Abstract:
A fiber pot, made of a combination of coconut fiber and natural latex rubber, is described that is able to be folded and compressed. Folding and compression of the fiber pots allows more pots to be placed within a shipping container thereby reducing shipping costs by approximately 75%. Because the folding fiber pots are made of coconut fiber and a natural latex rubber, they are 100% biodegradable and horticultural products contained within do not need to be removed prior to planting. This eliminates the root shock that horticultural products normally experience when planted in a different soil.

Description:
FIELD 
       [0001]    This disclosure relates to containers that are used to grow and hold horticultural products, especially root-bearing plants to be transplanted by the customer. 
       BACKGROUND 
       [0002]    Known horticultural containers are primarily made of plastic. A small percentage of the market consists of “green” containers made of wood fiber, corn, cocoa starch, or paper products. All known “green” containers are rigid and non-folding. In order to ship these containers, they are nested, one within the other, which is space consuming. The containers are solid and the horticultural product root systems remain confined within the container as the root systems grow and expand, resulting in the root system growing in a circular pattern and becoming “root bound”. Prior to planting, the horticultural products must be removed from the containers, and placed directly into a different soil, which can result in soil shock to the root system. In addition, the root system may need to be shaved to release the bound roots, which leaves the roots exposed and susceptible to diseases. 
       SUMMARY 
       [0003]    A fiber pot, made of a combination of coconut fiber and natural latex rubber, is described that is able to be folded and compressed. Folding and compression of the fiber pots allows more pots to be placed within a shipping container thereby reducing shipping costs by approximately 75%. Because the folding fiber pots are made of coconut fiber and a natural latex rubber, they are 100% biodegradable and horticultural products contained within do not need to be removed prior to planting. This eliminates the root shock that horticultural products normally experience when planted in a different soil. 
         [0004]    Due to the density of the combination of the coconut fiber and latex rubber, the root system of the horticultural products are able to grow directly through the pots, eliminating the problem of bound roots. In addition, the roots are able to be air pruned, eliminating the need to shave bound roots. Air pruning also encourages the horticultural product to grow more roots, which results in healthier root systems. Horticultural products are generally fruits, vegetables, flowers, herbs, and ornamentals used for landscaping. Ornamentals can be, for example, trees, shrubs, bushes, evergreens, etc. 
         [0005]    In one example, the coconut fiber and latex rubber are combined and formed to make a generally cylindrically shaped container with an open top and a closed bottom. In one embodiment, the top is slightly larger in diameter than the bottom, resulting in a slight taper of the generally cylindrically shaped container. The pot&#39;s lip and base may be made of two layers of the coconut and latex rubber which gives it strength, permeability, biodegradability and flexibility. The flexible nature of the materials allows the pot to be folded and for the pot to return to its original configuration. The top area of the container can be made of three layers of the coconut and latex rubber, giving the top area additional strength, helping to provide the pot the ability to return to its original configuration, e.g. to a circular shape, and for carrying, machine handling, or attachment of handles. Indentations may be formed on the bottom and sides of the container which allow the container to be easily folded. It should be realized that the containers can be made in any shape or size but it is preferred that the container be cylindrically shaped and have capacities of 1 to 10 gallons, for example, 1, 2, 3, 5, 7 and 10 gallons. 
     
    
     
       DRAWINGS 
         [0006]      FIG. 1  illustrates a “fully opened” fiber pot. 
           [0007]      FIG. 2  illustrates an interior view showing the bottom and side wall of the fiber pot. 
           [0008]      FIG. 3  illustrates an exterior view showing the bottom and side wall of the fiber pot. 
           [0009]      FIG. 4  illustrates the bottom of the fiber pot detailing the indentation. 
           [0010]      FIG. 5  illustrates a cross section view of an indentation in the fiber pot. 
           [0011]      FIG. 6  illustrates a partially compressed fiber pot. 
           [0012]      FIG. 7  illustrates a side view of a fully compressed fiber pot. 
           [0013]      FIG. 8  illustrates a fiber pot without a lip. 
       
    
    
     DETAILED DESCRIPTION 
       [0014]    The fiber pot  10 , as shown in  FIGS. 1 and 2 , is formed from a combination of compressed coconut fiber, known as coir, and latex rubber. Coconuts are a renewable resource and are readily available. The coconut seed is separated from the husk pulp. 
         [0015]    The coir fibers and pith are found in the husk pulp and can be soaked to separate the fiber from the pith. The fiber is removed, cleaned and dried for use in making the fiber pot. Some advantages of using coir fiber is that it is a pH neutral material, is free of bacteria and fungal spores, and naturally contains a tanic acid which resists mold and termites. 
         [0016]    Natural latex rubber is extracted from rubber trees and is used as a binding agent. Natural latex rubber is an elastomer (an elastic hydrocarbon polymer) that was originally derived from a milky colloidal suspension, or latex, found in the sap of some plants. Natural latex rubber is a polymer of isoprene—most often cis-1,4-polyisoprene—with a molecular weight of about 100,000 to 1,000,000. Typically, a small percent of other materials, such as proteins, fatty acids, resins and inorganic materials are found in natural latex rubber. Natural latex rubber is advantageous in that it is not brittle, it returns to generally its original shape, and it is non-toxic and biodegradable. In one embodiment, when the pots are above ground and in normal conditions, of the pot will take approximately two years to biodegrade. But, if the thickness of the pot is increased, the time to biodegrade will increase. It is to be realized that synthetic latex rubbers can also be used if they have been chemically treated to be biodegradable. But, chemically treating synthetic latex rubbers is costly, thereby making the use of these latex rubbers, for the purpose of making the fiber pots, less desirable. 
         [0017]    In one embodiment, the coconut fiber is pressed into a large sheet and one side is sprayed with latex rubber. The coconut fiber and latex rubber sheet is then heated to 80 to 90° C. The sheet is turned over and the unsprayed side is then sprayed with latex rubber. The sheet is then re-heated to 80 to 90° C. and is roller pressed to the desired thickness. The large sheets can be cut to obtain smaller sheets of the desired shape and size. The sheets are press molded in the shape of the fiber pot including the indentations. Multiple layers can be incorporated during the press molding process to obtain a multi-layer fiber pot. The formed fiber pots are hand sprayed with heated latex and the top edge can be cut. The formed pots can then be folded and packed. 
         [0018]    It should be realized by those skilled in the art that the embodiments described herein are not limiting and that even though the preferred embodiment is that of a fiber pot that is generally circular in shape, the fiber pot may be any shape including, but not limited to, square, rectangular, elliptical, etc. 
         [0019]    An example of a folding fiber pot  10  will now be described with reference to  FIG. 1-7 . The fiber pot  10  includes a continuous side wall  12 , a first end  14 , a second end  16 , a first indentation  18 , a second indentation  20 , and a third indentation  22 . 
         [0020]    The continuous side wall  12 , as shown in the embodiment of  FIG. 1 , includes a first end  24 . Opposite the first end  24  is a second end  26 . The side wall  12  material is a combination of coconut fiber and latex rubber. In one embodiment, the relative amount of coconut fiber is in the range of 70% to 80% and the relative amount of latex rubber is in the range of 20% to 30%. The material may be press molded in layers and the side wall  12  may contain a plurality of layers. In one example, the side wall  12  is made of two layers of compressed coconut fiber and latex rubber. Two layers allow for permeation of root systems and aids in the biodegradability of the product while providing the strength needed to contain the horticultural product and soil. The thickness of the walls is a determination of the life span of the fiber pot. Thinner walls will biodegrade faster than a thicker walled fiber pot. Once the pot is placed below ground level, the roots will penetrate the walls of the pot. The fibers will begin to deteriorate once placed below ground level and will open and disintegrate into the soil. Depending on needs, the wall thickness or number of layers may be adjusted. In one embodiment, the wall thickness is adjusted by the number of layers used. In another embodiment, the wall thickness is adjusted by using more material per layer. In addition, an area  28  extending approximately 1/20 to ¼, most preferably 1/10, of the height H of the side wall  12  from the first end  24  toward the second end  26  may be made of additional layers of compressed coconut fiber and latex rubber, e.g. three. This is done to provide additional stability, strength, and shape restoration properties. In one example, the first end  24  can include a lip  30 . In another example, as shown in  FIG. 8 , the first end  24  can be provided as a straight wall without a lip  30 . In another example, the side wall  12  can incorporate a plurality of handles relatively close to or at the first end  24 . 
         [0021]    The first end  14  is located at the terminus of the first end  24  of the side wall  12  and has a diameter D 1 . The first end  14  is open and provides access for the introduction of horticultural materials into the fiber pot  10 . 
         [0022]    In this embodiment, the second end  16  is made of a combination of coconut fiber and latex rubber, is located at the terminus of the second end  26 , and has a diameter D 2 . The material is press molded in layers and the second end  16  contains a plurality of layers. In one example, the second end  16  is made of two layers of the combination of coconut fiber and latex rubber. Two layers allow for permeation of root systems and aids in the biodegradability of the product while providing the strength needed to contain the horticultural product and soil. 
         [0023]    The second end  16 , as shown in the embodiment of  FIGS. 1 and 4 , may be continuous and unitary with the terminus of the second end  26  of the side wall  12  thereby closing the container at the terminus of the second end  26 . The second end  16  includes a first axis  32  and a second axis  34  that is perpendicular to the first axis  32 . A first indentation  18  is disposed along the first axis  32 . The first indentation  18  extends across the second end  16 , preferably spanning the maximum dimension of the second end  16 . The first indentation  18  has a first end  36  and a second end  38  opposite the first end  36 . 
         [0024]    The side wall  12  has a second indentation  20  and a third indentation  22  each extending from the second end  26  in the direction of the first end  24 . The second indentation  20  and third indentation  22  can extend partially or fully from the second end  26  to the first end  24 . In one embodiment, the second indentation  20  and third indentation  22  may extend approximately one-third of the distance from the second end  26  to the first end  24 . In another embodiment, the second indentation  20  and third indentation  22  may extend approximately one-half of the distance from the second end  26  to the first end  24 . The second indentation  20  extends from the first end  36  of the first indentation  18  and the third indentation  22  extends from the second end  38  of the first indentation  18 . The indentations  18 ,  20 ,  22  allow for the folding of the fiber pot  10  in a predetermined manner, resulting in the fully compressed fiber pot  10  shown in  FIG. 7 . 
         [0025]    One example, as detailed in  FIGS. 3 and 5 , has the groove  44  of the first indentation  18  located on an exterior surface  40  of the second end  16  and the grooves  44  of the second  20  and third  22  indentations on an exterior surface  42  of the side wall  12 . The purpose of this is direct the folding of the material in one direction towards the interior of the fiber pot  10 . As shown in  FIG. 6 , the second end  16  is folded along the first indentation  18 . The side wall  12  is folded using the second  20  and third  22  indentations and opposites sides  46 ,  48  of the side wall are brought together. The folding allows for the compaction of the fiber pot  10  so that a larger number of folded pots can be shipped versus unfolded pots, in the same size shipping container. For example, using a 40 foot (12.2 meters) high cube shipping container, it is possible to put 14,000 uncompressed three-gallon pots in each container. After compressing or folding a three-gallon fiber pot, it is possible to put 48,000 compressed three-gallon pots in each 40′ high cube shipping container, thereby reducing shipping costs by over 75%. In general, there is a 300-400% increase in the number of compressed pots that can be shipped in the same size container versus uncompress pots, regardless of the size of the pot. 
         [0026]    Other aspects of the fiber pot  10  include that the diameter D 1  of the first end  14  be equal to or less than the diameter D 2  of the second end. The capacity of the fiber pot  10  generally is at least one gallon (3.5 liters), but can be any size. Preferred embodiments are of fiber pots with 1, 2, 3, 5, 7 and 10 gallon capacities. 
         [0027]    The examples disclosed in this application are to be considered in all respects as illustrative and not limitative. The scope of the invention is indicated by the appended claims rather than by the foregoing description; and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein.