Method and system for maintaining temperature-sensitive materials within a target temperature range for an extended time. In one embodiment, the system keeps materials within a temperature range of +2° C. to +8° C. and includes an insulated container, a product box, ice packs, and organic phase-change material (PCM) packs. The ice packs are preconditioned to a very low temperature, such as −20° C. The organic PCM packs do not require preconditioning and may be kept at room temperature. In use, the frozen ice packs and the warm organic PCM packs may be loaded into the insulated container, together with a payload in the product box. Preferably, the frozen ice packs are sandwiched between a pair of organic PCM packs on each face of the product box. The masses of ice and organic PCM are selected so that, upon thermal equilibration, the ice and organic PCM are within the target temperature range.

A package can include an insulated envelope configured to contain a thermal element therein to reduce thermal transfer between the thermal element and the atmosphere. The insulated envelope can include an outer liner and an insulating material disposed within the outer liner. An amount of the insulating material can be selected to control temperature of the outer liner and/or rate of heat transfer to the thermal element.

Biodegradable insulating structures and panel systems, and methods for producing and assembling the biodegradable insulating structures are provided. The biodegradable insulating structures include biodegradable foam panels formed from biobased polymer foam beads which include polylactic acid. The biodegradable foam panels have edges that form a seal with adjacent biodegradable foam panels to restrict thermal energy transfer at the edges.

A thermal insulation article includes a thermally insulating pad shaped to be positioned in a cavity of a rectangular prism shipping container. The pad includes a solid compostable panel formed primarily of starch and/or plant fiber pulp that holds together as a single unit, and a water-proof or water-resistant film forming a pocket enclosing the panel. The panel includes a first section, a second section, and a third section connecting the first section to the second section, the first and second section each having a central portion and two flaps that extend from the central portion beyond the third section, and wherein the panel is foldable into an open box.

An insulated shipping container is provided for maintaining a substantially uniform internal temperature. The base, walls and lid of an outer box define an enclosure. An insulating body and an insulating cover are located within the enclosure and define an insulated cavity. A chamber having a plurality of chamber sides is configured to hold one or more payloads at the substantially uniform internal temperature. A temperature control material distribution structure is located within the insulated cavity for constraining motion of temperature control material units. The temperature control material distribution structure comprises at least one partitioned tray or trough. The at least one partitioned tray comprises a tray bottom; and a plurality of partition walls extending away from the tray bottom and defining a plurality of partition compartments.

An insulated shipping container is provided for maintaining a substantially uniform internal temperature. The base, walls and lid of an outer box define an enclosure. An insulating body and an insulating cover are located within the enclosure and define an insulated cavity. A chamber having a plurality of chamber sides is configured to hold one or more payloads at the substantially uniform internal temperature. A temperature control material distribution structure is located within the insulated cavity for constraining motion of temperature control material units. The temperature control material distribution structure comprises at least one partitioned tray or trough. The at least one partitioned tray comprises a tray bottom; and a plurality of partition walls extending away from the tray bottom and defining a plurality of partition compartments.

An insulative insert for a shipping container includes at least one insulative pad and an inner layer. The at least one insulative pad is formed from fibers of a first material having a first strength. The first material includes at least one of cellulose and synthetic polymer. The inner layer is formed from a second material having a second strength that is greater than the first strength. The inner layer is joined to the at least one insulative pad to form the insulative insert. The insulative insert is configured to lie flat in an unfolded position and to form a cube shape in a folded position.

An insulation packaging assembly includes a box including a top side wall, a bottom side wall, and a plurality of lateral side walls, the box defining a box cavity; a first insulation liner positioned within the box cavity, the first insulation liner defining a first end and a second end opposite from the first end, the first insulation liner defining a first fold, a second fold, and a third fold, the first fold defining the first end, the third fold defining the second end, a first bend line defined between the first fold and the second fold, a second bend line defined between the second fold and the third fold; a second insulation liner positioned within the box cavity, the second insulation liner defining a third end and a fourth end opposite from the third end, the first insulation liner defining a fourth fold.

A method of collapsing a box from an expanded configuration to a collapsed configuration is disclosed. The method of collapsing a box from an expanded configuration to a collapsed configuration, the box comprising a side panel and a bottom panel attached to the side panel, can comprise bending a center fold line of the side panel; unbending a length fold line defined between the side panel and the bottom panel; bending a first corner fold line that extends from a bottom panel corner of the bottom panel to an edge fold line of a center subpanel of the bottom panel; and bending a second corner fold line that extends from the bottom panel corner to a longitudinal center line that bisects a bottom panel edge of the bottom panel.

Disclosed is a box, a modular box assembly, and a method of assembling a box. The box can comprise a center panel defining a first side, a second side opposite the first side, a first end, and a second end opposite the first end; a first locking panel extending from the first side, the first locking panel comprising a pair of wings, each of the wings defining a locking slot; a second locking panel extending from the second side, the second locking panel comprising a pair of locking tabs, each of the locking tabs engaging a corresponding one of the locking slots; a first side flap panel extending from the first end; and a second side flap panel extending from the second end.