Insulated box

Abstract

A method for assembling an insulated box assembly includes positioning an inner corrugated portion and an insulated layer between a plurality of side portions of an outer corrugated portion, the inner corrugated portion including a plurality of side panels hingedly coupled together, the insulated layer extending around the plurality of side panels, the insulated layer coupled to the inner corrugated portion, the insulated layer positioned between the inner corrugated portion and the outer corrugated portion, the insulated layer including at least one insulation batt, the plurality of side panels defining a top end and a bottom end of the inner corrugated portion, a bottom panel being positioned at the bottom end below the insulated layer, the plurality of side panels and the bottom panel at least partially defining a cavity, an opening to the cavity being defined at the top end, and enclosing the cavity with a top.

That which is claimed is: 
     
         1 . A method for assembling an insulated box assembly, the method comprising:
 positioning an inner corrugated portion and an insulated layer between a plurality of side portions of an outer corrugated portion, the inner corrugated portion comprising a plurality of side panels hingedly coupled together, the insulated layer extending around the plurality of side panels, the insulated layer coupled to the inner corrugated portion, the insulated layer positioned between the inner corrugated portion and the outer corrugated portion, the insulated layer comprising at least one insulation batt, the plurality of side panels defining a top end and a bottom end of the inner corrugated portion, a bottom panel being positioned at the bottom end below the insulated layer, the plurality of side panels and the bottom panel at least partially defining a cavity, the cavity being insulated by the insulated layer, an opening to the cavity being defined at the top end, and   enclosing the cavity with a top.   
     
     
         2 . The method of  claim 1 , wherein enclosing the cavity with a top comprises:
 positioning the top between the plurality of side portions; and   covering the opening with the top.   
     
     
         3 . The method of  claim 1 , wherein the top comprises a corrugated panel. 
     
     
         4 . The method of  claim 1 , wherein the top comprises a top insulation batt. 
     
     
         5 . The method of  claim 4 , wherein the top further comprises a corrugated panel coupled to the top insulation batt. 
     
     
         6 . The method of  claim 1 , wherein enclosing the cavity with a top comprises positioning the top between the plurality of side panels. 
     
     
         7 . The method of  claim 1 , wherein outer corrugated portion extends around the bottom panel and at least one side panel of the plurality of side panels. 
     
     
         8 . The method of  claim 1 , wherein:
 a portion of the outer corrugated portion is hingedly connected to the plurality of side portions; and   the bottom panel is position between the plurality of side portions and above the portion.   
     
     
         9 . The method of  claim 8 , wherein the bottom panel is positioned in facing contact with the portion. 
     
     
         10 . The method of  claim 1 , wherein:
 the plurality of side panels comprises a first side panel, a second side panel, a third side panel, and a fourth side panel; and   the insulated layer extends around the first side panel, the second side panel, the third side panel, and the fourth side panel.   
     
     
         11 . The method of  claim 10 , further comprising:
 folding the second side panel about a first fold line to position the second side panel substantially perpendicular to the first side panel;   folding the third side panel about a second fold line to position the third side panel substantially perpendicular to the second side panel; and   folding the fourth side panel about a third fold line to position the fourth side panel substantially perpendicular to the third side panel.   
     
     
         12 . The method of  claim 1 , wherein the at least one insulation batt comprises an insulation material extending continuously from a first end of the at least one insulation batt to a second end of the at least one insulation batt. 
     
     
         13 . The method of  claim 1 , wherein the inner corrugated layer comprises cardboard. 
     
     
         14 . The method of  claim 1 , wherein the insulation layer is repulpable. 
     
     
         15 . The method of  claim 1 , wherein the at least one insulation batt is adhesively coupled to the inner corrugated portion.