Abstract:
A Hinged Mud Ring Cover and Method of Use for providing a hinged intermediate mounting surface on which a device may be installed prior to being wired. The Hinged Mud Ring Cover generally includes a box mounting plate with an access aperture operationally coupled to an electrical box, the access aperture facilitating access to an interior of the electrical box when the box mounting plate portion is coupled to the electrical box, and a device mounting plate portion hinged to the box mounting plate portion for mounting the device allowing the use of both hands for wiring the device.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of the filing date of U.S. Provisional Application Ser. No. 62/221,230, filed on Sep. 21, 2015 and entitled A Hinged Mud Ring Electrical Box Cover, the entire disclosure of which is incorporated herein by reference. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not Applicable 
       JOINT RESEARCH AGREEMENT 
       [0003]    Not Applicable 
       STATEMENT REGARDING PRIOR DISCLOSURES BY THE INVENTOR OR A JOINT INVENTOR 
       [0004]    Not Applicable 
       BACKGROUND OF THE INVENTION 
       [0005]    Field of the Invention 
         [0006]    The present invention relates to mud rings and more particularly pertains to a new Hinged Mud Ring Cover and Method of Use for providing a means of mounting a device to be installed on an intermediary plate to facilitate ease of wiring and provide additional safety for the device and the installer. 
         [0007]    Description of the Prior Art 
         [0008]    The use of mud rings is known in the prior art. More specifically, mud rings heretofore devised and utilized are known to consist basically of familiar, expected and obvious structural configurations. Illustrative examples of known prior art include the following: 
         [0009]    U.S. Pat. No. 5,931,325 issued to Filipov on Aug. 3, 1999; 
         [0010]    U.S. Pat. No. 7,645,936 issued to Magno on Jan. 12, 2010; 
         [0011]    U.S. Pat. No. 7,468,486 issued to Yan on Dec. 23, 2008; 
         [0012]    U.S. Pat. No. D555,108 issued to Strong on Nov. 13, 2007. 
         [0013]    Each of these illustrative example of prior art provide basic mud ring functionality in providing an interface between electrical boxes, which are typically installed prior to the installation of wall surface materials, and the user interface portion of the device to be installed, such as an outlet, switch, sensor, or other similar device. 
         [0014]    When working inside of an electrical box, on wiring or connections for example, it is difficult to complete that work with one hand while holding the device being connected to or mounted on the electrical box in the other hand. 
         [0015]    Performing an installation of this nature with a standard mud-ring can be time consuming, inefficient or even unsafe. The device can be dropped connection wires can be damaged or the job may require an additional user to simply hold the device. 
         [0016]    In these respects, the Hinged Mud Ring Cover and Method of Use according to the present invention substantially departs from the conventional concepts and designs of the prior art, and in so doing provides an apparatus primarily developed for the purpose of providing a hinged intermediate mounting surface on which a device may be installed prior to the device being wired in place. 
         [0017]    Using the hinged mud-ring electrical box cover, the device is installed and is suspended by the electrical box allowing simultaneous access to the front and rear (wired end) of the device during completion of the installation set-up or wiring process. The user is also free to use both hands to complete the installation. 
       SUMMARY OF THE INVENTION 
       [0018]    In view of the foregoing disadvantages inherent in the known types of mud rings now present in the prior art, the present invention provides a new Hinged Mud Ring Cover construction wherein the same can be utilized for improving the speed and safety of device installation and device setup or maintenance. 
         [0019]    As stated above, when working inside of an electrical box, on wiring or connections for example, it is difficult to complete that work with one hand while holding the device being connected to or mounted on the electrical box in the other hand. The invention claimed here solves this problem. 
         [0020]    The hinged mud-ring electrical box cover enables the user to mount the electrical or data device to the mud-ring, then swing open the mud-ring and complete the wiring and connections or other operations with both hands. When the installation is complete, the user can simply swing the hinged mud-ring closed over the electrical box and lock it in place. 
         [0021]    The claimed invention differs from what currently exists. A standard mud-ring is an electrical box cover designed to house and protect electrical wiring, switches, receptacles and other electrical or data devices. Device mounting holes are pre-tapped to accept device fasteners. The mud-ring is fastened to the electrical box with mounting screws. This invention differs from what currently exists in that the device, once mounted to the hinged mud-ring, is suspended by the electrical box allowing simultaneous access to the front and rear of the device during completion of the installation, set-up or wiring process. With a standard mud-ring there is no access to the rear (wired end) of the device once it is mounted to the electrical box. Though there are standard mud-rings and general purpose hinged covers or hinged weather proof electrical box covers, there are no similar inventions to date. 
         [0022]    This invention is an improvement on what currently exists. This invention facilitates installation and maintenance of devices mounted on mud-rings and installed on to electrical boxes. With conventional mud-rings there is no access to the rear (wired end) of the device once the mud-ring is installed on the electrical box. The user must remove the mud-ring and device from the electrical box and either hold the device in one hand while working with the other hand, let the device hang from wire connections, have another user hold the device being installed or set the device down someplace. This invention allows for hands-free completion and total attention to the installation. 
         [0023]    In the event that the user needs to read installation instructions perform discreet adjustments or focus on detail during the installation process, holding onto the device with one hand, constantly setting down and picking up or hanging the device during the installation process can be distracting, frustrating or even unsafe. 
         [0024]    Using the hinged mud-ring the user is unfettered and can use both hands and focus on the job at hand. The user can read installation instructions while observing the device or making connections or adjustments and there is no need for a second user to hold the device and there is no chance that the device will be dropped or the wires damaged. 
         [0025]    There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. 
         [0026]    In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting. 
         [0027]    As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention. 
         [0028]    Further advantages of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated preferred embodiments of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0029]    The invention will be better understood and objects of the invention will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein: 
           [0030]      FIG. 1  is a schematic isometric view of a new Hinged Mud Ring Cover and Method of Use according to the present invention. 
           [0031]      FIG. 2  is a schematic front view of the present invention. 
           [0032]      FIG. 3  is a schematic side view of the present invention. 
           [0033]      FIG. 4  is a schematic side view of the present invention. 
           [0034]      FIG. 5  is a schematic isometric view of and embodiment of the present invention. 
       
    
    
     DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0035]    With reference now to the drawings, and in particular to  FIGS. 1 through 5  thereof, a new embodying the principles and concepts of the present invention and generally designated by the reference numeral  10  will be described. 
         [0036]    As best illustrated in  FIGS. 1 through 5 , the Hinged Mud Ring Cover  10  generally comprises a box mounting plate  20  and a device mounting plate  30 . The box mounting plate  20  may be coupled to or mounted to an electrical box  2 . The box mounting plate  20  typically includes an access aperture  22  for facilitating access to an interior of the electrical box  2  when the box mounting plate  20  is mounted to the electrical box  2 . The device mounting plate  30  may be coupled to the box mounting plate  20 . The device mounting plate typically includes a device access aperture  32  for facilitating access to a back side of a device  4  to be mounted to the device mounting plate  30 . However, the present invention also contemplates embodiments in which the device mounting plate  30  does not include a device access aperture, and instead is designed to merely close the mud ring rather than mounting a device. 
         [0037]    While the box mounting plate  30  may include at least one mounting slot  24  or mounting aperture for selectively coupling the box mounting plate  20  to the electrical box  2 . It is generally preferred that the box mounting plate  20  include four mounting slots  24 , each positioned adjacent to an associated corner to facilitating mounting the box mounting plate  20  to the electrical box  2  using standard screws. 
         [0038]    It is important to note, that while the standard screw/slot configuration described above is a preferred configuration, it is possible to use one or more plate securing means to either selectively or permanently couple the box mounting plate to the electrical box. Illustrative examples of such securing means include the combination of a press fit fastener with an aperture, spring clips, slot and tab configurations, zip tie type fasteners, and other suitable mechanical fasteners. 
         [0039]    Preferably, the device mounting plate  30  includes a mud ring segment  34  which extends outwardly along a perimeter edge  33  of the device access aperture  32 . This mud ring segment  34  can be sized for a variety of depths and purposes. It is conceived by the present invention that the mud ring portion  34  may be a separate component which is coupled to the device mounting plate  30 . 
         [0040]    In at least one preferred embodiment, the mud ring segment  34  further includes a pair of device mounting flanges  35  extending from opposite ends of the mud ring segment  34 , and that each device mounting flange  35  include a threaded aperture to facilitate the mounting of a device onto the device mounting plate  30 . 
         [0041]    Preferably, the device mounting plate  30  is hinged to the box mounting plate  20 . This can be accomplished by using a hinge formed in part  41  on the box mounting plate  20  and in part  42  on the device mounting plate  30  with a rod  43  serving as a coupling between the two hinge portions  41 , 42 , by a separate hinge  40  which is coupled to both the box mounting plate  20  and the device mounting plate  30 , or by a living hinge when the present invention  10  is formed from a polymeric material. Additionally, it is possible to use a tab and slot arrangement to provide a pivotal connection without an actual “hinge” without departing from the scope of the invention. 
         [0042]    The present invention may also include a spring member  45  used in conjunction with the hinge to either urge the device mounting plate  30  into a normally open or a normally closed position relative to the box mounting plate  20 . The normally closed position is defined as the device mounting plate  30  substantially abutting the box mounting plate  20 . The normally open position is defined as the device mounting plate  30  being positioned away from the box mounting plate  20 . 
         [0043]    Further, the present invention may also utilize a stop member  47  to inhibit over-travel of the hinge beyond a designated position. 
         [0044]    In a further preferred embodiment the device mounting plate  30  further includes four embossed screw relief portions  36  for covering screws used to mount the box mounting plate  20  to the electrical box, when the device mounting plate  30  is in a closed position relative to the box mounting plate  20 . 
         [0045]    In yet a further embodiment, the device mounting plate  30  includes at least one slot or aperture  38  substantially aligned with one of the mounting slots  24  or mounting apertures of the box mounting plate  20 . Thus, the device mounting plate  30  may be held in a closed position relative to the box mounting plate  20  by one or more screws. 
         [0046]    In an alternate but also preferred embodiment the box mounting plate  20  further includes a threaded aperture  29  adjacent to an edge of the box mounting plate  20  and the device mounting plate  30  further includes an aperture  39  adjacent to an edge of the device mounting plate  30  and substantially aligned with the threaded aperture  29  of the box mounting plate  20  when the device mounting plate  30  is in a closed position relative to said box mounting plate  20 . A screw is selectively positioned through the aperture  39  of the device mounting plate  30  and the threaded aperture  29  of the box mounting plate to hold the plates in a closed position. 
         [0047]    Additionally, it should be noted that the present invention also contemplates configurations in which alternate securing means are used to hold the device mounting plate in a closed position relative to the box mounting plate. Illustrative examples of such securing means include the combination of a press fit fastener with an aperture, spring clips, slot and tab configurations, zip-tie type fasteners, and other suitable mechanical fasteners. 
         [0048]    In at least one further embodiment, the box mounting plate  20  further includes a stud mounting segment  50  for selectively securing the box mounting plate  20  to a stud or other support structure. This allows the hinged mud ring  10  to be used in applications with or without an electrical box, such as low voltage applications. 
         [0049]    The present invention also contemplates embodiments in which the device mounting plate  30  is hinged or otherwise pivotally coupled to an electrical box  60  directly. This may either be implemented through mechanical means or as a living hinge in instances in which the electrical box  60  and the device mounting plate  30  are integrally formed from a polymeric material. 
         [0050]    While the foregoing discussion has been addressed in terms of generally rectangular implementations of electrical boxes, it should be understood by those skilled in the art that the present invention is immediately applicable with implementations for electrical boxes which are generally octagonal, square, round, or other geometric shapes. 
         [0051]    Now, turning to one further preferred embodiment, as an illustrative example only and not for purposes of limitation, we will discuss the basic manufacturing, assembly, and use of an embodiment of the present invention. 
       The Illustrative Example of The Invention Discussed Below Includes: 
       [0052]    1. Mud-ring (“Device Mounting Plate”) 
         [0053]    2. Flat Mounting Plate (“Box Mounting Plate”) 
         [0054]    3. Hinge Pin 
         [0055]    4. Locking Screw 
         [0056]    5. Mounting Screws ( 4 ) 
         [0057]    The mud-ring has two rolled hinge knuckles, half swaged and forms one leaf of the hinge assembly. The mud-ring also has a thru hole in a recess to accommodate the locking screw and two threaded mounting holes to accommodate the installation of an external device. The mud-ring has four round recess features to accommodate the heads of the mounting screws which are oriented beneath the recesses when the assembly is in the closed position. The mud ring has a large rectangular opening, in the center through which wires, connections or devices can pass through to an electrical box. 
         [0058]    The flat mounting plate has three rolled hinge knuckles, half swaged and forms the second leaf of the hinge. The flat mounting plate has four slots through which it can be fastened to an electrical box using the mounting screws. The flat mounting plate also has a threaded hole to accommodate the locking screw. The flat mounting plate has a large rectangular opening in the center through which wires, connections or devices can pass through to an electrical box. 
         [0059]    The Hinge Pin is inserted through the two hinge knuckles of the mud-ring and the three hinge knuckles of the flat mounting plate joining the two halves of the hinge formed by the mud-ring and the flat mounting plate. 
         [0060]    The Locking Screw passes through the mud-ring locking screw hole and is inserted into the flat mounting plate threaded locking screw hole to fasten the hinge assembly in the closed position. 
         [0061]    The Mounting Screws pass through the slots in the flat mounting plate and fasten the flat mounting plate to an electrical box. 
         [0062]    When the locking screw of the hinged mud-ring electrical box cover is removed, the hinged mud-ring assembly can be opened exposing the slots of the flat mounting plate. The flat mounting plate can be fastened to an electrical box by installing the mounting screws through the slots and into to the electrical box. An electrical device can then be installed on to the mud-ring using the two threaded mud-ring mounting holes. Wiring, connections and other installation operations of the electrical device can now be completed on both the front and rear of the device, with two hands, while the hinged mud-ring electrical box cover is in the opened position. When the installation operations are complete, the user can swing the hinged mud-ring closed over the electrical box. The locking screw can now be installed through the mud-ring locking screw hole and inserted into the flat mounting plate locking screw hole to fasten the hinged mud-plate assembly in the closed position. If any maintenance has to be completed in the future the locking screw can be removed and the hinged mud-ring electrical box cover can be swung open for access to the electrical device, adjustments and connections. 
       How to Make the Invention 
       [0063]    Sheet metal fabrication is used to make articles in metal or alloy sheets within a range from 10 Gauge (3.25 mm) to 32 Gauge (0.274 mm). Sheet metal fabrication includes cutting shaping and forming of sheet metals by use of punching machines and presses. The manufacturing processes of sheet metal parts can be classified in material removal and material deformation. Material removal process can be a stage of creating a 2D shape such as a development of a sheet metal part by punching, notching, or nibbling. Deformation process can be a stage of bending or stretch sheet metal part into a 3D complex shape. 
         [0064]    Mud-ring 
         [0065]    Shear—Shear flat material in desired strip widths 
         [0066]    Blank—Cut out approximate outside shape of part 
         [0067]    Draw—Draw large rectangular shape 0.600 deep 
         [0068]    Emboss—Form ( 4 ) round recesses 
         [0069]    Emboss—Form lock screw recess 
         [0070]    Punch—Cut out large rectangular opening and ( 3 ) round holes 
         [0071]    Blank Trim—Cut outside periphery to exact shape 
         [0072]    Form—Form curl hinge (3 hits} 
         [0073]    Tap—Tap ( 2 ) holes 
         [0074]    Flat Mounting Plate 
         [0075]    Shear—Cut flat material into desired strip widths 
         [0076]    Blank—Cut flat material to outside shape of part 
         [0077]    Punch—Cut out large rectangular opening and ( 4 ) slots 
         [0078]    Form—Form curl hinge (3 hits) 
         [0079]    Tap—Tap ( 1 ) hole 
         [0080]    Assembly 
         [0081]    1. Assemble Mud-ring plate, Flat mounting plate and hinge pin 
         [0082]    Since this is a relatively simply assembly and mechanism most of the elements are necessary. That being said, the mounting screw recesses in the mud-ring could be eliminated if flat head as opposed to pan head screws were used to fasten the flat mounting plate to an electrical box so as not to cause interference between the mounting screws and the mud-ring. The locking screw recess could also be eliminated as its value is mostly aesthetic. The locking screw could be a tamper proof type screw to add extra security and protect the assembly and electrical box. 
         [0083]    There are many types of hinges that can be employed by an assembly like this. A Slip Joint Hinge can be used for easy removal of the mud-plate from the Flat mounting plate. A “Stop” function can be added to hinge to limit its rotation. A Spring Hinge could be used to hold the mud-ring in an open or closed position. The hinge could also be arranged on the top, bottom or side. If a flexible material or plastic like polypropylene were to be the material used a “living hinge” could also be employed. 
         [0084]    There are many shapes, types and sizes of electrical box covers or mud-rings that could be utilized for this invention. This example uses the basic form of a 4″ Square Mud-Ring, for 1 device, flat and a 4″ Square Mud-Ring, for 1 device, raised ⅝″ with a hinge in between. This design could be used for any electrical box cover including outlet covers, junction box covers, switch covers, etc. and with various sizes and types; single-gang, 2-gang, 4-gang, etc. The hinged mud-ring could be integrated with the electrical box itself directly rather than with the flat mounting plate then to the electrical box. There would also be opportunity to use different materials in addition to standard steel, galvanized steel and stainless steel, plastic, carbon fiber, etc. 
       How to Use the Invention: 
       [0085]    When working inside of a standard electrical box, on wiring or connections for example, it is difficult to complete that work with one hand while holding the device being connected to or mounted on the electrical box in the other hand. This invention enables the user to mount an electrical or data device to an electrical box while maintaining hands-free access to the inside of the box and back side of the device. 
         [0086]    The user simply opens hinged mud-ring electrical box cover and mounts the flat mounting plate to the electrical box with the hinge side to the left. The user then installs the device to the hinged mud-ring. With the mud-ring in the open position the user can then complete the wiring, connections or any other operations with both hands while the device is suspended by the hinged mud-ring electrical box cover. When the installation is complete, the user simply swings the hinged mud-ring closed over the wiring and electrical box and locks it in place in the closed position with the locking screw. Step by step instructions are as follows: 
         [0087]    1. Remove the locking screw of the hinged mud-ring electrical box cover. 
         [0088]    2. Open the hinged mud-ring assembly to expose the mounting slots of the flat mounting plate. 
         [0089]    3. Fasten the flat mounting plate to the electrical box (hinge side to the left) by installing the mounting screws through the mounting slots and into to the electrical box. 
         [0090]    4. Install the electrical device on to the mud-ring using the two threaded mud-ring mounting holes. 
         [0091]    Note: Wiring, connections and other installation operations of the electrical device can now be completed, with two hands, while the hinged mud-ring electrical box cover is in the opened position. 
         [0092]    5. When the installation operations are complete, swing the hinged mud-ring closed over the electrical box. 
         [0093]    6. Install he locking screw through the mud-ring locking screw hole and inserted into the flat mounting plate threaded locking screw hole to fasten the hinged mud-plate assembly in the closed position. 
         [0094]    Note: If any maintenance has to be completed in the future the locking screw can be removed and the hinged mud-ring electrical box cover can be swung open for access to the electrical device, adjustments and connections. 
         [0095]    With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention. 
         [0096]    Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.