Patent ID: 7597053

Claim:
A composite base rail system comprising a bottom tray with upstanding sides and one or more base rails for cushioning and supporting an object, the base rail comprising: a flat rectangular base sheet formed from a first paperboard sheet; a folded member formed from a second paperboard sheet, the folded member comprising two elongated rectangular edge panels, each edge panel defining a rectangular surface that is affixed to an opposing edge of the base sheet, two parallel, spaced apart, upwardly extending beads longitudinally disposed along the length of the folded member between the edge panels, each bead comprising a flat, load bearing top panel and inner and outer downwardly extending side panels, each side panel defining an obtuse included angle with the top panel, the folded member further comprising a central panel extending between the inner side panels adjacent the base sheet and connected to the inner side panels along fold lines; the bead inner side panels and the central panel defining three sides of a center space having a trapezoidal cross section; the two beads and the base sheet defining a pair of elongated cavities, each cavity having a trapezoidal cross section; at least one first resilient foam member interposed between the beads and having a trapezoidal cross sectional shape complementary to that of the center space such that the first resilient foam member is captured on three sides by the central panel and the two inner side panels; and at least one pair of second resilient foam members, each second resilient foam member having a trapezoidal cross sectional shape complementary to that of the longitudinal cavities such that each second resilient foam member is captured within one of the two longitudinal cavities; wherein the second resilient foam members and the first resilient foam members are substantially coextensive; and wherein the base rails are placed within the bottom tray with the base sheet adjacent the bottom tray.