Abstract:
A temporary and disposable cover for an electrical box. The cover includes a faceplate, side walls, and flexible tabs projecting inwardly from the side walls. When placed upon an electrical box with a permanent cover, the indents seat behind the sidewalls of the permanent cover and hold the temporary cover thereon. While seated upon the electrical box, the temporary cover protects the permanent cover and the forward portion of the electrical box from spatter, overruns, or any other misdirected applications of stucco mud to the surface surrounding the electrical box. After the stucco has cured, the temporary cover is disposed of. The temporary cover is capable of being manufacture at a low cost per unit, thereby permitting it to be disposed of after the stucco has been cured.

Description:
FIELD OF THE INVENTION 
   This invention relates to temporary covers for electrical boxes and specifically to temporary and disposable cover that protects an electrical box from spatter and overrun encountered when stucco mud is applied to the area surrounding the electrical box. 
   BACKGROUND OF THE INVENTION 
   Buildings are commonly covered with stucco, especially in hot areas such as the Southeastern and Southwestern areas of the United States. Typically the building framework is first erected. Electrical services are then typically installed to the framework so that each receptacle, light fixture, and other electrical device can be mounted securely to an exposed stud or beam. Electrical wiring is then completed to each device and a substrate installed to cover the framework. Stucco is then typically spread over the substrate to provide a pleasing finished surface for the building. 
   Unfortunately, stucco frequently sticks to items other than the intended substrate, such as the electrical boxes that have been mounted in the substrate. Thus, during the application of stucco to the substrate, the installer must slow down and take care not to get stucco on the exposed portion of the electrical box. Many outdoor electrical boxes include a permanent cover to protect the electrical device installed within from weather such as snow or rain. Stucco installers then, as a result of spreading mud around the electrical box, frequently create spatter or overruns that contaminate the exposed portions of the electrical box or the permanent cover. Once the stucco cures, the spatter or overrun is not easily removed and this leads to an unsightly electrical box installation. 
   Some stucco installers apply masking tape around the outer portion of the electrical box to limit the portions of the box exposed to the stucco mud. This is not entirely satisfactory as it slows down the job and it is difficult to properly cover the entire permanent cover and exposed portions of the electrical box. Additional time is lost when the installer must later return and remove all of the tape from the electrical box and from the permanent cover. 
   What is needed therefore is a device to temporarily cover an electrical box and its permanent cover. The device should be capable of being manufactured at a low cost per unit, as it will be temporary and disposed of after the stucco wall has cured. The device should also be easy to install and easy to remove from the electrical box. 
   SUMMARY OF THE INVENTION 
   The invention is a temporary and disposable cover for an electrical box. The cover includes a faceplate, a sidewall, and flexible tabs projecting inwardly from the sidewall. When placed upon an electrical box with a permanent cover, the flexible tabs seat behind the sidewalls of the permanent cover and hold the temporary cover to the electrical box. While seated upon the electrical box, the temporary cover protects the permanent cover and the forward portion of the electrical box from spatter, overruns, or any other misdirected applications of stucco mud to the surface surrounding the electrical box. After the stucco has cured, the temporary cover is simply disposed of. The temporary cover can be produced at low cost, thereby allowing it to be disposed of after the stucco has been cured. 
   OBJECTS AND ADVANTAGES 
   One advantage of the temporary and disposable electrical box cover is that it protects the permanent cover and the forward portion of the electrical box from spatter, overruns, or other stucco contamination during the stucco application step. 
   Another advantage provided by the temporary and disposable electrical box cover is that it can be produced at low cost, allowing it to be disposable after it is used. 
   A further advantage provided by the temporary and disposable electrical box cover is that it enables the stucco installers to complete the stucco application in less time, as they will not need to slow down during application of stucco mud around the electrical box. 

   
     DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of a temporary and disposable electrical box cover according to the present invention installed on an electrical box. 
       FIG. 2  is a rear view of a temporary and disposable electrical box cover according to the present invention. 
       FIG. 3  is a sectional view of the temporary and disposable electrical box cover taken along line  3 — 3  of  FIG. 2 . 
       FIG. 4  is a front view of the temporary and disposable electrical box cover of  FIG. 2 . 
       FIG. 5  is an end view of the temporary and disposable electrical box cover as viewed from line  5 — 5  of  FIG. 4 . 
       FIG. 6  is a side view of the temporary and disposable electrical box cover exploded away from an electrical box having a permanent cover and with the temporary cover in alignment to be installed on the electrical box. 
       FIG. 7  is a side view of the temporary and disposable electrical box cover and the electrical box of  FIG. 6  after the temporary cover has been installed on the electrical box. 
       FIG. 8  is a perspective view of a recessed electrical box with a permanent cover of the type that can be protected by the temporary and disposable cover of the present invention. 
       FIG. 9  is a perspective view of a recessed electrical box and a permanent cover with a temporary and disposable cover installed thereon. 
       FIG. 10  is a perspective of the temporary cover and electrical box of  FIG. 9  but after the electrical box has been mounted on a wall with the stucco wall covering partially installed around a portion of the electrical box. 
       FIG. 11  is a side view of the temporary and disposable electrical box cover exploded away from an electrical box having recesses in the sidewall of the electrical box and with the temporary cover in alignment to be installed thereon. 
   

   
     
       
             
           
             
             
           
         
             
                 
             
             
               Table of Nomenclature 
             
             
               21) The following is a listing of part numbers used in the drawings along 
             
             
               with a brief description: 
             
           
        
         
             
               Part Number 
               Description 
             
             
                 
             
             
               20 
               temporary and disposable electrical box cover 
             
             
               22 
               faceplate 
             
             
               24 
               rear surface of faceplate 
             
             
               26 
               faceplate sidewall 
             
             
               28 
               inner surface of faceplate sidewall 
             
             
               30 
               outer surface of faceplate sidewall 
             
             
               32 
               edge of faceplate sidewall 
             
             
               34 
               flexible tab 
             
             
               36 
               latch of electrical box 
             
             
               38 
               extension 
             
             
               40 
               front surface of faceplate 
             
             
               42 
               forward surface of flexible tab 
             
             
               44 
               electrical box with permanent cover 
             
             
               45 
               wall 
             
             
               46 
               permanent cover 
             
             
               47 
               back edge of permanent cover 
             
             
               48 
               sidewall of permanent cover 
             
             
               50 
               sidewall of electrical box 
             
             
               52 
               flange 
             
             
               54 
               directional arrow 
             
             
               56 
               holes in flange 
             
             
               58 
               substrate 
             
             
               60 
               stucco layer 
             
             
               70 
               electrical box 
             
             
               72 
               sidewall of electrical box 
             
             
               74 
               front edge of electrical box 
             
             
               76 
               outer surface of electrical box 
             
             
               78 
               recess in outer surface of electrical box 
             
             
               80 
               directional arrow 
             
             
               82 
               juncture of sidewall and faceplate 
             
             
               θ 
               angle of sidewall of temporary cover with respect to the 
             
             
                 
               faceplate 
             
             
               d 1   
               first distance from forward surface of tab to rear surface of 
             
             
                 
               faceplate 
             
             
               d 2   
               distance flexible tabs extend from inner surface of faceplate 
             
             
                 
               sidewall 
             
             
               d 3   
               clearance between flexible tabs laterally across temporary 
             
             
                 
               cover 
             
             
               d 4   
               clearance between flexible tabs longitudinally across 
             
             
                 
               temporary cover 
             
             
               d 5   
               distance sidewall of temporary cover extends from faceplate 
             
             
               d 6   
               distance of recess from front edge of electrical box 
             
             
                 
             
           
        
       
     
   
   DETAILED DESCRIPTION OF THE INVENTION 
   The present invention comprises a temporary and disposable cover for use in protecting an electrical box mounted on a building that will be finished with stucco. The cover prevents spatter and overrun from contaminating the permanent cover and the outer portion of the electrical box that will extend outwards from the stucco wall surface. 
   With reference to a preferred embodiment depicted in  FIGS. 2 and 3 , the temporary and disposable electrical box cover  20  includes a faceplate  22  with a rear surface  24 . A sidewall  26  is integral with and extends rearward from the faceplate  22 . The faceplate sidewall  26  includes an inner surface  28 , an outer surface  30 , and an edge  32 . A plurality of flexible and resilient tabs  34  extend inwardly from the inner surface  28  of the faceplate sidewall  26 . The cover  20  further includes an extension  38  from the outer surface  30  of the faceplate sidewall  26  to enable the cover  20  to clear outward extending portions of an electrical box, such as the latch  36  shown in  FIG. 6 , that it will be used in conjunction with. 
   Referring to the sectional view of the temporary and disposable cover  20  in  FIG. 3 , the faceplate  22  further includes a front surface  40 . Each of the flexible tabs  34  includes a forward surface  42  facing the rear surface  24  of the faceplate  22 . The forward surface  42  of each flexible tab  34  is located a first distance d 1  from the rear surface  24  of the faceplate  22 . Preferably, the flexible tabs  34  extend between 0.05 and 0.07 inch from the inner surface  28  of the sidewall  26  of the faceplate  22 , indicated by distance d 2  in  FIG. 2 . 
   Reference to the front view of the cover  20  in  FIG. 4  shows that the faceplate  22  is substantially rectangular-shaped for use with a conventional rectangular-shaped electrical box such as that shown in  FIG. 8 . The temporary and disposable cover of the present invention is not however limited to a rectangular shape as other shapes can be formed to cover electrical boxes of other shapes, such as circular-shaped boxes. 
   Referring to  FIG. 6 , the temporary and disposable cover  20  of the present invention is used for protecting an electrical box  44  after it is secured to a wall  45  and during the installation of stucco wall covering (not shown) around the box. An electrical box  44  for exterior use typically includes a permanent cover  46  having sidewalls  48  as shown in  FIG. 6 . The sidewalls  48  of the permanent cover  46  include a back edge  47 . The electrical box  44  also includes sidewalls  50  and may include a flange  52  for use in securing the electrical box  44  to the wall  45 . An electrical box as shown in  FIG. 6  is disclosed in U.S. Pat. No. 6,956,171, the entire contents of which is incorporated herein by reference. 
   Preferably, the temporary and disposable cover  20  of the present invention is formed from a sheet of plastic resin material in a vacuum thermoforming process. Any conventional plastic resin for thermoforming may be used to construct the cover including polyvinyl chloride, polyethylene terephthalate, polystyrene, or polypropylene. Preferably, the disposable cover is thermoformed to a thickness of between 6 and 12 mils, thereby enabling the cover to be flexible and resilient. 
   To operate the present invention, the temporary and disposable cover  20  is simply pressed forwards, in the direction of the arrows  54  in  FIG. 6 , upon the permanent cover  46  and the electrical box  44 . Being thermoformed of plastic, the faceplate  22 , sidewall  26 , and flexible tabs  34  are of generally the same thickness and the flexible tabs  34  are resilient and capable of being deformed. The clearance between the flexible tabs  34  on the cover  20 , depicted by distances d 3  and d 4  in  FIG. 4 , is less than the distance across the permanent cover  46  on the electrical box  44  in the respective lateral and longitudinal directions. As the cover  20  is pressed upon the electrical box  44 , the flexible tabs  34  are biased outwardly by the sidewalls  48  of the permanent cover  46 . 
   Referring to  FIG. 7 , after the flexible tabs  34  clear the back edge  47  of the permanent cover  46 , the flexible tabs  34  snap inwardly to their unbiased positions and thereby hold the temporary cover  20  on the electrical box  44 . Pushing the temporary cover  20  fully upon the electrical box  44  therefore enables the forward surfaces  42  of the flexible tabs  34  to snap inwardly and engage the sidewalls  48  of the permanent cover  46  thereby holding the temporary cover  20  on the electrical box  44 . The preferred thickness of the cover enables the cover to be manufactured at a low cost and also contributes greatly to the flexibility and resiliency of the flexible tabs  34 . 
   Preferably, the sidewall  26  of the temporary cover  20  extends between 0.60 and 0.80 inch from the rear surface  24  of the faceplate  22 , indicated by distance d 5  in  FIG. 7 . Thus the sidewall  26  of the temporary cover  20  acts as a skirt to prevent stucco mud (not shown) from contaminating the permanent cover  46  and the forward portion of the sidewalls  50  of the electrical box  44 . The temporary cover  20  therefore protects the portion of the electrical box sidewalls  50  that is beyond the eventual intended layer of stucco. 
     FIG. 8  depicts in perspective view an electrical junction box  44  of the type having a permanent cover  46 . Although the electrical box  44  shown includes a flange  52 , the temporary cover  20  would also work equally well to cover a non-flanged electrical box of the type having a permanent cover as described herein. The flanged electrical box  44  as depicted in  FIG. 8  includes a flange  52  having a plurality of holes  56  which will facilitate the adhesion of stucco (not shown) to the flange  52 . This type of electrical box, which is designed specifically for stucco applications, includes boxes designated Dry Box Vertical Masonry/Stucco Single Gang with Clear Cover (DBVM1C) and Dry Box Vertical Masonry/Stucco Single Gang with White Cover (DBVM1W), and are available from Arlington Industries of Scranton, Pa. 
   After the temporary and disposable cover  20  of the present invention is secured to the electrical box  44 , as shown in  FIG. 9 , the cover  20  protects the permanent cover  46  and the forward portion of the electrical box sidewalls  50  that is expected to be beyond the eventual applied layer of stucco. The cover  20  may be produced of either clear or opaque plastic.  FIG. 9  depicts an electrical box  44  covered and protected by a clear temporary cover  20 . As shown in  FIG. 1 , the temporary cover  20  can also be constructed of opaque plastic. 
   Referring to  FIG. 9 , the sidewall  26  of the temporary cover  20  extends around the entire periphery of the faceplate  22 , thereby enabling the cover  20  to grasp and hold securely onto the electrical box  44  after it is pushed thereon. As a result of the sidewall extending around 100% of the periphery of the faceplate  22  and 100% of the periphery of the permanent cover  46  and the electrical box  44 , the temporary cover  20  cannot be easily shifted or knocked off the box without intent to do so. However, the disposable cover  20  can be easily removed when required, as it is releasable by grasping the temporary cover  20  behind the edge  32  of the sidewall  26  and pulling outwards from the electrical box  44 . 
   To further assist the holding action of the temporary cover  20  to the electrical box  44 , as shown in  FIG. 6 , the sidewall  26  of the temporary cover  20  is not normal with respect to the faceplate  22  but is flared outwards at an angle  0  preferably of between 2 and 5 degrees from normal or perpendicular with the faceplate  22 . Additionally, the inner dimensions across the temporary cover  20  at the juncture  82  of the sidewall  26  and the faceplate  22  are generally equal to the outer dimension across the permanent cover  26 . Therefore, when the cover  20  is pushed fully upon the permanent cover  26 , there is a tight fit of the temporary cover  20  upon the permanent cover  26 . 
   With reference to  FIG. 10 , the electrical box  44  is shown mounted to the substrate layer  58  of a building and depicts a portion of the stucco layer  60  that has been applied to the substrate  58 . The temporary and disposable cover  20  can remain in place on the electrical box  44  until the stucco has cured. 
   The temporary and disposable electrical box cover  20  can also be used to for an electrical box  70  that does not include a permanent cover, as shown in  FIG. 11 . Electrical box  70  includes sidewalls  72 , a front edge  74 , an outer surface  76  on the sidewalls  72 , and one or more recesses  78  in the outer surface  76  of the sidewalls  72 . The recesses  78  are located a distance d 6  from the front edge  74  of the electrical box  70 . This distance d 6  is generally equal to the first distance d 1  from the forward surface  42  of the flexible tab  34  to rear surface  24  of the faceplate  22  (as shown in  FIGS. 3 and 11  and described herein). Therefore, when the temporary cover  20  is pushed in the direction of the arrows  80  in  FIG. 11  upon the electrical box  70 , the flexible tabs  34  will snap inwardly and the forward surfaces  42  of the tabs  34  will engage the corresponding recess  78  of the electrical box  70  thereby securing the temporary cover  20  to the electrical box  70 . 
   After the stucco is installed completely around the periphery of the electrical box as described herein, the temporary cover  20  is simply disposed of. The permanent cover of the electrical box is then available to protect the interior electrical device against weather elements such as snow and rain. 
   Having thus described the invention with reference to a preferred embodiment, it is to be understood that the invention is not so limited by the description herein but is defined as follows by the appended claims.