Foam transportation tray

Abstract

A protective transportation tray, and method of manufacture thereof, having a top foam layer, the top layer having a top and a bottom, wherein the top layer has walls that traverse substantially from the top to the bottom of the top layer and circumnavigating a plurality of tear outs. The top layer is a foam that preferably has a density greater than 1.7 lbs/ft 3 and is affixed to a bottom plate, preferably substantially beneath the side wall of the top layer.

We claim:  
     
         1 . A protective transportation tray comprising: 
 a top layer having a top and a bottom and comprising a foam, wherein the top layer has foam walls circumnavigating a plurality of foam tear outs and traversing substantially from the top to the bottom of the top layer; and    a bottom plate, wherein the bottom plate is substantially affixed to the walls of the top layer.    
     
     
         2 . The tray of  claim 1  wherein the bottom plate has a higher rigidity than the top layer.  
     
     
         3 . The tray of  claim 1  wherein the foam has a density greater than 1.7 Lbs/CuFt.  
     
     
         4 . The tray of  claim 3  wherein the foam has a density greater than 2.0 lbs/CuFt.  
     
     
         5 . The tray of  claim 4  wherein the foam has a tensile strength greater than 20 lbs/in.  
     
     
         6 . The tray of  claim 1  wherein the tray is substantially a cuboid.  
     
     
         7 . The tray of  claim 1  wherein the bottom plate has a higher rigidity than the top layer.  
     
     
         8 . The tray of  claim 1  wherein the top layer is fabricated from one piece of foam.  
     
     
         9 . The tray of  claim 1  wherein the affixation of the top layer and bottom plate comprises a uniform affixator.  
     
     
         10 . The tray of  claim 9  wherein the uniform affixator is a spray affixator.  
     
     
         11 . A method of manufacturing a protective transportation tray, the method comprising the steps of: 
 scoring a piece of foam, wherein the foam has a top and a bottom, and wherein the step of scoring has the steps of: 
 wall scoring the foam wherein the step of wall scoring creates a wall that substantially circumnavigates the outer perimeter of the foam and substantially traversing between the top and bottom of the top layer;  
 tear-out scoring the foam wherein the tear-out scoring creates a plurality of inner tear-out pieces within the wall perimeters; and affixing the foam substantially along the bottom of the walls to a plate.  
   
     
     
         12 . The method of  claim 11  further comprising the step of selectively removing a tear-out foam piece to provide a selected void for placement of an item to be transported.  
     
     
         13 . The method of  claim 11  further comprising the step of 
 selectively removing a plurality of tear-out foam pieces to provide a plurality of a selected voids for placement of a plurality of items to be transported.  
 
     
     
         14 . The method of  claim 13  wherein the step of selectively removing a plurality of tear-out foam pieces comprises the step of removing non-contiguous tear-out foam pieces.  
     
     
         15 . A protective transportation tray comprising: 
 a top layer having a top and a bottom and comprising a foam, wherein the top layer has foam walls circumnavigating a plurality of foam tear outs; and    a bottom plate, wherein the bottom plate is affixed to the bottom of the top layer and the bottom plate has a substantially high rigidity than the top layer.    
     
     
         16 . The tray of  claim 16  wherein the bottom plate is affixed to the top layer comprising the utilization of a uniform affixator.  
     
     
         17 . The tray of  claim 16  wherein the uniform affixator is a spray affixator.  
     
     
         18 . A protective transportation tray comprising: 
 a top layer having a top and a bottom and comprising a foam, wherein the top layer has foam walls circumnavigating a plurality of foam tear outs; and    a bottom plate, wherein the bottom plate is affixed to the bottom of the top layer wherein the affixation of the bottom plate and top layer is with a uniform affixator.    
     
     
         19 . The tray of  claim 18  wherein the uniform affixator is a spray affixator.  
     
     
         20 . A protective transportation case for items comprising: 
 a plurality of stackable transportation trays, wherein the transportation tray comprises: 
 a top layer having a top and a bottom and comprising a foam, wherein the top layer has foam walls circumnavigating a plurality of foam tear outs; and  
 a bottom plate, affixed substantially at the walls of the top layer; and  
   a carrying case; wherein the plurality of stackable transportation trays are stacked one on another, and removably inserted substantially within the carrying case.    
     
     
         21 . The case of  claim 20  wherein the rigidity of the bottom plate is substantially higher than the top layer.  
     
     
         22 . The case of  claim 20  wherein the carrying case can be closed to cover all sides of the inserted stackable trays.  
     
     
         23 . The case of  22  wherein the carrying case has a closeable opening that provides clearance for removal or insertion of a stackable tray.