Abstract:
A water resistant floor box cover assembly including a flange including an opening therethrough adapted to permit access to electrical connectors and a cover securable to the flange. The cover is movable between a closed position wherein the opening is covered and an open position wherein the opening is uncovered to permit access to the outlet box. The flange also includes an inner wall and an outer wall extending about the opening. The inner and the outer walls define a channel disposed therebetween. The outer wall including a slot formed therein providing a path out of the channel. The slot permits water in the channel to exit therefrom away from the opening.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention relates to an electrical floor box cover assembly and more particular to a floor box cover assembly which resists the intrusion of water.  
         BACKGROUND OF THE INVENTION  
         [0002]    In office space and other commercial environments it is often desired to have access to electrical outlets or other electrical connections at locations located a distance from standard wall outlets. In order to safely accommodate such situations, floor boxes are typically used. These boxes may be located in the floor near or at the location, such as under a work cubicle or near a piece of machinery, where the connection is needed. The electrical connections may be electrical outlets, telephone jacks or data connections used for networking computers.  
           [0003]    Floor boxes may include a flange which sits on top of the floor surface and included an opening to permit access to the electrical connections. A cover is typically removably positionable over the opening to prevent inadvertent contact with the connectors and to restrict debris from contaminating the connectors. One such covered floor box is shown in U.S. Pat. No. 6,179,634.  
           [0004]    Covers may be designed to also restrict the entry of water through the opening. Floor boxes may be exposed to water when the floors are cleaned or from inadvertent spillage. Floor box covers used on tile or cement floors may be subjected to a significant amount of cleaning water as the floors are cleaned. Floor box covers located on carpeted floors are typically less likely to be subjected to water as the floors are cleaned by waterless methods. However, the use of stream cleaners does subject the cover to water.  
           [0005]    In order to prevent water from intruding past the cover and onto the electrical connections below, a gasket is typically used. The gasket may be placed between the cover and the flange as shown in U.S. Pat. No. 6,265,662 or between the cover and a face plate as in U.S. Pat. No. 6,179,634. Without the use of the gasket, the covers in these two patents and in typical floor box covers will permit water to enter through the opening. Gaskets are typically made from a resilient material which can degrade over time rupture or become separated from its seat. If any of these events should occur, the cover is vulnerable to water intrusion and the electrical components will be exposed to water. This may result in degradation of the connections from corrosion and/or short circuiting. Furthermore, water which passes by the gasket is not diverted away from the opening, but is permitted to flow off the flange into the opening.  
           [0006]    Accordingly, it would be desirable to provide a floor box cover which resists the intrusion of water without the use of a sealing gasket and diverts water away from the cover opening.  
         SUMMARY OF THE INVENTION  
         [0007]    It is an advantage of the present invention to provide an electrical floor box cover assembly.  
           [0008]    It is also an advantage of the present invention to provide a water resistant electrical floor box assembly.  
           [0009]    It is another advantage of the present invention to provide a water resistant electrical floor box assembly which directs water away from the opening.  
           [0010]    It is a further advantage of the present invention to provide a water resistant electrical floor box assembly which includes a cover including a biasing device for retaining the cover in the closed position.  
           [0011]    It is yet a further advantage of the present invention to provide an electrical floor box cover assembly having a cover which lays substantially flat when fully open.  
           [0012]    In the efficient attainment of these and other advantages, the present invention provides an electrical floor box cover assembly including a cover and a flange with the cover being securable to the flange and movable between an open and closed position. The flange defines an opening adapted to permit access to electrical connectors. The flange includes an inner wall and an outer wall extending about the opening and a channel disposed between the inner and the outer walls. The outer wall includes an interruption formed therein providing a path out of the channel, the slots permitting water in the channel to exit therefrom away from the opening.  
           [0013]    The cover includes an outer periphery extending over the channel to restrict water from entering the channel. The inner wall defines the opening and the flange is bounded by a tapered surface, the interruption extends through the tapered surface to permit water in the channel to run off of the flange away from the opening.  
           [0014]    The cover is pivotably secured to the flange by a hinge. In the preferred embodiment, the hinge includes a projection extending from the cover and the flange has a depression for receiving the projection. The hinge further includes a hinge pin disposed on the cover, and a retainer securable to the flange over the pin. The retainer holds the cover on the flange and permits rotation of the cover between an open and closed position. The pin includes a pair of opposed ends which are supported on the cover. The pin is resilient and the retainer prevents translational movement of a central portion of the pin and permits movement of lateral portions of the pin such that the cover can translate to effect locking and unlocking of the cover in the closed position. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0015]    [0015]FIG. 1 is a top perspective view of the floor box cover assembly of the present invention shop the cover in an open position.  
         [0016]    [0016]FIG. 1A is a top perspective view of an alternative embodiment of the floor box cover assembly of the present invention shop the cover in an open position.  
         [0017]    [0017]FIG. 1B is a cross-sectional view of the floor box cover assembly taken along line IB-IB of FIG. 1.  
         [0018]    [0018]FIG. 2 is an exploded top perspective view of the floor box cover of FIG. 1.  
         [0019]    [0019]FIG. 3 is a top perspective view of the floor box cover of FIG. 1 showing the cover in the closed position.  
         [0020]    [0020]FIG. 4 is a cross-sectional view of the floor box cover assembly taken along line IV-IV of FIG. 3.  
         [0021]    [0021]FIG. 5 is a top plan view of the bottom surface of the cover and the retainer of FIG. 1 showing the cove in the normal state.  
         [0022]    [0022]FIG. 6 is a top plan view plan view of the bottom surface of the cover and the retainer of FIG. 5 showing the cover in the deflected position.  
         [0023]    [0023]FIG. 7 is a perspective view of an alternative embodiment of the present invention.  
         [0024]    [0024]FIG. 8 is a cross-sectional view of the floor box cover assembly taken along line VIII-VIII of FIG. 7.  
         [0025]    [0025]FIG. 9 is a top perspective view showing the cover in an open position of the invention of FIG. 7.  
         [0026]    [0026]FIG. 10 is an exploded to perspective view of the invention of FIG. 7 with one of the cover sections removed for clarity.  
         [0027]    [0027]FIG. 11 is a cross-sectional view of the floor box cover assembly of FIG. 7 showing one of the cover sections in the fully open position and the other cover section in the fully closed position.  
         [0028]    [0028]FIG. 12 is a top perspective view of a further alternative embodiment of the floor box electrical assembly of the present invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0029]    The present invention provides a floor box cover which sits on top of an electrical box positionable in a floor. The electrical box may include connections for power or voice/data devices. The floor box cover of the present invention provides an improved resistance to water thereby maintaining the covered electrical connections dry and free from contamination. Water resistance is achieved through use of a channel which diverts water away from the cover and the electrical box below.  
         [0030]    With reference to FIGS.  1 - 4 , floor box cover assembly  10  includes a cover  12  which is securable to flange  14  such that cover  12  is movable to selectively cover and uncover an opening  16  to provide access to electrical connectors  11  held within the outlet box  13 . In the preferred embodiment, cover  12  is pivotably attached to flange  14  by hinge  18 . Flange  14  is preferably a generally annular member having a central opening  16  through which access to the electrical connectors  11  is obtained. It is within the contemplation of the invention that flange  14  could be of any one of a variety of shapes, e.g., round, square, rectangular, etc., to conform to the shape of the outlet box disposed below. Cover flange  14  which may be formed of a metallic or plastic material includes tabs  20  having apertures  22  to permit fasteners (not shown) to pass through and into corresponding apertures in the outlet box  13 . Flange  14  provides a transition from the surrounding floor to the outlet box and may be placed over a variety of floor surfaces including carpet, wood or tile.  
         [0031]    Referring additionally to FIG. 1B, flange  14  includes an annular channel  30  extending about opening  16  and has a bottom  32  peripherally bounded by an upstanding outer wall  34  and an upstanding inner wall  36 . Extending radially beyond outer wall  34  is an annular beveled surface  38  which end at the peripheral edge  39  of the flange  14 . When an electrical box  13  is installed, cover flange  14  and cover  12  are slightly raised above the surface of the floor. Beveled surface  38  provides a smooth tapered transition from the floor to prevent tripping. Flange  14  further includes a plurality of slots  40  formed in the outer wall  34  and beveled surface  38  which creates interruptions in outer wall  34 . Channel  30  and slots  40  provide a water resistance feature to the present invention which will now be described.  
         [0032]    Floor boxes may be subjected to water that is used in floor cleaning or from accidental spillage. Floor box cover assembly  10  provides resistance of the intrusion of water past opening  16  and protects the electrical connectors found beneath the cover in the outlet box  13 . When cover  12  is in the closed position, a radially outer portion  42  of the cover extends over a portion of channel  30  to restrict water from entering channel  30 . Accordingly, most of the water will run off the cover and down the beveled surface  38  of cover flange  14 . A narrow gap  50  exists between the outer edge of cover  12  and cover flange  14 . With cover  12  is in the closed position, water that is not shed directly off will instead be diverted to channel  30  through gap  50 . Inner wall  36 , which extends above channel bottom  32  and the bottom of slots  40 , restricts the water collected in channel  30  from entering the opening  12 . The water in channel  30  will then drain out through slots  40 . Accordingly, when the cover  12  and cover flange  14  are exposed to water such as when the floors are cleaned or when a liquid is spilled, the liquid will be shed away and not permitted to seep into the opening  16  to the electrical connectors. Channel  30  may be pitched such that any water that enters the channel  30  is directed to the slots  40 . Furthermore, due to the use of the channel  30  and slots  40 , no gasket is necessary between cover  12  and flange  14  in order to prevent water from intruding. Cover  12  may be employed in carpeted floors which may be subjected to cleaning water such as from steam cleaning.  
         [0033]    In an alternative preferred embodiment shown in FIG. 1A, a gasket  52  may be placed between cover and cover flange to create an even greater resistance to water infiltration. Cover  12  may include a groove disposed in the undersurface thereof. Gasket  52  may be sized to fit within groove and be held in place by a friction fit or adhesive. When cover  12  is in the closed position, gasket  52  is engaged and a waterproof seal is created between cover  12  and flange  14 . Accordingly, any water which enters channel  30  is not only drained away through the slots but is also prevented from entering the opening by a gasket-tight seal. Even if water should get past the gasket it still may be drained out through the slots  40 , thereby preventing water from entering opening  16 . This embodiment provides an even higher degree of water intrusion resistant and would be suitable for use in tile floor applications which could be subjected to standing water.  
         [0034]    Referring FIGS. 2 and 5- 6 , in the preferred embodiment, cover  12  rotates between the open and closed position by way of hinge  18  which provides the pivotal connection between cover  12  and flange  14 . Hinge  18  may also as assist in retaining cover  12  in the closed position. Hinge  18  may include a pin  54  extending between and secured in a pair of spaced tabs  56  extending from the back edge  58  of the cover  12 . Pin  54  may be formed of a resilient material such as steel. Flange  14  may include a hinge seat  60  in which tabs  56  and pin  54  may be disposed. A retainer  62  may be positioned over pin  54  and be fastened to flange  63 . Retainer  62  includes an under surface including a longitudinally extending groove  64  for receiving pin  54 . Groove  64  may include a central portion  68  which fits in close relationship to pin  54  to hold the pin  54  against translational movement. Groove  64  also includes a pair of peripheral portions  66  extending from central portion  68  to the edged of the retainer  62 . Groove  64  in peripheral portions  66  is widened such that a clearance is provided around the pin  54  to permit translational movement of pin  54 . With the hinge  18  formed in this manner, translational movement of cover  12  by a force F in a direction toward hinge  18 , causes pin  54  to flex and cover  12  to translate as shown in FIG. 6. When pin  54  is flexed, it creates a biasing force B acting against the rearward movement of cover  12  and urges cover  12  to a forward position. The front edge of cover may include a projection  70  which includes a corresponding recess  72  in flange  14 . When cover  12  is rotated in to the closed position, projection  70  engages a portion of flange causing cover  12  to translate against the biasing force of pin. As shown in FIG. 4, when cover  12  is moved to the final closed position, projection  70  enters recess  72  and cover translates forward. Projection  70  is positioned in recess  72  thereby restricting the movement of cover  12  into the open position.  
         [0035]    Referring additionally, to FIG. 3, in order to open cover  12  to obtain access to the electrical connections lying below, a user would move cover in a direction toward hinge  18  and against the biasing force of pin  54 . Gap  50  created between cover  12  and the outer wall  34  of flange  14  permits a degree of translational movement of cover  12 . Cover projection  70  moves out of recess  72  and cover  12  may be rotated toward the open position. This opening procedure may be easily done by inserting a screwdriver or similar tool into a notch  74  formed in flange  14  and prying up cover  12 .  
         [0036]    It is also within the contemplation of the present invention that hinge  18  connection between cover  12  and flange  14  may include a variety of known hinge structures including tabs supported on the cover having protrusions insertable within indentations in flange  14 . Alternatively, the pin could be securely retain throughout its length and not permitted to flex as in the preferred embodiment. The locking mechanism could include a rotary latch such as a ¼ turn latch or other latching device known in the art.  
         [0037]    In an alternative embodiment shown in FIGS.  7  to  11 , floor box cover assembly  100  may include a split cover with the cover  102  being formed of two sections  104 ,  106  pivotably mounted to a flange  108 . Cover  102  covers up an opening  109  which creates access to electrical connectors. In the embodiment shown, opening  109  includes a formed section  109   a  which provides cutouts  109   b  to accommodate the electrical connectors. The two cover sections  104  and  106  include adjoining edges,  104   a  and  106   a  respectively, which when closed form a seam  120  running down the center of the cover  102 . Flange  108  includes a tapered edge  110  which is partially covered by cover sections  104  and  106  when in the closed position. Water will run off the cover sections onto tapered edge  110  away from cover  102 . In order to prevent water from entering the opening  109  through the center seam  120  one of the cover sections  104 , includes an upwardly facing U-shaped groove  122  extending along the straight adjoining edge thereof. The other cover section  106  includes a corresponding grooved edge  126  which is inverted with respect the grooved edge  122  of cover section  104 . When on the closed position the grooved sections interlock. This creates a restriction for water to enter between the cover sections  104 ,  106  and most water falling upon the cover  102  will be diverted away. Any water which enters through the centerseam  120  between the cover sections will enter the upwardly facing groove  122  of cover section  104 . Groove  122  has two ends  128  which terminate over tapered slots  116  formed in flange  108 . Water that may collect in the groove  122  will be channeled to the outer periphery of the cover  102  where it falls into one of the slots  116  which are aligned with the ends of seam  120 . Accordingly, water will be diverted away from the opening keeping the electrical connections dry.  
         [0038]    In this embodiment cover sections  104 ,  106  may be pivotably attached to the flange  108  such that they lay substantially flat on the floor when in the fully open position as shown in FIGS. 9 and 11. Each cover section  104 ,  106  is attached with a similarly formed hinge  130 , therefore, hinge  130  will described with respect to one cover section. With reference to FIG. 10, a portion of flange  108  outer surface may include a pair of spaced upstanding hinge structures  132  which include indentations  134 . Cover section  104  includes an extension  136  having a pair of spaced flexible resilient tabs  138  each having a pin  140  extending outwardly in opposing directions. The pins  140  may be snap fit into the indentations  134  of the hinge structures  132  thereby creating a pivotable connection between the cover section  104  and flange  108 . Between the hinge structures  132 , the flange  108  tapers downwardly creating a pocket  152  for receiving the hinge section  136  extending from the cover  104  section. This permits the cover section  104  to rotate approximately 180 degrees and lie flat against the surrounding floor when in the fully open position. Preferably, cover section  104  when open extends no higher than the top of flange  108 . This flat orientation limits interference with surrounding structures.  
         [0039]    In order to maintain cover sections in the closed position, pocket  152  may include a depression  150  which cooperates with a bump  154  on cover extension  136 . As cover section  104  in moved into the closed position, the bump  154  snaps into the depression  150 . Some effort must be exerted on the cover section to then move it out of the closes position as the bump  154  is captured in the depression  150 . Cover sections  104 ,  106  are preferable formed of a resilient material such as plastic or metal such that a degree of flexibility exist allowing the snap fit cooperation between bump  154  and depression  150 . In an alternative embodiment (not shown), the bump may be formed on the flange and the cooperating depression formed on the cover.  
         [0040]    Referring to FIG. 12, a further alterative embodiment is shown having a single cover  204  when in the open position is allowed to lie flat. The cover assembly  200  has a flange  208  with a cover  204  attached using hinge  230 . Flange  208  has a similar channel  210  as described in the embodiment shown in FIGS.  1 - 4  having an inner wall  212 , an outer wall  214  and a slot  216  to allow water trapped within channel  210  to drain away from cover  204 . Hinge  230  may be similarly constructed as the hinge described in the embodiment shown in FIGS.  7 - 11  which has two upstanding extensions  232  having indentations (not shown). Cover  204  also includes an extension  236  which has pins (not shown) which are inserted into the indentations in the upstanding extensions  232 . The pins allow for pivotal movement of the cover  204  to be from a closed to open position. As in the prior embodiment, flange  208  tapers down to form a pocket  250  for receiving the extension  236  of the cover  204  when it is in an open position and can lie substantially flat and rotate approximately 180° so that it is in contact with the surrounding floor. Preferably, the cover section  204  extends no higher than the top of the hinge extension  232 . This flat orientation limits interference by the cover  204  with any objects around the cover assembly  200  when in an open position.  
         [0041]    Although preferred embodiments of the present invention have been described herein with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments and that various other changes and modifications may be affected herein by one skilled in the art without departing from the scope or spirit of the invention, and that it is intended to claim all such changes and modifications that fall within the scope of the invention.