US3602423A - Mailbox and method of fabricating same - Google Patents

Mailbox and method of fabricating same Download PDF

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Publication number
US3602423A
US3602423A US787973A US3602423DA US3602423A US 3602423 A US3602423 A US 3602423A US 787973 A US787973 A US 787973A US 3602423D A US3602423D A US 3602423DA US 3602423 A US3602423 A US 3602423A
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Prior art keywords
lid
receptacle
mailbox
rib
panel
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US787973A
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Gregory O Corkery
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EVANS Manufacturing CO JACKES
JACKES-EVANS Manufacturing Co
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EVANS Manufacturing CO JACKES
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    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47GHOUSEHOLD OR TABLE EQUIPMENT
    • A47G29/00Supports, holders, or containers for household use, not provided for in groups A47G1/00-A47G27/00 or A47G33/00 
    • A47G29/12Mail or newspaper receptacles, e.g. letter-boxes; Openings in doors or the like for delivering mail or newspapers

Definitions

  • a novel ribbing design on the lid permits it to be formed by molding with minimum material required and assures good torsional rigidity, assuring good weatherproof qualities.
  • a novel hinge construction improves operability and assembly while improved sealing against the elements is obtained.
  • a drop flag is located where it is not visible unless moved to the signalling position.
  • This invention relates .to mailboxes in general and, more specifically, is directed to a new and improved mailbox design of simplified construction having improved features not found curbside for delivery, similar to rural delivery.
  • Some conventional rural mailboxes are suitable from the standpoint of weathertightness, however, are not completely acceptable from the consumer's viewpoint and, therefore, a need has existed for a mailbox which is weathertightand has acceptable aesthetic qualities,
  • the mailbox must have a durability somewhat greater than the conventional mailbox design because its locationmade it more susceptible to abusive treatment.
  • the mailbox hadto have good'corrosion'resistance qualities and-an attractive appearance which would satisfy the sophisticated tastes of the suburban community.
  • the present invention relates to a new and improved mailbox of the vertical or horizontal type which fulfills the-need outlined above and is suitable for house or curbside mounting.
  • the mailbox design incorporates novel features includinga composite metal and plastic construction enhancing its durability, corrosion resistance and appearance.
  • a novel hinge construction permits conventional forming techniques to be utilized in forming the components of the receptacle portion of the mailbox, while injection-molding techniques are used to form the cover or lid.
  • the novel hinge design also permits rapid assembly of the two components with sealing coopera-' tion between the rear of the lid and the body of the box assured to provide weatherproof qualities heretofore not obtainable with mailboxes of comparable design at a competitive cost.
  • a uniquely mounted signal means is provided which, when not in use, is stored beneath the bottom of the box virtually hidden from view.
  • FIG. 1 is a front elevational view of a horizontal mailbox design
  • FIG. 2 is a top plan view of the mailbox shown in FIG. 1;
  • FIG. 3 is an end elevational view of the mailbox shown in FIGS. 1 and 2;
  • FIG. 4 is a rear elevational view of the mailbox shown in FIGS. 1-3;
  • FIG. 5 is a bottom plan view of the mailbox shown in FIGS. 1-4;
  • FIG. 6 is an enlarged cross-sectional view taken generally along the line 66 of FIG. 5 and illustrating the drop flag mounting;
  • FIG. 7 is an enlarged rear elevational view of the hinge construction joining the lid to the box
  • FIG. 8 is a cross-sectional view taken generally along the line 8-8 of FIG. 2 and illustrating the weatherproof seal at the rear of the lid;
  • FIG; 9 is a front elevational view of the aesthetic mailbox of the ever-present invention. 7
  • FIG. l0 is a'rear elevational view of the mailbox shown in FIG. 9;
  • FIG. 11 is a side elevational view ofthe mailbox shown in FIGS. 9-and 10;
  • FIG. 12 is a bottom plan view of the mailbox shown in FIGS.
  • FIG. l3' is a top plan view of the mailbox shown in FIGS. 9-12; 1
  • FIG. 14 is an enlarged cross-sectional view taken generally along the line l4- 14 of FIG. 10 to illustrate the weatherproof seal
  • FIG. 15 is a view similar to FIG. 14 with the lid open;
  • FIG. 16 is a rear elevational view of the lid to show the ribbing to provide torsional rigidity
  • FIG. 17 is a cross-sectional view taken generally along the line 17-17 of FIG. 16 and illustrating the structural ribs in elevation;
  • FIG. 18 is a fragmentary cross-sectional view taken generally along the line 18-18'of FIG. 12 and illustrating the flag mounting with phantom lines showing it in the extended or signalling position.
  • a mailbox is indicated generally at 10 and includes a receptacle or mail receiving portion 11 and lid 12.
  • the receptacle 11 may be formed of sheet metal and includes a front panel 13, back panel 14 and end panels 15 and l6joining the front and back panels 13 and 14 to form a boxlike structure.
  • a bottom panel 17 extends angularly upward toward the rear panel as shown in dotted lines in FIG. 3 and closes off the bottom of the box.
  • the back panel may be provided with raised bosses 20 and 21 at opposite ends to provide for proper spacing relative to the mounting surface.
  • Apertured bosses 22, 23, 24 and 25 are formed centrally of the back panel 14 to assist in spacing and permit fastening to the mounting surface (not shown).
  • the bottom panel 17 is formed integral with the front panel 13 and joined to the rear panel 14 by rivets 26, 27 and 28.
  • the back panel 14 and end panels 15 and 16 are integral, being joined to the front panel 13 by conventional folded joints 30 and 31.
  • the upper margin of the back panel 14 is bent angularly inward as at 32 and then is reversely bent outward, as shown at 33, to form a longitudinal rib 33.
  • the rib 33 extends continuously from one end panel 15 to the opposite end panel 16.
  • Each of the end panels is provided with upwardly projecting arcuate portions 35 and 36, each of which is apertured to form a socket for mounting the lid 12. This will be described i5 greater detail below.
  • the lid 12 is formed of molded plastic and includes a top panel 40 which slopes downwardly to angularly intersect the front panel 41; End panels 42 and 43 extend downwardly in overlapping relation to the respective end-panels 15 and 16 on the receptacle 11 when the lid 12 is in the closed position. As is evident in the bottom'plan vie of FIG. 5, the end panels 42 and 43 are in closely spaced relation to the corresponding panels on the receptacle 11 to provide good weather tightness. In actual practice, the spacing is somewhat less than that indicated in FIG. 5, however, is exaggerated for clarity.
  • a raised bead 44 defines the margins of the front panel 41 and, as shown in FIG. 1, frames an area which may be decorated with a simulated wood grain design.
  • An ornament of any desired type which is shown in phantom at 45 may be used to further embellish the ornamental appearance.
  • a raised bead 46 extends around the sides and rear edge of the top panel 40 to provide good rigidity and acts as a barrier to prevent water from flowing over the rear edge of the top panel 40.
  • the raised beads 44 and 46 add rigidity to the lid or cover 12 while permitting the quantity of plastic to be reduced in the central area.
  • the lid 12 may be molded as an integral unit, requiring only the addition of suitable ornamentation before it is assembled.
  • bosses 50 and 51 which form hinge knuckles.
  • a longitudinal rib 52 extendsbetween the bosses 50 and 51, being axially coextensive with the circumferential surfaces thereof.
  • the boss 50 is provided with a radially projecting lug having a shoulder 53 which is adapted for engagement with the fixed rib 33 on the receptacle 1 1 to control the degree of opening of the lid 12.
  • the boss 51 is provided with an identical form of shoulder.
  • the cylindrical boss 50 is located in axially spaced relation to the end panel 42 of the lid 12 which forms a hinge knuckle. This forms a mounting area 54 to receive the socket forming portion 35 on the end panel 15.
  • a hinge pin 55 is press-fitted into apertures 56 and 57 formed in the end wall 42 and cylindrical boss 50, respectively, and mounts the lid 12 for hinged movement.
  • the fixed 'rib 33 projects radially inward toward the axis about which the lid pivots.
  • the angular rib 52 formed on the lid 40 is positioned in closely spaced relation to the rib 33 and is located on a segment of a circle coaxial with the axis of hinge movement.
  • the longitudinal rib 33 and arcuate rib 52 cooperate to form a weather seal at the rear of the mailbox 10.
  • the back panel 14 is mounted against a flat surface such as a post, wall of a residence or the like.
  • the raised bead 46 at the rear of the top panel and forward slope of the panel 40 act to shed any moisture which may be deposited on the panel 40 from the front side.
  • the all-plastic construction assures that the mailbox will not be corroded by moisture which is deposited on the lid and does not completely run off.
  • the metal used in the receptacle 11 is galvanized and provided with a protective coating of paint or the like. Since it is normally positioned vertically, the likelihood of corrosion is diminished.
  • a signal flag 60 is formed of metal having marginal flanges 61, 62, 63 and 64 to provide rigidity.
  • the side flanges 61 and 63 also form sockets for hinge mounting of the flag beneath the mailbox.
  • a pair of angle brackets 65 and 66 are joined to the bottom panel 17 by means of rivets 67 and 68.
  • the angle brackets are held against rotation about the rivets 67 and 68 by means of dimples or raised portions 70 and 71, 72 and 73, respectively, which are formed in the bottom wall 17 for engagement with opposite side margins of the angle brackets.
  • the upstanding side flanges 61 and 63 at opposite ends of the flag 60 are provided with an elongated aperture of the type shown in elevation at 74 in the flange 61 in FIG. 6.
  • a rivet 75 extends through the angle bracket 65 and joins the flag to the angle bracket for sliding and pivoting movement.
  • a similar rivet 76 cooperates with upstanding flange 63 in a similar manner.
  • the flange 62 is grasped and the entire flag is moved forward until the rivet 75 engages the arcuate end of the elongated opening 74. At this point, the flag is free to pivot to the dropped or vertical position shown in phantom lines in FIG. 6. As can be appreciated, the flag is now exposed in front elevation whereby the postman will be alerted to pick up outgoing mail, as the flag 60 serves the same function as a flag on the conventional rural mailbox.
  • the mailbox 110 consists of a receptacle 111 which may be formed of sheet metal and lid 1 12 formed of molded plastic.
  • the receptacle 111 includes a front panel 113, back panel 114 and end panels 115 and 116 joining the front and back panels 113 and 114, respectively. As seen in FIGS. 12 and 18, a bottom panel 117 extends angularly upward toward the rear panel 114 to form a shallow recess to accommodate a signal flag shown generally at 118 and which will be described in detail hereinafter.
  • the back panel may be pro vided with raised bosses 120 and 121 to serve as spacing means for use in mounting the mailbox 110 against a flat sur face.
  • Apertured bosses 122, 123, 124 and 125 are formed above the bosses 120 and 121 and include apertures to accommodate suitable mounting fasteners such as bolts, screws or the like.
  • the bottom panel 117 is formed integral with the front panel 113 and includes a terminating flange 119 which permits attachment to the back panel 114 by means of a rivet 119' (FIG. 10).
  • the back panel 114 and end panels 115 and 116 are formed integral and are joined to the front panel 113 by folded sheet metal joints and 131 of conventional design.
  • the receptacle 111 of the mailbox may be formed of sheet metal material with suitable corrosion inhibitors applied such as galvanizing and painting. It is contemplated that the receptacle could be formed of molded plastic as an alternative.
  • the upper margin of the back panel 114 is formed with an angularly inwardly folded extension of shoulder 132 which is upwardly bent as at 133 to form a longitudinally extending rib which is best seen in FIG. 10.
  • the rib 133 is provided with cutaway portions 128 and 129 at opposite ends adjacent the respective end panels for reasons to become apparent.
  • the lid 112 includes a top panel which intersects a front panel 141. If desired, the front panel maybe provided with a suitable applique such as the simulated wood grain finish shown. This may be provided with suitable ornamentation of any desired type, such as the fleunde-lis shown in phantom (FIG. 1).
  • the lid 112 includes end panels 142 and 143 which are disposed in overlapping relation to the respective end panels 115 and 116.
  • the clearance between the end panels 1 15 and 1 16 on the receptacle and the end panels 142 and 143 on the lid 112 is slightly exaggerated for clarity, however, in actual practice the end panels 142 and 143 are very closely spaced, e.g., in the range of about one to two times the thickness of the material of which the receptacle 114 is formed to provide for a good weather seal along the margins. Since the top is formed of plastic, sticking or binding against the side wall will not be a problem if contact should occur.
  • the front panel 145 is provided with a raised bead 146 around its margin which adds rigidity and serves to frame and highlight the ornamentation.
  • a similarly shaped bead 146 extends around the sides and rear edge of the top panel 140 as shown in FIG. 13.
  • the raised. bead 146 provides additional rigidity in the top panel and also forms a dam or barrier to prevent water from flowing over the rear edge.
  • the lid 112 is provided with good overall rigidity which permits the thickness of the plastic material forming the lid to be maintained at a minimum. As will become apparent when FIGS. 16 and 17 are specifically described, this reduces the material requirements with the obvious effect on manufacturing costs.
  • cylindrical bosses 150 and 151 which are located slightly inwardly spaced from the end panels 142 and 143 on the lid 112. As shown in FIG. 14, the raised bead 146 is solid when viewed in cross section, having a flat surface 152 on its underside which extends between the bosses 150 and 151.
  • the surface 152 is closely spaced from the upstanding longitudinal rib 133 on the back panel 114 toform a labyrinthtype weather seal.
  • the overhang provided by the rib 133 being located inwardly of the rear margin of the lid 112, combined with the close spacing, serves to prevent the entry of the elements into the receptacle 111 when the lid is in the closed position.
  • the surface 152 on the underside of the bead engages the upstanding longitudinal rib 133 forming a stop to limit the degree of opening.
  • the shape of the cooperating parts forming this seal prevent any water which may collect on the lid from flowing into the receptacle 11 1 when the lid is in this position.
  • the flag or signal means 118 is illustrated in cross section in FIG. 18 and in bottom plan in FIG. 12. Structurally speaking, the flag is identical to the flag shown in FIGS. 5 and 6, being provided with identical elongated slots 160 (only one shown) on opposite ends of the flag 118; Suitablerivets 161 and 162 (FIG. 12) mount the flag for sliding and angular movement between the hidden positions shown in FIG. 18 in solid lines to the signalling position shown at 163 in phantom lines in FIG. 18. As expected, the flag must be moved forward until the rivets 161 and 162 engage the rear portion of the slot and then the flag is free to pivot to the position shown in phantom lines.
  • a novel bracing arrangement is molded integrally with the lid 112 to provide good torsional rigidity. Due to its overall length, rigidity of the lid is required to obtain good weatherproof qualities and proper functioning of the hinges. As can be appreciated, torsional rigidity can be provided'by simply increasing the overall thickness of the lid, which is disadvantageous because of the increase in material and cost. In the present design, the material thickness has been maintained at a minimum with torsional rigidity assured through a novel ribbing arrangement.
  • the ribbing is provided in the form of X-braces 170 and 171 of identical elevational shape which are molded integral with the lid 112.
  • the rib 170 isuniquely shaped, contrary to what would logically be expected, being thickened at its ends as at 172 and 173 while being relatively thin at the center portion of the panel where the rib 171 intersects, which is of identical shape.
  • the material thickness for the lid 112 may be maintained at a minimum without a loss of torsional rigidity which is required for smooth functioning and a proper fit of the lid with the receptacle 111.
  • the plastic ornamentation 145 is joined to the lid 112 by the heat staking on the backside such as that shown at 174, 175 and 176.
  • the heat staking on the backside such as that shown at 174, 175 and 176.
  • other forms of fastening techniques may be used, depending upon the ornamentation and materials.
  • the mailbox designs of the present invention provide advantages not available with constructions shown in the prior art.
  • the present hinge construction assures smooth functioning of the lid under all types of weather conditions.
  • the mailbox of the present invention provides improved weatherproof qualities while not requiring special expensive sealing or close tolerances.
  • mass production techniques may be used with the expected economic saving.
  • the present mailboxes also incorporate a unique signal feature which heretofore was reserved for rural-type mailboxes. This permits the present mailboxes to have use in suburban delivery locations as well as city residential areas, providing greater versatility.
  • a weather seal formed at the rear edge of said lid and top edge of said receptacle, said weather seal including a continuous longitudinal rib extending toward said axis and a longitudinal rib formed on said lid and being disposed in closely adjacent and noncontacting relation to said longitudinal rib on said receptacle, said rib on said lid being movable in a path about said axis while remaining closely spaced in noncontacting relation to said rib on said receptacle to form a weatherproof barrier, said longitudinal rib on said receptacle being located in a plane intersecting said axis, and said longitudinal rib on said lid being arcuately shaped and extending rearwardly of said receptacle rib for movement along a circular path around said axis to maintain it in spaced, closely adjacent and noncontacting relation with said rib.
  • said hinge means including cylindrical bosses formed integral with said lid and being located inwardly of the'ends thereof, each of said cylindrical bosses being disposed in spaced relation to side panels formed at opposite sides of said lid, an aperture extending through each of said side panels and an aperture formed in each of said cylindrical bosses, each of said apertures being formed coaxially with said axis, and apertures formed in opposite end walls of said receptacle, said apertured end walls being adapted for disposition between said cylindrical boss and said side panels, and a hinge pin press-fitted into each of said cylindrical bosses and sidepanels on said lid and extending through said aperture on said end of said receptacle for mounting said lid for hinge movement.
  • a mailbox having a receptacle portion and a lid portion joined together at their top and rear edges, respectively, for articulated movement and wherein said receptacle portion of said mailbox is vertically elongated
  • said lid being formed of molded plastic material and including intersecting brace means formed integral on the reverse side of said lid, said brace means extending generally from side to side and being of increased thickness at the end portions relative to the lid portions.
  • a mailbox of the type having a boxlike portion adapted to serve as a receptacle for mail and a lid to protect the contents of said receptacle from the weather
  • said receptacle including a vertical back panel, a front panel and end panels joining said front and back panels and a bottom panel joining said front and back and end panels, said bottom panel sloping downward from said back panels to form a recessed area beneath said bottom panel, and flag means mounted in said recess and being adapted for manual release for downward extension to serve as a signal means, said flag means being provided with a pair of elongated slots, fastener means extending through said slots and attaching said flag means to said end panels closely adjacent said bottom panel.
  • a mailbox of the type having a boxlike portion adapted to serve as a receptacle for mail and a lid to protect the contents of said receptacle from the weather
  • said receptacle including a vertical back panel, a front panel and end panels joining said front and back panels and a bottom panel joining front panel on said receptacle, a sealing rib extending along the rear margin of said lid and a cooperating sealing rib on said receptacledisposed in opposition to said sealing rib on said lid, and hinge means at opposite ends of said mailbox to mount said lid for swinging movement relative to said receptacle while maintaining the sealing rib on said receptacle and sealing rib on said lid in closely spaced relation.

Abstract

A mailbox formed of composite materials to improve corrosion resistance, structural rigidity, ease of assembly and operability. A novel ribbing design on the lid permits it to be formed by molding with minimum material required and assures good torsional rigidity, assuring good weatherproof qualities. A novel hinge construction improves operability and assembly while improved sealing against the elements is obtained. A drop flag is located where it is not visible unless moved to the signalling position.

Description

United I States Patent Inventor St. Louis, Mo.
Appl. No. 787,973
Filed Dec. 30, 1968 Patented Aug. 31, 1971 Assignee Jacks-Evans Manufacturing Company St. Louis, Mo.
MAILBOX AND METHOD OF FABRICATING SAME 6 Claims, 18 Drawing Figs.
u.s. c1 232/17, 232/34 1m. 01 A473 29/12 Field ofSearch 232/17, 19, 45,44, 38,46,47; 16/191, 135
Referenm Cited UNITED STATES PATENTS 429,922 6/1890 Johnston .L 232/45 729,110 5/1903 Young 232/34 Saltonstall t. 232/38 2,500,829 3/1950 Jacobson 16/191 2,573,691 12/1951 Gieseler 232/17 2,578,693 12/1951 Gieseler 232/19 2,613,031 10/1952 Joyce 232/35 2,641,018 6/1953 Snyder 16/191 2,873,062 2/1959 Corne11.... 232/17 3,054,643 9/1962 Militano" 297/D1G. 2 3,173,723 3/1965 l-loren 297/1310. 2
Primary Examiner-Francis K. Zugel Attorney-Robert E. Wagner ABSTRACT: A mailbox formed of composite materials to improve corrosion resistance, structural rigidity, ease of assembly and operability. A novel ribbing design on the lid permits it to be formed by molding with minimum material required and assures good torsional rigidity, assuring good weatherproof qualities. A novel hinge construction improves operability and assembly while improved sealing against the elements is obtained. A drop flag is located where it is not visible unless moved to the signalling position.
'MAiusox AND METHOD or FABRICATING SAME .This invention relates .to mailboxes in general and, more specifically, is directed to a new and improved mailbox design of simplified construction having improved features not found curbside for delivery, similar to rural delivery. Some conventional rural mailboxes are suitable from the standpoint of weathertightness, however, are not completely acceptable from the consumer's viewpoint and, therefore, a need has existed for a mailbox which is weathertightand has acceptable aesthetic qualities, The mailbox must have a durability somewhat greater than the conventional mailbox design because its locationmade it more susceptible to abusive treatment. In addition, the mailbox hadto have good'corrosion'resistance qualities and-an attractive appearance which would satisfy the sophisticated tastes of the suburban community. Not of any lesser importance than the-foregoing features, such mailboxis required'to be manufacturedat a cost-which would put it in the economic reach otIa-broad spectrum of potential consumers. In conventional rural mailboxes, some form of signal means is included which alerts the postman to the need for pickups as well as deliveries. This feature was also to be incorporated in the proposed design without detracting from the asthetic appearance, with the ever present cost considerations in mind.
The present invention relates to a new and improved mailbox of the vertical or horizontal type which fulfills the-need outlined above and is suitable for house or curbside mounting. The mailbox design incorporates novel features includinga composite metal and plastic construction enhancing its durability, corrosion resistance and appearance. A novel hinge construction permits conventional forming techniques to be utilized in forming the components of the receptacle portion of the mailbox, while injection-molding techniques are used to form the cover or lid. The novel hinge design also permits rapid assembly of the two components with sealing coopera-' tion between the rear of the lid and the body of the box assured to provide weatherproof qualities heretofore not obtainable with mailboxes of comparable design at a competitive cost. A uniquely mounted signal means is provided which, when not in use, is stored beneath the bottom of the box virtually hidden from view. Additional features contributing to the improved appearance and structural qualities of the design are found in the unique construction of the lid of the vertical mailbox. Torsional rigidity of the lid is assured by a unique bracing arrangement which can be integrally molded with the lid. Because of the novel lid design, good structural overall rigidity is provided as well as onewhich presents an attractive appearance.
It is an object of the present invention to provide a new and improved mailbox of composite construction having improve weatherproof qualities.
It is a further object of this invention to provide a new and improved mailbox construction having a unique hinge design permitting rapid assembly of the components forming the mailbox.
It is a still further object of this invention to provide a new and improved mailbox construction having a uniquely mounted and easily operable signal means.
3 It is further object of this invention to provide a new and improved mailbox construction having a uniquely braced lid which provides for torsional rigidity and good strength.
Other features and advantagesnot specifically se forth in the above objectives will become apparent upon consideration of the accompanying drawings and following description.
. 2 IN THE DRAWINGS I FIG. 1 is a front elevational view of a horizontal mailbox design; Y
FIG. 2 is a top plan view of the mailbox shown in FIG. 1; FIG. 3 is an end elevational view of the mailbox shown in FIGS. 1 and 2;
FIG. 4 is a rear elevational view of the mailbox shown in FIGS. 1-3;
FIG. 5 is a bottom plan view of the mailbox shown in FIGS. 1-4;
FIG. 6 is an enlarged cross-sectional view taken generally along the line 66 of FIG. 5 and illustrating the drop flag mounting;
FIG. 7 is an enlarged rear elevational view of the hinge construction joining the lid to the box;
FIG. 8 is a cross-sectional view taken generally along the line 8-8 of FIG. 2 and illustrating the weatherproof seal at the rear of the lid;
FIG; 9 is a front elevational view of the aesthetic mailbox of the ever-present invention; 7
FIG. l0is a'rear elevational view of the mailbox shown in FIG. 9;
FIG. 11 is a side elevational view ofthe mailbox shown in FIGS. 9-and 10;
FIG. 12 is a bottom plan view of the mailbox shown in FIGS.
FIG. l3'is a top plan view of the mailbox shown in FIGS. 9-12; 1
FIG. 14 is an enlarged cross-sectional view taken generally along the line l4- 14 of FIG. 10 to illustrate the weatherproof seal;
FIG. 15 is a view similar to FIG. 14 with the lid open;
FIG. 16 is a rear elevational view of the lid to show the ribbing to provide torsional rigidity;
FIG. 17 is a cross-sectional view taken generally along the line 17-17 of FIG. 16 and illustrating the structural ribs in elevation; and
FIG. 18 is a fragmentary cross-sectional view taken generally along the line 18-18'of FIG. 12 and illustrating the flag mounting with phantom lines showing it in the extended or signalling position.
Referring now to FIG. 1, a mailbox is indicated generally at 10 and includes a receptacle or mail receiving portion 11 and lid 12. As seen in FIGS. 1 5, the receptacle 11 may be formed of sheet metal and includes a front panel 13, back panel 14 and end panels 15 and l6joining the front and back panels 13 and 14 to form a boxlike structure. A bottom panel 17 extends angularly upward toward the rear panel as shown in dotted lines in FIG. 3 and closes off the bottom of the box.
As seen in FIGS. 2, 4 and 5, the back panel may be provided with raised bosses 20 and 21 at opposite ends to provide for proper spacing relative to the mounting surface. Apertured bosses 22, 23, 24 and 25 are formed centrally of the back panel 14 to assist in spacing and permit fastening to the mounting surface (not shown). The bottom panel 17 is formed integral with the front panel 13 and joined to the rear panel 14 by rivets 26, 27 and 28. The back panel 14 and end panels 15 and 16 are integral, being joined to the front panel 13 by conventional folded joints 30 and 31.
' As seen in FIGS. 4 and 8,'the upper margin of the back panel 14 is bent angularly inward as at 32 and then is reversely bent outward, as shown at 33, to form a longitudinal rib 33. As seen in FIGS. 4 and 7, the rib 33 extends continuously from one end panel 15 to the opposite end panel 16. Each of the end panels is provided with upwardly projecting arcuate portions 35 and 36, each of which is apertured to form a socket for mounting the lid 12. This will be described i5 greater detail below.
The lid 12 is formed of molded plastic and includes a top panel 40 which slopes downwardly to angularly intersect the front panel 41; End panels 42 and 43 extend downwardly in overlapping relation to the respective end- panels 15 and 16 on the receptacle 11 when the lid 12 is in the closed position. As is evident in the bottom'plan vie of FIG. 5, the end panels 42 and 43 are in closely spaced relation to the corresponding panels on the receptacle 11 to provide good weather tightness. In actual practice, the spacing is somewhat less than that indicated in FIG. 5, however, is exaggerated for clarity.
A raised bead 44 defines the margins of the front panel 41 and, as shown in FIG. 1, frames an area which may be decorated with a simulated wood grain design. An ornament of any desired type which is shown in phantom at 45 may be used to further embellish the ornamental appearance. A raised bead 46 extends around the sides and rear edge of the top panel 40 to provide good rigidity and acts as a barrier to prevent water from flowing over the rear edge of the top panel 40. The raised beads 44 and 46 add rigidity to the lid or cover 12 while permitting the quantity of plastic to be reduced in the central area. The lid 12 may be molded as an integral unit, requiring only the addition of suitable ornamentation before it is assembled.
At the rear margin of the top panel 40 and adjacent opposite end panels 42 and 43 is provided cylindrical bosses 50 and 51 which form hinge knuckles. A longitudinal rib 52 extendsbetween the bosses 50 and 51, being axially coextensive with the circumferential surfaces thereof. As seen in FIG. 8,
' the boss 50 is provided with a radially projecting lug having a shoulder 53 which is adapted for engagement with the fixed rib 33 on the receptacle 1 1 to control the degree of opening of the lid 12. The boss 51 is provided with an identical form of shoulder.
As seen in FIGS. 2, 4 and 7, the cylindrical boss 50 is located in axially spaced relation to the end panel 42 of the lid 12 which forms a hinge knuckle. This forms a mounting area 54 to receive the socket forming portion 35 on the end panel 15. A hinge pin 55 is press-fitted into apertures 56 and 57 formed in the end wall 42 and cylindrical boss 50, respectively, and mounts the lid 12 for hinged movement.
As seen in FIG. 8, when the receptacle 11 and lid 12 are as sembled, the fixed 'rib 33 projects radially inward toward the axis about which the lid pivots. The angular rib 52 formed on the lid 40 is positioned in closely spaced relation to the rib 33 and is located on a segment of a circle coaxial with the axis of hinge movement.
After assembly of the lid 12 to the receptacle 11, the longitudinal rib 33 and arcuate rib 52 cooperate to form a weather seal at the rear of the mailbox 10. In a normal installation, the back panel 14 is mounted against a flat surface such as a post, wall of a residence or the like. In such event, the raised bead 46 at the rear of the top panel and forward slope of the panel 40 act to shed any moisture which may be deposited on the panel 40 from the front side. In this respect, the all-plastic construction assures that the mailbox will not be corroded by moisture which is deposited on the lid and does not completely run off. The metal used in the receptacle 11 is galvanized and provided with a protective coating of paint or the like. Since it is normally positioned vertically, the likelihood of corrosion is diminished.
As seen in FIGS. and 6, a signal flag 60 is formed of metal having marginal flanges 61, 62, 63 and 64 to provide rigidity. The side flanges 61 and 63 also form sockets for hinge mounting of the flag beneath the mailbox. A pair of angle brackets 65 and 66 are joined to the bottom panel 17 by means of rivets 67 and 68. The angle brackets are held against rotation about the rivets 67 and 68 by means of dimples or raised portions 70 and 71, 72 and 73, respectively, which are formed in the bottom wall 17 for engagement with opposite side margins of the angle brackets. The upstanding side flanges 61 and 63 at opposite ends of the flag 60 are provided with an elongated aperture of the type shown in elevation at 74 in the flange 61 in FIG. 6. A rivet 75 extends through the angle bracket 65 and joins the flag to the angle bracket for sliding and pivoting movement. A similar rivet 76 cooperates with upstanding flange 63 in a similar manner.
In order to move the flag to the dropped or signalling position, the flange 62 is grasped and the entire flag is moved forward until the rivet 75 engages the arcuate end of the elongated opening 74. At this point, the flag is free to pivot to the dropped or vertical position shown in phantom lines in FIG. 6. As can be appreciated, the flag is now exposed in front elevation whereby the postman will be alerted to pick up outgoing mail, as the flag 60 serves the same function as a flag on the conventional rural mailbox.
Referring now to FIGS. 9-17, a vertical style of composite mailbox incorporating novel features of the design of FIGS. 1-8 will be described. The mailbox 110 consists of a receptacle 111 which may be formed of sheet metal and lid 1 12 formed of molded plastic.
The receptacle 111 includes a front panel 113, back panel 114 and end panels 115 and 116 joining the front and back panels 113 and 114, respectively. As seen in FIGS. 12 and 18, a bottom panel 117 extends angularly upward toward the rear panel 114 to form a shallow recess to accommodate a signal flag shown generally at 118 and which will be described in detail hereinafter.
As seen in FIGS. 10, 12 and 13, the back panel may be pro vided with raised bosses 120 and 121 to serve as spacing means for use in mounting the mailbox 110 against a flat sur face. Apertured bosses 122, 123, 124 and 125 are formed above the bosses 120 and 121 and include apertures to accommodate suitable mounting fasteners such as bolts, screws or the like.
As best seen in FIG. 18, the bottom panel 117 is formed integral with the front panel 113 and includes a terminating flange 119 which permits attachment to the back panel 114 by means of a rivet 119' (FIG. 10). The back panel 114 and end panels 115 and 116 are formed integral and are joined to the front panel 113 by folded sheet metal joints and 131 of conventional design. As noted above, the receptacle 111 of the mailbox may be formed of sheet metal material with suitable corrosion inhibitors applied such as galvanizing and painting. It is contemplated that the receptacle could be formed of molded plastic as an alternative.
Referring now to FIG. 15, the upper margin of the back panel 114 is formed with an angularly inwardly folded extension of shoulder 132 which is upwardly bent as at 133 to form a longitudinally extending rib which is best seen in FIG. 10. The rib 133 is provided with cutaway portions 128 and 129 at opposite ends adjacent the respective end panels for reasons to become apparent.
The lid 112 includes a top panel which intersects a front panel 141. If desired, the front panel maybe provided with a suitable applique such as the simulated wood grain finish shown. This may be provided with suitable ornamentation of any desired type, such as the fleunde-lis shown in phantom (FIG. 1). The lid 112 includes end panels 142 and 143 which are disposed in overlapping relation to the respective end panels 115 and 116. In the drawings, the clearance between the end panels 1 15 and 1 16 on the receptacle and the end panels 142 and 143 on the lid 112 is slightly exaggerated for clarity, however, in actual practice the end panels 142 and 143 are very closely spaced, e.g., in the range of about one to two times the thickness of the material of which the receptacle 114 is formed to provide for a good weather seal along the margins. Since the top is formed of plastic, sticking or binding against the side wall will not be a problem if contact should occur.
The front panel 145 is provided with a raised bead 146 around its margin which adds rigidity and serves to frame and highlight the ornamentation. A similarly shaped bead 146 extends around the sides and rear edge of the top panel 140 as shown in FIG. 13. The raised. bead 146 provides additional rigidity in the top panel and also forms a dam or barrier to prevent water from flowing over the rear edge. Through the use of the raised beads 144 and 146, the lid 112 is provided with good overall rigidity which permits the thickness of the plastic material forming the lid to be maintained at a minimum. As will become apparent when FIGS. 16 and 17 are specifically described, this reduces the material requirements with the obvious effect on manufacturing costs.
At opposite ends of the rear margin of the top panel 40 is formed cylindrical bosses 150 and 151 which are located slightly inwardly spaced from the end panels 142 and 143 on the lid 112. As shown in FIG. 14, the raised bead 146 is solid when viewed in cross section, having a flat surface 152 on its underside which extends between the bosses 150 and 151.
The surface 152 is closely spaced from the upstanding longitudinal rib 133 on the back panel 114 toform a labyrinthtype weather seal. The overhang provided by the rib 133 being located inwardly of the rear margin of the lid 112, combined with the close spacing, serves to prevent the entry of the elements into the receptacle 111 when the lid is in the closed position. When the lid is fully opened as shown in FIG. 15, the surface 152 on the underside of the bead engages the upstanding longitudinal rib 133 forming a stop to limit the degree of opening. The shape of the cooperating parts forming this seal prevent any water which may collect on the lid from flowing into the receptacle 11 1 when the lid is in this position.
' The flag or signal means 118 is illustrated in cross section in FIG. 18 and in bottom plan in FIG. 12. Structurally speaking, the flag is identical to the flag shown in FIGS. 5 and 6, being provided with identical elongated slots 160 (only one shown) on opposite ends of the flag 118; Suitablerivets 161 and 162 (FIG. 12) mount the flag for sliding and angular movement between the hidden positions shown in FIG. 18 in solid lines to the signalling position shown at 163 in phantom lines in FIG. 18. As expected, the flag must be moved forward until the rivets 161 and 162 engage the rear portion of the slot and then the flag is free to pivot to the position shown in phantom lines.
A novel bracing arrangement is molded integrally with the lid 112 to provide good torsional rigidity. Due to its overall length, rigidity of the lid is required to obtain good weatherproof qualities and proper functioning of the hinges. As can be appreciated, torsional rigidity can be provided'by simply increasing the overall thickness of the lid, which is disadvantageous because of the increase in material and cost. In the present design, the material thickness has been maintained at a minimum with torsional rigidity assured through a novel ribbing arrangement.
Referring to FIGS. 16 and 17, it can be seen that the ribbing is provided in the form of X-braces 170 and 171 of identical elevational shape which are molded integral with the lid 112. As shown in FIG. 17, the rib 170 isuniquely shaped, contrary to what would logically be expected, being thickened at its ends as at 172 and 173 while being relatively thin at the center portion of the panel where the rib 171 intersects, which is of identical shape. With this design, it has been found that the material thickness for the lid 112 may be maintained at a minimum without a loss of torsional rigidity which is required for smooth functioning and a proper fit of the lid with the receptacle 111.
As seen in FIG. 16, the plastic ornamentation 145 is joined to the lid 112 by the heat staking on the backside such as that shown at 174, 175 and 176. Obviously, other forms of fastening techniques may be used, depending upon the ornamentation and materials.
From the foregoing, it can be seen that the mailbox designs of the present invention provide advantages not available with constructions shown in the prior art. Fox example, the present hinge construction assures smooth functioning of the lid under all types of weather conditions. Due to its novel design, the mailbox of the present invention provides improved weatherproof qualities while not requiring special expensive sealing or close tolerances. Thus, mass production techniques may be used with the expected economic saving. The present mailboxes also incorporate a unique signal feature which heretofore was reserved for rural-type mailboxes. This permits the present mailboxes to have use in suburban delivery locations as well as city residential areas, providing greater versatility.
Upon a consideration of the foregoing, it will become obvious to those skilled in the art that various modifications may be made without departing from the invention embodied herein. Therefore, only such limitations should be imposed as are indicated by the spirit and scope of the appended claims.
I claim:
1. In a mailbox having a receptacle portion and a lid portion joined together at their top and rear edges, respectively, for
. articulated movement about an axis, the improvement comprising a weather seal formed at the rear edge of said lid and top edge of said receptacle, said weather seal including a continuous longitudinal rib extending toward said axis and a longitudinal rib formed on said lid and being disposed in closely adjacent and noncontacting relation to said longitudinal rib on said receptacle, said rib on said lid being movable in a path about said axis while remaining closely spaced in noncontacting relation to said rib on said receptacle to form a weatherproof barrier, said longitudinal rib on said receptacle being located in a plane intersecting said axis, and said longitudinal rib on said lid being arcuately shaped and extending rearwardly of said receptacle rib for movement along a circular path around said axis to maintain it in spaced, closely adjacent and noncontacting relation with said rib.
2. The improvement in mailboxes as, defined in claim 1 wherein said receptacle portion and said lid portion are joined by hinge means at opposite ends of said lid and receptacle, said hinge means including cylindrical bosses formed integral with said lid and being located inwardly of the'ends thereof, each of said cylindrical bosses being disposed in spaced relation to side panels formed at opposite sides of said lid, an aperture extending through each of said side panels and an aperture formed in each of said cylindrical bosses, each of said apertures being formed coaxially with said axis, and apertures formed in opposite end walls of said receptacle, said apertured end walls being adapted for disposition between said cylindrical boss and said side panels, and a hinge pin press-fitted into each of said cylindrical bosses and sidepanels on said lid and extending through said aperture on said end of said receptacle for mounting said lid for hinge movement.
3. The improvement in mailboxes as defined in claim 1 wherein said receptacle portion and said lid portion are joined by hinge means at opposite ends of said lid and receptacle, respectively, said hinge means comprising a cylindrical boss formed integral with said lid inwardly of the ends thereof and hinge pin means press-fitted into each of said bosses to join said lid portion to said receptacle portion.
4. In a mailbox having a receptacle portion and a lid portion joined together at their top and rear edges, respectively, for articulated movement and wherein said receptacle portion of said mailbox is vertically elongated, the improvement comprising said lid being formed of molded plastic material and including intersecting brace means formed integral on the reverse side of said lid, said brace means extending generally from side to side and being of increased thickness at the end portions relative to the lid portions.
5. In a mailbox of the type having a boxlike portion adapted to serve as a receptacle for mail and a lid to protect the contents of said receptacle from the weather, said receptacle including a vertical back panel, a front panel and end panels joining said front and back panels and a bottom panel joining said front and back and end panels, said bottom panel sloping downward from said back panels to form a recessed area beneath said bottom panel, and flag means mounted in said recess and being adapted for manual release for downward extension to serve as a signal means, said flag means being provided with a pair of elongated slots, fastener means extending through said slots and attaching said flag means to said end panels closely adjacent said bottom panel.
6. In a mailbox of the type having a boxlike portion adapted to serve as a receptacle for mail and a lid to protect the contents of said receptacle from the weather, said receptacle including a vertical back panel, a front panel and end panels joining said front and back panels and a bottom panel joining front panel on said receptacle, a sealing rib extending along the rear margin of said lid and a cooperating sealing rib on said receptacledisposed in opposition to said sealing rib on said lid, and hinge means at opposite ends of said mailbox to mount said lid for swinging movement relative to said receptacle while maintaining the sealing rib on said receptacle and sealing rib on said lid in closely spaced relation.

Claims (6)

1. In a mailbox having a receptacle portion and a lid portion joined together at their top and rear edges, respectively, for articulated movement about an axis, the improvement comprising a weather seal formed at the rear edge of said lid and top edge of said receptacle, said weather seal including a continuous longitudinal rib extending toward said axis and a longitudinal rib formed on said lid and being disposed in closely adjacent and noncontacting relation to said longitudinal rib on said receptacle, said rib on said lid being movable in a path about said axis while remaining closely spaced in noncontacting relation to said rib on said receptacle to form a weatherproof barrier, said longitudinal rib on said receptacle being located in a plane intersecting said axis, and said longitudinal rib on said lid being arcuately shaped and extending rearwardly of said receptacle rib for movement along a circular path around said axis to maintain it in spaced, closely adjacent and noncontacting relation with said rib.
2. The improvement in mailboxes as defined in claim 1 wherein said receptacle portion and said lid portion are joined by hinge means at opposite ends of said lid and receptacle, said hinge means including cylindrical bosses formed integral with said lid and being located inwardly of the ends thereof, each of said cylindrical bosses being disposed in spaced relation to side panels formed at opposite sides of said lid, an aperture extending through each of said side panels and an aperture formed in each of said cylindrical bosses, each of said apertures being formed coaxially with said axis, and apertures formed in opposite end walls of said receptacle, said apertured end walls being adapted for disposition between said cylindrical boss and said side panels, and a hinge pin press-fitted into each of said cylindrical bosses and side panels on said lid and extending through said aperture on said end of said receptacle for mounting said lid for hinge movement.
3. The improvement in mailboxes as defined in claim 1 wherein said receptacle portion and said lid portion are joined bY hinge means at opposite ends of said lid and receptacle, respectively, said hinge means comprising a cylindrical boss formed integral with said lid inwardly of the ends thereof and hinge pin means press-fitted into each of said bosses to join said lid portion to said receptacle portion.
4. In a mailbox having a receptacle portion and a lid portion joined together at their top and rear edges, respectively, for articulated movement and wherein said receptacle portion of said mailbox is vertically elongated, the improvement comprising said lid being formed of molded plastic material and including intersecting brace means formed integral on the reverse side of said lid, said brace means extending generally from side to side and being of increased thickness at the end portions relative to the lid portions.
5. In a mailbox of the type having a boxlike portion adapted to serve as a receptacle for mail and a lid to protect the contents of said receptacle from the weather, said receptacle including a vertical back panel, a front panel and end panels joining said front and back panels and a bottom panel joining said front and back and end panels, said bottom panel sloping downward from said back panels to form a recessed area beneath said bottom panel, and flag means mounted in said recess and being adapted for manual release for downward extension to serve as a signal means, said flag means being provided with a pair of elongated slots, fastener means extending through said slots and attaching said flag means to said end panels closely adjacent said bottom panel.
6. In a mailbox of the type having a boxlike portion adapted to serve as a receptacle for mail and a lid to protect the contents of said receptacle from the weather, said receptacle including a vertical back panel, a front panel and end panels joining said front and back panels and a bottom panel joining said front and back and end panels, said bottom panel sloping downward from said back panel to form a recessed area beneath said bottom panel, and flag means mounted in said recess and being adapted for manual release for downward extension to serve as a signal means, said lid including a top panel and downwardly depending side panels adapted for disposition in overlapping relation with said end panels on said receptacle and a front panel adapted for overlapping said front panel on said receptacle, a sealing rib extending along the rear margin of said lid and a cooperating sealing rib on said receptacle disposed in opposition to said sealing rib on said lid, and hinge means at opposite ends of said mailbox to mount said lid for swinging movement relative to said receptacle while maintaining the sealing rib on said receptacle and sealing rib on said lid in closely spaced relation.
US787973A 1968-12-30 1968-12-30 Mailbox and method of fabricating same Expired - Lifetime US3602423A (en)

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Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4875621A (en) * 1988-06-27 1989-10-24 Dolores Chivers Apartment mailbox signal device
US5461932A (en) * 1991-07-15 1995-10-31 Texas A & M University System Slotted orifice flowmeter
USD378463S (en) * 1995-06-07 1997-03-11 Chaenomeles, Inc. Mail box
USRE35569E (en) * 1993-11-04 1997-07-29 Chaenomeles, Inc. Mail box
US20110290963A1 (en) * 2007-05-01 2011-12-01 Crow-Erickson, Inc. Container and Universal Bracket System
US10143320B1 (en) * 2018-02-13 2018-12-04 John R. Batts Package locking system
USD985877S1 (en) * 2019-04-17 2023-05-09 Robert Venuti Mailbox

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4875621A (en) * 1988-06-27 1989-10-24 Dolores Chivers Apartment mailbox signal device
US5461932A (en) * 1991-07-15 1995-10-31 Texas A & M University System Slotted orifice flowmeter
USRE35569E (en) * 1993-11-04 1997-07-29 Chaenomeles, Inc. Mail box
USD378463S (en) * 1995-06-07 1997-03-11 Chaenomeles, Inc. Mail box
US20110290963A1 (en) * 2007-05-01 2011-12-01 Crow-Erickson, Inc. Container and Universal Bracket System
US8534623B2 (en) * 2007-05-01 2013-09-17 Crow-Erickson, Inc. Container and universal bracket system
US10143320B1 (en) * 2018-02-13 2018-12-04 John R. Batts Package locking system
USD985877S1 (en) * 2019-04-17 2023-05-09 Robert Venuti Mailbox

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