Patent ID: 12256677

DETAILED DESCRIPTION

The present invention overcomes the problems associated with the prior art, by providing a weed barrier for planting garden plants, which minimizes work, maximizes visual appeal, and provides a healthy growing environment for plants. A weed barrier of the present invention eliminates a large amount of work associated with weeding, laying out a garden, watering, and cleaning up at the end of the gardening season. In the following description, numerous specific details are set forth (e.g., specific weed barrier dimensions, configurations, etc.) in order to provide a thorough understanding of the invention. Those skilled in the art will recognize, however, that the invention may be practiced apart from these specific details. In other instances, details of well-known agricultural practices (e.g., planting, weeding, irrigating, etc.) and components have been omitted, so as not to unnecessarily obscure the present invention.

FIG.1shows a perspective view of a plurality of weed barriers100and a dripper hose102disposed on soil104and configured into a plurality of garden rows106a-106c, according to one example embodiment. Dripper hose(s)102is/are positioned on soil104in straight, parallel lines and weed barriers100are laid over hose102in direct contact with soil104. With weed barriers104properly positioned over hose102, a plurality of plant starts108are planted directly through weed barriers104and into soil104directly thereunder. Dripper hose102has a permeable outer wall so as to slowly and uniformly distribute water to soil104and, therefore, directly to plant starts108when supplied with pressurized water from a water source110connected thereto.

Weed barriers100are opaque, rigid structures adapted to accommodate many planting configurations. As shown in garden row106a, weed barriers104are arranged such that the long edges of adjacent weed barriers100abut one another. This allows weed barriers to have a greater width of weed prevention. As shown in garden rows106band106c, weed barriers104are configured such that the short edges of adjacent weed barriers100abut one another. This provides narrower rows and a greater row length of weed prevention using less weed barriers104. Depending on the particular type plant, weed barriers104can be arranged and used accordingly. For example, for plants that require more space when matured, it may be desirable to configure weed barriers100as shown in row106a. Conversely, for plants that require less space, it may be desirable to configure weed barriers100as shown in rows106b-106c. Not only are weed barriers100configurable with respect to one another and hose102, they also provide for many different planting arrangements such as, number of plants through each weed barrier100, distance between plants, layout of plants, etc. As shown inFIG.1, it is not necessary to plant a plant through each hole of weed barriers100. However, for plants requiring minimal spacing, one or more plants can be planted through every hole of weed barriers100.

Weed barriers104provide several other benefits that will be discussed in further detail with reference to other figures. For example, when arranged close to one another, weed barriers104effectively protect hose102from sun damage such as, for example, checking/dry rot. As another example, weed barriers104also effectively slow the evaporation of moisture from soil104, so that less water from water source110is required to water plant starts108. As yet another example, weed barriers100also permits airflow to soil104thereunder. This effectively permits oxygen to reach soil104, which promotes healthy plant growth. It also mitigates pest problems such as, for example, slugs which otherwise thrive under non-breathable, moisture retaining materials (i.e. plastic). As yet another example, weed barriers104collect and guide impinging water (i.e., rain water, sprinkler water, etc.) falling thereon toward the roots of plant starts108.

FIG.2shows a top perspective view of weed barrier100, which includes a rigid unitary body formed from a moisture-wicking, permeable material, a top surface200, and an opposite bottom surface202. Specifically, weed barrier100is a paper pulp structure formed, for example, via a vacuum molding process. The paper pulp is biodegradable and recyclable. This and other embodiments can facilitate weed control in a 100% organic garden. Alternate embodiments can be formed from polypropylene plastic, which can be reused and/or recycled. As another alternative, weed barrier100can be formed from leaf pulp (or other environmental waste, e.g. grass clippings), which is abundant and typically considered waste. A leaf pulp embodiment would decrease the price of manufacture (by using a practically worthless input) and the environmental footprint of the product, which is important to many current and prospective home gardeners.

Top surface200is configured to receive impinging water and defines an array of basins204to direct the water toward an opening206formed at the bottom208of each basin204. Openings206facilitate the planting of plants therethrough into the underlying soil. In this example, each opening206includes an aperture210to facilitate the removal of a break-out center portion212. For example, apertures210allow a cutting tool (e.g., knife, saw, drill blade, etc.) to be inserted through bottoms208of basins204. Optionally, openings206can be perforated or scored to facilitate the removal of center portions212with or without the assistance of a tool. As yet another option, openings206may be left completely open during the manufacturing of weed barriers100thus eliminating center portions212altogether. As yet another option, openings206can be omitted during manufacture and left for the user to create entirely. The example embodiment provides a gardener with eight of center portions212and, thus, multiple options for positioning plants, which can be utilized for planting various species, based on the needs of each individual species. For example, a gardener can plant eight small plants, four medium-sized plants, or two large plants in each tray.

Bottom surface202defines a plurality intersecting hose channels214formed between basins204. Hose channels214allow weed barrier100to be positioned over hoses (i.e. soaker hose102) and on underlying soil without causing weed barrier100to be unlevel. In this example, hose channels214include one long hose channel214aand three short hose channels214b. Hose channels214bare parallel to one another and perpendicularly intersect hose channel214a. This provides the user freedom to arrange weed barriers100in various different configurations.

FIG.3is a top view of weed barrier100showing two of eight center portions212removed. In this example, the user has chosen to plant two plant starts in weed barrier100, one through the bottom left center portion212and the other through the top right center portion212.

In this example embodiment, there are eight basins204arranged in an array and separated by four channels214. In many applications, it is beneficial to have twice as many basins204as hose channels214in a single weed barrier, because it makes the weed barrier very versatile in terms of configurations/arrangements. However, the particular configuration and number of basins204and hose channels214will depend on the particular application. Likewise, the particular geometry of basins204will depend on the particular application. For example, basins204have generally planar sidewalls and planar bottoms208but may also be more rounded.

In this particular embodiment, weed barrier100is 23¾ inches long, 16 inches wide, and weighs between ¼ and ½ pound. A garden row utilizing 12 weed barriers100will accommodate a 25′ soaker hose, which is a standard length, with little wasted length. Openings206are two inches in diameter and apertures210are ⅜ inches in diameter. Additionally, openings206are only ½ inch away from the lower edge of channel214aand, therefore, the center of a planted plant's root system will be within two inches of a soaker hose disposed in hose channel214a.

The weight, thickness, and/or density of weed barrier100can be adjusted to control the rate of biodegradation. In particular, increasing the weight/thickness of weed barrier100will increase the length of time required for weed barrier100to decompose. For example, weed barrier100made at a weight in the range of ⅓ lb.-½ lb. will last for approximately one growing season, but the weight can be increased to extend the useful life of weed barrier100. As another example, weed barrier100can be manufactured to have an average thickness within a first predetermined range (e.g., ¼″±⅛″) to last one growing season and be tillable into the soil thereafter. Alternatively, weed barrier100can be manufactured to have a greater thickness, within a second predetermined range, to facilitate collection, storage, and reuse in one or more subsequent growing seasons. In addition, the rate of degradation can be accelerated or decelerated using additives that decrease or increase the rate of degradation.

FIG.4is a side view of weed barrier100, which is 2 3/16 inches tall including a lip400around the peripheral edge for preventing soil from getting into basins204. As shown, hose channels214bextend completely through weed barrier100uninterrupted.

FIG.5is a cross-sectional side view of weed barrier100taken along line A-A ofFIG.4. Weed barrier100and hose102are shown positioned on top of soil104with hose102extending completely through hose channel214a. In this example, center portion212is removed from opening206and a plant start108is planted therethrough into the underlying soil104. The planting of plant start108is done after weed barrier100is positioned on soil104over hose102. Generally, this involves making a depression in soil104directly under opening206by pressing, for example, a finger through opening206and making a depression that is large enough to receive roots500of plant start108or seeds for new plants. As shown, the basin204on the left is not being used and, therefore, still includes center portion212.

Various means for supplying water to roots500of plant start108can be employed and are made more efficient by weed barrier100. One means includes supplying water through hose102. When pressurized water is supplied through hose102, it slowly flows through permeable sidewalls502of hose102, thereby saturating the underlying soil104and the portion of bottom surface202defining hose channel214a. Another means of supplying water includes either rain water or sprinkler water falling directly on top surface200of weed barrier100. Basins204are tapered such that the water falling onto basins204is accumulated and guided toward openings206, where it then flows through to the underlying soil. Not only does weed barrier100collect and guide impinging water, it also effectively slows the evaporation of the water from the underlying soil104such that more can be absorbed by roots500. Because weed barrier100is wicking and permeable, it can also dry to allow better air flow to the underlying soil104and prevent stagnant pools from forming under weed barrier100.

In this example, weed barrier100is 14¾ inches wide and provides about 6 inches on either side of hose channel214afor weed prevention. This space limits the competition for resources, such as water and/or fertilizer, between garden plants and weeds.

FIG.6shows a garden system600for preventing weed growth and supplying water to a garden. System600includes a plurality of weed barriers100, a dripper hose102, and instructions602for using system600. As shown, weed barriers100are stackable and, therefore, occupy minimal space when stored, shipped, and/or shelved. More specifically, top surfaces200of weed barriers100are contoured to receive bottom surfaces202of weed barriers100. As previously mentioned, hose102is a dripper hose having a permeable sidewall for slowly allowing the passage of water therethrough. Instructions602include instructions for positioning hose102on soil and positioning weed barriers100over hose102to prevent weed growth. Instructions602further include information identifying weed barriers100as weed barriers and/or indicating that weed barrier100is suitable for use in a garden.

FIG.7is a perspective view of an elevated (raised-bed) garden700using weed barrier system600. As shown, garden700includes wood planks702fastened together to form rectangular retaining wall that is two boards high from ground level. Of course, garden700is then filled with soil. Hose102is connected to a water source704and laid out on the soil along a path indicated by dashed line706. The opposite end of hose102is closed to maintain internal water pressure thereof. With hose102laid out, weed barriers100are positioned in a rectangular array, as shown, such that hose102meanders through hose channels (not visible) along line706. In this configuration, every basin204is no further than one basin away from hose102. Furthermore, the majority of the underlying soil is blocked from sunlight by weed barriers100and, therefore, remains substantially weed free during operation. After seasonal use, weed barriers100can be stacked up and stored for later use. Optionally, weed barriers100can be left alone to eventually break down naturally, because weed barriers100are biodegradable.

FIG.8shows a top view of an alternate weed barrier800. Weed barrier800is substantially similar to weed barrier100except that openings802have a plurality of apertures804to facilitate the removal of center portions806thereof. As shown, the center portion806of the top left basin808has been removed in preparation for receiving a plant start. Alternatively, weed barrier800can include precut, breakout center portions to lessen a gardener's work requirement even further by eliminating the need to cut along a scored circle to open an opening.

FIG.9shows a perspective view of another alternate weed barrier900. Weed barrier900is shown positioned around the trunk a pre-existing tree902. Weed barrier900includes two physically separate halves904, which allow it to be applied to, and removed from, rooted plants. Like weed barriers of previous embodiments, weed barrier900is a paper pulp structure formed, for example, via a vacuum molding process. The paper pulp is biodegradable and recyclable.

FIG.10shows a perspective view of weed barrier900before use. Weed barrier900includes a single basin1000contoured to direct the water toward apertures1002formed at the bottom1004thereof. Apertures1002are formed generally around the drip line of a tree to allow water accumulated in basin1000to flow into the underlying soil near the drip line. Bottom1004includes a plurality of concentric openings1006to accommodate for varying tree trunk diameters. Specifically, there are three break-out rings1008to accommodate small, medium, and large diameter trees.

FIG.11shows a perspective view of weed barrier900with the small and medium break-out rings1008removed to accommodate for a medium sized tree.FIG.11also shows the individual halves of weed barrier900physically separated from one another.

FIG.12shows a side view of a plurality of weed barriers900stacked and nested together. Halves904of weed barrier900are geometrically identical and, therefore, the two halves904of a single weed barrier900can be stacked and nested together without occupying a great deal of space. As shown, there are eight halves904stacked together and, therefore, four of weed barriers900.

FIG.13is a perspective view of another alternate weed barrier1300. Weed barrier1300is substantially identical to weed barrier900except that weed barrier1300is a unitary body rather than two physically separated halves. Weed barrier1300includes a separation1302extending from the outer edge of a first break-out ring1304to a peripheral edge of weed barrier1300, to facilitate the placement of weed barrier1300around a rooted plant. To place weed barrier1300around, for example, the trunk of a tree, the appropriate one of break-out rings1304are removed. Then, weed barrier1300is flexed until the separation of1302is spread apart a sufficient distance to pass the plant therethrough. Once the plant stem or trunk is centered in the opening created by the removal of break-out ring1304, weed barrier1300is laid on the ground around the plant base.

FIG.14is a perspective view of another alternate weed barrier1400. Weed barrier1400includes a hose channel1402and four openings1404. Hose channel1402is configured to receive a hose such as, for example, a dripper hose. Hose channel1402is functionally the same as previously mentioned hose channels and, therefore, will not be described in further detail. Openings1404facilitate the planting of plants therethrough. In this example, openings1404are perforated X's that can be pushed open, drilled, cut, etc. Weed barrier1400is stackable and nestable. Optionally, weed barrier1400can include water passages, to facilitate the flow of water from the top surface to the soil below, and surface features configured to direct incident water to the water passages.

FIG.15is a perspective view of another alternate weed barrier1500. Weed barrier1500includes a basin1502to direct the impinging water toward an opening1504(FIG.16) formed at the bottom1506(FIG.16) thereof.

FIG.16is a cross-sectional, perspective view of weed barrier1500taken along line B-B ofFIG.15. As shown, the sidewalls1600of basin1502are rounded and tapered. Weed barrier1500is stackable and nestable.

FIGS.17A-17Cillustrate a method of using system600in a typical application.

In a first step, as illustrated inFIG.17A, soaker hose102is laid down along the desired location for the row of plants. Next, as illustrated inFIG.17B, soil104in the vicinity of soaker hose102is treated with a soil additive1700such as, for example, fertilizer and/or lime, based on the current state of soil104, the needs of potential plants, etc. Finally, as illustrated inFIG.17C, each of weed barriers100is placed over hose102, such that hose102is positioned within the hose channels214of weed barriers100. Weed barriers100are also pushed into soil104slightly, so that they are not displaced by wind and/or other common environmental factors. Each weed barrier100is placed end-to-end with the previous weed barrier100until all 12 weed barriers100are placed over the 25 foot soaker hose. Then, plant starts can be planted through openings206, as shown inFIG.1.

FIG.18is a flowchart summarizing a method1800of manufacturing a weed barrier. In a first step1802, a moisture-wicking material is provided. Then, in a second step1804, a rigid body is formed from the moisture-wicking material. Next, in a third step1806, a basin is formed in the rigid body. Finally, in a fourth step1808, an opening is formed in the bottom of the basin. Second step1804, third step1806and/or fourth step1808can all be performed simultaneously as, for example, a single step of forming the rigid body with basins and openings therein.

FIG.19is a flowchart summarizing a method1900of using a weed barrier. In a first step1902, a weed barrier having a basin formed in a rigid body is provided. Next, in a second step1904, a hose having a permeable wall is provided. Then, in a third step1906, a plant is provided. Next, in a fourth step1908, the hose is positioned on soil. Then, in a fifth step1910, the weed barrier is positioned over the hose. Finally, in a sixth step1912, the plant is inserted into the soil through an opening in the basin of the weed barrier.

FIG.20shows a top perspective view of a weed barrier2000, which includes a rigid unitary body formed from a moisture-wicking, permeable material, a top surface2002, and an opposite bottom surface2004. Specifically, weed barrier2000is a paper pulp structure formed, for example, via a vacuum molding process. The paper pulp is biodegradable and recyclable. This and other embodiments can facilitate weed control in a 100% organic garden. As an alternative, weed barrier2000can be formed from leaf pulp.

Top surface2002defines a 2×4 array2005of basins2006that are configured to receive impinging water. The bottom wall of each basin2006defines perforations2008in the shape of an X to allow the user to selectively break openings through the bottom wall. By breaking open the bottom of a basin2006, the user may place the roots of a plant and/or seeds therethrough into the underlying soil. Optionally, perforations2008may be omitted and the user may cut openings through basins2006using a tool such as a knife. In such a case, the bottom of each basin may include indicia such as, for example, a mark indicating the center of the basin, concentric rings indicating different size hole edges, cutting guides, etc. The example embodiment provides a gardener with eight of basins2006and, thus, multiple options for positioning plants, which can be utilized for planting various species, based on the needs of each individual species. For example, a gardener can plant eight small plants, four medium-sized plants, or two large plants in each tray.

Top surface2002and bottom surface2004, together, define opposite sides of a flange2010formed completely around the top perimeter edge2012of the array2005of basins2006. In this example, top surface2002and bottom surface2004of flange2010are generally planar surfaces that are parallel to one another. Flange2010is configured to overlap the flange of an adjacent weed barrier2000. This overlap allows adjacent weed barriers2000to be moved toward or away from one another without permitting sunlight to pass between the two. In this example, flange2010has a length LF=1.0 inch, which is the shortest horizontal distance between the outer edge2012of array2005of basins2006to the outer edge2014of weed barrier2000. Details related to flange2010will be discussed further with reference to upcomingFIGS.24A-25C.

Flange2010at least partially surrounds the array2005of basins2006and has a first side edge2016, a second side2018edge opposite first side edge2016, a first end edge2020extending between first side edge2016and second side edge2018, and a second end edge2022opposite first end edge2020. Flange2010has a first width defined as a shortest distance between a first side edge2024of array2005and first side edge2016of flange2010. Flange2010has a second width defined as a shortest distance between a second side edge2026of array2005and second side edge2018of flange2010. Flange2010has a third width defined as a shortest distance between a first end edge2028of array2005and third end edge2020of flange2010. Flange2010has a fourth width defined as a shortest distance between a second end edge2030of array2005and second end edge2022of flange2010.

FIG.21shows a bottom perspective view of a weed barrier2000. Bottom surface2004defines a plurality of intersecting hose channels2100formed between basins2006. Hose channels2100allow weed barrier2000to be positioned over hoses (i.e. soaker hose102) and on underlying soil without causing weed barrier2000to be unlevel. In this example, hose channels2100include one long hose channel2100aand three short hose channels2100b. Hose channels2100bare parallel to one another and perpendicularly intersect hose channel2100a. This provides the user freedom to arrange weed barriers2000in various different configurations.

FIG.22shows a top perspective view of a stack of weed barriers2000nested together. In this example, the stack includes twelve weed barriers2000that, together, cover the entire footprint of a 4 ft×8 ft raised bed garden.

FIG.23is a perspective view of an elevated (raised-bed) 4 ft×8 ft garden2300using the twelve weed barriers2000and a soaker hose2302. As shown, garden2300includes wood planks2304fastened together to form a rectangular retaining wall that is two boards high from ground level. Of course, garden2300is then filled with soil. Hose2302is connected to a water source2306and laid out on the soil along a path indicated by dashed line2308. The opposite end (not shown) of hose2302is closed to maintain internal water pressure thereof. With hose2302laid out, weed barriers2000are positioned in a rectangular array, as shown, such that hose2302meanders through hose channels (not visible) along line2308. In this configuration, every basin2006is no further than one basin away from hose2302. Furthermore, the underlying soil is blocked from sunlight by weed barriers2000and, therefore, remains substantially weed free during operation. As shown, there are 96 basins2006and, therefore, 96 potential plant locations. After seasonal use, weed barriers2000can be stacked up and stored for later use. Optionally, weed barriers2000can be left alone to eventually break down naturally, because weed barriers2000are biodegradable.

FIG.24Ashows a cross-section of garden2300taken along line A-A ofFIG.23with weed barriers2000in a first position. In this first position, the two outside weed barriers2000are disposed inward toward the middle weed barrier2000such that there is substantial overlap of the flanges2010of the outside weed barriers and flange2010of the middle weed barrier2000. As a result, the flanges2010of the outside weed barriers2000are disposed slightly away from the inside wall of planks2304. The space between weed barriers2000and the inside wall of planks2304allows plants to grow therebetween if desired. Otherwise, this gap may be closed as illustrated inFIG.24B.

FIG.24Bshows a cross-section of garden2300taken along line A-A ofFIG.23with weed barriers2000in a second position. In this second position, the two outside weed barriers2000are disposed a little further away from the middle weed barrier2000such that there is less overlap of the flanges of the outside weed barriers and flange of the middle weed barrier2000. As a result, the flanges of the outside weed barriers2000abut the inside walls of planks2304such that no sunlight passes therebetween.

In view ofFIGS.24B and24A, it should be recognized that the overlap between weed barriers2000remains as weed barriers2000are slid slightly toward or away from one another. By maintaining constant contact between flanges2010of adjacent weed barriers2000, no sunlight can reach the underlying soil therebetween and cause weed growth between adjacent weed barriers2000. Furthermore, this constant overlapping of flanges2010allows weed barriers2000to cover the entirety of gardens that may be slightly off in terms of dimensions. For example, if a raised bed garden that is supposed to be 48 in×96 in is actually 47.5 in×96.5 in, the position of the twelve weed barriers2000can be adjusted so that they still cover the entire soil surface by moving weed barriers2000closer together in the x direction and further away from one another in the y direction. Flange2010essentially allows the dimensions of the hosting garden to be off within a predetermined tolerance while still maintaining overlap between adjacent weed barriers2000.

FIGS.25A,25B, and25Cshow top plan views of twelve weed barriers2000arranged in an intermediate position, a maximum position, and a minimum position, respectively. Note that, apart from the peripheral edge of basins2006depicted by the center rectangle, the details of basins2006are removed fromFIGS.25A-25Cto clearly show the relationships between overlapping flanges2010.

In the intermediate position shown inFIG.25A, the flange2010of each weed barrier2000is positioned halfway over adjacent flanges2010wherein the edges of underlying flanges2010are shown as dotted lines. As a result, the array of twelve weed barriers2000extends a total of 48 inches in the x-direction and 96 inches in the y-direction.

In the minimum position shown inFIG.25B, the flange2010of each weed barrier2000is positioned completely over adjacent flanges2010such as those illustrated inFIG.24A. As a result, the array of twelve weed barriers2000extends a total of 48 inches—LFin the x-direction and 96″−1.5 LFin the y-direction where LF=flange length. In this example, LF=1 inch, so weed barriers2000extend a total of 47 inches in the x-direction and 94.5 inches in the y-direction.

In the maximum position shown inFIG.25C, the flange2010of each weed barrier2000is positioned just slightly over adjacent flanges2010such as those illustrated inFIG.24B. As a result, the array of twelve weed barriers2000extends a total of 48 inches+LF in the x-direction and 96″+1.5 LFin the y-direction where LF=flange length. As previously mentioned, LF=1 inch in this example, so weed barriers2000extend a total of nearly 49 inches in the x-direction and nearly 97.5 inches in the y-direction.

In view ofFIGS.25A-25C, it should be recognized that flanges2010alleviate manufacturing/construction imperfections in the garden walls by providing a tolerance of +/−LF in the x-direction and +/−1.5 LF in the y-direction. This is particularly beneficial when a gardener purchases a raised-bed garden that advertises as 48″96″ but has slightly different dimensions, which is often the case. For example,FIG.26shows a raised-bed garden that has 47 inch top and bottom sides and 97.5 inch sides. Because these off dimensions of the raised-bed garden fall within the aforementioned tolerances, the soil area of the raised bed garden is still completely covered by the twelve weed barriers2000. In this example, the array of weed barriers2000are contracted in the x-direction to compensate for the shorter distance between the sidewalls of the garden and expanded in the y-direction to compensate for the longer distance between the top and bottom walls.

The magnitude of the tolerance provided by flanges2010is dictated by flange length LF. That is, the greater LF, the greater tolerance to garden dimensions that can be achieved by weed barriers2000. For example, increasing flange length LFto 2.0 inches allows a 3×4 array of weed barriers2000to extend between 46 inches to 50 inches in the x-direction and 93 inches to 99 inches in the y-direction. In other words, a 2.0 inch flange length provides a 4.0 inch range in the x-direction and a 6 inch range in the y-direction. Of course, given the same outer dimensions of weed barrier2000, an increase in LF requires a decrease in the peripheral dimensions of the array of basins2006. It may also be advantageous to decrease LF to, for example, 0.25 inches to achieve larger basins2006for raised bed gardens having dimensions very close to the advertised dimensions. The invention is not limited to a specific flange length LF. Flange length LF may range from 0.25 inches to beyond 6 inches in some cases.

In the current example weed barrier2000(dimensions shown inFIG.20), LF=1.0 inch, the distance from one basin outer side edge to an adjacent basin outer side edge in the x-direction is 14.33 inches, the distance from the uppermost edge of a top basin to the lowermost edge of a bottom basin is 22.375 inches, and the height h of weed barrier2000is 1.25 inches. In this example wherein LF=1.0 inch, the ratio of flange length FL to basin width in the x-direction is 1:7.25. The ratio of flange length FL to basin height in the y-direction is 1:5.7. The ratio of flange length FL to the height of weed barrier2000is 1:1.25.

FIG.27shows a top perspective view of an alternate weed barrier2700that is substantially similar to weed barrier2000, the only difference being that weed barrier2700has a flange2702that extends from only two of the four sides. Weed barrier2700still has the same overall outer dimensions as that of weed barrier2000. That is, weed barrier2700has a width of 16.33 inches in the x-direction, a length of 24.375 inches in the y-direction, and a height of 1.125 inches in the z-direction.

FIG.28shows a top plan view of an array of twelve weed barriers2700. Even with flange2702only extending around two of the four sides of weed barriers2700, an array of twelve weed barriers2700still provides a range of 2 LFof extendibility in the x-direction and 3 LFin the y-direction while still covering the entire area of underlying soil.

In all of the previously described embodiments, the weed barriers are formed from a moisture-wicking, permeable material that is rigid when cured. Specifically, the aforementioned rigid weed barriers are paper pulp structures formed, for example, via a vacuum molding process. The paper pulp is biodegradable and recyclable. However, alternate wicking materials and manufacturing methods can be used without departing from the main scope of the present invention. For example, the weed barriers can be formed from leaf pulp (or other environmental waste, e.g. grass clippings), which is abundant and typically considered waste. Accordingly, the weed barriers can be formed from any type of rigid, moisture/air permeable, wicking material.

During the manufacturing of any of the aforementioned weed barriers, agricultural additives can optionally be added to the wicking material. This can be done when the paper pulp is in a slurry state by adding the agricultural additives directly to the slurry before it is molded into a rigid body. The weed barriers need not necessarily be impregnated with such additives, but the additives can instead be applied to the weed barrier after it is made rigid. For example, the additive can be sprayed on, the weed barrier can be dipped in the additives, etc. Such additives include, but are not limited to, fungicides, herbicides, pH adjusting agents, fertilizers, copper compounds, etc.

The description of particular embodiments of the present invention is now complete. Many of the described features may be substituted, altered or omitted without departing from the scope of the invention. For example, alternate layouts of the basins in the trays (e.g., 6×2, 4×4, etc.), may be substituted for the current 4×2 layout. This and other deviations from the particular embodiments shown will be apparent to those skilled in the art, particularly in view of the foregoing disclosure.