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: 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 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 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 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: 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 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.

Abstract: A bubble A-B liner insulation package includes a box defining a box cavity, an A-liner configured to be positioned in the box cavity, the A-liner constructed from a first panel of liner material defining three A-liner portions, and a B-liner configured to be positioned in the box cavity adjacent to the A-liner, the B-liner constructed from a second panel of liner material defining three B-liner portions. The liner material comprises at least a first bubble layer formed from a thermoplastic film, an upper layer joined to an upper side of the bubble layer, and a lower layer joined to a lower side of the bubble layer, wherein at least one of the thermoplastic film, the upper layer, and the lower layer is at least partially comprised of metallized high density polyethylene (MHDPE).

Abstract: A method of assembling a meal kit tray from a single blank including a bottom panel, wherein the bottom panel is configured to support a bag containing refrigerated items and a cold pack, wherein the single blank further comprises a bottom panel; a side panel extending outwardly from at least a portion of the bottom panel, the side panel joined to the bottom panel along a first fold line defining a joint, wherein the first fold line is interrupted by at least one perforation line segment defining a standoff; and a wing extending outwardly from the side panel, the wing joined to the side panel along a second fold line defining a joint, the wing defining a free end; wherein the method comprises the steps of rotating the side panel upwardly about the first fold line to cause the standoff to separate from the side panel; and rotating the wing downwardly about the second fold line.

Abstract: A modular box assembly includes a box with side panels defining a box cavity, a first thermal liner positioned within the box cavity, the first thermal liner including a first insulation batt disposed between sheets, the first thermal liner defining three first liner panels, at least one box side panel being covered by a first liner panel, and a second thermal liner positioned within the box cavity, the second thermal liner including a second insulation batt disposed between sheets, the second thermal liner defining three second liner panels. At least one other of the side box panels is covered by a second liner panel. The bottom box panel is covered by either a first liner panel not covering any side box panel or a second liner panel not covering any side box panel. Each insulation batt can be formed from a mixture of thermoplastic binder fibers and reinforcement fibers.

Abstract: An insulated packaging assembly can include a box having a plurality of sides and a bottom; a liner having a plurality of sides defined by a plurality of end panels; 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 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 shipping assembly for transporting refrigerated items includes an outer box defining an outer box cavity and a bottom panel, a bottom insulator box assembly received in the outer box cavity atop the bottom panel, an insulated inner box positioned in the outer box cavity above the bottom insulated box assembly, the insulated inner box defining an 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 spaced position, relative to outer box panels, by predetermined gap distances; and a top insulator box assembly partially received in the inner box cavity, such that first and second overhang portions of a top panel of the top insulator box assembly rest upon the ridge of the insulated inner box.

Abstract: A tray comprising a bottom panel defining a first bottom panel side, a second bottom panel side, a first bottom panel end, and a second panel bottom end; a first side panel extending upward from the first bottom panel side and a second side panel extending upward from the 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 arranged laterally between the first side panel and the second side 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 a support surface.

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 and a temperature-preserving liner applied to the paper base layer; and the insulating bag defines an interior cavity configured to receive bag contents therein.

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: An insulated box assembly can include an insulated liner defining a liner cavity, the liner including a pair of opposing main liner panels, a pair of opposing side liner panels, and a bottom liner panel, the main liner panels, the side liner panels, and the bottom liner panel each being defined by an insulation batt encapsulated in a panel cavity defined between a pair of blank sheets, each panel cavity of each main panel and each side panel being enclosed by a liner border, and the panel cavity of the bottom liner panel being enclosed by a bottom border, wherein the bottom border forms a bottom seam along a perimeter of the bottom liner panel with portions of the liner borders of the main liner panels and side liner panels.