Mail slot insert with foam attachment

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Solution Overview

Problem

Existing mail slot inserts are not adaptable to varying door dimensions, leading to air leaks and the need for new inserts, which can allow cold and hot air, as well as pests, to enter buildings.

Innovation Solution

An adjustable mail slot insert with L-shaped frame members and adjustable components, including protrusions and channels, allows for horizontal and vertical adjustment to fit any door size, combined with deformable foam and magnetic flaps for air-tight sealing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a fixed-size mail slot insert is used, then the installation is simple, but it does not adapt to varying door dimensions creating air gaps

Engineering Contradiction:

Improveadaptability to door dimensionsVSAvoidinsert structure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The mail slot insert incorporates adjustable components including telescoping side rails with extension members that can be moved between retracted and extended positions. This dynamic structure allows the insert to adapt its dimensions to fit various door slot sizes while maintaining a relatively simple base structure that can be configured as needed.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The insert is divided into modular components including side rails, extension members, cross members, and sealing elements that can be independently adjusted and positioned. This segmentation allows each component to be optimized for its specific function while collectively providing adaptability to different door dimensions without requiring complete redesign.

Inventive Principle:

Principle #1Segmentation

2Ease of operation

If a smaller mail slot insert is used in a larger slot, then installation is easier, but air gaps are created allowing cold and hot air to flow through

Engineering Contradiction:

Improveease of installationVSAvoidair leakage

Core Design Contradiction:

Ease of operationVSLoss of energy

Solution Approach 1:

The insert incorporates flexible foam sealing members and weatherstripping elements that can be compressed and molded to fill irregular gaps between the insert frame and the door slot opening. These flexible sealing components conform to the specific dimensions of the door slot, preventing air leakage while accommodating variations in slot size.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The insert allows for adjustment of its effective sealing perimeter through telescoping rails and movable cross members. By changing the dimensional parameters of the insert frame to match the door slot dimensions, the sealing surfaces are optimized to eliminate gaps while maintaining ease of installation through simple adjustment mechanisms.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If a custom-sized mail slot insert is manufactured, then air tightness is improved, but the cost and complexity of obtaining a new insert increases

Engineering Contradiction:

Improveair tightnessVSAvoidmanufacturing flexibility

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The insert design incorporates universal adjustment mechanisms that allow a single insert model to serve multiple door slot sizes. The telescoping rails, extendable cross members, and adjustable sealing systems enable one insert design to reliably seal various slot dimensions, eliminating the need for multiple custom-manufactured insert sizes while maintaining air tightness.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Adaptability or versatility

If an adjustable mail slot insert is used, then adaptability to any door size is achieved, but the device complexity increases

Engineering Contradiction:

Improveadjustability to door dimensionsVSAvoidframe structure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The adjustable components of the insert, including extension members and telescoping rails, are designed to nest within each other when not in use. This nesting arrangement allows the adjustable mechanisms to be compact when retracted, reducing the apparent complexity of the overall structure while maintaining full adjustability functionality when needed.

Inventive Principle:

Principle #7Nested doll (Nesting)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The adjustable insert provides a secure, air-tight fit in any mail slot, preventing air and pest entry while being easy to install, regardless of door thickness or size, ensuring effective insulation and protection.

Implementation Method 1

the flap further comprises a resistant deformable foam material

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

magnetic flaps for air-tight sealing

Methodology Applied

Scientific EffectMagnetism: Magnetism

Data Source

PatentUS11771254B2Mail slot insert with foam attachment

Publication Date: 2023.10.03 BOTA INC

AI summary

An adjustable mail slot insert may include two top members connected to one another and two bottom members connected to one another. Each bottom member may include a side leg and a bottom leg. Each top member may include a side leg and a top leg. One top member may be connected to one bottom frame member and another top frame member may be connected to another bottom frame member. The insert may be adjustable in a horizontal direction and a vertical direction through movement of the members relative to one another.