Abstract:
A unitary blank of foldable material for forming a carton for containing an object during transport and storage, the blank having: a back panel, first side panel, a front panel, a second side panel, a lid, four bottom tabs, two one-piece support flaps, and two split support flaps. The two on-piece support flaps and two split support flaps form an internal support structure in the bottom of the carton formed by folding the unitary blank. Objects or small appliances positioned within the carton are secured in such a manner as to provide additional support and drop protection to the object or appliance. The carton is folded in such a way so as to add structural integrity to the final carton by the use of stabilizing flaps and an internal support structure. The carton is also designed so as to minimize the material used.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    This invention relates to folding cartons and blanks therefor, and more particularly to cartons for containing items for transport, storage, and display. More specifically, the present invention relates to a recloseable cardboard carton for shipping and storage of a small appliance such as an iron for ironing fabric, clothes and the like.  
           [0002]    The traditional method for shipping is to position objects within the shipping carton in a manner so as to be easily removed. The cartons are typically formed so as to minimize cost resulting in cartons that do not reseal in an effective manner and that lack structural integrity. In order to manufacture such cartons by automation, it is desirable to form these cartons out of a single sheet of material, called a blank, by successively folding the various sides to create the carton.  
           [0003]    The use of foldable cardboard and paperboard for shipment and storage is well known. Similarly, the use of boxes with folding flaps for reusability is also well known and is disclosed in U.S. Pat. Nos. 2,337,039; 2,713,965; and 3,770,187.  
           [0004]    A problem associated with these cartons is that the object within the carton can be damaged during shipping and handling from manufacturing to the retail display store and even on the floor of the display store due to minimization of materials and therefore the sacrificed structural integrity of the carton.  
           [0005]    The present invention provides a carton formed from a unitary blank wherein the carton is used for both shipping, storage, and displaying purposes. The carton is of the recloseable type to allow the object contained therein to be removed and replaced into the carton. The carton is designed with added structural integrity and drop protection by the use of an internal support structure and stabilizing flaps while still minimizing the overall amount of material used to form the carton blank. The object is wedged into the carton by the stabilizing flaps into a specific position thereby providing additional support and drop protection to the object. The internal support structure of the carton is designed to assist in wedging the object into a specific position and provides shock absorption in the event that the carton is dropped with the object in the carton.  
         BRIEF SUMMARY OF THE INVENTION  
         [0006]    Briefly stated, the present invention comprises a unitary blank of foldable material for forming a carton for containing an object during transport and storage. The blank includes a back panel having a top edge, a bottom edge, a first side edge and a second side edge. The blank also includes a first side panel having a front edge, a top edge, a bottom edge and a rear edge hingedly connected to the first side edge of the back panel. A front panel is provided having a top edge, a bottom edge, a first side edge, and a second side edge hingedly connected to said front edge of said first side panel. The blank further includes a second side panel having a top edge, a bottom edge, a front edge hingedly connected to the first side edge of the front panel and a rear edged hingedly connected to the second side edge of the back panel. A lid including a front edge and rear edge is hingedly connected to the back panel top edge. A first bottom tab has a bottom edge and a top edge which is hingedly connected to the bottom edge of the second side panel. A second bottom tab has a bottom edge, a top edge which is hingedly connected to the bottom edge of the back panel and a first support flap slit. A third bottom tab has a bottom edge and a top edge which is hingedly connected to the bottom of the first side panel. A fourth bottom tab has a bottom edge, a top edge which hingedly connected to the bottom edge of the front panel, and a second support flap slit. A first one-piece support flap is included having a top edge, a first side edge, a second side edge, and a bottom edge which is hingedly connected to the bottom edge of the second bottom tab. A second one-piece support flap incorporates a top edge, a first side edge, a second side edge, and a bottom edge which is hingedly connected to the bottom edge of said fourth bottom tab. A first split support flap is provided having a top edge, a first side edge, a second side edge and a bottom edge which is hingedly connected to the bottom edge of the first bottom tab. The first split support flap includes a slit extending between the bottom and top edges. A second split support flap has a top edge, a first side edge, a second side edge, and a bottom edge which is hingedly connected to the bottom edge of the third bottom tab. The second split support flap includes a slit extending between the bottom and top edges.  
           [0007]    Briefly stated, the present invention is also directed to a carton formed from a unitary blank of foldable material for containing an object during transport and storage. The carton includes a parallelopiped having opposing first and second end walls, opposing front and back panels, and opposing first and second side panels. An internal support structure extends inwardly from an inside surface of the second end wall. The internal support structure and the second end wall are formed by support flaps extending from at least two of the front, back, first side and second side panels that are folded into a configuration for wedging the object into a specific position. 
       
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS  
       [0008]    The foregoing summary, as well as the following detailed description, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, an embodiment which is presently preferred is shown in the drawings. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown.  
         [0009]    In the drawings:  
         [0010]    [0010]FIG. 1 is a top plan view of a blank for forming a carton in accordance with a preferred embodiment of the present invention;  
         [0011]    [0011]FIG. 2 is a top perspective view of a carton in accordance with a preferred embodiment of the present invention wherein the flaps have yet to be placed in the folded position;  
         [0012]    [0012]FIG. 3 is a top perspective view of the carton shown in FIG. 2 with one of the flaps in the folded position;  
         [0013]    [0013]FIG. 4 is a top perspective view of the carton shown in FIG. 2 with two of the flaps in the folded position;  
         [0014]    [0014]FIG. 5 is a top perspective view of the carton shown in FIG. 2 with three of the flaps in the folded position;  
         [0015]    [0015]FIG. 6 is a top perspective view of the carton shown in FIG. 2 with four of the flaps in the folded position;  
         [0016]    [0016]FIG. 7 is a bottom perspective view of the carton shown in FIG. 2 with the first end flaps in a folded position and the second end flaps in a partially folded position;  
         [0017]    [0017]FIG. 8 is a bottom perspective view of the carton shown in FIG. 2 with one of the second end flaps in the folded position;  
         [0018]    [0018]FIG. 9 is a bottom perspective view of the carton shown in FIG. 2 with two of the second end flaps in the folded position;  
         [0019]    [0019]FIG. 10 is a bottom perspective view of the carton shown in FIG. 2 with three of the second end flaps in the folded position;  
         [0020]    [0020]FIG. 11 is a bottom perspective view of the carton shown in FIG. 2 in an assembled form;  
         [0021]    [0021]FIG. 12 is a enlarged top perspective view of the carton shown in FIG. 2 in the assembled form;  
         [0022]    [0022]FIG. 13 is a top perspective view of the carton shown in FIG. 12, partially broken away; and  
         [0023]    [0023]FIG. 14 is a bottom perspective view of the carton shown in FIG. 11, partially broken away. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0024]    Certain terminology is used in the following description for convenience only and is not limiting. The words “right”, “left”, “lower”, and “upper” designate directions in the drawings to which reference is made. The words “inwardly” and “outwardly” refer to directions toward and away from, respectively, the geometric center of the carton, blank and designated parts thereof. The terminology includes the words above specifically mentioned, derivatives thereof and words of similar import. Additionally, the word “a” is used in the claims and in the corresponding portions of the specification, means “at least one”.  
         [0025]    Referring now to the drawings in detail, wherein like numerals indicate like elements throughout, there is shown in FIGS.  1 - 14  a preferred embodiment of a carton in accordance with the present invention shown in both blank and assembled forms.  
         [0026]    [0026]FIG. 1 illustrates a unitary, one-piece blank  10  which is used to form a carton  11  for containing an object, appliance or item (not shown, hereafter “object”) for transport and storage. In the present embodiment, it is preferred that the object to be stored within the carton  11  formed by the blank  10  be an iron for ironing fabric, clothes, or the like (not shown). However, it is understood by those of ordinary skill in the art that the present invention is not limited to any particular type of object or item to be stored within the carton  11  formed by the blank  10 .  
         [0027]    The blank  10  is preferably made of a generally continuous sheet of paperboard, cardboard, polymeric material or any other suitable material. However, it is understood by those of ordinary skill in the art from reading this disclosure, that the present invention is not limited to making the blank  10  of any particular material.  
         [0028]    The blank  10  includes a generally rectangular back panel  12  having a top edge  12   a , bottom edge  12   b , a first side edge  12   c , and a second side edge  12   d . The back panel need not be rectangular. A first generally rectangular side panel  14  has a front edge  14   a , a top edge  14   b , a bottom edge  14   c , and a rear edge  14   d . The first side panel  14  is preferably the same size and shape as the back panel  12  but need not be. The rear edge  14   d  of the side panel  14  is hingedly connected to the first side edge  12   c  of the back panel  12 . A first side stabilizing flap  16  has a top edge  16   a , a bottom edge  16   b , a rear edge  16   c , a first front edge riser  16   d , and a second front edge riser  16   e . The first side stabilizing flap  16  is hingedly connected to the top edge  14   b  of the first side panel  14 . The first and second front edge risers  16   d  and  16   e  form a staircase like edge along the front of the first stabilizing flap  16 . The distance from the rear edge  16   c  to the front edge  16   d  of the first side stabilizing flap  16  is slightly less than the corresponding width from the front edge  14   a  to the rear edge  14   d  of the first side panel  14 . Similarly, the distance from the rear edge  16   c  to the second front edge  16   e  of the first side stabilizing flap  16  is less than the corresponding width from the first front edge  16   d  to the rear edge  16   c  of the first side stabilizing flap  16 . The risers  16   d ,  16   e  are formed by removing the material of the unitary blank  10  in the area outside the staircase shaped riser combination. The first stabilizing flap  16  further comprises a tongue shaped member  16   f  along the top edge  16   a  of the first stabilizing flap  16  proximate to the rear edge  16   c  of the first side stabilizing flap  16 . The tongue shaped member  16   f  may be other shapes. The tongue shaped member  16   f  is used to provide additional stability to the carton  11  formed from the unitary blank  10  and in particular to wedge together other flaps described below and the object stored therein.  
         [0029]    As used herein, the term “hingedly connected” is used to mean, with respect to cardboard, forming a score line in the cardboard for permitting the cardboard to bend with respect to itself. In FIG. 1, score lines are represented by dashed lines. However, it is understood by those of ordinary skill in the art of this disclosure, that the present invention is not limited to forming a hinged connection between panels by forming a score line in cardboard. Perforated, partially slotted, etc., could be used without departing from the spirit and scope of the invention.  
         [0030]    The unitary blank  10  has a front panel  18  having a top edge  18   a , a bottom edge  18   b , a first side edge  18   c , and a second side edge  18   d . The front panel  18  is preferably the same size and shape as the rear panel  12 , but need not be. The second side edge  18   d  of the front panel  18  is hingedly connected to the front edge  14   a  of the first side panel  14 . A front stabilizing flap  20  has a top edge  20   a , a bottom edge  20   b , a first side edge  20   c , and a second side edge  20   d . The front stabilizing flap  20  is hingedly connected to the top edge  18   a  of the front panel  18 . The front stabilizing flap  20  further comprises a front stabilizing flap scoreline  21  proximate to and substantially parallel to the bottom edge  20   b  of the front stabilizing flap  20 . The front stabilizing flap  20  is preferably rectangular, but may be other shapes. The distance between the front stabilizing flap scoreline  21  and the bottom edge  20   b  of the front stabilizing flap  20  is generally related to the thickness of the material of construction of the unitary blank and the radius of curvature of corners formed by folding the front stabilizing flap  20  as described below. The front stabilizing flap  20  also includes a font stabilizing flap crease line  19  proximate to and substantially parallel to the top edge  20   a  of the front stabilizing flap  20 . But, the front stabilizing flap crease line  19  need not be parallel to the top edge  20   a  of the front stabilizing flap  20  and may be in other orientations on the front stabilizing flap  20 . The front stabilizing flap crease line  19  may be beneficial for folding the unitary blank  10  when forming a carton, since the front stabilizing flap may be longer than an opening formed by folding the front panel  18 , rear panel  12 , and side panels  14 ,  24  into a parallelepiped. An insert tab  22  is cut partially in the front panel  18  and partially from the front stabilizing flap  20 . The insert tab  22  has a top edge  22   a , a bottom edge  22   b , a first side edge  22   c  and a second side edge  22   b . The insert tab  22  is hingedly connected on the bottom edge  22   b  to a portion of a front panel  18 , and is formed by cutting through the material along the first side edge  22   c , the top edge  22   a , and the second side edge  22   d  of the insert tab  22 . The insert tab  22  is generally rectangular, but the insert tab  22  may be other shapes. The insert tab  22  may include chamfered or rounded corners  22   e ,  22   f  between the top edge  22   a  and the fist side edge  22   c  and between the top edge  22   a  and the second side edge  22   d  of the insert tab  22 , respectively. The corners  22   e  and  22   f  of the insert tab  22  may also be squared or other shapes. The insert tab  22  further includes an insert tab fold line  23  that traverses the insert tab  22  slightly below an imaginary line defined by the top edge  18   a  of the front panel  18 . The fold line  23  may be located in other orientations on the insert tab  22 .  
         [0031]    A second side panel  24  has a top edge  24   a , a bottom edge  24   b , a front edge  24   c  and a rear edge  24   d . The second side panel  24  is preferably the same size and shape as the first side panel  14 , but need not be. The rear edge  24   d  of the second side panel  24  is hingedly connected to the second side edge  12   d  of the back panel  12 . A second side stabilizing flap  26  has a top edge  26   a , a bottom edge  26   b , a front edge  26   c , and a rear edge  26   d . The second side stabilizing flap  26  is hingedly connected to the top edge  24   a  of the second side panel  24 . The second side stabilizing flap  26  is similar in shape and length to the front stabilizing flap  20 , but may be other shapes. The second side stabilizing flap  26  is preferably not as wide as the second side panel  24 . The second side stabilizing flap  26  further includes a first fold line  27   a  and a second fold line  27   b . The first fold line  27   a  of the second side stabilizing flap  26  traverses the second side stabilizing flap  26  from the front edge  26   c  to the rear edge  26   d , and the first fold line  27   a  is preferably proximate to and parallel to the bottom edge  26   b  of the second side stabilizing flap  26 . The first fold line  27   a  of the second side stabilizing flap  26  need not be parallel to the bottom edge  26   b  of the second side stabilizing flap  26 , and may be in other orientations and locations on the second side stabilizing flap  26 . The distance between the first fold line  27   a  of the second side stabilizing flap  26  and the bottom edge  26   b  of the first stabilizing flap is generally determined by the size and shape of the object (not shown) that may be stored in the carton  11  formed from folding the unitary blank  10 . The second fold line  27   b  of the second side stabilizing flap  26  is generally parallel to the first fold line  27   a  of the second side stabilizing flap  26 , and is located between the first fold line  27   a  and the top edge  26   a  of the second side stabilizing flap  26 . The second fold line  27   b  may be cut or creased deeper than the first fold line  27   a  of the second side stabilizing flap  26  in order to allow the second fold line  27   b  to be folded at an acute angle as described below. A chamfer or rounded corner  26   e  may be formed between the top edge  26   a  and the rear edge  26   d  of the second side stabilizing flap  26 . The corner  26   e  of the second side stabilizing flap  26  may be other shapes as well. The second side stabilizing flap  26  also has a receiving hole  56  cut from a generally central area between the first fold line  27   a , the top edge  26   a , the front edge  26   c  and the rear edge  26   d  of the second side stabilizing panel  26 . The hole  56  has a top edge  56   a , a bottom edge  56   b , a front edge  56   c , and a rear edge  56   d . The hole  56  is preferably rectangular, but need not be, and is preferably symmetrical as viewed in relation to the second fold line  27   b  of the second side stabilizing flap  26 . The hole  56  may have rounded or chamfered corners  56   e ,  56   f ,  56   g ,  56   h  between the top edge  56   a  and the front edge  56   c , the top edge  56   a  and the rear edge  56   d , the bottom edge  56   b  and the rear edge  56   d , and the bottom edge  56   b  and the front edge  56   c , respectively. The corners  56   e ,  56   f ,  56   g ,  56   h  may also be squared or other shapes. The hole  56  is generally sized based upon the size and shape of the object (not shown) to be stored in a carton  11  formed from folding the unitary blank  10 .  
         [0032]    A lid  28  includes a front edge  28   a , a rear edge  28   b , a first side edge  28   c , and a second side edge  28   d . The lid  28  is preferably the same length and shape as the front stabilizing flap  20 , but need not be. The width of the lid  28  as measured from the first side edge  28   c  to the second side edge  28   d  is slightly wider than the width of the rear panel  12  as measured from the first side edge  12   c  to the second side edge  12   d . However, the lid  28  may be other widths. The rear edge  28   b  of the lid  28  is hingedly connected to the top edge  12   a  of the back panel  12 . Chamfered or rounded corners  28   e ,  28   f  may extend between the front edge  28   a  and the first side edge  28   c  and between the front edge  28   a  and the second side edge  28   d  of the lid  28 , respectively. But, the corners  28   e ,  28   f  of the lid  28  may be squared or other shapes. The lid  28  further comprises a closing flap fold line  51  that traverses the lid  28  from the first side edge  28   c  to the second side edge  28   d  of the lid  28 . The closing flap fold line  51  is preferably parallel to and proximate to the front edge  28   a  of the lid  28 , but may be in other orientations and locations on the lid  28 . The closing flap fold line  51  is located a distance, as measured from the rear edge  28   b , approximately equivalent to the width of the first side panel  14  as measured between the front edge  14   a  and the rear edge  14   d  of the first side panel  14 . The area between the closing flap fold line  51  and the front edge  28   a  of the lid  28  defines the closing flap  50 . The lid  28  also includes a tab receiving slot  52  cut along a portion of the length of the closing flap fold line  51 . The tab receiving slot  52  is preferably symmetrical as viewed relative to the imaginary mid-point of the closing flap fold line  51 . The tab receiving slot  52  is preferably slightly wider than the insert tab  22 . In one preferred embodiment shown in FIG. 1, the tab receiving slot  52  is cut in a squared, U-shaped form extending into the closing flap  50  from the closing flap fold line  51 . The tab receiving slot  52  may be cut in other shapes and orientations.  
         [0033]    A first bottom tab  30  has a bottom edge  30   a , a top edge  30   b , a first side edge  30   c  and a second side edge  32   d . The first bottom tab  30  is preferably rectangular in shape and is at least as wide as the second side panel  24 . The first bottom tab  30  has a length slightly less than one half the width of back panel  12 . But, the first bottom tab  30  may be other shapes. The top edge  30   b  is hingedly connected to the bottom edge  24   b  of the second side panel  24 .  
         [0034]    A second bottom tab  32  has a bottom edge  32   a , a top edge  32   b , a first side edge  32   c , and a second side edge  32   d . The second bottom tab  32  is preferably rectangular in shape and has a width slightly less than the width of back panel  12 . The top edge  32   b  of the second bottom tab  32  is hingedly connected to the bottom edge  12   b  of the back panel  12 . The second bottom tab  32  further includes a first support flap slit  34  proximate to the imaginary midpoint of the bottom edge  32   a  of the second bottom tab  32 . The first support flap slit  34  extends from the bottom edge  32   a  of the second bottom tab  32 , but does not completely traverse the second bottom tab  32 . The first support flap slit  34  may be a single cut in the second bottom tab  32 , but the first support flap slit  34  is preferably a rectangular shaped hole with a width slightly larger than twice the thickness of the material of the unitary blank  10 .  
         [0035]    A third bottom tab  36  has a bottom edge  36   a , a top edge  36   b , a first side edge  36   c , and a second side edge  36   d . The third bottom tab  36  is preferably similar in size and shape to the first bottom tab  30 , but need not be. The top edge  36   b  of the third bottom tab  36  is hingedly connected to the bottom edge  14   c  of the first side panel  14 .  
         [0036]    A fourth bottom tab  38  has a bottom edge  38   a , a top edge  38   b , a first side edge  38   c , and a second side edge  38   d . The fourth bottom tab  38  is preferably the same size and shape as the second bottom tab  32 , but may be other sizes and shapes. The top edge  38   b  of the fourth bottom tab  38  is hingedly connected to the bottom edge  18   b  of the front panel  18 . The fourth bottom tab  38  further includes a second support flap slit  40  proximate to the imaginary midpoint of the bottom edge  38   a  of the fourth bottom tab  38 . The second support flap slit  40  extends from the bottom edge  38   a  of the fourth bottom tab  38 , but does not completely traverse the fourth bottom tab  38 . The second support flap slit  40  may be a single cut in the fourth bottom tab  38 , but the second support flap slit  40  is preferably a rectangular shaped hole with a width slightly larger than twice the thickness of the material of the unitary blank  10 . The second support flap slit  40  is preferably the same size and shape as the first support flap slit  34 , but the support flap slits  34 ,  40  may be different shapes without diverging from the present invention.  
         [0037]    A first one-piece support flap  42  has a top edge  42   a , a first side edge  42   b , a second side edge  42   c , and a bottom edge  42   d . The bottom edge  42   d  of the first one-piece support flap  42  is hingedly connected to the bottom edge  32   a  of the second bottom tab  32 . A second one-piece support flap  44  has a top edge  44   a , a first side edge  44   b , a second side edge  44   c , and a bottom edge  44   d . The bottom edge  44   d  of the second one-piece support flap  44  is hingedly connected to the bottom edge  38   a  of the fourth bottom tab  38 . The one-piece support flaps  42 ,  44  may be almost as wide as the bottom tabs  36 ,  38 . The first side edge  42   b ,  44   b  of each one-piece support flap  42 ,  44  extends at an acute angle with respect to each bottom edge  42   d ,  44   d .  
         [0038]    A first split support flap  46  has a top edge  46   a , a first side edge  46   b , a second side edge  46   c  and a bottom edge  46   d . The bottom edge  46   d  of the first split support flap  46  is hingedly connected to the bottom edge  30   a  of the first bottom tab  30 . The first split support flap  46  also has a slit extending between the bottom edge  46   d  and top edge  46   a  at approximately the imaginary midpoint of the bottom edge  46   d  of the first split support flap  46 . The slit in the first split support flap  46  may merely be a cut in the material, but the slit in the first split support flap  46  is preferably a rectangular portion of material removed from the first split support flap  46  that is symmetrical about an imaginary line dividing the first split support flap  46  into equal portions between the first side edge  46   b  and the second side edge  46   c  of the first split support flap  46 . The first split support flap  46  further comprises symmetrical notches at the end of the slit in the first split support flap  46  proximate to the top edge  46   a  of the first split support flap  46 .  
         [0039]    A second split support flap  48  has a top edge  48   a , a first side edge  48   b , a second side edge  48   c  and a bottom edge  48   d . The bottom edge  48   d  of the second split support flap  48  is hingedly connected to the bottom edge  36   a  of the third bottom tab  36 . The second split support flap  48  includes a slit extending between the bottom edge  48   d  and top edge  48   a  at approximately the imaginary midpoint of the bottom edge  48   d  of the second split support flap  48 . The slit in the second split support flap  48  may merely be a cut in the material, but the slit in the second split support flap  48  is preferably a rectangular portion of material removed from the second split support flap  48  that is symmetrical about an imaginary line dividing the second split support flap  48  into equal portions between the first side edge  48   b  and the second side edge  48   c  of the second split support flap  48 . The second split support flap  48  further comprises symmetrical notches at the end of the slit in the second split support flap  48  proximate to the top edge  48   a  of the second split support flap  48 . The second split support flap  48  is preferably split in a similar manner to the first split support flap  46 , but need not be. The top edges  46   a ,  48   a  of the split support flaps  46 ,  48  have a first rounded corner extending between the first side edge  46   b ,  48   b  and the top edge  46   a ,  48   a , and a second rounded corner extending between the second side edge  46   c ,  48   c  and the top edge  46   a ,  48   a . The first split support flap  46  may have a generally narrow portion of material removed from the area between the bottom edge  46   d  and the top edge  46   a  proximate the second side edge  46   b  of the first split support flap  46  such that there is a distinct gap between the second side edge  46   b  of the first split support flap  46  and the second side edge  42   c  of the first one-piece support flap  42 . The second split support flap  48  may have a generally narrow portion of material removed from the area between the bottom edge  48   d  and the top edge  48   a  proximate the first side edge  48   b  and the second side edge  48   c  of the second split support flap  48 , such that the width of the second split support flap  48  as measured between the first side edge  48   b  and the second side edge  48   c  of the second split support flap is slightly less than the width of the third bottom tab  36  as measured between the first side edge  36   c  and the second side edge  36   d  of the third bottom tab  36 .  
         [0040]    The unitary blank  10  of foldable material has a size in the range of 2.75-3.25 square feet. The foldable material may be cardboard, paperboard, polymeric material or the like. The material is preferably between about 0.5 mm and 4 mm thick. The material is preferably corrugated cardboard, but may be any corrugated, single layered, multi-layered, or double walled material, or the like.  
         [0041]    A glue flap  54  has a top edge  54   a , a first side edge  54   b , a second side edge  54   c , and a bottom edge  54   d . The second side edge  54   b  of the glue flap  54  may be hingedly connected to the first side edge  18   c  of the front panel  18 . The top edge  54   a  preferably extends at a slight angle from the second side edge  54   c  to the first side edge  54   b  of the glue flap  54 . The bottom edge  54   d  preferably extends at a slight angle from the second side edge  54   c  to the first side edge  54   b  of the glue flap  54 . The glue flap  54  is then preferably a symmetrically shaped trapezoid with the first side edge  54   b  being shorter than the second side edge  54   c  of the glue flap  54 . But, the glue flap  54  may be rectangular or other shapes. The glue flap  54 , as described in greater detail below, is for applying an adhesive or other mechanisms of attachment to join the glue flap  54  to the inside surface of the second side panel  24  when folding the unitary blank  10  into the carton  11 .  
         [0042]    FIGS.  2 - 11  show a preferred series of steps used to form the carton  11  from the unitary blank  10 , as shown completed in FIG. 12. The second side panel  24  is folded along the score line located at the rear edge  24   d , to a position perpendicular to the back panel  12 . The first side panel  14  is folded along a score line located at the rear edge  14   d  of the first side panel  14  to a position perpendicular to the back panel  12  and parallel to the folded position of the second side panel  24 . The front panel  18  is folded along a score line located at the second side edge  18   d  to a position perpendicular to the first side panel  14  and parallel to the back panel  12 . The glue flap  54  is folded along a score line located at the second side edge  54   c  to a position perpendicular to the front panel  18 . In the preferred embodiment, the glue flap  54  is positioned within the carton  11  for cosmetic purposes and is attached proximate to the front edge  24   c  of the second side panel  24  with an adhesive such as liquid glue formed from a chemical solvent mixture. However, it would be appreciated by those skilled in the art that other means, such as staples or other mechanical fasteners, tape or some other type of adhesive, may be used for joining the glue flap  54  to the second side panel  24 .  
         [0043]    As shown in FIG. 3, the front stabilizing flap  20  is folded along the top edge  18   a  of the front panel  18  and front stabilizing flap score line  21  so that it is substantially parallel with the front panel  18  and is located inside the carton  11 . It may be necessary to slightly bend the front stabilizing flap  20  along crease line  19  in order to maneuver the front stabilizing flap  20  into the carton  11 . The insert tab  22  is folded along the bottom edge  22   b  of the insert tab  22  so that the insert tab  22  is perpendicular to the front panel  18 . The insert tab  22  is folded again along the insert tab score line  23  so that the area of the insert tab  22  between the top edge  22   a  of the insert tab  22  and the insert tab score line  23  is parallel to the front panel  18 . The first side stabilizing flap  16  is folded along the first side stabilizing flap score line  17  such that the area between the first side stabilizing flap score line  17  and the top edge  16   a  of the first side stabilizing flap  16  is perpendicular to the remaining area of the first side stabilizing flap  16 . The second side stabilizing flap  26  is folded along the first fold line  27   a  so that the area of the second side stabilizing flap  26  between the first fold line  27   a  and the top edge  26   a  of the second side stabilizing flap  26  is at an obtuse angle to the remaining portion of the second side stabilizing flap  26 . The second side stabilizing flap  26  is then folded along the second fold line  27   b  at an acute angle away from the inside of the carton  11 .  
         [0044]    As shown in FIG. 4, the second side stabilizing flap  26  is folded along a score line located at the top edge  24   a  of the second side panel  24  to a position perpendicular with the second side panel  24  such that the area of the second side stabilizing flap  26  between the first fold line  27   a  and the top edge  26   a  of the second side stabilizing flap  26  is substantially inside carton  11 . The second side stabilizing flap  26  may again be adjusted by creasing along the first and second score lines  27   a ,  27   b  in order to accommodate an object that may be stored inside the carton  11  as necessary.  
         [0045]    As shown in FIG. 5, the first side stabilizing flap  16  is folded along a score line located at the tope edge  14   b  of the first side panel  14  such that it is perpendicular with the first side panel  14  such that the area of the first side stabilizing flap  16  between the first side stabilizing flap score line  17  and the top edge  16   a  of the first side stabilizing flap  16  is substantially inside the carton  11 . The first side stabilizing flap may be further adjusted by creasing along score line  17  in order to support the second side stabilizing flap  26  and the object inside the carton  11  more tightly.  
         [0046]    As shown in FIG. 6, the lid  28  is folded along a score line located at the rear edge  28   b  to a position perpendicular to the back panel  12 . The closing flap  50  is folded along a score line located at the front edge  28   a  of the lid  28  to a position perpendicular to the lid  28  and parallel to the front panel  18 , and the closing flap  50  is then positioned within the carton  11  substantially adjacent to the front panel  18 . The top edge  22   a  of the insert tab  22  is then inserted into the tab receiving slot  52  until the portion of the insert tab between the insert tab fold line  23  and the bottom edge  22   b  of the insert tab  22  is flush with the front panel  18 . The insert tab  22  and the tab receiving slot  52  form a locking mechanism which keeps the lid  28  from lifting.  
         [0047]    As shown in FIG. 7, the second one-piece support flap  44  if folded along a score line located at the bottom edge  44   d  of the second one-piece support flap  44  to a position perpendicular with the fourth bottom tab  38 .  
         [0048]    As shown in FIG. 8, fourth bottom tab  38  is folded along a score line located at the top edge  38   b  of the fourth bottom tab  38  such that the fourth bottom tab  38  is perpendicular to the front panel  18  and the second one-piece support flap  44  is substantially inside the carton  11  and parallel to the front panel  18 . The first one-piece support tab  42  is folded along a score line located at the bottom edge  42   d  of the first one-piece support tab  42  such that the first one-piece support tab  42  is perpendicular to the second bottom tab  32 .  
         [0049]    As shown in FIG. 9, the second bottom tab  32  is folded along a score line located at the top edge  32   b  of the second bottom tab  32  to a position perpendicular with the back panel  12  and wherein the first one-piece support flap  42  is located substantially within the carton  11  and is parallel to the back panel  12 . Thus, the second one-piece support flap  44  is preferably substantially adjacent to the first one-piece support flap  42  inside the carton  11 . The second split support flap  48  is folded along a score line located at the bottom edge  48   d  of the second split support flap  48  such that the second split support flap  48  is perpendicular to the third bottom tab  36 .  
         [0050]    As shown in FIG. 10, the third bottom tab  36  is folded along a score line located at the top edge  36   b  to a position perpendicular with the first side panel  14  wherein the second split support flap  48  slides into the first and second support flap slits  34 ,  40 . The first split support flap  46  is folded along a score line located at the bottom edge  46   d  of the first split support flap  46  to a position perpendicular with the first bottom tab  30 .  
         [0051]    As shown in FIG. 11, the first bottom tab  30  is folded along a score line located at the top edge  30   b  of the first bottom tab  30  to a position perpendicular to the second side panel  24  wherein the first split support flap  46  slides into the first and second support flap slits  34 ,  40 . Thus, the first split support flap  46  is substantially adjacent to the second split support flap  48  inside the carton  11 , and the split support flaps  46 ,  48  are bisected by the one-piece support flaps  42 ,  44 . The resultant cross structure formed from the split support flaps  46 ,  48  and the one-piece support flaps  42 ,  44  is shown in FIG. 13. The cross structure is configured for wedging an object (not shown) into a specific position within the carton  11 . One leg of the cross formed by the first side edge  42   b  of the first one-piece support flap  42  and the first side edge  44   b  of the second one-piece support flap  44  is angled in order to support the object (not shown) which has a similar but opposite angled shape, such as the nose of an iron for ironing fabric, clothes, and the like.  
         [0052]    Referring to FIG. 12, in use, the carton  11  is formed from the blank  10 , as described above. In the illustrated embodiment, the object (not shown) is positioned within the carton  11  in a fashion which is conducive to shipping and handling.  
         [0053]    As shown in FIG. 14, the front stabilizing flap  20  extends into the carton  11  and is adjacent to the front panel  18  in order to provide additional support and drop protection to the object or appliance in the carton  11 . The second side stabilizing flap  26  also extends into the carton  11  and is folded into a configuration for wedging the object into a specific position and for adding structural integrity to the carton  11  thereby providing additional drop protection for the object within the carton  11 . The hole  56  in the second side stabilizing flap  26  may accommodate a portion of the object while providing equal support on opposite sides of a less than rectangular object within the carton  11 . The first side stabilizing flap  16  also extends into the carton  11  and is folded into a configuration for wedging the second side stabilizing flap  26  into a specific position and adds structural integrity to the carton  11  thereby providing additional drop protection to the object or appliance stored within the carton  11 . The tongue shaped member  16   f  engages the second side support flap  26  along the second fold line  27   b  of the second side support flap  26  increasing the contact of the second side stabilizing flap  26  with the object within the carton  11 .  
         [0054]    It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims.