A method of assembling a box assembly, comprising: folding an exterior piece from a flat configuration to a three-dimensional configuration defining a cavity, the exterior piece comprising a plurality of middle portions and a plurality of upper portions joined to the middle portions by fold lines; folding an interior piece from a flat configuration to a three-dimensional configuration defining a cavity, the interior piece comprising a bottom panel and a plurality of side panels; inserting the interior piece into the exterior piece to define a space between the middle portions of the exterior piece and the side panels of the interior piece; and folding the upper portions of the exterior piece to cover the space.

A box assembly comprising a box defining an interior, the interior defining a bottom interior wall and a side interior wall connected to the bottom interior, and an insert for the box, the insert comprising a center segment configured to cover the bottom interior wall, and a rail joined to the center segment, the rail configured to cover the side interior wall.

A box is made by folding a sheet of material. Preferably, the box is formed by applying adhesive and folding using a machine, and a waterproof or water resistant coating is applied so that the box is configured for use as a cooler. The box includes (a) a storage portion, including a bottom panel, a first end panel, a second end panel, a first side panel, and a second side panel; (b) four corner panels; (c) a top panel including tabs; and (d) a latching panel attached to the first side panel and pivotable relative thereto about a fold line, the latching panel including first and second subpanels. The latching panel includes cuts extending between and dividing the first and second subpanels through which the tabs respectively extend when the cooler is in a closed position.

A panel that can be assembled into a container includes a unitary outer wall formed of recyclable plant-fiber pulp and pre-cut to be folded into a box, and one or more pads laminated to the outer wall and covering portions of the outer wall that when folded into the box provide sidewalls and floor of the box such that the pads cover interior surfaces of the sidewalls of the box. Each pad includes a thermally insulative layer of starch and/or cellulose and/or plant fiber pulp.

A box is made by folding a sheet of material. Preferably, the box is formed by applying adhesive and folding using a machine, and a waterproof or water resistant coating is applied so that the box is configured for use as a cooler. The box includes (a) a storage portion, including a bottom panel, a first end panel, a second end panel, a first side panel, and a second side panel; (b) four corner panels; (c) a top panel including tabs; and (d) a latching panel attached to the first side panel and pivotable relative thereto about a fold line, the latching panel including first and second subpanels. The latching panel includes cuts extending between and dividing the first and second subpanels through which the tabs respectively extend when the cooler is in a closed position.

An insulated box assembly includes an insulated box, the insulated box including a box, the box including a bottom panel and a side panel, the side panel attached to the bottom panel, the box defining a box cavity; and an insulated panel attached to the side panel, the insulated panel including an insulation batt and a sheet, the insulation batt enclosed between the side panel and the sheet; and an insulated cavity panel, the insulated cavity panel disposed within the box cavity, the insulated cavity panel including a cavity sheet and a cavity insulation batt, the cavity sheet encapsulating the cavity insulation batt.

Apparatus and methods for assembling thermally insulated containers are disclosed. In one example, an apparatus for inserting a first insulating liner panel and a second insulating liner panel into a rectangular box to form a thermally insulated container includes a first station with a flap opening assembly, a second station with a first liner panel insertion assembly for inserting a first liner panel within the box, and a third station with a second liner panel insertion assembly for inserting a second liner panel within the box. A box transfer system is configured to transfer the box between the first station, the second station, and the third station. A flap guide system maintains the at least two of the lid flaps of the box in the open configuration as the box is transferred from the first station to the third station.

A storage and shipping container system for a set of specific related components, such as multiple blood products, which conveys the components in pre-determined ratios, having a thermally-insulated main container with a plurality of internal chambers, and at least one attached auxiliary container which is thermally-insulated. Optionally, the system is provided with wheels and a collapsible handle for easy movement of one system, and configured for stacking of multiple similar systems for bulk transportation.

A method for insulating a box including positioning at least one insulation batt in facing contact with at least one side panel of an inner cardboard layer, the at least one side panel at least partially defining an inner cavity; and adhesively coupling the at least one insulation batt to the at least one side panel, the at least one insulation batt at least partially insulating the inner cavity.

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.