Patent Publication Number: US-2005138862-A1

Title: Method and apparatus for packaging horticultural products

Description:
This application is a continuation-in-part of U.S. patent application Ser. No. 10/866,147 with a filing date of Jun. 14, 2004, and this application claims priority from U.S. Provisional Application Ser. No. 60/533,021, entitled “Device For Shipment of Horticultural Products,” filed Dec. 27, 2003. The entireties of both applications are incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION  
      1. Field of the Invention  
      The invention relates generally to horticultural products, and more particularly to a method and apparatus for packaging horticultural products such as cut flowers.  
      2. Discussion of the Background  
      The market for horticultural products, particularly cut flowers, is large and continues to grow. In this industry, it is important that the horticultural product be fresh when it is presented to a consumer. The freshness of the horticultural product will determine both (1) how the product initially appears to the consumer, and (2) how long the product will last for the consumer. The product&#39;s initial appearance is particularly important in a retail setting such as a cut flower display in a store because consumers will often base their purchasing decision on the initial appearance. However, initial appearance is also important when pre-paid flowers are delivered to a consumer. How long the flowers last is also an important part of customer satisfaction—most customers will not be happy with flowers that wilt the day after they are received no matter how nice they looked the previous day.  
      The manner in which horticultural products are shipped plays an important role in both the initial appearance of the horticultural product and how long the horticultural product will last. Today, cut flowers are typically shipped from a grower by airfreight without water. Then they are either repackaged into an upstanding, open box with 1″-2″ of water on the bottom such that the ends of the stems can take up water to keep the flowers fresh, or they continue through distribution without water. With either method, the flowers are typically refrigerated to preserve their freshness. Both of these methods have obvious drawbacks. Shipping the flowers dry reduces their life no matter how well they are refrigerated. Shipping the flowers in an open container partially filled with water requires that the containers not be overturned during shipping, which increases shipping costs and distribution time.  
      Some attempts to provide a device that will allow flowers to be shipped such that their stems are in water have been disclosed in the patent literature. However, each of these alternative devices has drawbacks and, to the knowledge of the inventor, none of the alternative devices has met with any commercial success.  
      U.S. Pat. No. 2,453,906 to Hamlet discloses a device including tubular container with a “stopper” made in whole or in part from a “resilient material” inserted into each end. The stopper in the top end of the tubular container includes a bore sized to give an air-tight fit around a stem. The stopper is of a size to make it fit hermetically in the top end of the tube. The bottom end of the tube also has a stopper with a bore formed therein. The bottom end also includes a flexible diaphragm that stretches to fill the void created when water is taken up by a stem.  
      This device has several drawbacks. First, the requirement for the flexible diaphragm increases the packaging cost. Second, the “resilient material” illustrated in the &#39;906 patent does not appear to be very resilient. The drawings show very little deformation of the material in areas where it is fitted into the tube. Given the issue date of the &#39;906 patent in 1945, it is very likely that the “resilient material” is rubber. The problem with a material of such a resiliency is that it requires a relatively close match between the size of the bore in the stopper and the diameter of a plant stem inserted therein. Plant stem diameters can vary from as little as {fraction (1/8)} inch to as much as {fraction (5/8)} inch or greater. Thus, it is necessary to either make the bore to a specific size to match a particular stem, or provide a plurality of stoppers with different sized bores to accommodate cut flowers of different sizes.  
      This is not a practical alternative for two reasons. First, flower stems are not regularly shaped and often have protrusions (e.g., rose stems have protrusions where thorns are removed). It would be necessary to size the bore to accept any protrusion or other irregularity. However, considering the relatively inflexible material of &#39;906 patent, the walls of bore may not contact the stem in areas other than the location of the protrusion or irregularity, resulting in a poor seal. Second, a requirement for matching stem sizes to bore sizes would be time-consuming, and therefore expensive, in a mass-production environment. This would be especially true in an automated mass-production environment in which thousands of flowers are packaged because stems would need to be measured, sorted and staged for insertion into pre-arranged stoppers of the correct size.  
      U.S. Pat. No. 5,315,782 describes a device including a flexible walled pouch filled with a “moisturized gel” of a “fluid paste consistency” (col. 2, lines 46-66). The top end of the pouch includes a “puncturable insert” made from a closed cell foam plastics material such as a “medium density polyethylene foam sold under the trade name JIFFYCELL.” Applicants believe this is a rigid foam of the type that is commonly green in color and used in floral arrangements. The edges of the bag are adhered to this foam, and no compression of the foam is disclosed. The &#39;782 patent teaches forming a hole for a plant stem in the foam insert by pushing a sharpened pencil through the foam.  
      The most significant drawback associated with the &#39;782 patent is that it does not form a good seal around the stem. The &#39;782 patent recognizes this when it states that “the tendency to leak is reduced by that fact that it is a gel material” in the pouch (col. 3, lines 49-50). If the seal around the stem were good, then it would not be necessary to use a “gel” rather than water. The poor seal is caused by the lack of compression and the use of a rigid foam. Another drawback associated with the &#39;782 device is that, because the foam is relatively rigid, it is again necessary to size the hole to the stem that is to be inserted therein.  
      U.S. Pat. No. 5,103,586 discloses a device including a rigid cup-shaped container, a first layer comprised of rigid foam, a second layer of a “penetrable elastomeric sealing elastomer . . . chosen to be sufficiently elastic to flow at about room temperature,” and an optional third layer also comprised of a rigid foam. The sealing elastomer is preferably an RTV silicone rubber made from a two part liquid silicone that cures into the desired flowable sealing elastomer. The chief drawbacks associated with this device are the cost associated with using multiple layers and the time required for the elastomer to cure.  
      U.S. Pat. Nos. 4,941,572 and 5,115,915 to Harris disclose a device comprising a rigid container with a non-absorbent foam block that is either preformed of a rigid foam material adhered to the container or formed from a foamed-in-place foam dispensed from an aerosol container. Col. 6, Ins 43-58. The preformed block embodiment of this device suffers from the drawbacks of having to use an adhesive to secure the block to the container and, because the foam is rigid, the need for sizing holes in the block to match the stems. The foam-in-place embodiment suffers from the high cost associated with aerosol foams, and requires something to hold the stems in place while the foam is introduced.  
     SUMMARY OF THE INVENTION  
      The aforementioned issues are addressed to a great extent by the present invention, which provides a method and apparatus for packaging a horticultural product, especially cut flowers, in which one or more stems are inserted into, and preferably through, a flexible foam block formed from a low density, low CFD (compression force/deflection) material disposed in an opening of container such that the foam is compressed. The compression of the foam insulates each stem and forms a water-tight seal around each stem to prevent water or other liquid inside the container from leaking during shipment of the horticultural product.  
      In some embodiments of the invention, the foam block is cut from a solid piece of foam or is molded to a desired shape. In other embodiments, the foam block is formed by rolling up a strip of foam that includes a plurality of V-shaped channels formed therein. In some embodiments of the invention, the container is rigid. In other embodiments, the container is flexible. In some embodiments of the invention with flexible containers, an elastic band is placed around the portion of the container contiguous to the foam block. The elastic band keeps compressive pressure on the block even if the block experiences “compression set,” which is a permanent deformation of a material after it has been exposed to compressive stress over a period of time.  
      In one aspect of the invention, the use of compression provides a significant advantage as compared to prior art devices in that it allows flower stems to be tightly packed during shipping. This reduces the amount of space required by an individual bouquet of flowers. Reducing space during shipping is very important for large-scale commercial operations in which multiple bouquets are shipped in a single package. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      The aforementioned advantages and features of the present invention will be more readily understood with reference to the following detailed description and the accompanying drawings in which:  
       FIG. 1   a  is a top view of a foam block according to one embodiment of the invention in an uncompressed state.  
       FIG. 1   b  is a perspective view of the foam block of  FIG. 1   a  in an embodiment of the invention in which the foam block is die-cut from a larger piece of foam.  
       FIG. 1   c  is a perspective view of the foam block of  FIG. 1   a  in an embodiment of the invention in which the foam block is molded.  
       FIGS. 2   a  and  2   b  are top views of a non-integral foam block in rolled (uncompressed) and unrolled positions, respectively, according to a second embodiment of the invention.  
       FIG. 3  is a perspective view of a shipping assembly employing a foam block and a flexible container (shown prior to compression of the foam block) according to a third embodiment of the invention.  
       FIG. 4  is a side cross-sectional view of a shipping assembly employing a foam block and a rigid container according to a fourth embodiment of the invention.  
       FIGS. 5   a  and  5   b  are exploded and assembled side cross sectional views, respectively, of the shipping assembly of  FIG. 4 .  
       FIGS. 6   a ,  6   b  and  6   c  are perspective, side and side views, respectively, of a container for use in a shipping assembly according to a fifth embodiment of the invention.  
       FIG. 7  is a perspective exploded view of a shipping assembly incorporating the container of  FIGS. 6   a - c.    
       FIG. 8   a  is a perspective view of a packaged horticultural product according to yet another embodiment of the invention.  
       FIG. 8   b  is a side cross-sectional view of portions of the product of  FIG. 8   a.    
       FIG. 9  is a side cross-sectional view of portions of an alternative product according to yet another embodiment of the invention.  
       FIGS. 10   a - c  are perspective view of a packaged horticultural product according to yet another embodiment of the invention.  
       FIGS. 11   a - c  are top, side cross sectional and perspective views, respectively, of a device for inserting stems into foam block according to still another embodiment of the invention.  
       FIG. 12  is a side cross sectional view of the device of  FIG. 11  in a second position.  
       FIGS. 13   a - c  are top, side cross sectional and perspective views, respectively, of the device of  FIG. 11  in a third position.  
       FIG. 14  is a side view of a portion of a bouquet of cut flowers arranged in a staggered presentation using the device of  FIG. 11 .  
       FIG. 15  is a perspective view of a light bulb disposed within a ballon according to still another embodiment of the invention  
       FIGS. 16   a  and  16   b  are side views of straws and plugs inserted into an opening of a foam block according to yet another embodiment of the invention.  
       FIG. 17  is a perspective view of a balloon stretching and water filling device.  
       FIG. 18  is a perspective view of a portion of the device of  FIG. 17  showing the device stretching the neck of a balloon.  
       FIG. 19  is a side view of a Christmas tree stand incorporating a foam block according to an embodiment of the invention.  
       FIG. 20  is a perspective view of a pair of fulfillment devices according to an embodiment of the invention.  
       FIG. 21  is a perspective view of one of the fulfillment devices of  FIG. 20  with a foam block through which a bouquet of flowers has been inserted.  
       FIG. 22  is a perspective view of a portion of the fulfillment device of  FIG. 20 .  
       FIG. 23  is a perspective view of a foam block loaded with flowers using the fulfillment device of  FIG. 20 .  
       FIG. 24  includes top and perspective views of a foam block with an oval cross-sectional shape according to an embodiment of the invention.  
       FIG. 25  is a perspective view of a conventional hand-tied bouquet.  
       FIG. 26  is a top view of a foam block suitable for use with a hand-tied bouquet according to an embodiment of the invention.  
       FIG. 27  is a top view of a foam block suitable for use with a pre-made bunch according to an embodiment of the invention.  
       FIGS. 28   a  and  28   b  are top and side views, respectively, of an embodiment of the invention using a foam block and a flexible container for a Christmas tree. 
    
    
     DETAILED DESCRIPTION  
      In the following detailed description, a plurality of specific details, such as types of foam and amounts of compression, are set forth in order to provide a thorough understanding of the present invention. The details discussed in connection with the preferred embodiments should not be understood to limit the present invention. Furthermore, for ease of understanding, certain method steps are delineated as separate steps; however, these steps should not be construed as necessarily distinct nor order dependent in their performance.  
      The invention is believed to have particular utility for the packaging of cut flowers for transportation and hence will be discussed primarily in that context herein. The invention should not be understood to be so limited and should be understood to be useful for packaging horticultural products for other purposes (e.g., display in a retail setting) and should also be understood to be useful with other horticultural products such as potted plants as well as other non-horticultural products having regular or irregular cross sections in the range of typical plant stems as described herein.  
      It has been discovered that the properties of the foam used in the foam block are very important to achieving a satisfactory seal around a plant stem. In particular, it has been discovered that a foam with a combination of low density and low CFD (compression force/deflection, which is a measure of the compressability, or softness, of the foam) is particularly well suited for the invention. Foams with densities between about 0.5 and 10 pounds per cubic foot (according to the ASTM-D-1667 method) and a CFD between about 0.5 and 10 psi (according to the ASTM-D-1056 method) are preferred. By way of comparison, a rubber stopper, which is believed to be the material used in the above-discussed &#39;906 patent to Hamlet, has a density on the order of 15-20 pounds per cubic foot and a CFD much higher than 10 psi.  
      Within the above-mentioned guidelines, there are several types of foams that are believed to be suitable for practicing the invention depending on the expected fluctuation in temperature and elevation within a given distribution scenario, including: elastomeric foams (which includes natural rubber-based foams, and synthetic rubber-based foams including EDPM and nitrile rubber based foams and blends thereof with vinyl, PVC, and EVA), polyethylene foams (including cross-linked polyethylene foams), and polyurethane foams. One foam that has been found to provide a good seal in the context of the invention is a vinyl nitrile foam sold under the name SBE-41 Vinyl Nitrile 4, product designation F-06721. This foam is a nitrile rubber/polyvinyl chloride blend with a density of 4 lb/ft 3 ±0.7 lb/ft 3  and a CFD of 3.5 psi±1.5 psi. It carries a 2Cl rating and has been combustion-modified to meet the standards set forth in UL 94HF-1 and FMVSS-302. Another foam believed to be suitable for use with the present invention is a cross-linked polyethylene foam sold under the mark Voltex MM200.  
      Because the foam block is used to form a watertight seal, closed cell foams are used in preferred embodiments of the invention. However, it is also possible to practice the invention using an open cell foam provided that the open cell foam is sufficiently compressed to form a watertight seal (the amount of compression used with an open cell foam will generally be higher than with a closed cell foam). An example of an open cell foam believed to be suitable for use with the present invention is Low Perm polyurethane foam. Generally, an open cell foam must be compressed by at least 40% in order for it to act as a closed cell foam. Thus, when used in the context of the present invention, such open cell foams must be compressed by 40% plus an additional amount commensurate with the amounts discussed below, which are relevant to closed cell foams.  
      In some embodiments of the invention, a foam block  100  is die-cut from a solid piece of foam in the shape shown in  FIGS. 1   a  and  1   b . The foam block  100  preferably includes one or more holes  110  for receiving the stems of cut flowers such as roses. The foam block  100  of  FIG. 1  includes 12 holes (as roses are typically sold by the dozen)  110 , but the number of holes can be more or less as desired. The holes  110  preferably range from about ¼″ to about ⅜″ in diameter. For example, in embodiments of the invention in which the stem sizes range from ⅛″ to ⅝″ and the vinyl nitrile foam discussed above is used for the block  100 , the size of the holes is ⅜″ when stems are inserted into the holes  110  without stretching the holes  110  prior to insertion of the stems. In embodiments in which fulfillment equipment (discussed in further detail below) is used to stretch the holes  110  prior to insertion of the stems, the hole size is ¼″. The foam block  100  also includes three smaller holes  120  with diameters of {fraction (3/16)}″. The smaller holes  120  are provided to accept greens (e.g., baby&#39;s breath) that accompany the bouquet of cut flowers in the holes  110 . As with the holes  110 , the number of smaller holes  120  can vary and, in some embodiments, no smaller holes  120  are provided. The holes  110  and  120  are typically spaced apart from other neighboring holes  110 ,  120  by {fraction (5/32)}″ to ½″, depending on stem size and the softness of the stems (generally, the more soft the stem is, the more room between stems is necessary).  
      Referring now back to  FIG. 1 ( b ), it can be seen that the vertical wall  102   b  of the foam block  100  is concave. This is as a result of the die cut process by which the foam block  100  is formed. This shape is advantageous in that it provides a somewhat more secure mechanical bond when used with a band such as the band  320  described below. It should be understood that the invention is not so limited and that other embodiments of the invention employ foam blocks with non-concave surfaces, such as the foam block  190  illustrated in  FIG. 1 ( c ) which includes a straight side wall  102   c . The foam block  190  may be formed by molding rather than die-cutting from a pre-formed piece of foam.  
      The foam blocks  100 ,  190  of  FIG. 1  are integrally formed. An alternative foam block  200  is illustrated in  FIGS. 2   a  and  2   b .  FIG. 2   a  is a top view of the block  200  rolled up into a cylindrical form. In this configuration, the block  200  includes a plurality of holes  210 , each preferably having the same ⅜″ diameter as the holes  100  of  FIG. 1   a . As shown in  FIG. 2   b , the block  200  is comprised of a length of foam having a plurality of channels  211  that terminate in partially circular portions  210 ′. When the length of foam is rolled up, the opposite walls of the channels  211  are in contact with each other leaving no space between them, and the partially circular portions  210 ′ are closed to form the holes  210 .  
      The foam blocks  100 ,  190 ,  200  illustrated above in  FIGS. 1 and 2  each have circular cross sectional shapes. However, the invention may be practiced with foam blocks of different shapes (e.g., square, oval, etc.). For example, a ten-hole foam block  2400  with an oval shape is illustrated in  FIG. 24 . This oval shape and the hole pattern illustrated in  FIG. 24  has been found to use less foam material while maintaining a minimum separation between holes as compared to a circular foam block with a similar hole pattern.  
      The foam blocks  100 ,  190 ,  200  of  FIGS. 1 and 2  preferably have a height H 1  of approximately one to two inches. However, in other embodiments, the heights of the foam blocks may be as short as one half of an inch or may be as tall as is desired, subject to the length of the stems and the container with which the foam block is used.  
       FIG. 3  illustrates a packaged horticultural product  300  according to an embodiment of the invention. The product  300  includes the foam block  100  of  FIGS. 1   a ,  1   b , but is should be understood that either the foam block  190  of FIG.  1   c  or the foam block  200  of  FIG. 2  could be used in its place. The foam block  100  is disposed in the opening of a container in the form of a flexible bag  310 . The bag  310  of  FIG. 3  is plastic, but rubber, latex or any other suitable material may be used in other embodiments. A band  320  is used to compress the bag  310  and the foam block  100  (which is shown prior to compression in  FIG. 3 ) so that a watertight seal is formed between the foam block  100  and the bag  320 , and between the foam block  100  and stems (not shown in  FIG. 3 ) disposed in the holes  110 ,  120  of the foam block  100 . The band  320  may be formed of any suitable material, and comprises a cable tie or nylon strapping in some embodiments of the invention. Such ties typically have a width of approximately {fraction (1/8)}″-1.5″.  
      In other embodiments of the invention, the band  320  is comprised of an elastic material. In one embodiment, the elastic material is natural Hevea crumb rubber, and the band  320  is 1.5″ wide, 0.06″ thick, and has a flat length of 1.5″ when used with a round foam block having a diameter between 2″ and 3.75″. Use of an elastic band  320  helps counteract any compression set that occurs in the foam block. Compression set refers to a permanent deformation in a material that occurs when the material is compressed over a period of time. When a non-elastic band  320  is used, reductions in diameter of the foam block due to compression set result in a decrease in compressive force exerted on the foam block by such a non-elastic band  320 . In contrast, the use of a properly sized elastic material in the band  320  allows a more uniform compressive force to be applied to the foam block even when it undergoes compression set.  
      Compressing the foam block  100  (again, shown prior to compression in  FIG. 3 ) is critical to making the product  300  watertight so that liquid inside the bag  310  does not escape during shipping regardless of the orientation of the product  300 . The foam block  100  of  FIGS. 1   a  and  1   b  should be compressed by an amount of at least 15% when included in the product  300  to ensure that a watertight seal is formed. Preferably, the amount of compression is in the range of 20%-60%, and more preferably in the range of 25%-55%. The aforementioned compression values should be understood to mean that the diameter of a circular foam block with one or more stems inserted therethrough has been reduced by the amount of the compression when the compressive force is applied diametrically around the circumference of the foam block. Thus, for example, if the diameter of the foam block  100  is 2.25″ prior to compression, compressing the foam block by 20% means that the foam block is compressed such that its diameter is reduced by 2.25″*0.20=0.45″. The diameter of such a foam block will be 2.25″-0.45″=1.8″ when the block is compressed by 20%.  
      The above-stated compression values can also be expressed as a reduction in cross-sectional area of the foam block in a plane corresponding to the direction in which the compressive force is applied. For example, compressing the block such that its diameter is reduced by 20% will reduce the cross sectional area by approximately 36%. When expressed in this fashion, the aforementioned compression ranges correspond to reducing the cross-sectional area by at least 28%, preferably between 36% and 84%, and more preferably still between 56% and 80%. The foregoing reductions in cross sectional areas are applicable to circular blocks as well as non-circular blocks.  
      The aforementioned values reduction in cross-sectional area do not include the effect of stems in the block, which do not compress. In a typical embodiment, a 2.25″ foam block includes a bouquet of a dozen roses with a stem size of 0.25.″ The area of such a foam block is 3.976 square inches (assuming the holes for the stems are also 0.25″), and the area of the stems is 0.589 square inches. Thus, the area of the foam in the foam block is 3.976−0.589=3.38 square inches. When the area of the block (including the stems and the foam) is reduced by 28%, its new area is 2.86.″ Because the stems do not compress, the area of the foam in the compressed block is 2.86″−0.589″=2.27.″ Thus, the foam in the block has been compressed from an area of 3.38″ to 2.27″, which is 2.27/3.38=0.67 or 67% of its original area, a reduction of 33%. Thus, a 28% reduction in cross sectional area of a 2.25″ inch block that includes a dozen stems with a diameter of a quarter inch translates to a 33% reduction in cross sectional area of the foam itself. The corresponding ranges of 36%-84% and 56%-80% translate to 42%-98.7% and 66%-89%.  
      The use of a low density, low CFD foam compressed in the amounts specified herein provides a water-tight seal without requiring the use of an adhesive or a sealer around the foam block, which saves time and money. The use of a low density, low CFD foam also allows use of the product  300  with plain water disposed within the bag  310 . This is an important improvement over techniques employed in some conventional applications (e.g., U.S. Pat. No. 2,453,906) that depend upon using a thicker fluid such as a gel rather than water to hydrate the plant in order to ensure that leaks do not occur. However, the foregoing should not be understood to limit the invention to use with water. Rather, it should be understood that the present invention is not limited to use with water and may be used with liquids of various viscosities, including liquids with viscosities approximately equal to that of water as well as liquids such as gels with higher viscosities. Such liquids may or may not contain plant nutrients or other substances.  
       FIG. 4  illustrates a packaged horticultural product  400  according to another embodiment of the present invention. The product  400  includes a plurality of flowers  420 , each having a stem  420   a  inserted into a respective hole  110  of foam block  100 . As with the product  300  discussed above, foam block  190  or foam block  200  may be used in place of the foam block  100 . Foam block  100  is disposed in a container  410 , which is preferably made from plastic and is partially filled with a liquid  425 .  
      The container  410  is illustrated in greater detail in  FIGS. 5   a  and  5   b . The container  410  includes a generally frustoconical lower portion  411  of height H 1  with a closed bottom  411   a  and an open top  411   b . A ridge  412  is formed around the open top  411   b . A cap  414  is placed on the open top  411   b . The cap  414  includes a lip  415  that mates with the ridge  412  on the lower portion  411  such that a watertight seal is formed when the cap  414  is pressed onto the lower portion  411 . The mechanical bond formed by the ridge  412  and lip  415  must be sufficiently strong such that the cap  414  will not become separated from the lower portion  411  during transportation of the product  400 .  
      The cap  414  includes a funnel shaped portion  416  and a generally cylindrical portion  417 . The cylindrical portion  417  includes a lower lip  419 . The lower lip  419  functions to retain the foam block  100  as illustrated in  FIG. 5   b . The cylindrical portion has a diameter D sized such that the foam block is compressed by an amount in the ranges discussed above. When the foam block is compressed in this range, a watertight seal is formed between the foam block and the stems  420   a  and the interior surface of the wall of the cylindrical portion  417  such that water or other fluid in the lower portion  411  of the container  410  will not leak regardless of the orientation of the product  400 .  
      In practice, it is preferable to insert the stems  420   a  into the foam block  100  first, next place the foam block  100  into the cylindrical portion  417  of the cap  414 , and then place the cap  414  on the lower portion  411 . The amount of air that is trapped and compressed in the lower portion  411  as a result of fitting the product  400  together in this manner is less than if the foam block  100  and stems  420  were fitted into the cap  414  after it was in place on the lower portion  411 . Keeping back pressure low can be important when the product is shipped by air in a partially or wholly de-pressurized cargo hold at high altitudes.  
      A container  600  for use in a packaged horticultural product according to yet another embodiment of the invention is illustrated in  FIGS. 6   a  and  6   b . The container  600 , which is again preferably formed from a flexible material such as plastic, has an open top  620  and a closed bottom  630 . A protrusion  610  is formed on one side of the container  600  such that the diameter D 3  of the container  600  is wider in the area of the protrusion  610  than the diameter D 4  of the bottom end  630  of the container  600 . The protrusion adds to the volume of water that the container  600  can hold. When the container is filled with a liquid to a level  640   c  near the top as shown in  FIG. 6   c , and is then laid on its side as shown in  FIG. 6   b , the water level  640   b  extends at least partially into the protrusion  610  such that the bottom  630  remains filled with liquid (provided that something is disposed within the open top  620  to prevent the liquid from escaping). This ensures that any stems disposed within the container  600  remain submerged in the liquid when the container  600  is laid on its side. In contrast, the liquid level in a container without the protrusion  610  would drop far lower when placed in its side, which would likely result in one or more stems being situated above the liquid level rather than remaining submerged.  
      A packaged horticultural product  700  incorporating the container  600  is illustrated in  FIG. 7 . The product  700  is preferably fitted together in the following manner. First, one or more stems  710  are inserted into corresponding holes  722  in a foam block  720 . The foam block may be of any of the types illustrated in  FIGS. 1   a,b,c  and  FIG. 2 .  
      When all of the stems  710  have been inserted into the block  720 , and any holes  722  in which no stem  710  has been placed have been plugged, the block  720  is inserted into an opening  732  in cap  730 . The opening is sized such that foam block  720  is compressed by an amount in the ranges discussed above.  
      Next, one or more side walls of the container  600  are depressed inward and, while the one or more side walls are depressed, the cap  730  is inserted into the open top  620  of container  600 . Depressing the side walls a small amount prior to insertion of the cap helps to prevent and/or minimize the amount of back pressure that is created when the cap  730  is pressed into place over the open top  620 . That is, when the force creating the depressions on the side walls is removed, the side walls return to their original position and the volume inside the container is increased, thereby providing additional room for the expansion of any air compressed as a result of placing the cap  730  on the top  620 .  
      The cap  730  is securely held in place over the open top  620  by a tear away strip  740  of the type that is commonly used on consumer beverage containers, especially plastic milk containers. Ridges  622 ,  623  formed around the circumference of the open top  620  aid in the formation of a mechanical bond between the top  620  and the cap  730  and tear away strip  740 , respectively. When the consumer wishes to remove the stems  710  from the product  700 , the tear-away strip  740  is torn away and the cap  730  is then removed from the top  620 . The consumer can then push the foam block  700  upward out of the cap  730  so that the block  720  decompresses. At that point, the stems  710  can be removed from the foam block  700 .  
       FIG. 8   a  illustrates a packaged horticultural product  800  according to yet another embodiment of the invention. The product  800  includes a foam block  810  through which a plurality of flower stems  801  (shown in phantom in  FIG. 8   a ) have been inserted. The foam block  810  is held in place by a cap  820 , which is attached to a container  830 .  
      Referring now to  FIG. 8   b , the cap  820  includes a threaded surface  822  that mates with a corresponding threaded surface  832  of an opening  831  of container  830 . The cap holds an insert  840  (into which the foam block  810 , not shown in  FIG. 8   b , is inserted) in place in the container opening  831 . The insert  840  includes a lip  844  that rests on an upper surface  834  of the opening  831 . The insert, which is preferably formed of a flexible plastic, includes a plurality of slits  842 . The slits  842  allow the portion of the insert  841  between the lists to flex, which facilitates the insertion of the foam block  810 . A band (not shown in  FIG. 8   b ; preferably similar to the band  320  discussed above in connection with  FIG. 3 ) is installed around the portion of the insert  841  in the area of the slits  842  to compress the foam block. The lip  849  on the insert  841  hold the band in place.  
      Although the rigid containers of the embodiments of the invention illustrated in  FIGS. 4-8  include removable caps, other embodiments of the invention use rigid containers that do not include any removable cap. In such embodiments, the foam block is placed directly into an opening of the container. The container may be a glass vase in such embodiments.  
       FIG. 9  illustrates an alternative assembly  990  that includes a container  930  with a threaded surface  932  that mates with a corresponding threaded surface  942  of a combination cap/insert  940 . A foam block (not shown in  FIG. 9 ) is inserted into the opening  941  of the insert  940  and held in place with a band (not shown in  FIG. 9 ) as discussed above in connection with  FIG. 8   b . When the cap/insert  940  is screwed onto the container  930 , the cap/insert  940  and the foam block disposed therein are held in place on the container  930 .  
       FIGS. 10   a - c  illustrates a latex bag (sometimes referred to as a stuffing balloon)  1010  that may be used in place of the bag  310  of  FIG. 3 . The bag  1010  is comprised of latex that will flex and stretch. This allows the bag  1010  to expand with changes in atmospheric pressure such as those encountered in an airplane cargo hold, thereby relieving pressure exerted on the foam block  1020  by air inside the bag  1010  under such conditions. More importantly, however, the use of a flexible bag  1010  allows the bag to conform to any available space in a shipping container. This is very important in situations in which a plurality of packaged horticultural products are shipped in a common container as it minimizes the volume required for the common container, which reduces shipping costs.  
      The neck  1011  of the bag  1010  may be pulled open as shown in  FIG. 10   b  by a balloon stretching device (or other equipment known in the art) so that a foam block  1020  may be inserted therein. A plurality of stems  1040  are inserted into corresponding openings  1022  in the foam block  1020  prior to insertion of the foam block into the neck  1011  of the bag  1010 . After the foam block  1020  has been inserted, a band  1030  (which may be similar to the band  320  of  FIG. 3 ) placed around the outside of the neck  1011  is used to compress the foam block  1020  as shown in  FIG. 10   c.    
      A balloon stretching device  1700  suitable for use with the bag  1010  is illustrated in  FIG. 17 . The device comprises a flat surface  1710  on which a plurality of radially disposed, movable arms  1720  are mounted on slidable tracks  1721 . A stretching projection  1722  is attached at a distal end of each of the arms  1720 . In operation, a bag  1010  is placed with the stretching projections  1722  disposed inside the neck  1011 . In those embodiments in which an elastic band is used, the elastic band is placed around an outside of the neck  1011  (not shown in  FIG. 17 ).  
      Referring now to  FIG. 18 , when the arms  1720  are slid along the track  1721  such that they move outward and away from each others, the stretching arms  1722  stretch open the neck  1011  of the bag  1010 . With the neck  1011  stretched open, a liquid (preferably water) may be introduced into the bag through water tube  1730 . In the embodiment illustrated in  FIGS. 17-18 , the water tube  1730  is mounted to one of the arms  1720  to simplify positioning of the water tube  1730 . However, in other embodiments, the water tube  1730  may be mounted apart from the arms  1722 . Referring now back to  FIG. 17 , the supply of liquid through tube  1730  is controlled by a solenoid operated valve  1740  connected to a supply line  1750 . The valve  1740  may be controlled manually by an operator using a foot switch  1790  so that a desired volume of liquid is released into the bag  1010 . Alternatively, a circuit (not shown in  FIG. 17 ) may be configured to open the valve  1740  for a period of time sufficient to release a pre-determined amount of liquid into the bag  1010  when an arm  1720  travels a certain distance outward along track  1721  and activates a switch (not shown in  FIG. 17 ). After the liquid has been released into the bag  1010 , a foam block (not shown in  FIG. 17 ), preferably with stems previously inserted through the passages thereof, is placed in the enlarged, stretched neck  1011 . The arms  1720  are then moved toward each other until the neck  1011  closes around the foam block.  
      An exemplary fulfillment device  1100  that facilitates insertion of stems in a foam block by stretching the passages in the foam block is illustrated in  FIG. 11 . The fulfillment device  1100  may be used with the balloon stretching device  1600  of  FIGS. 17 and 18 , but may also be used independently of the balloon stretching device  1600  (e.g., in embodiments of the invention in which a non-elastic plastic bag or a rigid container are employed). The fulfillment device  1100  includes a plurality of upstanding tubes  1110  with positions that correspond to holes in a foam block (such as the holes  110  of  FIG. 1 ). Each of the tubes  1110  has a slightly larger diameter than the corresponding hole of the foam block. Each of the tubes  1110  has a corresponding finger  1120  disposed therein. The device  1100  also includes four stages  1150 ,  1160 ,  1170 ,  1180  that are movable with respect to each other, except that stages  1150  and  1170  are always separated by supports  1155 .  
      The fulfillment device  1100  is used as follows. First, the stages are manipulated as shown in  FIG. 12  such that stages  1160 ,  1170  and  1180  are contiguous to each other. This results in the upper edge of tubes  1110  being even with a top edge  1151  of stage  1150  and the upper portions  1121  of fingers  1120  extending above stage  1150 . The upper portions  1121  of the fingers are tapered such that they are narrower than the holes in a foam block (not shown in  FIG. 13 ) with which the device  1100  is used. At this point, the foam block is set in place over stage  1150  such that the fingers  1120  are within the corresponding holes. Next, stage  1160  is moved toward stage  1150  such that the tubes  1110  extend beyond the upper surface  1151  of stage  1150  as shown in  FIG. 13 . In this position, they are inserted into and stretch a corresponding hole of a foam block. Next, stage  1180  is moved away from stage  1170  as shown in  FIG. 11  such that most or all of the tubes  1110  are empty and can accept a flower stem. After flower stems have been inserted into each of the tubes  110 , the tubes  1110  are removed from the foam block. This allows the holes in the foam block to close around the stems and the foam block is ready for compression.  
      Because the fingers  1120  are of differing heights, flower stems are positioned in the foam block such that they are at different depths. Thus, the fulfillment device  1100  allows stems of cut flowers  1410  to be inserted through a foam block  1420  by varying amounts, which allows a plurality of equal-length cut flowers  1410  to be staggered in the manner illustrated in  FIG. 14 . This is important because staggering the flowers reduces the size of a packaged horticultural product, which reduces shipping costs. In the prior art, staggering was accomplished by arranging the heads of cut flowers in a staggered pattern, and then cutting all of the stems evenly. This sacrifices the length of some of the stems, with the result that the individual stems of the flowers in the bouquet are of unequal length.  
      Alternative fulfillment devices  2000 ,  2100  that facilitate insertion of stems in a foam block are illustrated in  FIG. 20 . As with the fulfillment device  1100  of  FIG. 11 , the fulfillment devices  2000 ,  2100  may be used with the balloon stretching device  1600  of  FIGS. 17 and 18 , but may also be used independently of the balloon stretching device  1600  (e.g., in embodiments of the invention in which a non-elastic plastic bag or a rigid container are employed).  
      The fulfillment devices  2000 ,  2001  include a base  2010  supported by feet  2011  such that the top surface of the base is at an acute angle, preferably approximately 25 degrees, with respect to the work surface  2099  on which the base  2010  rests. An upstanding rod  2020  is perpendicularly attached to the base such that it is offset approximately 25 degrees from vertical. A pair of arms  2022  are attached to the upstanding rod  2020 . As shown in  FIG. 21 , the arms  2022  form a rack that supports a bouquet of flowers  2098  as the flowers are inserted in a foam block.  
      Referring now back to  FIG. 20 , also attached to the base is an upstanding cylinder  2030  which accepts a foam block  2050  (the device  2000  is shown with a foam block of a smaller diameter that accepts approximately 12 stems, while the device  2001  is shown with a foam block of a larger diameter that accepts approximately 20 stems). In embodiments suitable for use with foam blocks having shapes other than circular, a correspondingly-shaped receptacle is used in place of the cylinder. The cylinder  2030  is illustrated in greater detail in  FIG. 22 . The inside diameter D of the cylinder sidewall  2031  is sized to accept the foam block  2050  without compression. The cylinder interior sidewall  2031  includes a shoulder  2032  that supports the foam block  2050  when it is placed in the cylinder  2030 .  
      An insert  2035  is attached to the cylinder interior sidewall  2031  below the shoulder  2032 . The insert serves two purposes. First, studs  2036  protruding approximately one quarter of an inch from the top of the insert  2035  provide support for the center portion of the foam block  2050  when it is placed in the cylinder  2030  while keeping the bottom of the foam block  2050  spaced apart from the top of the insert  2035  (the studs  2036  are preferably positioned such that they will not correspond to any hole in the foam block  2050  regardless of the angular orientation of the foam block  2050  in the cylinder  2030 ). Second, the insert  2035  regulates the depth to which stems can be inserted into the passages of the foam block  2050  that align with the insert  2035  when the foam block is placed in the cylinder. The insert  2035  has a circular central portion  2035   a  that aligns with the center seven holes of the foam block  2050 . The insert also has a straight portion  2035   b  and a flared portion  2035   c  connected between the central portion  2035   a  and the cylinder interior sidewall  2031 .  
      These straight and flared portions  2035   b,c  will correspond to one and two holes, respectively, of the 13 holes along the outer periphery of the block  2050 . Thus, the insert  2035  will align with a total of ten of the twenty holes in foam block  2050 . Stems can only be inserted to a depth of one quarter of an inch (the height of the studs  2036 ) past the bottom of the foam block  2050  into the ten holes of the foam block  2050  that align with the insert  2035 . In contrast, stems can be inserted to a depth equal to the distance between the shoulder  2032  and the base  2010  into the ten holes of the foam block  2050  that do not align with the insert  2035 . This will result in the stems of the flowers being staggered as shown in  FIG. 23 . When this arrangement is used with cut flowers having stems of equal length, the flowers will be correspondingly staggered. Preferably, the insert is shaped such that half of the holes in the foam block will be aligned with the insert. More preferably still, half of the holes in the foam block will be aligned with the insert regardless of the angular orientation of foam block with respect to the insert.  
      In some embodiments (e.g., those illustrated in  FIG. 4 ) it may be necessary or desirable to relieve any back pressure caused by compressed air in the container. To relieve such back pressure, the straw piece  1630  shown in  FIGS. 16   a  and  16   b  may be inserted into a hole of a foam block  1600 —preferably prior to compression of the foam block  1600 . As the foam block  1600  is compressed, the foam squeezes around straw piece  1630  but the straw piece  1630  prevents the hole from being squeezed closed, thereby preventing back pressure by providing a means for air in the container to escape as it is compressed through insertion of the foam block into the opening of the container. If the straw piece  1630  is removed after the block  1600  is compressed, the hole in which the straw piece  1630  was positioned will squeeze shut.  
      There are some circumstances in which it may be desirable to have the straw piece  1630  in the foam block  1600  even in the absence of a concern for back pressure. For example, it may be desirable to provide the ability to add water and nutrient to the container after a packaged horticultural product has been fully assembled (e.g., when the packaged horticultural product is being displayed in a retail store or when the packaged horticultural products are shipped in bulk to a distribution point and then are held for some period of time before final distribution). Straw piece  1630  may be used to inject water and other nutrients into the container. A plug  1631   a  ( FIG. 16   a ) or  1631   b  ( FIG. 16   b ) is then inserted into the top end of straw piece  1630  to seal the same and prevent water from escaping from the container. (In alternative embodiments, a cap—with or without a tab which can be grasped between a thumb and forefinger to facilitate removal of the cap—is used in place of a plug.) The plug  1631   a  or  1631   b  may be removed as necessary in order to add additional water or nutrient to the container and then be replaced. It should be noted that the diameter of plug  1631   a  or  1631   b  is preferably slightly larger than the inside diameter of straw piece  1630  and deforms when forced inside straw piece  1630  to create an excellent, water tight seal. This may be accomplished through ridges  1631   a   1 ,  1631   a   2  extending from the body of plug  1631   a  as shown in  FIG. 16   a , or through a bulbous portion  1631   b   1  in the body of plug  1631   b  as shown in  FIG. 16   b . In addition, the friction cause by deforming the plug  1631   a  or  1631   b  prevents it from inadvertently being dislodged from the straw piece  1630  and allowing water to leak from the container.  
      In other embodiments, one or more of the openings may be filled by a plug (not shown in the figures) or left vacant, in which case the compression of the foam block will close the opening.  
      In the embodiments discussed above, the stems are preferably inserted through the passages formed in the foam block such that the ends of the stems extend past a lower surface of the block and are submerged in liquid in the container. However, in alternative embodiments, the stems are inserted into the passages such that the ends of the stems are near, but do not extend beyond, the lower surface of the foam block. Because of the proximity of the ends of the stems to the lower surface of the foam block, the ends of the stems will remain exposed even when the foam block is compressed. Thus, if the container is filled with water, the stems will be able to take up the liquid. The container is such embodiments is preferably a balloon-type container that will collapse as liquid is taken up by the stems such that the ends of the stems will remain in contact with the liquid.  
      In still other embodiments, a block of conventional floral foam of the type that passes water may be placed adjacent to the lower surface of the water-tight foam block of the present invention. The stems may extend past the lower surface of the water-tight foam block and into the block of conventional floral foam such that the stems may take up water in the conventional foam.  
      Embodiments of the invention may also be used in conjunction with a type of bouquet known in the art as a hand-tied bouquet. In a hand-tied bouquet, such as the hand-tied bouquet  2500  of  FIG. 25 , the stems of the cut flowers in the bouquet are arranged such that they are at an angle with each other and are tied together at a “cinch point”  2510  with wire or some other suitable material. A foam block  2600  suitable for use with such a bouquet is illustrated in  FIG. 26 . The foam block  2600  includes a plurality of arms  2610 . The foam block  2600  may be inserted up into the bouquet  2500  in the direction U to a position below the cinch point  2510  such that each stem of the bouquet  2500  is disposed in one of the channels  2620  formed by the spaces between the arms  2610 . With the stems so disposed, the arms  2610  may then be twisted in a counter-clockwise direction CCW such that each of the stems are surrounded by the arms  2610 . The foam block is then compressed in the ranges discussed above to form a watertight seal. The foam block  2600  is then preferably inserted into the opening of a rigid container or a flexible opening surrounded by a band and compressed by an amount within the ranges discussed above. If a bag with a flexible opening is used, a band, preferably elastic, may be used to compress the foam block as described above.  
      The invention may also be used with what is known in the art as a pre-made bunch, which is a group of cut flowers (typically a group of 10) tied together with an elastic band. Unlike the hand-tied bouquet of  FIG. 25 , the stems in the pre-made bunch are not spread apart in a tee-pee shape but rather are grouped together and generally parallel. A foam block  2700  suitable for use with a pre-made bunch is illustrated in  FIG. 27 . The block  2700  is used as follows. First, two of the stems are pulled apart from the bunch (without removing the stems from the elastic band) and inserted into the holes  2730 . Then, with the elastic still around the bunch, each of the remaining eight stems of the bunch is fitted into one of the passages  2720  formed by the arms  2710 . This may be accomplished by spreading apart the stems with one&#39;s hands and sliding the foam block up into the pre-made bunch in the manner discussed above in connection with hand-tied bouquets. Of course, it is also possible to separate the flowers in the pre-made bunch and insert them, one at a time, into the passages  2720 ; and it is also possible to use the foam block  2700  with loose stems. After all of the stems have been inserted into the foam block  2700 , the arms  2710  are twisted in a counter-clockwise manner as indicated by the arrow CCW such that the arms close around the stems to form a water-tight seal. The foam block  2700  is then preferably inserted into the opening of a rigid container or a flexible opening surrounded by a band and compressed by an amount within the ranges discussed above.  
       FIG. 19  illustrates an application of the present invention to packaging a cut tree such as a Christmas Tree. A conventional Christmas tree stand  1950  includes a container  1951  having support legs  1952 , a peg  1958  inside the base on which the trunk  1949   a  of a Christmas tree  1949  stands to steady it and to keep a portion of the bottom of trunk  1949   a  out of contact with the bottom of the container  1951  so that the trunk  1949   a  can take up water, and turn-in screws  1953  that engage the side of trunk  1949   a  to hold it upright. Surrounding the trunk is a foam block  1956 . The foam block is disposed in, and compressed by, a holder  1954  with a funnel-shaped portion  1954   a  and a cylindrical portion  1954   b . The cylindrical portion  1954   b  has ridges  1957  that secure the foam block  1956  in place. The holder  1954  is fastened to sidewall of container  1954  by a plurality of supports  1955 . When a tree  1949  is to be mounted in the stand  1950 , the screws  1953  are backed out most or all the way, the foam piece  1956  is wrapped around the trunk  1949   a  and the tree  1949  and foam piece  1956  are then forced into funnel piece  1954   a , which compresses the foam  1956  as it passes into cylinder piece  54   b. Screws    1953  are then screwed against the sides of tree  1949  to steady it in an upright position. Foam piece  1956  preferably has at least one hole  1956   a  therethrough that permits water and nutrient poured into funnel piece  1954   a  to pass through the bottom of the holder  1954  to the container  1951  and be taken up by the trunk  1949   a  of the tree  1949 .  
       FIGS. 28   a  and  b  are top and side views, respectively, of another embodiment of the invention suitable for packaging a cut tree such as a Christmas tree. A strip of foam  2820  approximately 2 inches wide and having a thickness T of approximately {fraction (5/8)}″ is wrapped around the bark  2802  of the Christmas tree trunk  2801  as shown in  FIG. 28   a . In embodiments where the foam strip is less than ⅝″ thick, the foam strip  2820  is wrapped around the trunk  2801  several times so that the total thickness of the foam is approximately at least ⅝.″ As shown in  FIG. 28   a , there may be a small area O where the ends of the foam strip  2820  overlap.  
      After the trunk  2801  is wrapped with the foam  2820 , the trunk  2801  is inserted into an opening of a bag  2810 , which is preferably made from latex or rubber and preferably has a thickness on its bottom of several millimeters so that it can withstand having the tree stood on the trunk  2801 . Preferably, a fill tube  2850  is passed through a hole (not shown in  FIG. 28   a ) in the foam strip  2820  so that water (or other liquid) can be added to the bag  2810  as the Christmas tree takes up the water. The fill tube  2850  is preferably provided with a plug  2851  or cap (not shown in  FIG. 28 ) to keep water from escaping from the fill tube  2850  when it is not in use. A band  2830 , preferably made from an elastic material, is placed around the opening of the bag  2810  and foam strip  2820  such that the foam is compressed. Preferably, the compression reduces the cross sectional area of the foam  2820  by at least 28%, and more preferably between 36% and 84%, and more preferably still between 56% and 80%. The foam is preferably made from materials discussed herein.  
       FIG. 15  is a perspective view of the use of a foam block  1510  with an inflatable balloon  1520  to form a decorative light fixture  1500 . The foam block  1510  includes two passages  1511 ,  1512  through which pass wires  1534 ,  1535  for a light socket  1530  holding a light bulb  1532  disposed inside of the balloon  1520 . A third passage  1513  is provided in the foam block  1510  to allow for a needle (not shown in  FIG. 15 ) to be inserted through the foam block  1510  to inflate the balloon  1520  (a plug is disposed in passage  1513  to prevent air from escaping after a filling operation). A band  1522  (similar to the band  320  of  FIG. 3 ) is placed around the neck of the balloon  1520  to compress the foam block  1510  so that air in the balloon  1520  does not escape. A plurality of light fixtures  1500  may be strung together in the manner of party lanterns.  
      Preferably, flowers and other horticultural products are placed in the shipping assemblies of the present invention as soon as possible after they are cut in order to extend their life as long as possible. In some embodiments of the invention, flowers are packaged at the grower&#39;s location and shipped directly to a consumer, preferably via a common carrier such as UPS or FEDEX. Alternatively, the flowers may be shipped to a retail location, where they can be displayed and sold while still in the packaging. This is particularly advantageous for retail establishments that desire to sell flowers but do not have the staff to repackage received flowers for retail sale. In such embodiments, the container (whether rigid or soft) preferably holds enough water such that the retail establishment does not have to add water to the container before it is sold to the consumer.  
      It should also be understood that the present invention is not limited to use with water and may be used with liquids of various viscosities, including liquids with viscosities approximately equal to that of water as well as liquids such as gels with higher viscosities. Such liquids may or may not contain plant nutrients or other substances.  
      Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.