An insulated packaging assembly can include a box including a top side wall, a bottom side wall, a first lateral side wall, a second lateral side wall, a third lateral side wall, and a fourth lateral side wall the box defining a cavity; a first thermal liner positioned in the cavity, a first portion of the first thermal liner positioned in contact with the top side wall, a second portion of the first thermal liner positioned in contact with the first lateral side wall, a third portion of the first thermal liner positioned in contact with the bottom side wall; and a second thermal liner defining a first end and a second end disposed opposite from the first end, the second thermal liner defining an inner surface and an outer surface disposed opposite from the inner surface.

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.

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.

A pallet cover suitable for use in covering at least a portion of a payload on a pallet and a kit for use in making the pallet cover. In one embodiment, the pallet cover includes a top wall, a front wall, a rear wall, a left side wall, and a right side wall, wherein the walls are detachably joined to one another. Each of the top wall, the front wall, the rear wall, the left side wall, and the right side wall includes a first fabric sheet and a second fabric sheet, the first and second fabric sheets being joined together to form a plurality of pockets. Each pocket may removably receive a temperature-control member containing a phase-change material. At least one of the top wall, the front wall, the rear wall, the left side wall and the right side wall includes a plurality of detachably joined portions.

A pallet cover suitable for use in covering at least a portion of a payload on a pallet and a kit for use in making the pallet cover. In one embodiment, the pallet cover includes a top wall, a front wall, a rear wall, a left side wall, and a right side wall, wherein the walls are detachably joined to one another. Each of the top wall, the front wall, the rear wall, the left side wall, and the right side wall includes a first fabric sheet and a second fabric sheet, the first and second fabric sheets being joined together to form a plurality of pockets. Each pocket may removably receive a temperature-control member containing a phase-change material. At least one of the top wall, the front wall, the rear wall, the left side wall and the right side wall may include a plurality of detachably joined portions.

Disclosed is a thermal insulating shipping container with a five-sided box wherein a bottom and four sides all have an inner layer of corrugated polymer, a middle layer of shrink-wrapped panels with each panel being a vacuum panel, and an outer layer of corrugated polymer. The container is formed by inserting polyurethane liquid into the gaps and spaces between the shrink-wrapped panels and the inner and outer layers and foaming the polyurethane liquid and allowing it to harden. Weather stripping may be adhered to the edges of the container which are opposite to the bottom of the container.

Method and system for storing and/or transporting temperature-sensitive materials. In one embodiment, the system is designed to keep a payload within a desired temperature range of +2° C. to +8° C. for an extended time in a warm ambient environment. The system includes a thermally insulated container and first and second phase-change materials, each of the phase-change materials having a different solid/liquid phase-change temperature. Both phase-change materials are preconditioned to a solid state for pack-out. The first phase-change material has a solid/liquid phase-change temperature that is within the desired temperature range and that is at or below a hibernation temperature of about +5° C. to +6° C. The second phase-change material has a solid/liquid phase-change temperature that is above the hibernation temperature. When placed in the warm ambient environment, both phase-change materials move towards melting; however, when subsequently placed in hibernation, the second phase-change material reverses the direction of its phase change, becoming recharged.

An insulated packaging assembly can include a box including a top side wall, a bottom side wall, a first lateral side wall, a second lateral side wall, a third lateral side wall, and a fourth lateral side wall the box defining a cavity; a first thermal liner positioned in the cavity, a first portion of the first thermal liner positioned in contact with the top side wall, a second portion of the first thermal liner positioned in contact with the first lateral side wall, a third portion of the first thermal liner positioned in contact with the bottom side wall; and a second thermal liner defining a first end and a second end disposed opposite from the first end, the second thermal liner defining an inner surface and an outer surface disposed opposite from the inner surface.

A method of assembling a box includes providing the box, the box comprising a center panel, a first locking panel, a second locking panel, a first side flap panel, and a second side flap panel; folding the first side flap panel and second side flap panel relative to the center panel; folding the first locking panel relative to the center panel, the first locking panel defining a locking slot; folding the second locking panel relative to the center panel at least partially over the first locking panel, the second locking panel defining a locking tab; and engaging the locking slot with the locking tab.

Novel method of preserving the internal environmental air temperature and thereby stabilizing the temperature within the cargo compartment of a transport container, and thereby protecting the cargo itself from degradation due to temperature fluxuations, including a freeze and heat barrier attained through the characteristics of the article of manufacture, composition of matter, and method of preservation of the internal environmental air temperature and proximate cargo within said cargo compartment; along with a machine or devise that is used as either a stand-alone container, or as an insert to retrofit existing containers so as to make said retrofitted devices capable of providing cooling over an extended period of time are disclosed. The inserted cargo compartments described herein are particularly useful for temperature-stabilizing cargo compartment shipping containers that are required to maintain a temperature below ambient for a time sufficient to complete delivery of the container and its contents. The shipping containers can be utilized to cost-effectively transport temperature-sensitive products.