Abstract:
A base for supporting a component of an appliance and a method of assembling the same, is formed from a single sheet having four opposing sides and a top of the base when erected. Two of the opposing sides include inner and outer panels that are affixed to one another to maintain the base in the erected configuration, and define an internal cavity therein for receiving the appliance component. When a force is applied to the appliance, the erected base supports the component, which may be the motor of a washing machine, within the internal cavity to inhibit movement of the component.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Ser. No. 61/826,678 filed May 23, 2013, the disclosure of which is incorporated herein in its entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to a lower shipping support for an appliance such as a washing machine and, more particularly a one-piece lower support for supporting internal components of a washing machine to inhibit movement of the components during transportation and storage. 
     BACKGROUND OF THE INVENTION 
     Conventional top-loading washing machines include a cylindrical tub that is located within an exterior housing. The motor which provides rotational movement for the tub is suspended within the housing, and is positioned below or underneath the tub and elevated above the surface on which the washing machine rests. This configuration is advantageous in that it allows for the motor to drive both the motion of a central agitator and a perforated basket, both of which are located within the cylindrical tub. However, the suspended motor configuration exposes the motor to the potential for impact damage from either contact with the tub or housing during shipment of the washing machine. 
     Providing a lower support that extends upwards into the washing machine housing and inhibits movement of the motor during shipment and storage of the washing machine decreases this potential for impact damage to the motor. However, such lower supports or shipping bases are often formed of multiple pieces or blanks of corrugated board that are folded and/or adhesively retained in the desired shape. This multiple piece construction is time consuming, expensive to manufacture, and introduces increased potential for inaccurate assembly. In the context of large scale manufacturing and shipment of washing machines, the additional steps required to combine multiple pieces to construct a lower support or shipping base constitutes a significant overhead cost and investment of time. 
     The present invention solves the aforementioned drawbacks by providing a lower support that is formed from a single piece or blank of packaging material, which can easily and accurately be assembled into the desired lower support shape by means of folding and adhesive bonding. The present invention provides a lower support that is particularly well suited for use in shipping washing machines, but may also be beneficial for other shipping and distribution needs, including the shipment of appliances that require internal component support. 
     SUMMARY OF THE INVENTION 
     The present invention provides a base or lower support for receiving and supporting an appliance or a component of an appliance, formed of a single blank or sheet. The sheet includes a first side and an opposing second side, each of which have an outer panel and an inner panel that are configured to be affixed in an overlapping position to maintain the base in an erected configuration. The sheet also includes third and forth sides located between the opposing first and second sides, a top panel extending between two opposing sides of the base and a discontinuous flange about the bottom of the base. The erected base includes a cavity defined by the four sides, which is configured to receive and support a component of the appliance therein, such as a washing machine motor. This inhibits the motor from undesirably moving during shipment and storage of the washing machine. 
     The present invention further provides a plurality of supporting blocks located on the upwardly facing surfaces of the flange. The supporting blocks are configured to receive and support the appliance thereon when the component is received within the cavity. 
     The present invention further provides an irregular or nonlinear edge around the upper surface of the internal cavity of the base, which is contoured to engage the underside of the washing machine or the washing machine motor and further inhibit movement of the motor. 
     The present invention further provides a selectively disengagable top panel, configured to further engage the lower surface of the washing machine motor to further inhibit movement of the motor. 
     The present invention further provides a method of assembling a blank or sheet comprising four sides, a top panel, and a discontinuous flange into the erected base. The method includes the steps of folding the sheet&#39;s four sides into an erected configuration, affixing the outer panels of two opposing sides to their corresponding inner panels, while overlapping; and extending a discontinuous flange outwardly from a lower edge of the base. A component of an appliance, such as a washing machine, can then be inserted into an internal cavity defined by the four sides. 
     Various other features, objects and advantages of the present invention will be made apparent from the following detailed description of the drawing figures. 
    
    
     
       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 or sheet of a lower support for an appliance such as a washing machine, according to one aspect of the present invention; 
         FIG. 2A  is a perspective view of the folded lower support of  FIG. 1  showing the lower support in an erected configuration; 
         FIG. 2B  is a perspective view similar to  FIG. 2A , showing the lower support in an erected configuration including a plurality support blocks on lower flanges; 
         FIG. 3  is a partial enlarged perspective view of the folded lower support of  FIG. 1  showing the upper portion of the lower support in an erected configuration including the top panel disengaged from the side panel; 
         FIG. 4  is a partial cross sectional side view of the folded lower support of  FIG. 2B  showing the lower support in an erected configuration supporting an appliance such as a washing machine, and an internal component of the washing machine, thereon; 
         FIG. 5  is a top plan view of an unfolded blank or sheet of a lower support for an appliance such as a washing machine, according to a first alternative embodiment of the present invention; 
         FIG. 6  is a perspective view of the folded lower support of  FIG. 5  showing the lower support in an erected configuration; 
         FIG. 7  is a top plan view of an unfolded blank of a lower support for an appliance such as a washing machine, according to a second alternative embodiment of the present invention; and 
         FIG. 8  is a perspective view of the folded lower support of  FIG. 7  showing the lower support in an erected configuration. 
     
    
    
     DETAILED DESCRIPTION 
     I. Embodiment One 
     Referring initially to  FIGS. 1-4 , there is shown a base or lower support  10  according to a first embodiment of the present invention. The lower support  10  generally is made of a sheet or blank  12  of packaging material. The packaging material may consist of corrugated board, cardboard, plastic or any similar material suitable for use in shipping container construction. Representatively, the corrugated board may consist of a fluted corrugated core located between two sheets of kraft paper or linerboard, in a manner as is known. The blank  12  may be stamped or cut from a sheet of the packaging material while in a substantially flat orientation, and subsequently folded to form the lower support  10 . The outer surface of the lower support  10  may be printed to display information such as contents details, shipping information, disassembly instructions, orientation indicia and the like. The outer surface of the lower support  10  may also contain advertising information or ornamental elements. 
       FIG. 1  illustrates the blank  12 , formed of a single piece of packaging material in a flat orientation. The blank  12  includes primarily an outer front panel  14 , an inner front panel  16 , an outer rear panel  18 , an inner rear panel  20 , a top panel  22 , a first side panel  24 , a second side panel  26 , a first side flange  28 , and a second side flange  30 . As illustrated in  FIG. 1 , the blank  12 , when in a flat orientation roughly approximates an irregular hexagonal shape with the front, rear and side panels  14 ,  16 ,  18 ,  20 ,  24 ,  26  roughly approximating irregular trapezoids. 
     The outer front panel  14  is hingedly attached to the first side panel  24  about a score line  32 , while the inner front panel  16  is hingedly attached to the second side panel  26  about a score line  34 . Similarly, on the opposing side of the blank  12 , the outer rear panel  18  is hingedly attached to second side panel  26  at a score line  36 , while the inner rear panel  20  is hingedly attached to the first side panel  24  at a score line  38 . The score lines  32  and  38  are located on opposing ends of the first side panel  24 , and the score lines  34  and  36  are located on opposing ends of the second side panel  26 . 
     The outer front panel  14  is located adjacent the inner front panel  16 , and separated therefrom by a cut line  40 . On the opposing end of the blank  12 , the outer rear panel  18  is also located adjacent the inner rear panel  20 , and separated therefrom by a cut line  42 . In this orientation the front panels  14 ,  16  are free to rotate about their score lines  32 ,  34 , respectively, while the rear panels  18 ,  20  are free to rotate about their respective score lines  36 ,  38 . 
     Still referring to  FIG. 1 , the top panel  22  is located between the first and second side panels  24 ,  26 . Top panel  22  is hingedly affixed to the first side panel  24  at a score line  44 . Score line  44  extends between the score lines  32  and  38 , and is configured to be located on the upper edge of the lower support  10 , when the lower support  10  is erected in a folded configuration. The opposing side of the top panel  22  is attached to the second side panel  26  at a perforated line  46 . Perforated line  46  extends between the score lines  34  and  36 , and is also configured to be located on the upper edge of the lower support  10 , when the lower support  10  is erected. As illustrated in  FIG. 1 , a void  48  may interrupt the perforated line  46 , and partially extend into both the top panel  22  and the second side panel  26 . 
     As illustrated in  FIG. 1 , first and second side flanges  28 ,  30  are affixed to the first and second side panels  24 ,  26 , respectively, along the edges opposite the top panel  22 . That is to say that the first side flange  28  is hingedly affixed to the first side panel  24  at a score line  50 , which is configured to be located on the lower edge of the lower support  10 , when the lower support  10  is erected. Similarly, the second side flange  30  is hingedly affixed to the second side panel  26  at a score line  52 , which is also configured to be located on the lower edge of the lower support  10 , when the lower support  10  is erected. In one embodiment, as illustrated in  FIG. 1 , the score lines  50 ,  52  may be interrupted by one or more perforation or cut lines  54  through the blank  12  of packaging material. These cut lines  54  may be linear or arched into the area of the side panels  24 ,  26 , as shown, and may provide increased flange surface area for supporting the washing machine and/or structural reinforcement to the side panels  24 ,  26 . 
     Similarly, the score lines  32 ,  34 ,  36 ,  38 , that separate the side panels  24 ,  26  from the front and rear panels  14 ,  16 ,  18 ,  20  respectively may also be interrupted by one or more perforation or cut lines  56 . As illustrated in  FIG. 1 , the cut lines  56  may have a curve, such as a sigmoidal or S-shaped curve that extends beyond the respective score line  32 ,  34 ,  36 ,  38 , and into the surrounding panel  14 ,  16 ,  18 ,  20 ,  24 ,  26 . Accordingly, when the lower support  10  is erected in a folded configuration and the panels  14 ,  16 ,  18 ,  20 ,  24 ,  26  are folded about their respective score lines  32 ,  34 ,  36 ,  38 , the cut lines  56  will result in the formation of one or more outwardly projecting tabs  58 . In the illustrated embodiment, the two outwardly projecting tabs  58  of each score line  32 ,  34 ,  36 ,  38 , engage one another when the lower support  10  is erected to provide structural reinforcement. However, other shapes of the cut lines  56  and tabs  58  are considered well within the scope of the invention. 
     Additionally, the front and rear panels  14 ,  16 ,  18 ,  20  may include one or more voids as is illustrated in  FIG. 1 . Specifically, the panels  14 ,  16 ,  18 ,  20  may include one or more lower voids  60  and/or one or more upper voids  62 . As illustrated in  FIG. 1 , the outer front and rear panels  14 ,  18  may each include two lower voids  60 , while the inner front and rear panels  16 ,  20  may each include one lower void  60 . When the lower support  10  is erected, the one lower void  60  of the inner front and rear panels  16 ,  20  will overlap or correspond with the one lower void  60  on the respective outer front and rear panels  14 ,  18  that is located nearest the cut line  40 ,  42 . These lower voids  60  may provide structural reinforcement to the panels  14 ,  16 ,  18 ,  20 , allow the lower support  10  to integrate with the remaining portions of the shipping container, allow the lower support  10  to engage other shipping containers when stacked, and/or allow the lower support to be maneuvered by either a person or a mechanical lift. 
     Furthermore, as illustrated in  FIG. 1 , the upper voids  62  are located along the upper edges of the front and rear panels  14 ,  16 ,  18 ,  20 . The upper voids  62  are configured to accommodate and engage the motor or other components of the washing machine, once the lower support  10  has been erected. Accordingly, the number, shape and orientation of the upper voids  62  may vary depending on the configuration of the motor or other components of the washing machine or appliance. As specifically illustrated in  FIG. 1 , the upper void  62  of outer front panel  14  is approximately centrally located along the upper edge of the outer front panel  14 , and extends downwardly therefrom. The upper void  62  of the inner front panel  16  extends across a portion of the upper edge of the inner front panel  16 , and is configured to overlap or correspond with the upper void  62  of outer front panel  14 , when the lower support  10  is erected. Alternatively, the upper void  62  of the outer rear panel  18  may be offset along the upper edge of the outer rear panel  18 , such that it is disposed adjacent the score line  36 . The corresponding upper void  62  of the inner rear panel  20  is therefore reduced to a curved corner near cut line  42  along a portion of the upper edge of the inner rear panel  20 , which is configured to overlap with the upper void  62  of outer rear panel  18 , when the lower support  10  is erected. 
     Turning now to  FIG. 2A , the blank  12  will be described in a folded and erected configuration to form lower support  10 . The blank  12  is folded approximately 90 degrees around the score lines  32 ,  34 ,  36 ,  38  until the inner and outer front panels  14 ,  16  and inner and outer rear panels  18 ,  20  overlap such that their respective upper and lower voids  60 ,  62  also overlap. The blank  12  is then retained in this folded configuration by means of applying adhesive between the inner and outer front panels  14 ,  16  and inner and outer rear panels  18 ,  20 . Alternatively, the front panels  14 ,  16  and rear panels  18 ,  20  may be retained in their folded configuration by means of fasteners, adhesive tape or any other known means of fixation. The side flanges  28 ,  30  are then folded outwardly around score lines  50 ,  52  respectively to form a base of support on which the lower support  10  rests. Once the side flanges  28 ,  30  have been folded, support blocks  64  may be placed on or fixed to the upper surface of the side flanges  28 ,  30 , as illustrated in  FIG. 2B . The support blocks  64  are configured to receive the housing of the washing machine or other appliance, either directly or indirectly thereon, and may be formed of a resilient or shock absorbent material such as foam. The upper surface of the blocks  64  may be flat as illustrated in  FIG. 2B , or they may be contoured to engage a portion of the washing machine or its housing therein. 
     Turning now to  FIG. 3 , once the lower support  10  has been retained in its folded configuration described above, the top panel  22  may be disengaged from the second side panel  26  to form an access to an interior cavity  66 . The top panel  22  may be disengaged from the second side panel by rupturing the perforated line  46 . Rupturing the perforated line  46  may be accomplished by grasping the top panel  22  through void  48  and pushing or pulling thereon, or alternatively placing the washing machine on top of the lower support  10  and allowing the weight of the machine or its internal component to rupture the perforated line  46 . Once the perforated line  46  has been ruptured, the top panel  22  will rotate about the score line  44  into the interior cavity  66 . The interior cavity  66  will have an irregular upper edge  68 , defined in part by score line  44  on the first side panel, perforated line  46  on the second side panel, and the upper voids  62  on the front and rear panels  14 ,  16 ,  18 ,  20 . In this folded or erected configuration, the weight of the washing machine or other applicance is supported by the side flanges  28 ,  30  and the motor or other internal components of the washing machine will be retained within the interior cavity  66  and rest along the irregular upper edge  68 , as shown in  FIG. 4 . In this manner, the base or lower support  10  is itself clamped between the appliance and the lower wall of the outer carton within, which the appliance is placed, and the truncated pyramid shape defined by the panels  14 ,  18 ,  24  and  26  extends upwardly into engagement with the bottom of the appliance component, such as the washing machine tub, while suspending an appliance component therebelow, such as a motor, within its interior thereby inhibiting movement of these components and preventing impact damage during shipment. 
     II. Embodiment Two 
     Turning now to  FIGS. 5 and 6  and initially  FIG. 5 , there is shown a base or lower support  100  according to a first alternative embodiment the present invention. The lower support  100  generally is made of a sheet or blank  102  of packaging material. As with the prior embodiment, the packaging material may consist of corrugated board having a fluted corrugated core located between two sheets of kraft paper or linerboard, cardboard, or any similar material suitable for use in shipping container construction. 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 erected lower support  100  illustrated in  FIG. 6 . The outer surface of the lower support  100  may be printed to display information such as contents details, shipping information, disassembly instructions, orientation indicia and the like. The outer surface of the lower support  100  may also contain advertising information or ornamental elements. 
       FIG. 5  illustrates the blank  102 , formed of a single piece of packaging material in a flat orientation. The blank  102  includes primarily a front panel  104 , a rear panel  106 , an outer first side panel  108 , an inner first side panel  110 , an outer second side panel  112 , an inner second side panel  114 , a top  116 , a first side flange  118 , and a second side flange  120 . As illustrated in  FIG. 5 , the blank  102 , when in a flat orientation roughly approximates an irregular hexagonal shape with the front, rear and side panels  104 ,  106 ,  108 ,  110 ,  112 ,  114 ,  116  roughly approximating irregular trapezoids. 
     The front panel  104  is hingedly attached to the outer first side panel  108  about a score line  122 , while the inner first side panel  110  is hingedly attached to the rear panel  106  about a score line  124 . Similarly, on the opposing side of the blank  102 , the rear panel  106  is hingedly attached to the outer second side panel  112  at a score line  126 , while the inner second side panel  114  is hingedly attached to the front panel  106  at a score line  128 . The score lines  122  and  128  are located on opposing ends of the front panel  104 , and the score lines  124  and  126  are located on opposing ends of the rear panel  106 . 
     The outer first side panel  108  is located adjacent the inner first side panel  110 , and separated therefrom by cut line  130 . On the opposing end of the blank  102 , the outer second side panel  112  is also located adjacent the inner second side panel  114 , and separated therefrom by cut line  132 . In this orientation the first side panels  108 ,  110  are free to rotate about their score lines  122 ,  124 , respectively, while the second side panels  112 ,  114  are free to rotate about their respective score lines  126 ,  128 . 
     Still referring to  FIG. 5 , the top panel  116  is located between the front and rear panels  104 ,  106 . Top panel  116  is hingedly affixed to the rear panel  106  at a score line  134 . Score line  134  extends between the score lines  124  and  136 , and is configured to be located on the upper edge of the lower support  100 , when the lower support  100  is erected in a folded configuration. The opposing side of the top panel  116  is attached to the front panel  104  at a perforated line  136 . Perforated line  136  extends between the score lines  122  and  128 , and is also configured to be located on the upper edge of the lower support  100 , when the lower support  100  is erected. As illustrated in  FIG. 5 , a void  138  may interrupt the perforated line  136 , and partially extend into the top panel  116 . 
     As illustrated in  FIG. 5 , first and second side flanges  118 ,  120  are affixed to the outer first and second side panels  108 ,  112 , respectively, along the edges opposite the top panel  116 . That is to say that the first side flange  118  is hingedly affixed to the outer first side panel  108  at a score line  140 , which is configured to be located on the lower edge of the lower support  100 , when the lower support  100  is erected. Similarly, the second side flange  120  is hingedly affixed to the outer second side panel  112  at a score line  142 , which is also configured to be located on the lower edge of the lower support  100 , when the lower support  100  is erected. In one embodiment, as illustrated in  FIG. 5 , the score lines  140 ,  142  may be interrupted by one or more perforation or cut lines  144  through the blank  102  of packaging material. These cut lines  144  may be linear or arched into the area of the outer first and second side panels  108 ,  112 , as shown, and may provide increased flange surface area for supporting the washing machine and/or structural reinforcement to the outer first and second side panels  108 ,  112 . 
     Similarly, the score lines  122 ,  124 ,  126 ,  128 , that separate the side panels  108 ,  110 ,  112 ,  114  from the front and rear panels  104 ,  106  respectively may also be interrupted by one or more perforation or cut lines  146 . As illustrated in  FIG. 5 , the cut lines  146  may have a curve, such as a sigmoidal or S-shaped curve that extends beyond the respective score line  122 ,  124 ,  126 ,  128 , and into the surrounding panel  104 ,  106 ,  108 ,  110 ,  112 ,  114 . Accordingly, when the lower support  100  is erected in a folded configuration and the panels  104 ,  106 ,  108 ,  110 ,  112 ,  114  are folded about their respective score lines  122 ,  124 ,  126 ,  128 , the cut lines  146  will result in the formation of one or more outwardly projecting tabs  148 . In the illustrated embodiment, the two outwardly projecting tabs  148  of each score line  122 ,  124 ,  126 ,  128 , engage one another when the lower support  100  is erected to provide structural reinforcement. However, other shapes of the cut lines  146  and tabs  148  are considered well within the scope of the invention. 
     Additionally, the front and rear panels  104 ,  106  may include one or more voids as are illustrated in  FIG. 5 . Specifically, the panels  104 ,  106  may include one or more lower voids  150  and/or one or more upper voids  152 . These lower voids  150  may provide structural reinforcement to the panels  104 ,  106 , allowing the lower support  100  to integrate with the remaining portions of the shipping container, allow the lower support  100  to engage other shipping containers when stacked, and/or allow the lower support to be maneuvered by either a person or a mechanical lift. 
     Furthermore, as illustrated in  FIG. 5 , the upper voids  152  are located along the upper edges of the inner and outer first and second side panels  108 ,  110 ,  112 ,  114 . The upper voids  152  are configured to accommodate and engage the motor or other components of the washing machine, once the lower support  100  has been erected. Accordingly, the number, shape and orientation of the upper voids  152  may vary depending on the configuration of the motor or other components of the washing machine or appliance. As specifically illustrated in  FIG. 5 , the outer first and second panels  108 ,  112  may each include one upper void  152 , while the inner first and second side panels  110 ,  114  may also include one upper void  152 . The upper void  152  of the outer first side panel  108  extends across a portion of the upper edge of the outer first side panel  108 , while alternatively, the upper void  152  of the inner first side panel  110  may be offset along the upper edge of the inner first side panel  110 , such that it is disposed adjacent the cut line  130 . The corresponding upper void  152  of the inner first side panel  112  is therefore reduced to a curved corner near cut line  130  along a portion of the upper edge of the inner first side panel  110 . Similarly, The upper void  152  of the outer second side panel  112  extends across a portion of the upper edge of the outer second side panel  112 , while alternatively, the upper void  152  of the inner second side panel  114  may be offset along the upper edge of the inner second side panel  112 , such that it is disposed adjacent the cut line  132 . The corresponding upper void  152  of the inner second side panel  114  is therefore reduced to a curved corner near cut line  132  along a portion of the upper edge of the inner first side panel  110 . 
     Turning now to  FIG. 6 , the blank  102  will be described in a folded and erected configuration to form lower support  100 . The blank  102  is folded approximately 90 degrees around the score lines  122 ,  124 ,  126 ,  128 , until the inner and outer first side panels  108 ,  1110  and inner and outer second side panels  112 ,  114  overlap such that their respective upper voids  152  also overlap. The blank  102  is then retained in this folded configuration by means of applying adhesive between the inner and outer first side panels  108 ,  110  and inner and outer second side panels  112 ,  124 . Alternatively, the firs side panels  108 ,  110  and second side panels  112 ,  114  may be retained in their folded configuration by means of fasteners, adhesive tape or any other known means of fixation. The side flanges  118 ,  120  are then folded outwardly around score lines  140 ,  142 , respectively to form a base of support on which the lower support  100  rests. Once the side flanges  118 ,  120  have been folded, support blocks  154  may be placed or fixed to the upper surface of the side flanges, as illustrated in  FIGS. 5 and 6 . The support blocks  154  are configured to receive the housing of the washing machine or other appliance, either directly or indirectly thereon, and may be formed of a resilient or shock absorbent material such as foam. The upper surface of the blocks  154  may be flat as illustrated in  FIG. 6 , or they may be contoured to engage a portion of the washing machine therein. 
     The top panel  116  may then be disengaged and the lower support  100  positioned to support the internal component(s) of an appliance such as a washing machine in the same manner as shown in  FIG. 4  and described previously. 
     III. Embodiment Three 
     Turning now to  FIGS. 7 and 8  and initially  FIG. 7 , there is shown a base or lower support  200  according to a second alternative embodiment the present invention. The lower support  200  generally is made of a sheet or blank  202  of packaging material. As with the prior embodiments, the packaging material may consist of corrugated board having a fluted corrugated core located between two sheets of kraft paper or linerboard, cardboard, or any similar material suitable for use in shipping container construction. 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 erected lower support  200  illustrated in  FIG. 8 . The outer surface of the lower support  200  may be printed to display information such as contents details, shipping information, disassembly instructions, orientation indicia and the like. The outer surface of the lower support  200  may also contain advertising information or ornamental elements. 
       FIG. 7  illustrates the blank  202 , formed of a single piece of packaging material in a flat orientation. The blank  202  includes primarily a front panel  204 , a rear panel  206 , an outer first side panel  208 , an inner first side panel  210 , an outer second side panel  212 , an inner second side panel  214 , a top  216 , a first side flange  218 , and a second side flange  220 . As illustrated in  FIG. 7 , the blank  202 , when in a flat orientation roughly approximates an irregular hexagonal shape with the front, rear and side panels  204 ,  206 ,  208 ,  210 ,  212 ,  214 ,  216  roughly approximating irregular trapezoids. 
     The front panel  204  is hingedly attached to the outer first side panel  208  about a score line  222 , while the inner first side panel  210  is hingedly attached to the rear panel  206  about a score line  224 . Similarly, on the opposing side of the blank  202 , the rear panel  206  is hingedly attached to the outer second side panel  212  at a score line  226 , while the inner second side panel  214  is hingedly attached to the front panel  206  at a score line  228 . The score lines  222  and  228  are located on opposing ends of the from panel  204 , and the score lines  224  and  226  are located on opposing ends of the rear panel  206 . 
     The outer first side panel  208  is located adjacent the inner first side panel  210 , and separated therefrom by cut line  230 . On the opposing end of the blank  202 , the outer second side panel  212  is also located adjacent the inner second side panel  214 , and separated therefrom by cut line  232 . In this orientation the first side panels  208 ,  210  are free to rotate about their respective score lines  222 ,  224 , while the second side panels  212 ,  214  are free to rotate about their respective score lines  226 ,  228 . 
     Still referring to  FIG. 7 , the top panel  216  is located between the outer first and second side panels  208 ,  212 . Top panel  116  is hingedly affixed to the outer first side panel  208  at a score line  234 . Score line  234  is extends between the score line  222  and score line  230 , and is configured to be located on the upper edge of the lower support  200 , when the lower support  200  is erected in a folded configuration. The opposing side of the top panel  116  is attached to the outer second side panel  212  at a score line  236 . Score line  236  extends between the score line  226  and 1cut line  232 , and is also configured to be located near the upper edge of the lower support  200 , when the lower support  200  is erected. 
     As illustrated in  FIG. 7 , first and second side flanges  218 ,  220  are affixed to the outer first and second side panels  208 ,  212 , respectively, along the edges opposite the top panel  216 . That is to say that the first side flange  218  is hingedly affixed to the outer first side panel  208  at a score line  238 , which is configured to be located on the lower edge of the lower support  200 , when the lower support  200  is erected. Similarly, the second side flange  220  is hingedly affixed to the outer second side panel  212  at a score line  240 , which is also configured to be located on the lower edge of the lower support  200 , when the lower support  200  is erected. In one embodiment, as illustrated in  FIG. 7 , the score lines  238 ,  240  may be interrupted by one or more perforation or cut lines  242  through the blank  202  of packaging material. These cut lines  242  may be linear or arched into the area of the outer first and second side panels  208 ,  212 , as shown, and may provide increased flange surface area for supporting the washing machine and/or structural reinforcement to the outer first and second side panels  208 ,  212 . 
     Similarly, the score lines  222 ,  224 ,  226 ,  228 , that separate the side panels  208 ,  210 ,  212 ,  214  from the front and tear panels  204 ,  206  respectively may also be interrupted by one or more perforation or cut lines  244 . As illustrated in  FIG. 7 , the cut lines  244  may have a curve, such as a sigmoidal or S-shaped curve that extends beyond the respective score line  222 ,  224 ,  226 ,  228 , and into the surrounding panel  204 ,  206 ,  208 ,  210 ,  212 ,  214 . Accordingly, when the lower support  200  is erected in a folded configuration and the panels  204 ,  206 ,  208 ,  210 ,  212 ,  214  are folded about their respective score lines  222 ,  224 ,  226 ,  228 , the cut lines  244  will result in the formation of one or more outwardly projecting tabs  246 . In the illustrated embodiment, the two outwardly projecting tabs  246  of each score line  222 ,  224 ,  226 ,  228 , engage one another when the lower support  100  is erected to provide structural reinforcement. However, other shapes of the cut lines  244  and tabs  246  are considered well within the scope of the invention. 
     Additionally, the front and rear panels  204 ,  206  may include one or more voids as is illustrated in  FIG. 7 . Specifically, the panels  204 ,  206  may include one or more lower voids  248  and/or one or more upper voids  250 . These lower voids  248  may provide structural reinforcement to the panels  204 ,  206 , allowing the lower support  200  to integrate with the remaining portions of the shipping container, allow the lower support  200  to engage other shipping containers when stacked, and/or allow the lower support to be maneuvered by either a person or a mechanical lift. 
     Furthermore, as illustrated in  FIG. 7 , the upper voids  250  are located along the upper edges of the outer and inner second side panels  212 ,  214  and the rear panel  206 . The upper voids  250  are configured to accommodate and engage the motor or other components of the washing machine, once the lower support  200  has been erected. Accordingly, the number, shape and orientation of the upper voids  250  may vary depending on the configuration of the motor or other components of the washing machine or appliance. As specifically illustrated in  FIG. 5 , the upper void  250  extends across a portion of the upper edge of the outer and inner second side panels  212 ,  214  and rear panel  206 . The corresponding upper void  250  of both the inner second side panel  214  and rear panel  206  are reduced to a corner near cut line  232  and score line  226 , respectively. 
     Turning now to  FIG. 8 , the blank  202  will be described in a folded and erected configuration to form lower support  200 . The blank  202  is folded around the score lines  222 ,  224 ,  226 ,  228 , until the inner and outer first side panels  208 ,  210  and inner and outer second side panels  212 ,  214  overlap such that their respective upper voids  250  also overlap. The blank  202  is then retained in this folded configuration by means of applying adhesive between the inner and outer first side panels  208 ,  210  and inner and outer second side panels  212 ,  224 . Alternatively, the first side panels  208 ,  210  and second side panels  212 ,  214  may be retained in their folded configuration by means of fasteners, adhesive tape or any other known means of fixation. The side flanges  218 ,  220  are then folded outwardly, approximately 90 degrees around score lines  238 ,  240 , respectively to form a base of support on which the lower support  200  rests. Once the side flanges  218 ,  220  have been folded, support blocks  252  may be placed or fixed to the upper surface of the side flanges, as illustrated in  FIGS. 7 and 8 . The support blocks  252  are configured to receive the housing of the washing machine or other appliance, either directly or indirectly thereon, and may be formed of a resilient or shock absorbent material such as foam. The upper surface of the blocks  252  may be flat as illustrated in  FIG. 8 , or they may be contoured to engage a portion of the washing machine therein. 
     The lower support  200  is then positioned to support the internal component(s) of an appliance such as a washing machine in the same manner as shown in  FIG. 4  and described previously. 
     Although specific embodiments are illustrated and discussed above, it is understood that the size and shape of the lower support  10 ,  100 ,  200  may vary greatly to accommodate the size and shape of the washing machine or other device requiring a lower support  10 ,  100 ,  200 . While the figures have illustrated lower support  10 ,  100 ,  200  configured to support the internal components of a conventional top-load washing machine, larger or smaller lower supports  10 ,  100 ,  200  are considered well within the scope of this invention. In this regard, lower supports  10 ,  100 ,  200  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 voids 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.