US 12,084,264 B2
Packaging system for a bicycle
Thomas S. Cooper, Gilroy, CA (US)
Assigned to Specialized Bicycle Components, Inc., Morgan Hill, CA (US)
Filed by Specialized Bicycle Components, Inc., Morgan Hill, CA (US)
Filed on Oct. 28, 2022, as Appl. No. 17/976,334.
Prior Publication US 2024/0140689 A1, May 2, 2024
Int. Cl. B65D 85/68 (2006.01); B65B 5/02 (2006.01); B65B 5/04 (2006.01); B65D 5/32 (2006.01); B65D 5/50 (2006.01)
CPC B65D 85/68 (2013.01) [B65B 5/028 (2013.01); B65B 5/04 (2013.01); B65D 5/321 (2013.01); B65D 5/5038 (2013.01); B65D 2585/6862 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A packaging system for a bicycle, the packaging system comprising:
a base tray including
a central panel;
a first tab extending away from a first longitudinal end of the central panel in a first direction,
a second tab extending away from a second longitudinal end of the central panel along a second direction that is opposite to the first direction,
a first side extending between the first tab and the second tab, and
a second side extending between the first tab and the second tab and located opposite the first side, the first side and the second side defining a length of the base tray;
a first vertical tower having a first aperture configured to receive the first tab of the base tray to interlock the first vertical tower to the base tray at the first end;
a second vertical tower having a second aperture configured to receive the second tab of the base tray to interlock the second vertical tower to the base tray at the second end; and
an outer carton configured to surround and interlock with the base tray, the first vertical tower, and the second vertical tower.
 
10. A base tray configured to be coupled to a first vertical tower and a second vertical tower, wherein the base tray, the first vertical tower, and the second vertical tower are configured to be surrounded by an outer carton to form a packaging system for a bicycle, the base tray comprising:
a bottom layer having a central panel, a first side panel formed on a first side of the central panel, and a second side panel formed on a second side of the central panel of the bottom layer and located opposite the first side panel;
a top layer having a central panel, a third side panel formed on a first side of the central panel, and a fourth side panel formed on a second side of the central panel of the top layer; and
an intermediate layer disposed between the top layer and the bottom layer such that the bottom layer is positioned underneath the intermediate layer and the top layer.
 
16. A method of assembling a packaging system for a bicycle, the packaging system including a base tray having a first tab defining a first end and a second tab located opposite the first end and defining a second end, a first vertical tower, a second vertical tower, a third vertical tower, and an outer carton configured to slide over each of the base tray, the first vertical tower, the second vertical tower, and the third vertical tower, the method comprising:
inserting the first tab of the base tray into a first aperture formed within the first vertical tower to interlock the first vertical tower to the base tray at the first end;
positioning the bicycle onto the base tray such that the base tray is disposed underneath the bicycle and the first vertical tower partially surrounds a rear wheel of the bicycle;
interlocking the third vertical tower with the first vertical tower as the third vertical tower engages a frame of the bicycle;
inserting the second tab of the base tray into a second aperture formed within the second vertical tower to interlock the second vertical tower to the base tray at the second end such that the second vertical tower partially surrounds a front wheel of the bicycle; and
sliding the outer carton over the base tray, the first vertical tower, the second vertical tower, and the third vertical tower.