Abstract:
A blank cover assembly for covering an electrical box. The blank cover assembly includes a mounting plate and a cover plate. Wide slots are provided in the mounting plate for receipt of fasteners for securing it to the electrical box. Openings in the mounting plate are capable of receiving posts from the cover plate for securing the cover plate over the electrical box. The cover plate is simply pressed onto the mounting plate in order to secure it thereto. The blank cover assembly provides a paintable blank cover that is free of visible fasteners and that blends easily with the wall to provide a convenient device for covering empty or unused electrical boxes.

Description:
FIELD OF THE INVENTION 
   This invention relates to unused electrical outlet boxes and specifically to a blank cover assembly for covering an unused electrical box. 
   BACKGROUND OF THE INVENTION 
   In newly constructed houses, electrical boxes on interior walls are frequently left empty. Typically, the houses are outfitted with electrical boxes that are pre-wired for components that will later be added by the homeowner, such as surround sound systems or electrical outlets. In existing buildings, electrical service is sometimes deemed unnecessary in some areas and electrical components are removed thereby creating unused electrical boxes. In each of these cases, there is an empty or unused electrical box that is unsightly if left uncovered and is also a potential hazard if live electrical wires remain in the box. 
   Typically these empty and unused electrical boxes are covered by a conventional blank cover plate that is available commercially. The blank cover plate includes apertures that match up with the threaded bores in the conventional electrical box. An installer typically inserts two screws through the apertures in the blank plate and thereby secures the plate to the threaded bores in the electrical box. 
   Although conventional blank cover plates cover the opening of an electrical box, they are unsightly as a result of the visible screws. Additionally, if the existing electrical box is not square with the wall, installing the blank cover with the screws will result in a blank cover that is skewed in the same manner as the underlying electrical box. 
   What is needed therefore is a blank cover that can be secured to an empty or unused electrical box with a minimal amount of effort. The cover should be a completely blank cover, without screws or any other fasteners visible to an observer. Additionally, the blank cover should be capable of being easily removed at a later date when it is desired to mount an electrical component in the underlying electrical box. The blank cover preferably would be of simple design and capable of being manufactured at low unit cost. Furthermore, the blank cover should be capable of receiving paint to enable it to be painted the same color as the wall it is mounted on to enable it to blend in visually with the wall and thereby provide an aesthetically pleasing solution to an empty or unused electrical box. 
   SUMMARY OF THE INVENTION 
   The invention is a blank cover assembly for covering an electrical box. The blank cover assembly includes a mounting plate and a cover plate. Wide slots are provided in the mounting plate for receipt of fasteners for securing to the electrical box. Openings in the mounting plate are capable of receiving posts from the cover plate for securing the cover plate over the electrical box. The cover plate is simply pressed onto the mounting plate in order to secure it thereto. The blank cover assembly provides a paintable blank cover that is free of visible fasteners and therefore blends easily with the wall. 
   OBJECTS AND ADVANTAGES 
   Several advantages are achieved with the blank cover assembly of the present invention, including:
         (1) The blank cover assembly provides a convenient device for covering an empty or unused electrical box so that it blends in with the wall and is substantially hidden to the observer.   (2) The blank cover assembly provides a completely blank cover for an electrical box, without screws or any other fasteners visible to an observer.   (3) The blank cover assembly requires only two pieces, a mounting plate and a cover plate to blank off an empty or unused electrical box.   (4) The blank cover assembly accepts paint and can therefore be painted to further blend the installed cover in with a wall.   (5) The blank cover assembly is easy to place in use by securing a mounting plate to an electrical box and simply pressing a cover plate into the mounting plate.   (6) Wide slots in the mounting plate provide an easy means for aligning the blank cover assembly to be square with the room that is installed in. This is an important feature in covering unused electrical boxes as many unused boxes are not correctly aligned at installation or have become misaligned over the years through normal use.       

   These and other objects and advantages of the present invention will be better understood by reading the following description along with reference to the drawings. 

   
     DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is an exploded perspective view of a preferred embodiment of a blank cover assembly for an unused electrical box according to the present invention. 
       FIG. 2  is a front view of a mounting plate that forms a portion of the blank cover assembly of  FIG. 1 . 
       FIG. 3  is a rear view of the mounting plate depicted in  FIG. 2 . 
       FIG. 4  is a side view of the mounting plate of  FIG. 2 . 
       FIG. 5  is a detail view of a U-shaped opening that forms a portion of the mounting plate of  FIG. 2 . 
       FIG. 6  is a sectional view of the U-shaped opening portion of the mounting plate taken along line  6 - 6  of  FIG. 5 . 
       FIG. 7  is a sectional view of the U-shaped opening portion of the mounting plate taken along line  7 - 7  of  FIG. 5 . 
       FIG. 8  is a rear perspective view of a cover plate that forms a portion of the blank cover assembly of  FIG. 1 . 
       FIG. 9  is a rear view of the cover plate of  FIG. 8 . 
       FIG. 10  is a side view of the cover plate depicted in  FIG. 9 . 
       FIG. 11  is a sectional view of the cover plate taken along line  11 - 11  of  FIG. 9 . 
       FIG. 12  is a sectional view of the cover plate taken along line  12 - 12  of  FIG. 9 . 
       FIG. 13  is a detail view of the post portion of the cover plate of  FIG. 11 . 
       FIG. 14  is an exploded view of the post portion of the cover plate in alignment with a mounting plate to be secured thereto according to the present invention. 
       FIG. 15  is a detail view of the post portion of the cover plate after being secured to a mounting plate in the blank cover assembly of the present invention. 
       FIG. 16  is a perspective view of the blank cover assembly of the present invention with the mounting plate secured to an unused electrical box and the cover plate in alignment to be secured to the mounting plate. 
       FIG. 17  is a perspective view of the blank cover assembly according to the present invention after being secured to an unused electrical box on a wall. 
   

   TABLE OF NOMENCLATURE 
   The following is a listing of part numbers used in the drawings along with a brief description: 
   
     
       
             
             
           
         
             
                 
             
             
               Part Number 
               Description 
             
             
                 
             
           
           
             
               20 
               blank cover assembly, preferred embodiment 
             
             
               22 
               mounting plate 
             
             
               24 
               cover plate 
             
             
               26 
               electrical box 
             
             
               28 
               fastening arrangement 
             
             
               30 
               slot 
             
             
               32 
               fastener 
             
             
               34 
               bore in electrical box 
             
             
               36 
               U-shaped opening 
             
             
               38 
               vertical axis 
             
             
               40 
               front surface of mounting plate 
             
             
               41 
               rear surface of mounting plate 
             
             
               42 
               countersunk periphery 
             
             
               44 
               outward-directed edge 
             
             
               46 
               reinforcement rib 
             
             
               48 
               first end of U-shaped opening 
             
             
               50 
               second end of U-shaped opening 
             
             
               52 
               alignment tab 
             
             
               54 
               front face of outward-directed edge 
             
             
               56 
               rear face of outward-directed edge 
             
             
               58 
               front surface of cover plate 
             
             
               60 
               rear surface of cover plate 
             
             
               62 
               post 
             
             
               64 
               inward facing side of post 
             
             
               66 
               teeth 
             
             
               68 
               channel 
             
             
               70 
               outward facing side of post 
             
             
               72 
               arcuate periphery of cover plate 
             
             
               74 
               convex side 
             
             
               76 
               concave side 
             
             
               78 
               proximal end of post 
             
             
               80 
               distal end of post 
             
             
               82 
               wall 
             
             
               84 
               outer periphery of mounting plate 
             
             
               86 
               outer periphery of cover plate 
             
             
               D1 
               distance between the teeth on the opposing posts 
             
             
               Θ1 
               angle of the front face of the outward-directed edge 
             
             
               Θ2 
               angle of the rear face of the outward-directed edge 
             
             
                 
             
           
        
       
     
   
   DETAILED DESCRIPTION OF THE INVENTION 
   With reference to  FIG. 1 , there is shown a preferred embodiment of the present invention, a blank cover assembly  20  including a mounting plate  22  and a cover plate  24  for covering an electrical box  26 . The mounting plate  22  includes a fastening arrangement  28  for securing the mounting plate  22  directly to the electrical box  26 . The fastening arrangement  28  includes a pair of slots  30  in the mounting plate  22  and fasteners  32  that thread into bores  34  in the electrical box  26 . As shown in  FIG. 1 , the slots  30  in the mounting plate  22  match the pattern and spacing of the bores  34  in the electrical box  26 . In the blank cover assembly  20  of the present invention, the slots  30  in the mounting plate  22  preferably are substantially wider than the bores  34  of the electrical box  26 . 
   Referring to  FIGS. 2 and 3 , the mounting plate  22  includes a pair of U-shaped openings  36  therein centered along a vertical axis  38  through the plate. The mounting plate  22  includes a front surface  40  and a rear surface  41 . A countersunk periphery  42  is provided in the front surface  40  of the mounting plate  22  surrounding each of the slots  30 . The U-shaped openings  36  of the mounting plate  22  each include outward-directed edges  44  facing outwardly with respect to the plate. 
   With reference to  FIGS. 3 and 4 , the rear surface  41  of the mounting plate  22  further includes a reinforcement rib  46 . The reinforcement rib  46  extends vertically between the U-shaped openings  36 . As shown in  FIG. 4 , the front surface  40  and the rear surface  41  of the mounting plate  22  are preferably planar. 
   As shown in  FIG. 5 , the U-shaped openings  36  of the mounting plate  22  include a first end  48  and a second end  50 . An alignment tab  52  is provided extending from the first end  48  of each U-shaped opening  36 . 
   Referring to  FIGS. 6 and 7 , the outward-directed edges  44  on the U-shaped openings  36  of the mounting plate  22  are angled away from the front surface  40  and the rear surface  41  to create a sharp outward-directed edge  44 . The front face  54  of the outward-directed edge  44  is at an angle Θ 1  with respect to the front surface  40  of the mounting plate  22  and the rear face  56  of the outward-directed edge  44  is at an angle Θ 2  with respect to the rear surface  41  of the mounting plate  22 . Preferably, angle Θ 1  is between 5 and 15 degrees and angle Θ 2  is between 25 and 35 degrees. 
   With reference to  FIG. 8 , the cover plate  24  includes a front surface  58 , a rear surface  60 , and two posts  62  extending from the rear surface  60 . The posts  62  include inward facing sides  64  with teeth  66  thereon. As shown in  FIG. 9 , the posts  62  of the cover plate  24  have a substantially U-shaped cross-section that provides an open channel  68  on the outward facing side  70  of the posts  62 . 
   Referring to  FIGS. 10 and 11 , the posts  62  are substantially perpendicular to the rear surface  60  of the cover plate  24 . The cover plate  24  includes an arcuate periphery  72 . The arcuate periphery  72  of the cover plate  24  includes a convex side  74  and a concave side  76 , with the convex side  74  forming the outer periphery of the front surface  58  and the concave side  76  on the rear surface  60  of the cover plate  24 . As shown in  FIG. 11 , the teeth  66  on the inward facing sides  64  of the posts  62  face each other. 
   As shown in  FIG. 13 , the posts  62  of the cover plate  24  each include a proximal end  78  and a distal end  80 . Preferably, the teeth  66  increase gradually increase in length from the distal end  80  to the proximal end  78  of the post. Therefore, as shown in  FIG. 11 , the distance D 1  between the teeth  66  on the opposing posts  62  decreases from the distal ends  80  to the proximal ends  78 . 
   Referring to  FIG. 1 , the blank cover assembly  20  of the present invention is placed in operation by first using the fastening arrangement  28  to secure the mounting plate  22  to an empty or unused electrical box  26 . A significant advantage provided by the blank cover assembly  20  of the present invention is the ability to square a cover plate  24  with respect to the wall  82 . In many cases, existing electrical boxes, through years of repeated use, become out of square with respect to the wall, with the vertical walls of the electrical box  26  being not exactly plumb with the wall. The blank cover assembly  20  of the present invention, as a result of the included wide slots  30  with their countersunk peripheries  42 , can be twisted with respect to the out-of-square electrical box  26  until the mounting plate  22  is square with the wall  82 , and then the fasteners  32  inserted in the wide slots  30  and tightened into the bores  34  in the electrical box  26  to secure the mounting plate  22  square with the wall  82 . After the mounting plate  22  is secured to the electrical box  26 , the cover plate  24  can be snapped onto the electrical box  26 . As a result of securing the mounting plate  22  square with the wall  82 , the cover plate  24  will also be square with the wall  82  when it is snapped onto the mounting plate  22 . 
   With reference to  FIGS. 14 and 15 , there is shown in  FIG. 14  an exploded view of the post portion  62  of the cover plate  24  in alignment with a mounting plate  22  to be secured thereto and in  FIG. 15  a view of the post portion  62  of the cover plate  24  after being secured to the mounting plate  22 . The alignment tabs  52  on the mounting plate  22  cooperate with the channels  68  on the cover plate  24  to align the cover plate  24  with the mounting plate  22  when the posts  62  of the cover plate  24  are pressed into the U-shaped openings  36  of the mounting plate  22 . As shown in  FIG. 15 , the alignment tabs  52  of the mounting plate  22  extend into the channels  68  of the posts  62  on the cover plate  24 . As the cover plate  24  is pressed onto the mounting plate  22 , the outward-directed edges  44  on the mounting plate  22  engage the teeth  66  on the posts  62  of the cover plate  24 . As a result of the teeth  66  increasing in size from the distal end  80  to the proximal end  78  of the posts  62  and the distance D 1  (see  FIG. 11 ) between the posts  62 , the cover plate  24  as it is snapped onto the mounting plate  22  is drawn ever tighter onto the mounting plate  22  as the posts  62  are advanced into the U-shaped openings  36  of the mounting plate  22 . As a result, after the cover plate  24  is fully snapped onto the mounting plate  22 , the cover plate  24  is held very securely to the mounting plate  22  and to the electrical box the mounting plate is secured to. 
   With reference to  FIG. 16 , the mounting plate  22  is shown secured to an electrical box  26  and with a cover plate  24  in alignment with the mounting plate  22  to be secured thereto by simply pressing the cover plate  24  onto the mounting plate  22  to form a blank cover assembly  20  according to the present invention. As shown in  FIG. 16 , the mounting plate  22  includes an outer periphery  84  that is of a larger size than the front outer periphery of the electrical box  26 . The mounting plate  22  therefore overlaps the front of the electrical box  26  and extends slightly onto the wall  82  surrounding the electrical box. For those situation in which there is a gap between an empty or unused electrical box  26  and the wall  82 , the blank cover assembly  20  of the present invention provides the advantage of masking the gap between the electrical box  26  and the wall  82 . The outer periphery  86  of the cover plate  24  is larger than the outer periphery  84  of the mounting plate  22 , thereby enabling the cover plate  24  to completely cover or mask the mounting plate  22  when the cover plate  24  is fully installed thereon. 
   With reference to  FIG. 17 , in the completed installation of the blank cover assembly  20  of the present invention, the cover plate  24  completely covers the underlying mounting plate and electrical box and provides an attractive, aesthetically pleasing device for covering an empty or unused electrical box. As shown in  FIG. 17 , the front surface  58  of the cover plate  24  is completely free of apertures or fasteners. The cover plate  24  is typically constructed of a paintable plastic thereby allowing the cover plate  24  to be painted in a color to match the wall. The resulting blank cover plate  24  results in an unobtrusive electrical box cover that blends in with the wall  82 . 
   As shown in  FIG. 1 , as a result of the mounting plate  22  being firmly secured to the electrical box  26  with fasteners  32  and the cover plate  24  being firmly secured to the mounting plate  22  by the snap in action of the posts (see  FIG. 15 ) within the U-shaped openings  36  of the mounting plate  22 , the blank cover plate  24  is firmly attached to the wall  82 . The blank cover plate  24  can be later removed from the electrical box  26  by firmly pulling it therefrom. However, even with the cover plate  24  removed from the electrical box  26 , the mounting plate  22  is still secured to the box and prevents any direct access to the electrical box  26  until it is purposely removed therefrom. As shown in  FIG. 1 , the blank cover assembly  20  of the present invention blanks off an electrical box  26  by use of a simple two-piece assembly, including a mounting plate  22  and a cover plate  24 . 
   Preferably, the mounting plate  22  and the cover plate  24  of the present invention are each molded in one-piece of plastic. The plastic the mounting plate  22  and cover plate  24  are molded from may include polyvinyl chloride, polycarbonate, acrylonitrile-butadiene styrene, or polyethylene. 
   Having thus described the invention with reference to a preferred embodiment, it is to be understood that the invention is not so limited by the description herein but is defined as follows by the appended claims.