Zero profile while in-use electrical outlet cover

An electrical outlet cover assembly includes an electrical outlet mounting box having a front edge that does not extend beyond a front surface of a wall. An extendable base is coupled with the electrical outlet mounting box and is slideable between collapsed and extended positions. When collapsed, a leading edge of the extendable base does not extend beyond the front surface of the wall. One or more guides resist decoupling of the extendable base and the electrical outlet mounting box. A lid is pivotably coupled with the extendable base, and one of the lid and the extendable base has a cord port along their respective edges. The lid has a front surface and is positionable between open and closed positions. The lid's front surface is substantially flush with the front surface of the wall when the base is collapsed and the lid is closed with respect to the extendable cover.

BACKGROUND

1. Technical Field

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

2. Background Art

Electrical outlets may be exposed to rain, snow, debris, and other contaminants when mounted in outdoor locations, such as exterior walls. While many different cover designs have sought to shield electrical outlets from weather-related contaminants when electrical connectors are coupled with the outlets, such covers may protrude from exterior walls where they may be damaged, may appear unsightly, or may interfere with movement around an exterior wall having such a cover. Typical examples of while-in-use cover designs include a lid coupled to a fixed base by a hinge.

SUMMARY

Aspects of this document relate to electrical device covers.

In one aspect, an electrical outlet cover assembly configured for mounting over an electrical outlet comprises an electrical outlet mounting box having a front edge, an inner surface and an opening large enough to receive an electrical outlet. The inner surface of the electrical outlet mounting box comprises one or more guides, and the front edge of the electrical outlet mounting box is configured such that it does not extend beyond a front surface of a wall when the electrical outlet mounting box is installed in the wall. An extendable base comprises a leading edge and an outer surface. The outer surface has one or more guides in mechanical cooperation with the one or more guides on the inner surface of the electrical outlet mounting box such that the extendable base is slidably coupled with the electrical outlet mounting box. The extendable base is slideable between a collapsed position and an extended position. In the collapsed position, the leading edge of the extendable base is configured such that it does not extend far beyond the front surface of the wall when the electrical outlet mounting box is installed on the wall. However, in the extended position, the one or more guides resist decoupling of the extendable base and the electrical outlet mounting box. A lid is further pivotably coupled with the extendable base, and at least one of the lid and the extendable base have a cord port along an edge of the respective lid and extendable base. The lid has a front surface and is positionable between an open position and a closed position with respect to the extendable base. The front surface of the lid is substantially flush with the front surface of the wall when the extendable base is in the collapsed position and the lid is in the closed position with respect to the extendable cover.

Particular implementations may include one or more of the following. The electrical outlet mounting box may comprise a recessed electrical outlet mounting box comprising at least two box mounting screw apertures on an inside surface of the box recessed at least one inch behind the front edge of the electrical outlet mounting box. The electrical outlet mounting box may comprise at least two box mounting screw apertures on an inside surface of the box less than one inch behind the front edge of the electrical outlet mounting box. The electrical outlet mounting box may comprise an external mounting flange. The one or more guides may comprise one or more guide rails and guide rail stops. The one or more guides may comprise one or more guide protrusions, guide protrusion channels, and guide protrusion stops. The extendable base may be held in the collapsed position via the communication of one or more guides disposed along the inside surface of the electrical outlet mounting box and the outside surface of the extendable base. The extendable base may be held in the extended position via the communication of one or more guide protrusions disposed along the inside surface of the electrical outlet mounting box with the outside surface of the extendable base. The lid may be movably coupled with the extendable base via a hinge. The hinge may be mounted on the inner surface of the electrical outlet mounting box. The hinge may extends from the edge of the lid and is coupled with the inner surface of the electrical outlet mounting box. The hinge may be biased to the closed position.

In another aspect, an electrical device cover assembly mountable over an electrical outlet comprises an electrical outlet mounting box having a front edge, an inner surface, and an opening large enough to receive an electrical device. The front edge of the electrical outlet mounting box is configured such that it does not extend beyond a front surface of a wall when the electrical outlet mounting box is installed in the wall. An extendable base comprises a leading edge and an outer surface slidably coupled with the electrical outlet mounting box, and the extendable base is slideable between a collapsed position and an extended position. A lid is pivotably coupled with the extendable base, and at least one of the lid and the extendable base comprises a cord port along an edge of the respective lid and extendable base. The lid comprises a front surface and is positionable between an open position and a closed position with respect to the extendable base. The front surface of the lid is substantially flush with the front surface of the wall when the extendable base is in the collapsed position and the lid is in the closed position respect to the extendable cover. Also, one or more guides on the inner surface of the electrical outlet mounting box are in mechanical cooperation with one or more guides on the outer surface of the extendable base, such that when the extendable base is in the extended position, the mechanical cooperation of the one or more guides resists decoupling of the extendable base from the electrical outlet mounting box.

Particular implementations may include one or more of the following. The electrical outlet mounting box may comprise a recessed electrical outlet mounting box having at least two box mounting screw apertures on an inside surface of the box that are recessed at least one inch behind the front edge of the electrical outlet mounting box. The electrical outlet mounting box may comprise at least two box mounting screw apertures on an inside surface of the box less than one inch behind the front edge of the electrical outlet mounting box. The electrical outlet mounting box may comprise an external mounting flange. The one or more guides may comprise one or more guide rails and stops.

In still another aspect, a method of installing an electrical device cover assembly comprises mounting an electrical outlet mounting box comprising a front opening within a wall such that a front edge of the electrical outlet mounting box does not extend beyond a front surface of the wall. The method also comprises receiving and coupling an electrical device within the electrical outlet mounting box. The method further comprises coupling a slidably extendable cover within the front opening of the electrical outlet mounting box, the extendable cover comprising a slidably extendable base configured to slide on guides on an inside surface of the electrical outlet mounting box and pivoting lid having a front surface. Sliding the extendable cover from an extended position to a collapsed position where the front surface of the pivoting lid is substantially flush with the front surface of the wall is also comprised in the method.

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 device cover and/or assembly procedures for an electrical device cover will become apparent for use with implementations of electrical device covers from this disclosure. Accordingly, for example, although particular electrical device cover assemblies, electrical outlet mounting boxes, openings, guides, expandable bases, lids, cord ports, mounting screw apertures, external mounting flanges, guide rails, guide rail stops, guide protrusions, guide protrusion stops are disclosed, such electrical device cover assemblies, electrical outlet mounting boxes, lids, and 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 electrical device cover assemblies, electrical outlet mounting boxes, lids and implementing components, consistent with the intended operation of an electrical outlet cover.

There are a variety of electrical outlet cover assembly implementations.FIGS. 1-4illustrate a first particular implementation of an electrical outlet cover assembly2. The electrical outlet cover assembly2comprises electrical outlet mounting box4comprising rear portion1and forward portion5. Mounting flange7is provided so that front edge6of electrical mounting box4can be mounted or installed in a wall, such as an exterior wall of a house or other building. Specifically, with rear portion1placed beneath front surface9of a wall as shown inFIG. 2, one or more fasteners may be used to attach mounting flange7to a portion of the wall that is beneath the front surface9of the wall, such that electrical outlet mounting box4is held in a fixed position with respect to the wall. With electrical outlet mounting box4mounted within the wall, a structural material for walls, such as Sheetrock®, plaster, paneling or the like may be installed over mounting flange7so that front edge6of electrical outlet mounting box4is flush (does not protrude beyond) front surface9of the wall.

Still referring toFIGS. 1 and 2, electrical outlet mounting box4comprises opening10, which is large enough to receive an electrical outlet11(FIG. 2). Electrical outlet mounting box4further comprises inner surface8. Electrical outlet11may be installed or mounted within electrical outlet mounting box4via at least two box mounting screw apertures16. In the particular implementation shown, the at least two box mounting screw apertures16are positioned at least one inch behind the front edge6of electrical outlet mounting box4, such that when electrical outlet11is mounted within electrical outlet mounting box4, the plug blade apertures13of electrical outlet11are recessed, or positioned behind, front edge6of electrical outlet mounting box4. In other particular implementations, such as the one discussed below in connection with the second particular implementation of electrical outlet cover assembly shown inFIG. 5, the at least two box mounting screw apertures16may be located less than one inch behind the front edge6of electrical outlet mounting box4, such that when electrical outlet11is mounted within electrical outlet mounting box4, the plug blade apertures of the electrical outlet are positioned less than one inch behind front edge6of electrical outlet mounting box4.

Further describingFIGS. 1 and 2, inner surface8of electrical outlet mounting box4comprises one or more guides which, depending upon the particular implementation, may comprise one or more guide rails12(which may comprise any rail, ridge, track, or the like), one or more guide protrusions14(which may comprise one or more protrusions, bumps, projections, or the like), or both. The operation of the one or more guide rails12and the one or more guide protrusions14will be described further below, in connection with their mechanical cooperation with extendable base26. Turning now to wall plate18, with electrical outlet11(FIG. 2) mounted within electrical outlet mounting box4, a user may install wall plate18so that it forms a frame around the electrical outlet and may resist the entry of foreign objects between the perimeter edge of electrical outlet11and the inner surface8of electrical outlet mounting box4. The detail of the internals of electrical outlet11are not shown inFIG. 2for simplicity of drawing. Those of ordinary skill in the art will understand what is needed for an electrical outlet. Wall plate18may be coupled with electrical outlet mounting box4via the at least two box mounting screw apertures16, or via other screw holes (or other fastener arrangement) that may be provided. In particular implementations, wall plate18may comprise one or more notches19, which may assist in keeping wall plate18aligned within opening10of electrical outlet mounting box4, and may therefore further resist the binding of wall plate18upon inner surface8of electrical outlet mounting box4as wall plate18is inserted within electrical outlet mounting box4.

Referring still toFIGS. 1 and 2, extendable base26comprises leading edge28, outer surface30, inner surface31, and one or more cord ports32(which allow an electrical cord to pass from electrical outlet11past front surface38of lid34when the electrical outlet is in use, the lid34is in a closed position, and whether extendable base26is in a collapsed position or an extended position). Alternatively, the one or more cord ports may be located in the lid, such as along the bottom edge of the lid, or in both the lid and the base. Inclusion of the cord port in the bottom edge of the lid may also assist by providing a finger pull through which to open the lid. For locations where the electrical outlet can be exposed to weather conditions or water or other contaminants, it is often desired to be able to protect the electrical outlet by closing the lid of the cover while a plug is plugged into the outlet. Such outlet covers are called while-in-use covers. Inner surface31comprises base hinge element40which is coupled to lid hinge element41(which extends from edges36of lid34) such that lid34is hingedly coupled with extendable base26via the hinge (which is formed through the mechanical cooperation of base hinge element40and lid hinge element41). Therefore, it will be understood that the hinge that is formed through the cooperation of base hinge element40and lid hinge element41extends from the edge of lid34and is coupled with inner surface31of extendable base26. In particular implementations, the hinge may be biased with a spring, or other biasing mechanism, in order to bias the lid34to a closed position with respect to extendable base26. It is expected that other hinge configurations and many biased hinge configurations are possible and may be substituted from the art into the particular implementation shown in the Figures without undue experimentation.

Turning specifically to extendable base26, outer surface30of extendable base26comprises one or more guides which, depending upon the particular implementation, may comprise one or more guide rail stops20, one or more guide protrusion channels,22, and/or one or more guide protrusion stops24. As noted above, inner surface8of electrical outlet mounting box4comprises one or more guides (which, depending upon the particular implementation, may comprise one or more guide rails12and/or one or more guide protrusions14). One or more guide rails12on the inner surface8of electrical outlet mounting box4may be aligned with one or more guide rail stops20on outer surface30of extendable base26, such that when extendable base26is slid between a collapsed position (FIG. 3) and an extended position (FIG. 4) with respect to electrical outlet mounting box4(described further below), the mechanical cooperation of one or more guide rails12with one or more guide rail stops20(which may comprise, a channel, a groove, a notch, or the like) may assist in maintaining the alignment of extendable base26with respect to electrical outlet mounting box4. It will be further understood that maintaining the alignment of extendable base26with respect to electrical outlet mounting box may assist in resisting the binding of outer surface30of extendable base26with respect to inner surface8of electrical outlet mounting box4, as the extendable base26is slid between its extended and collapsed positions.

The mechanical cooperation of the one or more guide protrusions14with respect to the one or more guide protrusion channels22and guide protrusion stops24will now be described. In particular, one or more guide protrusions14on the inner surface8of electrical outlet mounting box4may be aligned with one or more guide protrusion channels22(which may comprise a channel, a groove, a notch, or the like) on outer surface30of extendable base26, such that when extendable base26is slid between a collapsed position and an extended position with respect to electrical outlet mounting box4(described further below), the mechanical cooperation one or more guide protrusions14with guide protrusion channels22may assist in maintaining the alignment of extendable base26with respect to electrical outlet mounting box4. It will be further understood that maintaining the alignment of extendable base26with respect to electrical outlet mounting box may assist in resisting the binding of outer surface30of extendable base26with respect to inner surface8of electrical outlet mounting box4, as the extendable base26is slid between its extended and collapsed positions.

Disposed within the forward and/or rear portions of the one or more guide protrusion channels22are one or more guide protrusion stops24(which may comprise an indentation, recess, depression, or the like). As extendable base26is slid to its collapsed position (with respect to electrical outlet mounting box4), one or more guide protrusions14may come to rest in the one or more guide protrusion stops24such that the further movement of extendable base26is mechanically resisted by the mechanical cooperation of the one or more guide protrusions14with the one or more guide protrusion stops24. Of course, the mechanical resistance caused by the cooperation of the one or more guide protrusions14with the one or more guide protrusion stops24may be overcome by exerting force. That is, once the extendable base is in its collapsed position, a user may move the extendable cover to an extended (or partially extended) position by pulling outwardly on the extendable base26with sufficient force to overcome the mechanical resistance caused by the cooperation of the one or more guide protrusions14with the one or more guide protrusion stops24.

Likewise, as extendable base26is slid to its fully extended position (with respect to electrical outlet mounting box4), one or more guide protrusions14may come to rest in the one or more guide protrusion stops24such that the further movement of extendable base26is mechanically resisted by the mechanical cooperation of the one or more guide protrusions14with the one or more guide protrusion stops24. Mechanical resistance of further movement of the extendable base26via the mechanical cooperation of the one or more guide protrusions14with the one or more guide protrusion stops24resists the decoupling of extendable base26with respect to electrical outlet mounting box4. Of course, the mechanical resistance caused by the cooperation of the one or more guide protrusions14with the one or more guide protrusion stops24may be overcome by exerting additional force. That is, once the extendable base is in its fully extended position, a user may move the extendable cover to an collapsed (or partially collapsed) position by pushing inwardly on the extendable base26with sufficient force to overcome the mechanical resistance caused by the cooperation of the one or more guide protrusions14with the one or more guide protrusion stops24. Moreover, a user wishing to decouple extendable base26from electrical outlet mounting box4may pull extendable base26outwardly from electrical outlet mounting box4with sufficient force so that the extendable base26becomes decoupled from the electrical outlet mounting box4.

Referring now specifically toFIGS. 3 and 4, the slide-ability of extendable base26with respect to electrical outlet mounting box4will be further described. As alluded to above, extendable base26is slideable between a collapsed position and an extended position (with respect to electrical outlet mounting box4). Referring specifically toFIG. 3, the collapsed position of extendable base26is illustrated. In particular, when the extendable base26is in the collapsed position, the leading edge28of extendable base26is flush with, or does not protrude beyond, front surface9of the wall within which the electrical outlet cover assembly2is installed. In particular implementations, the front surface38of the lid34is also substantially flush with the front surface9of the wall (seeFIG. 6for example) when the lid is closed. Although in other implementations the lid may rest against the front surface of the wall or extend slightly beyond the front surface. In particular implementations, the front surface38of the lid may be textured or colored to match the front surface9of the wall. Referring now toFIG. 4, the expanded position of extendable base26(with respect to electrical outlet mounting box4) is shown. In particular, when the extendable base26is in the extended position, the leading edge28of extendable base26extends beyond front surface9of the wall. Of course, extendable base26may be also positioned in a partially-extended or a partially-collapsed position.

Turning now toFIG. 5, a second particular implementation of an electrical outlet cover assembly3is illustrated. As alluded to above, in the second particular implementation of an electrical outlet cover assembly3, the at least two box mounting screw apertures16(obscured in this view) may be located less than one inch behind the front edge6of electrical outlet mounting box4, such that when electrical outlet11is mounted within electrical outlet mounting box4, the plug blade apertures13of the electrical outlet are positioned less than one inch behind front edge6of electrical outlet mounting box4. It will be clear therefore, that when extendable base26is in a collapsed position with respect to electrical outlet mounting box4(as shown), the plug blade apertures13of electrical outlet11may be substantially flush with (recessed less than an inch behind) leading edge28of extendable base26

It will be understood by those of ordinary skill in the art that the concepts of using electrical outlet mounting boxes, extendable bases, and lids to cover an electrical outlet in a collapsed and an expanded position, as disclosed herein, is not limited to outdoor covers or to the specific implementations shown herein. For example, it is specifically contemplated that the components included in a particular implementation of an electrical device cover may be formed of any of many different types of materials or combinations that can readily be formed into shaped objects and that are consistent with the intended operation of an electrical outlet cover. For example, the components may be formed of: rubbers (synthetic and/or natural) and/or other like materials; polymers and/or other like materials; plastics, and/or other like materials; composites and/or other like materials; metals and/or other like materials; alloys and/or other like materials; and/or any combination of the foregoing.

Furthermore, the electrical outlet mounting boxes, extendable bases, lids, hinges, guides, wall plates, and any other components forming a particular implementation of an electrical outlet cover assembly may be manufactured separately and then assembled together, or any or all of the components may be manufactured simultaneously and integrally joined with one another. Manufacture of these components separately or simultaneously may involve extrusion, pultrusion, vacuum forming, injection molding, blow molding, resin transfer molding, casting, forging, cold rolling, milling, drilling, reaming, turning, grinding, stamping, cutting, bending, welding, soldering, hardening, riveting, punching, plating, and/or the like. If any of the components are manufactured separately, they may then be coupled or removably coupled with one another in any manner, such as with adhesive, a weld, a fastener, any combination thereof, and/or the like for example, depending on, among other considerations, the particular material(s) forming the components.

It will be understood that particular 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 outlet cover assembly may be utilized. Accordingly, for example, although electrical outlet mounting boxes, extendable bases and lids 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 outlet cover assembly may be used.

In places where the description above refers to particular implementations of an electrical outlet cover assembly, 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 outlet covers. 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.