Electrical junction box cover and related assemblies and methods for completing electrical installations

This invention relates to electrical junction box covers for temporary use during application of drywall and other finish work. Electrical junction boxes include any type of electrical outlet or switch box, including communication boxes for cable, Ethernet, phone, or any other related system. The covers of the invention prevent debris from entering the electrical junction boxes during the application of drywall and finish work. The covers protect electrical and data cabling and provide substantial efficiencies in construction of residential and commercial structures.

BACKGROUND

This application claims priority to U.S. Provisional Patent Application Ser. No. 62/212,963 filed Sep. 1, 2016. The above referenced provisional patent application is incorporated herein by reference as if restated in full. All references cited herein, including, but not limited to patents and patent applications, are incorporated by reference in their entirety.

Construction of residential and commercial structures involves multiple phases and trades people. The steps are generally completed in a specific order, and each step may depend on completion of the preceding step. Also, because the construction of such structures inherently involves trades people with different expertise, it is common for separate construction steps to depend on completion of an earlier step and to be performed by completely different personnel.

The current construction process generally includes:1) Framers erect the walls, floors and ceilings of the structure. The walls may be constructed of wood or metal studs, and the floor and ceiling joists of wood or metal beams;2) After rough framing of walls is complete and before erecting the wall panels, a tradesperson such as an electrician installs dedicated electrical junction boxes for electrical and data communication wiring by attaching the boxes to the wall studs or ceiling joists;3) The electrician routes wiring from a main panel to each box, depending on the function intended for the box and the access that will be provided to the occupant. The installation is a rough process where the wiring and junctions are not active (e.g., hot). In current practices, wires and cabling with bare terminal ends are capped off, rolled up and pushed back into the box. Thus, terminal end of the cables are typically not connected to their intended fixture, such as a light switch, electrical outlet or data port until completion of a later finishing step as described below;4) Drywall installers install drywall over the walls and ceilings by attach the wall panels to the studs and joists. To allow access to the electrical junction boxes, the drywall installers rough cut a hole to accommodate the electrical junction box and remove the resulting cut-out panels from the drywall using a router or other rough cut tool. The shape of the cut out opening is meant to roughly match the shape of the electrical junction box, so that the resulting drywall surface will closely surround the junction boxes that are already in place. During drywall installation, it is common that cutting out holes for one or more of the junction boxes is inadvertently missed and the box becomes permanently covered. This typically occurs if the box did not protrude enough from the stud when the box was attached to the stud. Also, some cut outs in the drywall may not be properly shaped and will require repairs to the drywall surrounding the protruding junction box. Such repairs are-typically performed with dry wall tape and joint compound, which is a spreadable sealant commonly referred to as “mud,” to clean up the final appearance-of the drywall surrounding the junction box. Also, because the drywall installers do not have ultimate responsibility for completing the electrical and data connections, it is common for drywall installers to cut or damage wires and cabling during installation of the drywall panels;5) Once drywall is hung and boxes have been cut out, drywall installers finish seams beneath the drywall sheets using tape and sealant and typically finish the border around the electrical junction boxes with joint compound to create a sealed border around the periphery of the junction boxes. The drywall installers may also texture the drywall and repair any imperfections in the final wall panels. During this process, extra joint compound and debris is commonly pushed into the previously installed electrical junction boxes and this debris can cover the terminal ends of the wiring and cabling and can damage the wires/cables thereby making future connection of sockets, switches, or data ports more difficult;6) Once the drywall process is completed the electrician returns to the job to complete the installation of the outlet, switch or communication fixture intended for the junction box. At this point, the electrician must clean and repair each junction box by hand to remove excess joint compound and debris prior to installing the hot outlets, switches, and communication wiring.

Another challenge confronting the electrician is the need to pull the electrical junction box away from the point of attachment of the electrical junction box to the wall beams to align the outer edge of the junction box with the planar surface of the drywall. Typically this is done by manually grabbing the metal outlet tabs that are provided on outlets and plugs. However, these structures are not designed for this purpose and are often flimsy due to damage to the drywall at the point of attachment-resulting in an unstable connection. Accordingly, these steps require additional manipulations of the junction box that can damage the surrounding drywall or the electrical junction box or the final fixtures.

Still further during the process of final electrical installation, electrician may accidentally damage the finished drywall around the box, particularly when manually removing debris and excess joint compound from a large number of junction boxes, resulting in the requirement of additional touch up work to the drywall surface that has to be done either by the electrician or by a subsequent drywall finishing operation.

Therefore, the process of completing dry wall and electrical finishing involves a series of steps by different trades people with different expertise and that can add expenses and delay to a building project.

SUMMARY OF THE INVENTION

The present invention is an electrical junction box cover and an assembly comprised of the electrical junction box together with the temporary cover-to protect the box and the electrical fixtures and cables contained within the electrical during drywall finish work. The invention includes the electrical junction box, the temporary cover, attachment mechanisms for joining the cover to the junction box, electrical and data-outlets contained within the junction box, together with cabling having a terminal end attached to the outlets and an intermediate end preferably contained within the junction box. The assembly includes the completely wired and connected electrical junction box, with the temporary protective cover having been removed, such that the internal fixtures, outlets and structures, such as plugs, switches, and data ports, are substantially free of debris and other contaminants such as extra joint compound.

The invention includes an assembly which comprises the electrical junction box and the temporary cover, together with the operative electrical and data components contained therein in any state of completion. In some instances, the temporary cover may be placed over the junction box with only bare wires, having a terminal end, contained therein. In other instances, the wiring for electrical structures, or data cabling can already be complete with the temporary cover in place to protect these components, and an intermediate end of the wiring or cabling terminates on a plug/receptacle for attachment to buildings wiring or cabling. The assembly can include a drywall border surrounding the electrical junction box wherein the temporary cover protects the internal structures during a drywall finishing process.

The methods of the invention include the steps of removably installing the junction box cover prior to installing drywall around the box, completing drywall finish work around the box with the removable cover in place, and removing the cover to permit access to the junction box. The methods of the invention include the steps of removing the junction box cover from its attachment to the junction box and attaching it to the junction box prior to drywall installation and after the electrician has wired the plug and or switch to the junction box. The outlets, switches, ports, and other functional components designed to be placed within the junction box can be installed by the electrician either-before or after the drywall installation step. In either case, the internal structure of the electrical junction box remains free of debris and excess joint compound.

In one embodiment of the invention, the electrical junction box is fitted with switches, outlets, data ports, or other functional apparatus prior to being attached to the wall during electrical “rough in” during the construction. In this embodiment, large-scale production of an electrical junction box is enabled wherein the electrical junction box is preassembled with functional components already hard wired in place. This reduces the installation at the residential or commercial structure to essentially a single step whereby the entire assembly is simply attached to the wall beam and the-intermediate end of the wiring is simply connected to the existing buildings wiring or cabling that is already in place. In such an embodiment, the terminal end of the wiring is attached to the functional components, and typically terminates outside the electrical junction box at a free end separate from the terminal end. In either case the entire electrical junction box and electrical switch/outlet/port component assembly are connected to the building electrical/data connection by attaching the wires at the free intermediate end of the assembly to the existing wiring in the building.

DETAILED DESCRIPTION OF THE INVENTION

This invention is electrical junction box covers and assemblies comprised of a removable cover for temporarily covering an electrical junction box during finish work. The electrical junction box cover temporarily protects the electrical junction box, particularly during drywall finishing steps. Most importantly, the cooperative relationship between the design of the temporary cover and industry-standard electrical junction boxes prevents debris from entering the junction box during construction, particularly where debris would impede the ability of an electrician to complete necessary wiring and electrical connections. The protective cover may be releasably attached to the electrical junction box then removed as desired, at any point during the construction process where the protection of the interior of the junction box is desired, and then removed as desired.

The temporary protective cover may be releasably affixed to an electrical junction box that is substantially completely wired, including a fully wired “hot” outlet, switch, or communication fixture (e.g., a cable, phone or Ethernet connection point). For the ease of reference the functional related fixtures (together with electrical, data ports, lighting, optical, digital and connectors for the outlets/fixtures contents of the electrical junction box, including items such as communication fixtures will be referred to collectively, but not exclusively, as an “outlet.” Furthermore, while the following description relies on a temporary junction box cover that is sized and configured to engagingly mate with industry standard electrical junction boxes, the present invention includes essentially any electrical box, including junction boxes, panels, arrays of switches and indicator lights, arrays of fuses or relays, and includes larger electrical boxes such as a main electrical panel, where the interior is protectable during a portion of the construction process on surrounding structures.

Methods of installing the electrical junction box, the removable electrical junction box cover, and for completing drywall and finish electrical work are also included in the invention, including methods for covering the junction box and manipulating the placement, and wiring thereof, to maximize efficiency of the building process.

The invention also includes completed assemblies featuring fully connected terminal ends of electrical wires and/or data cables where in the outlet fixture is completely wired and contained within the assembly comprised of the combination of the electrical junction box and the removable cover. In this embodiment, the terminal ends of the wires or cables are completely connected to completely secured outlet within the junction box and the opposite or immediate end is disposed outside the junction box and available for connection to existing wiring at the residential or commercial installation. For delivery and installation the entire wiring/cabling, from the immediate end to the terminal end attached to the outlets may be contained within the interior housing of the junction box. In this embodiment, the only connection that need be made is between the wires or cables existing at the structure and the intermediate end of the wiring or cables located outside the junction box, and may be joined.

In the following description of the embodiments illustrated in the figures features generally relating to a single outlet configuration are designated with reference numbers in the100s, while features generally relating to a double outlet configuration are designated with reference numbers in the200s, although one of ordinary skill in the art will appreciate that many of these structures are similar or identical in configuration and design and differ simply in dimensions between single, double, triplet and quad outlet configurations.

Referring toFIGS. 1a-1h, the invention is comprised of an electrical junction box cover100that is releasably attached to the electrical junction box170, the cover100includes a cover surface110and four perimeter walls120each extending away from the cover surface110, and terminating in an edge. Two of the peripheral walls120terminate in a pair of first edges121, while the other two terminate in a pair of second edges122. As described below, the first and second edge pairs121,122sealingly engage corresponding structures on the box170about the outer periphery of each of the cover100and the electrical junction box170. Accordingly, the overall dimensions of the cover100, specifically the length of the peripheral wall20, and hence the length of the first edges121and the second edges122are matched to the dimensions of the junction box170. Accordingly, these dimensions for the cover100match the industry standard dimensions for a box170, but may readily be altered according to the design of the junction box170.

In a corresponding manner to the cover100, the junction box170is comprised of four box peripheral walls191that terminate at four upper edges. Two of the box peripheral walls190, terminate at a pair of third edges191, while the other two box peripheral walls190terminate at a pair of fourth edges192. A conforming engagement between the cover100and the box170is created by providing a cover with dimensions such that the length of the first pair of edges121matches the length of the third pair of edges191and the length of the second pair of edges122matches the length of the fourth pair of edges192.

The height of the peripheral wall120is greater than the height of the highest point along a vertical distance of the outlet160extending away from the plane formed by the outer periphery of the box170, and preferably less than one inch. This is simply to provide clearance when the first and second edge pairs121,122are brought into engagement with the third and fourth pairs of edges191,192along substantially the outer periphery of the box100when the cover100is securely, but releasably attached to the junction box170by virtue of the means for attachment130. The perimeter of the cover100, and preferably the second edge pair122may include one or more recesses124within the outer edge to provide a more effective seal between the outer peripheral wall of the junction box170and the edges121,122of the perimeter wall120of the cover100. The recesses124may be sized to provide clearance space to structures such as outlet tabs162of an outlet160when the cover100is installed over an outlet160. The one or more recesses124may be sized to accommodate support structures for the outlet160or specifically to have a greater length than the total length of the distance between the outlet tabs162. The outlet support structures such as may be traversed172to receive a fastener132that also traverses the removable cover to enter the complementary attachment fixture172to allow for removable attachment of the cover100to the junction box170.

Accordingly, the cover100may also include one or more structures to provide the function of releasably attaching the cover100to the junction box170. In the embodiment ofFIG. 1a, the attachment structure is comprised of holes130that traverse the body of the cover100and have a meeting engagement with structure on the box170to facilitate removable attachment of the cover100. Also as seen inFIG. 1a, simple fasteners132may traverse both of the cover100and a fixture associated with the box170in order to provide for releaseable attachment of the cover100junction box170shown inFIG. 1a.

Referring again toFIGS. 1a-1f, the attachment means130provides a connection point for releasably attaching the cover100to the electrical junction box170at any point when the electrician has finished preparing the junction box170and expects that additional trades people will be working around the box170such that the electrician desires to protect the contents of the box170from contamination with debris. The attachment means130may be any mechanical expedient that provides for releasable attachment of the cover100to the box170. As shown in, for example,FIGS. 1a, 2a, 4a-4d, 4g, 5a-5eand 7a-b, a fastener132can traverse holes130in the cover100and engage complimentary attachment features172formed in the box170. In the embodiment ofFIG. 1a, the complimentary attachment feature172is simply a receiving hole into which the fastener132passes after traversing the body of the cover100.

Other examples include a conventional screw, nail, pen, or tie, including zip ties or other adjustable ties that ensure close engagement between the cover100and the box170.

Any attachment means130may be located in a recessed surface, at corners of the cover, as is illustrated in, for example,FIG. 4d). The attachment structures130may also be recessed with respect to the opposite edge surface (inside bottom surface) of the cover100to accommodate various junction box plaster ring180geometries. The junction box plaster rings180are commonly referred to as “mud rings” and are secured within the junction box170.

In an embodiment of the invention featuring a junction box plaster ring180, the attachment means may connect the cover100to the plaster ring180rather than directly to the box170. Because the plastic ring180is necessarily permanently attached to the box170, this configuration provides equivalent releasable connection of the cover to the box170/plaster ring180combination.

As described below in connection with the specific commercial junction box170, the recessed attachment features130are particularly preferred in commercial applications (e.g.,FIG. 4d-4g). In commercial applications, each metal junction box170routinely surrounds a plaster ring180to which sockets160are attached and the sockets160typically feature an outlet tab162or plurality thereof that are disposed between the sealing edges121,122,191,192of both the cover100and the box170respectively.

In an illustrative embodiment of the box170, the box170has complimentary attachment features172(e.g., holes or bosses) for the attachment means130to engage and attach to, such as via fasteners132. The goal of the shape and design of the peripheral wall120of the cover100is to provide an effective dust and debris seal around the periphery of the engagement between the lower edge of the peripheral wall120and the upper edge of the wall of the box170.

As noted above, the combination of the sealing engagement between the first and second edge pairs121,122of the peripheral wall120, the upper cover surface110, and the sealing combination with the third and fourth edge pairs191,192of the junction box170into the completed assembly to temporarily form a barrier between any components in the interior of the junction box170and any source of debris or contamination. While the contents of the junction box170may include a fully wired box170, completely connected to electrical wiring and/or cables at the terminal end thereof, including a “hot” outlet160while the finish work such as drywall, mudding, taping and painting is completed, the cover100also prevents the box170from being completely covered during the installation of drywall. The cover100prevents the junction box itself, as well as any associated outlets, from being damaged during drywall installation. Accordingly, whether or not the wiring or cable connections are complete, the cover100prevents debris such as drywall, spackle or paint from entering the box170. This is particularly important when the electrical junction box170contains fixtures such as ethernet cables, optical fibers, cable connections, and other sensitive electronic connectors that would be damaged, perhaps in ways that are not immediately apparent to the naked eye, during construction.

The cover100is sufficiently rigid and sized such that the dimensions of the edge of the perimeter wall120match the specific junction box170to which the cover100is releasably attached. As shown inFIGS. 4-10, the junction boxes170may be sized to accommodate a plurality of outlets160, but in each case, the outer periphery of the cover100is sized to engagingly mate with the outer periphery of the top edges121,122,191,192of the junction box170. Because of the meeting engagement of the box170and the cover100, drywall installers can easily and cleanly cut around the both the cover100and the box170when performing a drywall finishing work. Therefore, when the cover is in place, the entire junction box assembly exists as an intact unit wherein the cover100protects the outlets disposed within the box170while subsequent drywall finishing processes are performed.

In this configuration, the electrician can complete all of the hot wiring functions, understanding that a drywall finishing process is yet to be completed, with an expectation that the electrical junction box, and the functional outlets contained therein, will be protected during the drywall process. This eliminates the need for the electrician who is trimming (installing plugs and switches) during the normal trimming stage to spend any extra time trying to figure out what the “rough in” electrician did when wiring the project initially and eliminates the need for the electrician to inspect the junction box170after the finished drywall process. Thus, the completed assembly is minimally comprised of the cover100, the box170, and the attachment means130and functions as an intact unit to reduce the labor required for the final electrical trim process to a minimum, thereby saving time and money and improving the safety of all of the electrical and data connections formed within the junction box170.

Referring toFIGS. 2a-2f, the electrical junction box cover200is releasably attached to the electrical junction box270generally as described above. The cover200includes four peripheral walls220extending away from the cover surface to220to form an enclosure. Two of the peripheral walls220terminate in a first edge pair221, while the second two terminate in a second edge pair222. The first and second pairs of edges221,222sealingly engage corresponding structures on the box270about the periphery of each of the cover200and the junction box270. As with the single outlet embodiment, the overall dimensions of the cover200match the industry standard for a double outlet box270, but may readily be altered according to the design of the junction box270. The height of each of the four peripheral walls is greater than the highest point along a vertical distance from the faceplate of the outlet262to the tallest feature of the outlet260. Accordingly, each peripheral wall290would have a larger vertical distance for an outlet260comprising a toggle switch, compared to an electrical outlet receptacle.

Accordingly, the length and width of the pairs of edges221,222are matched to the dimensions of the corresponding edges291,292of the junction box270, which is typically, but not necessarily an industry-standard dimension. With appropriate dimensions, sealing engagement is provided when the edges221,222of the cover200are brought into conforming engagement with the edges291,292of the box270. As in the embodiment ofFIGS. 1a-1f, recesses224may be provided and sized to provide clearance space for structures such as the outlet tabs262of the outlet260when the cover200is engaged with the outlet270. The recesses224are preferably formed in the second edge222of the cover200, but may be formed in any edge structure to accommodate the geometry of the outlet260and particularly the outlet tabs262.

FIG. 3is a flowchart illustrating an embodiment of a method300of installing an electrical outlet160as described above with respect toFIGS. 1-to2and4-10. The method outline ofFIG. 3assumes that the outlets160are wired into the junction box170prior to installation of the removable cover100. As noted above, however, the removable cover can be installed at any point at which a desire exists to protect the internal space of the junction box170from contamination with debris. Accordingly, the flow chart ofFIG. 3is exemplary of one embodiment of the invention, and does not restrict performance of the invention to precisely following the steps as indicated, or in the exact order thereof, except as otherwise indicated herein.

Referring specifically toFIG. 3, in step310athe walls of a structure are erected by framers in a conventional manner requiring only that the frame is adequate to support the electrical junction box170as described herein. For example, the walls may be erected using wood or metal studs for walls and wood or metal beams for the ceilings and floors in a conventional manner, as long as these structures provide adequate structural support for attachment of drywall as described herein and placement of the junction box170.

In step310b, the electrician runs electrical wiring from a main panel to the desired location of the electrical junction box170. This is considered a minimal step to establish electrical connection from the main panel to each of a plurality of junction boxes170. However as is apparent from the disclosure herein, in addition to electrical wiring the step can include establishing a functional connection for data cables, optical fibers, ethernet connections, LAN connections, and any manner of electrical, optical, digital, or other connection that requires establishing a tangible, physical connection to a point of access by an inhabitant of a space who operates a switch, or utilizes an outlet, or performs any other conventional function associated with a junction box170.

As noted above, the invention also includes an embodiment whereby electrical or data connection is established from a central or main access panel and terminates near, but outside, the enclosure of the junction box170such that a pre-assembled junction box/cover assembly101can be provided requiring only formation of an electronic or data connection at an intermediate point (outside the junction box170). In step320an electrician attaches the box170to the wall studs or ceiling joists and routes the wiring from the main panel to the box170.

In step330, the electrician snaps off a portion of the metal outlet tabs prior to installing the outlet160in the box170. The removal of a portion of the outlet tabs162gives the drywall installers a cleaner box to work around without any significant protrusions from the outlet160sticking out beyond the perimeter of the box170. The outlet tabs162,262are shown inFIGS. 1aand 2a, and are shown removed inFIGS. 5c-5e. In some embodiments, the outlet tabs162,262are completely broken off for standard outlets and switches. In other embodiments, such as for decora outlets and switches, only the outside portion of outlet tabs162are broken off leaving the middle portion of the outlet tab for installation of a faceplate cover later (FIGS. 5c-5e).

In step340the electrician installs the outlet in the box. At this point the electrical connection to the main panel is complete and the outlet is hot once the main panel is activated.

In step350, the electrician installs the temporary protective cover using complementary attachment features on opposite corners of the cover that line up with attachment features on the box.

In step360, the drywall is installed over the wall studs and the ceiling joists. The installers cut out panels around the boxes that were installed by the electrician. The cover over the box protrudes from the studs sufficiently to ensure that the box is not inadvertently covered during the drywall process.

In step370, the finish work is completed around the box. The finish work may include taping, mudding, sanding and painting the drywall.

Beneficially, step380does not have to be done by an electrician. Step380could be completed by a builder's handyman or someone with only general knowledge of outlets at a much lower cost than hiring an electrician. In step380, the cover is removed by detaching the temporary protective cover from the box (e.g., by removing the fasteners in the opposite corners of the cover that attach the cover to the box).

In step385a, the outlet is loosened (but not removed) from the box.

In step385b, the breakaway reinforcement tabs are removed from the inside of the cover (e.g., broken off) and then placed between the outlet and the box at the top and bottom of the outlet. When needed, the outlet(s) are then tightened back to the box with the tabs creating a stable installation of the outlet against the box (FIGS. 5dand 5e).

In step390, the final finished cover or fixture is installed over the outlet to complete the process.

In some embodiments, the cover100includes reinforcement tabs150. Reinforcement tabs150may be breakaway reinforcement tabs150that can be detached from the cover100and used to stabilize the outlet160attachment to the box170. Detachment of the reinforcement tabs from the cover100may occur by bending and fracturing the connection of the reinforcement tab150to the cover100. The connection of the reinforcement tabs150to the cover100may be similar in geometry to a living hinge, as is known in the art of plastic injection molding.

The breakaway reinforcement tabs150are molded into the box170or the cover110and typically project up from a bottom surface or side surface of the box170or cover110. Once broken off, the reinforcement tabs150are inserted between the outlet160and the box170. Placement of the reinforcement tabs150between the outlet160and the box170provides a solid reaction surface for the installed outlet160to be secured against. In some embodiments, the reinforcement tabs150each include one or more slots152to accommodate fastening the outlet160to the box170and include a receiving abutment (not shown) to slots152.

Referring toFIGS. 4a-4e, a residential embodiment of the combination cover100and box170is shown revealing internal structures of each. The embodiment features reinforcement tabs150projecting up from an interior surface of the cover110along the long axial length thereof. The second pair of edges122each have recesses124to accommodate placement of an outlet160, including outlet tabs162therein. The embodiment ofFIG. 4aalso features a holding fixture131for easy attachment of a fastener132. The holding fixture131is molded into an external surface of the Box170for easy access when releasably engaging the cover100to the box170. In this embodiment, the attachment function is performed by simply removing the fasteners132from the holding fixture131and passing the faster132through the openings in the attachment means130to reversibly secure the cover100to the box170. When attached, the conforming edge pairs121,122and191,192will effectively seal the interior contents of the box against contamination and debris. The interior of the box170shows ports151molded into the rear surface of the box170. The ports151are comprised of an opening temporarily closed with a snap tab152that is removable to allow electrical wiring or data cabling to be inserted into the box174for operative or functional attachment to outlet160.

FIGS. 4f-4gare atypical commercial embodiment showing a junction box plastering180(or “mud ring”) attached to an outlet160. The exterior of the plastering ring180contains mating fixtures153that match corresponding attachment points154on the box170. As illustrated inFIG. 4g, by aligning the mating fixtures153with the attachment points154the combination of the box170and plastering ring180securely locates the outlet160in the combined assembly. To protect the outlet160, cover100is oriented above the outlet160and fastener132is passed through the attachment fixture130to secure the combined assembly.

Referring toFIG. 5a-g, a double outlet embodiment is comprised of a holding fixture231affixed to the external portion of a peripheral wall290of the box270. The reinforcement tabs250are disposed in a transverse orientation on the interior surface of the cover200. The attachment fixture272is disposed at opposite corners of the box272engage with the attachment means230of the cover200.FIGS. 5band 5creveal a box270having ports located in a bottom surface of the box270and having snap tabs252removed from a pair of the ports151for insertion of electrical wiring or data communication cabling. InFIG. 5c, a pair of outlets to 60 are shown in a conventional orientation within the box270.

FIG. 5fshows an embodiment including additional attachment features272positioned such that a fastener232(not shown here) would traverse the cover200and engage empty mating fixtures253on the plastering ring280.

FIGS. 6aand 6billustrate embodiments for covering round electrical junction box670. The round electrical junction box670may be temporarily covered and protected by a corresponding round electrical junction box cover600a(FIG. 6a),600b(FIG. 6b). Electricians install one of the round electrical junction box covers600a,600bhaving outlet inserts602a,602band hooks604a(FIG. 6a) or cutouts604b(FIG. 6b) over the outlet660. The hooks604aor cutouts604bprovide geometry to hold the wire of the outlet160that is plugged into it in place, when the wire is snaked through at least one of the hooks604aor cutouts604a. In some embodiments this allows other trades people to have temporary power throughout the house during the course of construction as compared to using the one outlet typically supplied during rough in or using a temporary electrical pole with power.

FIGS. 7a-7bare photos of an illustrative prototype of a temporary protective cover secured to an electrical junction box with drywall installed around the box according to embodiments of the invention.

Referring toFIGS. 8a-8c, the invention includes a combined assembly101having a box170attached to a cover100by a breakaway fixture155that allows the manufacture of the combined assembly101by molding a unitary structure wherein the box170and the cover100can be readily separated and utilized as described above.

The breakaway fixture155is any structural feature that allows ready separation of the cover110from the box170by manually separating the two components by hand. Typically, one simply grasps each component, rotates the components around an axis formed by the break away component155and physically separates the two pieces. A number of simple expedients are known for such a function, including a living hinge as described above, a perforated then, plastic molded segment, or any of a number of breakaway tabs provide this function.

As in the above-described embodiments, the edges of both the cover100and the box170are sized and oriented to fit into conforming engagement about the periphery of each edge. In use, the user simply breaks structure155to separate the cover100from the box170and assembles the wiring and electrical components as described above.FIG. 8c, is a cross-section view around line8C ofFIG. 8B.FIGS. 9a-9care a dual outlet embodiment of the combination component ofFIGS. 8a-8c.

The advantage of the combination component is that the appropriately -sized corresponding cover200is molded at the same time as the box207and so the conforming engagement between the box270and the cover200is assured. Careful control of the molded dimensions ensures that the breakaway fixture155attachment means between the cover200and the box270are in excellent alignment and ensures a secure assembly of the final combination.

For the embodiment ofFIGS. 8a-8cand 9a-9c, the user typically follows the steps of introducing electrical wiring or communication cabling through the port151,251and then attaches the wiring/cabling to the outlet160,260. Attachment fixtures on each of the box170,270are pre-molded to fit standard corresponding attachment fixtures on the outlet160,270. Once electrical or data communication connection is made between the wiring and the outlet160,270, the outlet is affixed to the box170,270and secured in place. The cover100,200is secured in place by virtue of the attachment means130, at any point at which the outlet160,270is secure. As described below in connection withFIG. 10, the wiring or data communication cabling may have a relatively short lead terminating at an intermediate end and of a length that is suitable to be contained within the box170,270. Preferably, this short wiring/cabling lead terminates in a simple connector, but may be left as a bare wire or cable. For mass assembly, the short wire/cable lead can be folded or coiled up, reinserted through port151,251such that the entire wiring assembly is contained within the box170,270. At any point following placement of the cover100,200in conforming engagement with the box170,270, the attachment means is used to secure the cover100,200to the box170,270. Upon secure engagement, such as with fastener132,232, the entire assembly can be shipped and is ready for installation at a building site.

Referring toFIG. 10, as noted above, the breakaway fixture155is any simple molded structural expedient that allows ready separation of the box component170,270from the cover component100,200. An option for the port151,251is either an open structure that is created, such as with the snap away tabs152,252or may be created to be resealable such as closure154that can be opened for insertion of the wiring/cabling into the housing of the box170. In such an embodiment, the method of assembly simply includes opening the closure154, connection of the wiring/cabling to outlet160,170, followed by placing the entire electrical/cabling lead (and optionally half of a connector pair) within the housing of the box170,270and closing the closure154. The cover100and box170are assembled in the same fashion as described above. However, when the combined component is used at the building site, the user simply opens closure154, retrieves the intermediate and of the wiring/cabling and attaches the wiring/cabling to the pre-existing wiring/cabling that is already in place at the wall, ceiling, or other rough structure at the building site. At this point the entire electrical assembly, with the cover100in place, is ready for installation of the drywall around the entire component assembly, requiring only removal of the cover100and the installation of a cosmetic or decorative cover plate to complete the entirety of the wiring/cabling and the outlet160,270installation process.

Various examples have been described and photos of prototypes including features of the embodiments have been provided. These specific examples and other examples are within the spirit of the invention are within the scope of the following claims.