Abstract:
A shipping carton having a force receiving area located adjacent opposing edges of the carton&#39;s top and bottom edges. The force receiving area is configured to deform in the presence of an external force and distribute that force through the force receiving area while minimizing the transfer of force directly to the appliance and minimizing damage to the surface panels of the shipping carton.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Ser. No. 61/827,882 filed May 28, 2013, the disclosure of which is incorporated herein in its entirety. 
    
    
     FIELD. OF THE INVENTION 
     The present invention relates to a shipping carton and, more particularly a shipping carton having integrated crumple zones for accepting lateral forces exerted on the carton during transportation. 
     BACKGROUND OF THE INVENTION 
     Large consumer appliances such as washing machines, dryers, dishwashers, ranges, freezers and refrigerators are typically packaged in individual cartons during their transportation from the manufacturer to the retailer, and ultimately to the end purchaser. The use of a carton is important in protecting the exterior of the appliance from potential damage, such as scratching and chipping the finish or even denting the appliance body. Conventional home appliance cartons are formed of one or more pieces of packaging material that form a six sided cuboid box surrounding the appliance. Due to the size and shape of these appliances, as well as the large quantity in which they are manufactured, they are typically shipped without being palletized. Accordingly, rather than use a forklift or similar lift truck to move the cartons, it is often more efficient to use a clamping lift truck that braces one or more cartons simultaneously with opposing lateral clamp arms. 
     However, the use of a clamping lift truck to lift and move appliance cartons can result in undesirable damage to the carton. In this regard, the opposing lateral forces exerted on the carton&#39;s side, from the clamps arms, compress the carton and transfer forces to the top and bottom of the carton, which are made up of folded and interconnected top and bottom flaps. These compressive forces are transmitted along the top and bottom corners of the carton at the front and the rear of carton, which can buckle to form a vertical crease along the front and/or rear panels of the carton. Typically this crease appears along the center of the carton and is visually unattractive. In some instances, this crease extends inwardly and can even contact the appliance contained therein, resulting in undesirable physical and esthetic damage to appliance. 
     An appliance carton typically includes L-shaped corner posts located between the carton wall and the appliance. These posts, which are typically made of a relatively stiff packaging material, assist in protecting the corners of the appliance and also provide sufficient strength to enable the cartons to be stacked. However, the corner posts also act to transfer the lateral clamping forces to the top and bottom of the carton, resulting in the crease mentioned above. 
     The present invention solves the aforementioned drawbacks by providing a shipping carton that includes an integrated corner crumple zone for accepting lateral forces exerted on the carton during handling and preventing transfer of the lateral clamping forces to the top and bottom corners of the carton. The present invention provides a carton that is particularly well suited for use in shipping appliances, but may also be beneficial for other shipping and distribution needs, including the shipment of products that have low tolerances to shipping related damage. 
     SUMMARY OF THE INVENTION 
     In one aspect, the present invention provides a shipping carton formed from a single blank or sheet of material, having a force receiving area located adjacent opposing edges of the carton&#39;s top and bottom edges. Each force receiving area is configured to deform in the presence of an external force and distribute that force through the force receiving area while minimizing the transfer of force directly to the appliance and minimizing deformation of the surface panels of the shipping carton. 
     In another aspect, the invention provides a dual layer top and bottom portion of the carton, where the force receiving areas of the top and bottom portions functionally cooperate. 
     In another aspect, the invention provides the force receiving areas of the top and bottom portions located at a position removed from the edge of the carton equal to a width of a support structure located within the carton, between the appliance and the carton. 
     In yet another aspect, the invention provides voids in at least one layer of the top and bottom of the carton configured to localize damage to the carton in the vicinity of the voids. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The drawings illustrate a representative embodiment presently contemplated for carrying out the present invention. It should be understood that the invention is not limited to the embodiments disclosed, and is capable of variations within the scope of the appended claims. 
       In the Drawings: 
         FIG. 1  is a top plan view of an unfolded blank of a container, according to one aspect of the present invention; 
         FIG. 2  is a perspective view of a folded container that is formed using the blank of  FIG. 1 , showing the container in a closed configuration; 
         FIG. 3  is an exploded perspective view of the folded container of  FIG. 2  with the container in an open configuration receiving a plurality of corner posts and a home appliance therein; 
         FIG. 4  is a perspective view of the folded container of  FIG. 2  showing the container in a closed configuration receiving an inwardly directed lateral force on opposing side walls, such as is experienced during clamping-type load handling, resulting in a controlled crumpling at select positions along the container walls and buckling of the container top and bottom; 
         FIG. 5  is a top plan view of an unfolded blank of a container, according to the first alternative embodiment of the present invention; 
         FIG. 6  is a perspective view of a folded container that is formed using the blank of  FIG. 5  showing the container in a closed configuration; 
         FIG. 7  is a perspective view of the folded container of  FIG. 6  showing the container in a closed configuration receiving an inwardly directed lateral force on opposing side walls, such as is experienced during clamping-type load handling, resulting in a controlled crumpling at select positions along the container walls and buckling of the container top and bottom; 
         FIG. 8  is a detail perspective view of a corner of the folded container of  FIG. 6  showing the container in a closed configuration prior to receiving an inwardly directed force; 
         FIG. 9  is a detail perspective view similar to  FIG. 8  showing the container in a closed configuration after receiving an inwardly directed force; 
         FIG. 10  is a top plan view of an unfolded blank of a top or bottom panel or cap of a shipping container, according to the second alternative embodiment of the present invention; and 
         FIG. 11  is a perspective view of an appliance to which top and bottom caps are secured, wherein each cap is formed from a folded blank of  FIG. 10 , and including a plurality of corner posts between the top and bottom caps. 
     
    
    
     DETAILED DESCRIPTION 
     I. Embodiment One 
     Referring initially to  FIGS. 1-4  and particularly  FIG. 1 , there is shown a shipping carton  100  according to one embodiment of the present invention. The shipping carton  100  generally is made of a sheet or blank  102  of packaging material. The packaging material may consist of corrugated board or any similar material suitable for use in shipping container construction. In a manner as is known, the corrugated board consists of a fluted corrugated core located between two sheets of kraft paper or linerboard, in a manner as is known. In one embodiment the flutes of the inner core have a longitudinal axis that is parallel to the longitudinal axis of the folded and erected carton  100 . The blank  102  may be stamped or cut from a sheet of the packaging material while in a substantially flat orientation, and subsequently folded to form the carton  100 . The outer surface of the carton  100  may be printed to display information such as contents details, shipping information, removal instructions, orientation indicia and the like. The outer surface of the carton  100  may also contain advertising information or ornamental elements. 
       FIG. 1  illustrates the blank  102 , formed of a single piece of packaging material, in a flat orientation. The blank  102  includes primarily a first side panel  104 , a front panel  106 , a second side panel  108  and a rear panel  110 . Each of these four panels  104 ,  106 ,  108 ,  110  also includes respective individual top panels  112 ,  114 ,  116 ,  118  and individual bottom panels  120 ,  122 ,  124 ,  126  extending from the top and bottom of each corresponding panel  104 ,  106 ,  108 ,  110 . Lastly, the rear panel  110  also includes a fixation panel  128 , extending from a side of the rear panel  110  between the top panel  118  and bottom panel  126 . As illustrated in  FIG. 1 , the fixation panel  128  may have a small top panel  130  and bottom panel  132  extending from the top and bottom of the fixation panel  128 , in line with the other top panels  112 ,  114 ,  116 ,  118  and bottom panels  120 ,  122 ,  124 ,  126  respectively. 
     Still referring to  FIG. 1 , the first side panel  104  is hingedly attached to the front panel  106  about a crease line  134 . The opposing side of the front panel  106  is hingedly attached to the second side panel  108  about a crease line  136 . The opposing side of the second side panel  108  is hingedly attached to the rear panel  110  about a crease line  138 , and the opposing side of the rear panel  110  is hingedly attached to the fixation panel  128  about a crease line  140 . As illustrated in  FIG. 1 , the crease lines  134 ,  136 ,  138 ,  140  are parallel in orientation, allowing the panels  104 ,  106 ,  108 ,  110 ,  128  to be folded into a cuboid carton  100  as is described in further detail below. 
     In addition to the above indicated side crease lines  134 ,  136 ,  138 ,  140  the blank  102  also includes a top crease line  142  and a bottom crease line  144 . The top crease line  142  extends along the upper side or edge of each panel  104 ,  106 ,  108 ,  110 ,  128  and hingedly attaches the top panels  112 ,  114 ,  116 ,  118 ,  130  respectively thereto. Similarly, the bottom crease line  144  extends along the lower side or edge of each panel  104 ,  106 ,  108 ,  110 ,  128  and hingedly attaches the bottom panels  120 ,  122 ,  124 ,  126 ,  132  respectively thereto. The top and bottom crease lines  142 ,  144  are each formed of a continuous crease that extends the entire length of the blank  102 , and form upper and lower edges of the erected carton  100 , when folded. While the lines  134 ,  136 ,  138 ,  104 ,  142 ,  144  have been described as “crease lines”, it is well within the scope of the invention that these lines may be formed of other methods, including but not limited to scoring or perforating. 
     Still referring to  FIG. 1 , the top and bottom panels  112 ,  114 ,  116 ,  118 ,  120 ,  122 ,  124 ,  126 ,  130 ,  132  will be described in further detail. As illustrated in  FIG. 1 , each of the top panels  112 ,  114 ,  116 ,  118  and bottom panels  120 ,  122 ,  124 ,  126  includes a similar pattern of crease lines and perforations, collectively referred to as a crumple zone described below. Specifically, each top and bottom panel  112 ,  114 ,  116 ,  118 ,  120 ,  122 ,  124 ,  126 , includes a crumple zone crease line  146 . The crumple zone crease line  146  is located adjacent the respective crease line  142 ,  144  and on the surface of the top or bottom panel  112 ,  114 ,  116 ,  118 ,  120 ,  122 ,  124 ,  126 . In the illustrated embodiment, the crumple zone crease line  146  may be located approximately between 0.5 and 5.0 inches from the respective top or bottom crease line  142 ,  144  and approximately 3.25 inches from the respective top or bottom crease line  142 ,  144 . While the crumple zone crease line  146  had been described as “crease lines”, it is well within the scope of the invention that this line  146  may be formed of other methods, including but not limited to scoring or perforating. 
     In addition to the crumple zone crease line  146 , each top and bottom panel  112 ,  114 ,  116 ,  118 ,  120 ,  122 ,  124 ,  126  also includes at least one primary crumple zone perforation line  148 , and may include one or more secondary crumple zone perforation lines  150 . The primary crumple zone perforation line  148  and secondary crumple zone perforation lines  150  are oriented perpendicular to the crumple zone crease line  146 . In the illustrated embodiment in  FIG. 1 , the blank  102  includes two secondary crumple zone perforation lines  150  for ever primary crumple zone perforation line  148 , with the secondary crumple zone perforation lines  150  being short lines located on opposing sides of the primary crumple zone perforation line  148 . As shown in  FIG. 1 , the primary crumple zone perforation line  148  may be located approximately between 0.5 and 5.0 inches from the respective side edge  152  of the corresponding top or bottom panel  112 ,  114 ,  116 ,  118 ,  120 ,  122 ,  124 ,  126 , and approximately 3.25 inches from the side edge  152  of the corresponding top or bottom panel  112 ,  114 ,  116 ,  118 ,  120 ,  122 ,  124 ,  126 . Accordingly, in a folded configuration as will be described in further detail below, the primary crumple zone perforation line  148  will overlie crumple zone crease line  146 . Again, while the primary crumple zone perforation line  148  and secondary crumple zone perforation lines  150  have been described as “perforation lines”, it is well within the scope of the invention that these lines  148 ,  250  may be formed of other methods, including but not limited to scoring or creasing. 
     Turning now to  FIGS. 2 and 3 , the blank  102  will be described in a folded and erected configuration to form carton  100 . The blank  102  is folded approximately 90 degrees around the score lines  134 ,  136 ,  138 ,  140  until the outer surface of fixation panel  128  overlaps with the inner surface of the first side panel  104 . The blank  102  is then retained in this folded configuration by means of applying adhesive between the outer surface of fixation panel  128  and the inner surface of the first side panel  104 . Alternatively, the fixation panel  128  and first side panel  104  may be retained in their folded configuration by means of fasteners such as staples, adhesive tape or any other known means of fixation. The bottom panels  120 ,  122 ,  124 ,  126 ,  132  are then folded inwardly, approximately 90 degrees around crease line  144  respectively to form a base of support on which the carton  100  rests. Once the bottom panels  120 ,  122 ,  124 ,  126 ,  132  have been folded they may be adhesively or alternatively fixed together to form an integrated base. The outer surfaces of bottom panels  122 ,  126  may be adhesively affixed to the inner surfaces of bottom panels  120 ,  124 ; or alternatively the outer surfaces of bottom panels  120 ,  124  may be adhesively affixed to the inner surfaces of the bottom panels  122 ,  126 . As shown in  FIG. 3 , after the bottom has been formed, an appliance  154  or other object may be inserted into the interior cavity formed within the carton  100 . Corner posts  156  and or other packaging materials may also be inserted into the carton  100 , surrounding the appliance  154 . The width of the corner posts  156  is representatively approximately equal to the distance from the crumple zone crease line  146  to the corresponding crease line  142 ,  144  as well as the primary crumple zone perforation line  148  to the side edge  152 . Once all of the contents have been placed into the carton  100 , the top panels,  112 ,  114 ,  116 ,  118 ,  130  may be folded inwardly, approximately 90 degrees around crease line  142  respectively to form a top to the carton  100  and adhesively or alternatively fixed together. As shown in  FIG. 2  the inner surfaces of top panels  112 ,  116  may be adhesively affixed to the outer surfaces of top panels  114 ,  118 ; or alternatively the inner surfaces of top panels  114 ,  118  may be adhesively affixed to the outer surfaces of the top panels  116 ,  120 . 
     Turning now to  FIG. 4 , once the carton  100  has been retained in its folded configuration described above, it may be subjected to opposing lateral forces such as those exerted by a clamp lift and indicated by arrows F, F′. When subjected to such forces, the first and second side panels  104 ,  108  may be forced inwards, in the direction indicated by arrows F, F′. In response to such inward movement of the first and second side panels  104 ,  108 , the forces applied to the first and second side panels  104 ,  108  are transferred to the weakened crumple zone crease line  146 , primary crumple zone perforation line  148 , and one or more secondary crumple zone perforation lines  150 , rather than directly to the front and rear panels  106 ,  110  and the top and bottom of carton  100 . This avoids buckling at the top and bottom corners of the front and rear panels  106 ,  110  and instead results in upward and downward flexing, bending, and movement at crumple zone crease line  146 , primary crumple zone perforation line  148 , and one or more secondary crumple zone perforation lines  150  at the top and bottom of the carton  100 , respectively. 
     Still referring to  FIG. 4 , the crumple zone crease line  146 , primary crumple zone perforation line  148 , and one or more secondary crumple zone perforation lines  150  are illustrated in a crumpled configuration in which a lateral force F has forced the second side panel  108  inwards, resulting in the vertical flexing or bending of the crumple zone at crease line  146 , primary crumple zone perforation line  148 , and one or more secondary crumple zone perforation lines  150  so as to absorb or receive the force F and thereby limit the carton  100  from undesirably and uncontrollably creasing or bending in other locations. The inward movement of the second side panel  108  is transitioned to upward bowing of the top of the carton  100 , downward bowing of the bottom of the carton  100 , and outward bowing of the front and rear panels  106 ,  110 . That is to say that the crumple zone crease line  146 , primary crumple zone perforation line  148 , and one or more secondary crumple zone perforation lines  150 , in combination with the underlying corner posts  156  act as a relief to insure that lateral movement of the upper end of second side panel  108  does not result in application of a lateral force to the top corner of carton  100 . That is, the presence of the crumple zone crease line  146 , primary crumple zone perforation line  148 , and one or more secondary crumple zone perforation lines  150  will localize any potential creasing of carton  100  to the area of the carton  100  that is in the approximate vicinity of the crumple zone crease line  146 , primary crumple zone perforation line  148 , and one or more secondary crumple zone perforation lines  150 . By way of localizing the potential creasing of carton  100 , as is illustrated in  FIG. 4 , the front and rear panels  106 ,  110  do not exhibit creasing or alternative damage, particularly around the center or middle of the carton  100 . As a result, the carton  100  has an improved esthetic appearance after shipment. Additionally, by localizing any potential creasing or carton  100  to an area adjacent a corner post, the present invention greatly reduces the risk of abrading, scratching and chipping the finish of the appliance or denting the appliance body. 
     II. Embodiment Two 
     Turning now to  FIGS. 5-9  and initially  FIG. 5 , there is shown a shipping carton  200  according to a second embodiment of the present invention. The shipping carton  200  generally is made of a sheet or blank  202  of packaging material. The packaging material may consist of corrugated board or any similar material suitable for use in shipping container construction. In a manner as is known, the corrugated board consists of a fluted corrugated core located between two sheets of kraft paper or linerboard, in a manner as is known. In one embodiment the flutes of the inner core have a longitudinal axis that is parallel to the longitudinal axis of the folded and erected carton  200 . The blank  202  may be stamped or cut from a sheet of the packaging material while in a substantially flat orientation, and subsequently folded to form the carton  200 . The outer surface of the carton  200  may be printed to display information such as contents details, shipping information, removal instructions, orientation indicia and the like. The outer surface of the carton  200  may also contain advertising information or ornamental elements. 
       FIG. 1  illustrates the blank  202 , formed of a single piece of packaging material, in a flat orientation. The blank  202  includes primarily a first side panel  204 , a front panel  206 , a second side panel  208  and a rear panel  210 . Each of these four panels  204 ,  206 ,  208 ,  210  also includes respective individual top panels  212 ,  214 ,  216 ,  218  and individual bottom panels  220 ,  222 ,  224 ,  226  extending from the top and bottom of each corresponding panel  204 ,  206 ,  208 ,  210 . Lastly, the rear panel  210  also includes a fixation panel  228 , extending from a side of the rear panel  210  between the top panel  218  and bottom panel  226 . As illustrated in  FIG. 5 , the fixation panel  228  may have a small top panel  230  and bottom panel  232  extending from the top and bottom of the fixation panel  228 , in line with the other top panels  212 ,  214 ,  216 ,  218  and bottom panels  220 ,  222 ,  224 ,  226  respectively. 
     Still referring to  FIG. 5 , the first side panel  204  is hingedly attached to the front panel  206  about a crease line  234 . The opposing side of the front panel  206  is hingedly attached to the second side panel  208  about a crease line  236 . The opposing side of the second side panel  208  is hingedly attached to the rear panel  210  about a crease line  238 , and the opposing side of the rear panel  210  is hingedly attached to the fixation panel  228  about a crease line  240 . As illustrated in  FIG. 5 , the crease lines  234 ,  236 ,  238 ,  240  are parallel in orientation, allowing the panels  204 ,  206 ,  208 ,  210 ,  228  to be folded into a cuboid carton  200  as is described in further detail below. 
     In addition to the above indicated side crease lines  234 ,  236 ,  238 ,  240  the blank  202  also includes a top crease line  242  and a bottom crease line  244 . The top crease line  242  extends along the upper side or edge of each panel  204 ,  206 ,  208 ,  210 ,  228  and hingedly attaches the top panels  212 ,  214 ,  216 ,  218 ,  230  respectively thereto. Similarly, the bottom crease line  244  extends along the lower side or edge of each panel  204 ,  206 ,  208 ,  210 ,  228  and hingedly attaches the bottom panels  220 ,  222 ,  224 ,  226 ,  232  respectively thereto. The top and bottom crease lines  242 ,  244  are each formed of a continuous crease that extends the entire length of the blank  202 , and form upper and lower edges of the erected carton  200 , when folded. While the lines  234 ,  236 ,  238 ,  204 ,  242 ,  244  have been described as “crease lines”, it is well within the scope of the invention that these lines may be formed of other methods, including but not limited to scoring or perforating. 
     Still referring to  FIG. 5 , the top and bottom panels  212 ,  214 ,  216 ,  218 ,  220 ,  222 ,  224 ,  226 ,  230 ,  232  will be described in further detail. As illustrated in  FIG. 5 , the top and bottom panels  212 ,  216 ,  220 ,  224  of the first and second side panels  204 ,  208 , respectively, include first and second crumple zone crease lines  246 ,  248 . The crumple zone crease lines  246 ,  248  are located adjacent the respective crease lines  242 ,  244  and on the surface of the top or bottom panel  212 ,  214 ,  216 ,  218 ,  220 ,  222 ,  224 ,  226 ,  230 ,  232 . In the illustrated embodiment, the first crumple zone crease line  246  may be located approximately between 0.5 and 1.0 inches from the respective top or bottom crease line  242 ,  244  and approximately 0.75 inches from the respective top or bottom crease line  242 ,  244 . In this illustrated embodiment, the second crumple zone crease line  248  may be located approximately between 0.5 and 1.0 inches from the first crumple zone crease line  246 , and approximately 0.75 inches from the first crumple zone crease line  246 . While the crumple zone crease lines  246 ,  248  have been described as “crease lines”, it is well within the scope of the invention that these lines  246 ,  248  may be formed of other methods, including but not limited to scoring or perforating. 
     The top and bottom panels  214 ,  218 ,  222 ,  226  of the front and rear panels  206 ,  210 , may also include respective first and second crumple zone crease lines  250 ,  252 , which are positioned to correspond with the crumple zone crease lines  246 ,  248  of the side panels  204 ,  208  when the blank  202  is folded into a carton  200 . The crumple zone crease lines  250 ,  252  are located adjacent the opposing sides  254 ,  256  of the top and bottom panels  214 ,  218 ,  222 ,  226  on the surface of the top or bottom panel  214 ,  218 ,  222 ,  226 . The crumple zone crease lines  250 ,  252  are also positioned approximately perpendicular to the crease lines  242 ,  244 . In the illustrated embodiment, crumple zone crease line  250  may be located approximately between 0.75 and 1.5 inches from the first side  254  of the panel  214 ,  218 ,  222 ,  226 , and approximately 1.1875 inches from the first side  254  of the respective panel  214 ,  218 ,  222 ,  226 . Similarly, crumple zone crease line  252  may be located approximately between 0.75 and 1.5 inches from the second side  256  of the panel  214 ,  218 ,  222 ,  226 , and approximately 1.1875 inches from the first side  254  of the respective panel  214 ,  218 ,  222 ,  226 . As also illustrated in  FIG. 5 , the first and second sides  254 ,  256 , of the top and bottom panels  214 ,  218 ,  222 ,  226  may include a taper or void  258  configured to facilitate folding blank  202  into carton  200  and crumpling of the crumple zone crease lines  246 ,  248 ,  250 ,  252 . Again, while the crumple zone crease lines  250 ,  252  have been described as “crease lines”, it is well within the scope of the invention that these lines  250 ,  252  may be formed of other methods, including but not limited to scoring or perforating. 
     Turning now to  FIGS. 6 and 8 , the blank  202  will be described in a folded and erected configuration to form carton  200 . The blank  202  is folded approximately 90 degrees around the score lines  234 ,  236 ,  238 ,  240  until the outer surface of fixation panel  228  overlaps with the inner surface of the first side panel  204 . The blank  202  is then retained in this folded configuration by means of applying adhesive between the outer surface of fixation panel  228  and the inner surface of the first side panel  204 . Alternatively, the fixation panel  228  and first side panel  204  may be retained in their folded configuration by means of fasteners such as staples, adhesive tape or any other known means of fixation. The bottom panels  220 ,  222 ,  224 ,  226 ,  232  are then folded inwardly, approximately 90 degrees around crease line  244  respectively to form a base of support on which the carton  200  rests. Once the bottom panels  220 ,  222 ,  224 ,  226 ,  232  have been folded they may be adhesively or alternatively fixed together to form an integrated base. As shown in  FIG. 6  the outer surfaces of bottom panels  222 ,  226  may be adhesively affixed to the inner surfaces of bottom panels  220 ,  224 ; or alternatively the outer surfaces of bottom panels  220 ,  224  may be adhesively affixed to the inner surfaces of the bottom panels  222 ,  226 . After the bottom has been formed, an appliance or other object may be inserted into the interior cavity formed within the carton  200 . Corner posts and or other packaging materials may also be inserted into the carton  200 , surrounding the appliance, as previously illustrated in  FIG. 3 . Once all of the contents have been placed into the carton  200 , the top panels,  212 ,  214 ,  216 ,  218 ,  230  may be folded inwardly, approximately 90 degrees around crease line  242  respectively to form a top to the carton  200  and adhesively or alternatively fixed together. As shown in  FIG. 6  the inner surfaces of top panels  214 ,  218  may be adhesively affixed to the outer surfaces of top panels  212 ,  216 ; or alternatively the inner surfaces of top panels  212 ,  216  may be adhesively affixed to the outer surfaces of the top panels  214 ,  218 . 
     Turning now to  FIGS. 7 and 9 , once the carton  200  has been retained in its folded configuration described above, it may be subjected to opposing lateral forces such as those exerted by a clamp lift and indicated by arrows F, F′. When subjected to such forces, the front and rear panels  206 ,  210  may be forced inwards, in the direction indicated by arrows F. F′. In response to such inward movement of the front and rear panels  206 ,  210 , the forces applied to front and rear panels  206 ,  210  are transferred to the weakened crumple zone crease lines  246 ,  248 ,  250 ,  252  rather than to the upper and lower corners between first and second side panels  204 ,  208  and the top and bottom of carton  200 . This avoids buckling at the top and bottom corners of first and second side panels  204 ,  208  and instead results in upward and downward flexing, bending, and movement at the crumple zone crease lines  246 ,  248 ,  250 ,  252  at the top and bottom of the carton  10 , respectively. 
     Still referring to  FIGS. 7 and 9 , the crumple zone crease lines  246 ,  248 ,  250 ,  252  are illustrated in a crumpled configuration in which a lateral force F′ has forced the rear panel  210  inwards, resulting in the flexing or bending of the crumple zone crease lines  246 ,  248 ,  250 ,  252  which absorb or receive the force F′ and thereby limit the carton  200  from undesirably and uncontrollably creasing or bending in other locations. The inward movement of the rear panel  210  at its intersection with top panel  218  is accommodated by the enlarged void area  258  of slot  260 , which acts as a relief to insure that lateral movement of the upper end of rear panel  210  does not result in application of a lateral force to the top corner of carton  200 . That is, the presence of the crumple zone crease lines  246 ,  248 ,  250 ,  242  will localize any potential creasing of carton  200  to the area of the carton  200  that is in the approximate vicinity of the crumple zone crease lines  246 ,  248 ,  250 ,  252 . By way of localizing the potential creasing of carton  200 , as is illustrated in  FIGS. 7 and 9 , the first and second side panels  204 ,  208  do not exhibit creasing or alternative damage, particularly around the center or middle of the carton  200 . As a result, the carton  200  has an improved esthetic appearance after shipment. Additionally, by localizing any potential creasing or carton  200  to an area adjacent a corner post, the present invention greatly reduces the risk of abrading, scratching and chipping the finish of the appliance or denting the appliance body. 
     Ill. Embodiment Three 
     Turning now to  FIGS. 10 and 11  and initially  FIG. 10 , there is shown a shipping carton cap  300  according to another embodiment of the present invention. The shipping carton cap  300  generally is made of a sheet or blank  302  of packaging material. The packaging material may consist of corrugated board or any similar material suitable for use in shipping container construction. In a manner as is known, the corrugated board consists of a fluted corrugated core located between two sheets of kraft paper or linerboard, in a manner as is known. In one embodiment the flutes of the inner core have a longitudinal axis that is parallel to the longitudinal axis of the folded and erected carton cap  300 . The blank  302  may be stamped or cut from a sheet of the packaging material while in a substantially flat orientation, and subsequently folded to form the carton cap  300 . The outer surface of the carton cap  300  may be printed to display information such as contents details, shipping information, removal instructions, orientation indicia and the like. The outer surface of the carton cap  300  may also contain advertising information or ornamental elements. 
       FIG. 10  illustrates the blank  302 , formed of a single piece of packaging material, in a flat orientation. The blank  302  includes primarily a center panel  304 , and four edge panels extending therefrom; namely, a front panel  306 , a first side panel  308 , a rear panel  310  and a second side panel  312 . Each of these four edge panels  306 ,  308 ,  310  and  312  is hingedly attached to the sides of the center panel  304  about a crease line  314 , which also defines the edge of the center panel  304 . 
     Still referring to  FIG. 10 , the front panel  306  is formed in part from a double layer of packaging material, and is formed from a first front panel section  316  and a second front panel section  318 . The first front panel section  316  is located between the center panel  304  and the second front panel section  318 . On one side, the first front panel section  316  is hingedly attached to the side of the center panel  304  about a crease line  314  while on the opposing side the first front panel section  316  is hingedly attached to the second front panel section  318  about a crease line  320 . In one embodiment of the present invention, as shown in  FIG. 10 , the crease line  320 , which divides the first and second front panel sections  316 ,  318 , includes a first crease line  322  and a second crease line  324  wherein the first and second crease lines  322 ,  324  are slightly offset such that when the first and second front panel sections  316 ,  318  are rotated approximately 180 degrees about the crease line  320  a void or space is left between the two panel sections  316 ,  318 . As will be described in further detail below, the void or space left between the two panel sections  316 ,  318  as a result of the two crease lines  322 ,  324  will accommodate portions of the first and second side panels  308 ,  312  therein when the blank  302  is in the folded configuration. Additionally, the second front panel section  318  includes a outwardly protruding tab  326 , which is configured to be received within a slot  328  that intersects the crease line  314  when the first and second front panel sections  316 ,  318  are rotated approximately 180 degrees about the crease line  320 , as to lock the front panel  306  in its folded configuration. While the crease lines  314 ,  320 ,  322 ,  324  have been described as “crease lines”, it is well within the scope of the invention that these lines  314 ,  320 ,  322 ,  324  may be formed of other methods, including but not limited to scoring or perforating. 
     Still referring to  FIG. 10 , the first side panel  308  is formed from a single layer of packaging material hingedly attached to the center panel  304  about a crease line  330 , and includes a first locking tab  332  and second locking tab  334  extending from the first side panel  308  in opposing directions. Specifically, the first locking tab  332  is located adjacent the front panel  306 , and is hingedly attached to the first side panel  308  about a crease line  336 , which is a continuation of the crease line  314  that divides the center panel  304  from the front panel  306 . In this arrangement, rotation of the first side panel  308  about the crease line  330  combined with rotation of the first locking tab  332  about the crease line  336  will allow the first locking tab  332  to be positioned within the void or space left between the two panel sections  316 ,  318  of the front panel  306 . That is to say that the front panel  306  and first side panel  308  will form an approximately 90 degree angle by way of retaining the first locking tab  332  between the two panel sections  316 ,  318 . 
     On the opposing end of the first side panel  308 , the second locking tab  334  is similarly located adjacent the rear panel  310 , and is hingedly attached to the first side panel  308  about a crease line  338 , which is a continuation of the crease line that divides the center panel  304  from the rear panel  310 . As will be described in further detail below, rotation of the first side panel  308  about the crease line  330  combined with rotation of the second locking tab  334  about the crease line  338  will allow the second locking tab  334  to be positioned between the two sections of the rear panel  310 , thereby forming an approximately 90 degree angle by way of retaining the second locking tab  334  within the rear panel  310 . 
     Additionally, the first side panel  308  includes a crumple zone crease line  340  which extends from two voids  342 , located at opposing ends of the crease line  330 , and which are configured to facilitate folding blank  302  into carton cap  300  and maintaining localized crumpling of the crumple zone crease line  340 . In the illustrated embodiment, crumple zone crease line  340  may be located in the center panel  304  approximately between 0.5 and 4.0 inches from the crease line  330  of the first side panel  308 , and approximately 1.5 inches from the first side panel  330 . 
     Still referring to  FIG. 10 , the rear panel  310  is formed in part from a double layer of packaging material, and is formed from a first rear panel section  344  and a second rear panel section  346 . The first rear panel section  344  is located between the center panel  304  and the second rear panel section  346 . On one side, the first rear panel section  344  is hingedly attached to the side of the center panel  304  about a crease line  348  while on the opposing side the first rear panel section  344  is hingedly attached to the second rear panel section  346  about a crease line  350 . In one embodiment of the present invention, as shown in  FIG. 10 , the crease line  350 , which divides the first and second rear panel sections  344 ,  346 , includes a first crease line  352  and a second crease line  354  wherein the first and second crease lines  352 ,  354  are slightly offset such that when the first and second rear panel sections  344 ,  346  are rotated approximately 180 degrees about the crease line  350  a void or space is left between the two panel sections  344 ,  346 . As was previously described, the void or space left between the two panel sections  344 ,  346  as a result of the two crease lines  352 ,  254  will accommodate the second locking tab  334  of the first side panel  308  therein along with a portion of the second side panel  312  when the blank  302  is in the folded configuration. Additionally, the second rear panel section  346  includes two outwardly protruding tabs  356 , which are configured to be received within slots  358  that intersect the crease line  348  when the first and second rear panel sections  344 ,  346  are rotated approximately 180 degrees about the crease line  350 , so as to lock the rear panel  106  in its folded configuration. While the crease lines  348 ,  350 ,  352 ,  354  have been described as “crease lines”, it is well within the scope of the invention that these lines  348 ,  350 ,  352 ,  354  may be formed of other methods, including but not limited to scoring or perforating. 
     Lastly, the second side panel  312  is formed from a single layer of packaging material hingedly attached to the center panel  304  about a crease line  360 , and includes a first locking tab  362  and second locking tab  364  extending from the second side panel  312  in opposing directions. Specifically, the first locking tab  362  is located adjacent the front panel  306 , and is hingedly attached to the second side panel  312  about a crease line  366 , which is a continuation of the crease line  314  that divides the center panel  304  from the front panel  306 . In this arrangement, rotation of the second side panel  312  about the crease line  360  combined with rotation of the first locking tab  362  about the crease line  364  will allow the first locking tab  362 , and particularly the end extension  368  to be positioned within the void or space left between the two panel sections  316 ,  318  of the front panel  306 . That is to say that the front panel  306  and second side panel  312  will form an approximately 90 degree angle by way of retaining the end extension  368  of the first locking tab  362  between the two panel sections  316 ,  318 . 
     The first locking tab  362  of the second side panel  312  differs from its counterpart on the first side panel  308  in part due to its shape. As shown in  FIG. 10 , the front panel  306  does not extend across the full length of the lower edge of the center panel  304 , resulting in a void  370  located adjacent the center panel  304  and front panel  306 . The void  370  is configured to allow a single thickness portion of the packaging material, from the first locking tab  362  of the second side panel  312  to extend across the void  370 , when the blank  302  is in a folded configuration. The single thickness packaging material located at the first locking tab  362 , and extending past the crease line  366  and into the lower portion of the second side panel  312  provides an area  372  for the application of a name plate, product identification information, advertising or other indicia to be applied to the carton cap  300 , while allowing the name plate or other indicia to remain flush relative to the dual thickness packaging material of the front panel  306 . 
     Continuing onto the opposing end of the second side panel  312 , the second locking tab  364  is similarly located adjacent the rear panel  310 , and is hingedly attached to the second side panel  312  about a crease line  374 , which is a continuation of the crease line  348  that divides the center panel  304  from the rear panel  310 . As was previously described, rotation of the second side panel  312  about the crease line  360  combined with rotation of the second locking tab  364  about the crease line  374  will allow the second locking tab  364  to be positioned between the two sections  344 ,  346  of the rear panel  310 , thereby forming an approximately 90 degree angle by way of retaining the second locking tab  364  within the rear panel  310 . 
     Additionally, the first side panel includes a crumple zone crease line  376  which extends from two voids  378 , located at opposing ends of the crease line  360 , and which is configured to facilitate folding blank  302  into carton cap  300  and maintaining localized crumpling of the crumple zone crease line  376 . In the illustrated embodiment, crumple zone crease line  376  may be located in the center panel  304  approximately between 0.5 and 4.0 inches from the crease line  360  of the second side panel  312 , and approximately 1.5 inches from the second side panel  312 . 
     Turning now to  FIG. 11 , the blank  302  will be described in a folded and erected configuration to form carton cap  300 . The blank  302  is folded approximately 90 degrees around the crease lines  314 ,  330 ,  348 ,  360 . The locking tabs  332 ,  334 ,  362 ,  364  of the first and second side panels  308 ,  312  are then folded approximately 90 degrees until they engage the first sections  316 ,  344  of the front and rear panels  306 ,  310  respectively. The second sections  318 ,  346  of the front and rear panels  306 ,  310  are then folded approximately 180 degrees about their crease lines  320 ,  350 , respectively. When fully folded the tabs  326 ,  356  of the front and rear panels  306 ,  310  are received within the corresponding slots  328 ,  358 , with the locking tabs  332 ,  334 ,  362 ,  264  held securely between the two sections of the front and rear panels  306 ,  310 , respectively. In this configuration the carton cap  300  is held in a folded configuration without the need for adhesive or any other fixation means. 
     As shown in  FIG. 11 , the bottom and top caps of the appliance packaging are formed from two identical carton caps  300 . After the bottom carton cap  300  has been formed, an appliance  380  or other object may be inserted into the interior cavity formed within the bottom carton cap  300 . Corner posts  382  and or other packaging materials may also be inserted into the bottom carton cap  300 , surrounding the appliance  380 . Once all of the contents have been placed into the bottom carton cap  300 , the top carton cap  302  is placed on top of the appliance  380  and corner posts  382 . The top and bottom carton caps  302 , appliance  380 , corner posts  382  and any additional packaging material are then stretch or shrink wrapped or alternatively fixed together. 
     Once the carton cap  300  has been retained in its folded configuration described above, it may be subjected to opposing lateral forces such as those exerted by a clamp lift and previously discussed in the preceeding embodiments. When subjected to such forces, the first and second side panels  308 ,  312  may be forced inwards. In response to such inward movement of the first and second side panels  308 ,  312 , the forces applied to first and second side panels  308 ,  312  are transferred to the weakened crumple zone crease lines  340 ,  376  rather than to the upper and lower corners between front and rear panels  306 ,  310  at the top and bottom carton caps  300 . This avoids buckling at the top and bottom corners of front and rear panels  306 ,  310  and instead results in upward and downward flexing, bending, and movement at the crumple zone crease lines  308 ,  312  at the top and bottom of the carton cap  300 , namely the center panel  302 , respectively. 
     Although specific embodiments are illustrated and discussed above, it is understood that the size and shape of the carton  100 ,  200 ,  300  may vary greatly to accommodate the size and shape of the appliance or other device contained within the carton  100 ,  200 ,  300 . While the figures have illustrated carton  100 ,  200 ,  300  approximately configured to receive a conventional consumer appliance, larger or smaller cartons  100 ,  200 ,  300  are considered well within the scope of the present invention. In this regard, carton  100 ,  200 ,  300  for other home appliances, furniture, or electronics are within the scope of this invention. Similarly, any number, location, variation or combination in the multiple styles of panels and crumple zone crease lines described herein is considered within the scope of the present invention. 
     It should be understood that the invention is not limited in its application to the details of construction and arrangements of the components set forth herein. The invention is capable of other embodiments and of being practiced or carried out in various ways. Variations and modifications of the foregoing are within the scope of the present invention. It also being understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present invention. The embodiments described herein explain the best modes known for practicing the invention and will enable others skilled in the art to utilize the invention.