Packaging system for a bicycle

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.

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.

A packaging system for a bicycle, the packaging system comprising:

• a base tray including
• a first tab defining a first end,
• a second tab located opposite the first tab and defining a second end,
• 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;
• wherein the first vertical tower includes multiple slits formed at a bottom portion of the first vertical tower, wherein the slits are configured to be slidably received by the base tray at the first end of the base tray.