Just a thought; have you tried casting to float?
$min_lat = (float) number_format($zip_lat - $lat_range, "4", ".", "");
$max_lat = (float) number_format($zip_lat + $lat_range, "4", ".", "");
$min_lon = (float) number_format($zip_lon - $lon_range, "4", ".", "");
$max_lon = (float) number_format($zip_lon + $lon_range, "4", ".", "");
-John
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