Modular box assembly

A method of manufacturing a modular box assembly, comprising the steps of:

• constructing an 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 pre-laminated material by
• attaching a first sheet in facing contact with the insulation batt, and
• attaching a second sheet in facing contact with the insulation batt opposite the first sheet;
• cutting the pre-laminated material to size to define a first laminated member;
• cutting the pre-laminated material to size to define a second laminated member;
• folding portions of the first laminated member to form a first thermal liner;
• folding portions of the second laminated member to form a second thermal liner;
• positioning the first thermal liner in a box cavity defined by a box;
• and
• 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.