Modular box assembly

A method of manufacturing a modular box assembly, comprising:

• obtaining a box comprising a plurality of side box panels extending upwardly from a bottom box panel;
• constructing a first insulation batt, a second insulation batt, and a third insulation batt by:
• combining thermoplastic binder fibers and reinforcement fibers to result in a fibrous web,
• heating the fibrous web to a temperature exceeding a glass transition temperature of the thermoplastic binder fibers, resulting in melting of the thermoplastic binder fibers, and
• cooling the fibrous web, the cooling causing the thermoplastic binder fibers to solidify and to couple reinforcement fibers together;
• constructing a first thermal liner by positioning the first insulation batt between a first sheet and a second sheet to form a first laminated member in which the first insulation batt is fully encapsulated in a single cavity defined between the first sheet and the second sheet, and by folding portions of the first laminated member to define three first liner panels formed as a single piece of insulation material, the three first liner panels each positioned within the single cavity;
• constructing a second thermal liner by positioning a second insulation batt between a third sheet and a fourth sheet to form a second laminated member and by folding portions of the second laminated member to define three second liner panels;
• constructing an insulated panel by positioning the third insulation batt between a fifth sheet and a sixth sheet;
• positioning the first thermal liner in a box cavity defined by the box;
• positioning the second thermal liner in the box cavity such that the first thermal liner and the second thermal liner together form an insulated cavity within the box cavity;
• and
• attaching the insulated panel to an outer side surface of at least a first side box panel of the plurality of side box panels.