Box liner

A method of assembling an insulated box assembly can include collapsing an insulated liner; aligning the insulated liner with a box opening of a box, the box defining an internal box cavity, the box including a pair of opposing main box panels, a pair of opposing side box panels, each side box panel of the pair of opposing side box panels attached to both main box panels of the pair of opposing main box panels, and a bottom box panel, the bottom box panel positioned at a bottom box end of the box, the bottom box panel attached to the main box panels and the side box panels, the main box panels, side box panels, and bottom box panel further defining the internal box cavity; inserting the insulated liner into the internal box cavity; and expanding the insulated liner.

JOINT RESEARCH AGREEMENT

The subject matter disclosed herein was developed and the claimed invention was made by, or on behalf of, one or more parties to a joint research agreement between MP Global Products LLC of Norfolk, Nebr. and Pratt Retail Specialties, LLC of Conyers, Ga., that was in effect on or before the effective filing date of the claimed invention, and the claimed invention was made as a result of activities undertaken within the scope of the joint research agreement.

TECHNICAL FIELD

This disclosure relates to packaging. More specifically, this disclosure relates to an insulated liner for box.

BACKGROUND

Packaging perishable or temperature sensitive contents for storage or shipping can pose challenges. The contents can spoil, destabilize, freeze, melt, or evaporate during storage or shipping if the temperature of the contents is not maintained or the packaging is not protected from hot or cold environmental conditions. Contents such as food, pharmaceuticals, electronics, or other temperature sensitive items can be damaged if exposed to temperature extremes. Many insulated packages are bulky and difficult to store prior to use. Many insulated packages cannot be recycled and are often disposed of in landfills.

SUMMARY

Disclosed is a method of assembling an insulated box assembly comprising collapsing an insulated liner, the insulated liner comprising a pair of opposing main liner panels, a pair of opposing side liner panels, each side liner panel of the pair of opposing side liner panels attached to both main liner panels of the pair of opposing main liner panels, the insulated liner defining a top liner end and a bottom liner end; a liner bottom, the liner bottom disposed at the bottom liner end, the bottom liner end defined distal from the top liner end; the pair of opposing main liner panels and the pair of opposing side liner panels at least partially defined by a blank liner panel, the blank liner panel comprising an insulation batt and a blank sheet, the blank sheet at least partially defining a liner cavity within the insulated liner, an opening to the liner cavity defined at the top liner end; aligning the insulated liner with a box opening of a box, the box defining an internal box cavity, the internal box cavity defining the box opening disposed at a top box end of the box, the box comprising a pair of opposing main box panels, a pair of opposing side box panels, each side box panel of the pair of opposing side box panels attached to both main box panels of the pair of opposing main box panels, and a bottom box panel, the bottom box panel positioned at a bottom box end of the box, the bottom box panel attached to the main box panels and the side box panels, the main box panels, side box panels, and bottom box panel further defining the internal box cavity; inserting the insulated liner into the internal box cavity; and expanding the insulated liner.

DETAILED DESCRIPTION

In one aspect, disclosed is an insulated box assembly and associated methods, systems, devices, and various apparatus. The insulated box assembly can comprised a box, an insulated panel, and an insulated liner. It would be understood by one of skill in the art that the disclosed valve body is described in but a few exemplary aspects among many. No particular terminology or description should be considered limiting on the disclosure or the scope of any claims issuing therefrom.

FIGS. 1A-Cdisclose and describe an insulated box assembly100in one aspect of the present disclosure.FIG. 1Ais an exploded view of an insulated box assembly100comprising a box110, an insulated liner140, and an insulated panel130. In the present aspect, the box110can be a chute box; however, in other aspects, the box110can be any suitable type of box. The box110can comprise a pair of opposing main box panels112, a pair of opposing side box panels114, a box bottom panel413(shown inFIG. 4A), and a lid116. The box110can define a top box end111and a bottom box end113, and the top box end111can be disposed opposite from the bottom box end113. The opposing main box panels112, the opposing side box panels114, and the box bottom panel413of the box110can define an internal box cavity122, and the internal box cavity122can define a box opening120positioned at the top box end111of the box110. The lid116can be attached to the box110at the top box end111by a lid hinge118, and the lid116can be configured to selectively move about and between an open position and a closed position. In the closed position, the lid116can be configured to cover the box opening120and seal the internal box cavity122. In the open position shown inFIGS. 1A-C, the lid116can be configured to uncover the box opening120, and a user can add or withdraw contents from the internal box cavity122. The internal box cavity122can be configured to receive the insulated liner140and the insulated panel130.

The insulated liner140can be configured to line the internal box cavity122. In the present aspect, the insulated liner140can comprise a liner bottom149, an opposing pair of main liner panels147, and an opposing pair of side liner panels145. The liner bottom149, the opposing pair of main liner panels147, and the opposing pair of side liner panels145can define a liner cavity150. The insulated liner140can comprise and be assembled from a bottom panel146and an opposing pair of blank liner panels141. The blank liner panels141can be attached in an opposing configuration by a pair of side seams143. Each blank liner panel141can define a main subpanel142positioned between a pair of side subpanels144. In the opposing configuration, the blank liner panels141are aligned and facing each other such that the main subpanels142of the respective blank liner panels141can be aligned and each of the side subpanels144of a one of the blank liner panels141is aligned with a different one of the side subpanels144of another of the blank liner panels141. Each of the main subpanels142of the blank liner panels141can define a one of the main liner panels147of the insulated liner140. Each of the side seams143can attach together a one of the side subpanels144from each of the blank liner panels141, thereby defining a one of the side liner panels145.

The bottom panel146can be positioned at a bottom liner end162of the insulated liner140. A liner opening148of the liner cavity150can be defined at a top liner end160opposite from the bottom liner end162. The bottom panel146can define the liner bottom149of the insulated liner140. In other aspects, the insulated liner140can be a one-piece insulated liner640, as shown inFIG. 6B, which can comprise a one-piece blank liner panel680, as shown inFIG. 6A. In such aspects, the liner bottom149, the opposing pair of main liner panels147, and the opposing pair of side liner panels145can be defined by the one-piece blank liner panel680.

As shown inFIG. 1A, the insulated liner140can be collapsed into a collapsed insertion configuration in which the side liner panels145can be folded inwards towards the liner cavity150, the main liner panels147can collapse inwards towards the liner cavity150, and the liner bottom149of the insulated liner140can be in a folded position. In this configuration, the side liner panels145do not interfere with the opposing side box panels114of the box110, and the collapsed main liner panels147provide a clearance between the insulated liner140and the opposing main box panels112. The clearance can facilitate insertion of the insulated liner140into the box110. In the collapsed insertion position, the insulated liner140can be inserted into the internal box cavity122through the box opening120. Inserting the insulated liner140fully into the internal box cavity122can assist in expanding the insulated liner140into an expanded configuration. This effect is further described below with respect toFIG. 2A.

FIG. 1Bis a perspective view of the insulated box assembly100ofFIG. 1A. As shown, the insulated liner140can be configured to fit within the internal box cavity122of the box110. In the expanded configuration, the insulated liner140can be sized and shaped complimentary to the internal box cavity122. The insulated liner140can conform to a shape defined by the internal box cavity122. The liner opening148can be positioned adjacent to the box opening120. The liner opening148can define a substantially rectangular shape complimentary in a size and a shape to the box opening120. In the present aspect, the main liner panels147can be in facing engagement with the main box panels112, the side liner panels145can be in facing engagement with the side box panels114, and the liner bottom149can be in facing engagement with the box bottom panel413(shown inFIG. 4A) of the box110.

FIG. 1Cis a perspective view of the insulated box assembly100ofFIG. 1A. As shown, the insulated panel130can be a top panel131configured to cover the liner opening148. The insulated panel130can comprise insulation, and a seal formed between the insulated panel130and the insulated liner140can increase an insulation value of the liner cavity150as shown inFIG. 4A. The lid116can be placed in the closed position (not shown) to enclose the insulated liner140and the insulated panel130within the internal box cavity122. The lid116can comprise a lip117which can be shaped complimentary to the box opening120. The lip117can form a box seal by overlapping a portion of the main box panel112, and the side box panels114at the top box end111of the box110.

FIG. 2Ais a perspective view of the insulated liner140ofFIG. 1Ain the collapsed insertion configuration. When the side liner panels145are folded inwards towards the liner cavity150, each pair of side subpanels144of the side liner panels145can fold relative to each other about the respective side seam143. Each side subpanel144can fold relative to a one of the main subpanels142about a side crease line242. Each of the side subpanels144can define an acute angle with an adjacent one of the main subpanels142.

In the present aspect, the insulated panel130, blank liner panel141, and bottom panel146can each demonstrate a positional memory which biases the panel130,141,146towards a flat, substantially planar configuration. When the panels130,141,146are subjected to a bending moment or force, the panels130,141,146can elastically deform; however when the bending moment or force is removed, the panels130,141,146can return to the substantially planar configuration. When the panels130,141,146are elastically deformed, internal stresses can produce a force which resists the deflection. As the degree of deflection increases, the internal stresses can increase, and the resisting force can increase as well. When the panels130,141,146are returned to the substantially planar configuration, the force can be minimized or eliminated. The force can be maximized when the panels130,141,146are folded in half.

When the main liner panels147are collapsed inwards towards the liner cavity150, the liner bottom149folds about a bottom crease line247. The bottom crease line247can substantially bisect the liner bottom149. The liner bottom149can fold downwards away from the side liner panels145exposing openings between the liner bottom149and the side liner panels145. The liner bottom149can demonstrate the positional memory which can exert a force F2biasing the liner bottom149towards the expanded configuration from the collapsed insertion configuration. The force F2can resist folding of the liner bottom149about the bottom crease line247. In the present aspect, the force F2can be exerted by the bottom panel146of the liner bottom149; however in other aspects in which the liner bottom149is defined by a blank liner panel, the force F2can be exerted by the blank liner panel. Once in the expanded configuration, a value of the force F2is minimized.

In the present aspect, the bottom panel146can be attached to the main subpanels142by a pair of bottoms seams246. In the present aspect, the bottom seams246can be flexible and do not demonstrate positional memory or a biasing force; however, in other aspects, the bottom seams246can be crease lines defined by a blank liner panel which can demonstrate positional memory and a biasing force.

The force F2can cooperate with a force F1to expand the insulated liner140from the collapsed insertion configuration to the expanded configuration. When the insulated liner140is inserted into the box110, interference between the box bottom panel413(shown inFIG. 4A) of the box110and the liner bottom149of the insulated liner140can urge the liner bottom149to unfold. As shown, the force F1can act on the liner bottom149proximate the bottom crease line247. The force F1can produce a moment about the bottom seams246which can bias the liner bottom149to unfold and flatten into a substantially planar configuration. The flattening of the liner bottom149can expand the opposing main liner panels147away from the liner cavity150.

FIG. 2Bis a perspective view of the insulated liner140ofFIG. 1Ain the expanded configuration. In the expanded configuration, a one of the main liner panels147can be parallel to another of the main liner panels147, and a one of the side liner panels145can be parallel to another of the side liner panels145. The liner bottom149can be substantially perpendicular to each of the main liner panels147and each of the side liner panels145. The side liner panels145, and the liner bottom149can be unfolded and substantially planar. The liner bottom149can be in non-sealing, connectionless contact with each of the side liner panels145. The main liner panels147can be expanded away from the liner cavity150.

In the present aspect, the blank liner panels141can also demonstrate the positional memory and exert a force F3biasing the side subpanels144to rotate about the side crease lines242away from the main subpanels142and towards the expanded configuration. In the expanded configuration, each of the side subpanels144can define a substantially right angle with the adjacent one of the main subpanels142. If the insulated liner140is not restrained by the box110, the side subpanels144can be biased to further unfold away from the main subpanels142to a collapsed storage position shown inFIG. 3C. In the present aspect, the side seams143can be flexible and do not demonstrate positional memory or a biasing force; however, in other aspects, the side seams143can be crease lines which can demonstrate positional memory and a biasing force.

The forces F1, F2, F3can cooperate to produce a self-expanding effect biasing the insulated liner140from the collapsed insertion configuration to the expanded configuration. The insulated liner140can be configured to self-expand from the collapsed insertion configuration to the expanded configuration when the insulated liner140is inserted or dropped into the internal box cavity122of the box110. The self-expanding effect can be desirable in order to reduce or eliminate manual manipulation of the insulated liner140when inserting the insulated liner140into the box110, such as in a manufacturing operation. The self-expanding effect can reduce the time required to assemble each insulated box assembly100or can facilitate automated assembly of the insulated box assemblies100such as by robotic or mechanized equipment.

FIGS. 3A-Cshow a perspective view of the assembly of the insulated liner140.FIG. 3Ais an exploded view of the insulated liner140comprising two blank liner panels141and a bottom panel146and the insulated panel130ofFIG. 1A. In the present aspect, panels130,141,146can each define a border which can each be a two-ply seam. The blank liner panels141can each define a liner border341extending around a perimeter of the respective blank liner panel141. The bottom panel146can define a bottom border308extending around a perimeter of the bottom panel146. The insulated panel130can define a panel border333extending around a perimeter of the insulated panel130. The liner border341can extend from the liner opening148to the bottom panel146.

FIG. 3Bis an exploded view of the insulated liner140and the insulated panel130ofFIG. 1Ain an aligned configuration. The two blank liner panels141are shown aligned in an opposing configuration, and the bottom panel146is folded about the bottom crease line247and aligned with each of the main subpanels142of the pair of blank liner panels141. At opposing ends of each blank liner panel141, a portion of each liner border341adjacent to a one of the side subpanels144can define a side border portion343. The side border portions343of a one of the blank liner panels141can be aligned and adjacent to the side border portions343of a second of the blank liner panels141.

Similarly, at opposing ends of the bottom panel146distal from the bottom crease line247, the bottom border308can define a pair of first bottom border portions346. A portion of each liner border341adjacent to the main subpanel142and distal from the liner opening148can define a second bottom border portion347. Each of the first bottom border portions346of the bottom panel146can be aligned with a different one of the second bottom border portions of the pair of blank liner panels141. In the position shown, the panels141,146are prepared to be attached to form the seams143,246. The aligned side border portions343of the opposing blank liner panels141can be attached in facing engagement to form the side seams143. Each of the sides seams143can be formed as a plain seam; however in other aspects, each of the side seams143can be a lap seam or any other type of seam. Each of the bottom seams246can be formed by attaching a one of the first bottom border portions346to a one of the second bottom border portions347in facing engagement. Each of the bottom seams246can be formed as a lap seam; however in other aspects, each of the bottom seams246can be a plain seam or any other type of seam. In other aspects, each of the bottom seams246can be formed by attaching a one of the first bottom border portions346directly to a one of the main subpanels142rather than to a portion of the liner border341.

FIG. 3Cis a perspective view of the assembled insulated liner140and the insulated panel130ofFIG. 1Ain an assembled configuration. In the present aspect, the bottoms seams246and the side seams143can be flexible and function as living hinges. Each of the side seams143can extend from the liner opening148to the bottom border portion347. The border portions343,346,347can be attached in facing engagement using a glue, adhesive, tape, cement, or any other method of attachment such as stitching or stapling.

In the embodiment shown inFIG. 3C, the insulated panel130can be the top panel131. In the present aspect, the top panel131can be separate and disconnected from the insulated liner140. In other aspects, the top panel131can be attached to the insulated liner140by a top seam (not shown) formed by attaching a portion of the panel border333to a portion of the liner border341proximate the liner opening148. The top seam (not shown) can also function as a living hinge allowing the top panel131to rotate about the top seam relative to the insulated liner140.

FIG. 3Cdepicts the insulated liner140in the collapsed storage configuration. In the collapsed storage configuration, the side liner panels145extend outwards and away from the liner cavity150, and the main liner panels147are collapsed together in facing engagement. Each of the side subpanels144can define an obtuse angle with an adjacent one of the main subpanels142. In this configuration, the force F3exerted about the side crease lines242by the positional memory of the blank liner panels141is minimized. Conversely, when the insulated liner140is in the collapsed insertion configuration shown inFIGS. 1A and 2A, the force F3is maximized as each of the blank liner panels141can be nearly folded in half about each of the side crease lines242. The collapsed storage configuration can be used for stacking, storing, or packaging the insulated liners140in bulk.

FIG. 4Ais a cross-sectional view of the insulated box assembly100ofFIG. 1Aviewed from line4-4ofFIG. 1C. In the aspect shown, the insulated box assembly100can optionally comprise three insulated panels130A,B,C. In other aspects, the insulated box assembly100can comprise greater or fewer than three insulated panels130. In the present aspects, the insulated panels130B and130C can be sized smaller than the insulated panel130A in order to facilitate insertion into the liner cavity150. In other aspects, the insulated panels130A,B,C can all be sized and shaped similarly. The insulated panel130A can be the top panel131positioned over the liner opening148.

The insulated panel130B can be a divider panel431which can partition the liner cavity150into a first insulated compartment450A and a second insulated compartment450B. This configuration can be desirable in order to maintain the first insulated compartment450A and the second insulated compartment450B at separate temperatures. In other aspects, the insulated box assembly100can comprise a plurality of divider panels431which can divide the liner cavity150into more than two insulated compartments450. In the present aspect, the divider panel431can be in a horizontal orientation configured to partition the liner cavity150top-to-bottom. In other aspects, the divider panel431can be in a vertical orientation configured to partition the liner cavity150side-to-side, front-to-back, or diagonally. In some aspects, the insulated box assembly100can comprise a plurality of divider panels431in both horizontal orientations and vertical orientations. In the present aspect, the panel border333of the divider panel431can form a seal with the main liner panels147and the side liner panels145of the insulated liner140. In some aspects, the divider panel431can rest upon contents of the second insulated compartment450B.

Insulated panel130C can be a floor panel432positioned on top of the bottom panel146. In some embodiments, the bottom panel146may not comprise insulation (not shown), and the floor panel432can be placed atop the bottom panel146of the liner bottom149to insulate the bottom liner end162. Such a configuration can be desirable in order to simplify manufacturing or reduce manufacturing steps. In the aspect shown, the bottom panel146comprises insulation, and the floor panel432can be positioned on top of the bottom panel146to provide increased insulation to the bottom liner end162. This configuration can be desirable when the contents of the liner cavity150are heavy and can compress the insulation at the bottom liner end162, thereby possibly rendering the insulation less effective. This configuration can also be desirable to provide increased insulation against conduction of heat through the bottom liner end162of the insulated liner140when the insulated box assembly100is resting upon a hot or cold environmental surface. As shown, each of the panels130,141,146can each be insulated.

FIG. 4Bis a detail view of the insulated box assembly100taken from detail4B ofFIG. 4A. As shown inFIGS. 4B and 4Cand described in further detail with regard toFIG. 5, the panels130,141,146can each comprise an insulation batt490encapsulated between a pair of blank sheets491. The insulation batt490can be positioned in a panel cavity492defined between the blank sheets491. The panel cavity492can be enclosed by a border493, which can be the panel border333, the liner border341, or the bottom border308. The border493can be formed by attaching together in facing engagement a perimeter portion495of each of the blank sheets491. In the present aspect, the perimeter portions495of the blank sheets491can be attached together by a first adhesive426which can be a glue, cohesive, cement, epoxy, or tape strip. In other aspects, the blank sheets491can be attached by another suitable method such as stitching or stapling.

FIG. 4Bshows the construction of the top panel131and the blank liner panel141. The top panel131can taper towards the panel border333which can define a beveled panel edge433. Similarly, the blank liner panel141can taper towards the liner border341which can define a beveled liner edge441proximate the liner opening148. When the top panel131is positioned to cover the liner opening148, the panel border333and the beveled panel edge433can cooperate with the liner border341and the beveled liner edge441to form a seal between the top panel131and the insulated liner140. The seal can improve an insulation value of the liner cavity150.

FIG. 4Cis a detail view of the insulated box assembly100taken from detail4C ofFIG. 4A.FIG. 4Cshows a one of the bottom seams246formed between the bottom panel146and the blank liner panel141. In the present aspect, each of the bottom seams246can be formed by attaching a one of the first bottom border portions346of the bottom panel146to a one of the second bottom border portions347of the blank liner panels141, as described relative toFIG. 3C, which can define a four-ply seam comprised of four overlapping perimeter portions495. Each of the side seams143can be a similarly constructed four-ply seam. The first bottom border portion346can be attached to the second bottom border portion347in facing engagement with a second adhesive427. The second adhesive427can be the same as the first adhesive426, or in other aspects, the second adhesive427can be a different type of adhesive such as a glue, cement, epoxy, or tape strip. As shown, the panel border333of insulated panel130C can cooperate with the insulated liner140to form a seal within the liner cavity150.

FIG. 5is a perspective view of a method of manufacturing for an insulated panel480. The insulated panel480can be representative of the insulated panels130, the blank liner panels141, the bottom panel146, or the blank liner panel680(shown inFIG. 6).

In a step501, an insulation batt490can be positioned between a pair of blank sheets491. The blank sheets491can be sized and shaped complimentary to each other; however in some aspects, the blank sheets491can differ in size and shape. Each sheet can define an outer edge595and a perimeter portion495proximate the outer edge595. The perimeter portions495can extend around the outer edge595of each of the respective blank sheets491. The insulation batt490, blank sheets491, and the insulated panel480can each be substantially flat and planar prior to assembly.

The blank sheets491can be sized to overhang the insulation batt490on all sides with the perimeter portions495extending beyond the insulation batt490. The perimeter portions495can each encompass an interior portion494of a different one of the blank sheets491. The interior portions494can be sized and shaped complimentary to the insulation batt490.

Surfaces of the blank sheets491facing the insulation batt490can be treated with an adhesive, such as the first adhesive426. In the present aspect, only the perimeter portions495of the blank sheets491can be selectively treated with the first adhesive. In some aspects, the first adhesive426can be a cohesive which is configured to selectively adhere only to other cohesive treated areas. In some aspects, the insulation batt490can also be adhered to the interior portions494of the blank sheets491.

In a step502, the blank sheets491can be aligned and positioned in facing engagement wherein the perimeter portions495can be attached by the first adhesive426(not shown). The insulation batt490can be aligned between the interior portions494. Attaching the perimeter portions495can form the border493of the insulated panel480. The border493can be a two-ply seam formed by two overlapping perimeter portions495. The border493can seal and enclose the insulation batt490within the panel cavity492, defined between the interior portions494of the blank sheets491. Portions of the insulated panel480containing the insulation batt490can define insulated portions590. In some aspects, the insulation batt490can be aligned off-center from the blank sheets491wherein the border493can extend outwards from the insulated portions590further in some areas than others.

In a step503, the perimeter portions495can be fully attached, thereby forming the completed border493. A taper from the insulated portion590to the border493can define a beveled edge496which can be similar to the beveled panel edge433of the insulated panel130and the beveled liner edge441of the blank liner panel141. The border493can extend outwards from the insulated portion590.

In other aspects, the insulated panel480may not comprise the border493fully encompassing the insulated panel480. In some aspects, some portions of the perimeter may expose an unfinished edge in which the insulation batt490is exposed. In some aspects, the insulated panel480may not define the border493on any portion of the perimeter of the insulated panel480, and the entire perimeter can define an unfinished edge. In such aspects, the insulated panel480can comprise pre-laminated paper and each of the blank sheets491can be attached in facing contact with the insulation batt490with, for example and without limitation, an adhesive. In some aspects in which the insulated panel480defines the border493, the insulation batt490can also be attached in facing contact with one or both of the blank sheets491. In some aspects, the pre-laminated paper can be provided in a roll, and the insulated panels480can be cut to size from the roll.

In different aspects, the insulation batt490can define different thickness from less than 1/16″ to over 2″; however, this range should not be viewed as limiting. In various aspects, the different panels130,141,146can each comprise insulation batts490of either different thicknesses or the same thickness. For example and without limitation, the bottom panel146can comprise an insulation batt490defining a thickness greater than that of an insulation batt490comprised by the blank liner panel141. In other aspects, each insulation batt490can vary in thickness and define contours between areas of greater thickness and areas of lesser thickness.

In some aspects, the thickness defined by the insulation batt490can affect a strength of the force exerted by the positional memory, such as forces F2and F3, and increasing the thickness of the insulation batt490can increase the force exerted by the positional memory. Conversely, decreasing the thickness of the insulation batt490can decrease the force exerted by the positional memory of the insulation batt490. One method of reducing the thickness of the insulation batt490can be to define a groove741,880into the insulation batt490as shown inFIG. 7andFIG. 8. In the present aspect, each groove can be a V-shaped groove defined into the insulation batt490to facilitate folding of the insulation batt490about the groove. In other aspects, the grooves can define a different shape, such as semicircular. In some aspects, the groove can be aligned with a crease line of the panel130,141,146, such as crease lines242,247, in order to allow the panel130,141,146to bend more easily about the respective crease lines242,247. Grooves can be desirable, for instance, for insulation batts490defining large thickness values which can be difficult to bend. Cutting grooves can also be desirable to concurrently optimize both the manufacturing process and the assembly process in which it can be desirable to use a single section of insulation batt490that does not exhibit positional memory at specific locations.

Additionally, a density defined by each of the insulation batts490can be varied in different aspects or between different insulation batts490comprised by a single insulated liner140. In some aspects, increasing the density of the insulation batt490can increase an insulation value of the insulation batt490. Increasing the density of the insulation batt490can also increase resistance to compression of the insulation batt490. Compression of the insulation batt490can be undesirable as compression can degrade the insulation value of the insulation batt490.

In some aspects, a plurality of insulation batts490can be encapsulated between the pair of blank sheets491. In these aspects, the plurality of insulation batts490can overlap one another or alternatively, can be positioned separate from one another. Separated insulation batts490can be encapsulated in separate, isolated panel cavities492divided by a portion of the border493extending across the insulated panel480(not shown). Separately encapsulating the plurality of insulation batts490into a single insulated panel480can be an alternative to attaching together separate insulated panels480with seams or other attachment methods. In some aspects, the insulated panels480can define shapes other than rectangular. The insulation batt490and the blank sheets491can be cut or shaped, such as by die cutting, in order to define different shapes for the insulated panels480.

FIG. 6Ais a top view of another aspect of the blank liner panel680. The blank liner panel680can be a one-piece blank liner panel680configured to form the one-piece insulated liner640ofFIG. 6Bwithout additional panels130,146,141,480. The blank liner panel680can be manufactured through the method shown inFIG. 5, and the blank liner panel680can be constructed similar to the insulated panel480. In the present aspect, the blank liner panel680can comprise a single, continuous insulation batt490; however, in other aspects, the blank liner panel680can comprise a plurality of insulation batts490. The blank liner panel680can define a pair of liner subpanels604connected by a bottom subpanel606. The blank liner panel680can define a border693extending around a perimeter of the blank liner panel680. Each liner subpanel604can define a pair of side border portions643of the border693positioned at opposite ends of the respective liner subpanel604. The blank liner panel680can be folded in half about a bottom crease line601to bring the liner subpanels604into facing engagement and to align the respective side border portions643of each of the liner subpanels604with one another. The bottom crease line601can correspond to and function similarly to the bottom crease line247of the insulated liner140.

The blank liner panel680can define a pair of liner crease lines602, each positioned at an intersection between a one of the liner subpanels604and the bottom subpanel606. The liner subpanels604can fold relative to the adjacent bottom subpanel606about the liner crease lines602. The liner subpanels604can each define a pair of side crease lines603. Each liner subpanel604can define a main subpanel642positioned between a pair of side subpanels644. For each liner subpanel604, the side crease lines603can extend between the main subpanel642and a different one of the side subpanels644. Each of the side subpanels644can fold about a one of the side crease lines603relative to the adjacent main subpanel642. In the present embodiment, the side crease lines603can be structurally and functionally similar to the side crease lines242. In some aspects, the insulation batt490underlying each liner crease line602can be cut to define a groove which can facilitate bending of the blank liner panel680about any of the crease lines601,602,603.

FIG. 6Bis a top view of another aspect of the insulated liner640. The insulated liner640can be formed by folding the blank liner panel680in half about the bottom crease line601and attaching each pair of aligned side border portions643in facing engagement in order to form a pair of side seams646. At each side seam646, a pair of side subpanels644, each defined by a different opposing liner subpanel604, can be attached by the respective side seam646. Similar to the insulated liner140, the insulated liner640can comprise a liner bottom649, an opposing pair of main liner panels647, and an opposing pair of side liner panels645. Each of the main liner panels647can be defined by a one of the main subpanels642of the liner subpanel604extending between the side crease lines603. Each of the side liner panels645can be defined by a one of the pairs of side subpanels644attached by a one of the side seams646. The liner bottom649can be defined by the bottom subpanel606extending between the liner crease lines602. The main liner panels647and the side liner panels645can define a liner opening648defined distal from the bottom crease line601.

FIG. 7is a top view of another aspect of a blank sheet491A and another aspect of an insulation batt490A for the blank liner panels141ofFIG. 3A. Each of the blank liner panels141can be formed by encapsulating the insulation batt490A between two blank sheets491A. The blank sheet491A can define a height HAand a width WA. The blank sheet491A can define the interior portion494A and the perimeter portion495A which can surround the interior portion494A. The interior portion494A can define a height HBand a width WD. The perimeter portion495A can define a top portion702and a bottom portion701opposite from the top portion702. Attaching two bottom portions701of two blank sheets491A together can form the second bottom border portion347. The perimeter portion495A can also define a pair of side portions743opposite from one another. Attaching two side portions743of two blank sheets491A together can form the side border portion343. The top portion702and the bottom portion701can each define a height HC, and the side portions743can each define a width WE. In the aspect shown, the width WEcan define a value greater than a value of height HC. In some aspects, the side portions743may extend further outwards than the top portion702or the bottom portion701. This configuration can be desirable to provide increased surface area for attaching the side border portions343of two separate blank liner panels141to form one of the side seams143. In some aspects in which the second bottom border portion347is configured to attach to one of the first bottom border portions346, the bottom portion701may extend further than the top portion702.

The blank sheet491A can define the side crease lines242. The side crease lines242can divide the interior portion494A into a main subpanel portion742and a pair of side subpanel portions744. The main subpanel portion742can correspond to the main subpanel142of the blank liner panel141, and the side subpanel portions744can correspond to the side subpanels144of the blank liner panel141. The main subpanel portion742can define a width WC, and the side subpanel portions744can each define a width WB.

In some aspects, the insulation batt490A can optionally define a pair of side grooves741which can be positioned to align with the side crease lines242when the insulation batt490A is aligned with the interior portion494A. However, in other aspects, the insulation batt490A may not define the side grooves741. The side grooves741can be defined into the insulation batt490A, such as by die cutting the side grooves741into the insulation batt490A. In the present aspect, the side grooves741can be V-shaped. The side grooves741can be configured to increase flexibility of the insulation batt490A which can be desirable, particularly in aspects in which the insulation batt490A is relatively thick, for example and without limitation when the insulation batt490A is greater than ½″ in thickness. The insulation batt490A can range in thickness from less than 1/16″ to over 2″. In some aspects, the preferred thickness range can be from less than 1″ to over 1.5″. The side grooves741can define a main insulation portion752and two side insulation portions754which can be sized and shaped substantially similar to the main subpanel portions742and the side subpanel portions744, respectively. The side grooves741can be defined on either one or both sides of the insulation batt490A. In some aspects, the side grooves741can extend completely through the insulation batt490A dividing the insulation batt490A into separate subpanels.

The insulation batt490A can define a width WFand a height HDwhich can each define a value substantially the same or slightly less, for example and without limitation 1″ less, than the width WDand height HB, respectively. This sizing allows the insulation batt490A to fit within the panel cavity (not shown) defined between the interior portions494A of two blank sheets491A when the perimeter portions495A are attached in facing engagement. Sizing the insulation batt490A slightly smaller than the interior portion494A can provide clearance for the thickness of the insulation batt490A, particularly in embodiments in which the insulation batt490A defines a large thickness such as ½″ or greater.

FIG. 8is a top view of another aspect of a blank sheet491B and another aspect of an insulation batt490B for the bottom panel146ofFIG. 3A. In this aspect, the blank sheet491B can define a width WHand a height HE. In the present aspect, the width WHof the blank sheet491B, which can correspond to a width of the bottom panel146, can have substantially the same value as the width WCof the main subpanel portion742, which can correspond to a width of the main subpanel142of the liner panel141. The blank sheet491B can define the interior portion494B and the perimeter portion495B which can extend around a perimeter of the blank sheet491B. The bottom border308of the bottom panel146can be formed by attaching two perimeter portions495B of two separate blank sheets491B together in facing engagement.

The interior portion494B can define a width WIand a height HG. In some aspects in which the side seam143is a lap seam, the height HGcan have substantially the same value as the combination of the width WEof the side portion743and the widths WBof the two side subpanel portions744. The combination of width WEof the side portion743and the widths WBof the two side subpanel portions744can be approximately equal to a combined width of a one of the side seams143and a pair of side subpanels144which can together define a one of the side liner panels145. In other aspects in which the side seam143is a plain seam, the height HGcan have substantially the same value as twice the widths WBof the two side subpanel portions744. With two blank sheets491B aligned and attached in facing engagement, the interior portions494B can define the panel cavity (not shown) which can contain the insulation batt490B.

The blank sheet491B can define the bottom crease line247which can bisect the blank sheet491B. The perimeter portion495B can define a pair of first bottom border portions846which can correspond to the first bottom border portions346of the bottom panel146. Portions of the perimeter portion495B at opposite ends of the bottom crease line247can define a pair of side border portions847. The side border portions847can each define a width WGand the first bottom border portions846can each define a height HF. In the present aspect, the width WGand the height HFcan define values which can be substantially the same; however, in other aspects the height HFcan define a value greater than the value of the width WG. This configuration can be desirable to provide additional surface area for attaching the first bottom border portions346to the second bottom border portions347or to the main subpanels142.

The insulation batt490B can define a width WJand a height HHwhich can each define a value substantially the same or slightly less, for example and without limitation 1″ less, than the width WIand height HG, respectively. Similar toFIG. 7, this sizing allows the insulation batt490B to fit within the panel cavity (not shown) defined between two blank sheets491B. Sizing the insulation batt490B slightly smaller than the interior portion494B can provide clearance for the thickness of the insulation batt490B, particularly in embodiments in which the insulation batt490B defines a large thickness such as ½″ or greater.

In some aspects, the insulation batt490B can optionally define a bottom groove880which can be similar in shape, form, and function to the side grooves741. The bottom groove880can be positioned to align with the bottom crease line247when the insulation batt490B is aligned on top of the interior portion494B. However, in other aspects, the insulation batt490B may not define the bottom groove880.

FIG. 9is a top view of another aspect of a blank sheet491C and another aspect of an insulation batt490C for the insulated panels130ofFIG. 3A. The blank sheet491C can define a width WJand a height HI. The panel border333of the insulated panels130can be formed by attaching two perimeter portions495C of two separate blank sheets491C together in facing engagement. The interior portion494C can define a width WMand a height HJ. With two blank sheets491C aligned and attached in facing engagement, the interior portions494C can define the panel cavity (not shown) which can contain the insulation batt490C.

The perimeter portion495C can define a pair of first panel border portions946and a pair of second panel border portions947. The second panel border portions947can each define a width WL, and the first panel border portions946can each define a height HK. In the present aspect, the width WGand the height HFcan define values which can be substantially the same.

The insulation batt490C can define a width WNand a height HLwhich can each define a value substantially the same or slightly less, for example and without limitation 1″ less, than the width WMand height HJ, respectively. This sizing allows the insulation batt490C to fit within the panel cavity (not shown) defined between two blank sheets491C. Sizing the insulation batt490C slightly smaller than the interior portion494C can provide clearance for the thickness of the insulation batt490C, particularly in embodiments in which the insulation batt490C defines a large thickness such as ½″ or greater.

In some aspects, such as when the insulated panel130corresponding to the blank sheet491C is the top panel131, the width WJand the height HIcan be sized complimentary to the size and shape of the liner opening148. In this aspect, the width WJcan define a value substantially the same as the width WCof the main subpanel portion742of blank sheet491A. In aspects in which the side seam143is a lap seam, the height HIcan define a value substantially the same as the combination of the width WEof the side portion743and the widths WBof the two side subpanel portions744. These widths can correspond to a combined width of the two side subpanels144and the side seam143which can together define a one of the side liner panels145as shown inFIG. 2B. In other aspects in which the side seam143is a plain seam, the height HIcan have substantially the same value as twice the widths WBof the two side subpanel portions744. In aspects in which the insulated panel130is the divider panel431or the floor panel432as shown inFIG. 4A, the width WJand the height HIcan be sized slightly smaller than the liner opening148to accommodate the thickness of the insulation batt490A of the blank liner panels141.

A method of assembling the insulated box assembly100can comprise configuring the insulated liner140in the collapsed installation configuration, aligning the insulated liner140with the box opening120of the box110, inserting the insulated liner140into the internal box cavity122, and configuring the insulated liner140to the expanded configuration. Configuring the insulated liner140in the collapsed insertion configuration can comprise folding the side liner panels145inwards towards the liner cavity150, collapsing the main liner panels147inwards towards the liner cavity150, and folding the liner bottom149. Configuring the insulated liner140to the expanded configuration can comprise expanding the main liner panels147away from the liner cavity150, unfolding the side liner panels145outwards from the liner cavity150, and unfolding the liner bottom149. Configuring the insulated liner140to the expanded configuration can further comprise self-expanding the insulated liner140with the force F2, F3exerted by the positional memory of the insulated liner. Configuring the insulated liner140to the expanded configuration can further comprise positioning a one of the main liner panels147, the side liner panels145, and the liner bottom149in facing engagement with a one of the main box panels112, the side box panels114, and the box bottom panel413. The method can further comprise covering the liner opening148with the insulated panel130and forming the seal between the insulated panel130and the insulated liner140.

In the present aspect, the blank sheets491can comprise paper, such as kraft paper; however, in other embodiments, the blank sheets491can comprise posterboard, cardboard, plastic sheeting, cloth, or any other suitable material. In some aspects, the pair of blank sheets491can each comprise a different material. In some aspects, the blank sheets491can be a water-proof or water-resistant material, such as water-resistant kraft paper. The insulation batt490can comprise paper or other paper fiber materials; however, in other aspects, the insulation batt490can comprise cotton, foam, rubber, plastics, fiberglass, mineral wool, or any other flexible insulation material. In the present application, the insulation batt490can be repulpable. In the present aspect, the insulated box assembly100can be 100% recyclable. In the present aspect, the insulated box assembly100can be single-stream recyclable wherein all materials comprised by the insulated box assembly can be recycled by a single processing train without requiring separation of any materials. In some aspects, only the insulated liner140can be single-stream recyclable. In the present aspect, the insulated box assembly100can be compostable. In the present aspect, the insulated box assembly100can be repulpable. In the present aspect, insulated box assembly100and each of the box110, the insulated liner140, and the insulated panel130can be repulpable in accordance with the requirements of the Aug. 16, 2013, revision of the “Voluntary Standard For Repulping and Recycling Corrugated Fiberboard Treated to Improve Its Performance in the Presence of Water and Water Vapor” provided by the Fibre Box Association of Elk Grove Village, Ill., which is hereby incorporated by reference in its entirety. In the present aspect, insulated box assembly100and each of the box110, the insulated liner140, and the insulated panel130can be recyclable in accordance with the requirements of the Aug. 16, 2013, revision of the “Voluntary Standard For Repulping and Recycling Corrugated Fiberboard Treated to Improve Its Performance in the Presence of Water and Water Vapor” provided by the Fibre Box Association of Elk Grove Village, Ill. In some aspects, the insulated box assembly100can be biodegradable.

Recyclable and repulpable insulation materials are further described in U.S. Patent Application No. 62/375,555, filed Aug. 16, 2016, U.S. Patent Application No. 62/419,894, filed Nov. 9, 2016, and U.S. Patent Application No. 62/437,365, filed Dec. 21, 2016, which are each incorporated by reference in their entirety herein.

The insulated box assembly100can be used in applications in which a user or mail carrier transports perishable or temperature-sensitive goods or contents. For example and without limitation, the insulated box assembly100can be used to transport groceries or medications. In some applications, a material such as ice, dry ice, or a freeze pack can be placed in the liner cavity150to maintain a temperature of goods for longer durations. Alternatively, the insulated box assembly100can be used to transport warm contents, such as takeout delivery of freshly-prepared food. In such applications, a heat pack or other heat source can be placed within the liner cavity to keep contents of the insulated box assembly100warm.

Many forms of packaging and insulation are not accepted by many recycling facilities or curb-side recycling programs in which a waste management service collects recyclables at a user's home. Examples such as bubble wrap or plastic-wrapped insulations may not be accepted. In some aspects, the insulated box assembly100can reduce waste and pollution by comprising materials which are recyclable or biodegradable. In aspects in which the insulated box assembly100is curb-side or single-stream recyclable, the user may be more likely to recycle the insulated box assembly100due to the ease of curb-side collection.