Modular shipping assembly with insulator wrap and inner insulator boxes

A shipping assembly [3000] for transporting refrigerated items, comprising:

• an outer box [102] defining a bottom [112] and an outer box cavity [113];
• a bottom insulator box assembly [122′] received in the outer box cavity [113] and superposed above the bottom [112] of the outer box [102], the bottom insulator box assembly [122′] comprising a closed box [122] defining a bottom insulator box cavity [152];
• an insulated inner box [124] positioned in the outer box cavity [113] above the bottom insulator box assembly [122′], the insulated inner box [124] defining an inner box cavity, [156], an outer periphery [3500] and a ridge [158];
• an insulation wrap [500] positioned in the outer box cavity [113], the insulation wrap [500] surrounding the outer periphery [3500] of the insulated inner box [124], the insulation wrap [500] comprising an insulation batt core [505] defining a core surface [505a,b] and a sheet layer [518,520] attached to the core surface [505a,b];
• and
• a top insulator box assembly [134′], comprising a top insulator box [134], wherein the top insulator box [134] defines a top insulator box cavity [139], the top insulator box [134] comprising a top panel [135] defining a first overhang portion [O1] and a second overhang portion [O2];
• wherein the ridge [158] of the insulated inner box [124] defines ridge end portions [130b,132b] comprising a front ridge portion [130b] and an opposed rear ridge portion [132b], a first side portion [126b] extending between the ridge end portions [130b,132b], and a second side portion [128b] extending between the ridge end portions [130b,132b] opposite the first side portion [126];
• and
• wherein the first overhang portion [O1] of the top panel [135] rests upon the first side portion [126b] of the ridge [158] and the second overhang portion [O2] of the top panel [135] rests upon the second side portion [126b] of the ridge [158]
• wherein the outer box [102] comprises
• an outer box side panel [104] defining a first side [103],
• an end panel [108] extending from at least a portion of the first side [103] of the outer box side panel [104], the end panel [108] joined to the outer box side panel [104] along a first fold line [103], the first fold line [103] defining a joint between the outer box side panel [104] and the end panel [108], the end panel [108] further defining a second fold line [3161] at a top side of the end panel [108], and
• a ridge panel [3119] extending from at least a portion of the second fold line [3161], the second fold line [3161] defining a joint between the end panel [108] and the ridge panel [3119], the ridge panel [3119] defining an elongated side [3179] opposite the second fold line [3161],
• a first end [3175] extending between the second fold line [3161] and the elongated side [3179],
• a second end [3177] opposite the first end [3175], the second end [3177] also extending between the second fold line [3161] and the elongated side [3179];
• wherein the ridge panel [3119] of the outer box [102] covers at least a portion of the ridge [158] of the insulated inner box [124];
• and
• wherein the second end [3177] of the ridge panel [3119] frictionally engages at least a portion of an inside surface [104a] of the outer box side panel [104].

A method of assembling a shipping assembly [3000] for transporting refrigerated items, comprising the steps of:

• moving into an open position top flaps [114,116], a rear flap [3125], and a front flap [3127] of an outer box [102], the outer box [102] comprising:
• a first outer box side panel [104] and an opposed second outer box side panel [106], a rear panel [108], and a front panel [110], the first outer box side panel [104], the second outer box side panel [106], the rear panel [108], and the front panel [110] together at least partially defining an outer box cavity [113], the rear panel [108] joined to the outer box side panel [104] along a first fold line [103], the first fold line [103] defining a joint between the outer box side panel [104] and the rear panel [108], the rear panel [108] further defining a second fold line [3161] at a top side of the rear panel [108];
• a ridge panel [3119] extending from at least a portion of the second fold line [3161], the second fold line [3161] defining a joint between an end panel and the ridge panel [3119], the ridge panel [3119] defining an elongated side [3179] opposite the second fold line [3161],
• a first end [3175] extending between the second fold line [3161] and the elongated side [3179],
• a second end [3177] opposite the first end [3175], the second end [3177] also extending between the second fold line [3161] and the elongated side [3179];
• wherein the ridge panel [3119] of the outer box [102] covers at least a portion of the ridge [158] of the insulated inner box [124];
• and
• wherein the second end [3177] of the ridge panel [3119] frictionally engages at least a portion of an inside surface [104a] of the outer box side panel [104];
• inserting a bottom insulator box assembly [122′] into the outer box cavity [113];
• inserting an insulated inner box [124] into the outer box cavity [113] above the bottom insulator box assembly [122′], the insulated inner box [124] defining an outer periphery [3500] and comprising a rear panel [132];
• positioning an insulation wrap [500] about the outer periphery [3500] of the insulated inner box [124];
• and
• pivoting the rear flap [3125] and the front flap [3127] of the outer box [102] inwardly toward a closed position until the rear flap [3125] and the front flap [3127] engage the insulated inner box [124] to restrain the insulated inner box [124] within the outer box cavity [113], such that the rear panel [132] of the insulated inner box [124] is spaced from the first outer box side panel [104] by a gap distance [3501].