Abstract:
A plant shipping system for transporting horticultural products and the like that is both user and plant friendly. The system includes opposing trays that form the top and bottom of a crate that are spaced apart by a support structure. The support structure comprises a plurality of interlocked upstanding panels to provide a sufficiently strong plant support system. The interlocking of the panels is facilitated by slots formed in each upstanding panel. A portion of a central panel is folded over to bolster the interlocking engagement of the upstanding panels and to maintain the panels in a substantially perpendicular orientation. Each end of the central panel comprises end member that engages a portion of the outermost upstanding panels. The upstanding panels include a plurality of apertures located on predetermined portions of the panels. Support members are inserted into predetermined apertures to define rack locations within the columns for housing of plants. The resulting support structure of the present invention provides strong, light-weight system for transporting products that has easy access to the interior storage space and enhances air flow therethrough.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention relates to containers used in the transportation and storage of horticultural items, and more particularly to a recyclable system for transporting plants that is strong, light-in-weight and capable of easy set up and break down.  
         BACKGROUND OF THE INVENTION  
         [0002]    The distribution of bedding plants, small woody plants, potting plants and other nursery stock begins at the grower. Growers of such horticultural items, as any supplier of goods, desire to cost effectively move their goods to market without diminishment of product quality.  
           [0003]    Horticultural and agricultural items such as young trees, shrubs, bushes, vines, and the like are typically transported in a potted or trayed condition. In the case of young plants, metal cartons or boxes are commonly used to transport a low number of plants per container. The metal cartons/crates are then loaded onto cargo trucks. In addition to being a very labor-intensive process, the commonly used cartons and crates expose the plants to a great deal of damage. Many times the crates are common shipping or moving boxes, wherein the plants are placed within the box and sealed. The plants are not usually secured in position within the box, which increases the chance of the plants being damaged due to shifting of the plants during transport. For example, plant crates are regularly shipped via airfreight, and handled by many people prior to reaching its destination. In many cases, even when the crates are labeled and marked, warning movers to handle the plants with care, the crates are mishandled or flipped over. Moreover, the typical transport boxes are not designed to make efficient use of the space within. Thus, numerous boxes are required to ship a given set of plants.  
           [0004]    Large metal racks are often used to transport a plurality of young plants. The plants are loaded into the bulky, heavy metal racks which are then placed into trucks and transported to garden supply stores or other retail outlets. Upon arrival at a retail outlet, the transported plants are unloaded and either displayed in the cumbersome transport racks, or loaded into a more consumer appealing display rack or container. In addition to handling issues, the reality is that the metal racks comprise a substantial portion of the total shipped weight sent by a grower, and therefore unavoidably represent a significant cost of the shipped product. Furthermore, the metal racks must be returned empty (i.e., “dead headed”) to the growers before they can be used again, which results in substantial return shipping costs, costs which are again ultimately reflected in the price of the product in the market place.  
           [0005]    In attempt to reduce reliance on expensive and inconvenient shipping containers, various types and configurations of paperboard or corrugated material shipping containers have been developed. Unfortunately, known paperboard containers have several shortcomings. For instance, a majority of such containers are designed for holding a small number of uniformly sized nursery flats. Each container is configured to only house single-sized plants, and as such, are ill suited for transporting the larger, taller, bulkier and substantially heavier plants with the smaller plants. Furthermore, known paperboard transport containers are little more than fully enclosed cardboard boxes, generally providing a poor environment for the storage of a product which is especially sensitive to its environment, and whose salability is greatly a function of appearance and health. Moreover, paperboard containers are usually not sufficiently sturdy to accommodate the stacking of many plants within a single container, or allow the stacking of containers one on top of another. Another disadvantage associated with paperboard shipping containers is that they are usually relatively difficult, thus expensive, to assembly, often times requiring glue, tape, staples etc. to maintain the origami-like folds frequently present in such box constructions.  
           [0006]    Accordingly, there is a need to provide a shipping container for the transport of plants that overcomes the shortcomings described above. There is a desire to provide a lightweight shipping container that is capable of efficiently housing a plurality of varying sized plants. There is a need for a shipping container that is easy to assemble and may be simply disposed or recycled after a single use. Additionally, there is a desire to provide a plant shipping container sufficient rigid to securely accommodate a plurality of plants, and capable of stacking the containers on top of one another.  
         SUMMARY OF THE INVENTION  
         [0007]    It is an object of the present invention to provide a rigid plant-shipping crate that minimizes plant damage during transport.  
           [0008]    Another object of the invention is to minimize the cost to ship and to minimize the amount of space needed to transport plants.  
           [0009]    Another object of the invention is to provide a plant shipping system that is easy to assemble, disassemble and discard.  
           [0010]    The present invention provides a strong, lightweight system for transporting plants that is both user and plant friendly. The plant shipping system of the present invention takes the form of a crate that includes opposing trays spaced apart by a support structure. The trays form a top and bottom for the stackable crate. Each of the trays have sidewalks and end walls. The sidewalls are orthogonal to the end walls to thereby define four corners for the opposing trays. The support structure is configured to form a plurality of spaced apart columns.  
           [0011]    To enclose and protect the support structure, two perimeter panels are disposed around the support structure, with the ends of the perimeter panels overlapping one another. The perimeter panels are positioned adjacent and between the side and end walls of the tray, and the outer edges of the upstanding panels. Each of the exterior corners of the perimeter panels is in substantial abutting alignment with each of the corners of the opposing trays to thereby form substantially enclosed crate.  
           [0012]    In order to provide a sufficiently strong plant support system, the support structure comprises a plurality of interlocked upstanding panels. Slots formed in each upstanding panel facilitate the interlocking of the panels. The upstanding panels define the columns of the crate that will house the plants. In one embodiment, one central upstanding panel is positioned perpendicular to the other upstanding panels. A portion of the central panel is folded over to bolster the interlocking engagement of the upstanding panels and to maintain the panels in a substantially perpendicular orientation. To further strengthen the crate, each end of the central panel comprises end member that engages a portion of the outermost upstanding panels.  
           [0013]    To make efficient use of the space within the crate and accommodate a plurality of plants, the upstanding panels include a plurality of apertures located on predetermined portions of the panels. Support members are releasably inserted into predetermined apertures to define rack locations within the columns for housing of plants. The support members may be adjusted (moved to any aperture) to accommodate varying sized products. The resulting support structure of the present invention provides easy access to the interior storage space of the crate and enhances airflow therethrough.  
           [0014]    The foregoing and other objects, features and advantages of the invention will become more readily apparent from the following detailed description of a preferred embodiment of the invention that proceeds with reference to the accompanying drawings. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0015]    [0015]FIG. 1 is an exploded perspective view of an embodiment of the present invention.  
         [0016]    [0016]FIG. 2 is a perspective view of a central upstanding panel of the present invention with a hidden line showing the panel in the unfolded position.  
         [0017]    [0017]FIG. 3 is a perspective view of the central upstanding panel of FIG. 2 interlocked with another upstanding panel  
         [0018]    [0018]FIG. 4 is a perspective view of the support structure of the embodiment of FIG. 1.  
         [0019]    [0019]FIG. 5 is a cross-sectional view taken along line  5 - 5  of FIG. 4 showing a longitudinal construction for the support structure in cross section.  
         [0020]    [0020]FIG. 6 is a perspective view of an embodiment of a support member of the present invention  
         [0021]    [0021]FIG. 7 is a cross-sectional view taken along line  7 - 7  of FIG. 8 showing the engagement of the support member with an upstanding panel.  
         [0022]    [0022]FIG. 8 is a perspective view of an upstanding panel of the present invention with support member attached thereto.  
         [0023]    [0023]FIG. 9 is a plan view of an alternative embodiment of an upstanding panel.  
         [0024]    [0024]FIG. 10 is a side view into the interior space of a crate according to the present invention, the lid having been removed, particularly illustrating the support structure configuration and arrangement.  
         [0025]    [0025]FIG. 11 is a side view into the interior space of a full crate, particularly illustrating the support structure configuration and arrangement.  
         [0026]    [0026]FIG. 12 is a side view of a crate, the lid having been removed, particularly illustrating an alternate support structure configuration and arrangement.  
         [0027]    [0027]FIG. 13 is a perspective view of the present invention with the lid on, and the crate completely enclosed. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0028]    Various embodiments of the present invention are shown and described to support and transport plants. It is to be understood that though these embodiments are shown and described in isolation, various features of each embodiment can be combined with the others to produce a variety of embodiments.  
         [0029]    Referring to FIG. 1, there is shown, consistent with the present invention, a shipping crate or container  10  of rectangular geometry for transporting and temporarily storing horticultural products, such as plants and the like. Opposing trays  12  and  14 , forming a top and bottom for the shipping crate  10 , are spaced apart by a support structure  15 . Two perimeter panels  16  are positioned to surround support structure  15 , to form an enclosed container.  
         [0030]    The top  12  and bottom  14  trays each have sidewalls  24  and end walls  22  that define a rim for each of the trays. The sidewalls  24  are orthogonal to the end walls  22  and thereby define four corners  26  for each of the opposing trays. In one embodiment, the container is preferably but not necessarily rectangular, the trays are rectangular, with the length of the tray side walls  24  being greater than the length of the tray end walls  22 . The rim of the tray is preferably a uniform height, and in all events is configured sufficiently to snugly engage and contain top and bottom portions of the support structure  15 , thereby establishing and maintaining the angular relationships between panels of support structure  15  and between support structure  15  and trays  12  and  14 .  
         [0031]    Support structure  15  comprises a plurality of upstanding panels  18  that are configured to define the interior volume of container  10 . Support structure  15  may be configured to achieve various shapes and sizes for storage and transport of products via predetermined interconnection of upstanding panels  18 . For example, as shown in FIGS. 1 and 4, support structure  15  is formed by interlocking connection of five upstanding panels  18  with a central upstanding panel  20 . The resulting support structure  15  is a generally rectangular shaped structure with eight vertically disposed, horizontally spaced open columns  28 . Upstanding panels  18  and central panel  20  are individually configured and aligned with respect to each other and trays  12  and  14  so as to form substantially closed ends and open sides for the stackable transport products in columns  28 . The open sides of container  10  facilitate access to the interior storage space and enhance airflow to and through stackable transport container  10 . Generally, the outermost upstanding panels  18  are positioned proximate end walls  24  of trays  12  and  14  so as have the end edges of upstanding panels  18  engage corners  26  of trays  12  and  14 .  
         [0032]    As shown in FIG. 2, central panel  20  begins as a substantially flat panel, as indicated by the hidden lines. Central panel  20  comprises a longitudinally bend or crease  30  that separates a bendable segment  32  and a central segment  34 , each segment have a first end and a second end. A plurality of slots  36  are formed in bendable segment  32 . Slots  36  extend from a side of central panel  20  and extend a predetermined distance across bendable segment  32  toward bend  30 . Preferably, the slots extend transverse the longitudinal axis of central panel  20 , however, slots  36  may extend in any desired manner and shape. A plurality of slots  38  are formed in central segment  34  and extend a predetermined distance from a side of central panel  20  toward bend  30 . It is important that slots  36  and  38  are configured such that when bendable segment  32  is bent as indicated by arrow A and bendable segment  32  overlays a portion of central segment  34 , slots  36  trace the shape of slots  38 . The tracing of the slots permits the insertion of an upstanding panel  18 , as will be discussed in detail below. Please note that the embodiment of FIGS.  1 - 5  only shows a single central panel  18  being used, however, the configuration of support structure  15  may include more than one central panel  18 .  
         [0033]    In an effort to further provide a rigid support structure  15 , an end member  40  is formed on the first and second ends of central panel  20 . End member  40  comprises two portions,  42  and  44 , that are pivotally connected to central panel  20 . One portion  42  is connected to bendable segment  32 , while the other portion  44  is connected to central segment  34 . As shown in FIGS. 2 and 3, the pivot connection of portions  42  and  44  is provided by a bend  46  such that when a slot  48  of upstanding panel  18  is interlocks with a slot  36  proximate end member  40 , portions  42  and  44  flex to engage an outer portion of panel  18 .  
         [0034]    Referring to FIGS. 3 and 4, each upstanding panel  18  comprises at least two slots  48  for engagement of slots  36  and  38  of central panel  20 . As shown, central panel  20  is configured to engage  5  upstanding panels  18  in a substantially perpendicular orientation. The present invention contemplates modification of central panel  20  to accommodate any number of upstanding panels  18 . The interlocking of upstanding panels  18  with central panel  20  is preferably achieved by frictional engagement or force fit. In the assembly operation, once bendable segment  32  is bent, a slot  48  of upstanding panel  18  is brought into contact with overlapping slots  36  and  38  of central panel  20 , or visa versa. Once the slots are in contact, a force is applied by the assembler to force the slots into frictional engagement. The overlapped portion of central panel  20  has the benefit of providing additional strength to the panel engagement via more frictional contact between panels  18  and  20 . The “double thick” area contact area between overlapped portion of panel  20  and panel  18  increases the rigidity of the connection by increasing support structure  15  resistance to transverse and axial forces that are exerted on the container during storage and transport. This increased rigidity enables the support structure to better maintain its predetermined configuration.  
         [0035]    As shown in FIG. 5, support structure  15  comprises a central panel  20  interlocked with each end of upstanding panels  18 . This means that each central panel  20 , in the bent condition, is approximately one-half the height of an upstanding panel  18 . The connection of a central panel  20  to each end of upstanding panels  18  has the benefit of further providing strength and rigidity to support structure  15 . The increased strength enables container  10  to accommodate more weight within out degradation of the container shape.  
         [0036]    In summary, support structure  15  of the present invention effectively divides container  10  into parallel columns  28 . In the embodiment of FIGS.  1 - 5 , the support structure  15  has five upstanding wall panels  18 . With this support structure configuration, each column  28  has two of the parallel upstanding panels  18  defining opposing exterior walls which are joined together or linked by a major upstanding center panel  20  (i.e., an interior upstanding panel that traverses the end walls  22  of trays  12  and  14  to thereby define a traversing interior wall for the container).  
         [0037]    Referring to FIGS.  6 - 8 , upstanding panels  18  are adapted to receive support members to facilitate the storage of products, such as plants. As shown in FIG. 6, the support members take the form of a rack  50 . Rack  50  comprises an engaging portion  52  and a plant support portion  54 . As shown in FIG. 8, upstanding panel  18  has a plurality of apertures  56  formed in predetermined locations. Racks  50  may be releasably positioned within apertures  56  to enable a product to rest on rack  50 .  
         [0038]    In one embodiment, as shown in FIG. 7, engaging portion  52  of rack  50  is substantially S-shaped. During insertion of an end of rack  50  into an aperture  56  the middle portion of the s-shaped engaging portion  52  is caused to rest within aperture  56 . One end portion of the s-shape rests on one side of panel  18  and the other end portion of the s-shape rests on the opposite side of panel  18 . This positioning of rack  50  causes support portion  54  to extend into the space of column  28 . Engaging end  52  of rack  50  may take on any shape that provides for simple rigid, releasable engagement with upstanding panels  18  while providing the ability to support the weight stored products. Rack  50  be made of a material sufficiently rigid to support a load, yet sufficiently flexible or malleable to be formed into a predetermined orientation. For example, rack  50  may be made of a strength wire, plastic material, or the like.  
         [0039]    A second rack  50  is also releasably placed within the upstanding panel  18  that is on the opposite side that defines column  28 . The second rack  50  is also placed at substantially the same vertical level as the first rack  50  to ensure that any product stored on the rack lies flat. The result is two racks  50  extending toward one another within column  28 . See FIGS.  10 - 12 .  
         [0040]    The apertures  56  formed on upstanding panels  18  may have any desired configuration. For example, apertures  56  may be vertically aligned as shown in FIGS. 1, 3,  4  and  8 . Alternatively, apertures  56  may be configured diagonally  58 , horizontally  60 , in a random array  62 , or the like. See FIG. 9. Forming various configurations of apertures provides container  10  with the benefit to be easily adjusted to accommodate varying sizes of horticultural products. Racks  50  are simply moved to the desired apertures  56  to store the intended product. The present invention diminishes the need to have various preformed sizes of containers to securely store and transport products. Referring to FIGS.  10 - 12 , a view of container  10  from the side reveals how racks  50  are positioned within columns  28  to support containers of plants  64 , as well as larger plants  66 .  
         [0041]    Apertures  56  are spaced far enough apart to maintain the quality of the plants while stored in the container by preventing the crowding of plants and by providing air circulation and ventilation necessary to sustain plant health during transport. For example, apertures  56  may be vertically spaced 2 or 4 inches apart. Alternatively, the container  10  with tray  12  and perimeter panels  16  removed, may be used as a storage unit to foster photosynthesis; specifically by providing easy access for watering and permitting light to reach the foliage of the plants.  
         [0042]    Perimeter panels  16  provide more support to upstanding wall panels  18  and central panel  20  to strengthen the stackable transport container  10  perimeter. The strengthening of the container perimeter better enables loaded containers to be stacked on top of one another, making more efficient use of space on transportation vehicles.  
         [0043]    Stackable transport container  10  of the subject invention is preferably fabricated from a recyclable material such as corrugated cardboard stock (i.e., two pieces of paperboard spaced apart by characteristic arches of wavy fluting lying therebetween). The corrugated cardboard stock may be treated so as to be substantially water-resistant, thus insuring sufficient rigidity and durability for the crate components throughout a variety of ground and transport environments. Such water resistant coatings (e.g., those produced and sold by Michelman, Inc. for instance Coating X300™, Michem® Coat 40/series etc.) are well known to those of skill in the paper board coating art, and generally should be selected so as to maintain rigidity and thereby stacking strength for the crates while likewise permitting recycling post use.  
         [0044]    As to panel thicknesses, the trays may be a two ply construct, having a total overall thickness sufficient to transport horticultural products. Support structure  15  may be a three ply corrugated construct for plant transport applications.  
         [0045]    Referring now to FIG. 13, a loaded container  10  according to the present invention is shown. The loaded containers may be stacked or bundled as desired. The present invention may be completely wrapped in shrink-wrap to protect container  10 , as well as the products inside from the elements. For example, the present invention may be loaded in the same manner as loading a common carrier cargo box. Container  10  may be positioned upon a pallet and bound thereto using strapping. The “palletization” of the stackable containers  10  using readily available pallets makes for supremely easy loading and unloading of the stacked crates. The overall height of the cargo bundle is predicated upon the available cargo height, which may typically be about eight feet.  
         [0046]    As such, the present invention may be formed in varying sizes and dimensions to facilitate ease of transport. Containers  10  are preferably but not necessarily dimensioned in accordance with generally available pallets (e.g., 40″×48″, 42″×48″, 48″×48″ etc.). A variety of container heights are optionally available from 48″ to 65″ to meet airfreight specifications. By forming containers according to the present invention within the above parameters, more products may be transported within a given amount of space than done by conventional containers. For example, a typical transport used to move horticultural products from growers is a truck with a storage capacity of 18 to 20 feet in length and a height limit of 8 feet. Conventional containers (42″×48″×48″) would permit the loading of 36 containers with 125 plants per container, for a total of 4500 plants able to be moved on the truck. A container according to the present invention (with dimensions of 48″×42″×44″) would permit the loading of 24 containers with 320 of the similar sized plants per container. The present invention permits the transport of 7680 plants with the same truck. Accordingly, the present invention enables more efficient use of given amount of space.  
         [0047]    It will be understood that this disclosure, in many respects, is only illustrative. Changes may be made in details, particularly in matters of shape, size, material and arrangement of parts without exceeding the scope of the invention. Accordingly, the scope of the invention is as defined in the language of the appended claims.