to maintain the rafts at certain level above the pond
surface. In combination, the ramp 8600 can prevent the raft from
dipping into the shallow pond and accordingly prevent contamination
of plants by the growth culture in the shallow pond. The system
8000 also includes a catchment area 8900 (also referred to as a
gutter 8900) to collect the growth culture that may be accidentally
spilled due to loading and/or unloading of rafts. In some examples,
a similar catchment area can also be included in the offloading end
of the pond.
[0070] The system 8000 also includes a conveyer 8700 to move rafts
in the growing shelf 8100. The conveyer 8700 includes a mechanical
pusher to push rafts along the length of the shelf 8100. Other
techniques can also be used. In one example, the raft conveyer 8700
includes a water pump to control a flow of the growing culture in
the shallow pond and this flow can move the rafts. In another
example, the conveyor 8700 can include an air flow apparatus to
control a flow of air across the rafts so as to move the rafts.
[0071] Vertically-Stacked Growing Systems Including Horizontal
Ventilation
[0072] FIGS. 10A and 10B show a schematic of a vertically-stacked
growing system 10000 including horizontal ventilation to achieve
desired temperature, humidity, and CO.sub.2 levels between stacked
layers. FIG. 10A shows four growing shelves 11000, 12000, 13000,
and 14000, each of which is in a different stage of construction,
so as to illustrate the structures in the system 10000. The first
shelf 11000 includes only the supporting structures, including
vertical beams 10050 and horizontal structural support 10070 and
base support 10072 mechanically coupled to the vertical beams
10050. The first shelf 11000 also shows an array of light strips
10071 disposed substantially parallel to the horizontal structural
support 10070.
[0073] An array of horizontal ventilation ducts 11500 (also
referred to as horizontal air ducts or air apertures) is disposed
along the length of the first shelf 11000. In some cases, the
horizontal ventilation ducts 11500 can be mechanically attached to
the vertical beams 10050 and/or the horizontal structure support
10070. The horizontal ventilation ducts 11500 can acquire air flow
from vertical ventilation ducts 11200 (see FIG. 10B). In one
example, the vertical ventilation ducts 11200 are exposed to the
ambient environment within the indoor farm. In another example, the
vertical ventilation ducts 11200 can have opening(s) coupled to the
outdoor environment. In this case, the vertical ventilation ducts
11200 may introduce cold air from the outdoor environment to
efficiently dissipate heat generated by LEDs in the growing system.
In yet another example, the vertical ventilation ducts 11200 can
have opening coupled to an air handling system which can provide
heating, cooling, humidification, dehumidification, carbon dioxide
injection, or otherwise conditioned air as useful to provide
desired environmental conditions in the growing area.
[0074] In operation, the horizontal ventilation ducts 11500 can
produce air flows perpendicular to the length of the shelf 11000
(and other shelves as well). Since multiple horizontal ventilation
ducts 11500 are disposed along the length of the shelf 11000, the
temperature, humidity, or other environment parameters can be
maintained at a substantially uniform level longitudinally.
Alternatively, different horizontal ventilation ducts 11500 at
different locations along the length of the shelf 11000 can be
configured to produce different air flows so as to create different
growth environments along the length of the shelf 11000. For
example, the beginning of the shelf 11000 may have a higher
temperature to facilitate growth of plants which are just
germinated, while the end of the shelf 11000 may have a higher
humidity to facilitate growth of nearly mature plants.
[0075] The second shelf 12000 includes decking 12075, including
side walls 12102, disposed on the supporting structures, which are
similar to the supporting structures shown in the first shelf
11000. In addition, a catchment area 12900 is also included in the
second shelf 12000 to collect growth culture that might be spilled
over the shallow pond in the growing shelves. The catchment area
12900 is coupled to a plumbing system 10090, which can be coupled
to source tanks of growing cultures. The spillover can either be
continuous as the primary draining method of the pond or
non-continuous in the case of another drain such as a stand pipe
located elsewhere in the pond. In both cases, one purpose of the
spillover/catchment area 12900 is to create a lesser height to lift
over the rafts 14500 so as to move the rafts 14500 out of the
ponds.
[0076] In the third shelf 13000, a liner 13100 is disposed on the
decking (e.g., 12075) so as to form a liquid container that can
hold liquid growing culture and form a shallow pond. In the fourth
shelf 14000, rafts 14500 used to hold plants are floating in the
shallow pond. Two lanes of rafts 14500 are included in each side of
the shelf 14000, but other numbers of lanes of rafts 14500 can also
be used.
[0077] FIG. 11 shows a top view of the second growing shelf 12000
shown in FIG. 10A. This top view shows the corrugated bottom of the
decking 12075. The corrugations are disposed along the width of the
shelf 12000, but each corrugation is parallel to the length of the
shelf 12000. It can also be seen that the vertical beams 10050 can
include "I" shape beams, which can have a simple mechanical
structure and provide secure mechanical support for the rest of the
system.
[0078] FIG. 12 shows a top view of the third growing shelf 13000
shown in FIG. 10A. The liner 13100 covers the corrugated bottom of
the decking 12075 and forms a flat bottom for the shallow pond.
FIG. 13 shows a top view of the fourth growing shelf 14000 shown in
FIG. 10A. The shelf 14000 includes two sides 14000a and 14000b.
Each side includes two lanes for rafts 14500, so four longitudinal
sequences of rafts 14500 can be loaded into the shelf 14000.
[0079] FIGS. 14A and 14B illustrate the ventilation system in the
vertically-stacked growing system 10000 shown in FIGS. 10A and 10B.
The horizontal ventilation ducts 11500 includes an array of
apertures 11550 defined by a ventilation strip 11520. In one
example, the ventilation strip 11520 can be a hollow rectangular or
square tube. In another example, the ventilation strip 11520 can
include a hollow cylindrical tube. The diameter of each aperture
11550 can be, for example, about 0.1 inch to about 5 inches (e.g.,
about 0.1 inch, about 0.2 inch, about 0.5 inch, about 1 inch, about
2 inches, about 3 inches, about 4 inches, or about 5 inches,
including any values and sub ranges in between). In one example,
all the apertures 11550 have the same diameter. In another example,
different diameters can be used for different apertures so as to
generate different growth conditions along the length of the
shelf.
[0080] In some examples, the array of apertures 11550 can include a
two-dimensional (2D) array of apertures. The 2D array of apertures
can include, for example, two rows, three rows, four rows, five
rows, six rows, seven rows, eight rows, nine rows, ten rows, or
more.
[0081] In one example, the apertures 11550 are disposed into a
periodic array and the pitch of the array can be about 1 inch to
about 5 inches (e.g., about 1 inch, about 2 inches, about 3 inches,
about 4 inches, or about 5 inches, including any values and sub
ranges in between). In another example, the apertures 11550 are
disposed into an aperiodic array. For example, the spacing between
adjacent apertures 11550 can change at different locations along
the ventilation strips 11520.
[0082] The apertures 11550 shown in FIGS. 14A and 14B have a round
shape. In practice, other shapes can be used as well, including
rectangular apertures, square apertures, and elliptical apertures,
among others.
[0083] FIGS. 15A and 15B show a side view and a perspective view,
respectively, of a vertical conveyance system 15600 to load rafts
into growing shelves and/or to collect rafts from growing shelves
15100 to 15400. The conveyance system 15600 includes a vertical
structure 15630 and a reception area 15650, which is disposed on
the vertical structure 15630 and can move along the vertical
structure 15630 via an actuator 15620 (e.g., a translation belt).
The reception area 15650 can receive a raft 15150 from any one of
the shelves 15100 to 15400 as the reception area 15650 is moving up
and down along the vertical structure 15630. In some examples, the
vertical conveyor system 15600 can move on the ground so as to
reach different stacks for rafts loading and unloading. In some
examples, each stack can have its own vertical conveyance system
15600. In some examples, one vertical conveyance system 15600 can
be shared by multiple stacks.
[0084] Indoor Farming Systems Including a Vertically-Stacked
Growing System
[0085] FIG. 16 shows a schematic of an indoor farming system 16000
including a vertically-stacked growing system 16100 that can be
substantially similar to any of the systems described above. The
growing system 16100 receives germinated plants from a germination
area 16200, where a seeding equipment 16300 plants seeds into rafts
for the seeds to germinate. The nutrients to grow the plants are
received from tanks 16400. In one example, the tanks 16400 can
include pre-mixed nutrient growth culture. In another example, the
tanks 16400 can include one or more fish tanks, where fish can grow
and provide the plant nutrient growth culture. In addition, the
fish tanks can also provide waters to water-cool LED lights in the
growing system 16100.
[0086] The farming system 16000 also includes harvesting equipment
16500 to harvest mature plants delivered by the growing system
16100. The harvested plants can be sent to a pre-cooling area
16700. An optional dry storage area 16900 in the system 16000 can
be used for long-term storage of other materials and supplies
needed for the operation of the farming system.
[0087] The growing system 16100 can be substantially similar to any
of the growing systems described above. In some examples,
additional components can included to for environmental control.
There may be aspects of a material handling architecture that can
either prevent a closer spacing of shelves or are caused by closer
shelf spacing. Issues preventing the closer spacing of shelves can
include: (a) the height of lights structure and other components;
(b) increased heating of the plants due to less distance between
lights and the plats; (c) the ventilation of a small space to bring
in carbon dioxide and remove heat and humidity (which can influence
optimal plant growth); and (d) the depth of the pond.
[0088] The depth of the pond for embodiments disclosed herein has
been reduced compared to deep water culture, and this allows for
moving shelves closer together. The disclosed embodiments can be
configured to avoid issues associated with such shortened ponds
that could otherwise have problems, including reduced oxygenation
of the water, reduced capacity to buffer changes in temperature, pH
and other water chemistry, and gradients in nutrient
availability.
[0089] The height of various system components can have a direct
relationship to the overall space between shelves. The relevant
components from bottom to top can be: the structural supports, the
decking of the shelf, the height of the pond walls (and indirectly
the height of the water), the space for the fully grown plants, an
air gap for ventilation and variation in plant height, and the
lights. By embedding the lights into the empty space between the
structural supports, the height of the shorter of those two
components can be reduced or eliminated. This can be accomplished
partly through novel illuminators, such as LED lights. In some
cases, the shelves may be adjustable, either manually or otherwise,
to accommodate different implementations (e.g., growing plants of
varying heights).
[0090] In some examples, the heat generated by artificial lights
can be the major heat source in the space. If left unchecked, this
heat can raise the air temperature beyond the upper limit tolerated
by the plants. Heat dissipation can thus become an important factor
in determining ventilation requirements. In some examples,
water-cooled LED lights can be used. This method combines energy
efficient LEDs, which produce less heat, with a more efficient heat
removal system compared to ventilation. This water can also be, for
example, routed to fish tanks to keep the temperature of tanks at
optimal conditions for fish growth without the use of additional
water heaters. Additionally, in some examples the lights can be in
contact with and thermally coupled to the decking above to transfer
the heat from the LEDs to the pond water to keep pond water and
LEDs at optimal temperature in a passive manner. The reduction in
the heat load can reduce power consumption for ventilation. In some
cases, active dissipation (e.g., via air flows) can still be used
to, for example, remove heat and water vapor introduced by the
plants and replace carbon dioxide used by the plants.
[0091] Without proper ventilation, the plants may create an
environment unsuitable for their continued growth. In some
examples, as the shelves get closer together, natural ventilation
of the plant environment becomes restricted and the need for
mechanical ventilation may increase. Shelves of plants can be
ventilated by fans moving air along the long axis of the shelf.
This may result in gradients of temperature, humidity, and carbon
dioxide as the air that moves across the plant canopy is depleted
of carbon dioxide and altered from optimal temperature and humidity
as the plants perform gas exchange with the air. These gradients
can reduce growth rates of plants because only a small section of
the shelf is under ideal conditions.
[0092] By moving rafts into and out of the ponds on the ends, fans
or a duct with periodic openings can be placed along the long axis
of the shelf. This is normally prevented by the need to access the
plants along this side in conventional systems. The performance of
longitudinal fans can be improved by placing fans at multiple
points along a shelf which can allow them draw in more air outside
the shelf. However, this approach can also use additional height to
fit the fans between the plants and the lights. By placing the
mechanical ventilation along the long axis, these gradients are
reduced to negligible levels due to the distance air travels across
the plants being reduced by orders of magnitude. For example, in
one configuration, the distance is reduced from 80 feet to 4 feet.
The reduced gradients can improve crop growth throughout the
system. In some embodiments, sensors and valves (connected to one
or more processors) can be utilized to
automatically/programmatically control and maintain desired
ventilation conditions.
[0093] In addition to improved crop growth, ventilating from the
side can also reduce the air gap above the plants. Plants can
typically only tolerate a small range of air velocities without
suffering mechanical damage or having their growth pattern
negatively affected. The volumetric flow rate of the air can be
determined based on the requirements to bring new air to control
temperature, humidity, and carbon dioxide levels. Moving across the
short axis reduces this requirement because the air has less
distance to be changed before being exhausted. Air velocity and
volumetric flow rate are related by the cross sectional area of the
space the air is moving through by the following equation:
Volumetric Flow Rate=Velocity.times.Cross sectional Area. The cross
sectional area is the height of the air gap multiplied by the width
of the air gap. By moving air across the long axis instead of along
it, the width of the air gap can be much longer, enabling a shorter
gap with the same cross sectional area and thus the same velocity
and flow rate. Additionally, the reduced flow rate requirements
reduce the required cross sectional area which reduces the height
of the gap.
[0094] Plumbing in Vertically-Stacked Growing Systems
[0095] The simplest plumbing configuration for a long narrow pond
is to pump in water at one end and drain it from the other.
However, in the shallow water culture as described herein, this can
result in nutrient gradients as plants near the input take more
nutrients and the roots of those plants block nutrient flow through
the pond. In some examples, these gradients can be controlled and
reduced by, for example, utilizing a customized pond with nutrient
apertures, and/or by running one or more pipes or tubes along the
bottom of the pond with holes along the length. Setting the size
and/or spacing of those apertures/holes appropriately, water and
nutrients can be added throughout the pond isometrically, i.e.,
with the same inflow rate to each portion of the pond. The pipe(s)
or tube(s) can be straight or can follow a sinusoidal and/or other
pattern.
[0096] In some examples, the pond can be configured with sensors
and controls such that nutrient deficiencies in certain locations
of the pond can be addressed individually. For example, if a
processor, running a program and connected to a series of sensors
and actuators, identifies a nutrient level outside of specified
parameters, the program can issue instructions to one or more
actuators to increase the nutrient level to a specified portion of
the pond.
[0097] In the system shown in FIG. 16, water for the pond can be
oxygenated to provide oxygen to the plant roots. A standard method
of adding oxygen to water is through the use of air stones.
However, air stones may be less effective in a short depth as
disclosed herein because there may be insufficient time for the air
bubbles to dissolve in the water before reaching the surface.
Injecting air into the plumbing prior to the ponds allows time for
the oxygen to be dissolved into the water, providing adequate
oxygen to the plant roots. Additionally, as with the nutrients,
some embodiments of the disclosure may use a processor-implemented
system for monitoring and maintaining oxygenation throughout the
pond within specified parameters.
[0098] As discussed above, some examples reduce the height of the
water and can therefore be more efficient. However, the reduction
in height of the water also reduces the volume of water in the
system, and in turn can reduce the water's ability to buffer
changes in water chemistry, such as pH or ammonia and nitrite
levels. For example, adding 0.0003 L of ammonia to 0.9997 L of
water changes the concentration of ammonia from 0 ppm (part per
million) to 300 ppm. Adding the same amount of ammonia to 99.997 L
of water changes the concentration of ammonia from 0 ppm (part per
million) to 3 ppm. The concentration of some compounds is what
determines the effect. pH affects the ability of plants to uptake
nutrients, while ammonia and nitrite are poisonous to fish and
plants until it is converted to nitrate.
[0099] As disclosed herein, the reduction in buffer can be
counteracted by increasing the size of the pump tank and/or
increasing the flow rate of the water through the system to improve
the effectiveness of the biological filters, which control these
levels. The reduction in height of the water can also reduce the
ability of the water to act as a temperature buffer for the water
and maintain the appropriate temperature for the roots. According
to some examples, this can also be mitigated by increasing the flow
rate of the water.
[0100] Additionally or alternatively, water used to cool the lights
can be routed into the ponds to transfer the heat from the lights
into the water and maintain a higher temperature. In some
implementations, processor-implemented methods, along with sensors
and actuators, can be used to provide precise control over such
parameters, as discussed above with reference to oxygenation and
nutrients. For example, when temperature sensors measure a
temperature below a specified parameter, the processor can issue an
instruction to a valve to redirect some or all of the LED-heated
water to the pond or portion thereof. This can be done continuously
until the measured parameter is back within range or can be done
stepwise/incrementally to avoid overshooting the desired
temperature. Additionally or alternatively, the lights can be
thermally coupled to the decking 75 in order to transfer heat to
the pond water of shelf above and provide greater thermal
dissipation for the lights.
[0101] Processor-Executed Methods
[0102] Some examples of the disclosure include method and systems
that utilize a pond routing algorithm or process. Such a process or
algorithm can be utilized for routing individual rafts into and out
of ponds, based on a variety of parameters, such as: (a) keeping
rafts in the ponds for specified times, such as a multiple of 7
days (or an alternating number such as 10 and 11 days that adds up
to a multiple of 7 days, etc.), so that the same harvest and
delivery schedule can be carried out on a weekly basis; (b) the
length of time in the ponds plus the length of time spent in a
germination area before the ponds can be chosen in general to
optimize yield per square foot of growing space per time.
[0103] In some examples, each pond can be set up to contain only
one species, in order to optimize the environmental conditions for
that species. In some examples, multiple species can be used
together if they are symbiotic, and such information recorded and
tracked.
[0104] In some examples, when rafts are harvested, the order of
harvest can follow the makeup of the finished product stock keeping
unit (SKU). Many SKUs can be a mix of several crops, and each
individual crop can be included in multiple SKUs. In some examples,
to harvest by SKU, first all the rafts of the first crop in that
SKU are harvested, then the next crop, and so on. In some other
examples, the rafts for a particular SKU can be harvested in an
order that optimizes freshness/taste. The harvest order can also be
configured to minimize changeover time on both the harvesting
machine (e.g., changing the height of the cutting blade, in between
crops, somewhat costly in terms of time), and on the washing,
drying and mixing steps (removing excess product, in between SKUs,
very costly in terms of time). Some examples can be configured such
that each SKU exactly or approximately includes specified
proportions of ingredient crops that define the SKU.
[0105] Some examples described herein can include mobile sensors in
a vertically stacked growing environment. In these cases, instead
of having many sensors installed above each growing layer, a small
number of "sensor assemblies" (e.g. one for multiple growing
layers) are able to move along rails installed next to or above
each growing layer, such that each layer is connected to adjacent
layers via rails. Multiple sensor assemblies are able to move along
the rails and thus throughout the entire growing area.
[0106] Sensors that can be used herein include, for example,
imaging sensors, such as thermal imaging sensors, fluorescent
imaging sensors, hyperspectral sensors, multispectral sensors, RGB
sensors, and Light Detection and Ranging (LIDAR) sensors, among
others. Sensors for detecting the distance between the sensor
assembly to the rafts can also be used. These sensors can be a
proxy for yields as higher-yield rafts sink deeper in the ponds. In
some examples, the system can use air chemistry sensors to measure
temperature, humidity, and/or CO.sub.2 in the area near the plants
or in the ambient environment. In some examples, light sensors can
be used for detecting performance or degradation of light fixtures.
In some examples, sensors for identifying the location of
individual rafts can be used to track the location of plants. In
yet other examples, the sensor assembly may include one or more
communication devices to communicate sensor information from the
sensor assembly to one or more computing devices and/or other
sensor assemblies, and/or receive information from one or more
computing devices and/or other sensor assemblies.
[0107] In one example, these sensors can be placed on rails for the
sensors to move from one shelf to another. Alternatively, sensors
can be fixed instead of being mobile. In yet another example,
mobile sensors can move throughout the growing area on unmanned
aerial vehicles (UAVs) instead of rails.
[0108] Some examples described herein can include improved raft
design that (a) use less media, (b) provide a better moisture
profile for the plants, and (c) enable growing microgreens (7-14
day old crop) as opposed to baby greens (14-28 day old crop).
Existing rafts feature either holes or slots. In one example, a
raft can incorporate a common "top area" in which the root
structure and surrounding media of each crop is connected
horizontally to those of its neighbors, thus allowing a horizontal
capillary wicking action in addition to vertical action. In another
example, a raft can have slanted rather than vertically straight
slots. This can balance moisture at the stem-root junction of the
plant (since moisture at this junction and above can cause the
plant to rot) while also minimizing the thickness of the raft and
thus the amount of media used.
[0109] In some cases, the rafts can be injection blow molded
plastic or otherwise molded plastic, rather than a foamed
polystyrene resin, enabling the trays to last about five times
longer. These trays also tend not to deform when subject to heat,
and can be easier to recycle. Various air gaps can also be used in
the profile of the raft.
[0110] Material Handling Process Using a Vertically-Stacked Growing
System
[0111] FIG. 17 illustrates a method 17000 of material handling
using a vertically-stacked growing system including processing
areas 17010a and 17010b. The method 17000 includes, at step 17100,
moving rafts from germination area (e.g., area 16200 shown in FIG.
16) to the level of ponds in the vertically-stacked grown system.
The rafts are then loaded into the corresponding ponds, at step
17200. At step 17300, the rafts are conveyed along the ponds as the
plants disposed in the rafts are growing. Once the plants are
mature and ready for harvesting, the rafts are unloaded off the
ponds, at step 17400. The unloaded rafts are transferred to the
vertical level of a harvesting machine, at step 17500. At step
17600, the rafts are loaded into the harvesting machine for
harvesting. More details of each step are described below.
[0112] Moving Rafts to Different Vertical Shelf Heights
[0113] In some cases, rafts can be initially stored in vertical
stacks in a germination room so save space. FIG. 18 shows a stack
18000 of four rafts 18100a, 18100b, 18100c, and 18100d
(collectively referred to as rafts 18100). Each raft 18100 includes
spacers 18150 (also referred to as feet 18150) on the bottom,
allowing for an air gap between adjacent rafts 18100 in the stack
18000. In this manner, the rafts 18100 can be stacked together
without any shelving structure. This configuration also facilitates
loading each raft 18100 into the growing system since there can be
no need to move any shelf structure. Once the rafts are ready to be
moved to the ponds (e.g., when the seed are germinated), they can
be de-stacked and shuttled up to the vertical growing layers.
[0114] FIGS. 19A and 19B show a schematic of a vertical
reciprocating conveyor 19000 to convey the rafts. In this
technique, a raft 19100 can begin in a stacked position, resting
within or on top of a de-stacker. The de-stacker can release the
raft 19100 out of the stack of rafts from the bottom of the raft
and place the released raft onto a short conveyor. The raft 19100
is then conveyed onto an arm 19200 of the vertical reciprocating
conveyor 19000. The arm 19200 includes wheels 19250 to facilitate
conveyance of the raft 19100. In some cases, the arm 19200 can be
attached to or is able to vertically slide up and down along the
end face of the growing shelves. The raft 19100 and reciprocating
arm 19200 can be put on horizontal rails if not attached to the
ends of the shelves. Once the arm 19200 reaches the level of the
desired growing layer, the arm 19200 can either tilt down or
flipper at the end of the arm is released, such that the raft 19100
slides down into the ponds.
[0115] FIG. 19B shows a schematic of the arm 19200 attached to a
growing shelf 19300, which includes a ramp 19500 to receive the
rafts 19100. The ramp 19500 includes a set of underwater rails
inside the inner edge of the pond in the growing shelf 19300 to
prevent the top of raft 19100 from dipping underwater. The arm
19200 of the vertical reciprocating conveyor with rails can have
free spinning wheels 19250 for the raft to slide across. If the
pond has multiple lanes, then the arm 19200 can be designed to
carry multiple rafts 19100 (the same as the number of lanes). The
arm 19200 can also be hinged on the side closest to the growing
shelves 19300, such that they can be rotated upwards for storage
when not in use, thus allowing walkway access.
[0116] Loading Rafts into the Ponds
[0117] In some cases, moving rafts into the pond can be different
from moving rafts out of the ponds because the plants typically
have only just sprouted in the former case. Accordingly, the plants
are usually smaller but more delicate at the loading stage,
compared to the plants at the unloading stage. Plants at this stage
also typically lack large root systems protruding from the bottom
of the raft. The short height of the raft and sprouted plants (if
any), as well as the lack of any protruding roots, means that
moving rafts into the ponds can be less complex than moving them
out.
[0118] Several physiological and food safety requirements can be
used as parameters for this component or step, including: (a)
avoiding mechanical damage to the plants and/or the structure of
the growing media; (b) avoiding dipping the top of the raft into
the water; and (c) preventing the raft from getting water onto the
top of other rafts, for example, through dipping or splashing.
[0119] Depending on the implementation, loading rafts into the
ponds can be accomplished by several methods. In one example, a
ramp can be used to load the raft into the pond (see, FIG. 19B). In
some cases, the ramp can be powered and function as a conveyor. In
some other cases, the ramp can be non-powered and function as a
slide such that raft can slide into the pond under gravity
force.
[0120] In another example, a robotic arm can be used to lift the
rafts over the lip of and into the pond. In some cases, the robotic
arm can lift the rafts from below. In some cases, the robotic arm
can squeeze the raft from the side, in which case the raft can be
placed on a rail leading to the ponds. In some cases, the robotic
arm can lift the rafts from above via, for example, using suction
forces.
[0121] In yet another example, the raft can be loaded into the
ponds via a weir. These techniques can offer substantial, material
improvements compared to manual methods, as they can increase both
the speed of the operation and reduce the possibility of human
errors. The danger of human error usually leads to a wider gap
between vertical growing layers in order to accommodate variations
in the manual placement of rafts into the ponds while respecting
parameters (a), (b), and (c) above.
[0122] Moving Rafts Through the Pond
[0123] In some cases, moving rafts through the ponds is employed to
fill the ponds with rafts. In this case, a new raft is loaded into
the pond via one end and another raft in the pond can be removed
from the other end of the pond. This end loading and unloading
allow the use of small spacing between vertical growing layers
because there is typically no need to handle the rafts from the
side of the shelves.
[0124] Various techniques can be used to move the rafts along the
length of the growing shelf, as well as to prevent the raft from
moving backwards in the pond and from rotating in an unwanted way.
In one example, the raft can be moved along the pond via flows of
the growth culture in the pond. To this end, a water pump can be
used to drive the flow with desired velocity and volume. The water
pump can induce the flow at the beginning of the pond (i.e., where
rafts are loaded into the pond) to push the rafts. Alternatively or
additionally, the water pump can induce the flow at the end of the
pond (i.e., where rafts are unloaded) to drag the rafts.
[0125] In some examples, adjacent ponds on the same shelf are
connected and water flow can be powered with either two pumps or a
reversible pump to cause the net flow of water to increase such
that flow rate is high enough for rafts to be floated over a
weir.
[0126] In another example, the rafts can be moved along the pond
using air flows. Similar to water pumps, multiple air pumps can be
used to create lengthwise air flows. In some cases, the air flows
are at the height of the rafts (not the plants in the rafts) so as
to avoid damaging the plants. In some cases, the air flows can
induce fluid flows in the pond, which in turn, can also drive the
raft along the pond. In some cases the last raft in the sequence
can have a sheet of material attached. The sheet of material can
act as a sail to catch the air flow, and can also protect the
plants from damage due to high air velocities.
[0127] In yet another example, a manual pusher or an automatic
pusher can be used to push new rafts into the ponds to drive those
rafts already in the pond. This method can also be used to remove
rafts from the end of the pond, as new ponds are pushed into the
pond.
[0128] In yet another example, a mechanical pusher can be used to
move rafts in the desired direction (see, e.g., FIG. 8). In yet
another example, the rafts can be linked together (e.g., via hooks)
back to back such that removal of rafts from the far end can pull
other rafts along the length of the pond.
[0129] In some cases, additional devices or components can be used
to prevent the rafts from moving backwards and/or rotating. In one
example, dividing walls or cables can be used to separate the ponds
into multiple rows (or lanes). Each row or lane can have a width
substantially equal to the width of the rafts such that the rafts
may not rotate in the lane. In another example, a material having
the property of asymmetric friction along a single axis can be used
(i.e., one friction along the forward direction and a different
friction along the opposite direction). This material can be
attached to the side walls of the ponds and/or to any dividing
walls in the pond. For example, a set of angled bristles running
the length of the side walls can be disposed in the pond to prevent
backward floating of rafts.
[0130] FIG. 20 shows a schematic of a system 20000 including a pond
20100 filled with rafts 20500 loaded from one end (also referred to
as the receiving end) of the pond 20100 and unloaded from the other
end of the pond 20100. The pond 20100 includes a ramp 20200 at the
receiving end to facilitate loading of rafts 20500. The pond 20100
also includes two end walls 20300a and 20300b. The end wall 20300a
is higher than the end wall 20300b, in which case rafts 20500 can
be removed from the pond 20100 by floating out of the pond 20100.
In the system 20000, the rafts 20500 can be moved along the length
of the pond 20100 (as indicated by the arrow above the pond 20100)
using any of the methods described above. In some cases, the water
level in the pond 20100 can be adjusted to reveal air gaps between
the rafts 20500 and the pond 20100. In one example, this can be
done by having the raft 20500 suspend themselves above the lowered
water level and stand on their own feet. In another example, the
rafts 20500 can stay on some rails.
[0131] Unloading Rafts Out of the Ponds
[0132] Moving rafts out of the pond properly can have significant
influence on the farming system including the yield and sanitary
conditions of the crops. This process is different from moving the
rafts into the ponds because the plants are typically much taller
and can have extensive root systems protruding from the bottom.
There are several parameters for moving the rafts out of the pond,
including: (a) avoiding damage to the plants to maintain product
quality; (b) avoiding damage to the roots to maintain turgidity of
plants and subsequent ability to harvest with automated equipment;
(c) avoiding dipping the plants or the top of the raft into the
water to maintain food safety standards; and (d) preventing the
raft from getting water onto the plants of another raft (for
example through dripping or splashing) to maintain food safety
standards.
[0133] FIG. 21 shows a mature tray of baby greens with roots
hanging through the raft. Methods and systems described herein can
protect the roots from damages to maintain turgidity and thus
harvestability of the plants.
[0134] FIG. 22 shows a tray of micro greens being removed from one
end of a pond. As can be seen, when removed manually, there is a
great risk of dipping the backside (left side in FIG. 23) of the
tray into the water due to the density of the shelves. If the
leaves touch the pond water, food safety is compromised, and they
are no longer a harvestable product.
[0135] FIG. 23 shows a schematic of a system 23000 using a weir
structure 23200 to unload rafts 23100 from water ponds 23350 in a
growing shelf 23300. In the system 23000, the side walls of the
pond 23350 are higher than the end wall over which the rafts 23100
are conveyed. A catchment area 23400 on the outside of the pond
23350 can be used to collect and divert the water.
[0136] In some examples, the flow rate of the water can be
increased in order to allow the rafts to float over the weir
without contacting the weir. In some examples, the flow can be kept
at a level such that there is a minimum overflow of water above the
weir. In these examples, the purpose of the shortened wall of the
weir is to reduce the distance a raft is raised in order to be
removed from the pond.
[0137] In some examples, a processor can be used to manage water
level so as to facilitate the unloading of the rafts 23100, as
there can be a substantial amount of calculations to determine the
amount of water added to the pond 23350 per unit time in order to
optimally raise the level of the water above the height of the weir
23200. To keep rafts from moving past the weir 23200, a gate (not
shown in FIG. 23) can be used. The gate may go across the entire
width of the raft 23100, or may go across only part of the raft
23100. In some cases, the gate may be mechanized or spring loaded
for opening and returning to original positions once a raft 23100
is removed.
[0138] When the rafts 23100 is pushed through (e.g., by some
pushing or pulling component or means), the particular raft 23100
moving out of the pond 23350 can be pushed onto arms or onto a
holding rack, allowing the water to pour over the weir 23200 into
the catchment area 23400, while the raft remains level. In one
example, these arms can be stationary and attached to each shelf to
receive the raft 23100. In another example, these arms can be
mobile and attached to a vertical track on the end of the shelving
system, allowing the arms to move up and down to pick up a raft
from any of the shelves.
[0139] In some examples, rafts can be removed by maintaining the
water level and retracting or removing a gate to allow horizontal
movement. The gate can, for example, retract like the doors of an
elevator, or it can retract by flipping open. There can be a
substantial amount of calculations to determine how deep the gate
may retract and how much water, if any, should be added to the pond
per unit time in order to optimize the unloading process.
Accordingly, in some cases, a processor and one or more sensors can
be used to perform the calculation. The sensors can include, for
example, water level sensors and root-length sensors. In some
cases, a second gate, and associated arms or holding rack, as
described above, can be used for the purpose of controlling when
rafts move past the first gate.
[0140] In some examples, rafts can be removed by a ramp, either
powered like a conveyor or non-powered like a slide. The ramp can
be substantially the same as the ramp 19500 shown in FIG. 19.
Additionally, in some examples, the operator or a mechanized
solution can introduce rafts at the loading side that push the
rafts on the offloading side up the ramp. In some examples, rafts
can be removed by a robotic arm that lifts the rafts over the lip
of and out of the pond, either by lifting from below, squeezing
from the sides, or using suction from above.
[0141] The unloading techniques described herein are advantageous
over manual unloading because they can reduce or eliminate human
error and increase speed. The danger of human error usually leads
to a wider gap between shelves, and therefore a lower yield per
area and volume of real estate. In particular, usage of a weir or
similar method does not require the raft to move upwards to go over
the pond wall or come out of the water, thereby eliminating the
risk of splashing or dripping onto other rafts and also eliminating
the need to increase the space between shelves for the lifting
action.
[0142] Moving Rafts from Different Shelf Heights to the Height of
Harvesting
[0143] In some cases, moving the rafts from multiple different
heights to a single common height, without the use of manual
methods such as human workers on a scissor lift, can be helpful to
reduce the operating costs of the farming system. Parameters for
moving the rafts from multiple levels to one level include not
damaging any part of the plant, either the leaves or the roots. The
leaves are the salable product, so any damage can reduce yields.
Damage to the roots can cause the plants to lose turgidity, which
cause the leaves to droop and may prevent the harvesting machine
from harvesting them. Another parameter is that the roots of one
raft may not drip onto the plants of another raft, to preserve food
safety and avoid contamination.
[0144] In some examples, dual use of vertical arms for both
catchment of rafts and conveying of rafts to another vertical level
can be utilized (see, e.g., FIGS. 15A and 15B). The arms described
above to catch rafts as they pass over a weir can also be used to
convey the rafts down or up to a different level. The arms can be
attached to or are able to vertically slide up and down the end
face of the growing shelf. Once a raft has been deposited via the
weir onto the arms, the arms can slide up and down to move the raft
to a different vertical level. In some examples, the pond can have
multiple lanes. In this case, the arms can be configured to hold
multiple rafts. Once the arms reach the level of the harvesting
machine, the raft can be discharged, for example, by tilting
downwards or by opening a set of flippers at the ends of the arms,
into a flume conveyor (see, e.g., FIGS. 24A and 24B).
[0145] In some examples, a set of underwater rails can be used to
prevent the rafts from dipping too deep into the flume. The arms
can, in some implementations, have free spinning wheels for the
raft to slide across (e.g., like the rails 19200 shown in FIG.
19B). In some cases, the arms can be hinged on the side closest to
the growing shelves, such that they can be rotated upwards for
storage when not in use, thus allowing walkway access.
[0146] In some examples, a solid, open-bottomed conveyor can be
used as the horizontal conveyor instead of the flume. In this case,
extra supports within the body of the horizontal conveyor may be
used to discharge the raft into the conveyor. Alternatively, a
non-reciprocating vertical conveyor can be used to move the rafts
between levels, passing through the horizontal conveyor and coming
up via a circular motion. In this instance, the non-reciprocating
vertical conveyor can be installed in addition to the catchment
arms.
[0147] Other methods and systems for moving the rafts from multiple
different heights to a single common height according to the
disclosure include a reciprocating or non-reciprocating vertical
conveyor, or an inclined conveyor or inclined flume between levels.
Using a vertical conveyor saves space compared to an incline
conveyor. The vertical conveyor is also capable of reaching each
level with a single device and motion, and has the ability to move
rafts from lower shelves up and from higher shelves down with the
same motion. The vertical conveyor can be placed on a horizontal
track shuttling the conveyor to the ends of different growing
systems. The vertical conveyor(s) can be freestanding or attached
to each shelf.
[0148] Yet another example may utilize manual unloading (while
standing on a lift) and a reciprocating or non-reciprocating
vertical conveyor. Both the lift and the reciprocating conveyor can
be placed on a horizontal track shuttling them as a unit to the
ends of different growing systems. In some cases, drip trays can be
used during unloading and vertically conveying rafts. The purpose
of drip trays is both to prevent the roots from one raft dripping
onto rafts or other items below, and also to keep the roots
hydrated and moist during their transit from the growing ponds to
the harvester and processing area. Drip trays can be designed to
hold one or more rafts, and can be designed to leave a gap between
the bottom of the drip tray and the bottom of the raft so that
there is space for roots. This gap can be achieved with features
either on the raft (such as feet) or on the drip tray (such as
ridges). Drip trays can either be permanently attached to a
vertical conveyor, or there can be a new drip tray associated with
each row or rows of rafts exiting the ponds.
[0149] Moving Rafts from the Growing Area to the Harvesting
Machine
[0150] In some examples, moving the rafts from the growing area to
the harvesting machine is the last step and, done properly, ensures
the quality of the harvested product. This step can have the same
parameters as above: not damaging any part of the plant, either the
leaves or the roots, and the roots of one raft must also not drip
onto the plants of another raft.
[0151] FIGS. 24A and 24B show a schematic of a growing system 24000
using a flume 24200 for raft conveyance. The system 24000 includes
multiple growing shelves 24300 where rafts 24100 are placed for
growing plants. Rafts 24100 with mature plants are unloaded (e.g.,
via rails 24400 shown in FIG. 24B) to the flume 24200, which
conveys the rafts 24100 toward, for example, a harvesting machine
using water flows. Element/components discussed above (e.g., the
weir, the ramp, and the brushes) can be additionally or
alternatively utilized here. The flume 24200 can be configured with
an accumulation section or feature to accommodate mismatched
throughput rates of the mechanism to remove rafts from the ponds
and of the harvesting machine.
[0152] Myceliated Feed
[0153] In some examples, myceliated feed can be used. Due to the
rapid growth cycles of the crops according to the disclosure, there
can be a high turnover of growing media, which can result in a
bloated waste stream. The spent grow media traditionally can be
converted into compost on site, which would take labor and space to
create an end product that may not be ultimately usable onsite, or
it can be shipped via a contracted service to an industrial
composter. Either way, the spent grow media is converted into a
less valuable product--compost.
[0154] In some examples, the use of myceliated grain, and other
agricultural byproducts, as feed stock for cattle and poultry can
increase the health and growth rate of the livestock. The use of
the spent growing media according to the disclosure as substrate
for mycelial growth can generate the far more valuable product of
fish feed, which typically accounts for 50% of the revenue
generated from the sale of the fish. By replacing fish feed with
myceliated growing media, a system according to the disclosure can
improve operating margins by reducing fish feed costs, husband
healthier and faster growing fish, and reduce the cost of waste
management. An adjacent benefit is the potential to use the
CO.sub.2 generated by the mycelium to increase the CO.sub.2 levels
in the plant growing area, which can increase photosynthesis rates
and the resultant yield.
[0155] The use of spent growing media, comprising of any or all of
coconut coir, vermiculite, perlite, peat moss, plant roots and
stems, etc., as the growing substrate from mushroom mycelium, can
be used to accomplish the following: reduce fish feed costs,
improve fish health and growth rates, reduce waste management
costs, and generate CO.sub.2 for increased plant growth.
CONCLUSION
[0156] While various inventive embodiments have been described and
illustrated herein, those of ordinary skill in the art will readily
envision a variety of other means and/or structures for performing
the function and/or obtaining the results and/or one or more of the
advantages described herein, and each of such variations and/or
modifications is deemed to be within the scope of the inventive
embodiments described herein. More generally, those skilled in the
art will readily appreciate that all parameters, dimensions,
materials, and configurations described herein are meant to be
exemplary and that the actual parameters, dimensions, materials,
and/or configurations will depend upon the specific application or
applications for which the inventive teachings is/are used. Those
skilled in the art will recognize, or be able to ascertain using no
more than routine experimentation, many equivalents to the specific
inventive embodiments described herein. It is, therefore, to be
understood that the foregoing embodiments are presented by way of
example only and that, within the scope of the appended claims and
equivalents thereto, inventive embodiments may be practiced
otherwise than as specifically described and claimed. Inventive
embodiments of the present disclosure are directed to each
individual feature, system, article, material, kit, and/or method
described herein. In addition, any combination of two or more such
features, systems, articles, materials, kits, and/or methods, if
such features, systems, articles, materials, kits, and/or methods
are not mutually inconsistent, is included within the inventive
scope of the present disclosure.
[0157] Also, various inventive concepts may be embodied as one or
more methods, of which an example has been provided. The acts
performed as part of the method may be ordered in any suitable way.
Accordingly, embodiments may be constructed in which acts are
performed in an order different than illustrated, which may include
performing some acts simultaneously, even though shown as
sequential acts in illustrative embodiments.
[0158] All definitions, as defined and used herein, should be
understood to control over dictionary definitions, definitions in
documents incorporated by reference, and/or ordinary meanings of
the defined terms.
[0159] The indefinite articles "a" and "an," as used herein in the
specification and in the claims, unless clearly indicated to the
contrary, should be understood to mean "at least one."
[0160] The phrase "and/or," as used herein in the specification and
in the claims, should be understood to mean "either or both" of the
elements so conjoined, i.e., elements that are conjunctively
present in some cases and disjunctively present in other cases.
Multiple elements listed with "and/or" should be construed in the
same fashion, i.e., "one or more" of the elements so conjoined.
Other elements may optionally be present other than the elements
specifically identified by the "and/or" clause, whether related or
unrelated to those elements specifically identified. Thus, as a
non-limiting example, a reference to "A and/or B", when used in
conjunction with open-ended language such as "comprising" can
refer, in one embodiment, to A only (optionally including elements
other than B); in another embodiment, to B only (optionally
including elements other than A); in yet another embodiment, to
both A and B (optionally including other elements); etc.
[0161] As used herein in the specification and in the claims, "or"
should be understood to have the same meaning as "and/or" as
defined above. For example, when separating items in a list, "or"
or "and/or" shall be interpreted as being inclusive, i.e., the
inclusion of at least one, but also including more than one, of a
number or list of elements, and, optionally, additional unlisted
items. Only terms clearly indicated to the contrary, such as "only
one of" or "exactly one of," or, when used in the claims,
"consisting of," will refer to the inclusion of exactly one element
of a number or list of elements. In general, the term "or" as used
herein shall only be interpreted as indicating exclusive
alternatives (i.e. "one or the other but not both") when preceded
by terms of exclusivity, such as "either," "one of," "only one of,"
or "exactly one of." "Consisting essentially of," when used in the
claims, shall have its ordinary meaning as used in the field of
patent law.
[0162] As used herein in the specification and in the claims, the
phrase "at least one," in reference to a list of one or more
elements, should be understood to mean at least one element
selected from any one or more of the elements in the list of
elements, but not necessarily including at least one of each and
every element specifically listed within the list of elements and
not excluding any combinations of elements in the list of elements.
This definition also allows that elements may optionally be present
other than the elements specifically identified within the list of
elements to which the phrase "at least one" refers, whether related
or unrelated to those elements specifically identified. Thus, as a
non-limiting example, "at least one of A and B" (or, equivalently,
"at least one of A or B," or, equivalently "at least one of A
and/or B") can refer, in one embodiment, to at least one,
optionally including more than one, A, with no B present (and
optionally including elements other than B); in another embodiment,
to at least one, optionally including more than one, B, with no A
present (and optionally including elements other than A); in yet
another embodiment, to at least one, optionally including more than
one, A, and at least one, optionally including more than one, B
(and optionally including other elements); etc.
[0163] In the claims, as well as in the specification above, all
transitional phrases such as "comprising," "including," "carrying,"
"having," "containing," "involving," "holding," "composed of," and
the like are to be understood to be open-ended, i.e., to mean
including but not limited to. Only the transitional phrases
"consisting of" and "consisting essentially of" shall be closed or
semi-closed transitional phrases, respectively, as set forth in the
United States Patent Office Manual of Patent Examining Procedures,
Section 2111.03.
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