Abstract:
A cover and bracket are provided for covering ceiling junction box openings in which there are no visible connecting devices on the face or outer surface of the cover. The cover has an inner surface and an outer surface. A peg is connected to the inner surface of the cover and includes raised ribs at an angle to the outer periphery of the cover. The bracket is adapted for connection to a junction box with connectors such as bolts or screws, and has one or more central engagement openings which are sized and shaped to selectively receive and engage the peg such that the cover holds fast to the junction box and covers the junction box opening and some portion of the surrounding ceiling surface. In a preferred embodiment, there are two central engagement openings. A first engagement opening contains spring engagement tabs that provide frictional holding of the peg. A second engagement opening is of a diameter less than the peg and ribs allowing the cover to be rotated clockwise therein. The central engagement openings may be elongated to permit inversion of the bracket for installation over junction boxes that are recessed into the ceiling.

Description:
FIELD OF THE INVENTION 
     This invention relates to covers and closures, and more particularly, to covers of electrical outlets and junction boxes. 
     BACKGROUND OF THE INVENTION 
     Homebuilders typically cover ceiling-mounted junction boxes immediately after installation to allow house buyers the opportunity to later select a ceiling-mounted device according to their own taste. This is often due to the wide variety of lights and fans and combinations available in many styles and sizes for ceiling installation. Earlier covers were usually of the cup or pie plate type. Such prior art covers were typically attached to the junction box using a bracket and screws. This prior art bracket included a threaded hole in its center, and a short length of small diameter threaded pipe threaded into the threaded hole in the bracket. The prior art cover included a hole in its center which was sized to receive the pipe. A decorative cap nut, in this prior art arrangement, was used to engage the protruding pipe and secured the prior art cover to the junction box. 
     Such prior art covers, although perhaps effective at covering the junction box, were highly visible and, to some, marred the appearance of the ceiling. The cap nut, although made in decorative finish, remained visible after installation of the prior art cover. Later, flat cover plates were developed to maintain a low profile when attached to the ceiling, thereby being less noticeable. The flat prior art cover plates were usually held in place against the ceiling by flat headed bolts that were screwed into threaded holes of a bracket. This type of prior art cover was an improvement over the earlier version in that it was less noticeable, however, the heads of the securing bolts had to be painted to match the cover and the surrounding ceiling. During installation of this type of cover, it was common for the installer to mar the surface of the cover while tightening the bolts (or screws) of the cover. The paint frequently chipped, making the cover visible and distracting. The cover of this type usually required “touch-up” with paint after the cover had been installed. It is characteristic of prior art covers that no matter how small or decorative, the connecting mechanism is always visible and apparent. 
     In U.S. Pat. No. 6,005,190 (hereinafter the &#39;190 patent), the present applicant for invention provided a decorative cover that overcame some of the deficiencies of prior art covers. This patent provided a cover that attached to a junction box and obscured the view of the box while at the same time eliminating the use of any protruding fasteners that would detract from the appearance of the cover. The cover of the &#39;190 patent was adaptable for covering junction boxes which were level with the surrounding ceiling and also for covering cover junction boxes recessed within a ceiling. 
     Although the &#39;190 patent provided a cover with many improvements over the prior art, the cover was still not optimal when used on a ceiling with an uneven or roughly textured surface. 
     It is therefore an object of the invention to provide a cover for electrical junction boxes which combines the pleasant appearance of the cover of the &#39;190 patent with an ability to cover junction boxes mounted within uneven or rough textured ceilings. 
     It is another object of the invention to provide such a cover, which attaches to a junction box in a manner that fasteners are hidden from view. 
     SUMMARY OF THE INVENTION 
     A cover plate for a ceiling-mounted electrical-junction box includes an inner surface and an outer surface. A peg is connected to the inner surface and extends generally perpendicularly therefrom a predetermined distance. According to a first embodiment, the peg includes raised ribs along its side. The ribs are angled with respect to the rim of the cover. A bracket is sized and shaped to be secured to the junction box, and includes two peg-engagement openings. The peg-engagement openings are sized and shaped to selectively receive and engage the ribs of the peg so that the cover holds fast to the bracket and covers the junction box opening and some portion of the surrounding ceiling. 
     The first of the peg-engagement openings preferably includes flexible tabs that support the peg and engage the ribs of the peg as it is pushed into the engagement opening. A second peg-engagement opening preferably is of a smaller diameter than the peg and ribs such that clockwise rotation of the cover will cause it to be pulled tightly into the opening. The first peg-engagement opening provides a quick push-in type connection mechanism that is appropriate for applying the cover to junction boxes within smooth surrounding walls. The second peg-engagement opening provides a means for securing the cover to junction boxes within uneven surrounding walls or roughly textured walls. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a top plan view of a preferred embodiment of a round, flat cover plate according to the present invention. 
     FIG. 2 is a side view of the cover plate of FIG.  1 . 
     FIG. 3 is a partial sectional view of the cover plate of FIG. 1 showing in detail the ribbed peg, according to the invention. 
     FIG. 4 is a partial side view of the cover plate of FIG.  1 . 
     FIG. 5 is a top plan view of a preferred embodiment of the connecting bracket according to the present invention. 
     FIG. 6 is a partial sectional view of the connecting bracket taken along line  6 — 6  of FIG. 5 showing details of the first peg-engagement opening. 
     FIG. 7 is a partial sectional view of the connecting bracket taken along line  7 — 7  of FIG. 5 showing details of the second peg-engagement opening. 
     FIG. 8 is an exploded perspective view of the preferred embodiment of the invention including the bracket in alignment to be secured to a junction box through outer openings and the cover plate in alignment to be secured to the first peg-engagement opening in the bracket. 
     FIG. 9 is an exploded perspective view of the preferred embodiment of the invention including the bracket in alignment to be secured to a junction box through inner openings and the cover plate in alignment to be secured to the second peg-engagement opening in the bracket. 
    
    
     REFERENCE NUMERALS USED IN THE SPECIFICATION AND DRAWINGS 
       20 —cover plate 
       22 —inner surface 
       24 —outer surface 
       26 —perimeter surface 
       28 —center point 
       30 —rim 
       32 —beveled edge 
       34 —peg 
       36 —axis 
       38 —remote end (of peg) 
       40 —tapered surface 
       42 —side surface 
       44 —raised ribs 
       46 —peak (of rib) 
       50 —bracket 
       52 —fasteners 
       54 —elongated body 
       56 —longitudinal axis 
       58 —opposing ends 
       60 —center portion 
       62 —strengthening ribs 
       66 —first peg-engagement assembly 
       68 —second peg-engagement assembly 
       70 —outer pair of openings 
       72 —inner pair of openings 
       74   a —first side of elongated body 
       74   b —second side of elongated body 
       76 —ring-shaped perimeter wall 
       78 —central opening (first peg-engagement assembly) 
       80 —engagement tab 
       82 —arcuate path 
       84 —remote end (of tab) 
       86 —arcuate edge (of tab) 
       88 —circular opening 
       90 —central opening (second peg-engagement assembly) 
       92 —circular perimeter wall 
       94 —grooves 
       96 —electrical junction box 
       98 —wall or ceiling structure 
       100 —opening of junction box 
       102 —apertures 
       104 —lower rim (of junction box) 
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to FIGS. 1 and 2, a flat cover plate  20  is shown defining an inner surface  22 , an outer surface  24 , a perimeter surface  26 , a center point  28 , and a rim  30 . It is preferred in this embodiment, that perimeter surface  26  and outer surface  24  meets with a beveled edge  32 , as shown, and that cover plate  20  is made from plastic. A peg or pin (hereinafter called “peg”)  34  is attached to inner surface  22 , extending generally perpendicularly from cover plate  20 , as shown in FIG. 2, along an axis  36 . Peg  34  is preferably integrally formed with cover plate  20  and is positioned at center point  28 . Peg  34  includes a remote end  38  that has a tapered surface  40 , and a side surface  42 . Although peg  34  may have any cross-sectional shape without departing from the gist of the invention, it is preferred that peg  34  have a generally circular cross-section, centered along axis  36 . 
     Referring to FIGS. 1-3, located along side surface  42  of peg  34  are a set of raised ribs  44  which extend in a longitudinal strip along the side of the peg  34 . Each raised rib of ribs  44  preferably extends circumferentially about side surface  42  less than 90 arc degrees, as illustrated in FIG. 1, and protrudes a predetermined distance beyond the circular cross-sectional shape of peg  34 , as shown in FIG.  3 . However, ribs  44  may have any shape and may extend circumferentially about side surface  42  greater than 90 degrees (including 360 arc degrees). Each raised rib  44  is preferably triangular in cross-section, as shown in FIG.  3  and the peak  46  of each rib  44  preferably extends 0.02 inch beyond the side surface  42  of the peg  34 . There are preferably twenty-five ribs  44  per inch along the side surface  42 . These dimensions of the ribs  44  are for illustrative purposes only as the size and the ribs per unit length of peg can be varied without departing from the scope of the invention. 
     A bracket  50 , according to a preferred embodiment of the invention, is shown in FIG.  5  and is used to secure cover plate  20  to a junction box (not shown). Bracket  50  is secured to the junction box using fasteners  52  (shown in FIGS.  8  and  9 ). Bracket  50  includes an elongated body  54  defining a longitudinal axis  56 , two opposing ends  58  and a wide center portion  60 . Bracket  50  is preferably made from a strong resilient plastic, as detailed below and is appropriately reinforced with integrally molded ribs  62 , and bosses  64  as those skilled in the art would appreciate. Located at the center portion  60 , and preferably integrally formed with body  54  are first  66  and second  68  peg-engagement assemblies. Located near each opposing end  58  and along longitudinal axis  56  is an outer pair of openings  70  having a width (measured transverse to longitudinal axis  56 ) slightly greater than the shaft diameter of the fastening screws  52  (see FIG.  8 ). An inner pair of openings  72  are provided on the elongated body  54  and are located farther from the opposing ends  58  of the bracket  50  than the outer pair  70 . As depicted in FIG. 5, each of the openings in the outer pair of openings  70  are located on opposite sides  74   a ,  74   b  of the elongated body  54  in the preferred embodiment of the bracket  50 . Likewise, each of the openings in the inner pair of openings  72  are located on opposite sides  74   a ,  74   b  of the elongated body  54  in the preferred embodiment of the bracket  50 . 
     Referring again to FIG. 5, the first peg-engagement assembly  66  includes a ring-shaped perimeter wall  76  defining a central opening  78 , and radially-inwardly directed engagement tabs  80 . Tabs  80  are preferably integrally formed with elongated body  54  and are generally coplanar with body  54 . There are preferably four such tabs  80  that are preferably equally spaced at 90 arc degree intervals within wall  76  so that, as described below, at least one tab  80  will engage with raised ribs  44  when peg  34  (not shown) is inserted into bracket  50 . Tabs  80  are molded in such a manner to provide a spring-like resiliency to each tab while maintaining its structural integrity, perhaps using conventional plastic-injection molding techniques known by those skilled in the art. In this arrangement, each tab  80  is resiliently displaceable along an arcuate path  82 , illustrated for one tab  80  in FIG.  6 . 
     Referring to FIGS. 5 and 6, each tab  80  in the first peg-engagement assembly  66  includes a remote end  84  that is generally adjacent to center portion  60  and includes an arcuate edge  86  so that collectively the four tabs define a circular opening  88  located at center portion  60 . Remote end  84  of each tab  80  is preferably formed as an arc having essentially the same radius as peg  34  so that the contact between each tab  80  and peg  34  is maximized. Circular opening  88  has an effective diameter that is at least equal to, and preferably smaller than the diameter of peg  34 . 
     Referring to FIG. 8, peg  34  of the cover  20  must be sufficiently rigid and strong to be pushed though the circular opening  88  of the first peg-engagement assembly  66  and deflect the tabs  80  sufficiently such that they hold the peg  34  of the cover plate  20  secure. 
     With reference to FIGS. 5 and 7, the second peg-engagement assembly  68  includes a central opening  90  including a circular perimeter wall  92  and two grooves  94  cut preferably along the entire length of the perimeter wall  92 . The central opening  90  of the second peg-engagement assembly  68  is of a diameter smaller than the width of the peg  34  and raised ribs  44  combined (not shown). 
     As explained below, the cover plate may be used in conjunction with either the first or second peg-engagement assembly to secure the cover to an electrical junction box. The first peg-engagement assembly is typically used when the surrounding ceiling surface is smooth and provides a means of quickly and easily pushing the cover plate onto the box. The second peg-engagement assembly provides a means of screwing the cover into the box. The second peg-engagement assembly pulls the cover toward the ceiling and provides a tighter fit to the box which is typically needed when the ceiling is uneven or has a rough-textured finish. 
     FIG. 8 illustrates operation of the invention using the first peg-engagement assembly  66 . As shown in FIG. 8, an electrical junction box  96  is typically mounted within a wall or ceiling structure  98  so that the opening  100  of the junction box  96  is exposed through the structure  98 . A user first examines the apertures  102  in the junction box  96  to determine whether the outer  70  or inner  72  pair of openings will be used for affixing the bracket thereto. FIG. 8 depicts a junction box  96  in which the apertures  102  are of a spacing equal to the spacing between the outer pair of openings  70 . Bracket  50  is therefore first secured to junction box  96  using fasteners  52  that pass through the outer  70  pair of openings. The design of the openings  70  provides an easy means of connecting the bracket  50  to the junction box  96 . Typically an installer would screw the fasteners  52  partially into the apertures of the junction box  96 . The bracket  50  is then brought into contact with the surrounding ceiling surface  98  and rotated in the direction shown by arrows “a” to seat the openings against the fasteners  52 . The fasteners  52  are then tightened thereby securing the bracket  50  to the box  96 . With the bracket  50  secured to the box  96 , the circular opening  88  of the first peg-engagement assembly  66  and the central opening  90  of the second peg-engagement assembly  68  are positioned very near the center of the junction box opening  100 . As depicted in FIG. 8, the cover plate  20  is then pushed in the direction shown by arrow “b” until the peg  34  enters the central opening  78  of the first peg-engagement assembly  66  and the raised ribs  44  on the peg  34  engage one or more of the tabs  80 . As peg  34  passes through central opening  78 , at least one resilient tab  80  flexes along arcuate path  82  (FIG. 6) to accommodate raised ribs  44 . The remaining tabs  80  function to guide and support peg  34  and may also provide frictional engagement with side surface  42  of peg  34 , or other raised ribs  44 . Peg  34  is advanced into central opening  78  until cover plate  20  abuts the surface of structure  98  (e.g., the ceiling). The resilient nature of cover plate  20  and engagement tabs  80  allow slight deformation of cover plate  20  upon insertion so that cover plate is tightly drawn against the surface of structure  98 . 
     The frictional engagement between raised ribs  44  and tabs  80  is sufficient to hold cover plate  20  tightly against the surface of structure  98 , yet easily overcome through prying should it be necessary to remove cover plate  20  from junction box  96  without damaging tabs  80 . Cover plate  20  may be re-installed following the steps listed above. 
     Operation of the invention using the second peg-engagement assembly  68  to secure the cover to a junction box is illustrated in FIG.  9 . Apertures  102  injunction box  96  are spaced a shorter distance apart than the apertures shown in FIG.  8 . In this instance, the inner pair of openings  72  is used to secure the bracket  50  to the junction box  96 . Similar to use of the outer pair of openings, the fasteners  52  may first be partially inserted into the apertures  102 . Bracket  50  may then be placed against the lower rim  104  of junction box  96  and rotated in the direction of arrow “c” in FIG. 9 to align the bracket  50  properly with the inner pair of openings  72 . Once bracket  50  is secured to the box  96 , the second peg-engagement assembly  68  is positioned near the center of the box  96 . Peg  34  of cover plate  20  may then be inserted into the central opening  90  in the second peg-engagement assembly  68  and cover  20  rotated in the direction of arrow “d” in FIG. 9 to cause the peg  34  and the raised ribs  44  to enter the central opening  90 . Raised ribs  44  are preferably at an angle sloping from left to right (FIG.  4 ). Therefore, as peg  34  of cover plate  20  is rotated clockwise as shown in FIG. 9, since central opening  90  is of a smaller diameter than the diameter of the raised ribs  44  and peg  34 , raised ribs  44  bite into the circular perimeter wall  92  (FIG. 7) of the second peg-engagement assembly  68  and cause cover plate  20  to be drawn toward the secured bracket  50 . Grooves  94  in the circular perimeter wall  92  assist raised ribs  44  in obtaining a bite within the second peg-engagement assembly. Cover plate  20  may then be rotated clockwise as far as desired by the installer. Typically an installer would rotate cover plate  20  until the rim  30  of the cover plate contacted the surrounding ceiling structure  98 . Since the second peg-engagement assembly  68  pulls the peg  34  and cover plate  20  upward, cover plate  20  can be fastened until the rim  30  of the cover contacts the ceiling structure  98 , creating a very attractive and unobtrusive cover for the junction box. As a result of the second peg-engagement assembly  68  being very nearly centered on the junction box  96 , and since the typical outer diameter of the cover plate is 5.4 inches and the typical maximum diameter of a ceiling junction box is 4.1 inches, the cover plate  20  typically extends well beyond the junction box  96  to enable the cover plate  20  to obstruct view of the entire box  96  and any breaks in the ceiling structure  98  around the box. The overall length of the bracket  50  is typically 5.1 inches, which enables the bracket  50  to span the electrical junction box  96  and some of the surrounding ceiling structure  98 . Therefore, if the ceiling structure  98  is uneven or of a roughly textured finish, the bracket  50  will contact the ceiling structure  98  and enable the cover plate  20  to be secured tightly against the structure. Since the bracket  50  spans the box  96  and contacts the ceiling structure  98 , the bracket  50  and cover plate  20  of the present invention may be used in those situations in which the junction box  96  is recessed within the ceiling structure  98 . 
     The cover plate is preferably made from a relatively rigid plastic and the ribbed peg is typically constructed of the same plastic and is formed as part of the cover plate. While any rigid thermoplastic polymer can be used, it is preferred that the thermoplastic be suitable for injection molding. Illustrative of thermoplastic polymers which can be used are polyvinyl chloride, polyamides, polyethylene, polypropylene, polystyrene, polyethylene terephthalate, polycarbonate and the like. Copolymers can also be employed as can suitable monomers. Polyvinyl chloride is the preferred polymer because of its functional properties and relative ease of manufacture. 
     Since it is usually desired to have the cover plate blend in with the ceiling it is preferred that the polymer be formulated to contain fillers and pigments which approximate the color of the ceiling (painted). A common color of ceilings is white or off-white. Other ingredients may be incorporated into the polymer formulation such as stabilizers, lubricants and the like. 
     The connecting bracket is also made from thermoplastic and can also be made by injection molding. While any of the polymers recited above can be employed, it is not necessary that bracket  50  be any particular color. 
     As noted above it is desirable that the face of cover plate  20  blend in with the ceiling for the same reason it is desirable that the face of cover plate  20  be embossed or etched with a finely detailed textured surface (such as a matte finish) to eliminate gloss, or reflective or high glare, which would stand out against the ceiling. The embossed surface can be created by texturing to the surface of the mold used in the injection molding process. The texture should be unobtrusive and help the cover blend with the ceiling. 
     It is desirable that the dimensions of the cover plate  20  should be sufficiently large to cover the junction box in the ceiling, the bracket, and some portion of the surrounding ceiling structure  98 . Frequently the junction box opening is cut somewhat oversize and for this reason some overlap should be provided. Additionally, different size junction boxes require different size openings. Accordingly, different size cover plates should be provided for different size junction boxes. It has been found that a cover plate of about 5.4 inches is satisfactory for the 4-inch opening on a standard junction box and is the preferred size for this box. It can of course be larger. 
     Peg  34  preferably has a diameter of 0.25 inch. Raised ribs  44  preferably extend beyond the side surface  42  of peg  34  by about 0.020 inch. In the first peg-engagement assembly  66 , a central opening  78  of about 0.24 inch is preferable and has proven to be satisfactory for tightly receiving a ribbed peg of the cited dimensions. Ribs  44  are preferably relatively fine so that the distance between the ribs is small and a tighter fit against the ceiling may be achieved. Ribs  44  having a count of about 25 to the inch have been found to be satisfactory, but other sized ribs and rib spacing could be used. For the second peg-engagement assembly  68 , the central opening  90  is preferably 0.250 inch in diameter to receive and engage the typical 0.265-inch outer diameter across the peg  34  and raised ribs  44 . The raised ribs  44  are preferably at an about a 15° angle with respect to the rim  30  of the cover plate  20 . 
     While the foregoing dimensions are preferred, they can of course be varied, provided the resultant peg  34  is easily pushed into the first peg-engagement assembly  66  and tightly held therein or easily rotated into the second peg-engagement assembly  68  and pulled tightly therein, as described above. 
     The length of peg  34  must be sufficient that it can pass through central opening  78  and contact engagement tabs  80  of the first peg-engagement assembly  66  or pass through central opening  90  and contact circular perimeter wall  92  of the second peg-engagement assembly  68 . For a flat cover plate, it has been found that a peg of about 0.81 inch in length is satisfactory. The present invention may be applied to a variety of different shaped cover plates, including flat (as described above and shown in FIGS. 1-2, saucer shaped, or a deep saucer shape, such as a cup shape (not shown). The distance between the inner surface and the rim of the cover plate increases in the saucer shape and the cup shape plates. In such versions, the length of peg  34  must be sufficiently long to extend beyond the inner surface of the cover plate and reach the peg-engagement assemblies  66 ,  68 . 
     From the foregoing description, one skilled in the art can easily ascertain the essential characteristics of this invention, and without departing from the spirit and scope thereof, make various changes and modifications of the invention to adapt it to various usages and conditions. It is therefore intended that the scope of the invention be limited only by the scope of the appended claims.