INSULATED PACKAGING WITH AIR GAP POSITIONING

Abstract

A shipping assembly for transporting refrigerated items includes an outer box defining an outer box cavity and a bottom panel, a bottom insulator box assembly received in the outer box cavity atop the bottom panel, an insulated inner box positioned in the outer box cavity above the bottom insulated box assembly, the insulated inner box defining an ridge and an inner box cavity, wherein ridge panels and retention flaps of the outer box engage end panels of the insulated inner box such that the insulated inner box is retained in a spaced position, relative to outer box panels, by predetermined gap distances; and a top insulator box assembly partially received in the inner box cavity, such that first and second overhang portions of a top panel of the top insulator box assembly rest upon the ridge of the insulated inner box.

Claims

1. An outer box blank, comprising: an outer box side panel defining a first side; an end panel extending from at least a portion of the first side of the outer box side panel, the end panel joined to the outer box side panel along a first fold line, the first fold line defining a joint between the outer box side panel and the end panel, the end panel further defining a second fold line at a top side of the end panel; a ridge panel extending from at least a portion of the second fold line, the second fold line defining a joint between the end panel and the ridge panel, the ridge panel defining an elongated side opposite the second fold line, a first end extending between the second fold line and the elongated side, and a second end opposite the first end, the second end also extending between the second fold line and the elongated side; and a retention flap extending from a portion of the elongated side of the ridge panel, the portion of the elongated side defining a third fold line, the third fold line defining a joint between the retention flap and the ridge panel, the retention flap defining a free edge opposite the elongated side, a first edge extending between the elongated side and the free edge, and a second edge opposite the first edge, the second edge also extending between the elongated side and the free edge.

2. The outer box blank of claim 1, wherein the ridge panel further defines a first shoulder portion extending along the elongated side for a first length measured from the first end of the ridge panel to the first edge of the retention flap, and a second shoulder portion extending along the elongated side for a second length measured from the second end of the ridge panel to the second edge of the retention flap; and wherein the second end of the ridge panel is configured to frictionally engage an inner surface of the outer box side panel upon assembly of an outer box from the outer box blank such that an insulated inner box engaged by the retention flap is spaced from the inner surface of the outer box side panel by a gap distance substantially equaling the second length of the second shoulder portion.

3. The outer box blank of claim 2, wherein the retention flap defines a handle aperture, the handle aperture configured to facilitate grasping of the retention flap to move it from an engaged position to a disengaged position relative to the insulated inner box positioned within the outer box.

4. The outer box blank of claim 1, wherein the outer box blank defines an inside surface coated with a repulpable insulating film.

5. An insulated inner box configured for placement within outer box, the insulated inner box formed from an inner box blank defining an inside surface and an outside surface, wherein the inside surface is coated with a repulpable insulating film; wherein the insulated inner box blank comprises a side panel defining a first top side and a second side adjacent to the first top side, a first top flap extending from at least a portion of the first top side of the side panel, the first top flap joined to the side panel along a first fold line defining a joint between the first top flap and the side panel, the first top flap defining a first top flap edge opposite the first fold line, a first side, and a second side opposite the first side, an end panel extending from at least a portion of the second side of the side panel, the end panel joined to the side panel along a second fold line, the second fold line defining a joint between the side panel and the end panel, the second fold line further defining a first side of the end panel, the end panel further defining a second side adjacent to the second fold line, and a second top flap extending from at least a portion of the second side of the end panel, the second top flap joined to the end panel along a third fold line defined by the second side of the end panel, the third fold line defining a joint between the end panel and the second top flap, the second top flap defining a second top flap edge opposite the third fold line, a first side and a second side opposite the first side, the second side of the second top flap defined by the first side of the first top flap, wherein the first side of the first top flap defines a first cut-out section extending downwardly from the first top flap edge and the second top flap edge, a second cut-out section axially spaced from the first cut-out section, the second cut-out section forming a partial gap between the first top flap and the second top flap, and a fourth fold line axially extending between the first cut-out section and the second cut-out section, the fourth fold line defining a joint between the first top flap and the second top flap.

6. The insulated inner box of claim 5, wherein an assembled state of the insulated inner box is defined by the first top flap assuming a downwardly folded position about the first fold line with respect to the side panel such that an exterior surface of the first top flap faces an exterior surface of the side panel to expose a coated inner surface of the first top flap; the second top flap assuming a downwardly folded position about the third fold line with respect to the end panel such that an exterior surface of the second top flap faces an exterior surface of the end panel to expose a coated inner surface of the second top flap; the side panel and the end panel assuming a folded position about the second fold line such that the side panel and the end panel are oriented substantially perpendicularly with respect to each other, and such that the first fold line and the third fold line together at least partially define a ridge of the insulated inner box; and the first top flap and the second top flap assuming a folded position about the fourth fold line such that the first top flap and the second top flap are oriented substantially perpendicularly with respect to each other

7. A top insulator box blank, comprising: an end panel defining a first side, a second side opposite the first side, a third side, and a fourth side opposite the third side; a top panel extending from at least a portion of the first side of the end panel, the top panel joined to the end panel along a first fold line defining a joint between the top panel and the end panel, the top panel defining a first side along the first fold line, a second side opposite the first fold line, a third side, and a fourth side opposite the third side; a bottom panel extending from at least a portion of the second side of the end panel, the bottom panel joined to the end panel along a third fold line defining a joint between the bottom panel and the end panel, the bottom panel defining a first side along the third fold line, a second side opposite the third fold line, a third side, and a fourth side opposite the third side; a side panel extending from at least a portion of the third side of the bottom panel, the side panel joined to the bottom panel along a fourth fold line defining a joint between the side panel and the bottom panel, the side panel defining a first side along the fourth fold line, a second side opposite the fourth fold line, a third side, and a fourth side opposite the third side; a first upper insulation retention flap extending from the second side of the side panel, the first upper insulation retention flap joined to the side panel along a fifth fold line defining a joint between the first upper insulation retention flap and the side panel, the first upper insulation retention flap defining a distal edge opposite the fifth fold line, a rear edge, and a front edge opposite the rear edge; a front panel extending from at least a portion of the second side of the bottom panel, the front panel joined to the bottom panel along a sixth fold line defining a joint between the front panel and the bottom panel, the front panel defining a first side along the sixth fold line, a second side opposite the sixth fold line, a third side, and a fourth side opposite the third side; and a second upper retention flap extending from at least a portion of the second side of the front panel, the second upper retention flap joined to the front panel along a seventh fold line defining a joint between the second upper retention flap and the front panel.

8. The top insulator box blank of claim 7, further comprising a locking tab extending from a portion of the second side of the top panel, the locking tab joined to the top panel along a second fold line defining a joint between the locking tab and the top panel.

9. The top insulator box blank of claim 8, wherein the second upper retention flap defines a slot, the slot configured to receive the locking tab when a top insulator box is assembled from the top insulator box blank; and wherein the locking tab is configured to maintain a closed configuration between the top panel and the bottom panel following insertion of the locking tab into the slot.

10. The top insulator box blank of claim 7, wherein the top insulator box blank defines an inside surface coated with a repulpable insulating film.

11. The top insulator box blank of claim 7, further comprising a front insulation retention flap extending from at least a portion of the third side of the side panel, the front insulation retention flap joined to the side panel along an eighth fold line defining a joint between the front insulation retention flap and the side panel.

12. The top insulator box blank of claim 11, further comprising a rear insulation retention flap extending from at least a portion of the fourth side of the side panel, the rear insulation retention flap joined to the side panel along a ninth fold line defining a joint between the rear insulation retention flap and the side panel.

13. The top insulator box blank of claim 7, wherein the top panel defines a thumb hole cut-out section configured to facilitate lifting of the top insulator box out of an outer box, the thumb hole cut-out section defining a thumb hole flap joined to the top panel by an eighth fold line.

14. A shipping assembly for transporting refrigerated items, comprising: an outer box defining a bottom and an outer box cavity; a bottom insulator box assembly received in the outer box cavity and superposed above the bottom of the outer box, the bottom insulator box assembly comprising a closed box defining a bottom insulator box cavity; an insulated inner box positioned in the outer box cavity above the bottom insulator box assembly, the insulated inner box defining an inner box cavity and a ridge; and the top insulator box assembly, the top insulator box assembly partially received in the inner box cavity of the insulated inner box, such that the first overhang portion of the top panel and the second overhang portion of the top panel rest upon the ridge of the insulated inner box.

15. The shipping assembly of claim 14, wherein the outer box further defines an outer box inside surface coated with a repulpable insulating film.

16. The shipping assembly of claim 15, further comprising a bottom insulation box stiffener positioned within the bottom insulator box cavity.

17. The shipping assembly of claim 14, wherein the closed box of the bottom insulator box assembly further defines a closed box inside surface coated with a repulpable insulating film.

18. The shipping assembly of claim 14, further comprising a bottom insulation batt element positioned within the bottom insulator box cavity.

19. The shipping assembly of claim 18, further comprising a sheet layer attached to at least one surface of the bottom insulation batt element.

20. The shipping assembly of claim 14, further comprising a bottom insulation box stiffener positioned within the bottom insulator box cavity.

21. A shipping assembly, comprising: an outer box defining a bottom and an outer box cavity; and an insulated inner box positioned in the outer box cavity adjacent to one of a bottom insulator box assembly and a top insulator box assembly, the insulated inner box defining an inner box cavity.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several aspects of the disclosure and together with the description, serve to explain various principles of the disclosure. The drawings are not necessarily drawn to scale. Corresponding features and components throughout the figures can be designated by matching reference characters for the sake of consistency and clarity.

[0016] FIG. 1 is an exploded perspective view of a shipping assembly for transporting refrigerated items, the assembly constructed in accordance with an aspect of the current disclosure.

[0017] FIG. 2 is a sectional exploded view of the shipping assembly illustrated in FIG. 1, taken along line 2-2 in FIG. 1.

[0018] FIG. 3 is a sectional perspective view of the shipping assembly of FIG. 1 in a substantially assembled state.

[0019] FIG. 4 is a front sectional view of the shipping assembly of FIG. 1 in a substantially assembled state.

[0020] FIG. 5 is a sectional view similar to FIG. 4, except showing the assembly rotated slightly upwardly to reveal more details of the underside of a top insulator box in the assembly.

[0021] FIG. 6 is a top view of the shipping assembly of FIG. 1, shown with the outer box top flaps in an open position to reveal the top of the top insulator box.

[0022] FIG. 7A is a top perspective view of the shipping assembly of FIG. 1, shown with the outer box top flaps in an open position, but excluding the top insulator box to reveal the positioning of the insulated inner box within the outer box.

[0023] FIG. 7B is a detail view of one of the outer box retention flaps shown in FIG. 7A.

[0024] FIG. 8 is a top perspective view similar to FIG. 7A, except showing the outer box retention flaps assuming an open position.

[0025] FIG. 9A is a perspective view of the inner insulated box shown in FIGS. 7A and 8.

[0026] FIG. 9B is a cross sectional diagram showing a composite material comprising a thin repulpable insulation film superposed upon a cardboard layer, the composite material used in various components of the shipping assembly of FIG. 1, including the inner insulated box of FIG. 9A.

[0027] FIG. 10 is a top perspective view of a bottom insulator box assembly comprising a portion of the shipping assembly of FIG. 1, the bottom insulator box shown removed from a cavity defined by the outer box but resting atop the outer box flaps for illustrative purposes.

[0028] FIG. 11A is a side perspective view of the bottom insulator box assembly of FIG. 10 shown with side flaps of the bottom insulator box open to expose a bottom insulation batt element encapsulated within the bottom insulator box.

[0029] FIG. 11B is a side perspective view of the bottom insulator box of the assembly of FIG. 10, also with the side flaps open as in FIG. 11A, except excluding the bottom insulation batt element to show the cavity defined by the bottom insulator box.

[0030] FIG. 12A is a top perspective view of the left side of the bottom insulator box assembly of FIG. 11A, with one of the side flaps shown in an open position and another of the side flaps shown in a substantially closed position.

[0031] FIG. 12B is a perspective view of the left side of the bottom insulator box assembly of FIG. 11A, shown with both side flaps open and with the bottom insulation batt element partially removed from the cavity defined by the bottom insulator box.

[0032] FIG. 13A is a top view of a top insulator box assembly comprising another portion of the shipping assembly of FIG. 1.

[0033] FIG. 13B is a bottom view of the top insulator box assembly of FIG. 13A.

[0034] FIG. 13C is a front view of the top insulator box assembly of FIG. 13A.

[0035] FIG. 14A is a top perspective view of the top insulator box assembly of FIG. 13A shown in a partially disassembled state to reveal a top insulation batt element contained therein.

[0036] FIG. 14B is a top perspective view of the top insulator box assembly of FIG. 13A shown in a progressively further disassembled state than that depicted in FIG. 14A, such that the retaining flaps of the top insulator box are shown in an unfolded position.

[0037] FIG. 14C is a front perspective view of the same state of disassembly of the top insulator box assembly depicted in FIG. 14B.

[0038] FIG. 15A is a perspective view of a subassembly comprising the top insulator box assembly of FIG. 13A seated partially within the inner insulated box illustrated in FIG. 1.

[0039] FIG. 15B is a rear perspective view of the subassembly illustrated in FIG. 15A.

[0040] FIG. 16 is a top view of an outer box blank for the outer box illustrated in FIG. 1, from the perspective of viewing the inside surface of the outer box blank.

[0041] FIG. 17 is a top view of an insulated inner box blank for the inner insulated box best illustrated in FIGS. 1, 2, and 9A, from the perspective of viewing the inside surface of the inner box blank.

[0042] FIG. 18 is a top view of a blank for the bottom insulator box illustrated in FIG. 1, from the perspective of viewing the inside surface of the blank.

[0043] FIG. 19 is a top view of a blank for the top insulator box illustrated in FIG. 1, from the perspective of viewing the inside surface of the blank.

[0044] FIG. 20 is an exploded perspective view of an alternate embodiment of a shipping assembly for transporting refrigerated items, the assembly constructed in accordance with another aspect of the current disclosure.

[0045] FIG. 21 is a perspective view of the outer box comprising a portion of the shipping assembly illustrated in FIG. 20, with a bottom insulating box assembly seated within a cavity defined by the outer box.

[0046] FIG. 22 is a front view of a rear flap comprising part of the outer box illustrated in FIG. 21, the rear flap oriented in an open position.

[0047] FIG. 23 is a front perspective view of the rear flap illustrated in FIG. 22 moved to a fully closed position following insertion of an insulated inner box into the outer box illustrated in FIGS. 21 and 22.

[0048] FIG. 24 is a top perspective view of a subassembly of the shipping assembly illustrated in FIG. 20, showing the insulated inner box seated within a cavity defined by the outer box.

[0049] FIG. 25 is an exploded perspective view showing the subassembly of FIG. 24 in exploded relation to the top insulator box assembly of FIG. 20.

[0050] FIG. 26 is an exploded perspective view of a second alternate embodiment of a shipping assembly for transporting refrigerated items, the assembly constructed in accordance with another aspect of the current disclosure.

[0051] FIG. 27 is a perspective view of the left side of the bottom insulator box assembly illustrated generally in FIG. 26, shown with both side flaps open and with a bottom box stiffener partially removed from the cavity defined by the bottom insulator box.

[0052] FIG. 28 is a top perspective view of the top insulator box assembly illustrated generally in FIG. 26, with the top insulator box opened to show a top box stiffener seated therein.

[0053] FIG. 29 is a front perspective view of an insulation element that can be used in the top and bottom insulator box assemblies of an alternate embodiment of the shipping assembly illustrated in FIG. 26.

DETAILED DESCRIPTION

[0054] The present disclosure can be understood more readily by reference to the following detailed description, examples, drawings, and claims, and their 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, 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.

[0055] The following description is provided as an enabling teaching of the present devices, systems, and/or methods in their 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 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.

[0056] As used throughout, the singular forms a, an and the include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to a quantity of one of a particular element can comprise two or more such elements unless the context indicates otherwise. In addition, any of the elements described herein can be a first such element, a second such element, and so forth (e.g., a first widget and a second widget, even if only a widget is referenced).

[0057] 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 comprises 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 or substantially, 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.

[0058] 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.

[0059] As used herein, the terms optional or optionally mean that the subsequently described event or circumstance can or cannot occur, and that the description comprises instances where said event or circumstance occurs and instances where it does not.

[0060] The word or as used herein means any one member of a particular list and also comprises any combination of members of that list. The phrase at least one of A and B as used herein means only A, only B, or both A and B; while the phrase one of A and B means A or B.

[0061] To simplify the description of various elements disclosed herein, the conventions of left, right, front, rear, top, bottom, upper, lower, inside, outside, inboard, outboard, horizontal, and/or vertical might be referenced. Unless stated otherwise, front describes that end of a blank or an assembled box or any portion thereof nearest to a primary or initial point of opening; rear is that end of the blank or the assembled box or any portion thereof that is opposite or distal the front; left is that which is to the left of or facing left from a person facing towards the front; and right is that which is to the right of or facing right from that same person facing towards the front. Horizontal or horizontal orientation describes that which is in a plane extending from left to right and aligned with the horizon. Vertical or vertical orientation describes that which is in a plane that is angled at 90 degrees to the horizontal.

[0062] As disclosed in the figures disclosing blanks 300,400,410,420, various line thicknesses and types can indicate certain characteristics of the geometry. In some aspects, a thicker solid line can indicate the edge of a part; a thinner solid line can indicate a bend line; a dash or dashed line can indicate a hidden edge (and edge covered by other geometry), a perforated cut or connection, or a boundary or boundaries of a detail view; a dot-dash line can indicate material that is cut away and not shown for clarity, and a double dot-dash line can indicate a boundary or boundaries of separately claimable elements. Unless otherwise specified, a geometric center of any thicker lines determine the shape and position of the disclosed geometry. Dimensions disclosed in the figures are recited in inches but are exemplary only, and it is contemplated that the blanks 300,400,410,420 and the shipping assemblies 100,2000,2600 formed therefrom can be any shape and size. In some aspects, for example and without limitation, the shipping assembly can be used for meat products such as those sold by Omaha Steaks.

Overview of Shipping Assembly Components and the Outer Box 102

[0063] FIG. 1 is an exploded view of a shipping assembly 100 for transporting refrigerated items, according to two respective aspects of the present disclosure. The assembly 100 includes an outer box 102, assembled from an outer box blank 300, to be described in greater detail with regard to FIG. 16. The outer box 102 comprises a first outer box side panel 104 (FIG. 2), a second outer box side panel 106, a rear panel 108, a front panel 110, a bottom 112, a first top flap 114 joined to the first outer box side panel 104 by a fold line 306 (FIG. 16), and a second top flap 116 joined to the second outer box side panel 106 by a fold line 308 (FIG. 16). The side panels 104, 106, the rear panel 108, the front panel 110 (not shown), and the bottom 112 of the outer box 102 collectively define an outer box cavity 113 (also shown in FIGS. 2, 9A, and 10), which can be further defined upon closure of the top flaps 114,116. As best seen in FIG. 2, the bottom 112 can comprise bottom flaps 112a,b, 111a and, although not shown, 111b. The top flaps 114, 116 cover an upper opening of the outer box 102 that would otherwise be formed at the upper ends of the side panels 104, 106, the front panel 110 (not shown), and rear the panel 108. The outer box 102 additionally comprises rear and front retention flaps 118, 120, respectively, joined to the top sides of the rear and front end panels 108,110, respectively. The retention flaps 118, 120 are discussed in greater detail with regard to FIGS. 7A-8. The outer box 102 of the present aspects can define a substantially rectangular cross-sectional shape (as best seen in FIGS. 3-5). However, in other aspects, the number of side and end panels can vary and/or the cross-section shape of the outer box 102 can vary-for example, the outer box 102 can define a triangular, square, or circular cross-sectional shape, or any other suitable cross-sectional shape. The outer box 102 can also comprise more or fewer top and bottom panels than those disclosed with regard to the present aspects of the current disclosure. The outer box 102 can be composed from corrugated cardboard and constructed as a regular slotted container (RSC), though other suitable materials for the outer box 102 are contemplated as being within the scope of the present disclosure.

[0064] The shipping assembly 100 can, in some aspects, further comprise a bottom insulator box assembly 122, received in the outer box cavity 113 of the outer box 102 and superposed above the bottom 112 of the outer box 102. As used herein, superposed above encompasses arrangements in which a bottom of the bottom insulator box assembly 122 contacts at least a portion of the outer box bottom 112 and, alternatively, in which the bottom insulator box assembly 122 is spaced from the outer box bottom 112. The bottom insulator box assembly 122 includes a bottom insulator box 122 (FIG. 2) assembled from a bottom insulator box blank 410 (FIG. 18), the bottom insulator box 122 defining a bottom insulator box cavity 152 (FIG. 2). The bottom insulator box assembly 122 also includes a bottom insulation batt element 200 (FIGS. 11A and 12B) positioned within the bottom insulator box cavity 152. The positioning and composition of the bottom insulation batt element 200 are discussed in further detail herein with regard to FIG. 11A. In the assembled state of the shipping assembly 100 exemplified in FIGS. 3-5, the bottom insulator box assembly 122 is positioned within the outer box cavity 113 and is superposed above the bottom 112 of the outer box 102.

[0065] In some aspects, the bottom insulator box 122 can be constructed of, with reference to FIG. 9B, an insulated material 10 such as a corrugated cardboard layer 11, the upper surface 13 of which is coated with a repulpable insulating film 12. Also as shown in FIG. 9B, the lower surface 11 of the corrugated cardboard layer 10 can remain uncoated. For all boxes disclosed herein that can be constructed of the insulated material 10, the side of the material 10 facing the cavity defined by the box is the coated side such that the upper surface 12a of the repulpable insulating film 12 defines the inside surface of the box panels defining the cavity.

[0066] Referring now to FIGS. 1-5, the shipping assembly 100 can, in some aspects, also include a top insulator box assembly 134 shown being partially received within the inner box cavity 156 of an insulated inner box 124 as well as completely received within the outer box cavity 113. The top insulator box assembly 134 includes a top insulator box 134 assembled from a top insulator box blank 420, discussed in greater detail herein with regard to FIG. 19. The top insulator box 134 comprises side panels 136, 138, a top panel 135, an end panel 140, a front panel 142, and a bottom panel 137, all of which collectively defines a top insulator box cavity 139. In some aspects, the insulated inner box 124 can be composed of the same insulated material 10 discussed above with regard to the bottom insulator box assembly 122 and the insulated inner box 124. Thus, the inner surfaces of each of these panels, that is, the surfaces facing the top insulator box cavity 139, are coated with the repulpable insulating film 12 discussed above with regard to FIG. 9B. The top insulator box assembly 134 also includes a top insulation batt element 201 (FIGS. 14A-14C) positioned within the top insulator box cavity 139. The positioning and composition of the top insulation batt element 201 are discussed in further detail herein with regard to FIGS. 14A-14C. In the assembled state of the shipping assembly 100 exemplified in FIGS. 3-5, overhang portions O1 and O2 (FIG. 4) of the top panel 135 suspend the upper insulator box assembly 134 above the bottom surface (bottom flaps 154a,b) of an insulated inner box 124, the box 124 described in further detail below.

The Insulated Inner Box 124

[0067] Referring again to FIG. 1, the shipping assembly 100 can, in some aspects, further comprise an insulated inner box 124 positioned in the outer box cavity 113 above the bottom insulator box assembly 122. As used herein, above encompasses arrangements in which a bottom 153 of the insulated inner box 124 contacts at least a portion of a top of the bottom insulator box assembly 122 and, alternatively, in which bottom 153 is spaced from the top of the bottom insulator box assembly 122. The insulated inner box 124 comprises side panels 126, 130, end panels 130, 132, and the bottom 153 comprised of bottom flaps 154a,b (FIG. 2), all of which partially define an inner box cavity 156 (FIGS. 2 and 4). The insulated inner box 124, which can be composed of the same insulated material 10 discussed above, can be assembled from an insulated inner box blank 400, discussed in greater detail with regard to FIG. 17. As best shown in FIGS. 1 and 9A, upper portions of the side panels 126, 128 and the end panels 130, 132 insulated inner box 124 are each folded outwardly at respective fold lines 126b, 128b, 130b, 132b, such that the surface 12a (FIG. 9B) of the repulpable insulating film 12 coating each of those panels face outwardly, such panel portions labeled as 126a, 128a, 130a, 132a and designated as top flaps in the insulated inner box blank 400 (FIG. 17). In the assembled configuration of the insulated inner box 124 illustrated in FIGS. 1 and 9A, the fold lines 126b, 128b, 130b, 132b collectively define a ridge 158 (FIGS. 8 and 9A) of the insulated inner box 124, with each of those fold lines defining a portion of the ridge 158. Also in this assembled configuration, the exterior surfaces of the panel portions labeled as 126a, 128a, 130a, 132a collectively define an outer periphery 3500 (FIG. 9A) of the insulated inner box 124. To the extent that the figures identified in this paragraph do not identify various panel edges and fold lines of the insulated inner box 124, these will be described herein with reference to the insulated inner box blank 400 (FIG. 17).

[0068] Once the insulated inner box 124 is fully seated within the outer box cavity 113, the retention flaps 118, 120 of the outer box 102 can be moved to a closed position to retain the insulated inner box 124 in a spaced relationship with respect to the side panels 104, 106 and the end panels 108, 110 of the outer box 102, as discussed in greater detail with regard to FIGS. 7A-8.

The Top Insulator Box Assembly 134

[0069] FIGS. 6 and 13A-13C provide greater detail concerning the top panel 135 and the manner in which the top insulator box assembly 134 is positioned within the inner box cavity 156 and within the outer box cavity 113. As best seen in FIG. 6, the top panel 135 can define a pair of thumb hole cut-out sections 135a,b configured to facilitate lifting of the top insulator box assembly 134 out of the outer box 102. Further details concerning the thumb hole cut-out sections are discussed herein with regard to FIG. 19. A top insulation batt element 201, positioned within the top insulator box cavity 139 (FIG. 2) is shown in FIG. 6 as being visible through both of the thumb hole cut-out sections 135a,b. The top insulation batt element 201 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 top insulator box assembly 134. In some aspects, the top insulation batt element 201 can be biodegradable, and in some aspects, the top insulation batt element 201 can be compostable. In a particular aspect, the top insulation batt element 201 can be formed from R-4 poly encapsulated thermal 100% recycled cotton, all of such materials discussed in U.S. Pat. No. 11,066,228 to Sollie et al., the disclosure of which is hereby incorporated by reference in its entirety. In some aspects, the top insulation batt element 201 can assume as prismatic shape, as best seen in FIGS. 14A-14C, to be discussed in greater detail herein; however, the particular shape of the top insulation batt element 201 illustrated in those figures is not intended to be limiting, and the element 201 can assume any other suitable shape.

[0070] Still referring to FIGS. 6 and 13A-13C, the top panel 135 of the top insulator box 134 of the assembly 134 further defines a first edge 210 and an opposed second edge 212. As best seen in FIG. 13C, the top panel 135 has a first width W1 that is greater than a second width W2 of the front 142 of the top insulator box 134. As a result, the first edge 210 of the top panel 135 extends laterally beyond the first side panel 136 to define a first overhang portion O1 of the top panel 135. Similarly, the second edge 212 of the top panel 135 extends laterally beyond the second side panel 138 to define a second overhang portion O2 of the top panel 135. Although the perspective of FIG. 13C suggests that portions 01 and O2 have different lengths, those lengths are preferably equal, as seen in FIG. 4, but in some aspects of the present disclosure, those respective lengths may differ. In the assembled state of the shipping assembly 100 exemplified in FIGS. 1-5, the first overhang portion 01 of the top panel 135 and the second overhang portion O2 of the top panel 135 rest upon the ridge 158 (FIGS. 8 and 9A) of the insulated inner box 124. In this spatial arrangement, the overhang portions O1 and O2 of the top panel 135 suspend the upper insulator box assembly 134 above the bottom surface (bottom flaps 154a,b) of the insulated inner box 124, as best seen in FIG. 4.

[0071] FIGS. 15A and 15B are perspective and rear views, respectively, of a subassembly comprising the top insulator box assembly 134 seated partially within the inner insulated box 124. Ridge portions 130b, 132b of the inner insulated box 124 are exposed in FIG. 15A because the top insulator box assembly 134 does not rest upon those portions of the ridge 158 (FIGS. 8 and 9A). Instead, the top insulator box assembly 134 rests upon the other two ridge portions obstructed from view by the upper panel 135, namely, the ridge portions 126b, 128b, over which the aforementioned overhang portions O1 and O2 of the upper panel 135 extend. The configuration shown is not meant to be limiting, however, and in other aspects the top insulator box assembly could instead extend over, and be supported by, the ridge portions 130b, 132b.

[0072] FIGS. 14A-14C illustrate the top insulator box assembly 134 in two disassembled states: one of them shown in FIG. 14A and the other shown in both FIGS. 14B and 14C, which both show a progressively further disassembled state than that depicted in FIG. 14A. Given that the insulator box 134 is composed of the insulated material 10, which includes the repulpable insulating film 12 discussed above with regard to FIG. 9B, various panel and flap surfaces are denoted in FIGS. 14A-14C, as well as in certain other figures that involve the insulated material 10, with the reference numeral 12 appearing as a suffix to the reference numeral unique to the part being designated. This numbering convention is done as a shorthand designation, acknowledging that the visible portion of the repulpable insulating film 12 is the upper (outer) surface 12a (FIG. 9B) of that film 12. To promote brevity, this numbering convention is applied to the figures only, and the suffix 12 is not repeated in the present textual descriptions. To the extent that FIGS. 14A-14C do not identify various panel edges and fold lines, these will be described herein with reference to the top insulator box blank 420 (FIG. 19).

[0073] In FIG. 14A, the top insulator box 134 has been opened to reveal the top insulation batt element 201 disposed on the bottom panel 137 (FIG. 2) of the top insulator box 134. The end panel 140 is connected to the top panel 135 on one side and to the bottom panel 137 on the other side. A locking tab 216 extends from a portion of the side of the top panel 135 extending between the first edge 210 and the second edge 212. In other words, the locking tab 216 extends from the side of the top panel 135 opposite the end panel 140. A left side upper insulation retention flap 218, which extends from the first side panel 136 (FIGS. 14B and 14C), is shown extending over a portion of the upper surface of the top insulation batt element 201 proximate the first side panel 136. Similarly, a right side upper insulation retention flap 220, which extends from the second side panel 138 (FIGS. 14B and 14C), is shown extending over a portion of the upper surface of the top insulation batt element 201 proximate the second side panel 138. The front panel 142 of the top insulator box 134 extends from a front side of the bottom panel 137, the front panel 142 joined to the bottom panel 137 along a fold line (not shown). The front panel 142 includes a front side from which extends a front upper insulation retention flap 214 that, in an assembled position, extends over a front portion of the upper surface of the top insulation batt element 201. The front upper insulation retention flap 214 defines a slot 214a therein, the slot 214a configured to receive the locking tab 216 when the top insulator box 134 is assembled from the top insulator box blank 420 (FIG. 19). The locking tab 216 can be configured to maintain a closed configuration between the top panel 135 and the bottom panel 137 following insertion of the locking tab 216 into the slot 214a. Although the various openings disclosed herein can be slot-shaped, they can assume any shape that suitably accommodates and lockably engages at least a portion of their corresponding locking tabs. FIG. 14A also shows that the top insulator box 134 further comprises a first front insulation retention flap 222 extending from at least a portion of the first side panel 136 and a second front insulation retention flap 226 extending from at least a portion of the second side panel 138. In some aspects, the top insulator box 134 can additionally include a first rear insulation retention flap 224 extending from at least a portion of the first side panel 136 and a second rear insulation retention flap 228 extending from at least a portion of the second side panel 138.

[0074] In FIGS. 14B and 14C, the side upper insulation retention flaps 218,220 have been folded outwardly, thereby fully exposing the sides of the top insulation bat element 201. The illustrated position more clearly shows the connection of the left side upper insulation retention flap 218 to the first side panel 136 along a fold line 230, and the connection of the right side upper insulation retention flap 220 to the second side panel along a fold line 232.

Positioning, Configuration, and Functions of Outer Box End Flaps

[0075] FIGS. 7A-8 illustrate the configuration of the retention flaps 118, 120 of the outer box 102, as well as that of related outer box elements and their functions relative to the insulated inner box 124. For clarity of illustration, the views of FIGS. 7A-8 omit the top insulator box assembly 134, which would otherwise be seated within the insulated inner box 124 in the manner discussed above with regard to FIGS. 15A and 15B. To the extent that FIGS. 7A-8 do not identify various panel edges and fold lines, these will be described herein with regard to the outer box blank 300 (FIG. 16).

[0076] FIG. 8 shows the insulated inner box 124 fully seated within the outer box 102, with all flaps and panels of the outer box 102 oriented in a fully open position. The outer box 102 includes ridge panels 119,121 that are respectively connected along panel fold lines 161,236 to the upper ends of the rear panel 108 and of the front panel 110 (FIG. 1). The rear ridge panel 119 defines an elongated side 179 opposite the panel fold line 161, a first end 175 extending between the panel fold line 161 and the elongated side 179, and a second end 177 opposite the first end 175, the second end 177 also extending between the panel fold line 161 and the elongated side 179. Similarly, the rear ridge panel 121 defines an elongated side 251 opposite the panel fold line 236, a first end 252 extending between the panel fold line 236 and the elongated side 251, and a second end 254 opposite the first end 252, the second end 254 also extending between the panel fold line 236 and the elongated side 251. Respective portions of the elongated sides 179,251 of the ridge panels 119, 121 define flap fold lines 163,238. The retention flaps 118,120 are respectively connected to the ridge panels 119,121 along the flap fold lines 163,238. Thus, the ridge panel 119 provides a double fold line arrangement, i.e., fold lines 161,163, as does the ridge panel 121, i.e., fold lines 236,238. With this configuration, the rear flap 125 (the combination of the rear ridge panel 119 and the rear retention flap 118) of the outer box 102 is moved to a fully open position when both the ridge panel 119 is pivoted fully outwardly about the panel fold line 161, and the rear retention flap 118 is pivoted fully outwardly about the flap fold line 163. Similarly, the front flap 127 (the combination of the front ridge panel 121 and the front retention flap 120) of the outer box 102 is moved to a fully open position when both the front ridge panel 121 is pivoted fully outwardly about the panel fold line 236, and when the front retention flap 120 is pivoted fully outwardly about the flap fold line 238. In the fully open position shown in FIG. 8, the entirety of the ridge 158 of the insulated inner box 124, that is, the combination of portions 126b, 128b, 130b, 132b, is fully visible.

[0077] FIG. 8 also shows shoulder portions 179a,b and 251a,b defined by the configuration of each retention flap 118,120 relative to each respective ridge panel 119,121. In particular, the rear retention flap 118 defines a free edge 165 opposite the elongated side 179, a first edge 171 extending between the elongated side 179 and the free edge 165, and a second edge 173 (FIG. 7B) opposite the first edge 171, the second edge 173 also extending between the elongated side 179 and the free edge 165. The rear ridge panel 119 defines a first shoulder portion 179a extending along the elongated side 179 for a first length measured from the first end 175 of the rear ridge panel 119 to the first edge 171 of the rear retention flap 118. The rear ridge panel 119 further defines a second shoulder portion 179b extending along the elongated side 179 for a second length measured from the second end 177 of the rear ridge panel 119 to the second edge 173 (FIG. 7B) of the rear retention flap 118. Similarly, the front retention flap 120 defines a free edge 240 opposite the elongated side 251, a third edge 246 (FIG. 16) extending between the elongated side 251 and the free edge 240, and a fourth edge 250 opposite the third edge 246, the fourth edge 250 also extending between the elongated side 251 and the free edge 240. The front ridge panel 121 defines a third shoulder portion 251a extending along the elongated side 251 for a third length measured from the first end 252 of the front ridge panel 121 to the third edge 246 (FIG. 16) of the front retention flap 120. The front ridge panel 121 further defines a fourth shoulder portion 251b extending along the elongated side 251 for a fourth length measured from the second end 254 of the front ridge panel 121 to the fourth edge 250 of the front retention flap 120.

[0078] Referring to FIGS. 7B, 8, and 16, edges each of the retention flaps 118,120 can, in some aspects, be further defined by chamfered portions. In particular, the first edge 171 of the rear retention flap 118 defines a first chamfered portion 167 that extends at an angle with respect to the free edge 165 of the rear retention flap 118, and the second edge 173 of the rear retention flap 118 defines a second chamfered portion 169 that also extends at an angle to the free edge 165. Similarly, the third edge 246 of the front retention flap 120 defines a third chamfered portion 242 that extends at an angle with respect to the free edge 240 of the front retention flap 120, and the fourth edge 250 of the front retention flap 120 defines a fourth chamfered portion 244 that also extends at an angle to the free edge 240.

[0079] FIGS. 7A and 7B illustrate a closed position of both the rear flap 125 (comprising the rear ridge panel 119 and the rear retention flap 118) and the front flap 127 (comprising the front ridge panel 121 and the front retention flap 120) of the outer box 102 with respect to the end panels 130, 132 of the insulated inner box 124. This closed position produces certain spatial relationships between the insulated inner box 124 and the side panels 104, 106 of the outer box 102. In particular, the rear ridge panel 119 covers ridge portion 132b (FIG. 8) of the of the insulated inner box 124. Additionally, the first end 175 of the rear ridge panel 119 frictionally engages at least a portion of an inside surface 106a of the second outer box side panel 106, while the second end 177 of the rear ridge panel 119 frictionally engages at least a portion of an inside surface 104a of the first outer box side panel 104. As best seen in FIG. 7B, the first edge 171 of the rear retention flap 118 frictionally engages at least a portion of an inside surface 126,12 of the first side panel 126 of the insulated inner box 124, while the second edge 173 of the rear retention flap 118 frictionally engages at least a portion of an inside surface 128,12 of the second side panel 128 of the insulated inner box 124. In this position, the rear retention flap 118 and the rear ridge panel 119 engage at least a portion of the rear panel 132 of the insulated inner box 124 such that the rear panel 132 is spaced from the first outer box side panel 104 by a first gap distance G1 substantially equaling the length of the second shoulder portion 179b of the rear ridge panel 119, and the rear panel 132 is also spaced from the second outer box side panel 106 by a second gap distance G2 substantially equaling the length of the first shoulder portion 179a of the rear ridge panel 119. Spatial relationships similar to those described above exist at the fronts of the outer box 102 and the insulated inner box 124. In particular, the front ridge panel 121 covers ridge portion 130b (FIG. 8) of the insulated inner box 124. Additionally, the first end 252 of the front ridge panel 121 frictionally engages at least a portion of an inside surface 104a of the first outer box side panel 104, while the second end 254 of the front ridge panel 121 frictionally engages at least a portion of an inside surface 106a of the second outer box side panel 106. The third edge 246 of the front retention flap 120 frictionally engages at least a portion of an inside surface 128,12 of the second side panel 128 of the insulated inner box 124, while the fourth edge 250 of the front retention flap 120 frictionally engages at least a portion of an inside surface 126,12 of the first side panel 126 of the insulated inner box 124. In this position, the front retention flap 120 and the front ridge panel 121 engage at least a portion of the front panel 130 of the insulated inner box 124 such that the front panel 130 is spaced from the first outer box side panel 104 by a third gap distance G3 substantially equaling the length of the third shoulder portion 251a of the front ridge panel 121, and is also spaced from the second outer box side panel 106 by a fourth gap distance G4 substantially equaling the length of the fourth shoulder portion 251b of the front ridge panel 121. In some aspects, gap distances G1 and G3 are identical, and gap distances G2 and G4 are identical, if the respective side panels of the insulated inner box 124 and of the outer box 102 are parallel to one another. In other aspects, all of the gap distances G1-G4 can equal one another. However, such identities between gap distances are not required.

[0080] The closed end flap position shown in FIGS. 7A and 7B also produces certain spatial relationships between the insulated inner box 124 and the end panels 108,110 (FIG. 1) of the outer box 102. In particular, the rear panel 132 of the insulated inner box 124 is restrained in a spaced relationship with respect to the rear panel 108 of the outer box 102, the separation defining a fifth gap distance G5 that substantially equals a depth of the rear ridge panel 119. Similarly, the front panel 130 of the insulated inner box 124 is restrained in a spaced relationship with respect to the front panel 110 of the outer box 102, the separation defining a sixth gap distance G6 that substantially equals a depth of the front ridge panel 121. It is therefore seen that the closed end flap position shown in FIGS. 7A and 7B produces air gaps on all four sides of the insulated inner box 124. These air gaps promote insulation of any food product placed within the inner box cavity 156 from conductive heat originating from external heat sources such as hot surfaces on which the shipping assembly 100 can be placed (including, for example, a front porch of a residence).

[0081] In some aspects, each of the retention flaps 118,120 can define handle apertures, as best exemplified in FIG. 7B. The rear retention flap 118 is shown defining a handle aperture 160, the handle aperture 160 configured to facilitate grasping of the rear retention flap 118 to move it from an engaged position to a disengaged position relative to the insulated inner box 124 positioned within the outer box 102. In some aspects, the handle aperture 160 can define a first end 170, a second end 172 opposite the first end 170, a first horizontal portion 174 extending from the first end 170, a second horizontal portion 176 extending from the second end 172, a first arcuate portion 178 extending between the first horizontal portion 174 and the second horizontal portion 176, a third horizontal portion 180 extending from the first end 170 opposite the first horizontal portion 174, a fourth horizontal portion 182 extending from the second end 172 opposite the second horizontal portion 176, a first notch portion 184 extending substantially perpendicularly to the third horizontal portion 180, a fifth horizontal portion 188 extending from the first notch portion 184 opposite the third horizontal portion 180, a second notch portion 186 extending substantially perpendicularly to the fourth horizontal portion 182, a sixth horizontal portion 190 extending from the second notch portion 186 opposite the fourth horizontal portion 180, and a second arcuate portion 192 extending between the fifth horizontal portion 188 and the sixth horizontal portion 190. In some aspects, the shape of the handle aperture 160 defined in the rear retention panel 118 can also be the shape of the handle aperture 162 (FIGS. 7A and 8) in the front retention panel 120, although this is not required, nor need either of the handle apertures 160, 162 be specifically configured as described above with regard to FIG. 7B.

The Bottom Insulator Box Assembly 122

[0082] Further details concerning the bottom insulator box assembly 122 will now be described with reference to FIGS. 2 and 10-12B. The bottom insulator box assembly 122 includes the bottom insulator box 122, which defines the bottom insulator box cavity 152 (FIGS. 2 and 11B), as well as the bottom insulation batt element 200 (FIGS. 11A and 12B) positioned within the bottom insulator box cavity 152. To the extent that FIGS. 2 and 10-12B do not identify various panel edges and fold lines of the bottom insulator box 122, these will be described herein with reference to the bottom insulator box blank 410 (FIG. 18).

[0083] FIGS. 2 and 10 show the bottom insulator box 122 defining side panels 148, 150, a rear panel 145, a front panel 147, a top panel 144, and a bottom panel 146, all of which define the bottom insulator box cavity 152. The top panel 144 defines a thumb hole cut-out section 144a configured to facilitate lifting of the bottom insulator box 122 out of the outer box cavity 113 of the outer box 102, when the bottom insulator box 122 has been positioned in the outer box cavity 113 with the bottom panel 146 facing upwardly. Also, in some aspects, as shown in FIG. 5, the bottom panel 146 can define a similar thumb hole cut-out section 146a. Additional such cut-out sections, and further details concerning them, are discussed with regard to the bottom insulator box blank 410 of FIG. 18.

[0084] FIG. 11A is a side perspective view of the bottom insulator box assembly 122 shown with side flaps of the bottom insulator box 122 open to expose a bottom insulation batt element 200 encapsulated within the bottom insulator box 122, and FIG. 11B is a side perspective view of the bottom insulator box 122, also with the side flaps open as in FIG. 11A, except excluding the bottom insulation batt element 200 to show the bottom insulator box cavity 152. These figures show that the left side 148 of the bottom insulator box 122 comprises an upper left side flap 194 and a cooperating lower left side flap 196. A side locking tab 198 extends from a portion of a distal edge 195 (FIG. 12A) of the upper left side flap 194. The lower left side flap 196 defines a side slot 196a, the side slot 196a configured to receive the side locking tab 198 when the bottom insulator box 122 is assembled from the bottom insulator box blank 410 (FIG. 18). The side locking tab 198 is configured to maintain a closed configuration between the top panel 144 and the bottom panel 146 following insertion of the side locking tab 198 into the side slot 196a. The bottom insulation batt element 200 shown in FIG. 11A can be composed of the same materials as the top insulation batt element 201 discussed above with regard to FIGS. 6 and 13A-13C. With the bottom insulation batt element 200 removed as shown in FIG. 11B, one is able to observe both the bottom insulator box cavity 152 and inside surface 150,12 of the right side panel 150 on the side of the bottom insulator box 122 opposite the opening at the left side 148.

[0085] FIG. 12A is a top perspective view of the left side 148 of the bottom insulator box assembly 122 with the upper left side flap 194 shown in an open position and the lower left side flap 196 shown in a substantially closed position, and FIG. 12B is a perspective view of the left side 148 of the bottom insulator box assembly 122, shown with both side flaps 194, 196 open and with the bottom insulation batt element 200 partially removed from the bottom insulator box cavity 152. FIG. 12A also shows that the bottom insulator box 122 defines a bottom 202, and that the side locking tab 198 is joined to the upper left side flap 194 along a fold line 195a substantially colinear with the distal edge 195 of the upper left side flap 194. The fold line 195a defines a joint between the side locking tab 198 and the upper left side flap 194. In some aspects, the bottom insulation batt element 200, like the top insulation batt element 201 discussed above, can assume a substantially prismatic shape, including an upper surface 204, a left side 206, and a front side 208. Finally, as will be discussed with regard to the bottom insulator box blank 410 of FIG. 18, the bottom insulator box 122 can additionally be provided with locking tabs and cooperating slots at each of its end panels.

Method of Assembling the Shipping Assembly 100

[0086] A method of assembling the shipping assembly 100 (FIG. 1) is now described with reference to all of the figures described above. The method can begin with moving into an open position the top flaps 114,116, the retention flaps 118,121, and the ridge panels 119,121 of the outer box 102, the open position best illustrated in, and discussed above with regard to, FIG. 8. Next, the bottom insulator box assembly 122 can be inserted into the outer box cavity 113, insertion of the bottom insulator box assembly 122 occurring until its bottom 202 contacts a bottom panel 111a,b of the outer box 102. The insulated inner box 124 can then be inserted into the outer box cavity 113 until the bottom 153 of the insulated inner box 124 contacts the top panel 144 of the bottom insulator box assembly 122.

[0087] With the insulated inner box 124 fully inserted into the outer box cavity 113, the ridge panels 119,121 of the outer box 102 are pivoted about their respective ridge panel fold lines 161,236 inwardly with respect to the inner box cavity 156 until the ridge panels 119,121 cover respective portions 130b, 132b of the ridge 158 defined by the end panels 130,132 of the insulated inner box 124, and until respective ends 175,177 and 252,254 of the ridge panels 119,121 frictionally engage at least a respective portion of each of the inside surfaces 104a, 106a of the outer box side panels 104,106. Next, the retention flaps 118,120 of the outer box 102 are respectively pivoted about retention flap fold lines 163,238 inwardly with respect to the inner box cavity 156 until the outer edges 171,173 and 246,250 of each retention flap 118,120 respectively engage at least a portion of the inner surfaces 126,12 and 128,12 of the insulated inner box side panels 126,128 such that the retention flaps 118,120 respectively cover at least portions of the inside surfaces of the respective end panels 130,132 of the insulated inner box 124.

[0088] Following the steps of pivoting the ridge panels 119,121 and pivoting the retention flaps 118,120, the insulated inner box 124 is restrained within the outer box cavity 113 such that: (1) the rear panel 132 of the insulated inner box 124 is spaced from the first outer box side panel 104 by a first gap distance G1 substantially equaling the length of the second shoulder portion 179b of the rear ridge panel 119; (2) the rear panel 132 of the insulated inner box 124 is spaced from the second outer box side panel 106 by a second gap distance G2 substantially equaling the length of the first shoulder portion 179a of the rear ridge panel 119; (3) the front panel 130 of the insulated inner box 124 is spaced from the first outer box side panel 104 by a third gap distance G3 substantially equaling the length of the third shoulder portion 251a of the front ridge panel 121; and (4) the front panel 130 of the insulated inner box 124 is spaced from the second outer box end panel 110 of the outer box 102 by a fourth gap distance G4 that substantially equals the length of the fourth shoulder portion 251b of the front ridge panel 121; (5) the rear panel 132 of the insulated inner box 124 is restrained in a spaced relationship with respect to the rear panel 108 of the outer box 102, the separation defining a fifth gap distance G5 that substantially equals a depth of the rear ridge panel 119; and (6) the front panel 130 of the insulated inner box 124 is restrained in a spaced relationship with respect to the front panel 110 of the outer box 102, the separation defining a sixth gap distance G6 that substantially equals a depth of the front ridge panel 121.

[0089] The method of assembling the shipping assembly 100 can further include the step of partially inserting the top insulator box assembly 134 into the inner box cavity 156 of the insulated inner box 124, such that the first overhang portion O1 of the top panel 135 and the second overhang portion O2 of the top panel 135 rest upon the ridge 158 of the insulated inner box 124.

The Outer Box Blank 300 (FIG. 16)

[0090] FIG. 16 is a top view of an outer box blank 300 for the outer box 102, from the perspective of viewing the inside surface of the outer box blank 300. The outer box blank 300 includes the first outer box side panel 104, which defines a first side 103, a second side 107, a third side 306, and a fourth side 322. As shown, the second side 107 can be distal from the first side 103, and the fourth side 322 can be distal from the third side 306. In some aspects, as shown, the first outer box side panel 104 can define a rectangular shape. In other aspects, the first outer box side panel 104 can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 103,107,306,322 or even a rounded shape. Adjacent sides such as the sides 103,306, the sides 306, 107, the sides 107,322, and the sides 322,103 can intersect at corners of the first outer box side panel 104.

[0091] A rear panel 108 can extend from at least a portion of the first side 103 of the first outer box side panel 104, the rear panel 108 joined to the first outer box side panel 104 along a fold line 103. The numbering convention used herein, where the same reference numeral denotes both a side and a fold line (such as the 103 just recited for both the first side and the fold line), is intentional and is meant to convey that the fold line runs along the length of the side assigned the same reference numeral as the side. The fold line 103 defines a joint between the first outer box side panel 104 and the rear panel 108. The rear panel 108 further defines a second side 105, a third side defining the rear ridge panel fold line 161 at a top side 161 of the rear panel 108, and a fourth side 326. As shown, the second side 105 can be distal from the first side 103, and the fourth side 326 can be distal from the third side 161. In some aspects, as shown, the rear panel 108 can define a rectangular shape. In other aspects, the rear panel 108 can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 103,105,161,326 or even a rounded shape. Adjacent sides such as the sides 103,336, the sides 326,105, the sides 105,161, and the sides 161,103 can intersect at corners of the rear panel 108.

[0092] A rear ridge panel 119 can extend from at least a portion of the rear ridge panel fold line 161, the rear ridge panel fold line 161 defining a joint between the rear panel 108 and the rear ridge panel 119. The ridge panel 119 can define an elongated side 179 opposite the rear ridge panel fold line 161, a first end 175 extending between the rear ridge panel fold line 161 and the elongated side 179, and a second end 177 opposite the first end 175, the second end 177 also extending between the second fold line 161 and the elongated side 179. Thus, the rear ridge panel 119 can be defined by the rear ridge panel fold line 161 as its first side, the elongated side 179 as its second side, the first end 175 as its third side, and the second end 177 as its fourth side. In some aspects, as shown, the rear ridge panel 119 can define a rectangular shape. In some aspects, the rear ridge panel 119 can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 161,179,175,177, or even a rounded shape. Adjacent sides such as the sides 161,175, the sides 175,179, the sides 179,177, and the sides 177,161 can intersect at corners of the rear ridge panel 119.

[0093] A rear retention flap 118 can extend from a portion of the elongated side 179 of the rear ridge panel 119, the portion of the elongated side 179 defining a rear retention flap fold line 163, the rear retention flap fold line 163 defining a joint between the rear retention flap 118 and the rear ridge panel 119. The rear retention flap 118 can define a free edge 165 opposite the elongated side 179, a first edge 171 extending between the elongated side 179 and the free edge 165, and a second edge 173 opposite the first edge 171, the second edge 173 also extending between the elongated side 179 and the free edge 165. In some aspects, the first edge 171 of the rear retention flap 118 can further define the first chamfered portion 167 that extends at an angle with respect to the free edge 165 of the rear retention flap 118, and the second edge 173 of the rear retention flap 118 can define a second chamfered portion 169 that also extends at an angle to the free edge 165. In some aspects, the rear retention flap 118 can further define a handle aperture 160 therein, the shape of which has already been described in detail with regard to FIG. 7B.

[0094] The rear ridge panel 119 can further define a first shoulder portion 179a extending along the elongated side 179 for a first length measured from the first end 175 of the rear ridge panel 119 to the first edge 171 of the rear retention flap 118. The rear ridge panel 119 can also define a second shoulder portion 179b extending along the elongated side 179 for a second length measured from the second end 177 of the rear ridge panel 119 to the second edge 173 of the retention flap 118. The first end 175 of the rear ridge panel 119 can be configured to frictionally engage at least a portion of an inside surface 106a of the second outer box side panel 106, while the second end 177 of the rear ridge panel 119 can be configured to frictionally engage an inner surface 104a of the first outer box side panel 104, upon assembly of the outer box 102 from the outer box blank 300. In such a configuration, a rear panel 132 of the insulated inner box 124 engaged by the rear retention flap 118 is spaced from the inside surface: (i) 104a of the first outer box side panel 104 by a first gap distance G1 (FIG. 7A) substantially equaling the second length of the second shoulder portion 179b, and (ii) 106a of the second outer box side panel 106 by a second gap distance G2 (FIG. 7A) substantially equaling the first length of the first shoulder portion 179a.

[0095] A second outer box side panel 106 can extend from at least a portion of the second side 105 of the rear panel 108, the second outer box side panel 106 joined to the rear panel 108 along a fold line 105 defining a joint between the second outer box side panel 106 and the rear panel 108. The second outer box side panel 106 can further define a second side panel end 109 opposite the fold line 105, third side 308, and a fourth side 324 opposite the third side 308. Thus, the second outer box side panel 106 can be defined by the fold line 105 as its first side, the second side panel end 109 as its second side, the third side 308, and the fourth side 324. In some aspects, as shown, the second outer box side panel 106 can define a rectangular shape. In some aspects, the second outer box side panel 106 can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 105,109,308,324, or even a rounded shape. Adjacent sides such as the sides 103,326, the sides 326,109, the sides 109,308, and the sides 308,105 can intersect at corners of the second outer box side panel 106.

[0096] A front panel 110 can extend from the second side 107 of the first outer box side panel 104, the front panel 110 joined to the first outer box side panel 104 along a fold line 107 defining a joint between the first outer box side panel 104 and the front panel 110. The front panel 110 can define an outer edge 304 opposite the fold line 107, the front ridge panel fold line 236, and a fourth side 328 opposite the front ridge panel fold line 236. Thus, the front panel 110 can be defined by the fold line 107 as its first side, the outer edge 304 as its second side, the front ridge panel fold line 236 as its third side, and the fourth side 328. In some aspects, as shown, the front panel 110 can define a rectangular shape. In some aspects, the front panel 110 can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 107,304,236,328, or even a rounded shape. Adjacent sides such as the sides 107,236, the sides 236,304, the sides 304,328, and the sides 328,107 can intersect at corners of the front panel 110.

[0097] In some aspects, the outer box blank 300 can further comprise a connection tab 117 extending from at least a portion of the second side panel end 109 of the second outer box side panel 106, the connection tab 117 configured to attach to a surface of the front panel 110 when the outer box 102 is assembled. The connection tab 117 can define an outer edge 302 opposite a line defining a junction between the connection tab 117 and the second side panel end 109.

[0098] A front ridge panel 121 can extend from at least a portion of the front ridge panel fold line 236, the front ridge panel fold line 236 defining a joint between the front panel 110 and the front ridge panel 121. The front ridge panel 121 can define an elongated side 251 opposite the fold line 236, a first end 252 extending between the front ridge panel fold line 236 and the elongated side 251, and a second end 254 opposite the first end 252, the second end 252 also extending between the front ridge panel fold line 236 and the elongated side 251. Thus, the front ridge panel 121 can be defined by the front ridge panel fold line 236 as its first side, the elongated side 251 as its second side, the first end 252 as its third side, and the second end 254 as its fourth side. In some aspects, as shown, the front ridge panel 121 can define a rectangular shape. In some aspects, the front ridge panel 121 can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 236,251,252,254, or even a rounded shape. Adjacent sides such as the sides 236,252, the sides 252,251, the sides 251,254, and the sides 254,236 can intersect at corners of the front ridge panel 121.

[0099] A front retention flap 120 can extend from a portion of the elongated side 251, the portion of the elongated side 251 defining a fold line 238, the fold line 238 defining a joint between the front retention flap 120 and the front ridge panel 121. The front retention flap 120 can define a free edge 240 opposite the elongated side 251, a third edge 246 extending between the elongated side 251 and the free edge 240, and a fourth edge 250 opposite the third edge 246, the fourth edge 250 also extending between the elongated side 251 and the free edge 240. In some aspects, the third edge 246 of the front retention flap 120 can define the third chamfered portion 242 that extends at an angle with respect to the free edge 240 of the front retention flap 120, and the fourth edge 250 of the front retention flap 120 can define a fourth chamfered portion 244 that also extends at an angle to the free edge 240. In some aspects, the front retention flap 120 can further define a handle aperture 162 therein, the shape of which has already been described in detail with regard to FIG. 7B.

[0100] The front ridge panel 121 can further define a third shoulder portion 251a extending along the elongated side 251 for a third length measured from the first end 252 of the front ridge panel 121 to the third edge 246 of the second retention flap 120, and a fourth shoulder portion 251b extending along the elongated side 251 for a fourth length measured from the second end 252 of the front ridge panel 121 to the fourth edge 250 of the front retention flap 120. The first end 252 of the front ridge panel 121 can be configured to frictionally engage at least a portion of an inside surface 104a of the first outer box side panel 104, while the second end 254 of the front ridge panel 121 can be configured to frictionally engage an inner surface 106a of the second outer box side panel 106, upon assembly of the outer box 102 from the outer box blank 300. In such a configuration, a front panel 130 of the insulated inner box 124 engaged by the front retention flap 120 is spaced from the inside surface: (i) 104a of the first outer box side panel 104 by a third gap distance G3 (FIG. 7A) substantially equaling the third length of the third shoulder portion 251a, and (ii) 106a of the second outer box side panel 106 by a fourth gap distance G4 (FIG. 7A) substantially equaling the fourth length of the fourth shoulder portion 251b.

[0101] A first top flap 114 can extend from at least a portion of the third side 306 of the first outer box side panel 104, and the third side 306 can define a fold line 306 that defines a joint between the first top flap 114 and the first outer box side panel 104. The first top flap 114 can further define a free (distal) edge 310 opposite the fold line 306, a first end 312, and a second end 314 opposite the first end 312. Thus, the first top flap 114 can be defined by the fold line 306 as its first side, the free edge 310 as its second side, the first end 312 as its third side, and the second end 314 as its fourth side. In some aspects, as shown, the first top flap 114 can define a rectangular shape. In some aspects, the first top flap 114 can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 306,310,312,314, or even a rounded shape. Adjacent sides such as the sides 306,312, the sides 312,310, the sides 310,314, and the sides 314,306 can intersect at corners of the first top flap 114.

[0102] A second top flap 116 can extend from at least a portion of the third side 308 of the second outer box side panel 106, and the third side 308 can define a fold line 308 that defines a joint between the second top flap 116 and the second outer box side panel 106. The second top flap 116 can further define a free (distal) edge 316 opposite the fold line 308, a first end 318, and a second end 320 opposite the first end 318. Thus, the second top flap 116 can be defined by the fold line 308 as its first side, the free edge 316 as its second side, the first end 318 as its third side, and the second end 320 as its fourth side. In some aspects, as shown, the second top flap 116 can define a rectangular shape. In some aspects, the second top flap 116 can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 308,316,318,320, or even a rounded shape. Adjacent sides such as the sides 308,318, the sides 318,316, the sides 316,320, and the sides 320,308 can intersect at corners of the second top flap 116.

[0103] A first side bottom flap 112a can extend from at least a portion of the fourth side 322 of the first outer box side panel 104, and the fourth side 322 can define a fold line 308 that defines a joint between the first side bottom flap 112a and the first outer box side panel 104. The first side bottom flap 112a can further define a free (distal) edge 342 opposite the fold line 322, a first end 344, and a second end 346 opposite the first end 344. Thus, first side bottom flap 112a can be defined by the fold line 322 as its first side, the free edge 342 as its second side, the first end 344 as its third side, and the second end 346 as its fourth side. In some aspects, as shown, the first side bottom flap 112a can define a rectangular shape. In some aspects, the first side bottom flap 112a can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 322,342,344,346, or even a rounded shape. Adjacent sides such as the sides 322,346, the sides 346,342, the sides 342,344, and the sides 344,322 can intersect at corners of the first side bottom flap 112a.

[0104] A second side bottom flap 112b can extend from at least a portion of the fourth side 324 of the second outer box side panel 106, and the fourth side 324 can define a fold line 324 that defines a joint between the second side bottom flap 112b and the second outer box side panel 106. The second side bottom flap 112b can further define a free (distal) edge 348 opposite the fold line 324, a first end 350, and a second end 352 opposite the first end 350. Thus, the second side bottom flap 112b can be defined by the fold line 324 as its first side, the free edge 348 as its second side, the first end 350 as its third side, and the second end 352 as its fourth side. In some aspects, as shown, the second side bottom flap 112b can define a rectangular shape. In some aspects, the second side bottom flap 112b can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 324,348,350,352, or even a rounded shape. Adjacent sides such as the sides 324,352, the sides 352,348, the sides 348,350, and the sides 350,324 can intersect at corners of the second side bottom flap 112b.

[0105] A first end bottom flap 111a can extend from at least a portion of the fourth side 326 of the rear panel 108, and the fourth side 326 can define a fold line 336 that defines a joint between the first end bottom flap 111a and the rear panel 108. The first end bottom flap 111a can further define a free (distal) edge 330 opposite the fold line 326, a first end 332, and a second end 334 opposite the first end 332. Thus, the first end bottom flap 111a can be defined by the fold line 326 as its first side, the free edge 330 as its second side, the first end 332 as its third side, and the second end 334 as its fourth side. In some aspects, as shown, the first end bottom flap 111a can define a rectangular shape. In some aspects, the first end bottom flap 111a can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 326,330,332,334, or even a rounded shape. Adjacent sides such as the sides 326,334, the sides 334,330, the sides 330,332, and the sides 332,326 can intersect at corners of the first end bottom flap 111a.

[0106] A second end bottom flap 111b can extend from at least a portion of the fourth side 328 of the front panel 110, and the fourth side 328 can define a fold line 328 that defines a joint between the second end bottom flap 111b and the front panel 110. The second end bottom flap 111b can further define a free (distal) edge 336 opposite the fold line 328, a first end 338, and a second end 340 opposite the first end 338. Thus, the second end bottom flap 111b can be defined by the fold line 328 as its first side, the free edge 336 as its second side, the first end 338 as its third side, and the second end 340 as its fourth side. In some aspects, as shown, the second end bottom flap 111b can define a rectangular shape. In some aspects, the second end bottom flap 111b can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 328,336,340,342, or even a rounded shape. Adjacent sides such as the sides 328,340, the sides 340,336, the sides 336,338, and the sides 338,328 can intersect at corners of the second end bottom flap 111b.

The Insulated Inner Box Blank 400 (FIG. 17)

[0107] FIG. 17 is a top view of an insulated inner box blank 400 for the inner insulated box 124, from the perspective of viewing the inside surface of the inner box blank 400. The insulated inner box blank 400 includes the first side panel 126, which defines a top side 126b, a second side 331 adjacent to the top side 126b, a third side 133 opposite the second side 331, and a fourth side 380 opposite the top side 126b. In some aspects, as shown, the first side panel 126 can define a rectangular shape. In some aspects, the first side panel 126 can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 126b,331,133,380, or even a rounded shape. Adjacent sides such as the sides 126b, 133, the sides 133,380, the sides 380,331, and the sides 331,126b can intersect at corners of the first side panel 126.

[0108] A first top flap 126a can extend from at least a portion of the top side 126b of the first side panel 126, the first top flap 126a joined to the first side panel 126 along a fold line 126b defining a joint between the first top flap 126a and the first side panel 126, the first top flap 126a defining a first top flap edge 356 opposite the fold line 126b, a first side 361, a second side 362 opposite the first side 361. In some aspects, as shown, the second end bottom flap 111b can define a rectangular shape. In some aspects, the first top flap 126a can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 126b,356,361,362, or even a rounded shape. Adjacent sides such as the sides 126b,361, the sides 361,356, the sides 356,362, and the sides 362,126b can intersect at corners of the first top flap 126a.

[0109] A front panel 130 can extend from at least a portion of the second side 331 of the first side panel 126, the front panel 130 joined to the first side panel 126 along a fold line 331, the fold line 331 defining a joint between the first side panel 126 and the front panel 130. The fold line 331 can further define a first side of the front panel 130, and the front panel 130 can further define a second side 333 opposite the fold line 331, a top side 130b adjacent to the fold line 331, and a fourth side 384 opposite the top side 130b. In some aspects, as shown, the front panel 130 can define a rectangular shape. In some aspects, the front panel 130 can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 331,333,130b,384, or even a rounded shape. Adjacent sides such as the sides 331,384, the sides 384,333, the sides 333,130b, and the sides 130b,331 can intersect at corners of the front panel 130.

[0110] A second top flap 130a can extend from at least a portion of the top side 130b of the front panel 130, the second top flap 130a joined to the front panel 130 along a fold line 130b defined by the top side 130b of the front panel 130, the fold line 130b defining a joint between the front panel 130 and the second top flap 130a. The second top flap 130a can define a second top flap edge 364 opposite the fold line 130b, a first side 366, and a second side opposite the first side 366, the second side of the second top flap 130a defined by the first side 361 of the first top flap 126a. In some aspects, as shown, second top flap 130a can define a rectangular shape. In some aspects, second top flap 130a can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 130b,364,366,361, or even a rounded shape. Adjacent sides such as the sides 130b,366, the sides 366,364, the sides 364,361, and the sides 361,130b can intersect at corners of the second top flap 130a.

[0111] The first side 361 of the first top flap 126a can define a first cut-out section 358 extending downwardly from the first top flap edge 356 and from the second top flap edge 364, a second cut-out section 359 axially spaced from the first cut-out section 358, the second cut-out section 359 forming a partial gap between the first top flap 126a and the second top flap 130a, and a fold line 360 axially extending between the first cut-out section 358 and the second cut-out section 359, the fourth fold line 360 defining a joint between the first top flap 126a and the second top flap 130a.

[0112] A second side panel 128 can extend from at least a portion of the second side 333 of the front panel 130, the second side panel 128 joined to the front panel 130 along a fold line 333, the fold line 333 defining a joint between the second side panel 128 and the front panel 130. The second side panel 128 can defining an end 131 opposite the fold line 333; a top side 128b, and a bottom side 382 opposite the top side 128b. Thus, the second side panel 128 can be defined by the fold line 333 as its first side, the end 131 as its second side, the top side 128b as its third side, and the bottom side 382 as its fourth side. In some aspects, as shown, the second side panel 128 can define a rectangular shape. In some aspects, the second side panel 128 can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 333,131,128b,382, or even a rounded shape. Adjacent sides such as the sides 333,382, the sides 382,131, the sides 131,128b, and the sides 128b,333 can intersect at corners of the second side panel 128.

[0113] A rear panel 132 can extend from at least a portion of the third side 133 of the first side panel 126, the rear panel 132 joined to the first side panel 126 along a fold line 133, the fold line 133 defining a joint between the rear panel 132 and the first side panel 126. The rear panel 132 can define a panel edge 325 opposite the fold line 133, a top side 132b, and a bottom side 386 opposite top side 132b. Thus, the rear panel 132 can be defined by the fold line 133 as its first side, the panel edge 325 as its second side, the top side 132b as its third side, and the bottom side 386 as its fourth side. In some aspects, as shown, the rear panel 132 can define a rectangular shape. In some aspects, the rear panel 132 can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 133,325,132b,386, or even a rounded shape. Adjacent sides such as the sides 133,132b, the sides 132b,325, the sides 325,386, and the sides 386,133 can intersect at corners of the rear panel 132.

[0114] In some aspects, a side panel connection tab 327 can extend from at least a portion of the end 131 of the second side panel 128, the side panel connection tab 327 configured to attach to a surface of the rear panel 132 when the insulated inner box 124 is assembled from the insulated inner box blank 400. The side panel connection tab 327 can define an outer edge 234, which is visible in the views of the assembled insulated inner box 124 shown in FIGS. 9A, 15A, and 15B.

[0115] A third top flap 128a can extend from at least a portion of the top side 128b of the second side panel 128, the third top flap 128a joined to the second side panel 128 along a fold line 128b, the fold line 128b defining a joint between the third top flap 128a and the second side panel 128. The third top flap 128a can define a third top flap edge 368 opposite the fold line 128b, a first side 370, and a second side 372 opposite the first side 370. In some aspects, as shown, the third top flap 128a can define a rectangular shape. In some aspects, the third top flap 128a can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 128b,368,370,372, or even a rounded shape. Adjacent sides such as the sides 128b,370 the sides 370,368, the sides 368,372, and the sides 372,128b can intersect at corners of the third top flap 128a.

[0116] A fourth top flap 132a can extend from at least a portion of the top side 132b of the rear panel 132, the fourth top flap 132a joined to the rear panel 132 along a fold line 132b, the fold line 132b defining a joint between the fourth top flap 132a and the rear panel 132. The fourth top flap 132a can define a fourth top flap edge 377 opposite the fold line 132b, a first side 378, and a second side 379 opposite the first side 378. Opposite the fold line 128b, a first side 370, and a second side 372 opposite the first side 370. In some aspects, as shown, the fourth top flap 132a can define a rectangular shape. In some aspects, the fourth top flap 132a can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 132b,377,378,379, or even a rounded shape. Adjacent sides such as the sides 132b,378, the sides 378,377, the sides 377,379, and the sides 379,132b can intersect at corners of the fourth top flap 132a.

[0117] In some aspects, a top flap connection tab 329 can be attached to the first side 370 of the third top flap 128a, the top flap connection tab 329 configured to attach to a surface of the fourth top flap 132a when the insulated inner box 124 is assembled from the insulated inner box blank 400. The first side 370 of the third top flap 128a can define a third cut-out section 371 defined between the top flap connection tab 329 and the third top flap 128a; a fourth cut-out section 373 axially spaced from the third cut-out section 371, the fourth cut-out section 373 forming a partial gap between the top flap connection tab 329 and the third top flap 128a; and a fold line 374 axially extending between the third cut-out section 371 and the fourth cut-out section 359, the fold line 374 defining a joint between the top flap connection tab 329 and the third top flap 128a. In some aspects, another fold line 375 can be defined between the side panel connection tab 327 and the top flap connection tab 329. The top flap connection tab 329 can also define an outer edge 376 opposite the fold line 374.

[0118] A first side bottom flap 154a can extend from at least a portion of the fourth side 380 of the first side panel 126, and the fourth side 380 can define a fold line 380 that defines a joint between the first side bottom flap 154a and the first side panel 126. The first side bottom flap 154a can further define a free (distal) edge 386 opposite the fold line 380, a first end 388, and a second end 390 opposite the first end 388. Thus, first side bottom flap 154a can be defined by the fold line 380 as its first side, the free edge 386 as its second side, the first end 388 as its third side, and the second end 390 as its fourth side. In some aspects, as shown, the first side bottom flap 154a can define a rectangular shape. In some aspects, the first side bottom flap 154a can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 380,386,388,390, or even a rounded shape. Adjacent sides such as the sides 380,390, the sides 390,386, the sides 386,388, and the sides 388,380 can intersect at corners of the first side bottom flap 154a.

[0119] A second side bottom flap 154b can extend from at least a portion of the fourth side 382 of the second side panel 128, and the fourth side 382 can define a fold line 382 that defines a joint between the second side bottom flap 154b and the second side panel 128. The second side bottom flap 154b can further define a free (distal) edge 398 opposite the fold line 382, a first end 394, and a second end 396 opposite the first end 394. Thus, the second side bottom flap 154b can be defined by the fold line 382 as its first side, the free edge 398 as its second side, the first end 394 as its third side, and the second end 396 as its fourth side. In some aspects, as shown, the second side bottom flap 154b can define a rectangular shape. In some aspects, the second side bottom flap 154b can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 382,298,394,396, or even a rounded shape. Adjacent sides such as the sides 382,396, the sides 396,398, the sides 398,394, and the sides 394,382 can intersect at corners of the second side bottom flap 154b.

[0120] A front bottom flap 155a can extend from at least a portion of the fourth side 384 of the front panel 130, and the fourth side 384 can define a fold line 384 that defines a joint between the front bottom flap 155a and the front panel 130. The front bottom flap 155a can further define a free (distal) edge 392 opposite the fold line 384, a first end 354, and a second end 402 opposite the first end 354. Thus, the front bottom flap 155a can be defined by the fold line 384 as its first side, the free edge 392 as its second side, the first end 354 as its third side, and the second end 402 as its fourth side. In some aspects, as shown, the front bottom flap 155a can define a rectangular shape. In some aspects, the front bottom flap 155a can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 384,392,354,402, or even a rounded shape. Adjacent sides such as the sides 384,388, the sides 388,392, the sides 392,354, and the sides 354,384 can intersect at corners of the front bottom flap 155a.

[0121] A rear bottom flap 155b can extend from at least a portion of the fourth side 386 of the rear panel 132, and the fourth side 386 can define a fold line 386 that defines a joint between the rear bottom flap 155b and the rear panel 132. The rear bottom flap 155b can further define a free (distal) edge 404 opposite the fold line 386, a first end 406, and a second end 408 opposite the first end 406. Thus, the rear bottom flap 155b can be defined by the fold line 386 as its first side, the free edge 404 as its second side, the first end 406 as its third side, and the second end 408 as its fourth side. In some aspects, as shown, the rear bottom flap 155b can define a rectangular shape. In some aspects, the rear bottom flap 155b can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 386,404,406,408, or even a rounded shape. Adjacent sides such as the sides 386,408, the sides 408,404, the sides 404,406, and the sides 406,386 can intersect at corners of the rear bottom flap 155b.

The Bottom Insulator Box Blank 410 (FIG. 18)

[0122] FIG. 18 is a top view of a blank 410 for the bottom insulator box 122, from the perspective of viewing the inside surface of the blank 410. The bottom insulator box blank 410 includes a right side panel 150 defining a first side 207, a second side 209 opposite the first side 207, a third side 211, and a fourth side 213 opposite the third side 211. In some aspects, as shown, the right side panel 150 can define a rectangular shape. In some aspects, the right side panel 150 can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 207,209,211,213, or even a rounded shape. Adjacent sides such as the sides 207,213, the sides 213,209, the sides 209,211, and the sides 211,207 can intersect at corners of the right side panel 150.

[0123] A top panel 144 can extend from at least a portion of the first side 207 of the right side panel 150, the top panel 144 joined to the right side panel 150 along a fold line 207 defining a joint between the top panel 144 and the right side panel 150. The top panel 144 can define a first side along the fold line 207, a second side 205 opposite the fold line 207, a third side 199, and a fourth side 203 opposite the third side 199. In some aspects, as shown, the top panel 144 can define a rectangular shape. In some aspects, the top panel 144 can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 207,205,199,203, or even a rounded shape. Adjacent sides such as the sides 207,199, the sides 199,205, the sides 205,203, and the sides 203,207 can intersect at corners of the top panel 144.

[0124] In some aspects, the top panel 144 can define thumb hole cut-out sections 144a,b configured to facilitate lifting of the bottom insulator box 122 out of the outer box 102. The thumb hole cut-out sections 144a,b can respectively define thumb hole flaps 144c,d. The thumb hole flap 144c can be joined to the top panel 144 by a fold line 231a, and the thumb hole flap 144d can be joined to the top panel 144 by a fold line 231b.

[0125] An upper left side flap 194 can extend from at least a portion of the second side 205 of the top panel 144, the upper left side flap 194 joined to the top panel 144 along a fold line 205 defining a joint between the upper left side flap 194 and the top panel 144. The upper left side flap 194 can define a distal edge 195 opposite the fold line 205, a first end 191, and a second end 193 opposite the first end 191. In some aspects, as shown, the upper left side flap 194 can define a rectangular shape. In some aspects, the upper left side flap 194 can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 205,195,191,193, or even a rounded shape. Adjacent sides such as the sides 205,191, the sides 191,195, the sides 195,193, and the sides 193,205 can intersect at corners of the upper left side flap 194.

[0126] A side locking tab 198 can extend from a portion of the distal edge 195 of the upper left side flap 194, the side locking tab 198 joined to the upper left side flap 194 along a fold line 195a defining a joint between the side locking tab 198 and the upper left side flap 194.

[0127] An upper rear flap 145 can extend from at least a portion of the third side 199 of the top panel 144, the upper rear flap 145 joined to the top panel 144 along a fold line 199 defining a joint between the upper rear flap 145 and the top panel 144. The upper rear flap 145 can define distal edge 219 opposite the fold line 199, a first end 221, and a second end 223 opposite the first end 221. In some aspects, as shown, the upper rear flap 145 can define a rectangular shape. In some aspects, the upper rear flap 145 can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 199,219,221,223, or even a rounded shape. Adjacent sides such as the sides 199,223, the sides 223,219, the sides 219,221, and the sides 221,199 can intersect at corners of the upper rear flap 145.

[0128] A rear locking tab 412 can extend from a portion of the distal edge 219 of the upper rear flap 145, the rear locking tab 412 joined to the upper rear flap 145 along a fold line 145a defining a joint between the rear locking tab 412 and the upper rear flap 145.

[0129] A bottom panel 146 can extend from at least a portion of the second side 209 of the right side panel 150, the bottom panel 146 joined to the right side panel 150 along a fold line 209 defining a joint between the bottom panel 146 and the right side panel 150. The bottom panel 146 can define a first side along the fold line 209, a second side 197 opposite the fold line 207, a third side 215, and a fourth side 217 opposite the third side 215. In some aspects, as shown, the bottom panel 146 can define a rectangular shape. In some aspects, the bottom panel 146 can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 209,197,215,217, or even a rounded shape. Adjacent sides such as the sides 209,217, the sides 217,197, the sides 197,215, and the sides 215,209 can intersect at corners of the bottom panel 146.

[0130] In some aspects, the bottom panel 146 can define a thumb hole cut-out sections 146a,b configured to facilitate lifting of the bottom insulator box 122 out of the outer box 102 when the bottom insulator box 122 has been positioned in the outer box 102 with the bottom panel 146 facing upwardly. The thumb hole cut-out sections 146a,b respectively define thumb hole flaps 146c, d. The thumb hole flap 146c is joined to the bottom panel 146 by a fold line 233a, and the thumb hole flap 146d is joined to the bottom panel 146 by a fold line 233b.

[0131] A lower left side flap 196 can extend from at least a portion of the second side 197 of the bottom panel 146 the lower left side flap 196 joined to the bottom panel 146 along a fold line 197 defining a joint between the lower left side flap 196 and the bottom panel 146. The lower left side flap 196 can define a distal edge 401 opposite the fold line 197, a first end 415, and a second end 417 opposite the first end 415. In some aspects, as shown, the lower left side flap 196 can define a rectangular shape. In some aspects, the lower left side flap 196 can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 197,401,415,417, or even a rounded shape. Adjacent sides such as the sides 197,417, the sides 417,401, the sides 401,415, and the sides 415,197 can intersect at corners of the lower left side flap 196. In some aspects, the lower left side flap 196 can define a side slot 196a, the side slot 196a configured to receive the side locking tab 198 when a bottom insulator box 122 is assembled from the bottom insulator box blank 410. Further, the side locking tab 198 can be configured to maintain a closed configuration between the top panel 144 and the bottom panel 146 following insertion of the side locking tab 198 into the side slot 196a.

[0132] A lower rear flap 416 can extend from at least a portion of the third side 215 of the bottom panel 146, the lower rear flap 416 joined to the bottom panel 146 along a fold line 215 defining a joint between the lower rear flap 416 and the bottom panel 146. The lower rear flap 416 can define a distal edge 403 opposite the fold line 215, a first end 405, and a second end 407 opposite the first end 405. In some aspects, as shown, the lower rear flap 416 can define a rectangular shape. In some aspects, the lower rear flap 416 can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 215,403,405,407, or even a rounded shape. Adjacent sides such as the sides 215,407, the sides 407,403, the sides 403,405, and the sides 405,215 can intersect at corners of the lower rear flap 416. The lower rear flap 416 can further define a rear slot 416a, the rear slot 416a configured to receive the rear locking tab 412 when the bottom insulator box 122 is assembled from the bottom insulator box blank 410. Further, the rear locking tab 412 can be configured to maintain a closed configuration between the upper rear flap 145 and the lower rear flap 416 following insertion of the rear locking tab 412 into the rear slot 416a.

[0133] An upper front flap 147 can extend from at least a portion of the fourth side 203 of the top panel 144, the upper front flap 147 joined to the top panel 144 along a fold line 203 defining a joint between the upper front flap 147 and the top panel 144. The upper front flap 147 can define a distal edge 225 opposite the fold line 203, a first end 227, and a second end 229 opposite the first end 227. In some aspects, as shown, the upper front flap 147 can define a rectangular shape. In some aspects, the upper front flap 147 can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 203,225,227,229, or even a rounded shape. Adjacent sides such as the sides 203,227, the sides 227,225, the sides 225,229, and the sides 229,203 can intersect at corners of the upper front flap 147. In some aspects, a front locking tab 414 can extend from a portion of the distal edge 225 of the upper front flap 147, the front locking tab 414 joined to the upper front flap 147 along a tenth fold line 147a defining a joint between the front locking tab 414 and the upper front flap 147.

[0134] A lower front flap 418 can extend from at least a portion of the fourth side 217 of the bottom panel 146, the lower front flap 418 joined to the bottom panel 146 along a fold line 217 defining a joint between the lower front flap 418 and the bottom panel 146. The lower front flap 418 can define a distal edge 409 opposite the fold line 217, a first end 411, and a second end 413 opposite the first end 411. In some aspects, as shown, the lower front flap 418 can define a rectangular shape. In some aspects, the lower front flap 418 can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 217,409,411,413, or even a rounded shape. Adjacent sides such as the sides 217,411, the sides 411,409, the sides 409,413, and the sides 413,217 can intersect at corners of the lower front flap 418. In some aspects, the lower front flap 418 can further define a front slot 418a, the front slot 418a configured to receive the front locking tab 414 when the bottom insulator box 122 is assembled from the bottom insulator box blank 410. Further, the front locking tab 414 can be configured to maintain a closed configuration between the upper front flap 147 and the lower front flap 418 following insertion of the front locking tab 414 into the front slot 418a.

The Top Insulator Box Blank 420 (FIG. 19)

[0135] FIG. 19 is a top view of a blank 420 for the top insulator box 134, from the perspective of viewing the inside surface of the blank 420. The top insulator box blank 420 includes an end panel 140 defining a first side 424, a second side 426 opposite the first side 424, a third side 450, and a fourth side 452 opposite the third side 452. In some aspects, as shown, the end panel 140 can define a rectangular shape. In some aspects, the end panel 140 can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 424,426,450,452, or even a rounded shape. Adjacent sides such as the sides 424,452, the sides 452,426, the sides 426,450, and the sides 450,424 can intersect at corners of the end panel 140.

[0136] A top panel 135 can extend from at least a portion of the first side 424 of the end panel 140, the top panel 135 joined to the end panel 140 along a fold line 424 defining a joint between the top panel 135 and the end panel 140, the top panel 135 defining a first side along the first fold line 424, a second side 422 opposite the first fold line 424, a third side 210, and a fourth side 212 opposite the third side 210. In some aspects, as shown, the top panel 135 can define a rectangular shape. In some aspects, the top panel 135 can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 424,422,210,212 or even a rounded shape. Adjacent sides such as the sides 424,210, the sides 210,422, the sides 422,212, and the sides 212,424 can intersect at corners of the top panel 135. In some aspects, the top panel 135 can further define thumb hole cut-out sections 135a,b configured to facilitate lifting of the top insulator box 134 out of the outer box 102. The thumb hole cut-out sections 135a,b can define respective thumb hole flaps 135c,d. The thumb hole flap 135a can be joined to the top panel 135 by a fold line 421a, and the thumb hole flap 135b can be joined to the top panel 135 by a fold line 421b. Also in some aspects, a locking tab 216 can extend from a portion of the second side 422 of the top panel 135, the locking tab 216 joined to the top panel 135 along a fold line 422a defining a joint between the locking tab 216 and the top panel 135.

[0137] A bottom panel 137 can extend from at least a portion of the second side 426 of the end panel 140, the bottom panel 137 joined to the end panel 140 along a fold line 426 defining a joint between the bottom panel 137 and the end panel 140. The bottom panel 137 can define a first side along the third fold line 426, a second side 428 opposite the third fold line 426, a third side 430, and a fourth side 432 opposite the third side 430. In some aspects, as shown, the bottom panel 137 can define a rectangular shape. In some aspects, the bottom panel 137 can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 426,428,430,432 or even a rounded shape. Adjacent sides such as the sides 426,432, the sides 432,428, the sides 428,430, and the sides 430,426 can intersect at corners of the bottom panel 137.

[0138] A left side panel 136 can extend from at least a portion of the third side 430 of the bottom panel 137, the left side panel 136 joined to the bottom panel 137 along a fold line 430 defining a joint between the left side panel 136 and the bottom panel 137. The left side panel 136 can define a first side along the fourth fold line 430, a second side 230 opposite the fourth fold line 430, a third side 442, and a fourth side 444 opposite the third side 442. In some aspects, as shown, the left side panel 136 can define a rectangular shape. In some aspects, the left side panel 136 can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 430,230,442,444 or even a rounded shape. Adjacent sides such as the sides 430,442, the sides 442,230, the sides 230,444, and the sides 444,430 can intersect at corners of the left side panel 136.

[0139] A first front insulation retention flap 222 can extend from at least a portion of the third side 442 of the left side panel 136, the first front insulation retention flap 222 joined to the left side panel 136 along a fold line 442 defining a joint between the first front insulation retention flap 222 and the left side panel 136. The first front insulation retention flap 222 can further define a distal side edge 456 opposite the fold line 442, a bottom edge 454, and a top edge 458 opposite the bottom edge 454. A first rear insulation retention flap 224 can extend from at least a portion of the fourth side 444 of the left side panel 136, the first rear insulation retention flap 224 joined to the left side panel 136 along a fold line 444 defining a joint between the first rear insulation retention flap 224 and the left side panel 136. The first rear insulation retention flap 224 can further define a distal side edge 460 opposite the fold line 444, a bottom edge 450, and a top edge 462 opposite the bottom edge 450.

[0140] A left upper insulation retention flap 218 can extend from the second side 230 of the left side panel 136, the left upper insulation retention flap 218 joined to the left side panel 136 along a fold line 230 defining a joint between the left upper insulation retention flap 218 and the left side panel 136, the left upper insulation retention flap 218 defining a distal edge 472 opposite the fold line 230, a rear edge 474, and a front edge 476 opposite the rear edge 474. In some aspects, the front edge 476 of the first upper insulation retention flap 218 can be angled with respect to the distal edge 478.

[0141] A front panel 142 can extend from at least a portion of the second side 428 of the bottom panel 137, the front panel 142 joined to the bottom panel 137 along a fold line 428 defining a joint between the front panel 142 and the bottom panel 137, the front panel 142 defining a first side along the fold line 428, a second side 434 opposite the fold line 428, a third side 454, and a fourth side 456 opposite the third side 454. In some aspects, as shown, the front panel 142 can define a rectangular shape. In some aspects, the front panel 142 can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 428,434,454,456 or even a rounded shape. Adjacent sides such as the sides 428,456, the sides 456,434, the sides 434,454, and the sides 454,428 can intersect at corners of the front panel 142.

[0142] A front upper retention flap 214 can extend from at least a portion of the second side 434 of the front panel 142, the front upper retention flap 214 joined to the front panel 142 along a fold line 434 defining a joint between the front upper retention flap 214 and the front panel 142, In some aspects, the front upper retention flap 214 can define a slot 214a, the slot 214a configured to receive the locking tab 216 when a top insulator box 134 is assembled from the top insulator box blank 420. Further, the locking tab 216 can be configured to maintain a closed configuration between the top panel 135 and the bottom panel 137 following insertion of the locking tab 216 into the slot 214a.

[0143] A right side panel 138 can extend from at least a portion of the fourth side 432 of the bottom panel 137, the right side panel 138 joined to the bottom panel 137 along a fold line 432 defining a joint between the right side panel 138 and the bottom panel 137. The right side panel 138 can define a first side along the fold line 432, a second side 232 opposite the fourth fold line 432, a third side 446, and a fourth side 448 opposite the third side 446. In some aspects, as shown, the right side panel 138 can define a rectangular shape. In some aspects, right side panel 138 can define a non-rectangular shape such as polygonal shape with fewer than four or more than four sides 432,232,446,448, or even a rounded shape. Adjacent sides such as the sides 432,448, the sides 448,232, the sides 232,446, and the sides 446,432 can intersect at corners of the right side panel 138.

[0144] A second front insulation retention flap 226 can extend from at least a portion of the third side 446 of the right side panel 138, the second front insulation retention flap 226 joined to the right side panel 138 along a fold line 446 defining a joint between the second front insulation retention flap 226 and the right side panel 138. The second front insulation retention flap 226 can further define a distal side edge 464 opposite the fold line 446, a bottom edge 456, and a top edge 466 opposite the bottom edge 456. A second rear insulation retention flap 228 can extend from at least a portion of the fourth side 448 of the right side panel 138, the second rear insulation retention flap 228 joined to the right side panel 138 along a fold line 448 defining a joint between the second rear insulation retention flap 228 and the right side panel 138. The second rear insulation retention flap 228 can further define a distal side edge 468 opposite the fold line 448, a bottom edge 452, and a top edge 470 opposite the bottom edge 452.

[0145] A right upper insulation retention flap 220 can extend from the second side 232 of the right side panel 138, the right upper insulation retention flap 220 joined to the right side panel 138 along a fold line 232 defining a joint between the right upper insulation retention flap 220 and the right side panel 138. The right upper insulation retention flap 220 can define a distal edge 478 opposite the fold line 232, a rear edge 480, and a front edge 482 opposite the rear edge 480. In some aspects, the front edge 482 of the right upper insulation retention flap 220 can be angled with respect to the distal edge 478.

First Alternate Embodiment of the Shipping Assembly

[0146] The present disclosure contemplates several modifications to the components of the shipping assembly 100 (FIG. 1), resulting in the alternate embodiments described below with regard to FIGS. 20-29.

[0147] FIG. 20 is an exploded perspective view of an alternate embodiment of a shipping assembly 2000 for transporting refrigerated items, the assembly 2000, constructed in accordance with another aspect of the current disclosure, and FIG. 21 is a perspective view of the outer box 2002 comprising a portion of the shipping assembly 2000, with a bottom insulating box assembly 2022 seated within a cavity 2013 defined by the outer box 2002. The outer box 2002 can be constructed identically to outer box 102 (FIGS. 1 and 16), except that: (i) the inside surface of the outer box 2002 is coated with the repulpable insulating film 12 discussed above with regard to FIG. 9B (hence the use of 12 as a second reference numeral designating the various inside surfaces labeled in FIGS. 21-25), and (ii) the configuration of the retention flaps 2618 and 2020 differs from that described above with regard to the retention flaps 118, 120 (FIGS. 7A-8) of outer box 102. Other than these outer box differences, the shipping assembly 2000 can be substantially identical to the shipping assembly 100 (FIGS. 1-5).

[0148] The outer box 2002 of the shipping assembly 2000 comprises a first outer box side panel 2004, a second outer box side panel 2006, a rear panel 2008, a front panel 2010, a bottom 2012, a first top flap 2014 joined to the first outer box side panel 2004 by a first top flap fold line 2306, and a second top flap 2016 joined to the second outer box side panel 2006 by a second top flap fold line 2308. The side panels 2004,2006, the rear panel 2008, the front panel 2010 (not shown), and the bottom 2012 of the outer box 2002 collectively define an outer box cavity 2013, which can be further defined upon closure of the top flaps 2014,2016. The top flaps 2014,2016 cover an upper opening of the outer box 2002 that would otherwise be formed at the upper ends of the side panels 2004,2006, the front panel 2010 (not shown), and rear the panel 2008. In a manner similar to that discussed above with regard to the connection tab 117 (FIG. 16), outer box 2002 may likewise be provided with a connection tab 2017 configured to attach to an outer surface of the front panel 2010 of the outer box 2002 upon assembly of the outer box 2002, the connection tab 2017 defining an outer edge 2302.

[0149] The outer box 2002 additionally comprises rear and front flaps 2025,2027, respectively, joined to the top sides of the rear and front end panels 2008,2010 at fold lines 2061,2236, respectively. The rear and front flaps 2025,2027 can be configured substantially identically to one another. The rear flap 2025 comprises a rear ridge panel 2019 and a rear retention flap 2018 joined to the rear ridge panel 2019 along a fold line 2063. Similarly, the front flap 2027 comprises a front ridge panel 2021 and a front retention flap 2020 joined to the front ridge panel 2021 along a fold line 2238.

[0150] FIGS. 22-24 illustrate the rear flap 2025 (comprising the rear ridge panel 2019 and the rear retention flap 2018) and the front flap 2027 (comprising the front ridge panel 2021 and the front retention flap 2021) in greater detail. FIG. 22 is a front view of the rear flap 2025 oriented in an open position, FIG. 23 is a front perspective view of the rear flap 2025 moved to a fully closed position following insertion of the insulated inner box 124 into the outer box 2002, and FIG. 24 is a top perspective view of a subassembly of the shipping assembly 2000, showing the insulated inner box 124 seated within a cavity 2013 defined by the outer box 2002.

[0151] Referring to FIGS. 22 and 24, the rear ridge panel 2019 of the rear flap 2025 can be configured substantially identically to the rear ridge panel 119 discussed above with regard to the shipping assembly 100 (FIGS. 1-5). Consequently, the rear ridge panel 2019 can be joined to the rear panel 2008 of the outer box 2002 along the fold line 2061 and can define a rectangular shape with opposed ends 2075,2077 and shoulder portions 2079a,b defined in a manner similar to the shoulder portions 179a,b (FIG. 16) of the rear ridge panel 119. The rear retention flap 2018, in a manner similar to the rear retention flap 118 (FIGS. 7A-8), is joined to the rear ridge panel 2019 along the fold line 2063 and defines opposed first and second edges 2071,2073 and chamfered portions 2067,2069 respectively leading from the first and second edges 2071,2073 to a free end 2065. However, the rear retention flap 2018 differs from the rear retention flap 118 in that the rear retention flap 2018: (i) has a smaller height H2018 than that of the rear retention flap 118 (exemplified in FIG. 16 to measure 5 inches); and (ii) omits the handle aperture 160 of the rear retention flap 118. As best seen in FIG. 24, the front ridge panel 2021 of the front flap 2027 can be configured substantially identically to the front ridge panel 121 discussed above with regard to the shipping assembly 100 (FIGS. 1-5). Consequently, the front ridge panel 2021 can be joined to the front panel 2010 of the outer box 2002 along the fold line 2236 and can define a rectangular shape with opposed ends 2052,2054 and shoulder portions 2251a,b defined in a manner similar to the shoulder portions 251a,b (FIG. 16) of the front ridge panel 121. The front retention flap 2020, in a manner similar to the front retention flap 120 (FIGS. 7A-8), is joined to the front ridge panel 2021 along the fold line 2238 and defines opposed first and second edges 2246,2250 and chamfered portions 2242,2244 respectively leading from the first and second edges 2246,2250 to a free end 2240. However, the front retention flap 2020 differs from the front retention flap 120 in that the same manner discussed above with regard to the differences between the rear retention flaps 118,2018.

[0152] Referring to FIG. 23, the insulated inner box 124 has been positioned within the cavity 2013 (FIG. 22) defined by the outer box 2002. The insulated inner box 124 defines at least the panels shown, namely, the first side panel 126, the end panel 132, and the second side panel 128, which respectively define fold lines, or ridge portions 126b, 132b (FIGS. 2), and 128b. The ridge portions 126b, 132b, 128b at least partially define the ridge 158 of the insulated inner box 124. In FIG. 23, the rear flap 2025 has been moved to a fully closed position such that the rear ridge panel 2019 covers ridge potion 132b (FIG. 2) of the ridge 158. FIG. 23 shows this fully closed position of the rear flap 2025 in the absence of the top insulator box assembly 134 (FIG. 20) merely for illustrative purposes. As discussed below with regard to FIGS. 24 and 25, the rear flap 2025 and the front flap 2027, in the absence of partial insertion of the top insulator box assembly 134 into the insulated inner box 124, have a natural tendency when moved toward a closed position to assume only a partially closed orientation, such that neither of the flaps 2025,2027 contact an associated end panel 132,130 of the insulated inner box 124. This condition can result either from a flap element failing to frictionally engage a box inside surface, from insufficient frictional force to allow the end flaps 2025,2027 to maintain a fully closed orientation in the absence of other assembly elements exerting force upon them, or a combination of both conditions. In such arrangements, the fully closed flap position depicted in FIG. 23 is reached only when the top insulator box assembly 134 is assembled into the insulated inner box 124, the rear retention flap 2018 can cover a portion of the end panel 132 of the insulated inner box 124. Unlike the arrangement shown in FIGS. 7A-8, however, the retention flap 2018 need not frictionally engage the insulated inner box 124 at both of the retention flap edges 2071,2073. In the exemplary arrangement of FIG. 23, for instance, the first retention flap edge 2071 frictionally engages the inside surface 126,12 of the first side panel 126, but the second flap edge 2073 is shown being spaced by a magnitude 2080 from the inside surface 128, 12 of the second side panel 128. The space shown at 2080 can result from dimensional variations attained when the outer box 2002 and/or the insulated inner box 124 are manufactured. Nevertheless, the closed rear flap 2025 tends to still restrain the insulated inner box 124 within the outer box 2002 so as to define air gaps between the panels of the insulated inner box 124 and corresponding panels of the outer box 2002. For example, the arrangement of FIG. 23 shows a gap G1 defined between the second side panel 128 of the insulated inner box 124 and the fold line 2306 defined between the first top flap 2014 and the first outer box side panel 2004 (FIG. 21) of the outer box 2002. The magnitude of the space 2080 can in some implementations be reduced upon movement of the first top flap 2014 to a closed position. Although not denoted in FIG. 23, it is to be understood that fully closed orientations of the rear panel 2025 and the front panel 2027 with respect to the end panels 132,130 of the insulated inner box 124 maintains air gaps between the respective end panels 130,132 and the respective front and rear panels 2010,2008 of the outer box 2002 in the same manner discussed above with regard to FIG. 7A at gaps G5 and G6.

[0153] Referring again to FIG. 24, the spatial relationships between the outer box 2002 and the insulated inner box 124 of the shipping assembly 2000 (FIG. 20) can be more readily perceived in their totality. In the absence of partial insertion of the top insulator box assembly 134 into the inner box cavity 156 of the insulated inner box 124, the outer box end flaps 2025,2027 have a natural tendency when moved toward a closed position to assume only a partially closed orientation, such that neither of the flaps 2025,2027 contact an associated end panel 132,130 of the insulated inner box 124. FIG. 24 shows respective first and second air gaps G1,G2 defined between the outer box 2002 and the insulated inner box 124. The first air gap G1 is defined between the second side panel 128 of the insulated inner box 124 and the first side panel 2004 of the outer box 2002. The first air gap G1 has a first gap width W.sub.G1 that can vary depending on the position along the first air gap G1 at which the first gap width W.sub.G1 is measured. For instance, if the second side panel 128 of the insulated inner box 124 is not exactly parallel to the first side panel 2004 of the outer box 2002, then the magnitude of W.sub.G1 can be smaller proximate the rear retention flap 2018 than proximate the front retention flap 2020, and vice versa. Similarly, the second air gap G2 is defined between the first side panel 128 of the insulated inner box 124 and the second side panel 2006 of the outer box 2002. The second air gap G2 has a second gap width W.sub.G2 that can vary depending on the position along the second air gap G2 at which the second gap width W.sub.G2 is measured. For instance, if the first side panel 126 of the insulated inner box 124 is not exactly parallel to the second side panel 2006 of the outer box 2002, then the magnitude of W.sub.G2 can be smaller proximate the rear retention flap 2018 than proximate the front retention flap 2020, and vice versa. Since the gap widths W.sub.G1 and W.sub.G2 need not be constant along the lengths of the respective air gaps G1 and G2, the arrangement of FIG. 24 also contemplates that the gap width W.sub.G1 need not always equal the widths of the respective shoulder portions 2079b,2251a of the rear and front ridge panels 2019,2021, and that the second gap width W.sub.G2 need not always equal the widths of the respective shoulder portions 2079a,2251b of the rear and front ridge panels 2019,2021.

[0154] FIG. 25 is an exploded perspective view showing the subassembly of FIG. 24 in exploded relation to the top insulator box assembly 134. When the top insulator box assembly 134 is partially inserted into the inner box cavity 156 of the insulated inner box 124 in the same manner discussed above with regard to FIGS. 15A and 15B, the front panel 142 of the top insulator box 134 engages the front retention flap 2020 and forces the front retention flap 2020 downwardly to assume the fully closed orientation discussed above with regard to FIG. 23. Similarly, such movement causes the end panel 140 (FIGS. 14A-14C) of the top insulator box 134 to engage the rear retention flap 2018 and to force the rear retention flap 2018 downwardly to assume the fully closed orientation discussed above with regard to FIG. 23. When forced into these fully closed orientations, the retention flaps 2018,2020 can exert opposing forces upon the insulated inner box 124, namely, the rear retention flap 2018 can exert a force tending to pull the rear panel 132 rearwardly, and the front retention flap 2020 can exert a force tending to pull the front panel 130 in an opposing frontward manner. Such opposing forces can act to restrain the insulated inner box 124 from movement in a longitudinal direction inside the outer box cavity 2013. Additionally, once the top insulator box assembly 134 is fully inserted into the insulated inner box 124 and into the outer box 2002, as best seen in FIG. 6, the opposed edges 210,212 of the top panel 135 of the top insulator box 134 can engage respective inside surfaces of the outer box side panels 106,104. Further, this fully inserted position can result in the side panels 136,138 of the top insulator box 134 engaging respective inside surfaces of the insulated inner box side panels 126,128. As a result, the illustrated inserted position of the top insulator box assembly 134 can act to restrain the insulated inner box 124 against lateral movement within the outer box cavity 2013.

Second, Third, and Fourth Alternate Embodiments of the Shipping Assembly

[0155] FIG. 26 is an exploded perspective view of a second alternate embodiment of a shipping assembly 2600 for transporting refrigerated items, the assembly 2600 constructed in accordance with yet another aspect of the current disclosure. Shipping assembly 2600 can be constructed identically to the shipping assembly 2000 (FIGS. 20-25), except that the construction of the bottom and top insulator box assemblies 2622,2634, respectively, differs from that of the corresponding insulator box assemblies 122,134 of the shipping assembly 2000. These differences are described below with regard to FIGS. 27 and 28.

[0156] FIG. 27 is a perspective view of the left side of the bottom insulator box assembly 2622 of the shipping assembly 2600, shown with both side flaps 2694,2696 of the bottom insulator box 2622 open and with a bottom box stiffener 2800 partially removed from a bottom insulator box cavity 2652 defined by the bottom insulator box 2622. The blank used to assemble the bottom insulator box 2622 can be identical to the blank 410 discussed above with regard to FIG. 18, except that the inside surface of the blank forming the bottom insulator box 2622 is not coated with the repulpable insulating film 12 (FIG. 9B) and can in fact omit any coatings. The additional difference between the bottom insulator box assembly 2622 and the bottom insulator box assembly 122 (FIG. 12B) is that the bottom box stiffener 2800 substitutes for the batt element 200 used in the bottom insulator box assembly 122. The bottom insulator box stiffener 2800, which enhances rigidity of the bottom insulator box 2622, can be constructed simply of a single strip of cardboard bent into a Z shape, although other suitable materials and other suitable shapes can be used for the bottom insulator box stiffener 2800.

[0157] FIG. 28 is a top perspective view of the top insulator box assembly 2634 of the shipping assembly 2600, with the top insulator box 2634 opened to show a top insulator box stiffener 2802 seated therein. The blank used to assemble the top insulator box 2634 can be identical to the blank 420 discussed above with regard to FIG. 19, except that the inside surface of the blank forming the bottom insulator box 2634 is not coated with the repulpable insulating film 12 (FIG. 9B) and can in fact omit any coatings. The additional difference between the top insulator box assembly 2634 and the top insulator box assembly 134 (FIGS. 14A-14C) is that the top insulator box stiffener 2802 substitutes for the batt element 201 used in the top insulator box assembly 134. The top insulator box stiffener 2800, which enhances rigidity of the top insulator box 2634, can be constructed simply of a single strip of cardboard bent into a Z shape, although other suitable materials and other suitable shapes can be used for the top insulator box stiffener 2802.

[0158] The present disclosure additionally contemplates a third alternate embodiment of a shipping assembly, which can be constructed identically to the shipping assembly 2600 (FIG. 26), except that, with regard to the bottom and top insulator box assemblies: (i) the boxes of those assemblies for the third alternate embodiment are constructed identically to the boxes 122, 134 of the shipping assembly 100 (FIGS. 1-5) and therefore are coated at their interior surfaces with the repulpable insulating film 12 (FIG. 9B); and (ii) a composite batt insulator 2900 (FIG. 29) substitutes for the stiffeners 2800,2800 discussed above with regard to FIGS. 27 and 28. The batt insulator 2900 can comprise the same insulation batt elements 200,201 respectively discussed above with regard to FIGS. 12B and 14A-14C, with the addition of a sheet layer 2902 attached to at least one surface of the insulation batt element 200,201. The sheet layer 2902 can be constructed of any of the paper-type materials, such as kraft paper, disclosed in U.S. Pat. No. 12,038,227, the disclosure of which is hereby expressly incorporated herein by reference in its entirety. The sheet layer 2902 can be attached to the insulation batt element 200,201 in any suitable manner, such as by means of an adhesive.

[0159] The present disclosure additionally contemplates a fourth alternate embodiment of a shipping assembly, which can be constructed identically to the third alternate embodiment described immediately above, except that the boxes for the top and bottom insulator box assemblies of the fourth alternate embodiment exclude the repulpable insulating film 12 (FIG. 9B).

Conclusion

[0160] The cardboard portions of the boxes disclosed above are preferably comprised entirely of curbside recyclable material, such as double-layered recyclable corrugated cardboard. Alternatively, the boxes can be constructed entirely of repulpable material, or comprised of some elements that are comprised of curbside recyclable material and some other elements that are comprised of repulpable material.

[0161] In some aspects, any of the panels and flaps of the blanks 300,400,410,420 that are described as being rectangular can be substantially rectangular (i.e., rectangular in shape minus any notches, chamfers, or other edge treatments). In some aspects, any of the panels and flaps of the blanks 300,400,410,420 that are described as being or defining some non-rectangular shape can be substantially that shape (i.e., that shape minus any notches, chamfers, or other edge treatments).

[0162] Components of the blanks 300,400,410,420, or the shipping assemblies 100,2000,2600 and their arrangement, can comprise both functional and aesthetic elements, and any feature described as having functional aspects can have or define any one of several aesthetic designs without altering the respective parts' functions. If aesthetic elements are shown in the drawings or possibly fall within the scope of broader claim elements without being directly claimed, such disclosure or claims should not be interpreted as assigning any function to such aesthetic elements which can therefore be separately protectable.

[0163] One should note that conditional language, such as, among others, can, could, might, or can, 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 comprise 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.

[0164] It should be emphasized that the above-described aspects 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 comprise one or more executable instructions for implementing specific logical functions or steps in the process, and alternate implementations are included in which functions might not be included or executed at all, can 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 can be made to the above-described aspect(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.