Note: Descriptions are shown in the official language in which they were submitted.
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MODULAR SUPPORT FOR PLANTS
FIELD OF INVENTION
[0001] The present invention relates to a modular support for plants,
especially for
vertical applications such as cladding a wall or building.
BACKGROUND OF THE INVENTION
[0002] The field of modular plant support entails systems for creating Green
Roofs,
also known as "planted roofs," "garden roofs" and "living roofs," and systems
for
creating Living Walls, also known as "planted walls", "green walls" and
"vertical
gardens".
[0003] Green Roof systems have been around since the 1950's, and Living Wall
systems since the 1980's, but modular technologies for producing both are much
younger. Modular Green ,Roof systems are widely dispersed around the. world,
with a
particular prevalence in Europe. Modular Living Wall systems are less
widespread,
though their popularity is=on the rise.
[0004] All of these systems, whether for roofs or walls, have certain common
features
- a module comprising a plurality of layers, plants, and a means to organize
modules
together into a larger.whole..
[0005] Notwithstanding these common *features, modular Green Roof systems and
modular Living Wall systems are not interchangeable. In particular, modular
Green
Roof technologies have not been successfully adapted to vertical applications
for
three main reasons: the significant differences between the way walls and
roofs are
constructed and must perform, the difficulty of managing water so that the.
plants stay
wet enough but water is still allowed to drain, and the challenge of retaining
soil (or
"growing medium") against the forces applied by wind and gravity.
[0006] Roofs resist predominantly vertical loads, including "dead loads" (such
as from
mechanical equi.pment), "live loads" (from inhabitation), and snow loads. Roof
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assemblies are hence robust, generally comprising a .solid series of layers
capable of .
bearing these loads. Typically the layers include the primary and secondary
structure,
insulation and waterproofing, and some form of cladding or ballast.
[0007] Walls resist predominantly lateral loads from wind, which can create
both
positive pressure and negative pressure (suction). Wall construction.is
generally
considerably lighter than roof construction, since it need not carry heavy
equipment
or snow, but the constant pressure changes wind loading creates can
nonetheless
compromise the waterproof membrane: In order to equalize the pressure
differential
created by wind loading, walls generally incorporate an unobstructed air gap
of at
io least 25 mm behind the cladding. This is a widespread standard type of wall
construction known as a "pressure=equalizing rainscreen," or simply a
"rainscreen."
[0008] On a roof the entire bottom surface of a module can bear downwards on
the
underlying roof surface, creating an even, distributed load. On a wall, with
or without
an air gap, a module must span between supports, resulting in concentrated
loads at
each end. This means that any module for a vertical application must be
structurally
strong enough to span between supports, to resist the concentrated loads this
creates at the anchor points, and to resist the wind loads that create
positive and
negative pressure on either side of it. Green Roof.systems generally have not
been
designed to meet these criteria.
[0009] On a roof water can be easily supplied and maintained around the roots
of the
plants. Every time it rains the plants will receive moisture and the challenge
is often
ensuring sufficient drainage so the roots do not rot. Rain, however, almost
never
provides sufficient moisture to plants in a vertical arrangement,
necessitating an
irrigation system. Even. with an irrigation system, water will drip down
through the
force of gravity, meaning there must. be either some kind .of measure to
maintain
water around the roots. of the plants, or the irrigation system must
constantly run.-
Water must nonetheless be provided some means of egress, or the plants will
quickly
develop root rot and the community will fail.
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[0010] Finally, on a roof, gravity helps to keep the growing medium in place
against
other forces like wind. On a wall, gravity is the enemy, causing growing
medium to
fall out of the modules, particularly in conjunction with wind. Some sort of
measure
must therefore be taken to hold the growing medium in place, without
interfering. with
the growth of the plants or the management of water. Green Roofing systems
have
generally not entailed'such a system, certainly not in a way integral to each
module.
[0011] These three challenges- structure, water management and growing medium
retention - explain why' modular Green' Roof technologies have not translated
into
vertical applications with any degree of commercial success.
io [0012] There are several modular Living Wall systems on the market today
that use
boxes made of plastic or metal to house the plants, rather like a series of
flower pots
arranged on their sides in a vertical pattern., These systems, although
enjoying some
commercial success, have experienced great difficulty in creating durable
plant
communities because, like flower pots, they trap the roots of the plants they
support
is preventing expansion. This means that within a few short years of
installation, the
plants die and must be replaced..These container-based modular living wall
systems
are quite different from the present invention and not very relevant to it.
But there are
two prior patents that have some relevance.
[0013] "Green roofing system including dimpled anchor layer" (US 2007/ 0 283
653
20 by Garner, G. et al., 13 December 2007) is a modular Green. Roof system
consisting
of a dimpled carrier layer, to which an anchor layer, comprising entangled
synthetic
or natural fibres, is affixed. The anchor layer can be preplanted, and the
modules
installed on a variety of roof:types in a variety-of different configurations.
In some
embodiments the carrier layer is waterproof and the modules can be organized
to
25 permit shingling action down'a roof slope, with the dimples serving as
water retention
compartments for the roots of the plants. -
[0014] Although this invention overcomes some of the'.shortcomings of other
modular
green roof systems, it is nonetheless not adaptable to vertical applications.
Many
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means of attaching the. modules to roofs are disclosed, but they all require
the
module to-bear on an underlying surface.. There is no.part of the module that
is L
structurally strong enough to span between anchors, or to handle 'the
concentrated
loads.this creates at the support points. The dimples, which retain water in
horizontal
and sloped applications, are. not able to retain water in vertical
applications. There is
no front cover to the modules, and hence nothing to retain growing medium or
to
secure the plants against gravity and wind. Finally, there is no part of the
module that
acts as a root barrier, meaning the inner wall layers are vulnerable to root
penetration, unless measures supplemental to the modules are taken.
[0015] "Cellular module for housing living plants particularly for cultivation
of vertical
walls" (CA 2 590 685 Al by Arnold, J. 6 July 2006) is a modular Living Wall
system
consisting of two identical layers of polymer-impregnated natural fibres
pressed
together'around a core of compacted growing medium or hydroponic substrate.
The
modules can be preplanted or planted on site after installation, and several
different.
means of anchoring the module to horizontal, sloping and vertical surfaces are
disclosed. This invention is designed with vertical applications in mind, and
is capable
of structurally spanning between 'support. points.and dealing with the
concentrated
loads created there. But it does not entail many.of the aspects of the present
invention, including -a water proof base layer, an integral- root barrier, and
a blind
fastening system. Furthermore, the materials disclosed are biodegradable and
hence
introduce the challenge that they will deteriorate over time.
[0016] In summary, while there have been many innovations in the field of
modular
plant support, there is as yet no completely satisfactory system to create
healthy
vertical plant communities as an integral part of a wall or building. It is
this void to
which the current invention is addressed. .
SUMMARY OF THE INVENTION
[0017] The present invention relates to a modular support for plants,
especially for
vertical applications such as cladding a wall or building. .
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[0018] In abroad aspect of the invention, there is provided a panel for a
modular
support for plants, comprising a waterproof structural backing comprising a
plurality
of perforations for receiving an anchor; a three dimensional contoured semi-
porous
cover comprising an array of diagonal slits and attached to the waterproof
structural
backing and enclosing a hydroponic substrate comprising an array of holes, the
diagonal slits of the three dimensional contoured semi-porous cover aligning
with the
holes of the enclosed hydroponic substrate, for support of a plant plus its
root plug in
the panel; the three dimensional contoured semi-porous cover and hydroponic
substrate positioned off-center of the waterproof structural backing,
providing two or
more consecutive extended edges; and the two or more consecutive extended
edges
providing fora regular overlapping arrangement of panels, like shingles, when
assembled into a modular support.
[0019] In another broad aspect of the invention, there is provided a modular
support
for plants comprising a plurality of panels, each panel comprising: a
waterproof
is structural backing comprising a plurality of perforations for receiving an
anchor; a
three dimensional contoured semi-porous cover comprising an array of diagonal
slits
and attached to the waterproof structural backing, and enclosing a hydroponic
substrate comprising an array of holes, the diagonal slits of the three
dimensional
contoured semi-porous cover aligning with the holes of the enclosed hydroponic
substrate, for support of a plant and its root plug in the panel; the three
dimensional
contoured semi-porous cover and hydroponic substrate positioned off-center of
the
waterproof structural backing, providing two or more consecutive extended
edges;
and the two or more consecutive. extended edges providing for a regular
overlapping
arrangement of panels, like shingles, allowing for development of a root
system of the
plant to extend into the hydroponic substrate of one or more adjacent panels
and
anchor the one or more adjacent panels one to another.
[0020] In another broad aspect of the invention, there is provided a water
management system integral to each panel that consists of three main
components -
water. proof structural backing, hydroponic substrate and three dimensional
contoured
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semi-porous cover. Each component works jointly with.the others to ensure that
water and wind-driven rain are kept out of the wall cavity, that water and
nutrients
from the irrigation system are held around the roots, and that excess water is
allowed
to drain away, so that the water and air ratio around the roots is.appropriate
to
prevent the development of root rot and ensure a healhty plant community.
[0021] In accordance with another aspect of the invention, the waterproof
structural
backing is the primary structural support of the panel and is capable of
carrying the
load of the other components - the three dimensional contoured semi-porous
cover,
saturated hydroponic substrate, plants and root plugs, as well as any
irrigation
io system - over spans between anchors of up to 2 meters. The waterproof
structural
backing is also capable of resisting the concentrated loads created at the
anchor
points, as well as lateral loads applied by wind.
[0022] In accordance with another aspect of the invention; the waterproof
structural
backing is impervious to water and air. It is also immune to rot and
biodegradation,
and is not broken down by UV light. It is the first component of the water
management strategy of the system, preventing water and wind-driven rain from
entering the inner layers of the wall cavity.
[0023] In accordance with another aspect of the- invention, the water proof
structural
backing is impervious to the roots and shoots of the plants it supports,
acting as the
primary, root barrier protecting the inner wall layers from root penetration.
As such it is
a root barrier that is entirely integral to each panel.
[0024] In accordance with another aspect of the invention, the water proof
structural
backing is flexible, able to conform to the shape of curves without
sacrificing any of
its other properties. It can even be bent around 90 degree corners. . .
[0025] In some embodiments, the water proof structural backing comprises, but
is not
limited to, reinforced thermoplastic olefin. It will be apparent to
technicians skilled in
.the art that other materials are also possible, provided they entail all of
the properties
outlined above. S
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[0026] In accordance with another aspect of the invention, the three
dimensional
contoured semi-porous cover wraps and contains the inner contents.of the
panel. It is
the secondary, structure for the panel and is capable of supporting the load
of the
saturated hydroponic substrate, plants and root plugs that it encloses, as
well as the
weight of any irrigation system, over a span of up to.2 meters. The three
dimensional
contoured semi-porous cover retains the growing medium around the root plug
against the forces of wind and gravity.
[0027] In accordance with another aspect of the invention, the three
dimensional
contoured semi-porous cover allows water to.pass through it at a reduced flow.
It
allows water to drain out of the panels in a controlled way over time,
:instead of all at
once. It is the second component of the water management system and
facilitates
water to enter and exit the..panels.
[0028] In another aspect of the invention, the semi-porous cover is permeable
to the
roots and shoots of the plants that it holds in place, This allows the roots
and shoots
of plants to cross from panel to panel, permitting the development of a much
larger
root system than the individually root bound plants of containerized systems..
This
large root mass is a key component of healthy plant communities in the natural
world..
[0029] In accordance with another aspect of the invention, the three
dimensional
contoured semi-porous cover is immune to rot and biodegradation as well as
breakdown-from UV light.
[0030] In another aspect, the three dimensional contoured semi-porous cover is
flexible and able to conform to the shape of curves without sacrificing any of
its other
properties. It can even be bent around 90 degree corners.
[0031] In some embodiments, the three dimensional contoured semi-porous cover
comprises, but is not limited to, felted synthetic fibres. It will be apparent
to the
technician skilled in the art; that other materials are also possible,
provided they entail
the above properties.
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[00.32] In accordance with another-aspect of the invention, the hydroponic
substrate is
a non-structural medium into which the plants root. It.is the third component
of the.
water management system and ensures that air,water and nutrients are held
around
the'roots of the plants in a ratio suitable to foster healthy plant growth.
[0033] In another aspect, the hydroponic substrate is lightweight.and
flexible, able to
conform to the shape of curves without sacrificing any of its other
properties. It can
even be bent around 90 degree .corners.'
[0034] In some embodiments the hydroponic substrate comprises, but is not
limited
to, mineral wool, polyester, wool, or a combination thereof. The technician
skilled in
the art will recognize that other materials are-also possible, provided. they
meet the
above criteria.
[0035] In accordance with another aspect of the invention, the diagonal slits
permit
the insertion of the plant plugs into the corresponding opening in the
hydroponic
substrate and retains the plants and their root plugs there while the root
systems
develop. The diagonality of the slits is a crucial innovation because it
maintains the
structural integrity of the three dimensional contoured semi-porous cover..
[0036] In accordance with another aspect of the invention, the panel is of
a.square,
rectangular, oval, round or hexagonal configuration.
[0037] Another aspect of the invention is careful ergonomic design. The
panelsare
sized to permit one person to comfortably, carry two pre-planted panels back-
to-back
in each hand, greatly facilitating pre-growing, transportation, staging and
installation.
[0038] In some embodiments, the panels provide a handle integral to the water
proof
structural backing, that facilitates easy handling during all stages of th.e
pre-growing,
transport and installation.. .
[0039] In accordance with another aspect of the invention, the panel as a
whole is
flexible and may.be bent up to ninety degrees around corners. It is therefore
an.
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advantage of the present invention that it can be used for curved and even
double
curvature surfaces.
[0040] In another embodiment, the present invention provides a modular support
for
plants which may be substantially vertical, such as for. a wall, or may be
angled such
as for a roof or awning. The modular support may even be installed-at greater
than
90 degree slopes, with other structural measures taken as necessary.
[0041] In another embodiment, the present invention provides a protective
building
cladding sufficient to protect the inner wall layers from wind-driven rain.
The
overlapping of the panels sheds water downwards like shingles, away from the
io building envelope.. It is an advantage of the current invention that it can
be an integral
component of a wall assembly, rather than applied to the exterior of a
completed wall.
[0042].In another embodiment, there is an air gap between the modular support
and
underlying wall layers of sufficient size to permit air circulation and
pressure
equalization between and behind the panels. It is an advantage of the current
1s invention that it can be used as the outer cladding in a "pressure-
equalizing rain
screen" wall assembly.
[0043] In another embodiment, a blind fastening system is provided, such that
each
anchor is concealed behind adjacent panels, except for the bottom. left
corner, where
a specially designed pocket in the semi-porous cover extends over the anchor.
The
20 pocket can be lifted out of the way for installation and then set back
to.completely
conceal the remaining anchor.
[0044] In another embodiment, the present invention provides methods of
manufacturing, pre-growing and installing a lightweight modular plant support
system.
[0045] Another objective is to promote the reintegration of indigenous plant
25 communities onto our built environment, and to provide a means to conduct
urban
agriculture. .
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[0046] It is therefore an advantage of some aspects of the present invention
to
provide a water and:energy efficient integrated irrigation system as part of
the plant
support system. The irrigation system is configured such that individual
panels may
be replaced without the need to disassemble the entire system. The irrigation
system
can be designed to use collected rain water, and to loop water so as to be
ultra water
efficient.
[0047] This summary of the invention does not necessarily describe all
features of the
invention. Other aspects, features and advantages of the present invention
will
become-apparent to those of ordinary skill in the art upon review of the
following
1o description.of specific embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0048] These and other features of the invention will become more apparent
from the
following description in which. reference is made to the appended drawings
wherein:
[0049] FIG 1 shows a perspective view of a typical panel.
[0050] FIG 2 shows components of the panel
[0051] FIG 3 shows a plan view of the panel
[0052] FIG 4 shows a perspective view of the hydroponic substrate
[0053] FIG 5 shows a plan view of planted panel
[0054] FIG 6 shows the components for assembling the panels into a modular
support
[0055] FIG 7 shows a panel being mounted onto a wall'surface, beginning the
assembly of the modular support
[0056] FIG 8 shows a plurality of overlapping panels mounted creating the
modular
support .
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[0057] FIG 9 shows, a plurality of overlapping panels assembled into a modular
support with an irrigation system being installed
DETAILED DESCRIPTION
[0058] In the description that follows, a number of terms are used-
extensively, the
following definitions are provided to facilitate understanding of various
aspects of the
invention. Use of examples in the specification, including examples of terms,
is for
illustrative purposes only and is not intended to limit the scope and meaning
of the
embodiments of the invention herein.
[0059] Referring to Fig. 1, a modular support for,plants according to some
io. embodiments of the invention is shown. The modular support comprises a
plurality of.
panels, each panel comprising a three dimensional contoured semi-porous cover
4
which is attached along all or a portion of the perimeter of the cover to a
waterproof
structural backing 2, and- contains an absorbent hydroponic substrate 3. The
cover 4
may be attached to the waterproof structural backing 2 by -any.suitable method
- for
example, by sewing or stitching, adhesive, welding (heat, high frequency).
Choice of
a suitable method will be dependent on the selected materials, and apparent to
those
familiar with use of such materials. If the panel is stitched, the thread is
must be UV
and mould resistant. The panel may be provided as a complete unit comprising
the
hydroponic substrate contained between the three dimensional contoured semi-
20, porous cover and waterproof structural backing, with substantially-the-
entire
perimeter of the cover attached to the backing. Alternately, the cover may be
attached to the backing along a portion of the perimeter, allowing for the
hydroponic
substrate to be inserted after manufacture. The cover may be made of any
suitable
material that provides structure-and protection of the hydroponic substrate
while
allowing air and water movement into and out of the panel, thus functioning as
an
integral component of the three part water management system.
[0060] Referring now to Fig.'s 3, 4 and 5 the hydroponic substrate 3 may be
made of '
any suitable material that provides a lightweight and absorbent growing
medium,
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support for plants, aeration and water supply, and nutrient retention at the
location of
the plant. Examples of such substrates include, but are not limited.to,
mineral wool,
polyester or wool, or a combination of these. The three dimensional contoured
semi-
-porous cover 4b has an array diagonal slits 4c which align with an array of
holes 3b
in the hydroponic substrate. These slits hold the plants and their growing
medium 5 in
place while their root system develops and anchors into the substrate. The
slits are
diagonal to maintain the structural integrity of the three dimensional
contoured semi-
porous cover material, and are of a dimension sufficient to hold the plant and
growing
medium in position. The openings in the substrate 3b can b.e packed full of
growing
io medium around the plant plug to ensure the roots do not dry out. The
system.is
therefore a hybrid of hydroponic medium and growing medium, entailing the best
features of both. The hydroponic portion ensures the system is lightweight and
flexible; the growing medium portion ensures that soil microbes and trace
minerals
important for plant health are always present.
[0061] Referring again to Fig. 1 the waterproof structural backing 2 prevents
rain and
water from falling behind the panel, restricts the roots to the front of the
panel, and
provides structural support for the unit as a whole. Perforations 2b in the
backing
allow the panel to be hung onto the anchoring system. These perforations can
be
sealed with waterproof material, such as a neoprene gasket, such that the
integrity of
the waterproofing assembly remains intact. The example illustrated in Fig. 1
shows
the three dimensional contoured semi-porous cover 4 attached off-center of the
waterproof structural backing 2, at or close to the edge of the backing of two
consecutive sides 8 and 9, with two consecutive sides of the backing extending
beyond the dimension of the cover, providing extended edges 6 and 7. The
width.of
the extended edges may vary with the overall size of the panel, but are to be
of
sufficient width to provide for secure perforations 2b that support the mass
of the
panel when in use and prevent a tear-out of the perforation when the panel is
attached to a support structure, such as a wall. The extended edges facilitate
overlapping attachment of a plurality of panels to a wall, roof or awning, to
permit
shingling action, draining water to the exterior.
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The waterproof structural backing 2 is flexible, and may be made of any
[Q062] 9 ~ Y suitable material that meets all of the criteria outlined above,
for example a plastic or
thermoplastic polyolefin.
[0063] The panel exemplified herein is illustrated as of a square
configuration: It will
be apparent to a skilled reader that the configuration may be rectangular,
hexagonal
or even circular. For a hexagonal.panel (not illustrated), the cover would
also
comprise a hexagonal configuration, and be attached at or close to the edge of
the
hexagonal shaped backing along three consecutive edges, with.three consecutive
sides of the backing extending beyond the dimension of the cover, providing an
io extended edge to facilitate overlapping attachment of a plurality of
panels.
PLANTING AND GROWING-PROCESS
[0064] Referring now to Fig.'s 4 and 5, Plant plugs 5 are inserted through the
openings in the cover 4c and into the holes 3b of the hydroponic substrate 3.
The
panel is coupled to a hydroponic growth system and the plant plugs allowed to
grow
until a root system is established and desired plant coverage of the panel is
.
achieved. Suitable or desired plant coverage of a panel may be dependent on
several factors including the intended application of the shingle, the
environment
where it is to be.placed', the plant type, growing medium, or on aesthetic .
considerations.
[0065] Plant plugs 5 including growing medium are commonly available as
nursery
items. The panel can be pre-grown before installation and or planted with
plugs after
installation.
[0066] When used in multiples, the panels are assembled in an overlapping.
fashion in
order to allow air flow while protecting the building envelope from direct
contact with
water, including wind-driven rain, thereby forming a pressure-equalizing
rainscreen, a
standard-type of wall construction: .
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[0067] Referring now to Fig. 7, to assemble a plurality of panels into a wall,
roof,
awning or other surface, holes 6b are drilled into the surface. Anchors 6 are
screwed'
and sealed into the holes, and perforations in vertical spacers-7 are aligned
and the
spacer placed on the anchors. Many non-biodegradable materials can be used for
the spacers, including but hot limited to, recycled' plastic and even cut
lengths of
irrigation tubing. The spacers can take many different shapes and forms; what
is
important is. that they can:hold the panels out from the wall surface. by at
least 25mm
to furnish the air gap necessary in a pressure-equalizing rainscreen. A first.
panel 1.is
then mounted onto the spacers 7 by aligning the Perforations 2b over the
anchors 6.
io The gaskets 8 are then placed over the panels, onto the anchor, to maintain
the
integrity of the waterproofing system. .
[0068] Referring now to Fig. 8, second and subsequent panels are placed in an
overlapping relationship, side to side, and bottom to top, so that the
extended edge of
a first, lower panel 9 is. positioned under the adjacent upper panel 10. This
method of
is layering allows the water to be shed away from the building envelope
through
shingling action, 'and provides a root barrier to protect the inner wall
layers. The
Fasteners 8b are then put on the anchors and secured with a bolt. Once
assembled,
the panels housing the plant plugs may be maintained by an irrigation system.
Conventional irrigation systems are available to provide sufficient volume of
water
20 appropriate to the climate or geographic location,' as well as-the plant
type or types.
Such an irrigation system may include, for example: a back-flow valve to
prevent
water in the irrigation system from entering the water supply; a filter or
filters to trap.
particulates and a flush valve to expel particulates from the system; a
regulator to
control the pressure in the system to prevent `blow-outs', or to ensure that
the water
25 is provided to the appropriate vertical level in the assembled, modular
support; a
fertilizer injector; a timer to provide automated control of irrigation; and
mainlines and
sublines to deliver water to the array of panels in the modular support.
[0069] Referring now to Fig. 9, after the panels are assembled, a mainline 11
is
attached to one-side of the panel assembly. Drip irrigation sub-lines 12 are
in fluid
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communication with the mainline and with each panel. In the example
illustrated,
each sub-line has drip emitters and is inserted inside the three dimensional
contoured semi-porous cover 4 along the top of each row of panels. These sub-
lines
then connect with the mainline. The mainline is then connected to a water
source and
the irrigation schedule is controlled by a computerized timer. A fertilizer
injector may
be included in the irrigation system to allow for introduction of nutrients,
insect or
plant growth regulators, or other desired water-soluble agents into the
system. As it is
an advantage of the system to permit.the growth of plants in a water efficient
way.
The irrigation system can be configured to use collected rain water and be
looped for.
io maximum efficiency.
[0070] In the assembled modular support comprising the plurality of panels,
each of
the cover and hydroponic substrate arrangements are adjacent, or nearly
adjacent,
and allow for growth of plant root systems into one or more adjacent panels'
cover
and hydroponic substrates, thus providing a larger area for root development.
This
is large entangled root mass is a typical feature of natural plant communities
and is an
advantage of the current invention.
[0071] One or more currently preferred embodiments have been described by way
of
example. It will be apparent to persons skilled in the art that a number of
variations
and modifications can be made without departing from the scope of the
invention as
20 defined in the claims.
AMENDED SHEET