Abstract:
Packaging systems, apparatuses, and methods are provided for improving handling and shipment of plantlets. A carton carrier for transporting trays of plantlets may be provided. The carton carrier may include a bottom panel for receiving plantlet trays having first and second ends and first and second sides. The carton carrier may also include supporting side walls extending upwardly from the first and second sides of the bottom panel. The supporting side walls each define a support surface or shoulder at the top thereof. The carton carrier may also include end wall panels extending outwardly from the first and second ends of the bottom panel. The end wall panels may be configured to be foldable upwardly from the bottom panel to form end walls.

Description:
TECHNICAL FIELD 
       [0001]    The subject matter described herein relates generally to systems, apparatuses, and methods for transporting plantlets. More particularly, the subject matter disclosed herein relates to the packaging of plantlets for transport employing carton carriers on which trays of plantlets may be placed. 
       BACKGROUND 
       [0002]    Shipping of plantlets, such as small or fragile plants, seedlings, cuttings, or the like, that have yet to reach maturity has always posed certain challenges for growers, distributors, and retailers. Keeping the plants in a viable condition and protecting them from handling damage are primary concerns during shipping. Further, distributors need to be able to ship plantlets in bulk to help maximize efficiencies associated with delivery and handling to lower the cost associated with each plantlet. 
         [0003]    Often, multiple trays of plantlets are stacked within a box container for bulk shipment of plantlets. The trays provide a holding area for soil to provide nutrients and water to each plantlet during shipment. To prevent the plantlets from being crushed or damaged by the stacking of the trays, the trays are often placed on stackable carton carriers that are insertable and stackable within the box container. While carton carriers may be made of many different materials, corrugated fiberboard carton carriers are typically used due to the fact that they are sturdy and inexpensive. Prefabricated corrugated fiberboard carton carriers that are reinforced on their bottoms and sides provide great durability. Such prefabricated carton carriers also greatly increase cost of the shipment of the plantlets due to their preassembly and bulk. 
         [0004]    Unassembled flat sheets of corrugated fiberboard, typically referred to as blanks, may also be used to create cartons that are stackable within boxes for holding trays of plantlets. Blanks may be used that provide support on all sides and the bottom of the carton carriers when assembled. However, these blanks have complex folding instructions and are often complicated to assemble. The number of folds to be made and the specific order in which the folding of the blanks must occur to create these carton carriers greatly impede the packaging of plantlets within the fields and green houses where the plantlets are to be packed. Therefore, the cost of assembly greatly increases the shipment cost associated with the plantlets. 
         [0005]    Simple blanks have been developed that can be formed into carton carriers having two walls which run parallel to each other. These carton carriers are easy to create from their corresponding blanks. The workers who load the plantlets can easily form a carton carrier by folding a first side and a second side of the blank to create the two parallel walls. In this manner, the carton carrier is formed by the parallel side walls having a bottom panel disposed between the side walls. The bottom panel provides a surface on which the tray of plantlets may rest. The side walls may also provide support for other carton carriers to be stacked above. By easily forming a carton carrier having two side walls, loading efficiencies can increase, thereby decreasing loading times and shipping cost associated with the plantlets. 
         [0006]    While blanks used to form these two-sided carton carriers can increase loading efficiencies, other problems arise with these carton carriers when they are used to ship trays of plantlets. Due to the nature of the plantlets and plantlet trays to be shipped, these two-sided carton carriers tend to bend along the bottom panel of the carton carrier parallel to the side walls. This bending of the carton carriers leads to an increased chance of plant damage and the collapsing of stacks of carton carriers within the shipping box. 
         [0007]    Also, the plantlet trays help to hold moisture within the soil in which the plantlets are placed to help sustain the plantlets. This moisture often evaporates within the box. The fiberboard of the carton carriers absorbs this moisture causing the carrier to lose strength. This is especially true on the bottom panel on which a plantlet tray rests. The weight of the plantlet tray causes the now moist bottom panel to sag. The sagging bends the carton carrier and the trays under its own weight, thereby increasing the chances of the sagging carton carrier to collapse and also causing the trays to bend inward which can lead to damage of the plantlets. 
         [0008]    In light of the above, a need exists for improved handling of plantlet trays within transport boxes, particularly with regard to decreasing the likelihood of damage to the plantlets within the transport boxes, while not negatively effecting loading efficiencies of these boxes. 
       SUMMARY 
       [0009]    In accordance with this disclosure, novel packaging systems, apparatuses, and methods are provided for improving handling and shipment of plantlets. 
         [0010]    It is a principal purpose of the present disclosure therefore to provide novel packaging systems, apparatuses, and methods for transporting trays of plantlets, such as within carton carriers and plantlet transport boxes. This and other purposes as may become apparent from the present disclosure are achieved, at least in whole or in part, by the subject matter described herein. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    A full and enabling disclosure of the present subject matter including the best mode thereof to one of ordinary skill of the art is set forth more particularly in the remainder of the specification, including reference to the accompanying figures in which: 
           [0012]      FIG. 1  shows a schematic perspective view of an embodiment of a carton carrier according to the present subject matter; 
           [0013]      FIG. 2  shows a schematic vertical cross-sectional view of the embodiment of the carton carrier of  FIG. 1  along lines I-I; 
           [0014]      FIG. 3  shows a perspective view of an embodiment of a blank used to create a carton carrier according to the present subject matter; 
           [0015]      FIG. 4  shows a schematic perspective view of the blank of  FIG. 3  used to create a carton carrier according to the present subject matter; 
           [0016]      FIG. 5  shows a perspective view of the blank of  FIG. 3  folded to form at least a portion of a carton carrier according to the present subject matter; 
           [0017]      FIG. 6  shows a schematic perspective view of an embodiment of a carton carrier used in a packaging system according to the present subject matter; 
           [0018]      FIG. 7  shows a perspective view of an embodiment of a packaging system according to the present subject matter; 
           [0019]      FIG. 8  shows a perspective view of the packaging system according to  FIG. 7 ; 
           [0020]      FIG. 9  shows a perspective view of the packaging system according to  FIG. 7 ; 
           [0021]      FIG. 10A  shows a perspective view of the packaging system according to  FIG. 7 ; 
           [0022]      FIG. 10B  shows a perspective view of the packaging system according to  FIG. 7 ; 
           [0023]      FIG. 11  shows a schematic side elevation view of an embodiment of a carton carrier according to the present subject matter; 
           [0024]      FIG. 12A  shows a schematic perspective view of an embodiment of a packaging system according to the present subject matter; and 
           [0025]      FIG. 12B  shows a schematic perspective view of the packaging system according  FIG. 12A . 
       
    
    
     DETAILED DESCRIPTION 
       [0026]    Reference will now be made in detail to presently preferred embodiments of the present subject matter, one or more examples of which are shown in the Figures. Each example is provided to explain the subject matter and not as a limitation. In fact, features illustrated or described as part of one embodiment can be used in another embodiment to yield still yet another embodiment. It is intended that the present subject matter covers such modifications and variations. 
         [0027]      FIG. 1  illustrates a carton carrier, generally designated as  10 , for use in transporting a tray, generally designated as  50 , of plantlets. Carton carrier  10  has a bottom panel  12  on which tray  50  may reside. Carton carrier  10  includes end walls, generally designated as  20 , on either end of carton carrier  10 . Further, carton carrier  10  has supporting side walls, generally designated as  30 , that extend upward from the sides of carton carrier  10 . Supporting side walls  30  may permit the stacking of other carton carriers thereon. Each supporting side wall  30  may have an outer side panel  32 , a top shelf panel  34  and an inner side wall panel  36 . The top shelf panels  34  can create upper support surfaces, or shoulders, on which another carton carrier may be placed when the carton carriers are inserted into a transport box. Carton carrier  10  may be dimensioned such that tray  50  fits securely between supporting side walls  30  and end walls  20 . For example, supporting side walls  30  and end walls  20  may abut against sides  52  and ends  54  of tray  50 , respectively. 
         [0028]    Carton carrier  10  may be made from any suitable material. For example, carton carrier  10  may be constructed from plastic, hardboard, fiberboard, or the like. For instance, carton carrier  10  can be made of a fiberboard, such as corrugated cardboard. Preferably, carton carrier  10  may be formed from the folding of a single blank as will be described below. 
         [0029]      FIG. 2  illustrates a cross-sectional view of carton carrier  10  shown in  FIG. 1  along the lines I-I. Supporting side walls  30  may have a triangular cross-sectional shape, such as an inverted triangular cross-section. However, the supporting walls  30  may also have other cross-sectional shapes, for example, rectangular, trapezoidal, or the like. Outer side wall panels  32  form the outside of supporting side walls  30 . Top shelf panels  34  forming upper support surfaces that can extend substantially parallel to bottom panel  12  of carton carrier  10  to provide a surface on which another carton carrier  10  may be placed, thereby permitting carton carriers  10  to be stackable. 
         [0030]    Supporting side walls  30  have a height D 1  that provides sufficient space D 2  above tray  50 , which is placed on bottom panel  12 . This space D 2  permits the plantlets that reside in tray  50  to extend upward without damage by another carton carrier  10  that may be placed upon upper support surfaces of supporting side walls  30 . Thus, the space D 2  between a top  56  of tray  50  may be great enough for the stalk or stem of the plantlets to stand upright in its natural posture without any unnecessary or harmful bending. Therefore, depending on the type of plantlet being transported, height D 1  of the supporting side walls  30  and the space D 2  above the tray  50  may vary. 
         [0031]    By having an inverted triangular cross-sectional shape with inner side wall panel  36  and outer side wall panel  32  converging at bottom panel  12  of carton carrier  10 , supporting side walls  30  also help to secure tray  50  within carton carrier  10  when carton carrier  10  is placed within a transport box. By having inner side wall panels  36  of supporting side walls  30  extending upwardly and inwardly at an acute angle α from the base  12  when carton carrier  10  is within a box, inner side wall panels  36  can help to keep tray  50  secured in carton carrier  10  by abutting sides  52  of tray  50  about top  56  of tray  50  at an angle to hold tray  50  in place. In this manner, carton carrier  10  may help to prevent a jostling of tray  50  during transport of the box in which carton carrier  10  is placed. By minimizing movement of tray  50  in a vertical direction, supporting side walls  30  help to prevent damage to the plantlets placed in tray  50 . 
         [0032]      FIG. 3  illustrates a blank, generally designated as  60 , that may be used to form a carton carrier  10 . Blank  60  can be folded along its creases to form end walls  20  and supporting side walls  30  of a carton carrier  10  described above. Blank  60  may be made of material such as plastic, hardboard, fiberboard, or the like. For example, blank  60  may be formed out of cardboard. Such cardboard may be corrugated. The corrugations within the cardboard add strength to the different panels within blank  60  to create a sturdier carton carrier  10 . Blank  60  includes bottom panel  12  formed between a first end crease  14 , a second end crease  16 , a first side wall crease  18  and a second side wall crease  19 . 
         [0033]    The first and second end creases  14  and  16  may define first and second ends of bottom panel  12 . Further, first side wall crease  18  and second side wall crease  19  may define first and second sides, respectively, of bottom panel  12 . 
         [0034]    Blank  60  also includes end wall panels  22  on opposite sides of first end crease  14  and second end crease  16  from bottom panel  12 . End wall panels  22  can be folded upward along first and second creases  14 ,  16  from bottom panel  12  to form end walls  20  of carton carrier  10 . On the opposite sides of the first and second side wall creases  18 ,  19  from bottom panel  12 , blank  60  includes outer side wall panels  32 , top shelf panels  34  and inner side wall panels  36  used to form supporting side walls  30 . Extending out from the sides of bottom panel  12 , each outer side wall panel  32  follows the respective side wall creases  18 ,  19 . Each of outer side wall panels  32  are followed by the respective top shelf panel  34  which is then followed by the respective inner side wall panel  36 . 
         [0035]    Each inner side wall panel  36  and top shelf panel  34  may be folded along supporting wall creases  38  as each outer side wall panel is folded along side wall creases  18 ,  19  to form supporting side wall  30 . The inner side wall panels  36  may be secured on or about the bottom panel  12  in a variety of ways. For example, glue, glue strips, tape, staples, or the like may be used to hold inner side wall panels  36  to bottom panel  12 . 
         [0036]    Other mechanical means may also be used. For instance, on an outer edge  40  of inner side wall panel  36 , one or more jags  42  may extend outward from blank  60 . These jags  42  may fit into corresponding sleeves or slots  44  cut into blank  60  along each of the side wall creases  18 ,  19  when top shelf panels  34  and inner side wall panels  36  are folded inward along supporting wall creases  38  as outer side wall panels  32  are folded upward along side wall creases  18 , 19  to form support walls  30 . Top shelf panel  34  may have finger apertures  46  cut into blank  60 . These finger apertures  46  permit easy insertion and removal of carton carrier  10  from the transport box in which it will be placed and/or removed. 
         [0037]      FIG. 4  illustrates a blank  60  with tray  50  of plantlets placed on bottom panel  12 . Tray  50  may be placed on bottom panel  12  and outer side wall panels  32  may be folded up along side wall creases  18 ,  19  in directions A 1 . Top shelf panel  34  may be folded around supporting wall creases  38  in directions A 2 , while inner side wall panel  36  may be folded over around supporting wall creases  38  in directions A 3  to form supporting side walls  30 . Once the outer side wall panels  32 , top shelf panels  34 , and inner side wall panels  36  are folded around and jags  42  are inserted into sleeves  44  (see  FIG. 3 ), the supporting side walls  30  of carton carrier  10  are formed. Similarly, the supporting side walls  30  may be formed before tray  50  is placed on bottom panel  12 . 
         [0038]    If the blank is made from corrugated cardboard as shown in  FIG. 4 , ribs  62  may run perpendicular to side wall creases  18 ,  19  and supporting side walls  30 , while running parallel to end creases  14 ,  16  and end walls  20 . These ribs  62  within the corrugation can also help stabilize carton carrier  10 . Also, blank  60  can be different sizes depending on the size of tray  50  which is to be used. Similarly, bottom panel  12  can be different widths and lengths and the panels, which form end walls and side walls may be different heights depending on the size of the tray and the size of the plantlets being transported. 
         [0039]    As shown in  FIG. 5 , once outer side wall panels  32  are folded along side wall creases  18 ,  19 , and top shelf panel  34  and inner side wall panel  36  are folded over along supporting wall creases  38  to form supporting side walls  30 , end panel  22  can be folded up to form end walls  20  to finish forming carton carrier  10 . However, with carton carrier  10  outside the box, the support walls  30  do not necessarily have to reside up against tray  50 . Further, end walls  20  will not necessarily have to reside against ends  54  of tray  50  even when carton carrier  10  is outside the transport box in which it will be inserted. 
         [0040]      FIG. 6  illustrates a carton carrier  10  being placed into a transport box  70 , once supporting side walls  30  are formed and tray  50  of plantlets are placed on bottom panel  12  of carton carrier  10 . As can been seen from  FIG. 6 , end panels  22  which form end walls  20  now have to be folded into a standing position to fit into a transport box, generally designated as  70 . Transport box  70  may have an interior  72  which is generally similar to the shape of the outer perimeter formed by supporting side walls  30  and end walls  20  of carton carrier  10  once carton carrier  10  is placed into transport box  70 . End panels  22  do not have to be folded along first and second end creases  14 ,  16  (see  FIG. 4 ) to form end walls  20  until carton carrier  10  is placed within transport box  70 . As carton carrier  10  is lowered into the interior  72  in direction B, end walls  74  of transport box  70  fold end panels  22  in a direction C along first and second end creases  14 ,  16  to form end walls  20 . Carton carrier  10  may be lowered into transport box  70  by using finger apertures  46  to lower carton carrier  10  into interior  72  of transport box  70 . Once carton carrier  10  is lowered into transport box  70 , transport box  70  may hold supporting side walls  30  and end walls  20  in an upright, or standing, position as shown in  FIG. 1 . At this point, carton carrier  10  is supported on four sides. End walls  20  help create a sturdier carton  10  by adding greater support in a direction perpendicular to supporting side walls  30  to prevent sagging of bottom panel  12 . 
         [0041]      FIG. 7  shows a carton carrier  10  being placed within a transport box  70 . A tray  50  may be placed upon bottom panel  12  of carton carrier  10 , and the panels that form supporting side walls  30  can be quickly folded to create the supporting side walls  30  in a timely manner. Top shelf panels  34  define finger apertures  46  therein to allow carton carrier  10  to be lowered into transport box  70 . As carton carrier  10  is placed within transport box  70 , end walls  74  of transport box  70  force end panels  22  upward to form end walls  20  of carton carrier  10 . Carton carrier  10  is then pushed downward into transport box  70  to until it rests firmly against an upper support surface of another carton carrier or against the bottom of transport box  70 . 
         [0042]      FIG. 8  shows a carton  10  disposed within transport box  70 . Carton carrier  10  has tray  50  disposed therein for carrying plantlets. Tray  50  resides on a bottom panel of the carton  10 . Transport box  70  supports supporting side walls  30  and end walls  20  of carton carrier  10  in upright positions to provide the desired protection to the plantlets that may be disposed within tray  50 . Side walls  76  of transport box  70  may help to support supporting side walls  30  of carton carrier  10  in an upright position and may push supporting side walls  30  against sides  52  of tray  50 . End walls  74  of transport box  70  may help to support end walls  20  of carton carrier  10  in an upright position and may push end walls  20  against ends  54  of tray  50 . Top shelf panels  34  provide upper support surfaces which allow for the stacking of a similar carton carrier within transport box  70  on top of upper support surfaces. 
         [0043]    As stated above, height H (see  FIG. 6 ) of transport box  70  may correspond to a height of a select number of carton carriers  10  that may fit within transport box  70 . For example, as shown in  FIG. 9 , height H of box  70  may permit six carton carrier  10  to be stacked within interior  72  of box  70  with the last carton being flush with an outer edge  73  of the interior  72  of transport box  70 . At this point, inner lids  78  and outer lids  79  may be closed onto the top carton carrier  10  to form a top wall of transport box  70 . Since top carton carrier  10  is flush with outer edge  73  of interior  72  of transport box  70 , this carton carrier  10  will also be flush with a top wall formed by inner lids  78  and outer lids  79  once these lids  78 ,  79  are folded into a closed position. 
         [0044]    As shown in  FIGS. 10A and 10B , inner lids  78  may be folded into a closed position with the outer lids  79  folded on top of the inner lids  78  and secured to form a top wall  80  of transport box  70 . Similar inner and outer lids may be folded and secured in a closed position to form a bottom wall of transport box  70 . The folding closed and securing of inner lids  78  and outer lids  79  further facilitate quick and easy shipment of the trays of plantlets. With the trays securely placed between the supporting side walls of the carton carrier and the carton carrier placed securely within transport box  70 , movement of the trays within transport box  70  is minimized or prevented. 
         [0045]    The inner and outer lids  78 ,  79  for both the top and the bottom of transport box  70  may have lengths and widths that permit full coverage of the opening of interior  72  of transport box  70  when each set of lids are folded into a closed position. For example, the edges  82  of inner lids  78  may abut against one another and the edges  84  of outer lids  79  may abut against one another. Alternatively, edges  82  of inner lids  78  may overlap one another when the inner lids  78  are folded in a closed position, while edges  84  of outer lids  79  may overlap one another when the inner lids  78  are folded in a closed position. By providing full coverage of the opening of interior  72  of transport box  70  with each set of lids  78 ,  79 , the plantlets contained within transport box  70  are better insulated against outside temperatures. Also, with each carton carrier  10  (see  FIG. 1 ) having end walls  20  and supporting walls  30 , at least two layers of walls exist between the plantlets within the trays in carton carriers  10  and the outer environment surrounding transport box  70 . Further, the strength in the width and length directions can be maximized. 
         [0046]      FIG. 11  illustrates a side view of a carton carrier  10  having a tray  50  residing upon bottom panel  12  of carton carrier  10  as carton carrier  10  resides within a transport box. The weight of tray  50  creates a downward force F 1  on the carton carrier  10 . This created force F 1  causes carton carrier  10  to want to bow inward in the directions E 1  and E 2  and thereby bend bottom panel  12  outward. By having end walls  20  folded upward and perpendicular to supporting side walls  30 , end walls  20  counteract the tendency of carton carrier  10  to bow inward caused by force F 1 . End walls  20 , which run perpendicular to supporting side walls  30 , resist the bowing tendency by adding strength to carton carrier  10  in a width direction on either end of carton carrier  10 . Even after carton carrier  10  is dampened through absorption of moisture from trays  50 , end walls  20  still help to minimize any sagging of bottom panel  12  due to the added stability by end walls  20 . In this manner, the sturdiness and stability of carton carrier  10  is greatly increased over carton carriers which have only two parallel side walls. At the same time, the amount of time needed to assemble cartons  10  is not increased, because no extra steps are needed to form end walls  20  within carton carrier  10 . This is due to the fact that end walls  20  may be pushed into place by placement of carton carrier  10  within the transport box used to ship the plantlets to a desired location. 
         [0047]    By having both end walls  20  and supporting side walls  30  within carton carrier  10 , carton carrier  10  is made more stable and less likely to bend or collapse because end walls  20  and supporting side walls  30  add support in three different directions. As seen in  FIG. 12A , supporting side walls  30  provide stability in a length direction Z with its inner side wall panel  36  and outer side wall panel  32  as well as top shelf panel  34 . Further, these panels  32 ,  34 ,  36  of supporting side wall  30  also provide stability in carton carrier  10  in a height direction Y. Finally, by having end wall panels  22  that fold up to create end walls  20  of carton carrier  10 , stability is created in a width direction X of carton carrier  10 . By having added stability in carton carrier  10  in width direction X, height direction Y, and length direction Z, a more stable carton carrier is created for placement of a tray  50  thereon. The added stability by supporting side walls  30  and end walls  20  in the directions X, Y, and Z help to minimize sagging or bending of carton carrier  10  and thereby tray  50  which is placed thereon. Thus, damage to the plantlets within tray  50  due to the stability of carton carrier  10  can be minimized. 
         [0048]    Transport box  70  with its end wall  74 , side wall  76 , inner lids  78  and outer lids  79  add stability in three directions as well. As shown in  FIG. 12B , side walls  76  add stability in direction Y and direction Z. End walls  74  add stability in direction X and direction Y, while outer lids  79  add stability in direction Z and inner lids  78  add stability in direction X as shown in  FIG. 12A . 
         [0049]    Further, depending on the corrugation of the fiberboard used to create carton carrier  10 , the ribs within the corrugation can also help stabilize carton carrier  10  in different directions. For example, the ribs of corrugation that run perpendicular to supporting side walls  30  may help to reinforce the stability of carton carrier  10  in both the height direction Y and the width direction X. Tray  50  placed within carton carrier  10  may also help to stabilize carton carrier  10  in both the width direction X and the length direction Z depending on the stability of tray  50 . Similarly, transport box  70  may be made of a corrugated fiberboard such that the ribs of the corrugation help to reinforce the stability of transport box  70  for protection of the plantlets contained within the trays on carton carrier  10  within transport box  70 . The ribs of the corrugation of the transport box  70  may reinforce transport box  70  in any or all of directions X, Y, and Z. 
         [0050]    The packing systems and apparatuses disclosed above are designed to be efficient in loading and unloading of boxes, while creating greater strength in the box with minimal use of a carton. Such a system reduces the labor cost of packing and unloading of plantlets, thereby reducing the overall cost associated with the plantlets. The system is easy to understand and can increase efficiency of packing and shipping plantlets, even in high volume production environments including third world countries where education of the work force may be limited. 
         [0051]    The embodiments of the present disclosure shown in the drawings and described above are exemplary of numerous embodiments that can be made within the scope of the appending claims. It is contemplated that the configurations for packaging trays of plantlets for transport can comprise numerous configurations other than those specifically disclosed. Thus, it is the applicant&#39;s intention that the scope of a patent issuing herefrom will only be limited by the scope of the appending claims.