PACKAGING SYSTEM FOR A BICYCLE

Abstract

A packaging system for a bicycle includes a base tray, a first vertical tower coupled to the base tray, a second vertical tower coupled to the base tray, and an axle protector configured to be coupled to a wheel of the bicycle. The axle protector includes a body portion configured to cover and shield an axle of the wheel along a side of the wheel, and a tab extending from the body portion. The tab is configured to engage a spoke of the wheel to couple the axle protector to the wheel.

Claims

1. A packaging system for a bicycle, the packaging system comprising: a base tray; a first vertical tower coupled to the base tray; a second vertical tower coupled to the base tray; and an axle protector configured to be coupled to a wheel of the bicycle, the axle protector including a body portion configured to cover and shield an axle of the wheel along a side of the wheel, and a tab extending from the body portion, the tab configured to engage a spoke of the wheel to couple the axle protector to the wheel.

2. The packaging system of claim 1, wherein the tab is a T-shaped tab.

3. The packaging system of claim 1, wherein the tab includes a stem and a strip coupled to the stem, wherein a junction point between the stem and the strip defines a V-shaped recess.

4. The packaging system of claim 1, wherein the tab is one of a plurality of tabs, and wherein each of the plurality of tabs is a T-shaped tab.

5. The packaging system of claim 1, wherein the axle protector is a first axle protector disposed on a first side of the wheel, and further comprising a second axle protector disposed on a second side of the wheel opposite the first side.

6. The packaging system of claim 1, further comprising the bicycle, wherein the axle protector is coupled to a front wheel of the bicycle.

7. The packaging system of claim 6, wherein the tab is folded in at least one location.

8. An axle protector assembly for a wheel of a bicycle, the axle protector assembly comprising: a first axle protector including a first body portion configured to cover and shield an axle of the wheel along a first side of the wheel, and a first tab extending from the first body portion, the first tab configured to engage the wheel to couple the first axle protector to the wheel; and a second axle protector including a second body portion configured to cover and shield the axle of the wheel along a second, opposite side of the wheel, and a second tab extending from the second body portion, the second tab configured to engage the wheel to couple the second axle protector to the wheel.

9. The axle protector assembly of claim 8, wherein the first tab is configured to engage a first spoke of the wheel when the first axle protector is coupled to the wheel, and wherein the second tab is configured to engage a second spoke of the wheel when the second axle protector is coupled to the wheel.

10. The axle protector assembly of claim 8, wherein the first tab is T-shaped, and wherein the second tab is T-shaped.

11. The axle protector assembly of claim 8, wherein each tab includes a stem and a strip coupled to the stem, and wherein a junction point between the stem and the strip defines a V-shaped recess.

12. The axle protector assembly of claim 8, wherein the axle defines an axle axis, and wherein the axle axis is configured to extend through both the first body portion and the second body portion when the first axle protector is coupled to the wheel and the second axle protector is coupled to the wheel.

13. An axle protector for a wheel of a bicycle, the axle protector comprising: a body portion configured to cover and shield an axle of the wheel along a side of the wheel; and a tab extending from the body portion, the tab configured to engage a first spoke of the wheel and a second spoke of the wheel to couple the axle protector to the wheel, wherein the tab is T-shaped.

14. The axle protector of claim 13, wherein the body portion is oval.

15. The axle protector of claim 13, wherein the tab is a first tab, and wherein the axle protector includes a second tab extending from the body portion.

16. The axle protector of claim 15, wherein the second tab is T-shaped.

17. The axle protector of claim 13, wherein the tab includes a stem and a strip coupled to the stem, and wherein a junction point between the stem and the strip defines a V-shaped recess.

18. The axle protector of claim 13, wherein the tab includes a first recess and a second recess, and wherein the first spoke is configured to be disposed within the first recess and the second spoke is configured to be disposed within the second recess to couple the axle protector to the wheel.

19. The axle protector of claim 13, further comprising the wheel, wherein the axle protector is coupled to the wheel.

20. The axle protector of claim 19, wherein the wheel is a front wheel of the bicycle.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0003] FIG. 1 is a front view of a packaging system, the packaging system including a front axle protector assembly.

[0004] FIG. 2 is a rear view of the packaging system of FIG. 1.

[0005] FIG. 3 is an enlarged, perspective view of a portion of the packing system of FIG. 1, illustrating the front axle protector assembly.

[0006] FIG. 4 is a perspective view of the front axle protector assembly of FIG. 1, coupled to a front bicycle wheel.

[0007] FIG. 5 is an exploded view of the front axle protector assembly of FIG. 1, showing a first axle protector and a second axle protector.

[0008] FIG. 6 is a perspective view of the first axle protector coupled to the front bicycle wheel.

[0009] FIG. 7 is an enlarged view of the first axle protector of FIG. 6.

DETAILED DESCRIPTION

[0010] Before any examples are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other examples and of being practiced or of being carried out in various ways.

[0011] In one example, a packaging system for a bicycle includes a base tray, a first vertical tower coupled to the base tray, a second vertical tower coupled to the base tray, and an axle protector configured to be coupled to a wheel of the bicycle. The axle protector includes a body portion configured to cover and shield an axle of the wheel along a side of the wheel. The axle protector also includes a tab extending from the body portion. The tab is configured to engage a spoke of the wheel to couple the axle protector to the wheel.

[0012] In another example, an axle protector assembly for a wheel of a bicycle includes a first axle protector having a first body portion configured to cover and shield an axle of the wheel along a first side of the wheel, and a first tab extending from the first body portion. The first tab is configured to engage the wheel to couple the first axle protector to the wheel. The axle protector assembly also includes a second axle protector having a second body portion configured to cover and shield the axle of the wheel along a second, opposite side of the wheel, and a second tab extending from the second body portion. The second tab is configured to engage the wheel to couple the second axle protector to the wheel.

[0013] In another example, an axle protector for a wheel of a bicycle includes a body portion configured to cover and shield an axle of the wheel along a side of the wheel, and a tab extending from the body portion. The tab is configured to engage a first spoke of the wheel and a second spoke of the wheel to couple the axle protector to the wheel. The tab is T-shaped.

[0014] FIGS. 1-7 illustrate a packaging system 10 to support a bicycle during transportation (e.g., during shipment). The bicycle 14 may include, for example, a front wheel 16, a rear wheel 20, a frame 24, and/or a handlebar 28. In the illustrated example, the bicycle 14 is not fully assembled. The rear wheel 20 is assembled to the frame 24. The front wheel 16 and the handlebar 28, however, are detached from the frame 24. In other examples, the handlebar 28 and/or the front wheel 16 are assembled to the frame 24. In yet other examples, both the front wheel 16 and the rear wheel 20 are detached from the frame 24. Other examples include other arrangements of bicycle components (assembled or detached) than that illustrated.

[0015] In some examples, the packaging system 10 may support a large mountain bicycle, or other heavier type of bicycle. In other examples, the packaging system 10 may support a more light-weight road bicycle, or other type of bicycle. In additional examples, the packaging system 10 may support an electric bicycle (i.e., ebike) and/or a utility bicycle.

[0016] With reference to FIGS. 1-3, the packaging system 10 may include a base tray 32, a rear tower 36, and/or a front tower 40. The base tray 32 may be formed as a single or multi-layered base tray 32. For example, the base tray 32 may be formed by a bottom layer 42, a top layer 52, and/or an intermediate layer (not shown) disposed between the bottom layer 42 and the top layer 52. Other examples include other numbers and arrangements of layers. The base tray 32 may, for example, allow the packaging system 10 to support heavier bicycles during transportation of the packaging system 10.

[0017] In some examples, the bottom layer 42 of the base tray 32 may include panels and/or tabs to facilitate coupling the base tray 32 to the rear tower 36 and/or the front tower 40. For example, the bottom layer 42 may include a central panel (not shown), a rear tab (not shown), and/or a front tab (not shown). The rear tab may extend from the central panel at a first end 46a of the base tray 32 and the front tab may extend from the central panel at a second, opposite end 46b of the base tray 32. The bottom layer 42 may also include a first side panel 48a (FIG. 1) and a second side panel 48b (FIG. 2). The side panels 48a, 48b may extend, for example, between the rear and front tabs of the bottom layer 42. As such, the side panels 48a, 48b may interlock with the rear tower 36 and/or the front tower 40 to couple the base tray 32 to the rear tower 36 and the front tower 40. In some examples, the bottom layer 42 may be corrugated. In other examples, the bottom layer 42 may include a flute cardboard material.

[0018] With continued reference to FIGS. 1-3, the top layer 52 of the base tray 32 may include a first slot 54a and a second slot 54b spaced from the first slot 54a such that a gap is formed therebetween. The first and second slots 54a, 54b may be arranged to align, for example, with additional slots of the intermediate layer (not shown). The first slot 54a and the second slot 54b may respectively receive the rear wheel 20 and the front wheel 16, such that a bottom portion of each of the rear wheel 20 and the front wheel 16 extends into the base tray 32 to help hold the rear wheel 20 and the front wheel 16 in place during transportation of the packaging system 10.

[0019] In the illustrated example, the first slot slots 54a and the second slot 54b are offset from each other such that the rear wheel 20 and the front wheel 16 are disposed on opposite sides of the base tray 32. The top layer 52 may also include a circular recess 55 (FIG. 2) defined therein and configured to receive a portion of the handlebar 28. As such, the top layer 52 may help to hold the handlebar 28 in place during transportation.

[0020] The rear tower 36 may include a plurality of panels 56a-d (e.g., front, rear, first side, and second side panels). The panels 56a-d may be coupled to each other such that the rear tower 36 forms a box-like structure. A tower slot 60 may be defined in a front panel 56a of the plurality of panels 56a-d. The size and shape of the slot 60 may allow the rear wheel 20 to extend into the rear tower 36 such that a portion of the rear wheel 20 is disposed within an interior of the rear tower 36. As such, the tower slot 60 of the rear tower 36 and the first slot 54a of the top layer 52 may be provided as retaining features to hold the rear wheel 20 in place during transportation of the packaging system 10.

[0021] The rear tower 36 may also include a recess (not shown) defined in a rear panel 56b of the plurality of panels 56a-d. The recess may receive a portion of the rear tab of the base tray 32 to interlock the rear tower 36 with the base tray 32 at the first end 46a of the base tray 32. Additionally, the rear tower 36 may include a first slit (not shown) defined at a bottom portion of a first-side panel 56c of the plurality of panels 56a-d and a second slit (not shown) defined at a bottom portion of a second-side panel 56d of the plurality of panels 56a-d. During assembly, the first and second slits may slidably receive the base tray 32 (the bottom layer 42, the intermediate layer, and/or the top layer 52) when the rear tower 36 is interlocked with the base tray 32.

[0022] The front tower 40 may include a central panel 64, a first side panel 68, and/or a second side panel 72. Each side panel 68, 72 may extend from a respective lateral side of the central panel 64. When the front tower 40 is in a folded position, the central panel 64, the first side panel 68, and the second side panel may define a space 74 (FIG. 2) sized and shaped to accommodate the bicycle 14. In some examples, the space 74 may accommodate a portion of the front wheel 16, the frame 24, and/or the handlebar 28.

[0023] The central panel 64 may include a recess (not shown) defined therein and configured to receive a portion of the front tab of the base tray 32 to interlock the front tower with the base tray 32 at the second end 46b of the base tray 32. A first slit (not shown) may be defined at a bottom portion of the first side panel 68. A second slit (not shown) may be defined at a bottom portion of the second side panel 72. During assembly, the first and second slits may slidably receive the base tray 32 (the bottom layer 42, the intermediate layer, and/or the top layer 52) when the front tower 40 is interlocked with the base tray 32.

[0024] With reference to FIG. 3, the packaging system 10 may include an intermediate piece 78 coupled to the front tower 40. One side of the intermediate piece 78 may interlock with a front panel 80 (FIGS. 1 and 2) of the front tower 40. The intermediate piece 78 may include a slot 81 defined therein and configured to receive a top portion of the front wheel 16. As such, the slot 81 of the intermediate piece 78 and the second slot 54b of the top layer 52 may act as retaining features to hold the front wheel 16 in place during transportation of the packaging system 10.

[0025] While not illustrated, the packaging system 10 may also include an outer carton, or cover, that extends down over the bicycle 14, and at least partially covers and encloses the base tray 32, the rear tower 36, the front tower 40, the intermediate piece 78, and/or the front panel 80.

[0026] With reference to FIGS. 1 and 3-7, the packaging system 10 may include an axle protector assembly 82 (e.g., a front axle protector assembly 82) coupled to a wheel (e.g., the front wheel 16, the rear wheel 20, or any other wheel). The axle protector assembly 82 may be used in combination with any of the other packaging system 10 features described herein (e.g., the base tray 32, the rear tower 36, the front tower 40, the intermediate piece 78, etc.). In other examples, the axle protector assembly 82 may be used alone as its own packaging system without any of the other packaging system 10 features described herein, or may be used in combination with other packaging features not shown.

[0027] In the illustrated example, the axle protector assembly 82 covers and shields an axle 84 (FIG. 4) of the front wheel 16. As illustrated, the axle protector assembly 82 may include a first axle protector 86a and/or a second axle protector 86b. The first axle protector 86a may be disposed on a first side of the front wheel 16, and the second axle protector 86b may be disposed on a second, opposite side of the front wheel 16.

[0028] With reference to FIGS. 3-7, the first axle protector 86a may include a first body portion 90a and at least one tab 94a (e.g., a first plurality of tabs 94a) extending from the first body portion 90a. The second axle protector 86b may include a second body portion 90b and at least one tab 94b (e.g., a second plurality of tabs 94b) extending from the second body portion 90b. The first body portion 90a and the second body portion 90b each has an oval shape. In other examples, the first body portion 90a and/or the second body portion 90b has a different shape (e.g., triangular, square, rectangular, circular, etc.).

[0029] With continued reference to FIGS. 3-7, the first axle protector 86a may be positioned such that a center portion 96a of the first body portion 90a is placed over the axle 84 of the front wheel 16 along the first side of the front wheel 16. The second axle protector 86b may also be positioned such that a center portion 96b of the second body portion 90b is placed over the axle 84 of the front wheel 16 along the second side of front wheel 16. As such, an axle axis 95 (FIG. 3) defined by the axle 84 of the front wheel 16 may extend through the center portions 96a, 96b of each of the first body portion 90a and the second body portion 90b.

[0030] With continued reference to FIGS. 3-7, at least one of the tabs 94a, 94b may be formed, for example, as a T-shaped tab. In the illustrated example, the first axle protector 86a includes multiple (e.g., four or five) T-shaped tabs 94a, and the second axle protector 86b also includes multiple (e.g., four or five) T-shaped tabs 94b. Other examples include different numbers of tabs 94a, 94b on each of the first axle protector 86a and the second axle protector 86b (e.g., more than five tabs, or less than four tabs, etc.). In some examples, only the first axle protector 86a includes a T-shaped tab 94a. In other examples, only the second axle protector includes a T-shaped tab 94b. Additionally, other examples include different spacings of tabs 94a, 94b than that illustrated, and/or other shapes of tabs 94a, 94b than that illustrated (e.g., tabs having shapes other than T-shapes).

[0031] With continued reference to FIG. 5, each tab 94a, 94b may include a stem 98a, 98b and a strip 102a, 102b coupled to the stem 98a, 98b. The stem 98a, 98b of each tab 94a, 94b may be coupled to and may extend from a corresponding body portion 90a, 90b (e.g., perpendicularly from an edge of the first body portion 90a or the second body portion 90b). The strip 102a, 102b of each tab 94a, 94b may be integrally formed, for example, with a corresponding stem 98a, 98b, and/or may be oriented to extend perpendicularly relative to the corresponding stem 98a, 98b. In other examples, the strip 102a, 102b may extend at an oblique angle relative to its corresponding stem 98a, 98b.

[0032] As illustrated in FIG. 5, recesses 106a, 106b (e.g., V-shaped recesses 106a, 106b) may be respectively defined at junction points between each stem 98a, 98b and each strip 102a, 102b. As described further herein, these recesses 106a, 106b may be sized and shaped to receive spokes 110 on the front wheel 16, to facilitate engagement of the tabs 94a, 94b with a wheel (e.g., the front wheel 16).

[0033] With reference to FIG. 3, in some examples, a tab 94a1 from the first axle protector 86a may engage a first spoke 110a1 and a second spoke 110a2 on the front wheel 16. The first spoke 110a1 may be disposed within a first recess 106a1 of the tab 94a1 while the second spoke 110a2 may be disposed within a second recess 106a2 of the tab 94a1 to interlock the tab 94a1 with the front wheel 16.

[0034] In other examples, the tab 94a1 from the first axle protector 86a may engage only one spoke 110a1 or 110a2 of the front wheel 16, or may engage more than two spokes (e.g., if the tab 94a1 is other than T-shaped, and includes for example only a single recess or more than two recesses).

[0035] With continued reference to FIG. 3, in the illustrated example, a tab 94b1 from the second axle protector 86b may engage a third spoke 110b1 and a fourth spoke 110b2. The third spoke 110b1 may be disposed within a first recess 106b1 of the tab 94b1 while the fourth spoke 110b2 may be disposed within a second recess 106b2 of the tab 94b1 to interlock the tab 94b1 with the front wheel 16.

[0036] In other examples, the tab 94b1 from the second axle protector 86b may engage only one spoke 110b1 or 110b2 of the front wheel 16, or may engage more than two spokes (e.g., if the tab 94b1 is other than T-shaped, and includes for example only a single recess or more than two recesses).

[0037] As illustrated in FIG. 3, once assembled, at least one of the tabs 94a from the first axle protector 86a may overlap one of the tabs 94b from the second axle protector 86b (e.g., along a radial direction extending from the axle axis 95). For example, the tab 94a1 of the first axle protector 86a seen in FIG. 3 may partially overlap one or more of the tabs of the second axle protector 86b. Similarly, the tab 94b1 of the second axle protector 86b seen in FIG. 3 may partially overlap one or more of the tabs of the first axle protector 86a. The positioning and overlapping nature of the tabs 94a, 94b may depend, for example, upon the relative positioning of the various spokes 110 of the front wheel 16. In some examples, the tabs 94a of the first axle protector 86a may not overlap at all with the tabs 94b of the second axle protector 86b, or may align and overlap completely.

[0038] In some examples, and during assembly, the tabs 94a, 94b may be folded. For example, each of the tabs 94a, 94b may be folded along a junction defined between the corresponding stem 98a, 98b and the body portion 90a, 90b of the tab 94a, 94b. As seen in FIG. 3, this folding may result in the stems 98a, 98b being folded approximately 90 degrees relative to the body portions 90a, 90b, such that the stems 98a, 98b extend generally parallel to the axle axis 95, and also perpendicular to the body portions 90a, 90b.

[0039] In some examples, and during assembly, the strips 102a, 102b may also, or alternatively, be folded in one or more locations. For example, the strips 102a, 102b may be folded slightly at the recesses 106a, 106b, such that ends (e.g., wings) of the strips 102a, 102b are angled slightly relative to the stems 98a, 98b as seen in FIG. 3. Other examples include other areas of folding, or degrees of folding, along the tabs 94a, 94b than that illustrated. In yet other example, tabs 94a, 94b are not folded.

[0040] While the illustrated axle protector assembly 82 includes both a first axle protector 86a and a second axle protector 86b, other examples may include just a single axle protector, or more than two axle protectors.

[0041] Overall, assembling the axle protector assembly 82 to a wheel (e.g., the front wheel 16, the rear wheel 20, or any other wheel) may protect the wheel, and inhibit or prevent the axle of the wheel from being damaged (e.g., due to scratches, dents, etc.) during a transportation process.

[0042] Some of the examples described herein may be further described by reference to the following numbered clauses: [0043] 1. A packaging system for a bicycle, the packaging system comprising: [0044] a base tray; [0045] a first vertical tower coupled to the base tray; [0046] a second vertical tower coupled to the base tray; and [0047] an axle protector configured to be coupled to a wheel of the bicycle, the axle protector including a body portion configured to cover and shield an axle of the wheel along a side of the wheel, and a tab extending from the body portion, the tab configured to engage a spoke of the wheel to couple the axle protector to the wheel. [0048] 2. The packaging system of clause 1, wherein the tab is a T-shaped tab. [0049] 3. The packaging system of any of the preceding clauses, wherein the tab includes a stem and a strip coupled to the stem, wherein a junction point between the stem and the strip defines a V-shaped recess. [0050] 4. The packaging system of any of the preceding clauses, wherein the tab is one of a plurality of tabs, and wherein each of the plurality of tabs is a T-shaped tab. [0051] 5. The packaging system of any of the preceding clauses, wherein the axle protector is a first axle protector disposed on a first side of the wheel, and further comprising a second axle protector disposed on a second side of the wheel opposite the first side. [0052] 6. The packaging system of any of the preceding clauses, further comprising the bicycle, wherein the axle protector is coupled to a front wheel of the bicycle. [0053] 7. The packaging system of any of the preceding clauses, wherein the tab is folded in at least one location. [0054] 8. An axle protector assembly for a wheel of a bicycle, the axle protector assembly comprising: [0055] a first axle protector including a first body portion configured to cover and shield an axle of the wheel along a first side of the wheel, and a first tab extending from the first body portion, the first tab configured to engage the wheel to couple the first axle protector to the wheel; and [0056] a second axle protector including a second body portion configured to cover and shield the axle of the wheel along a second, opposite side of the wheel, and a second tab extending from the second body portion, the second tab configured to engage the wheel to couple the second axle protector to the wheel. [0057] 9. The axle protector assembly of clause 8, wherein the first tab is configured to engage a first spoke of the wheel when the first axle protector is coupled to the wheel, and wherein the second tab is configured to engage a second spoke of the wheel when the second axle protector is coupled to the wheel. [0058] 10. The axle protector assembly of clause 8 or clause 9, wherein the first tab is T-shaped, and wherein the second tab is T-shaped. [0059] 11. The axle protector assembly of any of clauses 8-10, wherein each tab includes a stem and a strip coupled to the stem, and wherein a junction point between the stem and the strip defines a V-shaped recess. [0060] 12. The axle protector assembly of any of clauses 8-11, wherein the axle defines an axle axis, and wherein the axle axis is configured to extend through both the first body portion and the second body portion when the first axle protector is coupled to the wheel and the second axle protector is coupled to the wheel. [0061] 13. An axle protector for a wheel of a bicycle, the axle protector comprising: [0062] a body portion configured to cover and shield an axle of the wheel along a side of the wheel; and [0063] a tab extending from the body portion, the tab configured to engage a first spoke of the wheel and a second spoke of the wheel to couple the axle protector to the wheel, [0064] wherein the tab is T-shaped. [0065] 14. The axle protector of clause 13, wherein the body portion is oval. [0066] 15. The axle protector of clause 13 or clause 14, wherein the tab is a first tab, and wherein the axle protector includes a second tab extending from the body portion. [0067] 16. The axle protector of any of clauses 13-15, wherein the second tab is T-shaped. [0068] 17. The axle protector of any of clauses 13-16, wherein the tab includes a stem and a strip coupled to the stem, and wherein a junction point between the stem and the strip defines a V-shaped recess. [0069] 18. The axle protector of any of clauses 13-17, wherein the tab includes a first recess and a second recess, and wherein the first spoke is configured to be disposed within the first recess and the second spoke is configured to be disposed within the second recess to couple the axle protector to the wheel. [0070] 19. The axle protector of any of clauses 13-18, further comprising the wheel, wherein the axle protector is coupled to the wheel. [0071] 20. The axle protector of clause 19, wherein the wheel is a front wheel of the bicycle.

[0072] Various features and advantages of the disclosure are set forth in the following claims.