WALL PLATE ASSEMBLY

A wall plate assembly is provided with a first wall plate portion to at least partially cover an electrical device, with a first lateral side with a first fastener and a second fastener formed partially along the first lateral side. A second wall plate portion to at least partially cover the electrical device, with a first lateral side with a first fastener formed partially along the first lateral side and sized to fasten in a length direction with the first wall plate portion second fastener, and a second fastener formed partially along the first lateral side and sized to fasten in the length direction with the first wall plate portion first fastener.

TECHNICAL FIELD

Various embodiments relate to wall plate assemblies for electrical devices.

BACKGROUND

A cover plate for a wall mounted electrical device is disclosed in Daniels et al. U.S. Pat. No. 7,939,756 B2, which issued on May 10, 2011, to Liberty Hardware Mfg. Corp.

SUMMARY

According to an embodiment, a wall plate assembly is provided with a first wall plate portion to at least partially cover an electrical device, with a first lateral side with a first fastener and a second fastener formed partially along the first lateral side. A second wall plate portion to at least partially cover the electrical device, with a first lateral side with a first fastener formed partially along the first lateral side and sized to fasten in a length direction with the first wall plate portion second fastener, and a second fastener formed partially along the first lateral side and sized to fasten in the length direction with the first wall plate portion first fastener.

According to a further embodiment, the first wall plate portion and the second wall plate portion have a common width in a lateral direction.

According to another further embodiment, the first wall plate portion and the second wall plate portion are each further provided with a substrate with a pair of lateral sides. The pair of lateral sides further define the first lateral side and a second lateral side.

According to an even further embodiment, the second lateral side of each substrate is further provided with a first fastener and a second fastener formed partially along the second lateral side.

According to another even further embodiment, the first fastener of the second lateral side of each substrate is sized to fasten in a length direction with the second fastener of first lateral side of each substrate.

According to yet another even further embodiment, the first fastener is a tapered projection or a tapered groove. The second fastener is the other of the tapered projection or the tapered groove.

According to another further embodiment, an end plate portion is provided with a first fastener and a second fastener to attach to the first lateral side or the second lateral side of each substrate.

According to an even further embodiment, the end plate portion is interchangeable to be installed to the first wall plate portion or the second wall plate portion in either upright direction to be installed to either lateral side of the first and second wall plate portions.

According to another further embodiment, each wall plate portion is further provided with a pair of rims, each extending along longitudinal edges of the substrate and away from the substrate to engage an upright support surface and to provide a decorative transition from the substrate to the upright support surface. The end plate portion is further provided with an outboard rim extending a length of the substrate to interconnect the pair of rims of an adjacent wall plate portion.

According to another further embodiment, each wall plate portion is further provided with a pair of rims, each extending along longitudinal edges of the substrate and away from the substrate to engage an upright support surface and to provide a decorative transition from the substrate to the upright support surface.

According to an even further embodiment, the pair of rims each have a width that is common with a width of the substrate. The pair of rims are each offset laterally from the substrate in opposed directions to provide an overhang from the substrate at one end of each lateral side and to provide a recess at another end of each lateral side.

According to another even further embodiment, the rim overhang provides a limit to translation of the first wall plate portion relative to the second wall plate portion.

According to another further embodiment, at least one of the first wall plate portion and the second wall plate portion is radially symmetrical about an axis perpendicular to the substrate with an increment of 180 degrees so that the at least one wall plate portion is interchangeable to be installed in either upright direction.

According to another further embodiment, a first seam cover extends partially over the first lateral side of the first wall plate portion. A second seam cover extends partially over the first lateral side of the second wall plate portion such that when the first wall plate portion is fastened to the second wall plate portion, the first seam cover and the second seam cover collectively cover a seam between the first lateral side of the first wall plate portion and the first lateral side of the second wall plate portion.

According to an even further embodiment, each seam cover extends along one half of a length of each wall plate portion to abut against a corresponding seam cover of an adjacent wall plate portion.

According to another further embodiment, the first wall plate portion and the second wall plate portion are each further provided with a substrate with a pair of lateral sides. The pair of lateral sides further defines the first lateral side and a second lateral side. A pair of rims, each extend along longitudinal edges of the substrate and away from the substrate to engage an upright support surface and to provide a decorative transition from the substrate to the upright support surface. A cross member extends across an intersection of the substrate and each rim to interconnect the first and second seam covers and provide a unitary ornamental appearance across the wall plate assembly.

According to another embodiment, a wall plate assembly is provided with a first wall plate portion to at least partially cover an electrical device, with a first lateral side with a first fastener formed therealong, and a first seam cover extending partially over the first lateral side. A second wall plate portion at least partially covers another electric device, with a first lateral side with a first fastener formed therealong and sized to fasten with the first fastener of the first wall plate portion, and a second seam cover extending partially over the first lateral side such that when the first wall plate portion is fastened to the second wall plate portion, the first seam cover and the second seam cover collectively cover a seam between the first lateral side of the first wall plate portion and the first lateral side of the second wall plate portion.

According to a further embodiment, a second fastener is formed along the first lateral side of the first wall plate portion. A second fastener is formed along the first lateral side of the second wall plate portion, sized to fasten with the second fastener of the first wall plate portion.

According to another embodiment, a wall plate assembly is provided with a first wall plate portion to at least partially cover an electrical device, with a substrate with a first lateral side with a first fastener and a second fastener formed partially along the first lateral side. A first end plate portion is provided with a first fastener sized to fasten in a length direction with the second fastener of the first wall plate portion, and a second fastener sized to fasten in the length direction with the first fastener of the first wall plate portion.

According to a further embodiment, the substrate defines a second lateral side. The second lateral side of the substrate is further provided with a first fastener and a second fastener formed partially along the second lateral side. A second end plate portion is provided with a first fastener sized to fasten in a length direction with the second fastener of the second lateral side of the first wall plate portion, and a second fastener sized to fasten in the length direction with the first fastener of the second lateral side of the first wall plate portion.

DETAILED DESCRIPTION

FIGS.1-5illustrate a wall plate assembly30according to an embodiment. The wall plate assembly30is designed to cover a wall mounted electrical device, such as a light switch, an electrical outlet, a dimmer switch, a fan switch, communication port, or the like. The electrical devices are often mounted in an electrical box within a wall. The combination, arrangement and order of the electrical devices is often limited by the available openings and patterns of wall plates. The wall plate assembly30is modular, configurable, interchangeable, expandable, and customizable so that an end user may combine, arrange, and order the wall plate assembly30for any quantity of electrical devices.

The wall plate assembly30includes a plurality of interchangeable wall plate portions32,34,36. For example, the wall plate portion32is a rocker wall plate portion32sized to receive a rocker switch, a slider switch, a rectangular outlet, or the like. By way of another example, the wall plate portion34is an outlet wall plate portion34for a duplex outlet. As another example, the wall plate portion36is a toggle wall plate portion for a toggle switch. Although the three wall plate portions32,34,36, are illustrated, any combination, and arrangement of wall plate portions32,34,36can be employed in the wall plate assembly30.

Each of the wall plate portions32,34,36include a common width and are assembled together by sliding along the edges as illustrated inFIGS.4and5. A pair of end plate portions38enclose lateral ends of the wall plate assembly30. The wall plate portions32,34,36,38are each interchangeable to permit an end user to arrange and assemble a customized wall plate assembly30for any number and combination of electrical devices. The wall plate assembly30provides a unitary appearance once assembled with any number of intermediate wall plate portions32,34,36between a pair of end plate portions38.

FIGS.6-12illustrate a wall plate portion40as a blank for covering a portion of a wall box for one or more electrical devices. The blank wall plate portion40has features in common with the other intermediate wall plate portions32,34,36. The blank wall plate portion40may be formed from polypropylene, or any suitable material. The blank wall plate portion40may be molded. The blank wall plate portion40includes a plate or a substrate42to cover the wall box and electrical device. The substrate42has a height to extend across the wall box. The substrate42has a width sized to match a spacing between electrical devices within the wall box. The substrate42may have a consistent thickness for a flat appearance, or variable to incorporate a surface finish or design.

The blank wall plate portion40is radially symmetrical about an axis into the wall with an increment of 180 degrees. Therefore, the blank wall plate portion40can be installed in either upright direction. The pair of exposed peripheral edges of the blank wall plate portion40are typically oriented at a top edge and a bottom edge of the blank wall plate portion40. A rim44is provided along the exposed peripheral edges of the wall plate portion40. The rims44extend rearward of the substrate42to engage the wall and to provide a decorative transition from the substrate42to the wall. The rims44have the same width as the substrate42. The rims44are also offset laterally from the substrate42to provide an overhang46from the substrate42on one end, and a recess48on the other end. The overhang46of each rim44is received within the recess48of an adjacent wall plate portion40upon assembly.

The substrate42has a pair of lateral sides50for engagement with a lateral side50of an adjacent wall plate portion32,34,36,38,40. A pair of fasteners52,54are provided on each lateral side50to connect to the adjacent wall plate portion32,34,36,38,40. The pair of fasteners52,54are complementary and sized to fasten to a corresponding pair of fasteners52,54on another lateral side50of the adjacent wall plate portion32,34,36,38,40. The pair of fasteners52,54are oriented to fasten to another pair of fasteners52,54by sliding in a height direction of the substrates42.

The first fastener52is illustrated as a tapered projection from the lateral side, often referred to as a dovetail52. The second fastener54is a corresponding tapered groove54sized to receive the dovetail52, and referred to as a dovetail groove54. To assemble adjacent wall plate portions, such as the wall plate portions32,34, the wall plate portions32,34are aligned as illustrated inFIGS.4and5. In this orientation, the dovetail52of the wall plate portion32is aligned with the dovetail groove54of the wall plate portion34. Likewise, the dovetail52of the wall plate portion34is aligned with the dovetail groove54of the wall plate portion32. Then the wall plate portions32,34are translated relative each other to fasten the dovetails52into the dovetail grooves54. The wall plate portions32,34are slid until the rim overhangs46engage the recesses48, providing a limit to the translation and an abutment that provides uniform aligned appearance as illustrated inFIGS.1-3.

Referring again toFIG.8, the dovetail52and the groove54are reversible for each lateral side50so either lateral side50may be fastened to any lateral side50of the wall plate portions32,34,36,38,40. Additionally, the dovetails52are tapered with a thickness that increases toward the overhang46to increase friction as the dovetails52are fastened into the grooves54. The increased width of the dovetails52and the lengthwise assembly motion further converges adjacent substrates42together to eliminate a gap between adjacent lateral sides50. The gap between adjacent lateral sides50is available in prior art designs with fasteners that attach in a direction perpendicular to the substrate42, which detract from the ornamentality and safety of the prior art wall plates.

Referring again toFIGS.6and7, each wall plate portion40may also include a pair of seam covers56extending partially along each lateral side50of the substrate42. The seam covers56extend over the lateral side50to cover a seam between abutting lateral sides50once assembled. The seam covers56each extend along one half of the length the substrate42to abut against the corresponding seam cover56of the adjacent wall plate portion32,34,36,38,40. The seam covers56collectively cover seams at the lateral sides50of the substrates42, while also providing an ornamental architectural appearance upon the wall plate assembly30. The wall plate portion40may also include an ornamental, architectural cross member58that extends across an intersection of the substrate42and each rim44to interconnect the seam covers56and provide a unitary ornamental appearance across the wall plate assembly30.

With reference now toFIGS.9and10, a pair of depressions60may each be formed within a rear surface of the substrate42to provide additional clearance to fastener heads of the electrical device within the wall box.

The rocker wall plate portion32is illustrated disassembled from the wall plate assembly30inFIG.13. The rocker wall plate portion32includes all of the features discussed above with reference to the blank wall plate portion40. The rocker wall plate portion32also includes a pair of fastener apertures62to attach the rocker wall plate portion32to the electrical device. Additionally, the rocker wall plate portion32includes a switch aperture64to receive a rocker switch or the like, from the electrical device.

The outlet wall plate portion34is illustrated disassembled from the wall plate assembly30inFIG.14. The outlet wall plate portion34also includes all of the of the blank wall plate portion40. The outlet wall plate portion34also includes a fastener aperture66to attach the outlet wall plate portion34to the electrical device. The outlet wall plate portion34also includes a pair of duplex apertures68to receive a pair of duplex outlets from the electrical device.

The toggle wall plate portion36is illustrated disassembled from the wall plate assembly30inFIG.15. The toggle wall plate portion36includes the features of the blank wall plate portion40. The toggle wall plate portion36also includes a pair of fastener apertures70to attach the toggle wall plate portion36to the electrical device. Additionally, the toggle wall plate portion36includes a switch aperture72to receive a toggle switch from the electrical device.

FIGS.16-22illustrate the end plate portion38disassembled from the wall plate assembly30. The end plate portion38has features in common with the intermediate wall plate portions32,34,36,40. The end plate portion38cooperates with the intermediate wall plate portions32,34,36,40to cover the wall box and electrical device. The end plate portion38has a height to extend across the wall box.

The end plate portion38can be installed in either upright direction to be installed to either lateral side of the intermediate wall plate portions32,34,36,40. The end plate portion38has as substrate74to align with the substrate42of an adjacent intermediate wall plate portions32,34,36,40. The end plate portion38also includes one inboard lateral side50for engagement with the lateral side50of the adjacent intermediate wall plate portion32,34,36,40. A pair of fasteners52,54, which are the dovetail52and the dovetail groove54, are provided on the lateral side50to connect to the adjacent intermediate wall plate portion32,34,36,40. To assemble the end plate portion38, such as to the wall plate portions32,36, the end plate portions38are aligned as illustrated inFIGS.4and5. In this orientation, the dovetail52of the end plate portions38are aligned with the dovetail grooves54of the wall plate portions32,36. Likewise, the dovetails52of the wall plate portions32,36are aligned with the dovetail grooves54of the end plate portions38. Then, the end plate portions38are translated relative to the wall plate portions32,36to fasten the dovetails52into the dovetail grooves54as illustrated inFIGS.1-3.

The end plate portion38includes a pair of rims76extending from the substrate74and the lateral side50to align with the adjacent rims44of the intermediate wall plate portions32,34,36,40. The rims76are also offset laterally from the substrate74to provide an overhang46from the substrate74on one end, and a recess48on the other end. The overhang46of each rim76is received within the recess48of an adjacent wall plate portion32,34,36,40upon assembly. The recess48of each rim76receives the overhang46of the adjacent wall plate portion32,34,36,40. The end plate portion38also includes an outboard rim78extending a length of the substrate74to interconnect the top and bottom rims76. The rims76,78extend around the periphery of the lateral side50to extend to the wall to enclose and at least partially conceal the electrical device or devices within the wall box. During assembly, the end plate portions38are slid until the rim overhangs46engage the recesses48, providing a limit to the translation and an abutment that provides uniform aligned appearance.

Each end plate portion38may also include a seam cover56extending partially along the lateral side50of the substrate74. The seam cover56extends over the lateral side50to cover a seam between abutting lateral sides50once assembled. The seam cover56extends along one half of the length the substrate74to abut against the corresponding seam cover56of the adjacent wall plate portion32,34,36,40. The seam covers56collectively cover seams at the lateral sides50of the substrates42,74while also providing an ornamental architectural appearance upon the wall plate assembly30.