Abstract: A method for preparing a foam-layered packaging material, which method includes the steps of providing an outer shell having a bottom wall and upwardly extending side walls defining an interior space and having an open top; pouring onto the bottom wall of the outer shell a predetermined quantity of a mixture of polyurethane foam-forming reactants; covering the open top of the outer shell with an inner protecting and cushioning layer so as to define a confined space within outer shell; and allowing the mixture of polyurethane foam-forming reactants to foam and completely fill the confined space with polyurethane foam while at the same time forming a direct bond between the foam and the inner cushioning layer over substantially the entire surface of the inner cushioning layer facing the confined space; wherein the predetermined quantity of the polyurethane foam-forming reactants is an amount effective to substantially completely fill the confined space with polyurethane foam and bond the foam with substantially