Patent ID: 12195266

DETAILED DESCRIPTION

The present disclosure can be understood more readily by reference to the following detailed description, examples, drawings, and claims, and the previous and following description. However, before the present devices, systems, and/or methods are disclosed and described, it is to be understood that this disclosure is not limited to the specific devices, systems, and/or methods disclosed unless otherwise specified, and, as such, can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.

The following description is provided as an enabling teaching of the present devices, systems, and/or methods in its best, currently known aspect. To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects of the present devices, systems, and/or methods described herein, while still obtaining the beneficial results of the present disclosure. It will also be apparent that some of the desired benefits of the present disclosure can be obtained by selecting some of the features of the present disclosure without utilizing other features. Accordingly, those who work in the art will recognize that many modifications and adaptations to the present disclosure are possible and can even be desirable in certain circumstances and are a part of the present disclosure. Thus, the following description is provided as illustrative of the principles of the present disclosure and not in limitation thereof.

As used throughout, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “an element” can include two or more such elements unless the context indicates otherwise.

Ranges can be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

For purposes of the current disclosure, a material property or dimension measuring about X or substantially X on a particular measurement scale measures within a range between X plus an industry-standard upper tolerance for the specified measurement and X minus an industry-standard lower tolerance for the specified measurement. Because tolerances can vary between different materials, processes and between different models, the tolerance for a particular measurement of a particular component can fall within a range of tolerances.

As used herein, the terms “optional” or “optionally” mean that the subsequently described event or circumstance can or cannot occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.

The word “or” as used herein means any one member of a particular list and also includes any combination of members of that list. Further, one should note that conditional language, such as, among others, “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain aspects include, while other aspects do not include, certain features, elements and/or steps. Thus, such conditional language is not generally intended to imply that features, elements and/or steps are in any way required for one or more particular aspects or that one or more particular aspects necessarily include logic for deciding, with or without user input or prompting, whether these features, elements and/or steps are included or are to be performed in any particular aspect.

Disclosed are components that can be used to perform the disclosed methods and systems. These and other components are disclosed herein, and it is understood that when combinations, subsets, interactions, groups, etc. of these components are disclosed that while specific reference of each various individual and collective combinations and permutation of these may not be explicitly disclosed, each is specifically contemplated and described herein, for all methods and systems. This applies to all aspects of this application including, but not limited to, steps in disclosed methods. Thus, if there are a variety of additional steps that can be performed it is understood that each of these additional steps can be performed with any specific aspect or combination of aspects of the disclosed methods.

Disclosed in the present application is a temperature-regulating lid and associated methods, systems, devices, and various apparatus. Example aspects of the temperature-regulating lid can comprise a lid box. Example aspects can also comprise a temperature-regulating insert. It would be understood by one of skill in the art that the disclosed insulating lid 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.

FIG.1illustrates top perspective view of a first aspect an insulated box assembly100, according to the present disclosure. As shown, the insulated box assembly100can comprise an outer box110, an inner box120, and an insulating lining130. According to example aspects, the inner box120can be positioned within an inner cavity230(shown inFIG.2A) of the outer box110, and the insulating lining130can be positioned therebetween. The inner box120can define a storage hollow430(shown inFIG.4A) for housing contents therein, such, as for example, perishable foods, pharmaceuticals, and other temperature-sensitive items. The insulating lining130can provide cushioning and climate control for the inner box120and the contents therein.

FIG.2Aillustrates top perspective view of an example aspect of the outer box110. The outer box110can define a front lateral sidewall212, a back lateral sidewall214, a left lateral sidewall216, and a right lateral sidewall218. The lateral sidewalls212,214,216,218can define a top end220of the outer box110and a bottom end222of the outer box110. Further, the lateral sidewalls212,214,216,218can define an inner surface224and an outer surface226of the outer box110. The inner surface224can define an inner cavity230, as shown. Moreover, a top opening232can be formed at the top end220of the outer box110, and a bottom opening382(shown inFIG.3A) can be formed at the bottom end222of the outer box110. The lateral sidewalls212,214,216,218can form four top corners234at the top opening232and four bottom corners384(shown inFIG.3B) at the bottom opening382. The use of the directional terms herein, such as right, left, front, back, top, bottom, and the like can refer to the orientation shown and described in the corresponding figures.

Example aspects of the outer box110can comprise a front top panel242extending from the front lateral sidewall212at the top end220of the outer box110and a back top panel244extending from the back lateral sidewall214at the top end220of the outer box110. The outer box110also can comprise a left top panel246extending from the left lateral sidewall216at the top end220and a right top panel248extending from the right lateral sidewall218at the top end220. According to example aspects, each of the top panels242,244,246,248can be monolithically formed with the outer box110and can be connected to the corresponding lateral sidewalls212,214,216,218, respectively, at a bend line247.

In example aspects, the right top panel248can define a first cover tab260at a first end261and a second cover tab262at a second end263. The left top panel246can also define a first cover tab260at a first end261and a second cover tab262at a second end263. As such, a first or second cover tab260,262can be formed proximate each of the top corners234of the outer box110, respectively. In example aspects, each of the first and second cover tabs260,262can be substantially L-shaped, as shown. The L-shaped first and second cover tabs260,262can define a leg264extending in a first direction and an arm266extending in a substantially perpendicular second direction. In the present aspect, the arm266can define and arm length that can be shorter than a leg length of the leg264. However, in other aspects, the arm length of the arm266can be about equal to or greater than the leg length of the leg264. In other aspects, the first and second cover tabs260,262can define any other suitable shape, including, but not limited to, a lowercase l-shape.

Referring specifically to the right top panel248, a proximal end of each of the first and second cover tabs260,262can be connected to the corresponding right lateral sidewall218at a bend line268, such that the first and second cover tabs260,262can fold relative to the right lateral sidewall218. In some aspects, the first and second cover tabs260,262can be monolithically formed with the right top panel248and can be connected to the right top panel248at a tear line (not shown). Example aspects of the tear line can be defined by perforations, slits, scoring, creases, or the like, which can facilitate tearing along the tear line, such that the first and second cover tabs260,262can be separated from the right top panel248, as shown. In other aspects, the first and second cover tabs260,262can be monolithically formed with the right top panel248and can be cut away from the right top panel248by a cutting tool, such as a cutting machine, scissors, a blade, or the like. In still other aspects, the first and second cover tabs260,262can be separately formed from the right top panel248. According to example aspects, the first and second cover tabs260,262of the left top panel246can be substantially the same as the first and second cover tabs260,262of the right top panel248.

Example aspects of the top panels242,244,246,248can be oriented in an open orientation, as shown inFIG.2A, wherein the top opening232is uncovered, and a closed orientation, wherein the top opening232is covered.FIG.2Billustrates the top panels242,244,246,248in a partially closed orientation. According to example aspects, in the closed orientation, the right top panel248and left top panel246, including the corresponding first and second cover tabs260,262(shown inFIG.2A), can be configured to fold toward the top opening232(shown inFIG.2A) to cover or partially cover the top opening232. The front top panel242and back top panel244can then be folded towards the top opening232to cover or partially cover the right top panel248and the left top panel246. In the fully closed orientation, the top opening232(shown inFIG.2A) can be completely covered and the top panels242,244,246,248can define a top sidewall250of the outer box110. Example aspects of the top sidewall250can be oriented about perpendicular to the lateral sidewalls212,214,216,218when the top panels242,244,246,248are secured in the closed orientation.

In various aspects, the front and back top panels242,244can be secured to the left and right top panels246,248by a fastener, such as an adhesive. The adhesive can be, for example, glue, an epoxy, tape, or the like; however, in other aspects, the front and back top panels242,244can be secured to the left and right top panels246,248by another fastener, such as stitching, staples, snaps, hook and loop fasteners, ties, etc. In still other aspects, the front and back top panels242,244may not be secured to the left and right top panels246,248. Example aspects of the front and back top panels242,244also can be secured to one another (or otherwise secured in the closed orientation) by a fastener, such as tape, or another adhesive. In other aspects, the front and back top panels242,244can be secured in the closed orientation by another suitable fastener, such as, stitching, staples, snaps, ties, hook and loop fasteners, etc., and in still other aspects, the front and back top panel242,244may not be secured to one another at all. In some aspects, any or all of the top panels242,244,246,248can be secured to one or all of the laterals sidewalls212,214,216,218.

FIG.3Aillustrates a bottom perspective view of the outer box110. As shown, the outer box110can comprise a front bottom panel372extending from the front lateral sidewall212at the bottom end222of the outer box110and a back bottom panel374extending from the back lateral sidewall214at the bottom end222of the outer box110. The outer box110also can comprise a left bottom panel376extending from the left lateral sidewall216at the bottom end222and a right bottom panel378extending from the right lateral sidewall218at the bottom end222. According to example aspects, each of the bottom panels372,374,376,378can be connected to the corresponding lateral sidewalls212,214,216,218, respectively, by a bend line377.

Example aspects of the bottom panels372,374,376,378can be oriented in an open orientation, as shown inFIG.3A, wherein the bottom opening382is uncovered, and a closed orientation, as shown inFIG.3B, wherein the bottom opening382is covered. According to example aspects, each of the front bottom panel372, back bottom panel374, left bottom panel376, and right bottom panel378can be folded in substantially the same manner as the top panels242,244,246,248(shown inFIG.2A). Referring toFIG.3B, in the closed orientation, the bottom opening382(shown inFIG.3A) can be completely covered and the bottom panels372,374,376,378(left and right bottom panels376,378shown inFIG.3A) can define a bottom sidewall380of the outer box110. Example aspects of the bottom sidewall380can be oriented about perpendicular to the lateral sidewalls212,214,216,218(back and right lateral sides214,218shown inFIG.2A). In various aspects, the front and back bottom panels372,374can be secured to the left and right bottom panels376,378by a fastener, as described above with respect to the left and right top panels246,248. Furthermore, example aspects of the front and back bottom panels372,374can be secured to one another by a fastener, such as tape379, as shown, as described above with respect to the front and back top panels242,244(shown inFIG.2A).

The outer box110of the present aspect can comprise the four lateral sidewalls212,214,216,218and can define a substantially square cross-sectional shape. However, in other aspects, the number of lateral sidewalls can vary and/or the cross-section shape of the outer box110can vary—for example, the outer box110can define a triangular, rectangular, or circular cross-sectional shape, or any other suitable cross-sectional shape. The outer box110of the present aspect can also comprise the four top panels242,244,246,248and the four bottom panels372,374,376,378; however, other aspects of the outer box110can comprise more or fewer top panels and/or bottom panels.

FIG.4Aillustrates a top perspective view of the inner box120of the insulated box assembly100(shown inFIG.1). The inner box120can define a front lateral sidewall412, a back lateral sidewall414, a left lateral sidewall416, and a right lateral sidewall418. The lateral sidewalls412,414,416,418can define a top end420of the inner box120and a bottom end422of the inner box120. Further, the lateral sidewalls412,414,416,418can define an inner surface424of the inner box120and an outer surface426of the inner box120. The inner surface424can define a storage hollow430, as shown. Moreover, a top opening432can be formed at the top end420of the inner box120, and a bottom opening (not shown) can be formed at the bottom end422of the inner box120. The lateral sidewalls412,414,416,418can form four top corners434at the top opening432and four bottom corners484at the bottom opening (only two of the four bottom corners484are visible).

Example aspects of the inner box120can comprise a front top flap442extending from the front lateral sidewall412at the top end420of the inner box120and a back top flap444extending from the back lateral sidewall414at the top end420of the inner box120. The inner box120also can comprise a left top flap446extending from the left lateral sidewall416at the top end420and a right top flap448extending from the right lateral sidewall418at the top end420. According to example aspects, each of the top flaps442,444,446,448can be monolithically formed with the inner box120and can be connected to the corresponding lateral sidewall412,414,416,418, respectively, at a bend line449, such that each of the top flaps442,444,446,448can fold relative to the corresponding lateral sidewall412,414,416,418.

As shown, each of the top flaps442,444,446,448can define a first flap section450proximate to the corresponding lateral sidewall412,414,416,418, and a second flap section452distal from the corresponding lateral sidewall412,414,416,418. The second flap section452can be connected to the first flap section450at a bend line454, such that the second flap section452can fold relative to the first flap section450. In some aspects of the top flaps442,444,446,448, an indentation460can be defined at a first end462and second end464of the second flap section452, such that the second flap section452can define a width that can be less than a width of the first flap section450. For example, as shown, the front and back top flaps442,444can comprise the second flap section452comprising an indentation460at each of the first end462and second end464, and thus can define a shorter width than the first flap section450.

The inner box120can comprise a front bottom panel472(shown inFIG.4B) extending from the front lateral sidewall412at the bottom end422and a back bottom panel474(shown inFIG.4B) extending from the back lateral sidewall414at the bottom end422. The inner box120can also comprise a left bottom panel476extending from the left lateral sidewall416at the bottom end422of the inner box120and a right bottom panel478extending from the right lateral sidewall418at the bottom end422of the inner box120. According to example aspects, each of the bottom panels472,474,476,478can be connected to the corresponding lateral sidewalls412,414,416,418, respectively, by a bend line477.

According to example aspects, each of the bottom panels472,474,476,478of the inner box120can be folded and secured in a closed orientation in substantially the same manner as the top panels242,244,246,248and bottom panels372,374,376,378of the outer box110, as described above with reference toFIGS.2B and3B. Referring toFIG.4B, in the closed orientation, the bottom opening (not shown) can be completely covered and the bottom panels472,474,476,478(left and right bottom panels476,478shown inFIG.4A) can define a bottom sidewall480of the inner box120. Example aspects of the bottom sidewall480can be oriented about perpendicular to the lateral sidewalls412,414,416,418(back and right lateral sidewalls414,418shown inFIG.4A).

Example aspects of the insulated box assembly100(shown inFIG.1) can comprise an temperature-regulating lid500, as shown inFIG.5A. The temperature-regulating lid500can be oriented in an open orientation, as shown inFIG.5A, and a closed orientation, as shown inFIG.5C. The temperature-regulating lid500can comprise a lid box510and an insulating lid liner560. Example aspects of the temperature-regulating lid500can define a front side flap512, a back side flap514, a left side flap516, a right side flap518, a top panel520, and a bottom panel522. Each of the side flaps512,514,516,518can be connected to the bottom panel522by a bend line524. Each of the right side flap518, left side flap516, and front side flap512can define an extension flap530extending therefrom distal from the bottom panel522. The extension flaps530can be connected to the corresponding side flaps512,516,518by a bend line532. A slot540can be formed at the bend line532between the front side flap512and the corresponding extension flap530, as shown.

Example aspects of the top panel520can extend from the back side flap514distal from the bottom panel522and can be connected to the back side flap514by a bend line542. A locking tab544can extend from the top panel520distal from the back side flap514and can be connected thereto by a bend line546. In some aspects, the top panel520can define a width great than a width of the bottom panel522, as shown. The width of the bottom panel522can generally define a width of the lid box510. The portions of the top panel520extending beyond the width of the lid box510can be defined as wings550of the top panel520. Example aspects of the wings550can be monolithically formed with the top panel520. In some aspects, one or each of the wings550can define a cut-out552.

According to example aspects, as the lid liner560can define a bottom surface562and a top surface (not shown), which can be substantially planar and parallel to one another. The lid liner560can be received on the bottom panel522, such that the bottom surface562of the lid liner560faces the bottom panel522. Example aspects of the lid liner560can comprise, for example, R-4 poly-encapsulated thermal 100% recycled cotton. Other aspects of the lid liner560can comprise, for example, polyester film, such as polyethylene terephthalate (PET) film, foams, pellets, fabrics, nonwovens, polyethylene, polyurethane, polypropylene or any other suitable material that can contribute towards a cushioned and climate controlled protective layer in the insulated box assembly100. In some aspects, the lid liner560can be biodegradable, and in some aspects, the lid liner560can be compostable.

FIG.5Billustrates the temperature-regulating lid500in the closed configuration. The extension flaps530can be folded over the lid liner560(shown inFIG.5A) to rest on the top surface (not shown) of the lid liner560. The top panel520of the lid box510can also be folded over the lid liner560to rest on the extension panels530and the top surface of the lid liner560. The locking tab544can be inserted through the slot540to maintain the temperature-regulating lid500in an assembled configuration, as shown. The wings550can extend beyond the width of the of the lid box510, as defined by the bottom panel522(shown inFIG.5A).

Referring toFIG.6A, example aspects of the insulating lining130(shown inFIG.1) can comprise one or more liners600. In the present aspect, the insulating lining130can comprise a sidewall liner610, as shown inFIG.6A, and a bottom wall liner640, as shown inFIG.6B. The sidewall liner610can define a top end620, a bottom end622, an inner surface624, outer surface626, a first end628, and a second end630. The first end628can be folded towards the second end630to generally form a front lateral side612, a back lateral side614, a left lateral side616, and a right lateral side618, as shown. As such, the sidewall liner610can generally define a square cross-sectional shape when folded and can define an inner lining cavity650. Referring toFIG.6B, the bottom wall liner640can define a substantially planar bottom liner surface642and a substantially planar top liner surface744(shown inFIG.7). In example aspects, the sidewall liner610and bottom wall liner640can positioned between the outer box110(shown inFIG.1) and the inner box120(shown inFIG.1) to provide both cushioning and climate control for the inner box120, as will be described in further detail below. In other aspects, the insulating lining130can comprise more or fewer separate liners600and/or the liners600can define a different configuration.

Various aspects of the liners600(e.g., the sidewall liner610and bottom wall liner640) of the insulating lining130(shown inFIG.1) and can comprise materials including, but not limited to, polyester film, such as polyethylene terephthalate (PET) film, foams, rubber, fiberglass, mineral wool, pellets, fabrics, nonwovens, polyethylene, polyurethane, polypropylene, paper, paper fiber, and any other suitable material that can contribute towards a cushioned and climate controlled protective layer in the insulated box assembly100. In some aspects, the sidewall liner610and/or bottom wall liner640can be biodegradable, and in some aspects, the sidewall liner610and/or bottom wall liner640can be compostable. In a particular aspect, the sidewall liner610and bottom wall liner640can be formed from R-4 poly-encapsulated thermal 100% recycled cotton.

In the present application, the insulating lining130and insulating lid liner560can 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 assembly100can be recycled by a single processing train without requiring separation of any materials or components of the insulated box assembly100. In the present aspect, the insulated box assembly100can be compostable. In the present aspect, the insulated box assembly100can be repulpable. In the present aspect, the insulated box assembly100and each of the outer box110, inner box120, insulating lining130, and the temperature-regulating lid500can 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, IL which is hereby incorporated in its entirety. In the present aspect, insulated box assembly100and each of the outer box110, inner box120, insulating lining130, and the temperature-regulating lid500can 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, IL.

Recyclable and repulpable insulation materials are further described in U.S. patent application Ser. No. 15/677,738, filed Aug. 15, 2017, U.S. Provisional Patent Application No. 62/375,555, filed Aug. 16, 2016, U.S. Provisional Patent Application No. 62/419,894, filed Nov. 9, 2016, and U.S. Provisional Patent Application No. 62/437,365, filed Dec. 21, 2016, which are each incorporated by reference in their entirety herein.

FIG.7illustrates a first step in assembling the insulated box assembly100(shown inFIG.1). In the present aspect, the bottom panels372,374,376,378(shown inFIG.3A) of the outer box110can be folded to the closed orientation define the bottom sidewall380(shown inFIG.3B), as described above with reference toFIG.3B, and the top panels242,244,246,248of the outer box110can be in the open orientation. The sidewall liner610and bottom wall liner640of the insulating lining130can be positioned within the inner cavity230. With the insulating lining130positioned in the inner cavity230of the outer box110, a volume of the inner cavity230can be reduced, and can be defined as the lining cavity650. The outer surface626(shown inFIG.6A) of the sidewall liner610can face the inner surface224of the outer box110, and the inner surface624of the sidewall liner610can face the lining cavity650. According to example aspects, the front lateral side612of the sidewall liner610can face the front lateral sidewall212of the outer box110, as shown. Similarly, the left lateral side616can face the left lateral sidewall216, the back lateral side614can face the back lateral sidewall214, and the right lateral side618can face the right lateral sidewall218. The bottom liner surface642(shown inFIG.6B) of the bottom wall liner640can face the inner surface224of the outer box110, and the top liner surface744of the bottom wall liner640can face the liner cavity450, as shown. Specifically, the bottom liner surface642of the bottom wall liner640can face the bottom sidewall380(shown inFIG.3B) of the outer box110. In example aspects, each of the lateral sides612,614,616,618of the sidewall liner610can contact the corresponding lateral sidewalls212,214,216,218of the outer box110, and the bottom liner surface642of the bottom wall liner640can contact the bottom sidewall380of the outer box110. In example aspects, the bottom wall liner640can be inserted through the top opening232of the outer box110, and then the sidewall liner610can be inserted through the top opening232of the outer box110, such that the bottom end622of the sidewall liner610can rest on the top liner surface744of the bottom wall liner640. In other aspects, the sidewall liner610and bottom wall liner640can be inserted into the inner cavity230of the outer box110in reverse order.

FIG.8illustrates a second step in assembling the insulated box assembly100. The inner box120can be positioned within the lining cavity650(shown inFIG.6A), such that the outer surface426of the inner box120can face the inner surface624(shown inFIG.6A) of the sidewall liner610. According to example aspects, the front lateral sidewall412of the inner box120can face the front lateral side612of the sidewall liner610, as shown. Similarly, the left lateral sidewall416can face the left lateral side616, the back lateral sidewall414can face the back lateral side614(shown inFIG.6A), and the right lateral sidewall418can face the right lateral side618(shown inFIG.6A). As such, the sidewall liner610can substantially wrap around the lateral sidewalls412,414,416,418of the inner box120. Further, the bottom panels472,474,476,478(front, back, and left bottom panels472,474,476shown inFIGS.4A and4B) of the inner box120can be folded to the closed orientation, as described above with reference toFIG.4B, to define the bottom sidewall480of the inner box120. The bottom sidewall480can face the top liner surface744(shown inFIG.7) of the bottom wall liner640(shown inFIG.6B) of the insulating lining130. In example aspects, each of the lateral sidewalls412,414,416,418of the inner box120can contact the corresponding lateral sides612,614,616,618of the sidewall liner610, and the bottom sidewall480of the inner box120can contact the top liner surface744of the bottom wall liner. According to example aspects, the inner box120can fit snugly within the lining cavity650(shown inFIG.6A), such that movement of the inner box120within the lining cavity650is substantially prohibited. In some aspects, contents such as perishable food, or other temperature-sensitive items, can be placed within the storage hollow430of the inner box120before inserting the inner box120into the lining cavity650, and in other aspects, the contents can be placed within the storage hollow430after the inner box120is inserted into the lining cavity650.

FIG.9illustrates a third step in assembling the insulated box assembly100, wherein the first and second cover tabs260,262(second cover tab262shown inFIG.2A) of the left and right top panels246,248(right top panel248shown inFIG.2A) can be folded towards insulating lining130and can generally rest against the top end620of the sidewall liner610proximate to the top corners234at the top end220of the outer box110.FIG.9specifically illustrates the first cover tab260of the left top panel246. The first cover tab260can be folded such that the leg264of the first cover tab260generally extends along the front lateral side612at the top end620of the sidewall liner610, and the arm266of the first cover tab260generally extends along the left lateral side616at the top end620of the sidewall liner610. Each of the other first and second cover tabs260,262can be folded in substantially the same manner.

FIG.10Aillustrates a fourth step, wherein the top flaps442,444,446,448of the inner box120can be folded away from the storage hollow430and towards the outer box110. For example, the front top flap442extending from the front lateral sidewall412of the inner box120can be folded generally toward the front lateral sidewall212of the outer box110. The first flap section450of the front top flap442can generally rest against the top end620(shown inFIG.6A) of the sidewall liner610(shown inFIG.6A) proximate to the top end420of the inner box120, and the second flap section452(shown inFIG.4A) of the front top flap442can be inserted between the front lateral side612(shown inFIG.6A) of the sidewall liner610and the front lateral sidewall212of the outer box110. Each of the right top flap448, left top flap446, and back top flap444can be folded in substantially the same manner, as shown. The first flap section450of the front top flap442can overlap the leg264(shown inFIG.2A) of the first cover tab260of each of the left and right top panel246,248, and the back top flap444can overlap the leg264of each of the second cover tabs262. The first flap section450of the left top flap446can overlap the arms266(shown inFIG.2A) of the first and second cover tabs260,262of the left top panel246, and the first flap section450of the right top flap448can overlap the arms266of the first and second cover tabs260,262of the right top panel248. As such, the top end620(shown inFIG.6A) of the sidewall liner610(shown inFIG.6A) can be completely covered by the first and second cover tabs260,262of the outer box110and the top flaps442,444,446,448of the inner box120, as illustrated.

In other aspects, the first and second cover tabs260,262of the outer box110and the top flaps442,444,446,448of the inner box120can be folded in a different fashion. For example,FIG.10Bis a close-up view of the first cover tab260adjacent to the back and left top flaps444,446. As shown, in the present aspect, the back and left top flaps444,446can be folded, as described above, before folding the first cover tab260. The leg264of the first cover tab260can be inserted under the adjacent back top flap444, and the arm266of the first cover tab260can overlap, and may rest on, the adjacent left top flap446.

FIG.11illustrates a fifth step in assembling the insulated box assembly100. The fifth step can comprise placing the temperature-regulating lid500over the top opening432(shown inFIG.4A) of the inner box120, such that the top opening432is completely covered and the storage hollow430is completely enclosed. According to example aspects, the wings550of the top panel520of the temperature-regulating lid500can be configured to rest on the front and back top flaps442,444(shown inFIG.4A), respectively, of the inner box120to support the temperature-regulating lid500at the top end420of the inner box120. In this configuration, the top panel520of the temperature-regulating lid500can be about flush with the top end220of the outer box110, as shown. In other aspects, the temperature-regulating lid500can be rotated about 90°, such that the wings550can rest on the left and right top flaps448,448. The front, back, left, and right side flaps512,514,516,518(shown inFIG.5A) of the temperature-regulating lid500can extend into the storage hollow430(shown inFIG.4A) and can face the front, back, left, and right lateral sidewalls412,414,416,418(shown inFIG.4A) of the inner box120, respectively. According to example aspects, the temperature-regulating lid500can be easy removed from the insulated box assembly100. A user can engage one or both of the cut-outs552in the wings550with a finger or multiple fingers and can lift the temperature-regulating lid500away from the insulated box assembly100to access the contents housed in the storage hollow430without the need to disassemble the insulated box assembly100.

FIG.12illustrates a sixth and final step in assembling the insulated box assembly100and illustrates the insulated box assembly100in a fully assembled configuration. With the insulating liner130(shown inFIG.1) and inner box120(shown inFIG.1) received and assembled within the inner cavity230(shown inFIG.2A) of the outer box110, the top panels242,244,246,248(left and right top panels246,248shown inFIG.2A) of the outer box110can be folded to the closed orientation, as described above with reference toFIG.2B, to define the top sidewall250of the outer box110, as shown. The top panels242,244,246,248can be fixed in the closed orientation by a fastener, such as tape379, as illustrated herein. In other aspects, any other suitable fastener, as described above, can be used to fix the top panels242,244,246,248in the closed orientation.

Thus, a method for assembling the insulated box assembly100can comprise providing an outer box110, the outer box110defining the inner cavity230, inserting the insulating lining130within the inner cavity230to define the lining cavity650, and inserting the inner box120into the lining cavity650. In some aspects, the method can further comprise folding the first and second cover tabs260,262over the top end620of the sidewall liner610and folding the top flaps442,444,446,448over the top end620of the sidewall liner610to fully cover the top end620of the sidewall liner610. According to example aspects, a method for using the insulated box assembly100can comprise assembling the insulated box assembly100, inserting contents into the storage hollow430of the inner box120, and sending the insulated box assembly100to a recipient.

FIG.13illustrates another example aspect of the outer box110, with the insulating lining130positioned in the inner cavity230. As shown, in the present aspect, the top panels242,244,246,248of the outer box110do not comprise the first and second cover tabs260,262(shown inFIG.2A). Instead, each of the top panels242,244,246,248can define a substantially rectangular shape and can be substantially similar in size and shape to the bottom panels372,374,376,378(shown inFIG.3A).

FIGS.14A and14Billustrate another example aspect of the inner box120(shown inFIG.1), wherein the inner box120can comprise a first inner box piece1430, as shown inFIG.14A, and a second inner box piece1450, as shown inFIG.14B. Referring toFIG.14A, the first inner box piece1430can comprise the left lateral sidewall416, the right lateral sidewall418and a first bottom sidewall1432. Each of the left lateral sidewall416and right lateral sidewall418can be monolithically formed with the first bottom sidewall1432and can be connected to the first bottom sidewall1432at a bend line1434. The left and right lateral sidewalls416,418can define the top end420and bottom end422of the inner box120. Each of the left lateral sidewall416and right lateral sidewall418can define a first side1436and a second side1438opposite the first side1436. Each of the first and second sides1436,1438can extend between the top end420and the bottom end422of the inner box120. A first side flap1440can extend from the first side1436of each of the left and right lateral sidewalls416,418and a second side flap1442can extend from the second side1438of the left and right lateral sidewalls416,418, as shown. The first and second side flaps1440,1442can be connected to the corresponding left and right lateral sidewalls416,418at a bend line1444, as shown, and can fold towards the storage hollow430(shown inFIG.4A).

The first inner box piece1430can comprise the left top flap446extending from the left lateral sidewall416at the top end420and the right top flap448extending from the right lateral sidewall418at the top end420. In the present aspect, the first flap section450of the left and right top flaps446,448can taper outward from the top end420to the second flap section452, as shown. As such, in example aspects, a width of the second flap section452of the left and right top flaps446,448can be greater than a width of the corresponding left and right lateral sidewalls416,418at the top end420of the inner box120(shown inFIG.1).

FIG.14Billustrates the second inner box piece1450of the inner box120. The second inner box piece1450can comprise the front lateral sidewall412, the back lateral sidewall414, and a second bottom sidewall1452. Each of the front lateral sidewall412and back lateral sidewall414can be monolithically formed with the second bottom sidewall1452and can be connected to the second bottom sidewall1452at a bend line1454. Each of the front lateral sidewall412and back lateral sidewall414can define a first side1456and a second side1458. The front top flap442can extend from the front lateral sidewall412at the top end420, and the back top flap444can extend from the back lateral sidewall414at the top end420. Each of the front and back top flaps442,444can extend beyond the first and second sides1456,1458of the corresponding front and back lateral sidewalls412,414, such that each of the front and back top flaps442,444can define a width greater than a width of the corresponding front and back lateral sidewalls412,414at the top end420.

FIG.15illustrates a step in assembling the insulated box assembly100, wherein the first inner box piece1430can be inserted into the lining cavity650(shown inFIG.6A) defined by the insulating lining130. The left lateral sidewall416(shown inFIG.14A) of the first inner box piece1430can face the left lateral side616(shown inFIG.14A) of the sidewall liner610, the right lateral sidewall418of the first inner box piece1430can face the right lateral side618(shown inFIG.6A) of the sidewall liner610, and the first bottom sidewall1432of the first inner box piece1430can face the bottom wall liner640(shown inFIG.6B). The first and second side flaps1440,1442(first side flaps1440shown inFIG.14A) of the left and right lateral sidewalls416,418can be folded such that the first side flaps1440face the front lateral side612of the sidewall liner610and the second side flaps1442face the back lateral side614of the sidewall liner610. The left and right top flaps446,448can be folded over the top end620of the sidewall liner610as described above with reference toFIG.10.

FIG.16illustrates a next step in assembling the insulated box assembly100, wherein the second inner box piece1450can be inserted into the lining cavity650(shown inFIG.6A). The front lateral sidewall412(shown inFIG.14B) of the second inner box piece1450can face the front lateral side612(shown inFIG.6A) of the sidewall liner610(shown inFIG.6A) and first side flaps1440(shown inFIG.14A). The back lateral sidewall414of the second inner box piece1450can face the back lateral side614(shown inFIG.6A) of the sidewall liner610and the second side flaps1442(shown inFIG.14A). The second bottom sidewall1452of the second inner box piece1450can face the first bottom sidewall1432(shown inFIG.14A) of the first inner box piece1430. In other aspects, the first inner box piece1430and second inner box piece1450can be inserted into the lining cavity650in reverse order, such that the second bottom sidewall1452of the second inner box piece1450faces the bottom wall liner640, and first bottom sidewall1432of the first inner box piece1430faces the second bottom sidewall1452.

The front and back top flaps442,444can be folded over the top end620(shown inFIG.6A) of the sidewall liner610, as described above with reference toFIG.10. As shown, in the present aspect, the front, back, left, and right top flaps442,444,446,448can fully cover the top end620of the sidewall liner610. With both the first and second inner box pieces1430,1450assembled in the lining cavity650, the inner box120can be fully assembled and can define the storage hollow430for receiving contents therein, such as perishable food or other temperature-sensitive items. According to example aspects, the inner box120can fit snugly within the lining cavity650, such that movement of the inner box120within the lining cavity650is substantially prohibited.

In some example aspects, the temperature-regulating lid500(shown inFIG.5) can be assembled with the insulated box assembly100, as described above with reference toFIG.11. Then, the top panels242,244,246,248of the outer box110can be folded and secured in the closed orientation, as described above with reference toFIG.12.

Thus, a method for assembling the insulated box assembly100of the present aspect can comprise providing an outer box110, the outer box110defining the inner cavity230, inserting the insulating lining130within the inner cavity230to define the lining cavity650, and inserting the first inner box piece1430and the second inner box piece1450into the lining cavity650to define the storage hollow430of the inner box120, the storage hollow430configured to receive contents therein. Example aspects of the method can further comprise folding the top flaps442,444,446,448over the top end620of the sidewall liner610to fully cover the top end620of the sidewall liner610.

FIG.17illustrates another aspect of the insulated box assembly100. The insulated box assembly can comprise the outer box110ofFIG.13, the insulating lining130, and the inner box120ofFIGS.4A-4B. The top flaps442,444,446,448of inner box120can be folded over the top edge620of the sidewall liner610, as described above. As shown, with the top panels242,244,246,248of the outer box110in the open orientation, the top end620of the sidewall liner610can be uncovered proximate the top corners234of the outer box110. When the top panels242,244,246,248of the outer box110are folded and secured in the closed orientation, as described above, the top end620of the sidewall liner610can be fully covered.

FIGS.18and19illustrates the lid box510for the temperature-regulating lid500(shown inFIG.27), according to another aspect the present disclosure. The lid box510can be similar to the lid box510shown inFIG.5A, and the temperature-regulating lid500can be similar to the temperature-regulating lid500shown inFIG.5A. Example aspects of the lid box510can be oriented in a substantially flat blank orientation, as shown inFIG.18, and an assembled orientation, as shown inFIG.27. The lid box510can define an inner surface2112and an outer surface2314(shown inFIG.20). Example aspects of the lid box510can define a top panel2120and a bottom panel2130. In some aspects, as shown, the bottom panel2130can define one or more holes2134formed therein. The holes2134can allow for the passage of air therethrough, as described in further detail below. The lid box510can further define a front side panel2136, a back side panel2138, a left side panel2140, a right side panel2150. Each of the back, left, and right side panels2138,2140,2150can be connected to the bottom panel2130by a bend line2139,2141,2151, respectively. The left side panel2140can define a first left extension flap2142extending therefrom, distal from the bottom panel2130, and a second left extension flap2144extending therefrom, adjacent to the back side panel2138. The first left extension flap2142can be connected to the left side panel2140by a bend line2143, and the second left extension flap2144can be connected to the left side panel2140by a bend line2145. Similarly, the right side panel2150can define a first right extension flap2152extending therefrom, distal from the bottom panel2130, and a second right extension flap2154extending therefrom, adjacent to the back side panel2138, as shown. The first right extension flap2152can be connected to the right side panel2150by a bend line2153, and the second right extension flap2154can be connected to the right side panel2150by a bend line2155. As shown, a first left slot2146can be formed at the bend line2141, a second left slot2148can be formed at the bend line2143, a first right slot2156can be formed at the bend line2151, and a second right slot2158can be formed at the bend line2153.

Example aspects of the top panel2120can extend from the back side panel2138distal from the bottom panel2130and can be connected to the back side panel2138by a bend line2121. In some aspects, the lid box510can define a tear line2122formed proximate an intermediate portion of the bend line2121. In other aspects, as shown, the tear line2122can extend generally between a left side2121aof the bend line2121and a right side2121bof the bend line2121. In the present aspect, the tear line2122can define a rear wing2123of the top panel2120. In some aspects, the top panel2120can define a width2124great than a width2132of the bottom panel2130. The opposing portions of the top panel2120extending beyond the width2132of the bottom panel2130can be defined as left and right wings2126,2128of the top panel2120. Example aspects of the left and right wings2126,2128can be monolithically formed with the top panel2120.

In the present aspect, the lid box510can define an engagement opening2160formed in the top panel2120. The engagement opening2160can be configured to allow the engagement of a user's hand/finger(s) therewith. Example aspects of the engagement opening2160can be partially or fully covered by an engagement flap2164, as shown. For example, in some aspects, as shown, an un-covered portion2162of the engagement opening2160can remain un-covered by the engagement flap2164to facilitate the insertion of a hand/finger(s) into the engagement opening2160and/or grasping the engagement flap2164. Example aspects of the engagement flap2164can be connected to the top panel2120via a bend line2165. The bend line2165can allow engagement flap2164to fold towards or away from an interior cavity2502(shown inFIG.22) of the assembled lid box510when manually manipulated by a user. In the present aspect, the un-covered portion2162of the engagement opening2160can be oriented distal to the bend line2165.

As shown, the front side panel2136can be connected to the top panel2120by a connecting strip2170. In the present aspect, the connecting strip2170can be connected to the top panel2120by a bend line2171, and the front side panel2136can be connected to the connecting strip2170by a bend line2137. The front side panel2136can define a left front tab2172and a right front tab2174, as shown. The lid box510can comprise a left front extension flap2180connected to the front side panel2136at a bend line2181proximate the left front tab2172and a right front extension flap2190connected to the front side panel2136at a bend line2191proximate the right front tab2174. As shown, the left front extension flap2180can define a left front extension flap tab2182distal from the front side panel2136, and the right front extension flap2190can define a right front extension flap tab2192distal from the front side panel2136.

FIGS.20-27illustrate an example aspect of a method of assembling the temperature-regulating lid500(shown inFIG.27). Referring toFIG.20, a first step in the method of assembling the temperature-regulating lid500can comprise folding the left side panel2140along the bend line2141towards the inner surface2112of the lid box510, such that the left side panel2140is oriented at about a right angle relative the bottom panel2130. The first left extension flap2142can also be folded along the bend line2143towards the inner surface2112of the lid box510, such that the first left extension flap2142can be oriented at about a right angle relative to the left side panel2140. The second left extension flap2144(shown inFIG.18) can be folded along the bend line2145towards the inner surface2112of the lid box510, such that the second left extension flap2144can be oriented at about a right angle relative to the left side panel2140. In other aspects, the left side panel2140, first left extension flap2142, and second left extension flap2144can be folded in any order that substantially achieves the same orientations. As shown, the right side panel2150, first right extension flap2152, and second right extension flap2154can be folded in a similar manner.

As shown inFIG.21, the back side panel2138can be folded along the bend line2139towards the inner surface2112of the lid box510, such that the back side panel2138can be oriented at about a right angle relative to the bottom panel2130. According to example aspects, the inner surface2112of the back side panel2138can generally abut the outer surface2314of the second left and right extension flaps2144,2154(left extension flap2144shown inFIG.18).

Referring toFIG.22, the top panel2120can then be folded along the bend line2121towards the inner surface2112of the lid box510, such that the top panel2120can be orientated at about a right angle relative to the back side panel2138(shown inFIG.18) and about parallel to the bottom panel2130. According to example aspects, in this orientation, the inner surface2112of the top panel2120can generally abut the outer surface2314of the first left and right extension flaps2142,2152(shown inFIG.18). In this orientation, the lid box510can define an interior cavity2502having an open end. Next, each of the left front extension flap2180and right front extension flap2190can be folded approximately 180° at the corresponding bend lines2181,2191, respectively, towards the outer surface2314of the lid box510, such that each of the left and right front extension flaps2180,2190can be oriented about parallel to the front side panel2136. In other aspects, the left and right front extension flaps2180,2190can be folded between about 90°-180°. Furthermore, in other aspects, the back side panel2138, top panel2120, and left and right front extension flaps2180,2190can be folded in any order that results in substantially the same orientations.

FIG.23illustrates a next step in the method of assembling the temperature-regulating lid500. The front side panel2136can be folded approximately 180° at the bend line2137into the interior cavity2502, such that the front side panel2136and the left and right front extension flaps2180,2190are oriented substantially parallel to the top panel2120(shown inFIG.18). In some aspects, the inner surface2112(shown inFIG.18) of the front side panel2136can abut the inner surface2112of the top panel2120. Furthermore, the left front tab2172(shown inFIG.18) can engage the second left slot2148(shown inFIG.18), and the right front tab2174(shown inFIG.18) can engage the second right slot2158(shown inFIG.18).

In a next step, as shown inFIG.24, each of the left front extension flap2180and the right front extension flap2190can be folded towards the bottom panel2130. As illustrated inFIG.25, the left and right front extension flaps2180,2190(left front extension flap2180shown inFIG.18) can be folded approximately 90°, such that the left and right front extension flaps2180,2190can be oriented at about a right angle relative to the front side panel2136(shown inFIG.18) and top panel2120. In some aspects, the inner surface2112of the left and right front extension flaps2180,2190can abut the inner surface2112of the left and right side panels2140,2150, respectively. As shown inFIG.26, the left front extension flap tab2182can engage the first left slot2146, and the right front extension flap tab2192can engage the second right slot2156to secure the lid box510in the assembled orientation.

FIG.27illustrates the temperature-regulating lid500in the assembled orientation. As shown, a temperature-regulating insert2402can be inserted into the cavity2502(shown inFIG.22) of the lid box510. For example, the temperature-regulating insert2402can be a bag of dry ice, as shown. The dry ice can cool the air within the cavity2502, and the holes2134(shown inFIG.18) in the bottom panel2130(shown inFIG.18) can allow for the passage of the cold air out of the cavity2502. In other aspects, the temperature-regulating insert2402can comprise, for example, R-4 poly-encapsulated thermal 100% recycled cotton, as shown inFIG.29. Other aspects of the temperature-regulating insert2402can comprise, for example, polyester film, such as polyethylene terephthalate (PET) film, foams, pellets, fabrics, nonwovens, polyethylene, polyurethane, polypropylene or any other suitable material that can contribute towards a cushioned and climate controlled protective layer in a box assembly2800(shown inFIG.33A). In some aspects, the temperature-regulating insert2402, or portions thereof, can be biodegradable and/or compostable.

FIG.28illustrates another example aspect of the lid box510oriented the blank orientation. As shown, example aspects of the lid box510can define the top panel2120, bottom panel2130, front side panel2136, back side panel2138, left side panel2140, and right side panel2150. Each of the back, left, and right side panels2138,2140,2150can be connected to the bottom panel2130by the corresponding bend line2139,2141,2151. The left and right side panels2140,2150can further comprise the corresponding first left and right extension flaps2142,2152connected thereto by the corresponding bend lines2143,2153, and the second left and right extension flaps2144,2154connected thereto by the corresponding bend lines2145,2155. Moreover, the left and right side panels2140,2150can comprise third left and right extension flaps2644,2654opposite the second left and right extension flaps2144,2154and connected thereto by corresponding bend lines2645,2655. In the present aspect, the first and second left slots2146,2148can each be formed at the bend line2143, and the first and second right slots2156,2158can be formed at the bend line2153. Furthermore, in the present aspect, the front side panel2136can be connected to the bottom panel2130by the corresponding bend line2137. The front side panel2136can define a front extension flap2680extending therefrom distal to the bottom panel2130and attached thereto at a bend line2681. A front slot2682can be formed at the bend line2681between the front side panel2136and the front extension flap2680.

The top panel2120can extend from the back side panel2138distal from the bottom panel2130and can be connected to the back side panel2138by the bend line2121. In the present aspect, the top panel2120can define a primary top panel2622and a secondary top panel2624. The secondary top panel2624can be distal from the back side panel2138and can be connected to the primary top panel2622by a bend line2625. Further, in example aspects, a secondary top panel locking tab2626can extend from the secondary top panel2624distal to the primary top panel2622and can be connected thereto by a bend line2627. The primary top panel2622can further comprise the left and right wings2126,2128, as shown, and in the present aspect, each of the left and right wings2126,2128can define a cut-out2629. Moreover, the primary top panel2622can comprise first and second left locking tabs2630,2632flanking the left wing2126and first and second right locking tabs2634,2637flanking the right wing2128. Each of the first and second left locking tabs2630,2632can be connected to the primary top panel2622by a bend line2631,2633, respectively, and each of the first and second right locking tabs2634,2637can be connected to the primary top panel2622by a bend line2635,12137, respectively.

FIG.29-32illustrates another aspect of a method of assembling the temperature-regulating lid500. Referring toFIG.29, according to example aspects, the temperature-regulating insert2402can define a bottom surface (not shown) and a top surface2704, which can be substantially planar and parallel to one another. In the present aspect, the temperature-regulating insert2402can comprise a pad formed from R-4 poly-encapsulated thermal 100% recycled cotton. In other aspects, the temperature-regulating insert2402can comprise any other suitable material, or combinations of materials, as described above. As shown, the temperature-regulating insert2402can be received on the inner surface2112of the bottom panel2130(shown inFIG.28), such that the bottom surface of temperature-regulating insert2402faces the inner surface2112of the bottom panel2130.

In some aspects, such as the aspect depicted inFIG.29, the temperature-regulating lid500can be 100% recyclable. For example, the temperature-regulating lid500can be single-stream recyclable wherein all materials comprised by the temperature-regulating lid500(including the lid box510and the temperature-regulating insert2402) can be recycled by a single processing train without requiring separation of any materials or components of the temperature-regulating lid500. In the present aspect, the temperature-regulating lid500can be compostable. In the present aspect, the temperature-regulating lid500can be repulpable. For example, in the present aspect, the temperature-regulating lid500, including the lid box510and the temperature-regulating insert2402, can 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, IL which is hereby incorporated in its entirety. Furthermore, in the present aspect, the temperature-regulating lid500, including the lid box510and the temperature-regulating insert2402, can 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, IL.

Recyclable and repulpable insulation materials are further described in U.S. patent application Ser. No. 15/677,738, filed Aug. 15, 2017, U.S. Provisional Patent Application No. 62/375,555, filed Aug. 16, 2016, U.S. Provisional Patent Application No. 62/419,894, filed Nov. 9, 2016, and U.S. Provisional Patent Application No. 62/437,365, filed Dec. 21, 2016, which are each incorporated by reference in their entirety herein.

Referring toFIG.30, the left and right side panels2140,2150(right side panel2150shown inFIG.28) can be folded at the corresponding bend lines2141,2151(bend line2151shown inFIG.28. The first left and right extension flaps2142,2152can also be folded at the corresponding bend lines2143,2153, such that the first left and right extension flaps2142,2152can lie parallel to, and may rest on, the top surface2704of the temperature-regulating insert2402. The second left and right extension flaps2144,2154(shown inFIG.28) can be folded towards the temperature-regulating insert2402, and the back side panel2138(shown inFIG.28) can be folded towards the temperature-regulating insert2402, such that the back side panel2138abuts the second left and right extension flaps2144,2154.

The first and second left locking tabs2630,2632(shown inFIG.28) and first and second right locking tabs2634,2637(shown inFIG.28) can be folded at the corresponding bend lines2631,2633,2635,12137(shown inFIG.28) towards the inner surface2112of the primary top panel2622, such that each of the first and second left locking tabs2630,2632and first and second right locking tabs2634,2637can be oriented at about 90° relative to the primary top panel2622. The primary top panel2622can be folded at the corresponding bend line2121towards the temperature-regulating insert2402to generally define the cavity2502(shown inFIG.22) within which the temperature-regulating insert2402can be received. In this orientation, the primary top panel2622can lie substantially parallel to, and may rest on, the top surface2704of the temperature-regulating insert2402and/or the first left and right extension flaps2142,2152. As the primary top panel2622is folded towards the temperature-regulating insert2402, the first and second left locking tabs2630,2632can be inserted into the first and second left slots2146,2148, respectively, and the first and second right locking tabs2634,2637can be inserted into the first and second right slots2156,2158(first right slot2156shown inFIG.28), respectively, to retain the primary top panel2622in the illustrated orientation. As shown, the secondary top panel2624can be folded away from temperature-regulating insert2402at the bend line2625.

Referring toFIG.31, the third left and right extension flaps2644,2654(shown inFIG.28) can be folded towards the temperature-regulating insert2402. Then, the front side panel2136can be folded at the corresponding bend line2137towards the temperature-regulating insert2402, and the front extension flap2680can be folded at the corresponding bend line2681towards the temperature-regulating insert2402, such that the front extension flap2680can lie parallel to, and may rest on, the top surface2704of the temperature-regulating insert2402. In some aspects, one or more portions of the front extension flap2680can be tucked under the first left and right extension flaps2142,2152to maintain the front extension flap2680in the illustrated orientation. Furthermore, the secondary top panel locking tab2626of the secondary top panel2624can be folded towards the temperature-regulating insert2402at the bend line2627, such that the secondary top panel locking tab2626is oriented at about 90° relative to the secondary top panel2624, as shown.

FIG.32illustrates a next and final step in the method of assembling the temperature-regulating lid500. As shown, the secondary top panel2624can be folded at the corresponding bend line2625towards the temperature-regulating insert2402(shown inFIG.27). The secondary top panel locking tab2626(shown inFIG.28) can be inserted through the front slot2682to retain the temperature-regulating lid500in the assembled orientation. In other aspects, the various elements of the lid box510can be folded in any order that achieves substantially the same assembled orientation of the temperature-regulating lid500.

FIG.33illustrates the assembled temperature-regulating lid500ofFIG.32mounted with the insulated box assembly100. The temperature-regulating lid500can be placed over the top opening432(shown inFIG.4A) of the inner box120, such that the top opening432is completely covered. As shown, the left wing2126can engage the left top flap446, and the right wing2128can engage the opposite right top flap448to support the temperature-regulating lid500on the inner box2820. In other aspects, the left and right wings2126,2128can engage the opposite front and back top flaps442,444. In aspects wherein the rear wing2123(shown inFIG.18) is present, the rear wing2123can also engage one of the top flaps442,444,446,448, depending upon the orientation of the temperature-regulating lid500.

To remove the temperature-regulating lid500from the box assembly100, a user can grasp and lift up on the left wing2126and/or the right wing2128to lift the temperature-regulating lid500away from the box assembly100. In another aspect, the user can grasp and lift the engagement flap2164(shown inFIG.18), if present, to lift the temperature-regulating lid500away from the box assembly100. In some aspects, the temperature-regulating lid500ofFIG.32can be positioned within the storage hollow430of the inner box120of the box assembly100for storage, as is shown and described further below with reference toFIG.48, before contents such as food are received therein.

FIG.34illustrates a close up view of the left top flap446of the inner box120, which can be substantially the same as the front, back, and right top flaps442,444,448(shown inFIG.4A). As shown, the left top flap446can define a first pair of bend lines2922,2924and a second pair of bend lines2926,2928. In some aspects, when folding the left top flap446over the sidewall liner610(shown inFIG.6A) housed between the inner box120and outer box110(shown inFIG.1), only some of the bend lines2922,2924,2926,2928can be utilized. For example, in one particular aspect, the left top flap446can be folded at bend lines2922and2926. In other aspects, any number and combination of the bend lines2922,2924,2926,2928can be utilized when folding the left top flap446over the sidewall liner610. Each of the front, back, and right top flaps442,444,448can be folded in substantially the same manner as the left top flap446.

FIG.35illustrates another aspect of the lid box510for the temperature-regulating lid500(shown inFIG.27), wherein the lid box510is shown in the blank orientation.FIG.36illustrates still another aspect of the lid box510for the temperature-regulating lid500, wherein the lid box510is shown in the blank orientation.

A method for assembling the insulated box assembly100ofFIG.1is also disclosed and is illustrated inFIGS.37-50. Referring toFIG.37, the method can comprise lying the sidewall liner610on a support surface3900and applying a first fastener (not shown), such as hot glue any other suitable fastener, to the inner surface624of the sidewall liner610at the first end628and a second fastener (not shown) to the inner surface624at the second end630(shown inFIG.6B). For example, in one aspect, hot glue can be applied to the first and second ends628,630of the sidewall liner610by a hot glue gun3910. As shown inFIG.38, the inner box120can be placed on the sidewall liner610at the first end628, such that a lateral sidewall of the inner box120(such as the front lateral sidewall412—shown inFIG.4A) engages the first fastener to attach the inner box120to the sidewall liner610. As shown inFIG.39, a next step can comprise wrapping the sidewall liner610around the remaining lateral sidewalls of the inner box120(such as back lateral sidewall414, a left lateral sidewall416, and a right lateral sidewall418—shown inFIG.4A). The second fastener can engage the inner box120to retain the sidewall liner610in the wrapped orientation, as shown.

In some aspects, the steps illustrated inFIG.37-39can be performed by a first person4102. Furthermore, in some aspects, as shown inFIG.40, the inner box120and sidewall liner610can next be passed from the first person4102to a second person4202. In other aspects, the first person4102can continue assembling the insulated box assembly100. As shown inFIG.41, the bottom wall liner640can be inserted into the inner cavity230of the outer box110, and can rest on the bottom sidewall380(shown inFIG.3B) of the outer box110. This step can be performed before, during, or after, any of the steps illustrated inFIGS.37-40.

Referring toFIG.42, the inner box120and sidewall liner610can then be inserted into the inner cavity230(shown inFIG.2) of the outer box110until the bottom sidewall480(shown inFIG.4B) of the inner box120engages the bottom wall liner640(shown inFIG.6A) received in the inner cavity230.FIGS.43-46illustrate the steps of folding the top flaps442,444,446,448of the inner box120over the sidewall liner610and positioning the first and second cover tabs260,262of outer box110. According to example aspects, the left and right top flaps446,448can be folded over the sidewall liner610. The first and second cover tabs260,262can then be folded towards the sidewall liner610such that the leg264of each cover tab260,262extends under the adjacent front or back top flap442,444, and the arm266of each cover tab260,262can rest on top of the adjacent left or right top flap446,448. The front and back top flaps442,444can then be folded over the sidewall liner610, such that the legs264of the cover tabs260,262are positioned between the sidewall liner610and the adjacent front or back top flap442,444. In other aspects, the arms266of each cover tab260,262can also be received between the sidewall liner610and the adjacent left or right top flap446,448. In still another aspect, the arms266of each cover tab260,262can also be received between the sidewall liner610and the adjacent left or right top flap446,448, and the leg264of each cover tab260,262can rest on top of the adjacent front or back to flap442,444.

As shown inFIG.47, fasteners4900, such as strips of adhesive for example, can be applied to the left top panel246and right top panel248of the outer box110. In some aspects, as shown inFIG.48, the temperature-regulating lid500or temperature-regulating lid500(shown inFIG.5A) can be received in the storage hollow430, as shown. In other aspects, the temperature-regulating lid500or temperature-regulating lid500can be mounted to the insulated box assembly100, as described above.FIG.49illustrates a next step wherein the left and right top panels246,248are folded towards the inner box120. As shown inFIG.50, the front top panel242and back top panel244can then be folded towards the left and right top panels246,248(shown inFIG.2A) and can engage the fasteners4900(shown inFIG.47) to retain the insulated box assembly100in the assembled orientation, as shown.FIG.51illustrates stacking the assembled insulated box assemblies100on a pallet5300.

Referring toFIG.52, some aspects of the insulated box assembly100can comprise slotted inserts5400, as shown, for use with dry ice (not shown). For example, in one particular aspect, dry ice can be inserted in the storage hollow430of the inner box120and a first slotted insert5400acan be received thereon. Contents such as perishable food, or other temperature-sensitive items, can then be placed within the storage hollow430on top of the slotted insert5400a. Another slotted insert5400bcan be placed on top of the contents within the storage hollow430, and additional dry ice can be placed on top of the slotted insert5400b. In some aspects, the temperature-regulating lid500can be placed on top of the additional dry ice and the insulated box assembly100can be sealed closed, such that the contents of the storage hollow are retained within the insulated box assembly100. According to example aspects, the dry ice can cool the air around it. Each of the slotted inserts5400a,bcan comprise one or more slots5402or holes through which cold air can pass to cool the contents of the storage hollow430. The slotted inserts5400a,bcan also protect the contents from contacting the dry ice. Other example aspects of the insulated box assembly100can comprise more or fewer slotted inserts5400.

FIG.53illustrates another aspect of the insulated box assembly100. As shown, the insulated box assembly100comprises the outer box110, the inner box120, and the insulating lining130received therebetween. The outer box110can comprise the top panels242,244,246,248and the bottom panels372,374,376,378(shown inFIG.3A). According to example aspects, each of the left and right top panels246,248can define a pair of chamfered distal corners5310. In some aspects, the chamfered distal corners5310can indicate that the left and right top panels246,248can be folded first when folding the top panels242,244,246,248towards the inner cavity230. The inner box120can comprise the top flaps442,444,446,448and the bottom panels472,474,476,478. As shown, in the present aspect, each the left and right bottom panels476,478can also define a pair of chamfered distal corners5320. The left and right bottom panels476,478can be folded towards the storage hollow430, and the front and back bottom panels472,474can be folded towards the storage hollow430thereafter, such that the front and back bottom panels472,474can be oriented below the left and right bottom panels476,478, relative to the orientation shown. As such, in some aspects, the chamfered distal corners5320can be provided to indicate that the left and right bottom panels476,478can be folded first. Furthermore, as shown, in the present aspect, the sidewall liner610of the insulating lining130can define a thickness that can be less than a thickness of the sidewall liner610shown inFIG.1.

FIG.54illustrates a close-up view of the left top flap446of the inner box120, which can also be representative of the front, back, and right top flaps442,444,448(right top flap448shown inFIG.53). As shown, the left top flap446can define the first flap section450and the second flap section452. The first flap section450can be connected to the left lateral sidewall416at the top end420of the inner box120at the bend line449. The second flap section452can be connected to the first flap section450at the bend line454distal from the left lateral sidewall416. As shown, in the present aspect, each of the bend lines449,454can be formed by a series of perforations5410. The perforations5410can facilitate folding at the bend lines449,454.

FIG.55is a side view of the insulated box assembly100showing the front and right lateral sidewalls212,218of the outer box110. As shown, a connector strip5510can extend from a first side of the right lateral sidewall218proximate the front lateral sidewall212, and the connector strip5510can be connected to the right lateral sidewall218at a bend line5512. The connector strip5510can be configured to fold along the bend line5512, such that the connector strip5510can abut the outer surface226of the outer box110at the front lateral sidewall212. The connector strip5510can be secured to the front lateral sidewall212with a fastener (not shown), such as, for example, staples, stitching, an adhesive such as glue, or the like, which can retain the lateral sidewalls212,214,216,218(back and left lateral sidewalls214,216shown inFIG.2A) in the assembled configuration shown inFIG.53.

FIG.56illustrates a close-up view of the left top panel246of the outer box110, which can also be representative of the right top panel248(shown inFIG.53), before the left top panel246is folded towards the inner cavity230. As shown, when the top flaps442,444,446,448(right top flap448shown inFIG.53) of the inner box120are folded over the sidewall liner610, top corner portions5612of the sidewall liner610proximate to the top corners234,434of the outer and inner boxes110,120can be exposed, as shown. As described above, the left top panel246can be connected to the left lateral sidewall216(shown inFIG.2A) at the bend line247. In the present aspect, the left top panel246can define a first panel section5610proximate to the left lateral sidewall216and a second panel section5620distal to the left lateral sidewall216, as shown. The second panel section5620can be connected to the first panel section5610at a bend line5622, such that the second panel section5620can fold relative to the first panel section5610. According to example aspects, the first panel section5610can define a length L1that can be greater than a length L2of the second panel section5620. The first cover tab260can extend from the first panel section5610partially alongside a first end5624of the second panel section5620, and the second cover tab262can extend partially alongside a second end5626of the second panel section5620. In the present aspect, each of the first and second cover tabs260,262can be substantially rectangular in shape, as opposed to the L-shaped cover tabs260,262described with respect toFIG.2A. In other aspects, the cover tabs260,262can define any other suitable shape.

FIG.57illustrates the left top panel246folded over the sidewall liner610(shown inFIG.53) and towards the inner cavity230. The first panel section5610of the left top panel246can be folded such that it is oriented substantially perpendicular to the left lateral sidewall216(shown inFIG.2A) and, in some aspects, the first panel section5610can rest on the first flap section450(shown inFIG.54A) of the left top flap446(shown inFIG.53). The first cover tab260and second cover tab262can cover the exposed top corner portions5612of the sidewall liner610proximate the corresponding top corners234,434. The second panel section5620can be wedged in between the front and back lateral sidewalls412,414of the inner box120and folded to be about perpendicular to the first panel section5610, as shown. In this orientation, the first end5624of the second panel section5620can abut the front lateral sidewall412and the second end5626of the second panel section5620can abut the back lateral sidewall414, such that the second panel section5620is retained between the front and back lateral sidewalls412,414of the inner box120. According to example aspects, the right top panel248(shown inFIG.53) can be folded in substantially the same manner.

FIG.58illustrates the temperature-regulating lid500in the assembled orientation, according to another example aspect of the disclosure. Example aspects of the temperature-regulating lid500can define the top panel2120and the bottom panel2130(shown inFIG.59). The top panel2120can define the left and right wings2126,2128extending therefrom. The top panel2120can further define the engagement opening2160formed therethrough, which can be configured to allow the engagement of a user's hand/finger(s) therewith. In the present aspect, a first T-shaped slit5810can be formed proximate to a first corner5812of the top panel2120, and a second T-shaped slit5820can be formed proximate to a second corner5822of the top panel2120diagonally opposite from the first corner5812. According to example aspects, a card (not shown) including indicia thereon can engage the first and second T-shaped slits5820,5822. For example, opposing corners of the card can be tucked in to the opposing first and second T-shaped slits5820,5822to retain the card on the temperature-regulating lid500. In one aspect, the card can be a recipe card. The recipe card can detail a recipe for preparing food contents received within the insulated box assembly100(shown inFIG.1). In other aspects, the card can be a contents card detailing the contents received within the insulated box assembly100, while in still other aspects, the indicia can represent any other information generally related to the insulated box assembly100or the contents therein. In some aspects, the indicia can be printed on the card, while in other aspects, the indicia can be formed on or attached to the card by any other suitable means known in the art. Furthermore, the card can be formed from printing paper, card stock, construction paper, or any other suitable paper or other material known in the art.FIG.59illustrates the bottom panel2130of the temperature-regulating lid500. In some aspects, as shown, the bottom panel2130can define the one or more holes2134formed therein. The holes2134can allow for the passage of air therethrough, as described above.

FIG.60is a front view of the temperature-regulating lid500, showing the interior cavity2502defined in the assembled orientation. According to example aspects, the temperature-regulating insert2402(shown inFIG.27) can be received within the interior cavity2502. In some aspects, the temperature-regulating insert2402can be a bag of dry ice, a cotton pad, or any other suitable insert. Furthermore, as shown, the temperature-regulating lid500of the present aspect can define various connecting flaps6010. The connecting flaps6010can be secured to corresponding elements of the temperature-regulating lid500by a fastener (not shown) to retain the temperature-regulating lid500in the assembled orientation. In the present aspect, the fastener can be an adhesive, such as glue. In other aspects, the fastener can be any other suitable fastener, including, but not limited to, hook and loop fasteners, staples, stitching, or the like. As also shown inFIG.60, example aspects of the temperature-regulating lid500can be formed from a corrugated fiberboard material comprising a first linerboard6020, a second linerboard6022, and a fluted corrugated sheet6024therebetween.

FIG.61illustrates the temperature-regulating lid500ofFIGS.58-60mounted on the insulated box100assembly ofFIG.53. As shown, in the present aspect, the left wing2126of the temperature-regulating lid500can be supported on the back top flap444of the inner box120and the right wing2128of the temperature-regulating lid500can be supported on the front top flap442of the inner box120, such that the storage hollow430(shown inFIG.4A) is completely enclosed. In other aspects, depending upon the shape of temperature-regulating lid, the left and right wings2126,2128can be supported on the left and right top flaps446,448of the inner box120. The top panel2120of the temperature-regulating lid500can face outward from the storage hollow430, such that a user can engage the engagement opening2160to remove the temperature-regulating lid500from the insulated box assembly100. In other aspects, the temperature-regulating lid500can be removed by gripping one or both of the left and right wings2126,2128and pulling the temperature-regulating lid500away from the insulated box assembly100.

FIG.62illustrates the insulated box assembly100and the temperature-regulating lid500therefor, according to another aspect. In the present aspect, the top panel2120of the temperature-regulating lid500can define a first left wing6210, a second left wing6212, and a third left wing6214therebetween, as shown. The top panel2120can also define a first right wing6220, a second right wing6222, and a third right wing6224therebetween. In the present aspect, the first left wing6210, second left wing6212, and third left wing6214can be supported on the back top flap444of the inner box120when the temperature-regulating lid500is mounted on the insulated box assembly100. Furthermore, the first right wing6220, second right wing6222, and third right wing6224can be supported on the front top flap442. In other aspects, the first, second, and third left wings6210,6212,6214can be supported on the left top flap446, and the first, second, and third right wings6220,6222,6224can be supported on the right top flap448.

One should note that conditional language, such as, among others, “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements and/or steps. Thus, such conditional language is not generally intended to imply that features, elements and/or steps are in any way required for one or more particular embodiments or that one or more particular embodiments necessarily include logic for deciding, with or without user input or prompting, whether these features, elements and/or steps are included or are to be performed in any particular embodiment.

It should be emphasized that the above-described embodiments are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the present disclosure. Any process descriptions or blocks in flow diagrams should be understood as representing modules, segments, or portions of code which include one or more executable instructions for implementing specific logical functions or steps in the process, and alternate implementations are included in which functions may not be included or executed at all, may be executed out of order from that shown or discussed, including substantially concurrently or in reverse order, depending on the functionality involved, as would be understood by those reasonably skilled in the art of the present disclosure. Many variations and modifications may be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the present disclosure. Further, the scope of the present disclosure is intended to cover any and all combinations and sub-combinations of all elements, features, and aspects discussed above. All such modifications and variations are intended to be included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure.