Electrical cover plate

Implementations of an electrical cover plate assemblies feature a frame having at least one adapter plate recess in a finished surface, the adapter plate recess comprising an electrical device aperture and at least one adapter coupling aperture through the frame such that the electrical device aperture is recessed with respect to the finished surface, at least one adapter plate configured to couple directly to the frame, and a door hingedly coupled to the adapter plate.

BACKGROUND

1. Technical Field

Aspects of this document relate generally to covers for electrical devices.

2. Background Art

Conventionally, to cover the exposed sides and wiring attached to electrical devices installed in electrical boxes, an electrical cover plate that includes openings that permit the exposed faces of the electrical devices is used. Removable tabs have been used to permit conversion of electrical device covers from one type to another, an example of which is shown and described in U.S. Pat. No. 6,642,453 to Shotey, et al. (issued Nov. 4, 2003) titled “Convertible electrical device cover and method for installing same,” the disclosure of which is hereby incorporated herein by reference. Since changing of the colors of electrical devices once installed (particularly switches) generally requires removing and reinstalling new electrical devices of the desired color, methods for covering the exposed surfaces of installed electrical devices such as switches have been devised, examples of which are shown are described in U.S. Pat. No. 6,384,354 to Shotey, et al. (issued May 7, 2002) titled “Cover for electrical switch,” the disclosure of which is hereby incorporated herein by reference. Also, various methods for quickly attaching an electrical device cover to an electrical device box have been sold by companies such as Lamson and Sessions, Inc. of Cleveland, Ohio under the Carlon brand and Cheetah USA Corp. of Salt Lake City, Utah.

SUMMARY

In one aspect, an electrical cover plate assembly comprises a frame having a finished surface and at least one adapter plate recess in the finished surface, the adapter plate recess comprising an electrical device aperture and at least one adapter coupling aperture through the frame such that the electrical device aperture is recessed with respect to the finished surface. The device further comprises at least one adapter plate configured to couple directly to the frame, the at least one adapter plate comprising at least one projection extending from a surface of the adapter plate on each of at least two opposing sides of the adapter plate and arranged to align with and extend into adapter coupling apertures in the adapter plate recess and a door hingedly coupled to the adapter plate. In particular implementations, the adapter plate may surround the door when the door is closed on the adapter plate.

Particular implementations of the electrical cover plate assembly include a door pin hinge that couples via a pin to an adapter pin hinge on the adapter plate. The door may further comprise a first clasp latch that is configured to interface with a recess in the frame such that when the first clasp latch is engaged, the first clasp latch must be disengaged to move the door. This clasp latch may be spring biased to a latched position. The device may further comprise a second clasp latch wherein both the first and second clasp latch must be disengaged to open the door.

In some implementations, the door may further comprises a first magnetic surface wherein the adapter plate recess further comprises an opposing magnet configured to interface with the first magnetic surface. The door may further comprise a metallic plate wherein the adapter plate recess further comprises a magnet, and wherein the metallic plate is configured to interface with the magnet. The door may be configured to automatically close.

In some implementations, the device may further comprise a spring coupled to a door pin hinge such that the spring is configured to provide a closing force to the door. The device may comprise a second door or more than one set of hinge holes through which a hinge pin may pass.

In another aspect, an electrical cover plate assembly comprises a frame having at least one adapter plate recess in a finished surface, the adapter plate recess comprising an electrical device aperture and at least one adapter coupling aperture through the frame such that the electrical device aperture is recessed with respect to the finished surface, at least one adapter plate configured to couple directly to the frame, and a door hingedly coupled to the adapter plate.

DESCRIPTION

This disclosure, its aspects and implementations, are not limited to the specific components or assembly procedures disclosed herein. Many additional components and assembly procedures known in the art consistent with the intended electrical cover plate and/or assembly procedures for an electrical cover plate will become apparent for use with implementations of an electrical cover plate from this disclosure. Accordingly, for example, although particular frames, adapter plates, electrical devices, and non-electrically powered structures are disclosed, such devices and structures and their implementing components may comprise any shape, size, style, type, model, version, measurement, concentration, material, quantity, and/or the like as is known in the art for such devices and structures and their implementing components, consistent with the intended operation of an electrical cover plate.

Structure

Referring toFIGS. 1aand1b, a frame10for an electrical cover plate is illustrated. The frame10includes a “finished surface”12that is the surface visible when the frame10is installed on an electrical device. As used herein, “finished” is intended to mean and include the final part that is visible when the assembly is completed. Nothing else is needed over the finished surface of the frame inFIG. 1a; it is complete and intended to be used and displayed without any other covering over that portion. The frame10also includes an adapter recess14which includes an electrical device aperture16and at least one box mounting screw aperture18. The extents6of the adapter recess14are the side walls surrounding it and forming the recess. The frame10shown inFIGS. 1aand1bshows that the box mounting screw apertures18may be keyhole slot apertures. Although other box mounting screw apertures may be used, keyhole slot apertures make installation of the frame10faster and easier than fully removing the box mounting screws from the electrical box prior to installation.

Although it is considered that in most cases a conventional electrical box, such as a conventional “blue box” manufactured by Lamson and Sessions, Inc. of Cleveland, Ohio under the Carlon brand, the frame may be adapted to couple with other custom electrical boxes. The electrical boxes manufactured by Cheetah USA Corp. of Salt Lake City, Utah is one example of an alternative box design to which the various frame implementations shown and described in this disclosure may be adapted. Referring toFIG. 2, a frame11is shown with mounting prongs22,24configured to couple with correspondingly adapted or formed apertures in the electrical box. The use of mounting prongs22,24coupled with apertures in an electrical box removes the need to use conventional box mounting screws used for installing electrical devices into the box to fasten the frame11to the box. Other quick-connect box designs are also on the market that allow a cover to be quickly installed onto an electrical box. Those of ordinary skill in the art will readily understand how to adapt the disclosed frame implementations to differing electrical box connections without undue experimentation.

FIGS. 3aand3billustrate front and rear views of an implementation of an adapter plate20sized and shaped to fit at least partially into the adapter plate recess16of the frame10is illustrated. The adapter plate20of this particular implementation includes two catch mechanisms26on an upper edge and two pawls32on a lower, opposing edge. As illustrated more closely in the close-up view ofFIG. 4a, the catch mechanism26of this implementation includes a catch28and a spring element30. The spring element30is configured to maintain a bias against the frame10when the adapter plate20is coupled to the frame10. Referring toFIG. 4b, a pawl32is illustrated for this implementation. The pawl32includes angled surfaces on two of its faces31and33. The angled faces31and33assist in respectively removing and inserting the adapter plate20. The pawls32and catch mechanisms26may couple to the frame10at an adapter plate recess14through coupling apertures34and36(seeFIGS. 1b,5a, and5b).FIGS. 5aand5billustrate close-up views of the relationship between an implementation of the adapter plate recess14, the coupling apertures34and36, and the respective catch mechanism26and pawl32.

FIGS. 6aand6billustrate a front and rear view of an implementation of an adapter plate21with removable tab sets38,40. The adapter plate21of this implementation is initially configured as a “blank” having no openings configured to accommodate an electrical device face. Among other uses, blank adapter plates may be useful for childproofing electrical devices. Blank adapter plates adapted for childproofing applications may also include plug blade apertures that are initially closed with a layer of stationary or moveable plastic, but can be made open such as through mechanical movement known in childproofing cover art or being penetrated through insertion of plug blades through a thin film of plastic over each of the plug blade apertures of the adapter plate.

Depending on whether the electrical device to be accommodated is a duplex or ground fault current interrupter (GFCI) receptacle for this implementation, either of the removable tab sets38,40may be removed to allow access to the face of the receptacle. The particular implementation illustrated inFIGS. 6aand6balso shows that the adapter plate21is designed to expose the face of the receptacle, while the particular implementation illustrated inFIGS. 3aand3bis designed to conceal the face of the receptacle while providing access through plug blade apertures to corresponding plug blade apertures in an electrical device behind the adapter plate20. Particular implementations may also include adapter plates designed to conceal part of an electrical device while providing removable tabs for exposing another part of the device (such as a reset button on a ground fault circuit interrupter (GFCI) device) if so desired.

Another particular implementation of an adapter plate42is illustrated inFIG. 7. For certain types of electrical devices, known as “decorator-style” or “decora-style” devices, the device face is a large rectangle. In combination with the frame10implementation ofFIGS. 1aand1b, the device face of a decora-style device will fill much of the electrical device aperture16in the frame10leaving only a small space in the adapter plate recess14along two of its edges. This is illustrated best in the implementations shown inFIGS. 14,15,18and20. To permit the adapter plate42to fit over a decora-style receptacle, two thin sides43are used to connect the top part of the adapter plate42to its lower portion. These thin sides43fill the remaining space in the adapter plate recess14at least up to an edge of the electrical device aperture16within the limits of any space required to ensure the receptacle and the adapter plate42will be able to be inserted and removed.

FIGS. 8athrough10billustrate various examples of electrical devices coupled to adapter plates for mounting in an implementation of a disclosed frame. For some of these examples, the electrical devices are coupled permanently to the adapter plate (in some cases even coupled by forming integrally with the adapter plate).FIGS. 8aand8billustrate front and rear views of a night light45or emergency light45implementation coupled to an adapter plate44. Although the implementation shown indicates that it may be plugged into a receptacle behind the adapter plate, by adapting the design to be battery powered, the light implementation may be used within a adapter plate recess regardless of whether there is a powered receptacle within the recess or not.FIG. 8ashows the front face of the adapter plate44which may be flat or nearly flat with a place for light from the nightlight45to escape.FIG. 8billustrates the rear of the adapter plate44which includes prongs46that fit into an electrical receptacle covered by the adapter plate44and the light bulb48within the nightlight. As an alternative to a light bulb48, other lighted films and electroluminescent materials may be used. These are common in the art of nightlights. One example is the Indiglo® material. The prongs46are inserted into the receptacle when the adapter plate44is inserted into the frame10thus powering the nightlight45.

FIGS. 9aand9billustrate another particular implementation of an adapter plate50which includes an air freshener51. The air freshener51is attached to the adapter plate50and a set of prongs52is attached to the rear of the adapter plate50illustrated inFIG. 10bto provide power to the air freshener. Like the nightlight45, the air freshener may receive power from a receptacle when the adapter plate50is inserted into the frame10, or may be adapted for battery or other power. Similarly, referring toFIGS. 10aand10b, an adapter plate54implementation that includes a carbon monoxide sensor55is illustrated. The adapter plate54can best be seen inFIG. 11b, which also shows the prongs56that connect the carbon monoxide sensor55to power when the adapter plate54is inserted into a frame10over a receptacle.

The use of an adapter plate44,50, and54implementation like those shown inFIGS. 8ato10bfor electrically powered devices may help ensure these devices are not easily removable and may add to the convenience, improve the aesthetic appearance, and improve the safety performance of these devices while they are in use. While electrical devices that are connected directly to power through a receptacle have been illustrated inFIGS. 8a-10b, electrical devices that are powered by batteries and do not require a power connection may be included in particular implementations. Those of ordinary skill in the art will readily understand how to modify various electrical devices for use with an adapter plate to secure the device to the wall plate frame from the disclosure provided herein.

FIGS. 11aand11bshow a particular implementation of an adapter plate58that includes a non-electrically powered device. The particular device shown inFIGS. 11aand11bis a hook59for a key chain or pet leash. Because the hook does not require electrical power, the adapter plate58can be installed in an adapter recess14in a frame10that does not have the electrical device aperture16filled by an installed electrical device. Alternatively, the adapter plate58can be installed over any electrical device that does not protrude above the finished surface12of the frame10(for example, a receptacle) if the adapter plate58is appropriately configured for the device behind it.

The principle of using an adapter plate that incorporates electrically or non-electrically powered devices can be extended to cover particular implementations of adapter plates intended to convert a universal electrical device that is configured to mount within a standard rocker switch or duplex outlet space in an electrical box from one device type to another. For example, an adapter plate configured with an interface that causes the universal electrical device to act as a toggle switch may initially be installed within the frame. If the user desires to remove the switch and replace it with a rocker switch interface, the toggle switch adapter plate can be removed and replaced with an adapter plate designed to convert the device to act as a rocker switch. Other implementations where the universal electrical device can be caused to operate as an electrical receptacle instead of a switch, for example, simply by exchanging appropriately configured adapter plates are contemplated.

FIG. 12illustrates a particular implementation of a four gang frame6that includes four different electrical devices, a duplex receptacle60, a GFCI receptacle62, a rocker switch64, and a decora-style receptacle66. ReferringFIG. 13, a cross section view along the sectional line A ofFIG. 12is shown with the frame removed but a reference line B shown which indicates that the duplex receptacle60is recessed relative to a reference line B level with the face of the GFCI receptacle62. The rocker switch64protrudes above the reference line61and the decora-style receptacle66is slightly recessed. Since the exposed faces of the electrical devices are not at the same level, their surfaces will not be co-planar if a conventional four gang electrical cover plate were installed.

Referring toFIG. 14, the viewable surface of the finished cover plate for the electrical devices can be rendered co-planar by the use of adapter plates68,70,72, and74which each vary in their thickness corresponding to the type of electrical device they conceal or with which they interface. For example, the portion of the adapter plate68that conceals the duplex receptacle60will need to be thicker than the portion of the adapter plate70that conceals the GFCI receptacle62so that the exposed surfaces of the adapter plates68and70are co-planar.FIG. 14illustrates the co-planar exposed surfaces of the adapter plates68,70,72, and74when installed over the electrical devices. The principle of varying the thickness of an adapter plate used to cover a particular electrical device type can permit a wide variety of different electrical devices to be rendered co-planar. Using conventional systems, co-planar implementations for differing device types was not possible. Referring toFIG. 15, sixteen (16) different electrical device adapter plates are shown mounted in a single frame9, all with exposed surfaces rendered co-planar by the use of an adapter plate of a corresponding thickness.FIG. 15also illustrates a plurality of different implementations for adapter plates that may be configured for virtually any type of electrical device. Only a limited number of examples is provided here due to the endless possibilities available. Many other implementations will become apparent from the disclosure provided here.

Another particular implementation of an adapter plate75is illustrated inFIGS. 16aand16b. The adapter plate75can be composed of a spacer plate76and a shell78. The spacer plate76of this implementation includes a plurality of tabs80which couple with a plurality of projections82from the shell78. The tabs80and the projections82permit the spacer plate76and the shell78to become an adapter plate75which can then be installed into a frame, such as frame10shown inFIG. 1a. To permit the adapter plate75to couple with the apertures34,36in the frame10for installation of the adapter plate75, a first prong86and a spring member88may be included at the upper side of the spacer plate76. On the opposing side of the spacer plate76a second prong90may be included. The first and second prongs86and90fit into the apertures34,36in the frame10when the adapter plate75is installed.

Referring toFIG. 17a, coupling of the spacer plate76and the shell78may be accomplished by providing a plurality of slots84in the projections82attached to the shell78. In the particular implementation shown inFIG. 17a, two sets of slots84are provided, which allow the spacing between the shell78and the spacer plate76to be adjusted, depending on which set of slots84the tabs80are currently engaged in.FIG. 17billustrates how by using the slots84and the tabs80to set the distance between the shell78and the spacer plate76, the exposed surface of the adapter plate75may be rendered co-planar with the exposed surface of an adjoining electrical device, in this case, a rocker switch. While the particular implementation of an adapter plate75has shown two sets of slots84, other particular implementations may include only one set of slots84so that the distance between the shell78and the spacer plate76is fixed.

Referring toFIG. 18, four different electrical devices92,94,96, and98have been installed within an electrical box2. As can be seen from the extreme example ofFIG. 18, the four devices92,94,96, and98are coupled loosely to the electrical box2through a plurality of box mounting screws91,93,95and97, and they are not aligned with one another either vertically or horizontally.FIG. 19shows a frame6placed over the four electrical devices92,94,96, and98and coupled to the electrical box through the plurality of box mounting screws91,93,95and97. The electrical devices92,94,96, and98are now aligned vertically and horizontally by the electrical device apertures16in the frame6. Alignment of the devices92,94,96, and98occurs automatically as the frame6is placed over the devices92,94,96, and98and is coupled to the electrical box through the box mounting screws91,93,95and97. Although box mounting screws and keyhole box mounting screw apertures are used in this particular implementation, alternative coupling methods and/or alternative box mounting screw aperture configurations may be used. The alignment feature is not dependent upon what method is used to couple the frame to the wall, electrical box or electrical device.

FIG. 20shows the frame6with the box mounting screws91,93,95and97tightened down into the box mounting screw apertures18.FIG. 21shows the frame6with three adapter plates102,104,106installed into the adapter plate recesses14of the frame6. The last adapter plate108is shown partially inserted into the apertures34in the adapter plate recess14to illustrate how the adapter plate106is installed into the frame6. Installation of the adapter plate108is completed by pushing the side of the adapter plate108that includes the pawls32into the apertures36in the adapter plate recess14. At that point, the adapter plate106“snaps in” to the adapter plate recess14and conceals the box mounting screw apertures18, the electrical device aperture16and fills the adapter plate recess14at least to the edge of the electrical device aperture16. Removal of the adapter plate106may be accomplished by inserting a thin flat object, such as a screw driver, into the narrow gap between the adapter plate106and the frame6near the pawls32(FIGS. 3a-4b) and applying a prying pressure.

Other Implementations.

Another particular implementation of an adapter plate122is illustrated inFIGS. 22-24. This implementation includes a hinged door120on the adapter plate122which is directly coupled to the frame121by seating tabs123into corresponding recesses in the frame121. As depicted, in particular implementations the door120is hinged along a left side, however, the door120may be hinged along any side of the adapter plate122. This implementation and the adapter plate implementation illustrated inFIGS. 25-27are contemplated to be configured like the implementations shown and described with reference toFIGS. 3,4,6and7, in the features they include to assist in engaging with the frame121. Although a specific separate description of those engagement mechanisms is not provided here, it should be understood that the frame121and the adapter plate122may specifically include the same coordinating engagement features as the previous embodiments.

The hinge may be a simple pin hinge with pins extending from two opposing sides of the door120into corresponding recesses in the adapter door frame or may comprise any other type of hinge structure. In the embodiments shown inFIGS. 22-27, the adapter plate surrounds the door when the door is closed on the adapter plate, but this is not required in every embodiment and the adapter plate hinge members may extend forward of the adapter plate to hold the door hinge pins. In particular implementations, along a non-hinging side of the door120, a magnetic or metal element124may be mounted to the door120. A corresponding metal or magnetic element124may be mounted to the door frame so that when the door120is closed, the two pieces124attract each other to hold the door120closed against the frame121. The adapter122surrounds and/or covers (see, e.g.FIGS. 3aand6a) the electrical device face and in these cases, the door120closes over the top of the electrical device face to hide the electrical device. In particular implementations of the embodiments illustrated inFIGS. 22-27, the door may be configured with a coil spring or other bias that biases the door to its closed position. For example, the adapter plate may comprise a spring coupled to a door pin to bias the door closed. Although the particular implementations ofFIGS. 22-27are single gang examples, the adapter plate may be configured similar to the other implementations provided throughout this disclosure such that it can engage into the frame openings within any of the various multiple-gang implementations as well.

In another aspect, particular implementations, such as that illustrated inFIGS. 25-27, may comprise a clasp on the adapter door. As shown, the hinged door120may further comprise a moveable clasp latch125located along a non-hinging side of the door120. In such implementations, the door frame121further comprises a corresponding recess126so that the moveable clasp latch125may extend into the recess126in the door frame. To open the door120, the user slides the moveable clasp latch125away from the frame edge toward the center of the door120to unlatch the door120. The moveable clasp latch125is spring biased to its latched position. The spring may be formed of metal, plastic, or any other suitable material. In other implementations, the hinged door120may comprise two moveable clasps that work together and move toward each other so that the user can pinch the clasps to release the latch and allow the door to open. The adapter122surrounds and/or covers the electrical device face and in this example, the door120closes over the top of the electrical device face to hide the electrical device. A rear side of the door120may comprise one or more recesses (not shown) to receive the socket face of the electrical outlet. In some implementations designed for child safety, the door latch may comprise a pair of door latches on adjacent opposing sides of the door so that opposing movement of the latches is required to open the door. Other forms of child safety latches may comprise other combinations of two or more movements to unlatch the door. An alternative embodiment allows for more convenient usage depending on the placement of the receptacle relative to other structures on the wall including, but not limited to, a medicine cabinet or an adjacent wall. Other embodiments may comprise two hinged doors, one for each receptacle of the electrical outlet, each door hingedly coupled to the adapter, but they may hinge to the side as in the embodiment ofFIG. 23, or may hinge both at the top of the door, or one at the top of the first door and one at the bottom of the second door so that they separate when they are both open.

In some aspects of the implementation, it may be desirable to allow a user to switch the swing direction of the door. Therefore, at least second set of holes may be included in the adapter frame, but any number of sets of holes may be included. In such implementations the user may simply snap the hinge pins into the desired hinge holes. For example, the product may be packaged so that at the time of sale, the hinge is on the left side but when installed, it may be determined that it is more desirable for the door to hinge on the right side. The user may then bend or flex the door sufficiently to allow the hinge pins to be removed from the left-paired hinge holes and then reinsert the pins into the right-paired hinge holes. A similar operation may allow a user to switch the cover between top-paired hinge holes and bottom-paired hinge holes. Another alternate implementation may provide that the door automatically closes under the bias of a spring comprised of plastic, metal, or any other suitable material.

Other implementations may comprise multiple doors as it may be desirable for the user to open a first door that leads to one receptacle while the other receptacle within a duplex device remains covered by a second door. This allows the second receptacle to remain protected while the first one is in use.

Still further implementations may allow for protection of non-receptacle devices including, but not limited to switches. In these implementations, the door may include a molded shape that conforms to the basic topography of the respective device.

It will be understood that implementations are not limited to the specific components disclosed herein, as virtually any components consistent with the intended operation of a method and/or system implementation for an electrical device cover may be utilized. Accordingly, for example, although particular frames, adapter plates, electrical devices, or non-electrically powered devices may be disclosed, such components may comprise any shape, size, style, type, model, version, class, grade, measurement, concentration, material, weight, quantity, and/or the like consistent with the intended operation of a method and/or system implementation for an electrical cover plate may be used.

In places where the description above refers to particular implementations of an electrical cover plate, it should be readily apparent that a number of modifications may be made without departing from the spirit thereof and that these implementations may be applied to other electrical cover plate designs. The accompanying claims are intended to cover such modifications as would fall within the true spirit and scope of the disclosure set forth in this document. The presently disclosed implementations are, therefore, to be considered in all respects as illustrative and not restrictive, the scope of the disclosure being indicated by the appended claims rather than the foregoing description. All changes that come within the meaning of and range of equivalency of the claims are intended to be embraced therein.