Abstract:
A convertible planting system includes a flexible sheet of material bent into an overlapped configuration to form a container defining an interior volume, the flexible sheet having a first broad surface covered with an engageable loop material, and a second broad surface from which touch fastener hooks extend in an area overlapping the first broad surface with the sheet of material bent to form the container; with the hooks releasably engaged with the loop material, and soil filling at least a portion of the interior volume of the container and in contact with the loop material. A gardener may plant a seed in the convertible planting system, peel back a portion of the sheet of material forming a wall of the container by releasably disengaging hooks and loops of the sheet of material, and reattach the portion of the sheet of material by reengaging the hooks and loops.

Description:
TECHNICAL FIELD 
       [0001]    This invention relates to the structure, manufacture, assembly and use of reusable potting containers for seedling growth. 
       BACKGROUND 
       [0002]    Disposable containers are often used for initiating and promoting plant growth. Initiating plant growth may begin with placing a mixture of soil and seedlings within a disposable or other type of container to form a plant system. Seedling germination subsequently occurs within the container. In some instances, the container is biodegradable, allowing the plant system to be planted directly within an outdoor soil mass for prolonged growth. In other cases, the container is non-biodegradable, and the plant system is placed atop a capillary mat in an indoor environment to promote germination at a controlled rate and/or to protect the plant system from garden animals. In such cases, gardeners often desire to inspect root growth within the soil to determine the health and maturity of the plant. In some examples, once the plant appears to have attained a desired maturity, the plant and soil are removed from the container by flipping the container over to release the plant and soil, which are then planted in an outdoor soil mass for further growth. During the release and replanting of the plant and soil, the roots may be damaged, which can detrimentally affect the health of the plant. 
       SUMMARY 
       [0003]    The invention involves a realization that certain attributes of a potting container can provide easy access to a plant seeded within the potting container, and removing the plant for transplanting, without damaging the plant, and that such attributes may be provided by a potting container fashionable from a flexible sheet of material featuring touch fastening surfaces. 
         [0004]    One aspect of the invention features a method of preparing a container for planting. The method includes bending a flexible sheet of material into an overlapped configuration to form a container defining an interior volume for holding soil. The flexible sheet has a first broad surface covered with an engageable loop material exposed over at least half of an interior surface area of the container, and a second broad surface from which touch fastener hooks extend in an area overlapping the first broad surface with the sheet of material folded to form the container, with the touch fastener hooks releasably engaged with the engageable loop material. The method also includes placing the soil in the interior volume of the container, in contact with the loop material. 
         [0005]    By “hooks” we mean male touch fastener elements configured to be releasably engageable with a fibrous surface to form a peelable fastening. Such hooks may be molded or formed by other means, and may be in the form of headed stems. 
         [0006]    In some implementations, the touch fastener hooks extend in an array covering a majority of an outer surface area of the container. 
         [0007]    In some examples, the loop material essentially covers the interior surface area of the container. 
         [0008]    In some cases, the loop material is a knit or non-woven material. 
         [0009]    In some instances, the loop material has a basis weight of between 40 and 400 grams per square meter. 
         [0010]    In some implementations, the loop material comprises hydroscopic fibers, such as nylon fibers. 
         [0011]    In some examples, the second broad surface is disposed on an outer surface of the container. 
         [0012]    In some cases, both the first and second broad surfaces are disposed on an inner surface of the formed container. 
         [0013]    In some instances, the flexible sheet of material comprises a continuous sheet of resin from which the touch fastener hooks extend on the second broad surface, the sheet of resin and stems of the touch fastener hooks together forming a contiguous mass of resin. 
         [0014]    Such a resin sheet and fastener hooks may be formed by a continuous roll-molding process, such as taught in U.S. Pat. No. 4,775,310 to Fischer, the entire contents of which are hereby incorporated by reference. 
         [0015]    In some implementations, the loop material and the continuous sheet of resin form a laminate in which some fibers of the loop material are at least partially embedded in the continuous sheet of resin, with other fibers exposed for engagement. 
         [0016]    In some examples, as bent, the flexible sheet forms the container having a base and defining a plant growth opening opposite the base, the plant growth opening being smaller than the base. In some cases the walls of the container slope inward toward the opening, giving the container a somewhat frustoconical or pyramidal shape that increases stability against tipping. 
         [0017]    In some cases, an outer surface of the base is covered by an array of the touch fastener hooks. 
         [0018]    In some instances, the flexible sheet of material is shaped to define flaps extending from a central portion of the sheet of material, and bending the flexible sheet of material includes bending the flaps to form respective sides of the container. 
         [0019]    In some implementations, the flexible sheet of material, prior to bending, defines slits that form drainage apertures through walls of the container. 
         [0020]    In some examples, the method further includes, prior to bending the flexible sheet of material, overlapping two separate flexible pieces of material to form the flexible sheet of material, the two pieces of material each having a loop material on one side and a field of engageable fastener hooks on the other side, such that the hooks of one of the two pieces releasably engage loops of the other of the two pieces. 
         [0021]    In some cases, each of the pieces of material forms a pair of oppositely-directed flaps of the flexible sheet of material. 
         [0022]    In some instances, the container as formed has a first wall with an interior surface covered with loops, and an adjacent wall with an interior surface covered with touch fastener hooks and releasably secured to the first wall by overlapping wall tabs extending outward from the container between the first and adjacent walls. 
         [0023]    In some implementations, the method further features forming multiple container portions, each defining a respective interior planting volume, one of the container portions having an outer surface carrying exposed touch fastener hooks, and another of the container portions having an outer surface covered with an engageable loop material, and then releasably engaging the container portions to form a connected container defining multiple planting volumes. 
         [0024]    In some examples, the method further includes overlapping and releasably attaching a container extension about a rim of the container formed by the sheet of material, thereby increasing a planting volume of the container. 
         [0025]    In some cases, the method further involves attaching a handle spanning opposite edges of the container adjacent an opening of the container, the handle being formed of a strip of flexible material having engageable loops that releasably engage hooks of the flexible sheet of material. 
         [0026]    In some implementations, the details of any of the above-described features can be implemented in accordance with any of the aspects of the invention discussed below. 
         [0027]    Another aspect of the invention features a convertible planting system that includes a flexible sheet of material bent into an overlapped configuration to form a container defining an interior volume. The flexible sheet has a first broad surface covered with an engageable loop material exposed over at least half of an interior surface area of the container, and a second broad surface from which touch fastener hooks extend in an area overlapping the first broad surface with the sheet of material bent to form the container, with the hooks releasably engaged with the loop material. The system also includes soil that fills at least a portion of the interior volume of the container, in contact with the loop material. 
         [0028]    Another aspect of the invention features a method of preparing a seedling for transplant. The method includes planting a seed in the convertible planting system described herein, growing a seedling from the seed, such that roots of the seedling contact the engageable loop material of the interior surface of the container, peeling back a portion of the sheet of material forming a wall of the container by releasably disengaging hooks and loops of the sheet of material, to expose the soil and an adjacent root of the seedling, and then reattaching the portion of the sheet of material by reengaging the hooks and loops that were disengaged. 
         [0029]    Another aspect of the invention features a planting container package. The planting container package includes one or more flexible sheets of material, each having a first broad surface covered with an engageable loop material, and a second broad surface covered with an array of touch fastener hooks. Each flexible sheet also has a perimeter shape configured to facilitate folding of each flexible sheet to form a planting container defining an interior volume for holding soil, with the engageable loop material exposed over at least half of an interior surface area of the planting container, and the hooks releasably engaged with the loop material to hold a shape of the planting container. The planting container package also includes packaging that includes the one or more flexible sheets of material. The packaging features instructions for folding the one or more sheets of material to form planting containers. 
         [0030]    Various embodiments of the convertible container may thus provide various advantages. For example, roots may grow from a seedling planted within the container to contact a fibrous inner surface of the container that also serves as an engagement surface to hold the container in its shape. Such root contact may promote lateral growth and extension of another root from a stem of the contacting root, and reduce the tendency of roots to wrap around the inner container walls. In some examples, such lateral root extension can minimize transplant shock to the seedling and roots. 
         [0031]    Many examples enable inspection of the growing root system by detaching one or more of the container walls and folding down the one or more container walls towards the base, to expose the soil and the roots, while allowing the container walls to be reattached after inspection. In some examples, folding down the one or more container walls to access the seedling and the soil can allow easy access to the seedling and the soil without tipping over the container to release the soil, and thus reduce the risk of damaging the roots. Upon removing the seedling and the soil from the container, the container may be reused for potting another seedling. 
         [0032]    In some instances, the plant system may be easily transported while the seedling and the soil remain within the container. The fastening surface on an underside of the base may permit the container to be releasably engaged with a fibrous surface supporting the container. Holes or slits through the base, side walls, or top walls of the container can be provided to allow for fluid migration from or into the soil or for access to deliver growth medium to the seedling and the soil. 
         [0033]    The soil cavity defined by the assembled container can be configured to provide increased soil capacity relative to some alternative potting containers. In some cases, the detachable feature of the container walls can permit planting of multiple seedlings having differing growth rates within the same container. 
         [0034]    Configuring the container to be disassemblable into a flat configuration between uses can conserve packaging and shipping space and provide packaging flexibility, thus providing relatively low shipping and handling costs. 
         [0035]    The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, aspects, and advantages of the invention will be apparent from the description, drawings, and claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0036]      FIG. 1  is a top view of a planting container preform in the form of a flat sheet. 
           [0037]      FIG. 2  is a side view of the planting container preform of  FIG. 1 . 
           [0038]      FIG. 3  is a perspective view of the planting container preform of  FIG. 1 , folded into a container having a stable, rectangular shape. 
           [0039]      FIG. 4  is a perspective view of the container of  FIG. 3 , with one wall partially detached for access. 
           [0040]      FIG. 5  is a perspective view of the container of  FIG. 3 , releasably attached to a fibrous wall. 
           [0041]      FIG. 6  is a perspective view of the planting container preform of  FIG. 1 , folded into a stable, non-rectangular shape. 
           [0042]      FIG. 7  is perspective view of a stack of the planting container preform of  FIG. 1 . 
           [0043]      FIG. 8  is a top view of a die-cut flat sheet configured to form part of a foldable container preform. 
           [0044]      FIG. 9  shows two of the sheets of  FIG. 8 , overlapped in a cross pattern to form a planting container preform similar to that of  FIG. 1 . 
           [0045]      FIG. 10  is a perspective view of the planting container preform of  FIG. 9 , folded into a container having a stable, rectangular shape and accessorized with features that provide convenience for its use. 
           [0046]      FIG. 11  is a perspective view of a stacked foldable container formed from the sheets of  FIG. 8 . 
           [0047]      FIG. 12  is a set of laterally attached containers formed from the planting container preform of  FIG. 9 . 
           [0048]      FIG. 13  is a perspective view of a bottom-openable planting container preform folded into a container having a stable, elongate shape. 
       
    
    
       [0049]    Like reference symbols in the various figures indicate like elements. 
       DETAILED DESCRIPTION 
       [0050]    Referring first to  FIG. 1 , a planting container preform  10  in the form of a plastic sheet includes two spaced apart, laterally tabbed walls  12  and two spaced apart, longitudinally tabbed walls  14  that extend from a common base  16 . In the example of  FIG. 1 , container preform  10  is illustrated in a disassembled, open configuration. Walls  12  are foldable along spaced apart edges  18  of base  16 , and tabbed walls  14  are foldable along spaced apart edges  20  of base  16 . Edges  18  extend perpendicular to edges  20 , such that walls  12  and tabbed walls  14  can be folded upward along edges  18  and edges  20 , respectively, and adhered to adjacent walls  12 ,  14  to form a substantially closed wall extending from base  16 . Tabs  22  extend laterally from each side of walls  14  and past edges  18 , thus extending vertically from base  16  when walls  14  are folded upward along edges  20 . Tabs  22  are further foldable upon walls  14 . Tabs  23  extend longitudinally from each end of walls  12  and are foldable upon walls  12 . 
         [0051]    By “foldable” or “folded” we do not mean to imply that a sharp bend or crease is necessary. Bending may involve only flexing the material from a flat to a curved condition in which the material remains under elastic bending stresses and is held in its container shape by fastening forces. 
         [0052]    A center hole  24  is located at a center of base  16 , and spaced apart holes  26 ,  28  within base  16  surround center hole  24 . Center hole  24  has a diameter larger than that of holes  26 ,  28 , and holes  26  have a diameter larger than that of holes  28 . 
         [0053]    As shown in  FIG. 2 , planting container preform  10  is formed from a thin, flexible sheet having an engageable surface  30  and a fastening surface  32  opposite engageable surface  30 . The engageable surface is substantially covered with a looped material  31 , such as a non-woven or lightweight knit, that is compatible with miniature touch fastening elements  33 , such as hooks, extending from and distributed across fastening surface  32 . In some instances, looped material  31  has a basis weight of 40-400 grams per square meter. The hooks generally may be any of several male touch fastener shapes, such as J hooks, mushroom hooks, and palm tree hooks, among others. Such a sheet can be manufactured as a laminate in a continuous roll-molding process, such as is taught in U.S. Pat. No. 5,260,015, the entire contents of which are incorporated here by reference. In such a laminate the loop material may be directly and intimately embedded in resin forming the base from which the fastener hooks extend. After the molding and lamination, the material having a hook side and a cooperative loop side may be readily die cut into the various shapes shown herein. In some cases, a sheet having an engageable surface may be attached to another sheet having a fastening surface, forming one sheet having an outer engageable surface and an outer fastening surface. 
         [0054]      FIG. 3  displays an example view of planting container preform  10  folded in an assembled configuration. Walls  12 ,  14  extend upward from base  16  and are releasably attached to adjacent walls  12 ,  14  via tabs  22 , forming a substantially closed, rectangular wall extending upward from base  16 . Walls  12 ,  14  further define an opening opposite base  16  and having a size and shape substantially equal to and the same as a size and shape, respectively, of base  16 . Engageable surface  30  forms the entire inner surface of folded container  10 , while fastening surface  32  forms the entire external surface of folded container  10 . In the example of  FIG. 2 , fastening sides (i.e., provided by surface  32 ) of tabs  22  are releasably attached to engageable sides (i.e., provided by surface  30 ) of walls  12 . However, in some examples, engageable sides of one or more tabs  22  can alternatively be connected to a fastening side of wall  12  (i.e., one or more tabs  22  may be disposed on external surface  32  of folded container  10 ). 
         [0055]    Now referring to  FIG. 4 , any of walls  12 ,  14  can be detached from assembled container preform  10  and folded down towards base  16  while the other walls  12 ,  14  remain attached to one another and folded upward from base  16 . A plant system  35  includes a seedling  37  planted in soil  39  within folded container  10 . A germination mix may be added to soil  39  to promote germination of seedling  37 , which grows roots  41  within soil  39 . The roots  41  may grow laterally to contact the inner surface of walls  12 ,  14 . It is believed that such contact may lead to propagation of additional lateral root shoots from the root trunk, and to inhibition of root circling of the soil mass along the container wall. Such root development can help to minimize transplant shock to seedling  37  and roots  41 . 
         [0056]    In some examples, a gardener may wish to inspect the roots of the seedling in the container to determine their health and maturity. This can be accomplished by detaching any of walls  12 ,  14  and folding them down toward base  16  in order to expose soil  39  and roots  41 . Folding down one or more (or all) of the walls of the container may be helpful for removing the mature seedling with little loss of soil mass and disturbance to the roots. After inspection, the folded down walls  12 ,  14  may be folded back up and reattached to form a substantially closed wall extending upward from base  16 . Upon removing seedling  37 , roots  41 , and soil  39  from folded container  10 , folded container  10  may be unfolded, cleaned, and stored for reuse in a subsequent planting season. 
         [0057]      FIG. 5  displays a plant system  43  including an assembled planting container preform  10  releasably attached to a fibrous wall  45  covered with a looped material (e.g., looped material  31 ) via fastening surface  32 . A vine seedling  47  extends from soil  39  within container  10  and has vine tendrils  49  engaged with fibers of wall  45 . Generally, fastening surface  32  on any of walls  12 ,  14  or the underside of base  16  of folded container  10  allows easy attachment of folded container  10  to a supporting fibrous surface. 
         [0058]    As shown in  FIG. 6 , foldable container  10  can be assembled such that the size of the opening opposite base  16  is substantially smaller than the size of base  16 . For example, this can be achieved by overlapping walls  12  and walls  14  beyond the area provided by tabs  22  to form a non-rectangular (e.g., trapezoidal) shaped wall. In some cases, assembling planting container preform  10  such that the opening is smaller than base  16  provides a plant system whose soil weight is concentrated near base  16  of folded container  10  as opposed to being substantially equally distributed within folded container  10  (e.g., as shown in  FIGS. 4 and 5 ). In some instances, assembling planting container preform  10  such that the opening is smaller than base  16  can guide a direction of seedling growth towards and through the opening from the soil planted within folded container  10 . 
         [0059]    Referring now to  FIG. 7 , several planting container preforms  10  can be stacked in a disassembled, flat configuration providing a set  51  that can be easily packaged and shipped. For example, in the disassembled, flat configuration, set  51  takes up relatively little space and can therefore be packaged in a thin container or packaged within a flexible, sealed plastic wrap. 
         [0060]      FIG. 8  displays an example view of a partial planting container preform  34  that can be assembled with another partial planting container preform  34  to form a foldable container. Partial preform  34  includes two spaced apart tabbed wall sections  36  extending from opposite, foldable edges of a base section  40 . Tabs  42  extend laterally from each side of the wall sections and past base edges  38 . 
         [0061]    A hole  46  is located at a center of base section  40 , and four sets of slits  48  are spaced around hole  46  for drainage. A set of slits  48  is also located at a center of each wall section  36 . Partial preform  34  is die-cut from the same material as discussed above with respect to  FIG. 1 . 
         [0062]    Two such partial preforms  34  may be overlapped in a cross arrangement, such as shown in  FIG. 9 , to form a container preform  54  that has a shape similar and functionally identical to that of  FIG. 1 . In this arrangement, the two base sections  40  of the partial preforms  34  are fully aligned and overlapped, with the wall sections  36  extending into different quadrants. Starting from the preform shown in  FIG. 9 , containers may be fashioned by folding the extending wall sections  36  to form various container shapes, such as those of  FIGS. 3 and 6 . 
         [0063]    For manually transporting such containers, an elongated strip of fastening material may be releasably attached as a handle to the upper portions of the container walls. Such a fastening material may be of the same constructions as the material of the container, with both male and female fastening surfaces, or may be simply a strip of hook tape secured to the fibrous sides of the container walls or a strip of loop material secured to the hook sides of the container walls. 
         [0064]    The preforms discussed above may be releasably configured in a number of different planting arrangements. For example, as shown in  FIG. 10 , a planting container preform  55  is assembled such that tabs  42  extend outward from wall sections  36 , forming a substantially closed, rectangular wall extending from base  40 . An engageable side of handle  57  is releasably attached to fastening surfaces  52  of opposing wall sections  36 . Alternatively, a fastening side of handle  57  can be releasably attached to engageable surfaces  50  of opposing wall sections  36 . Folded container  55  further includes a window  59  that allows viewing of soil and seedling roots within the folded container such that a wall section  36  does not need to be detached and folded down from the folded container in order to view the soil and seedling roots. Window  59  can be formed from a clear plastic that, in some cases, is laminated to provide rigidity to the window  59 . 
         [0065]      FIG. 11  displays a stacked container  56  forming an elongated potting cavity suitable for tubers or seedlings with deeper root systems. Stacked foldable container  56  includes two upper sections  58  stacked upon one another and upon a base container  54  of similar construction to that of  FIG. 2 . Each upper section  58  includes two partial preforms  34  of  FIG. 5  connected to form a tube, with their wall sections  36  overlapping and their bases  40  on opposite sides of the tube. Tabs  42  extending downward from wall sections  36  within top section  58  attach to adjacent wall sections  36  within bottom section  58 . Similarly, tabs  42  extending downward from wall sections  36  within bottom section  58  attach to adjacent wall sections  36  within folded container  54 . In the example of  FIG. 11 , engageable surfaces  50  of tabs  42  are releasably attached to fastening surfaces  52  of wall sections  36 . However, fastening surfaces of one or more tabs  42  may alternatively be releasably attached to engageable surfaces  50  of wall sections  36 . In some embodiments, a stacked foldable container may include one or several sections  58 . 
         [0066]    As shown in  FIG. 12 , two or more foldable containers  54  may be laterally coupled to form a container set  60 . In the example of  FIG. 9 , tabs  42  extending laterally from left and right foldable containers  54  attach to and overlap tabs  42  of a center adjacent foldable container  54 , thereby providing container set  60  that includes separate cavities. 
         [0067]    While many of the above examples of planting containers feature four foldable walls, other examples may include a different number of foldable walls. Furthermore, the foldable walls may be of various or differing shapes than those shown. For example,  FIG. 13  displays a planting container preform  62  including two end walls  64  and two side walls  66  and assembled at the bottom of folded container  62  via wall sections  68  and wall sections  70  extending from end walls  64  and side walls  66 , respectively. Planting container preform  62  also includes one or more openings  67  through which seedlings  37  can grow through from soil  39  encased by folded container  62 . Accordingly, folded container  62  is disassembled by peeling the wall sections  68 ,  70  away from one another at the bottom of the container. The disassembled folded container  62  may be lifted over the seedlings  37  to expose the seedlings  37  and the soil  39 . 
         [0068]    In some implementations, bending a wall of a foldable container to assemble the container can provide a shape to the container without necessarily producing a crease or a sharp fold in the container preform. 
         [0069]    In some embodiments, a cover can be sized to fit over and be included with any of the containers described above. The cover can serve to protect immature seedlings and in some examples. The cover is generally of a light weight construction and, in some instances, includes a clear top, such that a plant within a folded container can be exposed to light while still being covered. 
         [0070]    In some embodiments, the above examples of planting containers can include selectively placed fastening surfaces atop larger engageable surfaces or selectively placed engageable surfaces atop larger fastening surfaces (i.e., a reverse mesh configuration). A reverse mesh configuration may be used, for example, to laterally attach one or more containers to one another to form a container set (e.g., to form a container set such as that shown in  FIG. 12 ). 
         [0071]    In some instances, the above examples of planting containers can be used as liners that can be inserted within a cavity of a garden pot. In this manner, the garden pot can hold any water drained from soil within a folded planting container, and the folded planting container can be removed from the garden pot to empty the garden pot of excess water or any other undesired particulates remaining in the garden pot once the folded planting container is removed. 
         [0072]    In some examples, a planting container preform can include a moisture or pH indicator strip for determining a moisture level or a pH, respectively, of soil within a folded planting container. For example, an indicator strip may be adhered to a fastening surface that allows the indicator strip to be adhered to an engageable surface of a folded container, such that the indicator strip is in contact with the soil but also extends away from the folded container such that the indicator strip is visible. 
         [0073]    In some cases, the sheet forming the above examples of foldable containers can be biodegradable, allowing an entire plant system to be planted outdoor within soil without the need to ultimately remove the folded containers from the soil. In some examples, non-woven surfaces of a foldable container can be infused with fertilizer. In some instances, the sheet can be made of a hydroscopic material, such as nylon (e.g., Velcro knit nylon 3905), which functions to absorb water from and release water to a surrounding environment. In this manner, the hydroscopic material can sometimes function as a water wick that transports water from one region of a container to another region of a container. 
         [0074]    In some examples, any of the walls extending from the bases of the above described example container preforms can be releasably attached to one another in a manner that allows expansion of a plant beyond edges of the attached walls. For example, folded container  10  can be assembled in a non-rectangular shape such that only end regions of tabs  22  are releasably attached to walls  12 . In such a configuration, folded container  12  has a bowed shape with openings between the walls  12 ,  14 , allowing seedling roots to push out against the walls  12 ,  14  as the seedling matures. 
         [0075]    While a number of examples have been described, the foregoing description is not intended to limit the scope of the claimed invention. There are and will be other examples and modifications within the scope of the following claims.