Abstract:
A weatherproof outlet plate cover assembly provides a weatherproof a universal lid that is diagonally hinged at a corner of the cover plate for unobstructed lateral and downward routing of electrical cables in either a horizontal of vertical location. The universal lid carries a sealing gasket that is spring biased against a projecting rim that circumscribes a center panel provided with a center opening(s) for use with either duplex or GFCI receptacles. The hinge design allows the use of one product in each formal for two applications—vertical plus horizontal mounting.

Description:
FIELD OF THE INVENTION 
     The present invention relates to cover plates for electrical boxes, and, in particular, a hinged lid for standard outlet cover plates. 
     BACKGROUND OF THE INVENTION 
     Electrical outlets are generally placed about the exterior of a residential home for enabling outdoor electrical service. Inasmuch as the outlets are exposed to weather conditions and adversely affected by moisture and contaminants, various covering devices have been used to weatherproof the electrical components. Where longer term connections are desired, hinged housings have been proposed wherein the weatherproofing is maintained when the outlet is in service. Examples of such approaches are disclosed in U.S. Pat. Nos. 6,028,268; 6,133,531; 3,813,640; D460,421; and D486,452. When continuous or extended term exterior service is required, dedicated in ground is commonly used as an alternative. 
     The majority of exterior residential uses are only temporary applications, such as seasonal lighting and power tool operation. Where electrical shorts may be experienced, electrical safety is readily provided by substituting a ground fault current interrupter (GFCI) for a conventional duplex receptacle. Weatherproofing for the receptacle is nonetheless desirable for ongoing protection, and hinged receptacle covers meeting applicable standards, such National Electric Code and/or the Underwriters Laboratory approvals, are widely available. While these covers provide generally satisfactory results, certain deficiencies are apparent. Many use a separate cover for each receptacle outlet. In others, such as disclosed in U.S. Pat. No. 4,381,063 a single side cover is provided. As the receptacle may be mounted in either a horizontal or vertical orientation, the covers can restrict the free downward and lateral routing the electrical cord. In order to provide convenient routing in both situations, side mount and top mount covers have been proposed. For instance, U.S. Pat. No. 5,763,831 discloses a universal cover plate having pairs of side and top hinge tabs that may be selectively used for the cover. The hinge tabs not required for the desired application are removed. The tabs and the cover project outwardly of the frontal profile of the cover plate and may not be compatible with recessed or limited access locations. 
     SUMMARY OF THE INVENTION 
     A weatherproof outlet plate cover assembly in accordance with the present invention provides a weatherproof a universal lid that is diagonally hinged at a corner of the cover plate for unobstructed lateral and downward routing of electrical cables in either a horizontal of vertical location. The universal lid carries a sealing gasket that is spring biased against a projecting rim that circumscribes a center panel provided with a center opening(s) for use with standard electrical devices, such as duplex or GFCI receptacles or electrical switches. In the open position, the lid is positioned within the frontal envelope of the cover plate allowing use in recessed and restricted access locations. The hinge design thus allows the use of one product of each configuration for two applications, i.e. vertical plus horizontal mounting. Moreover, the design may be may be utilized in multiple-gang configurations, either with a single cover or multiple hinge sets. 
     Accordingly, it is an object of the present invention to provide a cover plate assembly for outdoor standard receptacles that may be mounted in either a vertical or horizontal orientation without restricting access for electrical connection. 
     Another object of the invention is to provide a weatherproof outdoor assembly for use with standard receptacles with minimal structural variation. 
     A further object of the invention wherein a corner mounted cover provides a weatherproof closure for outdoor electrical receptacles. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
       The above and other features of the present invention will become apparent upon reading the following description of the preferred embodiments taken in conjunction with the accompanying drawings in which: 
         FIG. 1  is a front perspective view of a universal outlet plate cover assembly for an electrical outlet box in accordance with embodiments of the invention showing the cover in the closed position; 
         FIG. 2  is a front perspective view of the universal outlet plate cover assembly for a duplex receptacle oriented in a horizontal position and showing the cover lid in the open position; 
         FIG. 3  is a front perspective view of a universal outlet plate cover assembly for a GFCI receptacle oriented in the vertical position and showing the cover lid in the open position; 
         FIG. 4  is a front view of the duplex outlet plate for the assembly of  FIG. 2 ; 
         FIG. 5  is a rear view of the outlet plate of  FIG. 4 ; 
         FIG. 6  is a cross sectional view taken along line  6 — 6  in  FIG. 4 ; 
         FIG. 7  is a cross sectional view taken along line  7 — 7  in  FIG. 4 ; 
         FIG. 8  is an enlarged cross sectional view of the detail in  FIG. 7 ; 
         FIG. 9  is a front view of the GFCI outlet plate for the assembly of  FIG. 3 ; 
         FIG. 10  is a front view of the universal cover lid for the assemblies; 
         FIG. 11  is a rear view of the cover lid of  FIG. 10 ; 
         FIG. 12  is to side view of the cover lid of  FIG. 10 ; 
         FIG. 13  is an enlarged cross section view of the detail in  FIG. 12 ; 
         FIG. 14  is perspective view of the lid spring; 
         FIG. 15  is a fragmentary cross sectional view of the cover lid for the assemblies of  FIGS. 2 and 3  in the open position; and 
         FIG. 16  is a fragmentary cross sectional view of the cover lid for the assemblies of  FIGS. 2 and 3  in the closed position; and 
         FIG. 17  is an enlarged fragmentary cross sectional view of the lid spring on the cover plate. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to  FIG. 1 , there is a universal outlet plate cover assembly  10  for electrical outlet boxes carrying standard receptacles prescribed by UL specifications, such a duplex, GFCI and toggle switches. The cover assembly comprises a cover lid  12  identical in both the duplex and GFCI configurations illustrated herein, and a cover plate  14  differing only in the openings for receiving and mounting on the receptacle. The cover plate  14  is of standard dimensions having laterally spaced long sides and longitudinally spaced short sides.  FIG. 2  illustrates the duplex embodiment and shows the assembly in a horizontal mounting position of the long sides with the cover lid  12  in the open position with respect to the duplex cover plate  14   a .  FIG. 3  illustrates the GFCI embodiment and shows the assembly in a vertical mounting position of the long sides with cover lid in the closed position with the GFCI cover plate  14   b . The cover lid  12  is pivotally supported on the cover plate  14  by a diagonal corner hinge assembly  16 . The cover lid  12  is self biased by a pair of lid springs  18  to a closed position overlying and weatherproofing the associated receptacle. In the open operative position, the cover lid  12  is inclined with respect to the cover plate, within the frontal profile thereof. The axis  18  of the hinge assembly  16  is inclined at an angle “A” with respect to the top short wall of the cover plate, allowing full unrestricted access from two sides in both horizontal and vertical mounting orientations for establishing electrical connections. An angle of about 60° is preferred. 
     As discussed above, both cover plates are identical in structure differing only in the provisions for receptacle and mounting, and common identification will hereinafter be used with respect to common structure. Referring to  FIGS. 4 through 8 , the cover plate  14   a  for the duplex assembly is a one-piece molded plastic or cast metal part having a generally rectangular base  20  circumscribed by a peripheral rim  22  outwardly bounded by a downwardly curved lip  24  and inwardly bounded by a thin walled generally upwardly extending shoulder  26  the inner surface of which is configured to circumscribe the outer periphery of either a duplex or a GFCI receptacle. A planar panel  27  extends inwardly from the shoulder  26  and includes a pair of spaced duplex apertures  28  spaced by a cross band  30  having a countersunk opening  32 . In assembly, the apertures are located and configured for receiving the duplex outlets and the opening receives a conventional mounting screw for attachment to the duplex receptacle. As described below, the panel  26  may be apertured for receiving a GFCI receptacle. 
     The corner hinge assembly  16  includes a hinge block  33  formed integrally diagonally across the upper left corner of the base  20 . The hinge block  33  includes a pair of spaced upwardly extending hinge posts  34  interconnected by an upwardly extending stop wall  36 . A pair of rectangular spring receiving recesses  38  are formed in the base  20  between the hinge posts  34  for receiving the cover lid springs  18  as shown in  FIG. 17 . As shown in  FIG. 8 , a downwardly extending and inwardly opening slot  40  in formed in each post  34  for receiving the hinge pins of the cover lid as described below for prescribing rotation about the hinge axis. The axis of rotation in the slots is along the axis  19 . Upwardly extending reinforcing ribs are formed adjacent the recesses  38 . As shown in  FIG. 5 , downwardly extending generally trapezoidal reinforcing ribs  44  are formed on the lower surface of the base adjacent the lateral ends. The ribs  44  engage the receptacle arms to increase the mounting stability of the assembly. 
     Referring to  FIGS. 14 and 17 , the springs  18  are formed of spring steel and comprise a planar base  50  and a deflectable spring arm  52 . The base  50  that engages the bottom wall  54  of the recess and terminates at one end with a downwardly turned tab  56  that is located in a locating slot  58  with a curved end  60  merging with the lower end of the spring arm  52 . The spring arm  52  includes a lower end  62 , a reversely curved middle section  64 , and an upper end  66  terminating with a reversely downwardly curved tip  68 . In assembly as described below, the spring arm  52  is downwardly deflected to provide a self closing biasing force on the cover lid  12 . 
     Referring to  FIGS. 3 and 9 , the GFCI cover plate  12   b  has an opening  70  in the panel  27  inwardly of the shoulder  26  to provide telescopic assembly with the GFIC receptacle and a pair of countersunk openings  72  for conventional assembly by mechanical fasteners to the mounting arms of the receptacle. In other respects, the cover plate  14   b  is structurally the same as cover plate  14   a.    
     Referring to  FIGS. 10 through 13 , the cover lid  12  is a one-piece molded plastic or metal casting comprising a generally rectangular lid section  70  having a diagonally outwardly extending hinge arm  72  at one corner and a diagonally outwardly extending lift tab  74  at the opposed corner. The lid section  70  has a planar top wall merging with the top walls of the hinge arm  72  and lift tab  74 . The cover lid  12  has a downwardly extending rim  76  about the lid section  72  outwardly circumscribing the shoulder  26  on the cover plates and forming a downwardly opening recess carrying a gasket  78  that sealingly engages the top surface of the shoulder  26  on the cover plate to form a weatherproof sealing interface in the closed position. The hinge arm  72  outwardly terminates with a pair of spaced fingers  80  carrying a pair of outwardly extending cylindrical hinge pins  82  aligned along axis  84 . In assembly as shown in  FIG. 8 , the hinge pins  82  are rotatably journaled in the slots  40  in the hinge posts  34  for prescribing rotation of the cover lid about the assembly axis  19  between the open and closed positions. As shown in  FIGS. 12 and 13 , the hinge fingers  80  terminate with a curved cam surface  86  having an origin  88  beyond the axis. In assembly as shown in  FIGS. 15 and 16 , the cam surface  86  deflects the tips of the springs creating a torque in the closing directions, thereby providing self biasing from the open position 
     It will thus be appreciated that the present invention provides an outlet plate cover assembly wherein a single diagonal corner hinge assembly between the cover lid and the cover plate provides wide access for cable routing in either a horizontal or vertical mounting a wherein a universal cover plate may be mounted on a universal cover plate, modified only at a central panel for accepting a standard receptacle selected from duplex or GFCI configurations. 
     For the other applications, such as switches, the center panel is appropriately apertured to receive the device. For use in multiple gang assemblies, the cover plate is provided with plural sets of openings for receiving the selected electrical devices and a single or multiple hinged cover lid(s) used for sealing the outlets and/or switches. 
     Having thus described a presently preferred embodiment of the present invention, it will now be appreciated that the objects of the invention have been fully achieved, and it will be understood by those skilled in the art that many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the sprit and scope of the present invention. The disclosures and description herein are intended to be illustrative and are not in any sense limiting of the invention, which is defined solely in accordance with the following claims.