# US 11,079,168 B2 · Modular box assembly > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,079,168 B2 - Document ID: US11079168B2 - Status: Granted - Kind: B2 - Application number: 16/381,678 - Filed: 2019-04-11 - Published: 2019-08-01 - Granted: 2021-08-03 - Earliest claimed: 2017-07-31 - Assignees: Pratt Retail Specialties, LLC - Applicants: Pratt Retail Specialties, LLC - Inventors: Jamie Waltermire; Paul Ott; Greg Sollie - Web page: https://patentgrep.com/patent/US11079168B2 ## CPC - F25D 23/06: Walls (F25D23/08 takes precedence; containers with thermal insulation B65D81/38) - B65D 25/28: Handles (of containers made by folding or erecting blanks made of paper B65D5/46; of bottles or jars B65D23/10 {; holders for glasses, bottles, cartons, plastic bags, cans A47G23/02}) - B65D 81/3888: {wrappers or flexible containers, e.g. pouches, bags (for shock absorbing purposes B65D81/03)} - F25D 23/067: {Supporting elements} - F25D 23/069: {Cooling space dividing partitions} - F25D 3/14: portable, i.e. adapted to be carried personally - F25D 5/02: portable, i.e. adapted to be carried personally - F25D 2201/12: using an insulating packing material - F25D 2323/061: Collapsible walls - F25D: REFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR (refrigerated showcases A47F3/04; thermally-insulated vessels for domestic use A47J41/00; refrigerated vehicles, see the appropriate subclasses of classes B60 - B64; containers with thermal insulation in general B65D81/38; heat-transfer, heat-exchange or heat-storage materials, e.g. refrigerants, or materials for the production of heat or cold by chemical reactions other than by combustion C09K5/00; thermally-insulated vessels for liquefied or solidified gases F17C; air-conditioning or air-humidification F24F; refrigeration machines, plants, or systems F25B; cooling of instruments or comparable apparatus without refrigeration G12B) - B65D: CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES ## Abstract A box assembly includes a box defining a box cavity within the box; and at least one insulated panel disposed within the box cavity, the at least one insulated panel including at least one board and at least one insulation batt, the at least one board laminated to the at least one insulation batt, the at least one insulated panel configured to at least partially insulate the box cavity. ## Claims ### Claim 1 A box assembly comprising: a box defining a box cavity within the box, the box comprising a plurality of side panels and a bottom panel, the plurality of side panels defining an opening to the box cavity positioned opposite from the bottom panel; a first liner disposed within the box cavity, the first liner defining a first end and a second end, the first end disposed opposite from the second end, the first liner comprising a first insulation batt, the first insulation batt extending continuously from the first end to the second end, the first insulation batt defining an inner surface and an outer surface, the first insulation batt defining a thickness between the inner surface and the outer surface, the thickness being constant from the first end to the second end when the first insulation batt is positioned in an unfolded configuration, a first bend line and a second bend line extending through the first insulation batt, the first liner folded about the first bend line and the second bend line into a C-shape, the first liner defining a first side panel, a second side panel, and a center panel, the first bend line defined between the first side panel and the center panel, the second bend line defined between the second side panel and the center panel, the first side panel covering the opening, the second side panel covering the bottom panel; and a second liner disposed within the box cavity, the second liner defining a third end and a fourth end, the second liner comprising a second insulation batt encapsulated between a first sheet and a second sheet by a border, the border coupling the first sheet to the second sheet, the border extending at least partially around the second insulation batt, a first portion of the border extending outwards from the third end and away from the second insulation batt, a second portion of the border extending outwards from the fourth end and away from the second insulation batt, the first portion of the border and the second portion of the border positioned in contact with the center panel of the first liner, a third bend line and a fourth bend line extending through the second insulation batt, the second liner folded about the third bend line and the fourth bend line into the C-shape, the second liner fitting together with the first liner to define an inner insulated cavity between the first liner and the second liner; and wherein the first insulation batt comprises a repulpable insulation material formed of a mixture of cellulose fiber and between about 2% and about 25% thermoplastic binder fiber distributed substantially randomly within the cellulose fiber, the thermoplastic binder being adhered to the cellulose fiber; and wherein subjecting the repulpable insulation material to a repulpability test produces greater than 85% fiber yield. ### Claim 2 (depends on 1) The box assembly of claim 1, wherein the second liner contacts at least a first side panel of the plurality of side panels and a second side panel of the plurality of side panels. ### Claim 3 (depends on 1) The box assembly of claim 1, wherein: the first liner comprises a third sheet and a fourth sheet; the first insulation batt is at least partially encapsulated between the third sheet and the fourth sheet; and the third sheet is attached to the fourth sheet by a second border which extends at least partially around the first insulation batt. ### Claim 4 (depends on 1) The box assembly of claim 1, wherein the first sheet comprises paper. ### Claim 5 (depends on 1) The box assembly of claim 1, wherein the first insulation batt is flexible. ### Claim 6 (depends on 1) The box assembly of claim 1, wherein: the first bend line and the second bend line are horizontally oriented; and the third bend line and the fourth bend line are vertically oriented. ### Claim 7 (depends on 1) The box assembly of claim 1, wherein the first insulation batt comprises a flexible insulation material. ### Claim 8 (depends on 1) The box assembly of claim 1, wherein: the inner surface of the first insulation batt faces the inner insulated cavity; and the outer surface of the first insulation batt faces the box. ### Claim 9 (depends on 1) The box assembly of claim 1, wherein the first sheet and the second sheet are defined by two halves of a single sheet. ### Claim 10 (depends on 1) The box assembly of claim 1, wherein the thermoplastic binder is a meltable polyethylene and polypropylene bi-component thermoplastic binder fiber. ### Claim 11 (depends on 1) The box assembly of claim 1, wherein the cellulose fiber comprises paper fiber. ### Claim 12 (depends on 1) The box assembly of claim 1, wherein the thermoplastic binder fiber defines a length of between about 0.5 mm to about 16 mm. ### Claim 13 A box assembly comprising: a box defining a box cavity within the box; a first liner disposed within the box cavity, the first liner defining a first end and a second end, the first end defined opposite from the second end, the first liner comprising a first insulation batt, the first insulation batt extending continuously from the first end to the second end, the first liner defining a first side panel, a second side panel, and a center panel, a first bend line defined between the first side panel and the center panel, a second bend line defined between the second side panel and the center panel, the first liner folded about the first bend line and the second bend line into a C-shape; and a second liner disposed within the box cavity, the second liner defining a third end and a fourth end, the second liner comprising a second insulation batt extending from the third end to the fourth end, the second liner folded about a third bend line and a fourth bend line into the C-shape, the second liner fitting together with the first liner to define an inner insulated cavity between the first liner and the second liner; and wherein the first insulation batt comprises a repulpable insulation material formed of a mixture of cellulose fiber and between about 2% and about 25% thermoplastic binder fiber distributed substantially randomly within the cellulose fiber, the thermoplastic binder being adhered to the cellulose fiber; and wherein subjecting the repulpable insulation material to a repulpability test produces greater than 85% fiber yield. ### Claim 14 (depends on 13) The box assembly of claim 13, wherein the thermoplastic binder is a meltable polyethylene and polypropylene bi-component thermoplastic binder fiber. ### Claim 15 (depends on 13) The box assembly of claim 13, wherein the cellulose fiber comprises paper fiber. ### Claim 16 (depends on 13) The box assembly of claim 13, wherein: the second insulation batt is encapsulated between a first sheet and a second sheet by a border; the border couples the first sheet to the second sheet; the border extends at least partially around the second insulation batt; a first portion of the border extends outwards from the third end and away from the second insulation batt; and a second portion of the border extends outwards from the fourth end and away from the second insulation batt. ### Claim 17 (depends on 13) The box assembly of claim 13, wherein the thermoplastic binder fiber defining a length of between about 0.5 mm to about 16 mm.