Nested insulated packaging

A method of assembling a nested insulated packaging comprising:

• positioning a first thermal liner in a cavity defined by an outer box, the outer box comprising an outer top side wall, an outer bottom side wall, and a plurality of outer lateral side walls;
• positioning an inner cardboard portion in the cavity with the first thermal liner at least partially positioned between the inner cardboard portion and the outer bottom side wall, the inner cardboard portion comprising a plurality of inner lateral side walls;
• and
• positioning a second thermal liner between the plurality of outer lateral side walls and the plurality of inner lateral side walls comprising folding the second thermal liner about a first bend line and a second bend line to reconfigure the second thermal liner from an unfolded configuration to a folded configuration, the second thermal liner defining a first end and a second end disposed opposite from the first end, the second thermal liner defining an inner surface and an outer surface disposed opposite from the inner surface, the second thermal liner comprising a single piece of nonwoven insulation material extending unbroken from the first end to the second end, the single piece of nonwoven insulation material defining the inner surface and the outer surface, the inner surface facing and contacting the inner cardboard portion, the outer surface facing and contacting the outer box, the second thermal liner defining a thickness between the inner surface and the outer surface, the thickness being uniform from the first end to the second end when the second thermal liner is in the unfolded configuration.

A packaging assembly comprising:

• an inner cardboard portion comprising a plurality of lateral side walls and a bottom side wall with a bottom side wall outer surface, the inner cardboard portion configured to be positioned within a box cavity;
• a first thermal liner configured to be positioned within the box cavity, the first thermal liner defining a first inner surface and a first outer surface each extending unbroken between first opposed ends, the first inner surface facing at least one of the lateral side walls and the bottom side wall outer surface of the inner cardboard portion when the inner cardboard portion and the first thermal liner are both disposed in the box cavity;
• and
• a second thermal liner configured to be positioned within the box cavity, the second thermal liner defining a second inner surface extending between second opposed ends, the second inner surface facing each lateral side wall of the inner cardboard portion that does not face the first inner surface when the inner cardboard portion, the first thermal liner, and the second thermal liner are all disposed in the box cavity.

A method of forming a packaging assembly configured for placement within a box cavity, comprising the steps of:

• positioning a first thermal liner with respect to an inner cardboard portion comprising a plurality of lateral side walls and a bottom side wall with a bottom side wall outer surface, the first thermal liner defining a first inner surface and a first outer surface each extending unbroken between first opposed ends, such that the first inner surface faces at least one of the lateral side walls of the inner cardboard portion;
• and
• positioning a second thermal liner with respect to the inner cardboard portion and to the first thermal liner, the second thermal liner defining a second inner surface extending between second opposed ends, such that the second inner surface faces each lateral side wall of the inner cardboard portion that does not face the first inner surface;
• and
• wherein the step of positioning the first thermal liner with respect to the inner cardboard portion further comprises causing the first inner surface to additionally face the bottom side wall outer surface.