Abstract:
The present invention is directed to a weatherproof electrical outlet box assembly for shielding and protecting electrical components from moisture comprising a faceplate for attaching to an outlet box, the faceplate being substantially planar, and perimetrically bounded by a substantially rectangular side edge, the faceplate having at least one aperture for receiving an electrical component and; the faceplate including a first hinge socket and a second hinge socket extending respectively from the side edge in substantially orthogonal orientation. The weatherproof electrical outlet box assembly further including a cover having a front wall, an opposed open end and a substantially rectangular perimetrical side wall therebetween defining a cover interior, the side wall having a rim bounding the open end, the cover including at least one access port through the side wall adjacent the open end for providing separate passageways into the interior of the cover; the cover including a first hinge pin and a second hinge pin extending respectively from the side wall adjacent the open end in substantially orthogonal orientation; and the cover being pivotally affixed to the faceplate by operative engagement of the hinge socket with the hinge pin of corresponding orientation and movable between an open and a closed position and wherein the hinge pin and the hinge socket that are not in operative engagement are not aligned.

Description:
FIELD OF THE INVENTION:  
       [0001]     This invention relates to a hinged electrical connection box cover for covering electric and/or electronic components, having a cover body, comprising a bottom and side walls, and open top defined by the said walls, wherein the cover can be closed over a selectively interchangeable faceplate, that is rigidly mounted to accommodate an electrical component and pivotally attached to the cover wherein the hinged front cover can be opened and closed whether the faceplate is oriented about either a horizontal or vertical axis, and provide weatherproof protection to the electrical component.  
       BACKGROUND OF THE INVENTION:  
       [0002]     Electrical boxes are used for a variety of applications wherein it is necessary to provide a termination point for electrical wires for splicing or connection to an electrical component. An electrical box is rigidly mounted on or in a wall in such locations to conveniently locate an electrical component. Depending on the application and location, electrical boxes can be mounted either in a horizontal or vertical orientation. Once mounted, the wires installed and connected to the electrical component therein, the box is closed with a face plate. The face plate must be chosen to match the installed electrical component, and covers the top opening of the connector box, thus preventing any damage to the components mounted in the box or accidental contact with live electrical wires.  
         [0003]     Due to the varied needs for electrical power and switching, it is sometimes necessary to mount a box in a location where it will be exposed to wet conditions. Typically, such installations can include an outdoor receptacle to provide electricity for lighting, power tools or appliances. When used in a location where the connector box will be exposed to water, it is necessary to provide for structure to ensure that water does not enter the box and thereby damage the components therein or cause a “short circuit”. An effective way to prevent water from entering an electrical box is to provide a cover for the faceplate thus providing a weatherproof seal.  
         [0004]     It would therefore be desirable to have an electrical connector box cover that can provide a weatherproof seal, with an exchangeable faceplate wherein the cover can be adapted to be used with a connector box that is mounted in either a horizontal or vertical orientation. Additionally it would be desirable to provide for a hinge on the faceplate such that the cover can be pivotally opened for gaining easy access to the components that are shielded by the cover. Additionally it would be useful for the cover to be adapted to be opened when the faceplate is oriented in either the horizontal or vertical direction without the need to modify the cover or the faceplate and provide a locking mechanism whereby the cover can be secured regardless of which position the box is mounted.  
       SUMMARY OF THE INVENTION  
       [0005]     The present invention is therefore directed to a weatherproof electrical outlet box assembly for shielding and protecting electrical components from moisture comprising a faceplate for attaching to an outlet box, the faceplate being substantially planar, and perimetrically bounded by a substantially rectangular side edge, the faceplate having at least one aperture form receiving an electrical component and; the faceplate including a first hinge socket and a second hinge socket extending respectively from the side edge in substantially orthogonal orientation. The present invention further including a cover having a front wall, an opposed open end and a substantially rectangular perimetrical side wall therebetween defining a cover interior, the side wall having a rim bounding the open end, the cover including a at least one access port through the side wall adjacent the open end for providing separate passageways into the interior of the cover; the cover including a first hinge pin and a second hinge pin extending respectively from the side wall adjacent the open end in substantially orthogonal orientation; and the cover being pivotally affixed to the faceplate by operative engagement of the hinge socket with the hinge pin of corresponding orientation and movable between an open and a closed position and wherein the hinge pin and the hinge socket that are not in operative engagement are not aligned. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0006]      FIG. 1  is a perspective view of the front of the electrical connector box cover and attached faceplate in a horizontal position, the cover and faceplate being in a closed position.  
         [0007]      FIG. 2  is a perspective view of the electrical connector box cover and attached faceplate in a vertical position, the cover and faceplate being shown in a open position.  
         [0008]      FIG. 3  is a detailed perspective view of the locking device and hinge of the electrical connector box and faceplate according to the present invention.  
         [0009]      FIG. 4  is a detailed perspective view of the inside of electrical connector box cover rim and knockout according to the present invention.  
         [0010]      FIG. 5  is a partial cross-sectional view of the electrical connector box cover and faceplate according to the present invention as seen along viewing lines V-V of  FIG. 1 .  
         [0011]      FIG. 6  is a perspective view of an alternate embodiment of the faceplate according to the present invention.  
         [0012]      FIG. 7  is a perspective view of another alternate embodiment of the faceplate according to the present invention.  
         [0013]      FIG. 8  is a perspective view of the electrical connector box cover and attached faceplate in a horizontal position, the cover and faceplate being in an open position.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0014]     There will be detailed below the preferred embodiments of the present invention with reference to the accompanying drawings. Like members are designated by like reference characters in all figures.  
         [0015]     The present invention is directed to a weatherproof cover for an electrical connector box for providing water protection to components accommodated therein without the use of a gasket, having selectively interchangeable faceplates for adaptation to a variety of electrical components and which can be utilized with a connector box mounted in either a horizontal or vertical orientation.  
         [0016]     Turning now to  FIG. 1 , the electrical connector box cover  100  of the present invention is shown. The electrical connector box cover  100  is a generally rectangular box-like member having a substantially planar rectangular front  102  that is perimetrically bounded by an outer wall  104 , that is comprised of four substantially planar side walls having two sets of substantially parallel sides. The outer wall  104  extends backwardly from the front  102  and has an outwardly flanged rim  106  at the back with an outside edge  108 . The rim  106  is preferably integrally formed on cover  100  as a single piece component.  
         [0017]     Depicted on outer wall  104  is a conventional plug knockout  110  of a type which is known in the art. The knockout  110  is a partially cut through opening or removable wall section. The knockout  110  is removed to create an opening through which a wire may pass for electrical connection to the enclosed device. In the embodiment shown, once the knockout has been removed it cannot be reinstalled. While knockout  110  is depicted on one surface of outer wall  104 , it will be appreciated that a plurality of knockouts can be positioned on any surface of the outer wall. It should be noted that while the edge of knockout  110  does not appear to extend onto flanged rim  106 , as will be seen in  FIG. 2 , the partially cut through opening on the inside of outer wall  104  reaches the edge of the outer flange. Therefore, the portion of rim  106  adjacent the knockout  110  is removed to form an unobstructed aperture. In addition, in  FIG. 1  there is depicted horizontal hinge socket  112  in pivotal engagement with horizontal cover hinge pin  114 . Cover locking device  116  is also shown in operative engagement with faceplate locking member  126  as explained in greater detail with respect to  FIG. 3 . As is well known, cover housing  100  may be formed of a variety of materials. In the particular embodiment depicted here, cover housing  100  is integrally formed of an injection molded, high impact synthetic plastic material, such as for example, clear Lexan.  
         [0018]     With further reference to  FIG. 1 , horizontally oriented cover  100  is shown in a closed position with respect to a faceplate  120 . Shown in  FIG. 1  is faceplate side edge  122 , faceplate locking devices  124  and  126 , and faceplate vertical hinge socket  128 . Locking devices  124  and  126 , extend from diagonally opposed corners of faceplate side edge  122  and are adapted to be fastened to complementary cover locking device  116 . Locking device  126  is shown in locking engagement with cover locking device  116  as described below. In this view, cover  100  is depicted as pivotally engaged to faceplate  120  in a horizontal orientation. As will be further described and depicted in  FIG. 2 , cover  100  can also be pivotally engaged to faceplate  120  in a vertical orientation.  
         [0019]     Turning again to  FIG. 2 , there is shown vertically oriented cover  100  of the present invention depicted in an open position with respect to faceplate  120 . Visible in the open position is the interior of rectangular front  102  and outer wall  104 , having an edge  202  that defines an opening into cover interior  204 , exterior rim  206  and vertical cover hinge pin  208  which is oriented horizontally during use. Visible on the interior surface of outer wall  104  are the partially cut through openings  209  forming knockouts  110 . Faceplate  120  has an inside surface  210  (facing the inside of cover  100 ) and an outside surface  212  (not visible), perimetrically bounded by a side edge  122 . The faceplate depicted is adapted to accommodating a single duplex receptacle, having a pair of openings  214 , which are positioned such that the faceplate will fit flush over the duplex receptacle when installed. However, faceplate  120  may be modified and configured to adapt to any number of electrical components, as depicted and described for example, in  FIGS. 6 and 7 . There is further shown a plurality of holes  216   a  and  216   b  for receiving fasteners, for example screws to attach the faceplate to a variety of different components, such as a duplex receptacle. Vertical hinge socket  128  (which is oriented horizontally during use) extends from side edge  122  for pivotally connecting to the vertical hinge pin  208 . There is further defined on the outside surface of the faceplate, a continuous protrusion  220  around the perimeter of the faceplate. Protrusion  220  is preferably integrally formed on the faceplate and is positioned on the faceplate such that it aligns with the inside edge of the outwardly flanged rim to form a seal as described below. A concave channel  222  is positioned along the inside edge of the continuous protrusion  220 . Concave channel serves to provide a barrier to water migration into the interior of cover  100  along the inside surface of faceplate  120 .  
         [0020]     Turning now to  FIG. 3  there is shown a detailed view of a portion of the exterior of cover  100  and faceplate  120  showing cover locking device  116  and faceplate locking device  126 . The same will also be true with respect to faceplate locking device  124 . More particularly,  FIG. 3  shows locking device  126  in locking engagement with cover locking device  116 . Cover locking device  116  comprises a stanchion  302  supporting an annular ring  304  comprised of an inside semi circle  304   a , and outside semi circle  304   b  and a locking tab support lip  306 . Faceplate locking device  126  comprises a support  308  stanchion, an annular ring (not visible) which is comprised of an inside semi circle and an outside semi circle, similar to structures  304   a  and  304   b , and a locking tab  312 . Annular ring  304  is adapted to align concentrically with the complementary structure on faceplate locking device  124  or  126 , and provides a passage through which a conventional lock shank of a padlock or other locking device (not shown) may be inserted. The lock can be a padlock, opened by key or combination. Annular ring  304  and the annular ring of locking device  124  and  126  are formed of offset semicircular portions thereby providing a gap between the structures for locking tab  312  to pass through. Furthermore, the locking device includes a snap closure mechanism that can be of a variety of types that are well known in the latching arts. In this exemplary embodiment depicted, the snap closure mechanism comprises the locking tab support lip  306  and locking tab  312 . Tab  312  is a post having four sides, projecting upwardly from faceplate locking device  124  or  126 , wherein the side located adjacent the cover locking device has a ramped or angled surface, with a notch  314  below the angled surface adapted to engage locking tab support lip  306  as shown in  FIG. 3 . The tab  312  is shown extending upwardly from locking device  124  and  126 . Both the tab  312  and tab support lip  306  are preferably formed integrally with cover  100  and faceplate  120  respectively from a resilient material.  
         [0021]     In operation, when cover  100  is pivotally engaged to faceplate  120  and rotated to a closing position, cover locking device  116  passes faceplate locking device  124  or  126 , whereby resilient locking tab  312  is elastically deformed laterally away from locking device  116 , until cover  100  is in the fully closed position. Once cover is fully closed, locking tab  312  springs back to its original position to releasably secure cover  100  on faceplate  120  whereby notch  314  engages locking tab support lip  306 . At the same time annular ring  304  and the annular ring of locking device  124  or  126  are concentrically aligned in order to permit the insertion of a lock such as a pad lock. In the specific embodiment of  FIGS. 1 and 2 , two locking devices  124  or  126  having resilient tabs  312  are provided on faceplate  120 , located at the edge of the faceplate on diagonally opposed corners for securely retaining the cover  100  against the faceplate  120 . To open cover  100 , the resilient tab  312  is manually bent away from locking device  116 , whereby notch  314  disengages from locking tab support lip  306 , permitting opening of the cover. By providing a cover and faceplate with a snap closure mechanism, the cover can be closed securely and tightly, thus maintaining a tight seal between the cover and faceplate.  
         [0022]     Turning now to  FIG. 4 , there is shown a detailed view of a portion of cover interior  204 . More particularly there is shown, cover support ledge  402 , exterior rim  206 , having an inside edge  404 , an outside edge  406  and a top edge  408 . Further, visible on the interior surface of outer wall  104  are the partially cut through openings  209  of knockouts  110 . The partial cut through opening comprises a “u-shaped” incision on the interior of outer wall  104  and exterior rim  206 . The incision weakens the outer wall and rim structure whereby a portion of that wall, the knockout  110 , can be easily removed to create a passage way through the cover. As previously noted, the partially cut through opening  209 , extends to the exterior rim  206 , thereby enabling removal of that portion of rim  106 .  
         [0023]      FIG. 5  depicts the cover  100  and faceplate  120  of the current invention as described above along cross-section V-V of  FIG. 1 . Extending from the inside surface  210  of faceplate  120  is continuous protrusion  220 , located around the perimeter of the faceplate and having an inner periphery  502 , an outer periphery  504  and a intermediate sealing surface  506 . Extending from the edge of the outer periphery  504 to side edge  122  is faceplate lip  510  wherein the bottom surface forms an outer sealing surface  512 . Located along the inner periphery  502  of continuous protrusion  220  is a concave channel  222  that forms a depression in the surface of the faceplate. When cover  100  is closed, inner sealing surface  506  bears upon cover support ledge  402  and outer sealing surface  512  bears upon top edge  408  of cover  100  to form a seal.  
         [0024]     In use, when cover  100  is closed, any water which may fall on the cover is channeled away from the cover and faceplate joint by the outwardly flanged rim  106 . Furthermore, there is a mechanical barrier to prevent water from entering cover  100  by means of a close tolerance fit between the outer sealing surface  512 and the flange top edge  408 . In addition, there is a secondary mechanical barrier by means of a close tolerance fit between the support ledge  402  and inner sealing surface  506 .  
         [0025]     Now turning to  FIG. 6  there is shown a perspective view of the outside surface of an alternate embodiment of the faceplate  600  according to the present invention. The embodiment shown in  FIG. 6  is adapted to cover a GFCI electrical receptacle, having an substantially rectangular aperture  602  adapted to receive a GFCI outlet. In addition, it would be apparent to one skilled in the art, that faceplate  600  can be adapted to cover various electric or electrical components as also shown and described, for example in  FIGS. 2 and 7 . The faceplate according to the present invention is selectively interchangeable according to the needs of a user. Alternate embodiments of faceplate  600  are adapted to cover a variety electrical components.  
         [0026]     In addition,  FIG. 6  depicts apertures  216 b having a keyhole shape for attaching the faceplate to a wall outlet, such as a receptacle box. The key hole apertures includes a substantially circular opening  610 , a slotted region  612  and a concave depression  614  surrounding the slotted region. The circular opening  610  is adapted for receiving an outwardly flanged fastener head, such as a screw head (not shown). The inner diameter of the circular opening  610  is substantially equal to the diameter of the fastener head to be received. Extending radially from the outer circumference of the circular opening is slotted region  612 , which has a width less than the diameter of the circular opening and substantially equal to the diameter of the fastener shank to be received. Furthermore, there is provided a concave depression surrounding the slotted region, for retaining the fastener head.  
         [0027]     In use, faceplate  600  is affixed to a wall outlet by positioning the circular openings  610  in alignment with fasteners that are secured to a mounting box. The head of the fasteners, typically screws, protrude through circular openings  610  once the faceplate has been attached to the mounting box. Faceplate  600  is then displaced laterally such that the fastener shank is received by slotted region  612  while the fastener head is retained within the concave depression thereby securely retaining the faceplate to the mounting box.  
         [0028]     Also shown in  FIG. 6  is a detailed view of hinge support sockets  112  and  128 , comprising an arched structure  616 , with a curved interior  618  an exterior  620  and a hinge pin retaining tab  622 . The interior  618  portion is adapted to concentrically receive either hinge pin  114  or  208  of cover  100 . Hinge socket  128  is mounted on faceplate  600  such that interior portion  618  is oriented towards the front of faceplate  600 . By mounting the hinge socket in this way, hinge pin  114  can be rotatably engaged to hinge socket  128  either before or after faceplate  600  has been securely affixed to an electrical component mounting box.  
         [0029]     In operation, the open portion of a hinge socket is fit over a hinge pin and snapped into place such that retaining tab  622  is elastically deformed to permit the hinge pin to fit concentrically within the arch interior  618 . Once in place, retaining tab  622  resiliently bears upon the hinge pin to hold it within the hinge socket. Cover  100  can thereby be pivoted to rotate into an open or closed position.  
         [0030]      FIG. 7  depicts an alternate embodiment of a faceplate according to the present invention, having a rectangular knockout plug  710 , adapted for use with a light switch, for example, and a circular knockout plug  712  adapted to receive a single round receptacle, such as, for example, an electrical socket typically used for 220v service. The faceplate can be adapted to either use by removing the appropriate knockout plug, however, once the knockout plug is removed, it can not be replaced. In addition, while the faceplate of  FIG. 7  is depicted as having a round and rectangular knockout plug, it would be apparent to have a faceplate having knockout plugs of a variety of alternate shapes for use with different electrical components.  
         [0031]     The faceplate embodiments depicted in  FIGS. 2, 6  and  7  are exemplary only, since it would be apparent to have a faceplate according to the present invention adapted to receive a variety of alternate electrical components.  
         [0032]      FIG. 8  depicts the electrical connector box cover  100  and faceplate  120  of the present invention in the open horizontal orientation, wherein cover  100  is rotated 180 degrees from the orientation depicted in  FIG. 2  with respect to faceplate  120 . In this view, hinge pin  114  and hinge socket  112  are pivotally engaged. While in either the horizontal or vertical position, the unused hinge socket and pin are positioned along opposite parallel sides of the faceplate and cover device respectively. Such arrangement prevents the unused hinge components from interfering with the opening and closing of the cover. Furthermore, in the horizontal orientation, cover locking device  116  engages with faceplate locking device  124 . Locking element  126  is not engaged in the orientation shown in  FIG. 8 .  
         [0033]     In operation, the faceplate, is rigidly mounted on an electrical component box, typically using screws. The component box can be an in-wall installation, or surface mounted wherein the box is affixed to a building structure, such as a wall or column. In one embodiment of the present invention, there is provided one outlet box cover  100  together with multiple faceplates, such as, for example those depicted in  FIGS. 2, 7  and  8 . The faceplate can be selectively chosen from among those provided to cover the electrical component, and mounted on an outlet box in either a horizontal orientation or vertical orientation. Unused faceplates can be discarded. Once faceplate  120  is securely mounted, the cover is attached to the faceplate using the hinges provided. The hinge sockets located on faceplate  120  are oriented such that the hinge pin can be pushed into the hinge socket and thereby resiliently retained by tab  622 . The hinge socket orientation, makes it possible to affixed the cover to the faceplate after the faceplate is securely mounted to the wall. To affix cover  100  to faceplate  120 , either hinge socket  128  or  112  is pivotally engaged to the corresponding horizontal  114  or vertical  208  hinge pin respectively. Either set of hinges can be selectively engaged without the need to modify the faceplate or the cover. It should also be understood that other intermating structure are equally suitable such that the described pin and socket interconnection is not the only structure usable for securing the cover to the faceplate. For example, the pin structure described could be secured to the faceplate and the socket structure could be secured to the cover. Bayonet, ball, male/female and even hermaphroditic structure are equally suitable for this purpose. Furthermore, there is no necessity that the intermating structure on the faceplate be the same nor is there any necessity that the intermating structure on the cover be the same. It is only necessary that the respective intermating structure on the cover and faceplate be configured to intermate or engage each other.  
         [0034]     In the preferred embodiment of the present invention, the faceplate and cover are mounted such that the cover opens by pivoting in an upward direction. For example, the faceplate is mounted with either a vertical or horizontal hinge socket positioned at the top wherein the corresponding cover hinge pin is pivotally engaged to that socket. Alternately, it is also possible to open the cover in a downward or lateral direction by positioning a hinge socket at the bottom or side of the faceplate respectively, and pivotally engaging the corresponding hinge socket. Either orientation can be achieved without any modification to the faceplate or cover.  
         [0035]     Once the faceplate and cover are pivotally engaged and the cover is closed, the preferred embodiment includes a locking device to maintain the cover in a closed position. As previously described, the locking device may include an annular ring for engaging a lock shank such as a padlock and a latching mechanism such as, for example, the snap device depicted and described in  FIG. 3 .  
         [0036]     It will be appreciated that the present invention has been described herein with reference to certain preferred or exemplary embodiments. The preferred or exemplary embodiments described herein may be modified, changed, added to or deviated from without departing from the intent, spirit and scope of the present invention. It is intended that all such additions, modifications, amendments, and/or deviations be included within the scope of the claims appended hereto.