Abstract:
A plant border system includes a flat and a plant tray. The flat defines a flat cavity and a flat top opening communicating with the flat cavity. An upstanding rim surrounds at least a portion of the flat top opening. The plant tray defines a tray cavity and a tray top opening communicating with the tray cavity. The tray cavity has a tray width and a tray length that is greater than the tray width. The plant tray includes a collar surrounding at least a portion of the tray top opening, the collar defining a downwardly opening channel. The flat is adapted to receive the plant tray in the flat cavity such that the rim is received in the channel and the flat is thereby structurally reinforced by the plant tray to resist flexure.

Description:
FIELD OF THE INVENTION 
   The present invention relates to plant trays and flats and, more particularly, to flats and tray systems for plant borders and methods for using the same. 
   BACKGROUND OF THE INVENTION 
   It is often desirable to plant a substantially continuous or semi-continuous strip of plants to form a landscape edging commonly referred to as a plant border. Plant borders are often planted along driveways, sidewalks, garden beds, fence lines, paths, courtyards and the like. It is desirable to provide such strips of plants in a manner that allows for convenient handling and planting. It is further desirable to provide means for cost-effectively and conveniently growing and packaging plant borders. 
   SUMMARY OF THE INVENTION 
   According to embodiments of the present invention, a plant border system includes a flat and a plant tray. The flat defines a flat cavity and a flat top opening communicating with the flat cavity. An upstanding rim surrounds at least a portion of the flat top opening. The plant tray defines a tray cavity and a tray top opening communicating with the tray cavity. The tray cavity has a tray width and a tray length that is greater than the tray width. The plant tray includes a collar surrounding at least a portion of the tray top opening, the collar defining a downwardly opening channel. The flat is adapted to receive the plant tray in the flat cavity such that the rim is received in the channel and the flat is thereby structurally reinforced by the plant tray to resist flexure. 
   According to further embodiments of the present invention, a flat is provided for carrying and supporting a plant tray of the type defining a tray cavity and a tray top opening communicating with the tray cavity, the tray cavity having a tray width and a tray length that is greater than the tray width, the plant tray including a collar surrounding at least a portion the tray top opening, the collar defining a downwardly opening channel. The flat defines a flat cavity and a flat top opening communicating with the flat cavity. The flat includes an upstanding rim surrounding at least a portion the flat top opening. The flat is adapted to receive the plant tray in the flat cavity such that the rim is received in the channel and the flat is thereby structurally reinforced by the plant tray to resist flexure. 
   According to method embodiments of the present invention, a method for using a plant tray system includes providing a flat defining a flat cavity and a flat top opening communicating with the flat cavity. The flat includes an upstanding rim surrounding at least a portion of the flat top opening. A plant tray defining a tray cavity and a tray top opening communicating with the tray cavity is provided. The tray cavity has a tray width and a tray length that is greater than the tray width. The plant tray includes a collar surrounding at least a portion of the tray top opening. The collar defines a downwardly opening channel. The plant tray is placed into the flat cavity such that the rim is received in the channel and the flat is thereby structurally reinforced by the plant tray to resist flexure. 
   Objects of the present invention will be appreciated by those of ordinary skill in the art from a reading of the figures and the detailed description of the preferred embodiments which follow, such description being merely illustrative of the present invention. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and, together with the description, serve to explain principles of the invention. 
       FIG. 1  is an exploded, perspective view of a plant border system according to embodiments of the present invention; 
       FIG. 2  is a top plan view of a flat forming a part of the plant tray system of  FIG. 1 ; 
       FIG. 3  is a side view of the flat of  FIG. 2 ; 
       FIG. 4  is an end view of the flat of  FIG. 2 ; 
       FIG. 5  is a bottom plan view of the flat of  FIG. 2 ; 
       FIG. 6  is a top plan view of a plant tray forming a part of the plant tray system of  FIG. 1 ; 
       FIG. 7  is a cross-sectional view of the plant tray of  FIG. 6  taken along the line  7 — 7  of  FIG. 6 ; 
       FIG. 8  is a perspective view of the plant tray system of  FIG. 1  in a first configuration; 
       FIG. 9  is a perspective view of the plant tray system of  FIG. 1  in a further configuration; 
       FIG. 10  is a perspective view of the plant tray system of  FIG. 1  in a further configuration; 
       FIG. 11  is a cross-sectional view of the plant tray system of  FIG. 1  taken along the line  11 — 11  of  FIG. 10 ; 
       FIG. 12  is a perspective view of the plant tray system of  FIG. 1  in a further configuration; and 
       FIG. 13  is a perspective view of a plant border assembly including the plant tray of FIG.  6 . 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   The present invention will now be described more fully hereinafter, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. In the drawings, like numbers refer to like elements throughout. Thicknesses and dimensions of some components may be exaggerated for clarity. 
   As used herein, “plant border” means an amount of growing medium into which a strip of a plurality of plants is fully or partially embedded. The plants may extend upwardly from the growing medium with the roots of the plants embedded in the growing medium. As used herein, “growing medium” means a substance that serves to support and sustain the plants and which is suitable for planting in a desired permanent or semi-permanent location with the strip of plants. Preferred growing media include potting soil, pine bark, peat and sand. Other suitable growing media include coir, compost and perlite. Exemplary plants which may be grown and planted using the present invention include, for example, Mondo Grass Fescue, Agapanthas, Leriope, flowers and other suitable plant varieties used for borders or when new planting is desired for erosion control and/or aesthetics. 
   With reference to FIGS.  1  and  8 - 12 , a plant border tray system according to preferred embodiments of the present invention is shown therein and generally designated  10 . The plant border system  10  includes one or more plant trays  100  and a support flat  150 . As discussed in further detail below, the flat  150  may be used to reinforce the plant trays  100  during filling, growing, storing, transporting and handling. The plant trays  100  are preferably substantially identical. The plant trays  100  may be filled with a plant border to form a plant border assembly such as the plant border assembly  101  shown in FIG.  13 . 
   With reference to  FIGS. 1 ,  6  and  7 , an exemplary one of the trays  100  includes a pair of opposed, tapered side walls  110  and a pair of opposed, tapered end walls  116 . The bottom of the tray  100  is formed by a pair of flat bottom walls  112 , and an inverted V-shaped bottom wall  114 . The inverted V-shaped walls  114  assist in stabilizing and inhibiting flexure of the tray  100 . The tray  100  defines a longitudinally extending cavity  102  and an upper, longitudinally extending opening  104  which communicates with the cavity  102 . Drain holes  113  are formed in the bottom walls  112 . 
   Preferably, the length L 1  (as measured from end wall  116  to end wall  116  at the top opening  104 ;  FIG. 6 ) of the cavity  102  is greater than the width W 1  (as measured from side wall  110  to side wall  110  at the top opening  104 ;  FIG. 6 ) of the cavity  102 . More preferably, the length L 1  is at least six (6) times the width W 1 . Most preferably, the length L 1  is between about six (6) and fourteen (14) times the width W 1 . Preferably, the length L 1  is between about 330 and 650 mm and the width W 1  is between about 38 and 76 mm. Preferably, the length L 1  is at least six (6) times the height H 1  ( FIG. 7 ) of the cavity  102 . The height H 1  of the cavity  102  is preferably between about 38 and 98 mm. Preferably, the cavity  102  has a volume of between about 600 and 2300 cm 3 . 
   A reinforcing collar  120  surrounds the upper portions of the side walls  110  and the end walls  116 . As shown in  FIG. 7 , the collar  120  includes an inner wall  121 A formed from the upper portions of the of the walls  110 ,  116  and an outer wall  121 B joined to the inner wall  121 A along a fold  121 C. The collar  120  is generally inverted U-shaped and defines a downwardly opening channel  126 . A flange  122  surrounds the tray  100  and extends horizontally outwardly from the collar  120 . The vertical depth H 2  of the channels  126  is preferably at least 8 mm. More preferably, the depth H 2  is between about 5 and 10 mm. The maximum width W 2  of the channels  126  is preferably at least 3 mm. More preferably, the width W 2  is between about 2 and 4 mm. 
   Recesses  124  are molded into the collar  120  on either side. Preferably, the recesses  124  are positioned a distance of between about 50 and 190 mm from the adjacent end wall  116 . Using the recesses  124 , a user may cut the tray  100  to remove an end portion of the tray to form an end opening. 
   The width W 3  ( FIG. 11 ) of the flange  122  is preferably selected to provided a prescribed spacing between the respective cavities  102  of adjacent trays  100  when the adjacent flanges  120  of the trays are in or are approximately in side-by-side abutment as shown in  FIGS. 10 and 11 . More particularly, the width W 3  of the flange  122  is selected to provide a desired gap for growth of plants in the trays  100  such that the plants of adjacent trays  100  will not “grow into” (i.e., interfere with) each other during the intended period between planting or placement in the trays  100  and removal from the trays  100  (typically between about 45 and 600 days). Preferably, the width W 3  is at least 3 mm. More preferably, the width W 3  is between about 2 and 4 mm. By providing the desired distance between plants, the plants are provided with room to fill out during growth periods. 
   The plant trays  100  are preferably formed of a continuous, molded, polymeric material. Suitable polymeric materials for the plant trays  100  include high impact polystyrene, ABS, PVC and polypropylene. The walls forming the plant trays  100  preferably have a substantially uniform thickness. Preferably, the thickness of the walls is less than 0.07 mm, and more preferably, is between about 0.02 and 0.07 mm. As a result, the walls of the plant trays  100  may be inherently flexible. While the rigidity of the trays  100  may be enhanced by the collar  120 , the trays  100  are nonetheless susceptible to flexure when in use, particularly when loaded with a plant border (e.g., the plant border  6 ). 
   A tray  100  and a plant border  6  together form a plant border assembly  101  as shown in FIG.  13 . The plant border  6  includes a growing medium  7  (e.g., soil) disposed in the cavity  102  and a plurality of plants  5  which have roots embedded in the growing medium  7  and which extend upwardly through the opening  104  of the tray  100 . While the plants  5  are shown as having substantial portions above the soil, the tray  100  may alternatively hold seeds or sprigs in the soil and ready for planting. 
   With reference to  FIGS. 1-5 , the flat  150  includes a pair of opposed, tapered side walls  160  and a pair of opposed, tapered end walls  166 . The bottom of the flat  150  is formed by a pair of flat bottom walls  162  and laterally extending raised walls  174 . The flat  150  defines a cavity  152  and an upper, longitudinally extending opening  154  which communicates with the cavity  152 . A pair of longitudinally extending separator walls  170  extend from end wall  166  to end wall  166  and define troughs  152 A,  152 B and  152 C in the cavity  152 . With reference to  FIG. 11 , each separator wall  170  includes a tapered inner wall  170 B, a tapered outer wall  170 A and a top wall  170 C connecting the respective walls  170 A and  170 B. The separator walls  170  define respective lengthwise extending lower channels  172 . Drain holes  163  are formed in the bottom walls  162 . 
   Preferably, the length L 4  (as measured from end wall  166  to end wall  166  at the top opening  154 ;  FIG. 2 ) of the cavity  152  is equal to the distance from the outer surface of the tray end wall  116  to the outer surface of the opposed tray end wall  116 , plus a prescribed tolerance as discussed below. Preferably, the width W 4  (as measured from side wall  160  to side wall  160  at the top opening  154 ;  FIG. 2 ) of the cavity  152  is sized to accommodate four of the trays  100  in close side-by-side proximity with their respective flanges  122  disposed substantially immediately adjacent one another as shown in FIG.  11 . The raised walls  174  are preferably raised a height H4 ( FIG. 11 ) of between about 2 and 3 mm above the bottom walls  162  to allow for drainage and air pruning of plants. 
   A rim  180  surrounds the upper portions of the side walls  160  and the end walls  166 . Preferably and as shown in  FIG. 11 , the rim  180  includes an inner wall  181 A formed from the upper portions of the of the walls  160 ,  166  and an outer wall  181 B joined to the inner wall  181 A along a fold  181 C. The rim  180  is generally inverted U-shaped and defines a downwardly opening channel  186 . A flange  182  surrounds the flat  150  and extends horizontally outwardly from the rim  180 . 
   The rim  180  has a non-uniform profile. The rim  180  includes relatively long lengthwise extending, raised side portions  188 A, L-shaped, raised corner portions  188 B, raised, laterally extending portions  188 C, raised, laterally extending portions  188 D, lengthwise extending recesses  184 A, laterally extending recesses  184 B, laterally extending recesses  184 C, and a laterally extending recess  184 D. The height H 5  ( FIG. 4 ) of the rim portions  188 A,  188 B,  188 C,  188 D above the recesses  184 A,  184 B,  184 C,  184 D is preferably at least 100 percent of the depth of the channels  126 . More preferably, the height H 5  is between about 3 and 4 mm. 
   The flat  150  is preferably formed of a continuous, molded, polymeric material. Suitable polymeric materials for the flat  150  include high impact polystyrene, ABS, PVC and polypropylene. The walls forming the flat  150  preferably have a substantially uniform thickness. Preferably, the thickness of the walls is less than 0.07 mm and, more preferably, is between about 0.02 and 0.07 mm. Thus, the walls of the flat  150  may be inherently flexible. The actual thickness may depend on the soil weight and desired load requirements. While the rigidity of the flat  150  may be enhanced by the rim  180 , the flat  150  may nonetheless be susceptible to flexure when no plant trays  100  are installed in the cavity  152 . 
   The tray system  10  may be used as follows to hold one or more of the trays  100 . The trays  100  may be empty or filled with growing medium and plants or other material. 
   With reference to  FIG. 8 , according to one configuration, a tray  100  is placed in the trough  152 A. According to another configuration as shown in  FIG. 9 , two additional trays  100  are placed in the trough  152 B in side-by-side arrangement. With reference to  FIGS. 10 and 11 , a further tray  100  may be placed in the trough  152 C. With reference to  FIG. 12  a pair of trays  100  may be placed in the troughs  152 A and  152 C with a third tray  100  placed alone in the center of the trough  152 B. It will be appreciated that a number of additional configurations are also possible: a pair of trays may be held in the trough  152 B with the troughs  152 A and  152 B remaining empty; a pair of trays may be held in the troughs  152 A and  152 C with the trough  152 B remaining empty; a tray may be held in the trough  152 C with the troughs  152 A and  152 B remaining empty; three trays may be held in the troughs  152 B and  152 C with the trough  152 A remaining empty; and a tray may be held in the center of the trough  152 B with one or both of the troughs  152 A and  152 C being empty. 
   The several tray configurations listed above allow for great flexibility in using the tray system  10 . One to four trays may be added to and removed from the flat  150  as needed while maintaining the stability of the tray system  10  and securely locating the tray or trays  100  in the flat  150 . The tray configurations also allow for equal spacing between two, three, or four trays. 
   The system  10  effectively accommodates plant borders of different dimensions. For example, four plant borders  101  with plants  5  of relatively modest sizes may be mounted as shown in FIG.  10 . On the other hand, three plant borders  101  having relatively large plants  5  may be mounted in the flat  150  as shown in  FIG. 12  to allow greater spacing between the plant borders. 
   The flat  150  and the trays  100  are cooperatively configured such that the trays  100  and the flat  150  stabilize one another to resist flexure (e.g., lateral bending, lengthwise bending, torsional flexure, or combinations thereof). As a result, the tray system  10  once assembled may have improved strength and/or rigidity as compared to the flat  150  or any of the individual trays  100  alone. Preferably and in accordance with certain preferred embodiments, the trays  100  and/or the flat  150  may be formed with thin walls, thereby reducing the material expense and weight (and attendant shipping costs and handling burden) as compared to thicker trays and/or flats that might otherwise be employed to attain the requisite rigidity. 
   As best seen in  FIG. 11 , the rim  180  of the flat  150  engages the collar of each tray  100  in the flat  150 . Depending on the trough  152 A,  152 B,  152 C within which the tray is mounted, the rim portions  188 A,  188 B,  188 C  188 D are received in the channel  126  of the tray. The channel  126  and the received rim portions are preferably of substantially the same size and shape. More particularly:
         1. If a tray  100  is seated in the trough  152 A or the trough  152 C, the rim portions  188 A and  188 B adjacent the trough will be received in the channel  126  of the tray. Portions of the outer wall  121 B of the collar  120  of the tray will seat in the recesses  184 B at each end of the associated trough. Each of the recesses  124  on the outer side wall  110  of the tray  100  is received in a respective one of the recesses  184 A;   2. If a pair of trays  100  are seated in the trough  152 B, the rim portions  188 C and  188 C will be received in the channels  126  of the trays. Portions of the outer walls  121 B of the collars  120  of the trays will seat in the recesses  184 C and  184 D at each end the trough  152 B; and   3. If a tray is seated in the center of the trough  152 B as shown in  FIG. 11 , the rim portions  188 D adjacent the trough will be received in the channel  126  of the tray. Portions of the outer wall  121 B of the collar  120  of the tray will seat in the recesses  184 C at each end of the trough  152 B.       

   With reference to  FIG. 4 , the length L 5  of the rim portion  188 B along the wall  166 , the distance L 6  between the outer edge of each rim portion  188 C and the inner edge of the adjacent rim portion  188 D, and the distance L 7  between the outer edges of the rim portions  188 D are preferably slightly less than the width of the lateral portion of the channel  126 . More preferably, the distances L 5 , L 6 , L 7  are between about 58 and 62 mm less than the receiving lateral length of the channel  126 . 
   The troughs  152 A,  152 B,  152 C are shaped to correspond to the shapes of the walls  110 ,  116  of the trays  100 . More particularly, the walls  160 ,  166 ,  170 A,  170 B of the flat  150  are sloped at substantially the same angle as the corresponding walls  110 ,  116 , respectively. The walls  160 ,  166 ,  170 A,  170 B of the flat  150  are spaced apart such that they are in close proximity to the adjacent walls of the tray. Preferably, the tolerances between each of the walls  160 ,  166 ,  170 A,  170 B of the flat  150  and the adjacent walls of the tray in each trough  152 A,  152 B,  152 C are between about 0.05 and 1.0 mm. 
   The raised bottom walls  174  may serve to maintain the trays  100  above a surface (e.g., the ground) supporting the tray system  10 . In this manner, the walls  174  may serve to keep the lower portions of the trays (and the contents thereof) out of a pool of water or the like collected on a support surface. Preferably, the trays  100  and the flat  150  are relatively dimensioned such that the trays  100  rest on the walls  174  rather than fully hanging from the rim  180 . Preferably, when the trays and flat are so situated, the rim  180  extends into between about 50 and 75 percent of the depth of the channels  126 . Preferably substantially the full height H 5  ( FIG. 4 ) is received in the channels  126 . 
   Notably, regardless of the selected tray configuration, the trays  100  may be securely positioned in the flat  150  so that the trays  100  do not slide in the flat  150 . Such positive location is provided by the engagements of the trays  100  with the rim portions  184 A,  184 B,  184 C,  184 D and the recesses  188 A,  188 B,  188 C,  188 D, as well as the seating within the complementary troughs  152 A,  152 B,  152 C. 
   Each plant border  6  held in the tray system  10  may be removed from the flat  150  when needed. The plant border  6  may be planted in a desired location in the ground by digging or otherwise forming a trench as described in Applicant&#39;s co-pending U.S. patent application Ser. No. 09/871,132, filed May 31, 2001, titled Trays for Plant Borders and Methods for Planting Plant Borders, inventor Todd Anthony Layt, the disclosure of which is incorporated herein by reference in its entirety. The tray  100  is cut or hand pulled (torn) along the recesses  124  and those portions of the tray walls  110 ,  112 ,  114  extending between the recesses  124 . The tray  100  may be cut using, for example, scissors, a knife or the like. An end portion formed by the cut is removed or folded away from a remaining portion of the tray to form an end opening. The plant border  6  is then slid out of the remaining tray portion through the opening and into the trench. In this manner, the plant border  6  may be removed from the tray  100  and installed in the trench with reduced or minimal disruption to the plant border  6 . That is, the tear away or cut away feature allows for internal loading of soil and root pressure but also allows for easy hand tearing away or cutting, which allows for easy plant removal without damaging the plant. 
   While particular plant trays  100  have been described herein, one or more of the plant trays  100  may be modified or replaced as desired. For example, any of the plant trays disclosed in the aforementioned co-pending U.S. patent application Ser. No. 09/871,132, may be used in place of the trays  100 . 
   Two or more of the plant trays  100  may be joined together. For example, two or more of the plant trays  100  may be integrally molded and joined along their adjacent flanges  122 . Perforations may be formed along the joinder to allow easy separation of the trays from one another when desired. Webbing may be provided between and joined (for example, by integrally molding) to the flanges of each of the trays, for example, as disclosed in the aforementioned co-pending U.S. patent application Ser. No. 09/871,132. Perforations may be provided between the webbing and the plant trays. 
   The flat  150  may be modified to hold more or less than four plant trays. The flat  150  may be modified to hold plant trays of other dimensions or configurations. 
   The flat  150  may be colored differently than the plant trays  100  to allow for quick and convenient assessment of the number and arrangement of plant trays or plant borders in the flat. 
   The foregoing is illustrative of the present invention and is not to be construed as limiting thereof. Although a few exemplary embodiments of this invention have been described, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the claims. Therefore, it is to be understood that the foregoing is illustrative of the present invention and is not to be construed as limited to the specific embodiments disclosed, and that modifications to the disclosed embodiments, as well as other embodiments, are intended to be included within the scope of the appended claims. The invention is defined by the following claims, with equivalents of the claims to be included therein.