Abstract:
Door stop and impact absorber bracket for restraining mailbox doors from opening beyond a selected swing radius. The bracket can fit underneath the mailbox behind an existing lower hanging lip. The door stop bracket is positioned such that it limits the door from swinging beyond a desired point (for example approximately 90 degrees) when the door is opened. The bracket can have an elongated rectangular planar central portion, with bent ends, together forming a generally C-shape. The bracket can have cushion pad to protect both the door, hinges other components and even the body of the mail box from being damaged from excessive vibrations when the door reaches the maximum opening point. The pad can also reduce objectionable impact noise effects that are created when a mailbox door accelerates in a free fall to a stop.

Description:
[0001]    This invention relates to mailboxes, in particular to apparatus, devices and methods of restraining a mailbox door from opening beyond a selected swing radius. 
       BACKGROUND AND PRIOR ART 
       [0002]    Mailboxes have been around for many years, and come in many sizes and shapes. The most popular mailboxes have an elongated compartment such as a rectangular housing with a flat roof or curved roof, and an access door that swings open based on a hinge mechanism the attaches the door to the lower front edge of the mailbox. However, mailbox doors tend to open much further than is needed. A typical mailbox door swings freely up to approximately 180 to approximately 270 degrees or more from a vertical upright closed position. The loosely swinging door has resulted in many problems. 
         [0003]    For example, a mailbox door that hangs down is more prone to be twisted and bent overtime rendering the door useless from closing the mailbox. A downwardly hanging door can also break off from the mailbox leaving the interior of the mailbox continuously open. A constantly open mailbox can allow for any mail type contents inside to become damaged by being exposed to weather elements, and/or allow for the mailbox contents to become dislodged and lost, and even stolen overtime. 
         [0004]    Additionally, a downwardly hanging bent and/or twisted mailbox door or portions of a door that remain can also be a snag hazard to others such as a mailman. 
         [0005]    Still furthermore, most mailboxes being metal are prone to additional problems. These mailbox doors typically swing open so that metal eventually impacts metal that can cause damage to either or both the door, the handle, hinges, floor, other components and even the mailbox itself overtime. Metal hitting metal has also been known to cause objectionable loud impact noises that are created when a mailbox door accelerates in a free fall to a dead impact stop. 
         [0006]    The constant banging between components can stress mailbox door hinges, other rotating points, welds and other assembly components causing parts to warp and/or loosen and/or fall off and/or become damaged overtime reducing the life of the mailbox. 
         [0007]    The inventor is not aware of apparatus, devices and methods that overcome all the problems listed above. Thus, the need exists for solutions to the above problems with the prior art. 
       SUMMARY OF THE INVENTION 
       [0008]    A primary objective of the present invention is to provide a restraint apparatus, device and method for limiting the swing opening radius of a mailbox door to stop at a generally horizontal orientation. 
         [0009]    A secondary objective of the present invention is to provide a restraint apparatus, device and method for preventing a mailbox door from swinging to a position where the door hangs beneath the mailbox. 
         [0010]    A third objective of the present invention is to provide a restraint apparatus, device and method for reducing the chances for the door to become twisted or bent overtime. 
         [0011]    A fourth objective of the present invention is to provide a restraint apparatus, device and method for reducing the chances for the door and/or hinges and/or other components from becoming detached from the mailbox which reduces chances of mail type contents from becoming dislodged and lost, and stolen overtime. 
         [0012]    A fifth objective of the present invention is to provide a restraint apparatus, device and method reducing the chances for the door to become a snag hazard to others. 
         [0013]    A sixth objective of the present invention is to provide a restraint apparatus, device and method for reducing damage to both a mailbox door and the mailbox itself as the door is being swung open. 
         [0014]    A seventh objective of the present invention is provide a restraint apparatus, device and method for reducing objectionable impact and collision noises and reducing vibration damage effects to both a mailbox door, other components and the mailbox itself as the door is being swung open. 
         [0015]    An eighth objective of the present invention is to provide a restraint apparatus, device and method for extending the operational life of the mailbox. 
         [0016]    The invention covers a mailbox door restraint apparatus, device and method that stop a freefall of a mailbox door being opened by reducing the amount of force as compared to a freefalling door with no restraint. The novel restraint reduces wear and tear on the door, rotational components and other mailbox assembly parts thereby increasing the operational life of the mailbox itself. 
         [0017]    A preferred embodiment of the invention can be a mailbox having a chamber having at least one open end, a door pivotally attached to the open end of the chamber, and a restraint member for stopping the door from swinging open from a vertical position beyond a generally horizontal position. 
         [0018]    The restraint member can include a bracket attached to both a lower front edge of the open end of the chamber, and to a lower edge of the door, the bracket having a portion which prevents the door from opening beyond the generally horizontal position. The bracket can have an elongated rectangular midportion and bent ends on opposite ends of the elongated rectangular midportion. The bent ends can include openings for allowing fasteners pass therethrough in order to fasten the bracket to the lower front edge of the open end of the chamber. 
         [0019]    A pad can be attached to a face portion of the bracket and be used for dampening vibration and sound impact between the door and the bracket when the door reaches the generally horizontal position. 
         [0020]    The restraint member can also include a lip portion which is attached to and hangs down beneath a lower front edge portion of the open end of the chamber behind a front lower hanging edge of the mailbox, wherein a portion of the door abuts against the lip portion which prevents the door from opening beyond the generally horizontal position. 
         [0021]    The restraint can be a bumper portion attached to a lower portion of the chamber for preventing the door from opening beyond the generally horizontal position. 
         [0022]    The invention can include a novel method of stopping a mailbox door from opening beyond a generally horizontal position, and can include steps of providing a mailbox having at least one open end, pivotally attaching a door to the open end of the mail box, and preventing the mailbox door from opening beyond a generally horizontal position. 
         [0023]    The preventing step can include the step of attaching a lip portion to hang beneath the open end of the mailbox. 
         [0024]    The preventing step can include the step of attaching a bracket having bent ends to a lower front edge of the open end of the mailbox. 
         [0025]    The novel method can also include the step of cushioning impact between the door and the mailbox when the door opens to the generally horizontal position. 
         [0026]    Further objects and advantages of this invention will be apparent from the following detailed description of the presently preferred embodiments which are illustrated schematically in the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0027]      FIG. 1  is a perspective side view of a prior art mailbox. 
           [0028]      FIG. 2  is another perspective view of the mailbox of  FIG. 1  with the door open. 
           [0029]      FIG. 3  is a front end view of the mailbox of  FIG. 2  along arrow X. 
           [0030]      FIG. 4  is a side cross-sectional view of  FIG. 3  along arrows  4 X. 
           [0031]      FIG. 4A  is an enlarged view of a portion of the door hinge of  FIG. 4 . 
           [0032]      FIG. 5  is a perspective side view of a mailbox with door closed using the novel invention. 
           [0033]      FIG. 6  is another perspective view of the mailbox of  FIG. 5  with the door open. 
           [0034]      FIG. 7  is a perspective lower view of the mailbox with door closed of  FIG. 5 . 
           [0035]      FIG. 7A  is an enlarged view of a lower front portion of the mailbox of  FIG. 7 . 
           [0036]      FIG. 8  is a perspective view of the mailbox with door open of  FIG. 6 . 
           [0037]      FIG. 8A  is an enlarged view of the lower front portion of the mailbox of  FIG. 8 . 
           [0038]      FIG. 9  is an exploded perspective side view of the mailbox, door and stop bracket. 
           [0039]      FIG. 10  is an exploded view underneath the mailbox, door, and stop bracket of  FIG. 9 . 
           [0040]      FIG. 11  is a front end view of the closed door of the mailbox using the novel stop bracket. 
           [0041]      FIG. 12  is a cross-sectional view of closed door mailbox of  FIG. 11  along arrows  12 X. 
           [0042]      FIG. 12A  is an enlarged view of the door hinge portion and stop bracket of  FIG. 12 . 
           [0043]      FIG. 13  is a front end view of the mailbox with an open door using the novel stop bracket. 
           [0044]      FIG. 14  is a cross-sectional view of the open door mailbox of  FIG. 13  along arrows  14 X. 
           [0045]      FIG. 14A  is an enlarged view of the door hinge portion and stop bracket of  FIG. 14 . 
           [0046]      FIG. 15  is a front end view of the mailbox with open door using the stop bracket and pad. 
           [0047]      FIG. 16  is a cross-sectional view of the door hinge, stop bracket and pad of  FIG. 15 . 
           [0048]      FIG. 16A  is an enlarged view of the door hinge, stop bracket and pad of  FIG. 16 . 
           [0049]      FIG. 17  is an upper perspective view of the novel stop bracket used in the invention. 
           [0050]      FIG. 18  is a left end view of the stop bracket of  FIG. 17  along arrow  18 X. 
           [0051]      FIG. 19  is a top view of the stop bracket of  FIG. 17  along arrow  19 Y. 
           [0052]      FIG. 20  is a front side view of the stop bracket of  FIG. 17  along arrow  20 X. 
           [0053]      FIG. 21  is a bottom view of the stop bracket of  FIG. 17  along arrow  21 Y. 
           [0054]      FIG. 22  is a right end view of the stop bracket of  FIG. 17  along arrow  22 X. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0055]    Before explaining the disclosed embodiments of the present invention in detail it is to be understood that the invention is not limited in its applications to the details of the particular arrangements shown since the invention is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation. 
         [0056]    A listing of components will now be described.
   Prior Art Mailbox  1     Main chamber of mailbox  10     Open access end of mailbox  12     Existing lower hanging front edge of mailbox  16 .   Existing floor of mailbox  15     Existing lower hanging side edges of mailbox  14 ,  18     Mailbox door  20     Inwardly bent side edges of door  22     Tab hinges pre-attached to door  32 ,  38     Rear edge portion of tab hinges  33 ,  39     Fasteners  33  attaching tab hinges to lower hanging side edges  14 ,  18  of mailbox   Invention Mailbox  100     Restraining Bracket  101     Rectangular Elongated Mid-portion  110     Angled Face of elongated mid-portion  110 A   First bent end  120     Fastener mounting holes  121     Second bent end  130     Fastener mounting holes  131     Fasteners (screws/nuts)  133 ,  135     Vibration and Sound absorbing and dampening pad  180     
 
         [0078]      FIG. 1  is a perspective side view of a prior art mailbox  1 .  FIG. 2  is another perspective view of the mailbox  1  of  FIG. 1  with the door  20  being opened exposing an open access end  12  for the mailbox.  FIG. 3  is a front end view of the mailbox  1  of  FIG. 2  along arrow X.  FIG. 4  is a side cross-sectional view of  FIG. 3  along arrows  4 X.  FIG. 4A  is an enlarged view of a portion of the door hinge  32  of  FIG. 4 . 
         [0079]    Referring to  FIGS. 1-4A , a typical mailbox  1  can include a main chamber having an open access end  12 . Across a bottom floor  15  of the mailbox  1  can be lower hanging side edges  14 ,  18 , and an existing lower hanging front edge  16 . A mailbox door  20  can include inwardly bent side edges  22  which help seal the door  20  over the open end  12  when the door  20  is in a closed position. Pre-attached to lower corner edges of the door  20  can be tab type hinges  32 ,  38  which extend perpendicular in from a planar face of the door  20 . Fasteners such as rivets  33  can attach the tab hinges  32 ,  38  into front portions of the lower hanging mailbox side edges  14 ,  18  behind the lower hanging mailbox front edge  16  in order to allow the door  20  to pivot relative to the mailbox open end  12 . As can be seen in  FIGS. 4 and 4A ; the tab hinges  32 ,  38  allow the door  20  to move up to approximately 180 degrees or more from an initial closed position shown in  FIG. 1 . 
         [0080]      FIG. 5  is a perspective side view  100  of a mailbox  10  with door  20  closed using the novel invention.  FIG. 6  is another perspective view of the mailbox  10  of  FIG. 5  with the door  20  opened along arrow R to no more than approximately 90 degrees from the access end  12  of the mailbox  100 . As can be readily seen, the novel invention does not change the general outside appearance of prior art mailboxes previously described. 
         [0081]      FIG. 7  is a perspective lower view of the mailbox  100  with door  20  closed of  FIG. 5 .  FIG. 7A  is an enlarged view of a lower front portion of the mailbox  100  of  FIG. 7  showing the rectangular mid portion  120  and fastened bent end  130  of the novel restraining bracket  101  with the tab hinge  32 . 
         [0082]      FIG. 8  is a perspective view of the mailbox  100  with door  20  open of  FIG. 6 .  FIG. 8A  is an enlarged view of the lower front portion of the mailbox  100  of  FIG. 8  showing the tab hinge  32  on the door  20  rotated to an open position where a rear edge portion  33  now abuts against the rectangular mid portion  120  of the novel restraining bracket  101 . 
         [0083]      FIG. 9  is an exploded perspective side view of the main chamber  10  of mailbox  100 , door  10  and stop bracket  101 , and fasteners  133 ,  135 .  FIG. 10  is an exploded view under the main chamber  10  of the mailbox  100 , door  20 , and stop bracket  101  of  FIG. 9 . 
         [0084]      FIG. 11  is a front end view of the closed door  20  of the mailbox  100  using the novel stop bracket.  FIG. 12  is a cross-sectional view of closed door mailbox  100  of  FIG. 11  along arrows  12 X showing the tab hinge  32  of the door  20  and stop bracket  101 . 
         [0085]      FIG. 12A  is an enlarged view of the door hinge portion of the tab hinge  32  and door  20  and stop bracket  101  of  FIG. 12 . 
         [0086]      FIG. 13  is a front end view of the mailbox  100  with an open door  20  using the novel stop bracket  101  which is positioned behind the existing lower hanging front edge of the mailbox floor  15 .  FIG. 14  is a cross-sectional view of the open door  20  of the mailbox  100  of  FIG. 13  along arrows  14 X.  FIG. 14A  is an enlarged view of the door hinge portion showing the tab hinge  32  on the door  20  rotated along arrow R to an open position where the rear edge  33  abuts against the front of the face of the rectangular mid portion  110  of the stop bracket  101  of  FIG. 14 . 
         [0087]      FIG. 17  is an upper perspective view of the novel stop bracket  101  used in the invention depicted in the preceding figures showing the elongated rectangular mid portion  110 , first bent end  120 , with fastener mounting holes  121 , and second bent end  130  with fastener mounting holes  131 .  FIG. 18  is a left end view of the stop bracket  101  of  FIG. 17  along arrow  18 X.  FIG. 19  is a top view of the stop bracket  101  of  FIG. 17  along arrow  19 Y.  FIG. 20  is a front side view of the stop bracket  101  of  FIG. 17  along arrow  20 X.  FIG. 21  is a bottom view of the stop bracket  101  of  FIG. 17  along arrow  21 Y.  FIG. 22  is a right end view of the stop bracket  101  of  FIG. 17  along arrow  22 X. 
         [0088]    The operation of using the novel invention will now be described in reference to  FIGS. 5-14  and  17 - 20 . The novel stop restraining bracket  101  can be attached underneath the floor  15  of the main chamber  10  of the mailbox  100 , behind the existing lower hanging front edge  16  of the mailbox and also slightly behind the door attached tab hinges  32 ,  38 . The bent ends  120 ,  130  of the novel bracket  101  can be attached to existing lower hanging side edges  14 ,  18  which are on both sides of the mailbox floor  15 . Fasteners  33 ,  35 ′ such as screws and nuts, rivets, welds, mechanical bends and interlocking types of slots and/or tabs, and the like, can fasten through openings  121 ,  131  in bent ends  120 ,  130  and into the lower hanging side edges  14 ,  18  below the mailbox floor  15 . 
         [0089]    When the door  20  of the mailbox is being opened, and pivots by way of tab hinges  32 ,  38 , the door can move in the direction of arrow R until the rear edges  33 ,  39  of the tab hinges  32 ,  38  abut against front portions of the elongated rectangular mid portion  110  of the stop restraining bracket  101 . The position of the elongated rectangular mid portion  110  prevents the tab hinges  32 ,  38  from opening the door  20  beyond an approximate 90 degree swing opening, which puts the door  20  approximately perpendicular to the open access end  12  of the main chamber  10  of the mailbox  100 . A preferred application would allow for the door  20  to end up approximately horizontal, and in a similar plane to the floor  15  of the mailbox  100 . 
         [0090]      FIG. 15  is a front end view of the mailbox with open door  20  using the stop bracket  101  and pad  180 .  FIG. 16  is a cross-sectional view of the door hinge portion of the tab hinge  32 , stop bracket  101  and pad  180  of  FIG. 15 .  FIG. 16A  is an enlarged view of the door hinge tab hinge  32  and door  20 , stop bracket  101  and pad  180  of  FIG. 16 . Here, a pad  180  such as a rubber material, plastic layered material, and the like can be positioned on a face portion of the elongated rectangular mid portion  110  of the stop restraining bracket  101 . The pad  180  can function as a cushion to absorb any vibration which can occur when the door  20  is being opened and would dampen and/or reduce any noise effects that would have existed by tab hinges of the door banging against the restraining bracket  101 . The pad would provide both sound and impact vibration dampening effects. 
         [0091]    The bracket  101  can be set in place at different angles to encompass a greater or less impact surface contact points. The mid portion of the bracket face  110 A can be angled (See  FIGS. 12A ,  14 A) to provide a greater contact surface area and/or a more precise contact points when the tab hinges  32 ,  38  rotate back. Positioning the bracket  101  to different angles can be used with different mailboxes and their doors. 
         [0092]    Although the invention describes using the restraint bracket to limit the opening of the mailbox door  20  to up to approximately ninety degrees, the location of the novel restraining bracket can be moved to allow the door  20  to open up to less than or greater than a perpendicular orientation. 
         [0093]    While the invention shows a bracket fastened in place by screw type fasteners, the restraint bracket can be attached in other ways. For example, the restraint bracket can be one member or plural members that are pre-stamped in place. For example, the restraint can be a lip edge that is bent downward. Alternatively, the restraint bracket can be welded in place. Alternatively, the restraint bracket can be riveted in place. 
         [0094]    The invention is intended to cover alternative versions of the restraint bracket that can be used. For example, a single elongated bolt or bar can pass through and be attached to both lower hanging side edges, where the bolt body surface functions as a stop to prevent the door from opening beyond a selected swing radius. The bolt can include a cylindrical sleeve and/or noncircular exterior shaped sleeve cover. 
         [0095]    Although a preferred application is using an elongated bracket or elongated bar/bolt, the invention can use instead two separate bumper members each fastened to the downwardly hanging sides. Still furthermore, a single bumper can be used that is shaped to allow one of the tab hinges  32 ,  38  to abut against limiting the swing radius of the door. The single bumper can be a small block shaped member or tab that can be fastened into one lower hanging side of the mailbox by screws, and the like. 
         [0096]    The invention can be retrofitted into existing mailboxes and/or made to be part of newly manufactured mailboxes. 
         [0097]    While the invention has been described, disclosed, illustrated and shown in various terms of certain embodiments or modifications which it has presumed in practice, the scope of the invention is not intended to be, nor should it be deemed to be, limited thereby and such other modifications or embodiments as may be suggested by the teachings herein are particularly reserved especially as they fall within the breadth and scope of the claims here appended.