WO2020222943A1

WO2020222943A1 - Telescoping insulated boxes

Info

Publication number: WO2020222943A1
Application number: PCT/US2020/024820
Authority: WO
Inventors: Greg Sollie; Jamie Waltermire; Shifeng CHEN
Original assignee: Pratt Retail Specialties, Llc
Priority date: 2019-05-02
Filing date: 2020-03-26
Publication date: 2020-11-05

Abstract

Disclosed is a blank configured to form a box, the blank comprising an outer side panel, an outer bottom panel joined to the outer side panel by a fold line, a connecting strip joined to the outer side panel by a fold line, an inner side panel joined to the connecting strip by a fold line, and an inner bottom panel joined to the inner side panel by a fold line.

Description

TELESCOPING INSULATED BOXES

TECHNICAL FIELD

[0001] This disclosure relates to foldable boxes. More specifically, this disclosure relates to insulated boxes.

BACKGROUND

[0002] Home delivery of food is becoming more common as the process becomes more

efficient and costs go down. Delivery boxes may alternatively need to keep the food hot or cold enough to, for example, prevent bacterial growth, prevent melting or congealing of the food, or simply maintain the edibility, texture, and flavor of the food. Another consideration for the type of box to use is its impact on the environment, as it relates to the reusability and recyclability of the boxes. Polystyrene foam boxes are prevalent in the food-delivery industry because of their low cost, but they are not commonly recycled. Thus, they take up a disproportionate volume of landfill space.

SUMMARY

[0003] It is to be understood that this summary is not an extensive overview of the disclosure.

This summary is exemplary and not restrictive, and it is intended neither to identify key or critical elements of the disclosure nor delineate the scope thereof. The sole purpose of this summary is to explain and exemplify certain concepts off the disclosure as an introduction to the following complete and extensive detailed description.

[0004] Disclosed is a blank configured to form a box, the blank comprising an outer side panel, an outer bottom panel joined to the outer side panel by a fold line, a connecting strip joined to the outer side panel by a fold line, an inner side panel joined to the connecting strip by a fold line, and an inner bottom panel joined to the inner side panel by a fold line.

[0005] Also disclosed is a method of assembling a box from a blank, the method comprising obtaining a blank comprising a plurality of outer side panels, the outer side panels connected to each other by a plurality of fold lines, a plurality of outer bottom panels each joined to each of the outer side panels by a fold line, a plurality of connecting strips each joined to each of the outer side panels by a fold line, a plurality of inner side panels each joined to each of the connecting strips by a fold line, and a plurality of inner bottom panels each joined to each of the inner side panels by a fold linejoining the outer side panels at opposite ends such that the outer side panels form a ring, folding the outer bottom panels to form a bottom of the box, the bottom and the ring of outer side panels defining an interior of the box, folding the inner side panels in towards the interior of the box, such that each inner side panel faces the corresponding outer side panel, and folding the inner bottom panels to face the bottom of the box.

[0006] Also disclosed is a box comprising: a side wall, the side wall comprising an outer side panel and an inner side panel and defining an insulation cavity between the outer side panel and the inner side panel, and a bottom wall, the bottom wall comprising an outer bottom panel joined to the outer side panel by a fold line, and an inner bottom panel joined to the inner side panel by a fold line.

[0007] Also disclosed is a telescoping insulated box assembly, comprising: an outer box, the outer box comprising a side wall and a bottom wall, the side wall and the bottom wall of the outer box each defining an insulation cavity; and an inner box, the inner box comprising a side wall and a wall forming a portion of a top side of the box assembly, each wall of the inner box defining an insulation cavity, the inner box sized to fit into the outer box such that the each of the side walls of the inner box faces one of the side walls of the outer box.

[0008] Also disclosed is a method of assembling a telescoping insulated box assembly,

comprising: assembling an outer box by folding an inner side panel into the outer box, the inner side panel joined to a connecting strip by a fold line, the connecting strip joined to an outer side panel by a fold line, the outer side panel, the connecting strip, and the inner side panel forming a side wall and defining an insulation cavity therebetween; assembling an inner box by folding an inner side panel of the inner box into the inner box, the inner side panel joined to a connecting strip by a fold line, the connecting strip joined to an outer side panel by a fold line, the outer side panel, the connecting strip, and the inner side panel forming a side wall and defining an insulation cavity of the inner box therebetween; and inserting the inner box into the outer box, such that an open top of the inner box is proximate a bottom of the outer box, and a bottom of the inner box forms a portion of a top side of the box assembly.

[0009] Also disclosed is a blank configured to form a box, the blank comprising an outer side panel; an outer bottom panel joined to the outer side panel by a fold line; a connecting strip joined to the outer side panel by a fold line; an inner side panel joined to the connecting strip by a fold line; and an inner bottom panel joined to the inner side panel by a fold line.

[0010] Also disclosed is a method of assembling a box from a blank, the method comprising obtaining a blank comprising a plurality of outer side panels, the outer side panels connected to each other by a plurality of fold lines, a plurality of outer bottom panels each joined to each of the outer side panels by a fold line, a plurality of connecting strips each joined to each of the outer side panels by a fold line, a plurality of inner side panels each joined to each of the connecting strips by a fold line, and a plurality of inner bottom panels each joined to each of the inner side panels by a fold linejoining the outer side panels at opposite ends such that the outer side panels form a ring; folding the outer bottom panels to form a bottom of the box, the bottom and the ring of outer side panels defining an interior of the box; folding the inner side panels in towards the interior of the box, such that each inner side panel faces the corresponding outer side panel; and folding the inner bottom panels to face the bottom of the box.

[0011] Also disclosed is a box comprising a side wall, the side wall comprising an outer side panel and an inner side panel and defining an insulation cavity between the outer side panel and the inner side panel, and a bottom wall, the bottom wall comprising an outer bottom panel joined to the outer side panel by a fold line, and an inner bottom panel joined to the inner side panel by a fold line.

[0012] Also disclosed is a box comprising a side wall comprising an inner side panel and an outer side panel; and an insulator pad positioned at least partially between the inner side panel and the outer side panel.

[0013] Various implementations described in the present disclosure may include additional systems, methods, features, and advantages, which may not necessarily be expressly disclosed herein but will be apparent to one of ordinary skill in the art upon examination of the following detailed description and accompanying drawings. It is intended that all such systems, methods, features, and advantages be included within the present disclosure and protected by the accompanying claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The features and components of the following figures are illustrated to emphasize the general principles of the present disclosure. Corresponding features and components throughout the figures may be designated by matching reference characters for the sake of consistency and clarity. [0015] FIG. 1 A shows a box comprising walls defining insulation cavities therein.

[0016] FIG. IB shows a cross-section of the box of Figure 1 A taken along line 110 of Figure 1A.

[0017] FIG. 2 shows a blank configured to form the box of Figure 1.

[0018] FIG. 3 shows a side view of the blank of Figure 2.

[0019] FIG. 4 shows a blank configured to form a box, in accordance with another aspect of the current disclosure.

[0020] FIG. 5 A shows the box corresponding to the blank of Figure 4, in a partially

assembled configuration.

[0021] FIG. 5B is a detail view of the box, in accordance with another aspect of the current disclosure.

[0022] FIG. 6 shows the box comprising insulator pads, wherein an inner side panel is folded into the box.

[0023] FIG. 7 shows a plurality of insulator pads, in accordance with another aspect of the current disclosure.

[0024] FIG. 8 shows the insulator pads, in accordance with another aspect of the current disclosure.

[0025] FIG. 9 is a perspective view of a telescoping insulated box.

[0026] FIG. 10 is a perspective view of an inner portion of the telescoping box partially inserted in an outer portion.

[0027] FIG. 11 is a perspective view of the inner portion side-by-side with the outer portion.

[0028] FIG. 12 is a perspective view of the telescoping box comprising access tabs.

DETAILED DESCRIPTION

[0029] The present disclosure can be understood more readily by reference to the following detailed description, examples, drawings, and claims, and the previous and following description. However, before the present devices, systems, and/or methods are disclosed and described, it is to be understood that this disclosure is not limited to the specific devices, systems, and/or methods disclosed unless otherwise specified, and, as such, can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.

[0030] The following description is provided as an enabling teaching of the present devices, systems, and/or methods in its best, currently known aspect. To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects of the present devices, systems, and/or methods described herein, while still obtaining the beneficial results of the present disclosure. It will also be apparent that some of the desired benefits of the present disclosure can be obtained by selecting some of the features of the present disclosure without utilizing other features. Accordingly, those who work in the art will recognize that many modifications and adaptations to the present disclosure are possible and can even be desirable in certain circumstances and are a part of the present disclosure. Thus, the following description is provided as illustrative of the principles of the present disclosure and not in limitation thereof.

[0031] As used throughout, the singular forms "a," "an" and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "an element" can include two or more such elements unless the context indicates otherwise.

[0032] Ranges can be expressed herein as from "about" one particular value, and/or to

"about" another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent "about," it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

[0033] For purposes of the current disclosure, a material property or dimension measuring about X or substantially X on a particular measurement scale measures within a range between X plus an industry-standard upper tolerance for the specified measurement and X minus an industry-standard lower tolerance for the specified measurement. Because tolerances can vary between different materials, processes and between different models, the tolerance for a particular measurement of a particular component can fall within a range of tolerances.

[0034] As used herein, the terms "optional" or "optionally" mean that the subsequently

described event or circumstance can or cannot occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.

[0035] The word "or" as used herein means any one member of a particular list and also includes any combination of members of that list. Further, one should note that conditional language, such as, among others, "can," "could," "might," or "may," unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain aspects include, while other aspects do not include, certain features, elements and/or steps. Thus, such conditional language is not generally intended to imply that features, elements and/or steps are in any way required for one or more particular aspects or that one or more particular aspects necessarily include logic for deciding, with or without user input or prompting, whether these features, elements and/or steps are included or are to be performed in any particular aspect.

[0036] Disclosed are components that can be used to perform the disclosed methods and systems. These and other components are disclosed herein, and it is understood that when combinations, subsets, interactions, groups, etc. of these components are disclosed that while specific reference of each various individual and collective combinations and permutation of these may not be explicitly disclosed, each is specifically contemplated and described herein, for all methods and systems. This applies to all aspects of this application including, but not limited to, steps in disclosed methods. Thus, if there are a variety of additional steps that can be performed it is understood that each of these additional steps can be performed with any specific aspect or combination of aspects of the disclosed methods.

[0037] Disclosed is a box comprising walls that define insulation cavities and associated methods, systems, devices, and various apparatus. Also disclosed is a telescoping insulated box and associated methods, systems, devices, and various apparatus. It would be understood by one of skill in the art that the disclosed box is described in but a few exemplary embodiments among many. No particular terminology or description should be considered limiting on the disclosure or the scope of any claims issuing therefrom.

[0038] For ease of understanding, the use of the directional terms herein, such as right, left, front, back, top, bottom, and the like can refer to the orientation shown and described in the corresponding figures, but these directional terms should not be considered limiting on the orientation or configuration required by the present disclosure. The use of ordinal terms herein, such as first, second, third, fourth, and the like can refer to elements associated with elements having matching ordinal numbers. For example, a first light bulb can be associated with a first light socket, a second light bulb can be associated with a second light socket, and so on. However, the use of matching ordinal numbers should not be considered limiting on the associations required by the present disclosure.

[0039] Figure 1 A shows in one exemplary aspect a box 100 comprising walls 102 defining insulation cavities 104 within each of the walls 102. The walls 102 can comprise a plurality of sides 106 and a bottom 108 of the box 100. The box 100 can comprise four or any other number of sides 106. The sides 106 and the bottom 108 can define an interior 110 of the box 100. The sides 106 and the bottom 108 can comprise the insulation cavities 104 when the box 100 is assembled in accordance with the present disclosure. Line 110-110 defines a cross-section, a perspective view of which is shown in Figure IB.

[0040] Figure IB is a cross-sectional view of the box 100 of Figure 1A. The cross-sectional plane is defined by line 110-110. The insulation cavities 104 can be defined within each of the walls 102, the construction of the walls 102 being described more fully below. In the current aspect, the insulation cavities 104 are empty and filled with air. In other aspects, various insulators such as repulpable or recyclable insulator pads 226 (described below) can fill the cavities 104.

[0041] Figure 2 shows in one exemplary aspect a blank 200 configured to form the box 100 of Figure 1. The blank 200 can comprise four outer side panels 202a,b,c,d, each connected to another by a parallel fold line 204. Each of four inner side panels 206a,b,c,d can be connected to one of the four outer side panels 202a,b,c,d by a connecting strip 208. Each connecting strip 208 can be connected to the respective outer side panel 202a,b,c,d by a fold line 210 along one edge 212 and be connected to respective the inner side panel 206a,b,c,d by a fold line 214 on an opposite edge 216. Each of a first and a third inner side panel 206a, c can comprise two tabs 207. Each of four inner bottom panels 218a,b,c,d can be connected to one of the four inner side panels 206a,b,c,d by a fold line 220. The blank can also comprise four outer bottom panels 222a,b,c,d, each connected to one of the four outer side panels 202a,b,c,d by a fold line 224.

[0042] Each of the four outer side panels 202a,b,c,d can be covered by an insulator pad or batt 226. The insulator pads 226 can comprise paper or other paper fiber materials;

however, in other aspects, the insulation batts 226 can comprise cotton, foam, rubber, plastics, fiberglass, mineral wool, or any other flexible insulation material. In the present application, the insulation batts 226 can be repulpable. In the present aspect, the box can be 100% recyclable. In the present aspect, the box 100 can be single-stream recyclable wherein all materials comprised by the box can be recycled by a single processing train without requiring separation of any materials or components of the box 100. In the present aspect, the box 100 can be compostable. In the present aspect, the box 100 can be repulpable. In the present aspect, the box 100 and the insulator pads 226 can be repulpable in accordance with the requirements of the August 16, 2013, revision of the “Voluntary Standard For Repulping and Recycling Corrugated Fiberboard Treated to Improve Its Performance in the Presence of Water and Water Vapor” provided by the Fibre Box Association of Elk Grove Village, IL. In the present aspect, the box 100 and the insulator pads 226 can be recyclable in accordance with the requirements of the August 16, 2013, revision of the“Voluntary Standard For Repulping and Recycling Corrugated Fiberboard Treated to Improve Its Performance in the Presence of Water and Water Vapor” provided by the Fibre Box Association of Elk Grove Village, IL.

[0043] Recyclable and repulpable insulation materials are further described in U.S. Patent Application Number 15/677,738, filed August 15, 2017, U.S. Provisional Patent

Application Number 62/375,555, filed August 16, 2016, U.S. Provisional Patent

Application Number 62/419,894, filed November 9, 2016, and U.S. Provisional Patent Application Number 62/437,365, filed December 21, 2016.

[0044] The insulator pads 226 can be configured or spaced to allow bending of the fold lines 204 between each of the outer side panels 202a,b,c,d such that the insulator pads 226 face the interior 110 of the box 100. A first and a third inner bottom panel 218a,c can also be covered by insulator pads 226. The insulator pads 226 can be affixed to the panels by glue, hot melt, double-sided tape, or any other method known in the art. In other aspects (not shown), insulator pads 226 can be omitted altogether. In such case, the insulation cavities 104 can use air as an insulating material.

[0045] In other aspects (not shown), the number of outer side panels 202a,b,c,d (and

corresponding panels) can be greater or less than four. In yet other aspects, the tabs 207 need not be on the first and third inner side panels 206a, c, and can be on any desired side panel 206.

[0046] The insulator pad 226 covering a fourth outer side panel 202d can be cut short, and the insulator pad 226 covering a first outer side panel 202a can extend past its edge, such that when the first and fourth outer side panels 202a, d are joined together— assembling the box in a 3-D configuration— the insulator pad 226 extending from the first outer side panel 202a can touch and can cover a portion of the fourth outer side panel 202d. In some aspects, the first outer side panel 202a can comprise a tab (not shown) that extends outward similar to the tab 207 of the first inner side panel 206a and the insulator pad 226 can cover the tab of the first outer side panel 202a. In these aspects, the tab beneath the insulator pad 226 covering the first outer side panel 202a can contact and can cover a portion of the fourth outer side panel 202d instead of the insulator pad 226.

[0047] Figure 3 shows a side view of the blank 200 of Figure 2. The insulator pads 226 can be cut along each of their edges 302 at the fold lines 204 between the outer side panels 202a,b,c,d. For example, each cut 304 can form an angle 306 with a plane of the blank 200. The angle 306 can be 45-degrees, such that when the box 100 walls 102 each form a 90-degree angle relative to each other, the cuts 304 of the insulator pads 226 are in facing or almost facing contact but are not compressed against each other.

[0048] Figure 4 shows another aspect of the blank 200 for the box 100 in accordance with the current disclosure. In the current aspect, the insulator pads 226 are omitted. The insulator pads 226 can be inserted during assembly of the box 100 or omitted. The connecting strips 208 can each comprise sides 402 which are angled towards each other in the direction of the inner side panels 206 from the outer side panels 202. For example and without limitation, the sides 402 of the connecting strips 208 can form approximately a 45-degree angle with the fold line 210 between the connecting strip 208 and the outer side panel 202. In this way, the connecting strips 208 can form a top surface 602 (shown in Figure 6) of the box 100, each side 402 of the connecting strips 208 in facing or almost facing contact with, without overlapping, one of the sides 402 of the adjacent connecting strips 208.

[0049] Figure 5 A shows the box 100 corresponding to the blank of Figure 4, in a partially assembled configuration. The first and the fourth outer side panels 202a, d are joined to form a ring 502 comprising the four sides 106 of the box 100.

[0050] Figure 5B is a detail view of the box 100, in accordance with another aspect of the current disclosure. In the present aspect, the box 100 can be assembled from a blank in which the connecting strips 208 can alternate between a rectangular shape 504 (the sides 402 of the connecting strips 208 perpendicular to the fold line 210 between the connecting strip 208 and the outer side panel 202) and a trapezoidal shape 506 (as shown in Figure 4). The two opposing inner side panels 206a, c connected to the rectangular connecting strips 504 can fold into the box 100 first, followed by the opposing inner side panels 206b, d connected to the trapezoidal connecting strips 506. In other aspects, different inner side panels 206a,b,c,d can have or be attached to the rectangular 504 or trapezoidal connecting strips 506. As such, the angled sides 402 of the trapezoidal connecting strips 506 can provide a symmetric look to the comers 508 of the box, while the sides 402 of the rectangular connecting strips 504 can be tucked under the trapezoidal connecting strips 506, such that no gap is defined therebetween to see inside the insulation cavities 104. Additionally, in some aspects, the box 100 can be dimensioned such that some of the inner side panels 206a,b,c,d cannot easily fold into the box 100 without bending. In such cases, an additional fold line 510 across the inner side panel 206a,b,c,d can allow for easier assembly. [0051] Figure 6 shows the box 100 having the insulator pads 226 (shaded), wherein one of the inner side panels 206 has been folded into the box 100. The connecting strip 208 can cover a top edge 604 of the insulator pad 226. Each inner side panel 206a,b,c,d can face the corresponding outer side panel 202a,b,c,d (not shown in Figure 6) and sandwich a respective one of the insulator pads 226 in each cavity 104 formed therebetween. The tabs 207 can fold to face the adjacent sides 106 of the box 100. The inner bottom panel 218 can form the bottom 108 of the interior 110 of the box 100. Another one of the insulating pads 226 (not shown) can be sandwiched between the inner bottom panel 218 and the outer bottom panels 222.

[0052] The blank 200 of Figure 2 can be assembled to form the box 100 in its 3-D

configuration by a following procedure. The first and the fourth outer side panels 202a, d can be joined together such that the insulator pads 226 face the interior 110 of the box 100. The outer bottom panels 222a,b,c,d can be folded to form the bottom 108 of the box 100. For example, the first and the third outer bottom panels 222a, c can be folded in first, followed by the second and fourth outer bottom panels 222b, d. The inner side panels 206a,b,c,d can be folded in towards the interior 110 of the box 100, such that the inner side panels 206a,b,c,d contact the insulator pads 226, and such that the inner bottom panels 218a,b,c,d face and lay over the outer bottom panels 222a,b,c,d. In the current aspect, for the blank 200 shown in Figure 2, the first and the third inner side panels 218a,c can be folded in first, such that the tabs 207 of the first and third inner side panels 218a,c are sandwiched between the second and fourth outer side panels 202b, d and the corresponding second and fourth inner side panels 218b,d. In another aspect, the second and fourth side inner panels 202b, d can be folded into the box 100 first, and then the first and third inner side panels 218a,c subsequently folded in, such that the tabs 207 are exposed to the interior 110 of the box 100 in the assembled configuration. This method can use the tabs 207 to hold down the second and fourth inner side panels 202b, d, while the previous method can allow the tabs 207 to remain hidden.

[0053] Furthermore, in the current aspect, the insulator pads 226 on the first and third inner bottom panels 218a,c can touch the outer bottom panels 222a,b,c,d. The second and fourth inner bottom panels 218b,d can then form the bottom 108 facing the interior 110 of box 100. In other aspects, the order of folding can be different, such that the bottom 108 and the sides 106 of the box still comprise insulation cavities 104.

[0054] In other aspects, such as when the number of outer side panels 202a,b,c,d (and

corresponding panels) vary from four, the procedure can be described more generally by the following steps: joining the outer side panels 202a,b,c,d at opposite ends 202a, d such that the outer side panels 202a,b,c,d form a ring 502; folding the outer bottom panels 222a,b,c,d to form the bottom 108 of the box 100, the bottom 108 and the ring 502 of outer side panels 202a,b,c,d defining the interior 110 of the box 100; folding the inner side panels 206a,b,c,d in towards the interior 110 of the box 100, such that the connecting strips 208 cover the top edges 604 of the insulator pads 226, and such that each inner side panel 206a,b,c,d faces the corresponding outer side panel 202a,b,c,d; and folding the inner bottom panels 218a,b,c,d to face the bottom 108 of the box 100.

[0055] Figure 7 shows another aspect of the insulator pads 226. In the present aspect, the insulator pads 226 can be individual pieces, unattached to a blank and inserted into the insulation cavities 104 during the assembly of the box 100. Two bottom insulation pads 702 can insulate the insulation cavity 104 of the bottom 108 of the box 100, which can also be called a bottom insulation cavity. The insulator pads 226 can comprise a covering or liner 704 that can be made of plastic, for example and without limitation, such that moisture is prevented from entering an interior of the insulator pads 226.

[0056] Figure 8 shows another aspect of the insulator pads 226. In the present aspect, a

singular side insulator pad 802 can fill a plurality of insulation cavities 104 (side insulation cavities) by wrapping circumferentially in the walls 102 of the sides 106 (side walls). A separate bottom insulation pad 702 can insulate the bottom insulation cavity.

[0057] Figure 9 is a perspective view of a telescoping insulated box assembly 900. The

telescoping insulated box assembly 900 can comprise an inner box 902 and an outer box 904. Each of the inner box 902 and the outer box 904 can be assembled according to the present disclosure as a box 100 comprising walls 102 that define insulation cavities 104 (shown in Figure 2). The telescoping box assembly 900 can be formed by the inner box 902, which is smaller than the outer box 904, upside down into the outer box 904, such that the bottom 108 of the box 100 forming the inner box 902 is a part of a top side 906 of the telescoping box assembly 900 opposite to a bottom side 908 of the telescoping box assembly 900, the bottom side 908 formed by the bottom 108 of the outer box 904. In other aspects (not shown), the telescoping box assembly 900 can be in a reversed orientation while carry contents, such that the bottom 108 of the outer box 904 can form the top side 906 of the telescoping box assembly 900 and the bottom 108 of the inner box 902 can form part of the bottom side 908 of the telescoping box assembly 900. The inner box 902 can be sized such that the inner box 902 slides snugly into the outer portion. Snugly can mean that the inner and outer portions 902,904 in an assembled telescoping box assembly 900 can press against each other with enough force such that frictional forces alone can keep the inner and outer portions 902,904 secured together, such that the portions 902,904 do not separate through gravitational forces when the telescoping box assembly 900 is empty or filled with contents up to a given weight and external force needs to be applied to separate the boxes 902,904. In other aspects, the fit can be designed to be looser or tighter as desired.

[0058] When the inner box 902 forms part of the top side 906 of the telescoping box

assembly 900, a handle 910 can be attached to the inner box 902. In some aspects, the handle 910 can be a strip of flexible plastic, the ends of which are adhesive, such that the handle also functions to secure the outer bottom panels 222a,b,c,d of the inner box 902 together. The handle 910 can be of sufficient strength to support the weight of the telescoping box assembly 900 and its contents, as well as to support pulling the inner box 902 out of the outer box 904 in order, for example, to retrieve the contents.

[0059] Figure 10 is a perspective view of the inner box 902 of the telescoping box assembly 900 partially inserted in (or telescoping from) the outer box 904.

[0060] Figure 11 is a perspective view of the inner box 902 placed side-by-side with the outer box 904, both portions facing in the same orientation, their bottoms 108 facing down and a top edge 1102 facing up. An exterior height 1104 of the inner box 902 can match an interior height 1106 of the outer box 904, such that when the inner box 902 is fully inserted into the outer box 904, the bottom 108 of the inner box 902 is level, or coplanar, with the top edge 1102 of the outer portion 104.

[0061] Figure 12 is a perspective view of the telescoping box assembly 900 comprising

access tabs 1202. Each access tab 1202 can comprise a telescope covering portion 1204 that can cover a comer (not shown) of the inner box 902, such that the inner box 902 is secured inside the outer box 904. The tabs 1202 can be attached to the outer box 904, such as by adhesives such as glue. Each tab 1202 can define cuts 1206 and perforations 1208 such that tearing a portion of the tab 1202 along the perforation 1208 can allow the covering portion 1204 to fold up and expose the comer of the inner box 902. As such, the inner box 902 can be removed from the outer box 904 after tearing the portion of the tab 1202 along the perforation 1208, such as by holding the outer box 904 and pulling on the handle 910 of the inner box 902 in an opposite direction.

[0062] In one exemplary aspect, a telescoping insulated box assembly can comprise an outer box, the outer box comprising a side wall and a bottom wall, the side wall and the bottom wall of the outer box each defining an insulation cavity; and an inner box, the inner box comprising a side wall and a wall forming a portion of a top side of the box assembly, each wall of the inner box defining an insulation cavity, the inner box sized to fit into the outer box such that the each of the side walls of the inner box faces one of the side walls of the outer box. In a further exemplary aspect, the side wall of the outer box can comprise an outer side panel; a connecting strip joined to the outer side panel by a fold line; and an inner side panel joined to the connecting strip by a fold line; and the outer side panel, the connecting strip, and the inner side panel can define the insulation cavity therebetween. In a further exemplary aspect, the bottom wall of the outer box can comprise an outer bottom panel joined to the outer side panel by a fold line; and an inner bottom panel joined to the inner side panel by a fold line; the insulation cavity can be a first insulation cavity; and the outer bottom panel and the inner bottom panel can define a second insulation cavity therebetween.

[0063] In a further exemplary aspect, the side wall of the inner box can comprise an outer side panel; a connecting strip joined to the outer side panel by a fold line; and an inner side panel joined to the connecting strip by a fold line; and the outer side panel, the connecting strip, and the inner side panel can define the insulation cavity therebetween. In a further exemplary aspect, the wall of the inner box forming a portion of a top side of the box assembly wall can be a bottom wall during assembly of the inner box, the bottom wall of the inner box comprising an outer bottom panel joined to the outer side panel by a fold line; and an inner bottom panel joined to the inner side panel by a fold line; the insulation cavity can be a first insulation cavity; and the outer bottom panel and the inner bottom panel can define a second insulation cavity therebetween.

[0064] In a further exemplary aspect, the insulation cavity of the bottom wall of the outer box can be filled with a repulpable insulator pad. In a further exemplary aspect, the insulation cavity of the side wall of the outer box can be filled with a repulpable insulator pad. In a further exemplary aspect, the outer box can comprise four side walls, each side wall comprising an outer side panel; a connecting strip joined to the outer side panel by a fold line; and an inner side panel joined to the connecting strip by a fold line; and the outer side panels, the connecting strips, and the inner sides panel can define the insulation cavities therebetween. In a further exemplary aspect, the outer box can comprise a side tab joined by a fold line to at least one of the inner side panels, the side tab covered by an inner side panel of an adjacent side wall such that the side tab is inside one of the insulation cavities. [0065] In a further exemplary aspect, a handle can be attached to the inner box on the wall forming the portion of the top side of the box assembly. In a further exemplary aspect, the handle can comprise adhesive ends, and the adhesive ends can be configured to secure a plurality of outer bottom panels of the inner box to form the wall of the inner box forming the portion of the top side of the box assembly. In a further exemplary aspect, an access tab can be attached to the outer box and covering a corner of the inner box, such that the inner box is secured inside the outer box. In a further exemplary aspect, the access tab can define a cut and a perforation such that tearing the perforation opens up the cut and exposes the corner of the inner box, allowing the inner box to telescope out of the outer box.

[0066] In another exemplary aspect, a method of assembling a telescoping insulated box assembly can comprise assembling an outer box by folding an inner side panel into the outer box, the inner side panel joined to a connecting strip by a fold line, the connecting strip joined to an outer side panel by a fold line, the outer side panel, the connecting strip, and the inner side panel forming a side wall and defining an insulation cavity

therebetween; assembling an inner box by folding an inner side panel of the inner box into the inner box, the inner side panel joined to a connecting strip by a fold line, the connecting strip joined to an outer side panel by a fold line, the outer side panel, the connecting strip, and the inner side panel forming a side wall and defining an insulation cavity of the inner box therebetween; and inserting the inner box into the outer box, such that an open top of the inner box is proximate a bottom of the outer box, and a bottom of the inner box forms a portion of a top side of the box assembly.

[0067] In a further exemplary aspect, the insulation cavity of the outer box is a first insulation cavity of the outer box, and the method can further comprise folding at least two outer bottom panels of the outer box; folding at least two inner bottom panels of the outer box; forming a second insulation cavity between the inner bottom panels and the outer bottom panels; and placing a plurality of insulator pads in the first and second insulation cavities. In a further exemplary aspect, the method can further comprise folding a side tab, the side tab joined by a fold line to one of the inner side panels, behind an inner side panel of an adjacent side wall, such that the inner side panel joined to the side tab is restricted from folding up.

[0068] In a further exemplary aspect, the method can further comprise placing a repulpable insulator pad in the insulation cavity of at least one of the outer box or the inner box. In a further exemplary aspect, the outer box can comprise four inner side panels, four connecting strips, and four outer side panels; the side panels, the connecting strips, and the outer side panels can define four side walls, and four portions of the insulation cavity can be defined within the four side walls. In a further exemplary aspect, the method can further comprise wrapping a single insulator pad around the four inner side panels inside the insulation cavity. In a further exemplary aspect, the method can further comprise attaching a handle to the inner box, the handle configured to allow the inner box to be pulled out of the outer box.

[0069] In another exemplary aspect, a blank configured to form a box can comprise an outer side panel; an outer bottom panel joined to the outer side panel by a fold line; a connecting strip joined to the outer side panel by a fold line; an inner side panel joined to the connecting strip by a fold line; and an inner bottom panel joined to the inner side panel by a fold line. In a further exemplary aspect, the blank can further comprise four outer side panels, four outer bottom panels, four connecting strips, and four inner side panels; each outer bottom panel can be joined to a one of the outer side panels by a fold line; each connecting strip can be joined to a one of the outer side panels by a fold line; each inner side panel can be joined to a one of the connecting strips by a fold line; and each inner bottom panel can be joined to a one of the inner side panels by a fold line. In a further exemplary aspect, an insulator pad can be attached to each of the inner side panels, and at least two of the insulator pads can each comprise a beveled edge where the two insulator pads meet. In a further exemplary aspect, an insulator pad can be attached to two non-adjacent inner bottom panels.

[0070] In a further exemplary aspect, the blank can comprise a side tab joined to the inner side panel by a fold line. In a further exemplary aspect, the connecting strip can comprise two sides angled towards each other in the direction of the inner side panel from the outer side panel. In a further exemplary aspect, the blank can be cut from one monolithic sheet. In a further exemplary aspect, the blank can comprise a first insulator pad attached to the inner side panel and a second insulator pad attached to the inner bottom panel. In a further exemplary aspect, the blank can be single-stream recyclable. In a further exemplary aspect, the blank can be repulpable.

[0071] In another exemplary aspect, a method of assembling a box from a blank can

comprise obtaining a blank comprising a plurality of outer side panels, the outer side panels connected to each other by a plurality of fold lines, a plurality of outer bottom panels each joined to each of the outer side panels by a fold line, a plurality of connecting strips each joined to each of the outer side panels by a fold line, a plurality of inner side panels each joined to each of the connecting strips by a fold line, and a plurality of inner bottom panels each joined to each of the inner side panels by a fold line; joining the outer side panels at opposite ends such that the outer side panels form a ring; folding the outer bottom panels to form a bottom of the box, the bottom and the ring of outer side panels defining an interior of the box; folding the inner side panels in towards the interior of the box, such that each inner side panel faces the corresponding outer side panel; and folding the inner bottom panels to face the bottom of the box.

[0072] In a further exemplary aspect, the method can further comprise sandwiching an

insulator pad between one of the outer side panels and one of the inner side panels. In a further exemplary aspect, the blank can further comprise a side tab joined by a fold line to at least one of the inner side panels, and the method can further comprise covering an adjacent inner side panel with the side tab. In a further exemplary aspect, the blank can further comprise a side tab joined by a fold line to at least one of the inner side panels, and the method can further comprise covering the tab with an adjacent inner side panel.

[0073] In a further exemplary aspect, a box can comprise a side wall, the side wall

comprising an outer side panel and an inner side panel and defining an insulation cavity between the outer side panel and the inner side panel, and a bottom wall, the bottom wall comprising an outer bottom panel joined to the outer side panel by a fold line, and an inner bottom panel joined to the inner side panel by a fold line. In a further exemplary aspect, the outer side panel and the inner side panel can be attached to each other at a top edge of the box. In a further exemplary aspect, the box can further comprise a plurality of side walls, each side wall comprising an outer side panel and an inner side panel and defining an insulation cavity between the outer side panel and the inner side panel, wherein the insulation cavities are each filled with insulator pads.

[0074] In a further exemplary aspect, the box can further comprise an insulator pad

positioned in the insulation cavity. In a further exemplary aspect, the box and the insulator pad can be repulpable. In a further exemplary aspect, the bottom wall can define an insulation cavity between the outer bottom panel and the inner bottom panel.

[0075] In another exemplary aspect, a box can comprise a side wall comprising an inner side panel and an outer side panel; and an insulator pad positioned at least partially between the inner side panel and the outer side panel.

[0076] One should note that conditional language, such as, among others, "can," "could," "might," or "may," unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain aspects include, while other aspects do not include, certain features, elements and/or steps. Thus, such conditional language is not generally intended to imply that features, elements and/or steps are in any way required for one or more particular aspects or that one or more particular aspects necessarily include logic for deciding, with or without user input or prompting, whether these features, elements and/or steps are included or are to be performed in any particular aspect.

[0077] It should be emphasized that the above-described aspects are merely possible

examples of implementations, merely set forth for a clear understanding of the principles of the present disclosure. Any process descriptions or blocks in flow diagrams should be understood as representing modules, segments, or portions of code which include one or more executable instructions for implementing specific logical functions or steps in the process, and alternate implementations are included in which functions may not be included or executed at all, may be executed out of order from that shown or discussed, including substantially concurrently or in reverse order, depending on the functionality involved, as would be understood by those reasonably skilled in the art of the present disclosure. Many variations and modifications may be made to the above-described aspect(s) without departing substantially from the spirit and principles of the present disclosure. Further, the scope of the present disclosure is intended to cover any and all combinations and sub-combinations of all elements, features, and aspects discussed above. All such modifications and variations are intended to be included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure.

Claims

CLAIMS That which is claimed is:

1. A telescoping insulated box assembly, comprising:

an outer box, the outer box comprising a side wall and a bottom wall, the side wall and the bottom wall of the outer box each defining an insulation cavity; and an inner box, the inner box comprising a side wall and a wall forming a portion of a top side of the box assembly, each wall of the inner box defining an insulation cavity, the inner box sized to fit into the outer box such that the each of the side walls of the inner box faces one of the side walls of the outer box.

2. The box assembly of claim 1, wherein:

the side wall of the outer box comprises

an outer side panel;

a connecting strip joined to the outer side panel by a fold line; and

an inner side panel joined to the connecting strip by a fold line; and

wherein the outer side panel, the connecting strip, and the inner side panel define the insulation cavity therebetween.

3. The box assembly of claim 2, wherein:

the bottom wall of the outer box comprises

an outer bottom panel joined to the outer side panel by a fold line; and an inner bottom panel joined to the inner side panel by a fold line;

wherein the insulation cavity is a first insulation cavity; and

wherein the outer bottom panel and the inner bottom panel define a second insulation cavity therebetween.

4. The box assembly of claim 1, wherein:

the side wall of the inner box comprises

an outer side panel;

a connecting strip joined to the outer side panel by a fold line; and

an inner side panel joined to the connecting strip by a fold line; and

5. The box assembly of claim 4, wherein:

the wall of the inner box forming a portion of a top side of the box assembly wall is a bottom wall during assembly of the inner box, the bottom wall of the inner box comprising

wherein the insulation cavity is a first insulation cavity; and

6. The box assembly of claim 1, wherein the insulation cavity of the bottom wall of the outer box is filled with a repulpable insulator pad.

7. The box assembly of claim 1, wherein the insulation cavity of the side wall of the outer box is filled with a repulpable insulator pad.

8. The box assembly of claim 1, wherein the outer box comprises four side walls, each side wall comprising

an outer side panel;

a connecting strip joined to the outer side panel by a fold line; and

an inner side panel joined to the connecting strip by a fold line; and

wherein the outer side panels, the connecting strips, and the inner sides panel define the insulation cavities therebetween.

9. The box assembly of claim 8, wherein the outer box comprises a side tab joined by a fold line to at least one of the inner side panels, the side tab covered by an inner side panel of an adjacent side wall such that the side tab is inside one of the insulation cavities.

10. The box assembly of claim 1, wherein a handle is attached to the inner box on the wall forming the portion of the top side of the box assembly.

11. The box assembly of claim 10, wherein the handle comprises adhesive ends, the adhesive ends configured to secure a plurality of outer bottom panels of the inner box to form the wall of the inner box forming the portion of the top side of the box assembly.

12. The box assembly of claim 1, further comprising an access tab attached to the outer box and covering a comer of the inner box, such that the inner box is secured inside the outer box.

13. The box assembly of claim 12, wherein the access tab defines a cut and a perforation such that tearing the perforation opens up the cut and exposes the comer of the inner box, allowing the inner box to telescope out of the outer box.

14. A method of assembling a telescoping insulated box assembly, comprising:

assembling an outer box by folding an inner side panel into the outer box, the inner side panel joined to a connecting strip by a fold line, the connecting strip joined to an outer side panel by a fold line, the outer side panel, the connecting strip, and the inner side panel forming a side wall and defining an insulation cavity therebetween;

assembling an inner box by folding an inner side panel of the inner box into the inner box, the inner side panel joined to a connecting strip by a fold line, the connecting strip joined to an outer side panel by a fold line, the outer side panel, the connecting strip, and the inner side panel forming a side wall and defining an insulation cavity of the inner box therebetween; and inserting the inner box into the outer box, such that an open top of the inner box is proximate a bottom of the outer box, and a bottom of the inner box forms a portion of a top side of the box assembly.

15. The method of claim 14, wherein the insulation cavity of the outer box is a first

insulation cavity of the outer box, and wherein the method further comprises:

folding at least two outer bottom panels of the outer box;

folding at least two inner bottom panels of the outer box;

forming a second insulation cavity between the inner bottom panels and the outer bottom panels;

and placing a plurality of insulator pads in the first and second insulation cavities.

16. The method of claim 14, further comprising

folding a side tab, the side tab joined by a fold line to one of the inner side panels, behind an inner side panel of an adjacent side wall, such that the inner side panel joined to the side tab is restricted from folding up.

17. The method of claim 14, further comprising placing a repulpable insulator pad in the insulation cavity of at least one of the outer box or the inner box.

18. The method of claim 14, wherein the outer box comprises four inner side panels, four connecting strips, and four outer side panels, the side panels, the connecting strips, and the outer side panels defining four side walls, and wherein four portions of the insulation cavity are defined within the four side walls.

19. The method of claim 18, further comprising wrapping a single insulator pad around the four inner side panels inside the insulation cavity.

20. The method of claim 14, further comprising attaching a handle to the inner box, the handle configured to allow the inner box to be pulled out of the outer box.

21. A blank configured to form a box, the blank comprising:

an outer side panel;

an outer bottom panel joined to the outer side panel by a fold line;

a connecting strip joined to the outer side panel by a fold line;

an inner side panel joined to the connecting strip by a fold line; and

an inner bottom panel joined to the inner side panel by a fold line.

22. The blank of claim 21, further comprising four outer side panels, four outer bottom panels, four connecting strips, and four inner side panels, wherein:

each outer bottom panel is joined to a one of the outer side panels by a fold line; each connecting strip is joined to a one of the outer side panels by a fold line;

each inner side panel is joined to a one of the connecting strips by a fold line; and each inner bottom panel is joined to a one of the inner side panels by a fold line.

23. The blank of claim 22, wherein an insulator pad is attached to each of the inner side panels, and at least two of the insulator pads each comprise a beveled edge where the two insulator pads meet.

24. The blank of claim 22, wherein an insulator pad is attached to two non-adjacent inner bottom panels.

25. The blank of claim 21, further comprising a side tab joined to the inner side panel by a fold line.

26. The blank of claim 21, wherein the connecting strip comprises two sides angled towards each other in the direction of the inner side panel from the outer side panel.

27. The blank of claim 21, wherein the blank cut from one monolithic sheet.

28. The blank of claim 21, further comprising a first insulator pad attached to the inner side panel and a second insulator pad attached to the inner bottom panel.

29. The blank of claim 28, wherein the blank is single-stream recyclable.

30. The blank of claim 28, wherein the blank is repulpable.

31. A method of assembling a box from a blank, the method comprising:

obtaining a blank comprising a plurality of outer side panels, the outer side panels connected to each other by a plurality of fold lines, a plurality of outer bottom panels each joined to each of the outer side panels by a fold line, a plurality of connecting strips each joined to each of the outer side panels by a fold line, a plurality of inner side panels each joined to each of the connecting strips by a fold line, and a plurality of inner bottom panels each joined to each of the inner side panels by a fold line;

joining the outer side panels at opposite ends such that the outer side panels form a ring;

folding the outer bottom panels to form a bottom of the box, the bottom and the ring of outer side panels defining an interior of the box;

folding the inner side panels in towards the interior of the box, such that each inner side panel faces the corresponding outer side panel; and

folding the inner bottom panels to face the bottom of the box.

32. The method of claim 31, further comprising sandwiching an insulator pad between one of the outer side panels and one of the inner side panels.

33. The method of claim 31, wherein:

the blank further comprises a side tab joined by a fold line to at least one of the inner side panels, and

the method further comprises covering an adjacent inner side panel with the side tab.

34. The method of claim 31, wherein: the blank further comprises a side tab joined by a fold line to at least one of the inner side panels, and

the method further comprises covering the tab with an adjacent inner side panel.

35. A box comprising:

a side wall, the side wall comprising an outer side panel and an inner side panel and defining an insulation cavity between the outer side panel and the inner side panel, and

a bottom wall, the bottom wall comprising an outer bottom panel joined to the outer side panel by a fold line, and an inner bottom panel joined to the inner side panel by a fold line.

36. The box of claim 35, wherein the outer side panel and the inner side panel are

attached to each other at a top edge of the box.

37. The box of claim 35, further comprising a plurality of side walls, each side wall

comprising an outer side panel and an inner side panel and defining an insulation cavity between the outer side panel and the inner side panel, wherein the insulation cavities are each filled with insulator pads.

38. The box of claim 35, further comprising an insulator pad positioned in the insulation cavity.

39. The box of claim 38, wherein the box and the insulator pad are repulpable.

40. The box of claim 35, wherein the bottom wall defines an insulation cavity between the outer bottom panel and the inner bottom panel.

41. A box comprising:

a side wall comprising an inner side panel and an outer side panel; and

an insulator pad positioned at least partially between the inner side panel and the outer side panel.