Abstract: A method of manufacturing a modular box assembly comprises constructing an insulation batt by combining thermoplastic binder fibers and reinforcement fibers in a fibrous web and heating the batt to a temperature exceeding a glass transition temperature of the thermoplastic binder fibers and melting of the thermoplastic binder fibers. Pre-laminated material is constructed by attaching a first sheet in facing contact with the insulation batt and attaching a second sheet in facing contact with the insulation batt opposite the first sheet. The pre-laminated material is cut to size to define first and second laminated members. Portions of the laminated member are folded to form first and second thermal liners. The first and second thermal liners are positioned in a box cavity defined by a box such that the first thermal liner and the second thermal liner together form an insulated cavity within the box cavity.

Abstract: A method of using a dual use box, the method comprising obtaining a dual use box that is configurable into a primary closed configuration and a secondary closed configuration, the dual use box comprising a first primary top panel defining a primary overlapping portion and a primary delivery address label; and a second primary top panel defining a primary underlying portion; and configuring the dual use box into the primary closed configuration by folding the primary overlapping portion over the primary underlying portion such that the primary delivery address label is visible.

Abstract: A blank includes an inner sheet having at least a base layer having a first side and a second side opposite the first side, the inner sheet including a film coupled to the first side of the base layer, and an outer sheet coupled to the second side of the base layer by an adhesive deposited between the outer sheet and the base layer such that a plurality of voids are formed between the outer sheet and the inner sheet, wherein the blank is configured to be folded into a multi-ply bag such that the film defines the inner cavity of the multi-ply bag.

Abstract: An insulated box assembly comprising an outer box comprising a plurality of outer lateral sidewalls, the outer lateral sidewalls defining an inner surface, the inner surface defining an inner cavity; an inner box comprising a plurality of inner lateral sidewalls, the inner box received in the inner cavity, the inner lateral sidewalls defining an outer surface, a storage hollow configured to receive contents therein, and a top end defining a top opening of the storage hollow; and a lid assembly positioned within the inner cavity, the lid assembly comprising a lid box defining an interior cavity.

Abstract: A packaging assembly comprising an insulation wrap comprising a top ledge defining a top opening of an insulated cavity defined by the insulation wrap; and an insulated plug comprising an outer panel and an insulated plug portion; wherein the insulated plug portion is positioned within the insulated cavity of the insulation wrap and a portion of the outer panel is positioned on the top ledge of the insulation wrap.

Abstract: An inner box includes a center panel defining a plurality of vents, a first side flap panel attached to a first side of the center panel, a second side flap panel attached to a second side of the center panel opposite the first side of the center panel, a first locking panel on a third side of the center panel, and a second locking panel on a fourth side of the center panel opposite the third side of the center panel.

Abstract: A method of collapsing a collapsible box includes providing the collapsible box, the collapsible box comprising: a plurality of side panels including a first side panel and a second side panel, each of the plurality of side panels defining a side panel top edge; a box bottom; and a box top comprising a plurality of top panels including a first top panel extending from the side panel top edge of the first side panel and a second top panel extending from the side panel top edge of the second side panel, the second top panel comprising an overlapping portion; folding the first side panel towards the second side panel to confront the first side panel with the second side panel; and folding the overlapping portion of the second top panel over a top panel top edge of the first top panel.

Abstract: A shipping assembly for transporting refrigerated items includes an outer box defining an outer box cavity, a bottom insulator box assembly received in the outer box cavity superposed above the bottom panel, an insulated inner box positioned in the outer box cavity above the bottom insulated box assembly, the insulated inner box defining a ridge and an inner box cavity, wherein ridge panels and retention flaps of the outer box engage end panels of the insulated inner box such that the insulated inner box is retained in a position spaced from outer box side panels, with an insulation wrap occupying the space between the insulated inner box and the outer box walls. A top insulator box assembly is partially received in the inner box cavity, such that overhang portions of a top panel of the top insulator box assembly rest upon the ridge of the insulated inner box.

Abstract: A blank to form an insert connected to an outer box, the blank including a first side; a second side positioned opposite the first side; a first main panel adjacent to a first support formation; a second main panel adjacent to the first support formation; a third main panel adjacent to the second main panel; a second support formation adjacent to the third main panel; a fourth main panel adjacent to the second support formation; and a connection panel adjacent to the fourth main panel.

Abstract: A box includes a plurality of sidewall panels; a bottom panel arranged at a bottom end of the sidewall panels; and a top panel arranged at a top end of the sidewall panels; wherein each sidewall panel is hingedly coupled to an adjacent sidewall panel by a foldable gusset.

Abstract: An insulated packaging assembly can include a box having a plurality of sides and a bottom; a liner defining an interior cavity and having a plurality of sides defined by a plurality of end panels; a liner top positioned within the interior cavity of the liner; and at least one separation feature connected to the side of the liner between the side of the liner and the corresponding side of the box; wherein each end of each end panel defines a protrusion tab, and a first separation feature of the at least one separation feature can include a protrusion tab of one of the end panels extending beyond an outer surface of an adjacent end panel.

Abstract: A cushioned mailer includes a paper outer layer comprising a tissue-grade paper material; a paper inner layer comprising a tissue-grade paper material and defining an inner cavity of the cushioned mailer, the inner cavity configured to receive contents therein, the inner cavity defining an opening at a top end of the cushioned mailer, the opening allowing access to the inner cavity; and an intermediate cushioning layer disposed between the paper outer layer and the paper inner layer, the intermediate cushioning layer comprising a plurality of cushioning inserts, each of the plurality of cushioning inserts being substantially uniform in size and shape.

Abstract: A box assembly comprising an outer box comprising a bottom end panel and a plurality of side panels extending upwardly therefrom; and a tray comprising a bottom panel; a first side panel extending upward from a first bottom panel side and a second side panel extending upward from a second bottom panel side; a first wing extending downward from the first side panel and a second wing extending downward from the second side panel; a first end panel and a second end panel arranged laterally between the first side panel and the second side panel; wherein each of the first wing and the second wing are configured to engage at least one of the first end panel and the second end panel and support the bottom panel above the bottom end panel and the tray is positioned in the interior cavity of the outer box.

Abstract: A cushioning sheet comprising a base layer defining a plurality of voids and a plurality of cushioning inserts, wherein each cushioning insert is received in a corresponding void and the base layer is covered with a material coating configured to limit the passage of air therethrough.

Abstract: An insulated box assembly comprising an outer box comprising a plurality of outer lateral sidewalls, the outer lateral sidewalls defining an inner surface, the inner surface defining an inner cavity; an inner box comprising a plurality of inner lateral sidewalls, the inner box received in the inner cavity, the inner lateral sidewalls defining an outer surface; a sidewall liner received in the inner cavity between the outer lateral sidewalls and the inner lateral sidewalls, the sidewall liner defining a liner outer surface and a liner inner surface opposite the liner outer surface; and a lid assembly disposed within the inner cavity, the lid assembly comprising a lid box and a lid liner.

Abstract: An insulating bag includes a pair of opposing side panels; a pair of opposing main panels, each side panel attached to each main panel, the pair of opposing main panels and the pair of opposing side panels together defining a top bag end and a bottom bag end opposite the top bag end; a pair of opposing main top flaps, each main top flap hingedly connected to a corresponding one of the main panels at the top bag end; a pair of opposing side top flaps, each side top flap hingedly connected to a corresponding one of the side panels at the top bag end; and a bottom panel disposed at the bottom bag end; wherein: the insulating bag comprises a paper base layer, a temperature-preserving liner applied to the paper base layer, and a protective layer positioned over the temperature-preserving liner; and the insulating bag defines an interior cavity configured to receive bag contents therein.

Abstract: A packaging assembly including an outer box including a plurality of side panels defining an interior cavity; and a wrap liner including an outer portion extending from a first panel to a second panel, the outer portion defining an outer hinge coupling the first panel to the second panel; a ledge portion extending across the first panel and the second panel, the ledge portion coupled to the outer portion by a first ledge hinge and a second ledge hinge; and an inner portion extending across the first panel and the second panel, a first inner hinge, and a second inner hinge each coupling the inner portion to the ledge portion; wherein the wrap liner is disposed within the interior cavity of the outer box.

Abstract: A telescoping insulated box assembly comprising an outer box blank configured to define an outer box comprising a plurality of outer side walls, the outer box blank comprising a first outer side panel, a first inner side panel, and a first connecting strip, the first connecting strip joined to a top of the first outer side panel by a first fold line and a top of the first inner side panel by a second fold line, the first outer side panel, the first inner side panel, and the first connecting strip configured to at least partially define a first outer sidewall defining a first insulation cavity within the first outer side wall; and an inner box blank configured to define an inner box.

Abstract: A method for insulating a box includes positioning an insulated panel adjacent to a side panel of the box, the insulated panel including an insulation batt and a sheet, the insulated panel defining a border extending around a perimeter of the insulation batt; and attaching a seam of the border to a portion of a perimeter area of the side panel.