U.S. patent application number 17/708160 was filed with the patent office on 2022-07-14 for integrated horticultural grow rack kit.
The applicant listed for this patent is Borroughs, LLC. Invention is credited to Adam J. Thomas, Dale W. Voelz.
Application Number | 20220217918 17/708160 |
Document ID | / |
Family ID | 1000006238852 |
Filed Date | 2022-07-14 |
United States Patent
Application |
20220217918 |
Kind Code |
A1 |
Voelz; Dale W. ; et
al. |
July 14, 2022 |
INTEGRATED HORTICULTURAL GROW RACK KIT
Abstract
A horticultural plant growing assembly includes a pair of
casings, each with a bottom and a side wall. Each side wall
includes an upper edge configured to engage one another to define a
cavity between the casings. The plant growing assembly further
includes a light system, and a plurality of frame members that are
connectable together to form a frame, with the light system being
attachable to the frame. The plant growing assembly is configurable
into a packaged configuration and an assembled configuration. In
the packaged configuration, the frame members and the light system
are contained within the cavity, and in the assembled configuration
the frame members are connected together to form the frame with the
light system attached to the frame. One of the casings includes a
shelf adapted to support a plant with the light system disposed
above the shelf.
Inventors: |
Voelz; Dale W.; (Portage,
MI) ; Thomas; Adam J.; (Kalamazoo, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Borroughs, LLC |
Kalamazoo |
MI |
US |
|
|
Family ID: |
1000006238852 |
Appl. No.: |
17/708160 |
Filed: |
March 30, 2022 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
16916638 |
Jun 30, 2020 |
11304384 |
|
|
17708160 |
|
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|
|
62869070 |
Jul 1, 2019 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A01G 9/249 20190501;
A01G 9/24 20130101; A01G 9/20 20130101; A01G 9/16 20130101; A01G
9/22 20130101; A01G 7/045 20130101 |
International
Class: |
A01G 9/16 20060101
A01G009/16; A01G 9/20 20060101 A01G009/20; A01G 9/24 20060101
A01G009/24; A01G 7/04 20060101 A01G007/04; A01G 9/22 20060101
A01G009/22 |
Claims
1. A horticultural plant growing assembly, said assembly
comprising: a pair of casings, with each said casing comprising a
bottom; and a plurality of frame members, said frame members being
connectable together to form a frame; wherein said plant growing
assembly is selectively configurable into a packaged configuration
and an assembled configuration, wherein in said packaged
configuration said casings are configured to be engaged together to
form a packaging case defining a cavity between said bottoms of
said casings with said frame members contained within said cavity,
and wherein in said assembled configuration said frame members are
connected together to form said frame with said frame engaged with
at least one of said casings.
2. The plant growing assembly of claim 1, wherein said frame
extends upwards from said at least one of said casings in said
assembled configuration whereby said one of said casings comprises
a bottom member of said plant growing assembly in said assembled
configuration.
3. The plant growing assembly of claim 2, wherein said bottom
member comprises a shelf configured to support a plant.
4. The plant growing assembly of claim 2, wherein the other of said
casings is engaged with an upper portion of said frame in said
assembled configuration whereby said other of said casings
comprises a top member of said plant growing assembly in said
assembled configuration.
5. The plant growing assembly of claim 2, further comprising an
electric light for projecting light for growing plants, and wherein
in said packaged configuration said electric light is contained
within said cavity, and wherein in said assembled configuration
said electric light is supported by said frame.
6. The plant growing assembly of claim 1, wherein said at least one
of said casings is engaged with an upper portion of said frame in
said assembled configuration whereby said one of said casings
comprises a top member of said plant growing assembly in said
assembled configuration.
7. The plant growing assembly of claim 6, further comprising an
electric light for projecting light for growing plants, and wherein
in said packaged configuration said electric light is contained
within said cavity, and wherein in said assembled configuration
said electric light is supported by said frame.
8. The plant growing assembly of claim 7, wherein said frame
extends upwards from said other of said casings in said assembled
configuration whereby said other of said casings comprises a bottom
member of said plant growing assembly in said assembled
configuration.
9. The plant growing assembly of claim 1, wherein said casings each
include perimeter walls disposed about said bottoms of said
casings, and wherein said perimeter walls of said one of said
casings engage with said perimeter walls of the other of said
casings when said casings are engaged together to form said
packaging case.
10. The plant growing assembly of claim 9, wherein said perimeter
walls of each said casing comprise upper edges, and wherein said
upper edges of said one of said casings engage with said upper
edges of said other of said casings when said casings are engaged
together to form said packaging case.
11. The plant growing assembly of claim 1, further comprising a
wrapper disposed about an exterior of said casings when in said
packaged configuration, wherein said wrapper includes a handle.
12. The plant growing assembly of claim 1, further comprising at
least one fan that is selectively attachable to said frame, and
wherein said fan is contained within said cavity in said packaged
configuration.
13. The plant growing assembly of claim 1, wherein said plurality
of frame members comprise elongate angled members and wherein said
frame members comprise horizontal frame members and vertical frame
members, and wherein when said frame members are connected to form
said frame said horizontal frame members are oriented horizontally
and said vertical frame members are oriented vertically.
14. The plant growing assembly of claim 1, further comprising a
reflective panel selectively attachable to said frame, wherein said
reflective panel is configured to wrap around a pair of side
sections and a back section of said frame, and wherein said
reflective panel is contained within said cavity in said packaged
configuration.
15. The plant growing assembly of claim 1, further comprising a
retractable reflective shade selectively attachable to said frame,
wherein said retractable reflective shade is configured to
selectively cover a front section of said frame and is configured
to selectively expand and retract to provide access to said bottom
member, and wherein said retractable reflective shade is contained
within said cavity in said packaged configuration.
16. The plant growing assembly of claim 1, further comprising a
plurality of growing containers, wherein said growing containers
are disposed within said cavity in said packaged configuration and
are configured to be disposed on said bottom member when in said
assembled configuration.
17. The plant growing assembly of claim 1, wherein said frame
members comprise a plurality of posts and wherein said posts are
vertically oriented when assembled into said frame, and further
comprising a screen that is contained within said cavity in said
packaged configuration and is selectively mountable to said posts
in said assembled configuration.
18. The plant growing assembly of claim 1, further comprising an
electric light for projecting light for growing plants, and wherein
in said packaged configuration said electric light is contained
within said cavity, and wherein in said assembled configuration
said electric light is supported by said frame.
19. The plant growing assembly of claim 18, wherein said electric
light comprises a light panel.
20. A horticultural plant growing assembly, said assembly
comprising: a pair of casings, with each said casing comprising a
bottom; an electric light for projecting light for growing plants;
and a plurality of frame members, said frame members being
connectable together to form a frame; wherein said plant growing
assembly is selectively configurable into a packaged configuration
and an assembled configuration, wherein in said packaged
configuration said casings are configured to be engaged together to
form a packaging case defining a cavity between said bottoms of
said casings with said frame members and said electric light
contained within said cavity, and wherein in said assembled
configuration said frame members are connected together to form
said frame with said electric light supported by said frame.
21. The plant growing assembly of claim 20, wherein in said
assembled configuration said frame is engaged with at least one of
said casings.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. application Ser.
No. 16/916,638, filed on Jun. 30, 2020, which claims priority to
U.S. Provisional Patent App. Ser. No. 62/869,070, filed Jul. 1,
2019, which are all hereby incorporated herein by reference in
their entireties.
BACKGROUND AND FIELD OF THE INVENTION
[0002] The present invention is directed to a compact plant growing
assembly kit, and in particular to a plant growing assembly
including frame members, top and base caps, and lights, where the
assembly may be integrally packaged within the top and base caps
for transport and sale.
[0003] Horticulture is known as the science and art of the
development and sustainable production of cultivated plants.
Horticultural crops are diverse and can include all manner of
plants. Indoor growing of plants is a popular activity and various
equipment is available to consumers for promoting growing,
including various lighting, watering and shelf systems. For
example, U.S. Pat. No. 7,654,036 B2 to Best Coast Growers discloses
a tubular grow rack that can be assembled in many different sizes,
is collapsible, and can support hanging objects.
SUMMARY OF THE INVENTION
[0004] The present invention provides a cost-effective,
pre-engineered, free-standing, all-in-one horticultural plant
growing assembly that is configurable into a packaged orientation
for convenient storage and shipment, and an assembled orientation
in which plants may be disposed on a shelf with a light positioned
above the plants. The plant growing assembly of the present
invention further eliminates the need to spend hours researching,
purchasing, and assembling multiple equipment options to
effectively grow a multitude of plants, such as cannabis, tomatoes,
lettuce, decorative indoor plants, etc. Additionally, the assembled
configuration of the plant growing assembly of the present
invention is aesthetically designed for use in any residential
space.
[0005] According to one form of the present invention, a
horticultural plant growing assembly includes a pair of casings,
with each casing having a bottom and a side wall defining a
perimeter of each casing. Each side wall of each casing includes an
upper edge with a flange. The flanges of the casings are
correspondingly shaped to be engaged together to define a cavity
between the bottoms of the casings. The plant growing assembly
further includes a light system with lights for projecting light,
and a plurality of frame members, with the frame members being
connectable together to form a frame. The light system is
selectively attachable to the frame. The plant growing assembly is
selectively configurable into a packaged configuration and an
assembled configuration. In the packaged configuration, the frame
members and the light system are contained within the cavity when
the flanges of the casings are engaged together. In the assembled
configuration, the frame members are connected together to form the
frame with the light system attached to the frame, and with the
frame engaged with and extending upward from at least one of the
casings whereby the at least one of the casings has a shelf
configured to support a plant with the light system being disposed
above the shelf.
[0006] According to an aspect, the light system includes a light
driver assembly and a plurality of light panels configured to be
assembled to form a light fixture. The light driver assembly and
the light fixture are configured to be selectively attachable to
the frame, and the light driver assembly and the plurality of
panels are contained within the cavity in the packaged
configuration.
[0007] According to another aspect, each of the plurality of light
panels is selectively connectable to the light driver assembly to
receive electrical power therefrom. An underside of each light
panel includes an array of LED lights, and an upside of each light
panel includes heat sinks.
[0008] According to yet another aspect, the light driver assembly
includes a pair of light intensity switches. One of the pair of
light intensity switches is configured to selectively adjust
intensity of red spectrum light and another one of the pair of
light intensity switches is configured to selectively adjust
intensity of white/blue spectrum light.
[0009] According to a further aspect, the horticultural plant
growing assembly further includes a pair of fan assemblies, each of
the fan assemblies including a carbonated filter. The pair of fan
assemblies is configured to be selectively attachable to the frame,
and the pair of fan assemblies is contained within the cavity in
the packaged configuration.
[0010] According to yet a further aspect, each of the pair of fan
assemblies is connectable to the light driver assembly to receive
electrical power therefrom.
[0011] According to still another aspect, the light fixture is
adjustably mountable to the frame whereby distance between the
light fixture and the shelf is selectively vertically
adjustable.
[0012] The plant growing assembly kit provides a system that is
collapsible into a convenient orientation for transport and sale
with no shipping waste, and when assembled is useable in various
configurations for growing plants, where all manner of plants may
be grown using the invention. The kit thus provides a
pre-engineered, all-in-one horticultural grow product for growing
plants that includes everything, less the seedlings, containers and
dirt, to grow plants indoors that is an all-in-one solution. These
and other objects, advantages, purposes and features of this
invention will become apparent upon review of the following
specification in conjunction with the drawings. The invention thus
provides a self-contained, pre-packaged, modularized rack and shelf
system for growing plants indoors. Its components are designed to
be convertible to various rack styles and provides adjustable
lighting variations to support the expedited growth of a wide
variety of plants. The product is all-inclusive providing most grow
components, step-by-step grow recipes, and is designed to minimize
shipping waste.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a perspective view of a plant growing assembly kit
in accordance with the present invention shown in a disassembled
and packaged orientation for transport and sale;
[0014] FIG. 2 is an exploded perspective view of the plant growing
assembly kit of FIG. 1 shown in a partially opened orientation;
[0015] FIG. 3 is a perspective view of pre-packaged components of
the plant growing assembly kit of FIG. 1 shown removed from the
bottom shelf and top cap upon opening;
[0016] FIG. 4 is an exploded perspective view of frame components
of the frame assembly of the plant growing assembly kit of FIG.
1;
[0017] FIGS. 5A and 5B are close-up perspective assembly views of a
selected corner of the frame assembly of FIG. 4;
[0018] FIG. 6 is a perspective view of the frame assembly shown
installed to the bottom shelf;
[0019] FIG. 7 is a partial exploded top perspective view of the
frame assembly of FIG. 6 shown with a pair of upper cross members
and a LED driver prior to mounting to the frame assembly;
[0020] FIG. 8 is a perspective view of the frame assembly of FIG. 7
shown with the upper cross bars and LED driver mounted to the frame
assembly;
[0021] FIG. 9A is an exploded perspective view of LED light panels
of a light system in accordance with an aspect of the present
invention shown with hanger brackets for mounting the LED light
panels;
[0022] FIG. 9B is a perspective view of the interconnected LED
light panels and hanger brackets of FIG. 9A shown with an
adjustable suspension system for mounting the LED light panels to
the frame assembly;
[0023] FIG. 10 is a perspective view of the frame assembly kit of
FIG. 8 shown with the light system mounted thereto, and with a
front reflective shade and a fixed reflective panel prior to
installation;
[0024] FIG. 11 is a perspective view of the sub-assembly of FIG. 10
shown with the front reflective shade, fixed reflective panel and a
top cap mounted onto the frame assembly to form a plant growing
assembly in accordance with an embodiment of the present invention;
and
[0025] FIG. 12 is a perspective view of the plant growing assembly
of FIG. 11, shown with a screen installed and a plurality of grow
bags placed on the plant growing assembly.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0026] The present invention will now be described with reference
to the accompanying figures, wherein the numbered elements in the
following written description correspond to like-numbered elements
in the figures. A plant growing assembly or grow rack kit 18 in a
packaged orientation for storage, transport and/or sale is
illustrated in FIG. 1. The plant growing assembly kit 18 is used to
construct a plant growing assembly 20, such as shown in FIGS. 11
and 12. In the illustrated embodiment of FIG. 1, the plant growing
assembly kit 18 is formed in the packaged orientation by way of a
packaging case 22 formed by a base or bottom member or pan or shelf
24 and a top member or top cap 26 with an outer wrapper 28 applied
there over. The wrapper 28 includes an integrated carrying handle
30 for ease of lifting that projects through an opening 32 in the
wrapper 28 when disposed about the bottom shelf 24 and top cap 26.
Of note, when in the packaged orientation of FIG. 1, the bottom
shelf 24 and top cap 26 form a clam shell arrangement with
additional disassembled components for constructing the assembly 20
contained in the cavity 34 (FIG. 2) formed between the bottom shelf
24 and top cap 26, including frame components, LED lights, a rack,
and growing containers for plants, as well as other accessories.
The plant growing assembly 20 is thus conveniently packaged when in
the orientation of FIG. 1, such as for store display and transport,
including for shipping and for a user to transport the kit 18 from
a store to a point of use, such as the residence of the purchaser.
Moreover, in the illustrated embodiment the kit 18 includes all of
the equipment needed for a user to grow plants via assembly 20 with
the exception of dirt and seeds, thus providing a self-contained,
portable and easy to assemble and use system for growing
plants.
[0027] With further reference to FIGS. 2 and 3, the base shelf 24
has a tray-like configuration with a bottom 36 surrounded by an
upright side wall 38 extending from the bottom 36, thereby forming
a cavity. The upright side wall 38 of the base shelf 24 defines an
upper or outer edge 40 about the perimeter of the base shelf 24.
Similarly, the top cap 26 includes an internal bottom, an upright
side wall 42 extending from the bottom, with the upright side wall
42 of the top cap 26 defining an upper or outer edge 44 about the
perimeter of the top cap 26. In the illustrated embodiment of FIG.
2, the upper edges 40 and 44 include correspondingly shaped
perimeter flanges that create an interference fit or
tongue-and-groove connection between the base shelf 24 and top cap
26 whenever they are connected together to form the packaging case
22. In other words, whenever the members 24 and 26 are engaged or
connected together, their respective perimeter flanges enclose or
seal the perimeters of the two members 24 and 26 together in a clam
shell arrangement to form the enclosed cavity 34 within which other
components of the assembly 20 may be stored in a disassembled
orientation. The base shelf 24 and top cap 26 thus form casings for
the packaging case 22 in the packaged orientation of FIG. 1.
[0028] Both the base shelf 24 and top cap 26 are symmetrical and
shaped as rectangles in the illustrated embodiment, though other
shapes are also possible. The interior surface or bottom 36 of the
base shelf 24 is tapered from its four corners towards an interior
front-middle region 37 of the base shelf 24 so that water
accumulated in the interior surface or on the bottom 36 is directed
for collection to a low point. The interior front-middle region 37
of the base shelf 24 may also include a drain opening (not shown)
to drain the water out of the interior of the base shelf 24.
Alternatively, water may be removed via a syringe.
[0029] In the illustrated embodiment the base shelf 24 and top cap
26 are molded from Expanded Polypropylene (EPP) material. In the
packaged orientation of FIG. 1, the base shelf 24 and top cap 26
may additionally be secured together by a pair of nylon straps 46
wrapped around the two members 24, 26 when they are engaged
together, for which purpose each of the base shelf 24 and top cap
26 include pairs of retention grooves 48 disposed on opposed sides,
with the grooves 48 being molded into the members 24, 26. The
retention grooves 48 assist in ensuring that straps 46 remain in
place about members 24, 26. The retention grooves 48 may
additionally provide reinforcement for the securing with straps 46.
Although members 24, 26 in the illustrated embodiment are
constructed of EPP, which provides excellent energy absorption,
high strength properties, superior durability, lightweight,
resistance to water, chemicals, and most oils, and is recyclable,
it should be appreciated that other suitable plastic materials may
be used, as well as alternative materials. The base shelf 24 and
top cap 26 may be constructed to be identical with the flanges of
their top edges 40, 44 configured to mate together, such as when
rotated 180 degrees with respect to each other.
[0030] With further reference to FIGS. 1 and 2, the wrapper 28 may
be constructed of cardboard with the overlapping end flaps that
include the handle 30 and opening 32 being glued in place in the
packaged orientation of FIG. 1. Optionally, the outer wrapper 28
may include exterior product graphics and/or detailed growing
instructions for specific plants or assembly and use instructions
may be pre-printed on the underside of the outer wrapper 28.
[0031] As understood from FIG. 2, when the plant growing assembly
kit 10 is in the packaged orientation, the hollow cavity 34 of the
packaging case 22 is configured to retain in pre-determined
positions various pre-packaged hardware components and accessories
of the plant growing assembly kit 18, which will be discussed in
more detail below.
[0032] Turning now to FIG. 3, the hardware components of the plant
growing assembly kit 18 include a pre-packaged frame component
bundle 50, a light system comprising a LED driver 52 and a set of
light panels packaged in a light panels box 54, a rolled-up front
reflective shade 56, a set various accessories packaged in an
accessories box 58, and a scrog screen 60. It will be understood
that the base shelf 24 and top cap 26 are also part of the hardware
components of the plant growing assembly kit 18 and are used to
construct the plant growing assembly 20, as will be described
below.
[0033] In the illustrated embodiment the frame component bundle 50
includes the following frame members or components: four vertical
posts 62, three face beams 64, one front fan mount 66, and four
side or end beams 68, such as shown in FIG. 4, and two upper cross
bars 69, as shown in FIG. 7. It will be understood that the frame
members included in the frame component bundle 50 form a frame or
frame assembly 70 of the plant growing assembly 20. It is
contemplated that each of the frame members is stamped out of
cold-rolled steel, such as 16-gauge steel, such that the frame
assembly 70 of the plant growing assembly 20 provides for a rigid
structure. It is further contemplated that all steel components of
the frame assembly 70 may be treated for rust resistance, including
being powder coated. Alternatively, the frame components may be
constructed of aluminum, plastic or another material. In addition
to the above noted frame members, the frame component bundle 50
also includes two light support brackets 72, as shown in FIGS. 9A
and 9B and discussed in more detail below.
[0034] Each vertical post 62 has an L-shaped cross-section and is
formed as a symmetrical and elongate angle with a pair of equal
flanges. Each vertical post 62 includes a plurality of stamped
holes 74 and tapered slots 76, such as shown for example in FIGS.
5A and 5B, disposed on each flange and at both ends of each
vertical post 62 for engagement with front fan mount 66, face beams
64 and side beams 68. Each vertical post 62 also includes apertures
at specific locations along the length that are used for attaching
other components and accessories to each vertical post 62, as
discussed further below.
[0035] Each face beam 64 is formed as an elongate angle with
unequal flanges and having the length approximately equal to the
length of each vertical post 62. As shown in FIG. 4, each face beam
64 includes stamped holes 78 and tabs 80 disposed at opposed ends
for engagement with respective vertical posts 62. Each face beam 64
also includes a plurality of holes at specific locations along the
length that are used for attaching other components and accessories
to each face beam 64, as discussed further below. The front fan
mount 66 is formed as an elongate angle with unequal flanges, where
a significantly wider flange of the front fan mount 66 forms a
panel that defines various holes, openings and apertures that are
used for attaching other hardware components and accessories to the
front fan mount 66, as discussed further below. The length of the
front fan mount 66 is equal to the length of each face beam 64. The
front fan mount 66 includes stamped holes 78 and tabs 80 disposed
at opposed ends in like manner to face beams 64 for engagement with
respective vertical posts 62.
[0036] Each side beam 68 is formed as an elongate angle with
unequal flanges and having the length of approximately half of the
length of each face beam 64. Each side beam 68 includes stamped
holes 78 and tabs 80 disposed at opposed ends for engagement with
respective vertical posts 62 (FIGS. 5A and 5B). Each side beam 68
also includes a plurality of holes at specific locations along the
length that are used for attaching other components and accessories
to each side beam 68, as discussed further below.
[0037] Each upper cross bar 69 is formed as a symmetrical and
elongate L-shaped angle with a pair of equal flanges and having a
length approximately equal to the length of each side beam 68. Each
upper cross bar 69 also includes a pair of ends 82 (FIG. 7) with
each end 82 including a hole used for attachment of each upper
cross bar 69 to a respective face beam 64 and front fan mount 66.
Each upper cross bar 69 also includes a notch 84 (FIGS. 7 and 8)
disposed generally at the center of each upper cross bar 69 that is
used as a locator and a retaining groove for hanging and supporting
the LED lights, as discussed further below.
[0038] FIGS. 4-8 illustrate the interconnection of the frame
members to form the frame 70, and additionally illustrate the
engagement of the frame 70 with the bottom shelf 24 as part of the
assembly process of forming grow rack assembly 20. In particular,
frame 70 is installed within bottom shelf 24 whereby the side wall
38 surrounds the lower portion of frame 70. As illustrated in FIGS.
5A and 5B, screws 86 and nuts 88 may be used to fixedly connect the
frame members together.
[0039] As discussed above, the light system packaged in the plant
growing assembly kit 18 includes the LED driver 52 and the set of
light panels, described in more detail below. As can be seen in
FIGS. 3 and 7, the LED driver 52 includes a metal housing 90 with a
pair of pre-wired water-resistant rotary switches 92, an on/off
switch 94, and three quick-connectors 96 for attachment of electric
cables for LED lights. LED driver 52 additionally includes a
pre-wired power cord with grounded 115V plug (not shown). The set
of LED light panels, pre-packaged in the light panels box 54, are
three separate ultra-thin, reinforced aluminum extruded light
panels 98, such as shown in FIG. 9A, that are configured to
interlock together to form a LED light fixture 100, such as shown
in FIG. 9B. Each light panel 98 includes lights on the underside,
such as arrays of LED lights, and approximately half an inch
ventilation holes strategically located throughout each panel 98 to
dissipate radiant heat from the LED lights. The upper side of each
light panel 98 includes a corrugated surface acting as heat sinks
for passive cooling. As shown in FIGS. 9A and 9B, each panel 98
further includes a pre-wired quick-connect water-resistant input
cable 102 to electrically connect each panel 98 to a respective
quick-connector 96 of the LED driver 52. Panels 98 are connected
together, including via a pair of support brackets 72. The support
brackets 72 include an angled flange that extends over all three
panels 72, with each bracket 72 being secured to each of the three
LED panels 98, such as by way of fasteners.
[0040] As shown in FIG. 9B, adjustable cable or rope hangers 104
are secured to each of the support brackets 72, which, as
understood from FIG. 10, enable the position of the LED light
fixture 100 to be vertically adjustable when installed to frame 70.
In the illustrated embodiment rope hangers 104 are fully adjustable
and are tear and rust resistant, and are made from 1/8'' diameter
solid braided polypropylene rope. Each rope hanger 104 includes an
internal zinc-plated steel gear with a push button 106, which
provides the means for vertical adjustment, and a carabiner clip
108 on one end of each rope hanger 104, as shown in FIG. 9B, for
attachment to respective side beams 68 of frame 70. As understood
from FIG. 10, the rope hangers 104 extend over cross bars 69, with
the respective ropes being slidably engaged within notches 84 for
guiding and positioning the LED light fixture 100. It should be
appreciated that the vertical position of the LED light fixture 100
may be adjusted based on the size or height of the plant being
grown using growing assembly kit 18.
[0041] The LED light fixture 100, in cooperation with the LED
driver 52, form a dimmable spectrum LED light system, when
assembled. The light system is configured to establish consistent
photosynthetic photon flux density (PPFD) values across the entire
plant canopy area for enhanced plant growth. Additionally, the
light system is configured to selectively apply different light
spectrums during specific plant growth stages for the best growth
of a variety of plants. An adjustable spectrum is created with two
rotary switches 92 that allow the user to adjust the intensity of
the red spectrum and white (blue) spectrum independently to provide
more versatility for crops like lettuce that can be challenging to
grow successfully indoors. For example, lettuce enjoys higher blue
spectrum and less red spectrum during its grow cycle for fuller and
denser heads, whereas tomatoes and cannabis prefer higher red
spectrum with the blue spectrum during the vegetable phase and a
great deal of red spectrum during the flower/fruiting phases.
[0042] The dimmable spectrum LED light system provides a number of
benefits for successful indoor growing of a variety of plants. For
example, the light system is configured to emit full spectrum
lighting, which provides plants everything they desire from natural
sunlight. The system is spectrum dimmable with Max. PPFD>700
umol/m2/s @ 2 ft above plant canopy using reflectors. The light
system provides 80% energy savings as compared to traditional
high-pressure sodium and metal halide lamps. The LED driver 52 is
damp rated for wet locations. The light system is operable with
wide voltage power supply AC100-240V, 50/60 Hz, PF>0.9. The
light system has a wide range of working temperature; from
-20.degree. C. to 40.degree. C., and relative humidity of 40% RH.
The light system is also environmentally friendly, as it does not
contain pollutants or harmful substances under ROHS. Additionally,
the light system of the plant growing assembly kit 18 is operable
to provide at least the following spectrums and wavelength: blue
400-470 nm, which promotes chlorophyll and carotenoid for
photosynthesis and leaf production; red 610-720 nm, which promotes
chlorophyll absorption for photosynthesis and photoperiodism; and
IR 720-1000 nm, which promotes cell growth influences blooming and
sprouting.
[0043] The front reflective shade 56, shown in FIG. 3 in a
rolled-up configuration for packaging, includes a plastic pull
chain 110 and weighted stabilizing bar 112 (FIG. 10). The front
reflective shade 56 is adapted to selectively fully expand and
retract into the rolled-up configuration via pull chain 110. The
front reflective shade 56 is made of a relatively thick Mylar film
that includes a highly durable diamond-textured surface on the
interior side of the reflective shade 56. Only in the rolled-up
configuration for packaging, the front reflective shade 56
additionally contains a fixed reflective panel 114, shown in an
expanded configuration in FIG. 10, that is rolled over in the front
reflective shade 56. The fixed reflective panel 114 is made of the
same material as the front reflective panel 56 and also includes
the highly durable diamond textured surface on the interior side of
the fixed reflective panel 114.
[0044] The set of various accessories pre-packaged in the
accessories box 58 includes the previously mentioned pair of rope
hangers 104 (FIG. 9B), and additionally includes a plurality of
grow bags 116 (FIG. 12), a timer (not shown), a
thermometer/hygrometer (not shown), pH control kit (not shown), a
soil tester (not shown), and a plug adapter (not shown). In the
illustrated embodiment, the grow bags 116 are collapsible 3-gallon
aeration fabric pots that are made from high-quality nonwoven
fabric and include built-in handles 118. The grow bags 116 promote
root expansion through better aeration, prevent a circling root
structure, and are permeable allowing excess water to drain through
the fabric and into the front-middle region 37 of the base pan 24.
The grow bags 116 are durable and reusable for several growing
seasons. The timer is a heavy-duty 7-day programmable plug-in unit
to control the plant lighting cycle on a typically grounded 115V/15
Amp residential outlet. The timer includes a built-in battery
backup, clear LCD digital display, automatic on/off function. The
timer is also programmable for Daylight Savings, and is UL
listed.
[0045] The supplied thermometer/hygrometer is an all-in-one
pre-calibrated gauge for measuring internal temperature and
humidity of the grow area. The thermometer/hygrometer includes an
easy-to-read display that displays daily high and low
temperature/humidity results, and a magnetic mount for attaching
the thermometer/hygrometer to one of the vertical posts 38 in the
grow area. The pH control kit provides for maximum plant growth by
monitoring pH levels of the water and nutrient mixture given to the
plants. The kit includes an 8 oz. jar of pH "up", an 8 oz. jar of
pH "down", a test tube, a 1 oz. indicator, and a vial. The soil
tester is a three-in-one meter designed to better understand plant
condition by monitoring soil moisture, soil pH value, and light
level. The tester includes a double-needle detection technology
that enhances the speed and accuracy of analyzing soil moisture and
pH levels. The tester does not need batteries. The plug adapter is
a 3-wire outlet adapter that converts any standard indoor
electrical outlet into a ground fault (GFCI) protected outlet. The
adapter includes a bright "red" light indicator that indicates when
the power is "ON". The tester also includes test and reset buttons
that allow for periodic testing of the adapter. The adapter is
compatible with 15-amp U-ground outlets and plugs, 2 or 3 wire, and
includes a trip level of 4-6 mA and is UL and CUL listed.
[0046] The scrog screen 60 is a wire trellis, which is utilized to
provide additional plant support and to control vertical growth
during the flowering stage. It maintains evenness in the plant
canopy by allowing the grower to gently bend the stems to force the
plant to grow laterally and diminish light intensity. The wire
trellis includes a 16-gauge vinyl-coated welded-wire steel mesh. As
shown in FIG. 12, screen 60 may be retained in a desired
orientation via a pair of trellis bungees 120 that are attachable
into apertures in posts 62, where bungees 120 are also contained
within kit 18.
[0047] The plant growing kit 18 further includes a pair fan
assemblies 122, shown for example in FIG. 10. Each fan assembly 122
includes an interior granulated carbon filter sandwiched between a
pair of safety grilles to remove unwanted odor from inside of the
plant growing assembly 20. The plant growing kit 18 additionally
includes a trimming scissors (not shown), a nutrient kit (not
shown), and a hardware bag (not shown) that contains fasteners,
including screws 86 and nuts 88 for attaching selective frame
components together, as well as fasteners for attaching the light
system to the frame assembly, and brackets and fasteners for
attaching the fixed reflective panel 114 to the frame assembly 70,
which will be described in more detail below.
[0048] According to the illustrated embodiment of FIG. 4, the frame
assembly 70 of the plant growing assembly 20 is constructed by
first connecting opposing ends of a pair of vertical posts 62 via a
pair of side beams 68 to form a first side 124 of the frame
assembly. As best shown in FIGS. 5A and 5B, the pair of vertical
posts 62 are connected by respective tapered slots 76 of each
vertical post 62 receiving and securely engaging with respective
tabs 80 of each respective side beam 68. A screw 86 with locknut 88
are used to secure/reinforce the connection. A second side 126 of
the frame assembly 70 is constructed in the same manner as
described above. The three face beams 64 and the front fan mount 66
are then used to interconnect upper and lower ends of the first and
second sides 124, 126 to form the frame assembly 70. The first and
second sides 124, 126 are interconnected in the same manner as
described above, i.e. by engaging respective tapered slots 76 of
each vertical post 62 with respective tabs 80 of each respective
face beam 64 and front fan mount 66, and securing the connection
with a screw 86 and locknut 88. It will be understood that the
front fan mount 66 is used to interconnect the upper ends of the
first and second sides 124, 126, with the significantly wider
flange of the front fan mount 66 serving as a front side or front
face of the frame assembly 70 and of the plant growing assembly
20.
[0049] Turning now to FIG. 6, the frame assembly is then placed
into the interior surface of the base shelf 24, with lower face
beams 64 and side beams 68 sitting flush on a raised edge 128
disposed around a perimeter of the interior surface of the base
shelf 24. With reference to FIGS. 7 and 8, the two upper cross bars
69 are mounted between the upper face beam 64 and the front fan
mount 66. A screw 86 and locknut 88 are used to secure each end
flange 82 of each upper cross bar 69 to respective upper face beam
64 and front fan mount 66. The LED driver 52 is then also mounted
between the upper face beam 64 and the front fan mount 66 by using
four truss head machine screws, with a pair of the screws 130
inserted through the front fan mount 66 (FIG. 8) and another pair
of the screws (not shown) inserted through the upper face beam 64.
The pair of rotary switches 92 and the on/off switch 94 of the LED
driver assembly 52 are fitted into respective apertures 132 and 134
of the front fan mount 66 (FIG. 7).
[0050] Turning now to FIGS. 9A and 9B, the LED light fixture 100 is
formed by nestling light panels 98 together with a tongue and
groove joint and further securing the connection by the two support
brackets 72 that are each coupled to each light panel 98. In the
illustrated embodiment of FIG. 9B, the smaller flange of each
support bracket 72 is coupled to each light panel 98 by three
stainless-thin hex head screws and wing nuts. An end of the rope
hanger 104, that is opposite the end with the carabiner clip 108,
is then attached to each support bracket 72 through the hole in the
larger flange of each support bracket 72. As best shown in FIG. 10,
the LED light fixture 100 can then be maneuvered into the frame
assembly 70 by each of the pair of rope hangers 104 extending over
respective upper cross bars 69 and attaching with the carabiner
clip 108 to respective center holes in the opposing upper side
beams 68. It will be understood that the notch 84 on each upper
cross bar 69 serves as an indicator and retaining groove for the
placement of each rope hangers 104. It should also be appreciated
that once the LED fixture 100 is installed in the frame assembly
70, the LED fixture 100 can be vertically adjusted, i.e. raised or
lowered, by pressing the push button 106 of each of the rope
hangers 104. The installation of the light system is completed by
plugging cables 102 of the LED light fixture 100 into respective
connectors 96 of the LED driver 52.
[0051] With continued reference to FIG. 10, the pair of fan
assemblies 122 are mounted into respective apertures 136 in the
front fan mount 66 (FIG. 8). The pair of fan assemblies 122 with
carbonated filters are designed to pull ambient room air through
the front bottom of the plant growing assembly 20, up through the
plant canopy, through the LED light fixture 100, up into the top
portion of the plant growing assembly 20, and out the front face of
the front fan mount 66 through the carbonated filters. This
provides the needed airflow for superior plant growth and to aid in
the reduction of odors that may form inside the plant growing
assembly 20 filled with plants. Each fan assembly 122 features an
airflow of 110 CFM, 2600 RPM, and a noise level of 47 dBA. Each fan
assembly 122 is fastened to the exterior face of the front fan
mount 66 and includes a 120V cord that plugs into an outlet on the
LED driver 52.
[0052] The fixed reflective panel 114 is secured to the sides and
back of the frame assembly 70, such as shown in FIG. 10, using push
rivets and Velcro provided in the hardware bag of the plant growing
kit 18. It will be understood that the reflective surface of the
fixed reflective panel 114 is faced inward. The front reflective
shade 56 is then mounted by first attaching corner brackets 138 to
the vertical posts 62 at the front side of the frame assembly 70,
and then mounting the front reflective shade 56 into the brackets
138 (FIG. 11), as spring-loaded ends of the front reflective shade
56 are adapted to clip into the corner brackets 138. The front
reflective shade 56 is designed as a roll-up window shade providing
ease of access during plant maintenance. It will be understood that
the reflective surface of the front reflective shade 56 is faced
inward. The top cap 26 is then fitted over the top of the frame
assembly 70, as shown in FIG. 11. It will be appreciated that top
cap 26 may now be turned into a useable top shelf or ergonomic work
surface for typical horticultural or other needs.
[0053] With reference to FIG. 12, unfolded grow bags 116 may now be
placed onto the interior surface of the base shelf 24. The pair of
trellis bungees 120 may now be attached. In the illustrated
embodiment, the end hooks of each bungee 120 attach through
pre-punched holes in diagonally positioned vertical posts 62 such
that the pair of trellis bungees 120 form an "X" pattern. The
trellis bungees 120 are used to provide support for the scrog
screen 60, which is placed over the trellis bungees 120. It will be
appreciated that the bungees 120 may be attached to form a
different pattern and that the screen 60 is vertically
repositionable as the trellis bungees 120 may be attached to other
holes along the height of the posts 62.
[0054] In the illustrated embodiment, the frame assembly 70 is
approximately four feet high by four feet wide and two feet deep,
with the bottom shelf 24 and top cap 26 dimensioned accordingly. It
should be appreciated, however, that alternative sizes and
configurations may be employed.
[0055] The present invention thus provides a plant growing rack
assembly system that is collapsible into a convenient orientation
for transport and sale with no shipping waste, and when assembled
is useable and adjustable to suit different planting requirements
for growing a variety of plants, including decorative flowering
plants, fruits, vegetables and other plants, including legalized
growing of cannabis. The provided kit thus provides a
pre-engineered, all-in-one horticultural grow product for growing
plants that includes everything, less the seedlings and soil/dirt,
to grow plants indoors. It is an all-in-one solution eliminating
the need for the consumer to spend hours researching equipment
options.
[0056] In the illustrated embodiments, the plant growing assembly
80 has a generally rectangular configuration, including the shelves
and frame when assembled. It should be appreciated that alternative
configurations may be employed within the scope of the present
invention. Still further, the illustrated frame may also be
alternatively configured, including having more or fewer frame
members, and altered orientations for such supports and manner of
interconnection thereof. Accordingly, changes and modifications in
the specifically described embodiments can be carried out without
departing from the principles of the present invention which is
intended to be limited only by the scope of the appended claims, as
interpreted according to the principles of patent law including the
doctrine of equivalents.
* * * * *