Patent Publication Number: US-11019952-B2

Title: Blow molded decorative post assembly

Description:
FIELD OF THE INVENTION 
     The present invention relates to protective post covers, and more particularly blow molded decorative post covers. 
     BACKGROUND OF THE INVENTION 
     Typically, mailboxes are mounted on wooden posts. These posts are vulnerable to damage and deterioration from weather, time, lawn mowers, vehicles, and the like. Traditional measures taken to protect wooden posts include painting the posts, partially or fully encasing the posts in brick or stone columns, planting shrubbery or bushes around the posts, or some combination thereof. However, these solutions are complex and costly: paint needs to be periodically reapplied, bushes need to be trimmed and maintained, and stone columns are expensive to build and replace if damaged. 
     Therefore, a need exists for a protective post cover having a simple, yet strong, design that is formed of a durable, cost-effective material. It is also desirable for such a protective post cover to have decorative features that give the impression of an expensive stone column. 
     SUMMARY OF THE INVENTION 
     Accordingly, embodiments of the present invention include devices, kits, and methods for assembling a blow molded decorative post cover. As used herein, the terms “first” and “second” are used to distinguish one element, set, object, or thing from another, and are not used to designate relative position or arrangement in time. 
     In one embodiment of the present invention, a blow molded post cover having a sleeve and a base is provided. The sleeve has an open bottom end and a hollow interior for receiving a post. The base includes a top cap, a bottom cap, and a plurality of side panels securable to the top cap and the bottom cap. The top cap has a first through-hole for receiving the sleeve, and the bottom cap has a second through-hole for receiving the sleeve. Each of the plurality of side panels has one or more protrusions on a rear surface such that each of the one or more protrusions bears against the sleeve when the base is installed on the sleeve. 
     In some embodiments, each of the plurality of side panels also includes a top end securable to the top cap of the base, a bottom end securable to the bottom cap of the base, a first side end, and a second side end. The first side end of any one of the plurality of side panels is configured to interlock with the second side end of any other one of the plurality of side panels. 
     In some embodiments, the first side end and the second side end of each of the plurality of side panels includes a series of notches and extensions. The notches and extensions of the first side end of a first side panel are configured to interlock with the extensions and notches of the second side end of a second side panel to secure the first side panel to the second side panel and form a seam having a plurality of transverse line segments. Each of the plurality of side panels also includes a decorative surface located on a front face of the side panel and continuing onto surfaces of each extension of the first and second side ends. 
     In some embodiments, the plurality of transverse line segments of the seam are straight line segments. Each straight line segment is generally perpendicular to its adjacent straight line segments. 
     In some embodiments, each of the plurality of side panels also includes at least one male slide and at least one male snap-lock located on the first side end, and at least one female slide and at least one female snap-lock located on the second side end. When a first side panel is interlocked with a second side panel, the at least one male slide of the first side panel engages the at least one female slide of the second side panel to align the first and second side panels, and the at least one male snap-lock of the first side panel engages the at least one female snap-lock of the second side panel to lock the first and second side panels together. 
     In some embodiments, the sleeve also includes a plurality of interior flexible protuberances configured to bear against the post. 
     In some embodiments, the base also includes a first channel adjacent peripheral edges of a bottom surface of the top cap, and a second channel adjacent peripheral edges of a top surface of the bottom cap. The first channel is configured to receive a top flange of the top cap of each of the plurality of side panels to secure the side panels to the top cap. The second channel is configured to receive a bottom flange of the bottom end of each of the plurality of side panels to secure the side panels to the bottom cap. 
     In some embodiments, the sleeve also includes a plurality of tapered exterior projections configured to interact with the top and bottom caps to secure the base to the sleeve. 
     In some embodiments, the sleeve also includes at least one arm. The at least one arm is adapted to support at least one mailbox. 
     In some embodiments, each of the top cap of the base, the bottom cap of the base, and the plurality of side panels of the base have decorative outer surfaces. 
     In another embodiment of the present invention, a method for assembling a blow molded post cover is provided. The method includes the steps of: inserting a sleeve through a first through-hole of a top cap of a base; securing a body of the base to the top cap; placing the sleeve in a second through-hole of a bottom cap of the base; and attaching the bottom cap of the base to the sleeve. The sleeve has an open bottom end and a hollow interior for receiving a post. 
     In some embodiments, before the securing step, the method also includes the step of interlocking a plurality of side panels together to form a body of the base. Each of the plurality of side panels includes a first side end having at least one male slide and at least one male snap-lock, and a second side end having at least one female slide and at least one female snap-lock. When a first side panel is interlocked with a second side panel, the at least one male slide of the first side panel engages the at least one female slide of the second side panel to align the first and second side panels, and the at least one male snap-lock of the first side panel engages the at least one female snap-lock of the second side panel to lock the first and second side panels together. 
     In some embodiments, the method also includes the step of inserting a post through the open bottom end into the hollow interior of the sleeve. 
     In some embodiments, the sleeve also includes a plurality of tapered exterior projections configured to interact with the top and bottom caps to secure the base to the sleeve. 
     In some embodiments, the method also includes the step of installing at least one arm to the sleeve. The at least one arm is adapted to support at least one mailbox. 
     In an alternative embodiment of the present invention, a kit for assembling a blow molded post cover is provided. The kit includes a sleeve and a base. The sleeve has an open bottom end and a hollow interior for receiving a post. The base includes a top cap having a first through-hole for receiving the sleeve, a bottom cap having a second through-hole for receiving the sleeve, and a plurality of side panels securable to the top and bottom caps. Each of the plurality of side panels has a first side end, a second side end, and one or more protrusions on a rear surface such that each of the one or more protrusions bears against the sleeve when the base is installed on the sleeve. The first side end of any one of the plurality of side panels is configured to interlock with the second side end of any other one of the plurality of side panels. 
     In some embodiments, the first side end and the second side end of each of the plurality of side panels includes a series of notches and extensions. The notches and extensions of the first side end of a first side panel are configured to interlock with the extensions and notches of the second side end of a second side panel to secure the first side panel to the second side panel and form a seam having a plurality of transverse line segments. The plurality of transverse line segments are straight line segments, and each straight line segment is generally perpendicular to its adjacent straight line segments. Each of the plurality of side panels also includes a decorative surface located on a front face of the side panel and continuing onto surfaces of each extension of the first and second side ends. 
     In some embodiments, each of the plurality of side panels also includes at least one male slide and at least one male snap-lock located on the first side end, and at least one female slide and at least one female snap-lock located on the second side end. When a first side panel is interlocked with a second side panel, the at least one male slide of the first side end engages the at least one female slide of the second side panel to align the first and second side panels, and the at least one male snap-lock of the first side panel engages the at least one female snap-lock of the second side panel to lock the first and second side panels together. 
     In some embodiments, the sleeve also includes a plurality of interior flexible protuberances configured to bear against the post. 
     In some embodiments, the base also includes a first channel adjacent peripheral edges of a bottom surface of the top cap, and a second channel adjacent peripheral edges of a top surface of the bottom cap. The first channel is configured to receive a top flange of a top end of each of the plurality of side panels to secure the side panels to the top cap. The second channel is configured to receive a bottom flange of a bottom end of each of the plurality of side panels to secure the side panels to the bottom cap. 
     In some embodiments, the sleeve also includes a plurality of tapered exterior projections configured to interact with the top and bottom caps to secure the base to the sleeve. 
     In some embodiments, the kit also includes at least one arm securable to the sleeve. The at least one arm is adapted to support at least one mailbox. 
     In some embodiments, each of the top cap of the base, the bottom cap of the base, and the plurality of side panels of the base have decorative outer surfaces. 
     Other objects of the present invention and its particular features and advantages will become apparent from the following detailed description, claims, and accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a side elevational view of a decorative blow-molded post cover according to an embodiment of the present invention. 
         FIG. 2  is side elevational detail view of a partially formed base of the post cover of  FIG. 1 . 
         FIG. 3  is a bottom perspective detail view of the bottom end of the sleeve of the post cover of  FIG. 1 . 
         FIG. 4  is a bottom perspective view of the top cap of the base of the post cover of  FIG. 1 . 
         FIG. 5  is a top perspective view of the bottom cap of the base of the post cover of  FIG. 1 . 
         FIG. 6  is a bottom perspective detail view of the top cap of  FIG. 4  attached to the sleeve of  FIG. 3 . 
         FIG. 7  is a front elevational view of a side panel of the base of the post cover of  FIG. 1 . 
         FIG. 8  is a side perspective view of the side panel of  FIG. 7 . 
         FIG. 9  is a rear perspective detail view of the first end of the side panel of  FIG. 7 . 
         FIG. 10  is a rear elevational detail view of a portion of the first end of the side panel of  FIG. 7 . 
         FIG. 11  is a rear perspective detail view of the second end of the side panel of  FIG. 7 . 
         FIG. 12  is a rear perspective detail view of a portion of the second end of the side panel of  FIG. 7 . 
         FIG. 13  is a front perspective view of two side panels secured together. 
         FIG. 14  is a rear perspective view of the side panels of  FIG. 13 . 
         FIG. 15  is a bottom perspective detail view of a partially formed base secured to the sleeve of  FIG. 3 . 
         FIG. 16  is a top perspective detail view of a partially formed base secured to the sleeve of  FIG. 3 . 
         FIG. 17  is a top perspective detail view of the arm of the post cover of  FIG. 1 . 
         FIG. 18  is a top perspective view of the mailbox mounting plate of the post cover of  FIG. 1 . 
         FIG. 19  is a bottom perspective view of the mailbox mounting plate of  FIG. 18 . 
         FIG. 20  is a top perspective detail view of the mailbox mounting plate attached to the arm in an unlocked position. 
         FIG. 21  is a top perspective detail view of the mailbox mounting plate attached to the arm in a locked position. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to the drawings, wherein like reference numerals designate corresponding structure throughout the views. The following examples are presented to further illustrate and explain the present invention and should not be taken as limiting in any regard. 
       FIG. 1  shows a blow-molded post cover  10  having a sleeve  20  and a base  30 . The base  30  is formed of a top cap  40 , a bottom cap  50 , and a body  60  formed of side panels  600  that surround the sleeve  20 , as shown in  FIG. 2 . Although the embodiment depicted in the drawing figures has four side panels forming a rectangular base, it is understood that any number of side panels can be used to form various shaped bases, such as cylindrical, triangular, hexagonal, etc. Preferably, the top cap  40 , bottom cap  50 , and body  60  have decorative outer surfaces to give the base  30  the appearance of being formed of traditional, more expensive materials, such as stone, brick, concrete, etc. 
     The sleeve  20  has an open bottom end  22  and a hollow interior  23 , as depicted in  FIG. 3 . After the post cover  10  is assembled, it is preferably installed onto an existing post, which has already been buried and secured in the desired location, by inserting the post through the open bottom end  22  into the hollow interior  23  of the sleeve  20 . In preferred embodiments, the sleeve has a plurality of interior protuberances  24  configured to bear against the post and better secure the sleeve  20  to the post. The interior protuberances  24  are preferably curved and flexible to account for variations in the post&#39;s dimensions such that the sleeve  20  is in constant contact with the post. Although the sleeve shown in the drawing figures has a generally square cross-section, it is understood that the sleeve can be differently shaped to conform to the shape of the post to be covered, such as cylindrical, triangular, hexagonal, etc. 
     Preferably, the sleeve  20  has a plurality of exterior projections  25 . The projections  25  taper along their lengths such that the top end of each projection  25  extends a distance out from the outer surface of the sleeve  20  and the bottom end of each projection  25  is essentially flush with the outer surface of the sleeve  20 . The projections  25  secure the top cap  40  and the bottom cap  50  to the sleeve  20 . The top cap  40  and the bottom cap  50  each have respective through-holes  42  and  52 , as shown in  FIGS. 4-5 . Preferably, through-holes  42 / 52  have a dimension that is equal to, or slightly greater than, the outer dimension of the sleeve  20 . Thus, as the sleeve  20  is inserted through the through-holes  42 / 52 , the top cap  40  and the bottom cap  50  slide along the tapered projections  25  and snap into place after passing the top ends of the projections, which resist removal of the top and bottom caps  40 / 50 . To prevent further insertion of the sleeve  20  through the through-holes  42 / 52 , the sleeve  20  preferably has a perimeter jog  26  that increases the outer dimension of the sleeve  20  to a dimension greater than the dimension of the through-holes  42 / 52 . In preferred embodiments, the distance between the uppermost projection  25  and the perimeter jog  26  is approximately the thickness of the top cap  40  such that the assembled base  30  is locked in place at a desired location on the sleeve  20 , as depicted in  FIG. 6 . 
     In preferred embodiments, each of the side panels  600  have the same structure, dimensions, and design to make assembly of the post cover  10  as simple as possible. As shown in  FIG. 7 , the side panels  600  have a top end  602  and a bottom end  604 . The top end  602  has a flange  606  extending up from the top of the side panel  600 , and the bottom end  604  has a flange  606  extending down from the bottom of the side panel  600 . Preferably, the top and bottom flanges  606  each have an interior surface that is essentially flush with the rear surface  608  of the side panel, as shown in  FIG. 8 . The top and bottom flanges  606  are configured to nest within corresponding channels  46 / 56  located in a bottom surface  44  of the top cap  40  and a top surface  54  of the bottom cap  50  to secure the side panels to the top and bottom caps. The channels  45 / 56  are preferably located adjacent the respective perimeters of the top and bottom caps  40 / 50  such that the assembled base forms a column with the perimeters of the top and bottom caps  40 / 50  being greater than the perimeter of the body  60 . In some embodiments, top and bottom flanges  606  each have a tab  607  that interacts with corresponding recesses  48 / 58  to help align and better secure the side panel  600  to the top and bottom caps  40 / 50 . 
     The side panels  600  have a first side end  610  and a second side end  612 . Preferably, the side ends have corresponding designs such that the first side end of any of the side panels interlocks with the second side end of any other side panel. As seen in the drawing figures, the side ends  610 / 612  have corresponding notches  609  and extensions  611  that interlock similar to jigsaw puzzle pieces. The face of the notch is provided with a generally smooth surface whereas the faces of the extension include decorative patterns and/or texture on the two outward facing sides. As the notches  609  are covered by an extension of another side panel, the un-decorated/textured notch surface is covered by an extension  611  which includes texture/decoration on the two outward facing sides (around the corner of the decorative post assembly). Preferably, when two side panels  600  are connected together, the notches  609  and extensions  611  of the connecting side ends  610 / 612  interlock to form a seam  615  having a plurality of transverse line segments, as depicted in  FIG. 13 . In preferred embodiments, the extensions  611  protrude out from the notches  609  approximately perpendicular thereto such that each transverse line segment of the seam  615  is approximately perpendicular to each adjacent transverse line segment. In some embodiments, the extensions  611  and notches  609  are shaped such that the transverse line segments of the seam  615  are at obtuse or acute angles to adjacent line segments. In other embodiments, the extensions  611  and notches  609  are shaped such that the transverse line segments are curved to form a seam having, for example, alternating concave and convex line segments. In the embodiment shown in the drawing figures, the front surface of the side panels  600  has a decorative surface  613 . Preferably, the decorative surface  613  continues onto the outermost side surface of the extensions  611  of side ends  610 / 612 , as shown in  FIG. 8 . Thus, when the side panels  600  are connected, the decorative surfaces  613  and the transverse line segments of the seam  615  give the base  30  a more realistic stone or brick appearance, as shown in  FIG. 13 . In the embodiments shown, the transverse line segments correspond with part of the stone line pattern on the decorative surfaces. There are additional simulated stone lines which are not part of the separable panels, but portions of the stone line pattern correspond with the extensions/notches described herein. The stone line pattern generally gives the appearance of mortar which would hold stones together. 
     In some embodiments, the first side end  610  of the side panels  600  has a male slide  614  located on a surface defining the top of each extension  611  and the second side end  612  has a female slide  616  located on a surface defining the bottom of each extension  611 , as shown in  FIG. 9 . The male slides  614  each have an elongated protrusion, and the female slides  616  each have an elongated trough that corresponds to the elongated protrusion of a male slide  614 . The male and female slides interact to properly align the side panels as they interlock. 
     In preferred embodiments, the first side end  610  of the side panels  600  has a male snap-lock  618  located on a surface defining the bottom of each extension  611 , and the second side end  612  has a female snap-lock  620  located on a surface defining the top of each extension  611 . The male snap-locks  618  each have an elongated protrusion with a centrally located tab projecting down from the elongated protrusion. The female snap-locks  620  each have an elongated trough, which corresponds to the elongated protrusions of a male snap-lock  618 , and a centrally located recess adapted to receive the tab of a male snap-lock  618 . The elongated protrusions and troughs of the male and female snap-locks interact to properly align the tabs and recesses of the male and female snap-locks such that when the side panels are fully interlocked, the tab of each male snap-lock drops into the recess of each corresponding female snap-lock to secure the side panels together. 
     In some embodiments, each side panel is uniquely shaped for when it is desired to form a base having an irregular shape. In these embodiments, the side panels preferably still interlock as described above, and the side panels are sequentially marked, labeled, engraved, etc., to simplify the post cover assembly. 
     In some embodiments, each side panel  600  has at least one protrusion  630  on the rear surface  608 . The protrusions  630  are sized and configured such that they bear against the sleeve  20  when the base  30  is installed on the sleeve  20 , as shown in  FIG. 2 . The protrusions  630  increase the stability of the post cover  10  by filling the gap between the body  60  of the base  30  and the sleeve  20  in embodiments where the interior perimeter of the body  60  is larger than the outer perimeter of the bottom end  22  of the sleeve  20 . Preferably, the location of the protrusions  630  alternates between several locations on each side panel  600  such that the side panels  600  can nest together to reduce the package density when the post cover  10  is sold/shipped as a kit. 
     In some embodiments, the post cover  10  includes an arm  70  adapted to support a mailbox via a mailbox mounting plate  80 . As shown in  FIG. 17 , the arm  70  has a protrusion  700  located on a top surface of the arm near the distal end of the arm. Protrusion  700  has a distal raised end  702 , a proximal raised end  704 , and a ramped tab  706  located between the two raised ends closer to the proximal raised end. The distal raised end  702  has a distal edge  701  and a proximal edge  703 . The proximal raised end  704  has a distal edge  705  and a proximal edge  707 . The ramped tab  706  has a raised edge  709  facing distal edge  705 . The protrusion  700  has lateral walls  712  running parallel with a longitudinal axis of the protrusion  700 , distal lateral channels  708  formed as undercuts in the distal raised end  702 , and proximal lateral channels  710  formed as undercuts in the proximal raised end  704  and cut-outs in the lateral walls  712 . 
     Preferably, the mailbox mounting plate  80  is shaped to correspond to protrusion  700  such that the plate  80  can be secured to the protrusion  700  in a slide-lock manner. As shown in  FIG. 18 , the plate  80  has a distal opening  81 , a proximal opening  82 , and a medial opening  83  located between the distal and proximal openings closer to the proximal opening. The distal opening  81  has a distal edge  812 , a proximal edge  814 , and lateral projections  84 . The proximal opening  82  has a distal edge  822 , a proximal edge  824 , and lateral projections  85 . Lateral projections  84 / 85  are located on lateral interior walls  88  and are preferably flush with the bottom surface  86  of the plate  80 , as depicted in  FIG. 19 . The plate  80  also includes holes  87  through which screws, or other fastening elements, can pass to attach a mailbox to the plate  80 . 
       FIGS. 20-21  show the preferred process for attaching the mailbox mounting plate  80  to the arm  70 . First, the plate  80  is inserted vertically onto the protrusion  700  such that the proximal edge  703  of the distal raised end  702  is in contact with the proximal edge  814  of the distal opening  81 , and the proximal edge  707  of the proximal raised end  704  is in contact with the proximal edge  824  of the proximal opening  82 , as shown in  FIG. 20 . In this unlocked position, the lateral protrusions  84 / 85  are aligned with the lateral channels  708 / 710 , and the ramped tab  706  is aligned with the medial opening  83 . Next, the plate  80  is slid horizontally along the arm  70  toward the sleeve  20  such that the lateral protrusions  84 / 85  enter the lateral channels  708 / 710  and the median bottom surface  89  defining the opening  83  slides up the ramped tab  706  until the raised edge  709  snaps into place within the opening  83 , as depicted in  FIG. 21 . In this locked position, the distal edge  701  of the distal raised end  702  is in contact with the distal edge  812  of the distal opening  81 , the distal edge  705  of the proximal raised end  704  is in contact with the distal edge of the proximal opening  82 , and the raised edge  709  of the ramped tab  706  secures the plate  80  to the arm  70  by resisting sliding of the plate  80  away from the sleeve  20  such that the lateral protrusions  84 / 85  cannot disengage from the lateral channels  708 / 710 . 
     In preferred embodiments, the arm  70  is part of the sleeve  20 , which are blow-molded to form one piece. In some embodiments, the arm  70  is separate from the sleeve  20  and requires installation by inserting a first end of the arm  72  through a through-hole in the sleeve  20  positioned near the upper end of the sleeve  21  and secured to the sleeve via fasteners, such as bolts, screws, and the like. In some embodiments, the arm  70  includes a support member  76 . Preferably, the support member  76  is blow-molded with the arm  70  and sleeve  20  to form one piece, but the support member  76  may also be part of a separate arm  70  to be attached to the sleeve  20  by inserting the lower end of the support member  77  into a hole in the sleeve  20  below the through-hole and secured via fasteners. As shown in  FIG. 1 , the installed arm  70  is approximately perpendicular to the longitudinal axis of the sleeve  20 . 
     Preferably, the post cover  10  is assembled according to the following method. First, the bottom end  22  of the sleeve  20  is inserted through the through-hole  42  of the top cap  40 . Second, the top cap  40  is secured to the sleeve  20  by sliding the top cap  40  along the length of the sleeve  20  until the top cap  40  passes over the uppermost of the plurality of tapered exterior projections  25 . Third, the body  60  of the base  30  is assembled by interlocking all of the side panels  600  together as described above. Fourth, the assembled base  30  is placed around the bottom end  22  of the sleeve  20  and secured to the top cap  40  by inserting the top flanges  606  of the body  60  into the channel  46  of the top cap  40 . Fifth, the bottom end  22  of the sleeve  20  is placed in the through-hole  52  of the bottom cap  50 . Sixth, the bottom cap  50  is attached to the sleeve  20  by sliding the bottom cap  50  along the length of the sleeve  20  until the bottom cap  50  passes over the lowermost of the plurality of tapered exterior projections  25 . Preferably, as the bottom cap  50  attaches to the sleeve  20  the bottom flanges  606  of the body  60  insert into the channel  56  of the bottom cap  50  to fully assemble the base  30  of the post cover  10 . Finally, the assembled post cover  10  is preferably installed on a post that has been buried and secured in a desired location by inserting the post through the open bottom end  22  and into the hollow interior  23  of the sleeve  20 . In some embodiments, the sleeve  20  includes a pre-attached arm  70 , and assembly of the post cover  10  includes the additional step of securing a mailbox to the arm  70  via mailbox mounting plate  80 . In other embodiments, assembly of the post cover  10  includes the additional steps of installing an arm  70  to the sleeve  20 , and securing a mailbox to the arm  70  via mailbox mounting plate  80 . 
     Although the invention has been described with reference to a particular arrangement of parts, features, and the like, and a particular method of assembling these arrangements and features, these are not intended to exhaust all possible arrangements, features, or methods of assembly. Indeed, many other modifications and variations will be ascertainable to those of skill in the art.