Abstract:
A two-tier cover assembly for a field service box. The two-tier cover assembly can be retrofitted to an existing field service electrical box to protect the electrical device that is housed therein. The cover assembly provides two configurations for protecting the electrical box, including an expanded and a collapsed configuration. In the expanded configuration, the cover assembly provides two cord openings that are accessible with the cover plate closed. In the collapsed configuration, the cord openings are completely closed to seal all openings and thereby protect the electrical device from rain, dirt, insects and other hazards.

Description:
FIELD OF THE INVENTION 
   This invention relates to covers for electrical boxes, and specifically to an adjustable two-tier cover assembly for attachment to an electrical box. 
   BACKGROUND OF THE INVENTION 
   Electrical boxes for outdoor use, commonly termed “FS” or field service boxes, are typically mounted on the exterior of buildings for providing convenient access to electrical outlets and other electrical devices such as switches and timers. To keep dirt, insects, and other debris out of the FS box, a simple hinged cover plate is typically provided for closing the front opening of the box. As a result of being mounted outdoors, FS boxes are exposed to the elements, including heat, cold, rain, insect infiltration, and similar hazards, which eventually may negatively affect the appearance and functioning of the box. Field service boxes constructed of metal for example, typically include hinged covers that become rusted and cease to function after repeated years of exposure to the elements. Additionally, conventional hinged covers are large, extending a substantial distance from the exterior wall and therefore unsightly and unattractive to the homeowner. Conventional hinged electrical box covers typically include cord openings that are open to the elements regardless of whether an electrical cord is plugged into the electrical box or not. Therefore, the interior of the conventional cover is always exposed to the elements, regardless of whether or not an electrical cord is plugged into the electrical device within the cover. 
   What is needed therefore is a cover assembly that can be installed over an existing or a new FS box to provide better protection to an electrical receptacle installed therein and which also provides an overall lower profile when the receptacle is not in use. What is needed is an electrical cover assembly that is adjustable to provide a first level of protection when electrical cords are connected to the installed electrical device and a second, more secure level of protection when the electrical device is not in use. 
   SUMMARY OF THE INVENTION 
   The invention is a two-tier cover assembly for a field service box. The two-tier cover assembly can be retrofitted to an existing field service electrical box to protect the electrical device that is housed therein. The cover assembly provides two configurations for protecting the electrical box, including an expanded and a collapsed configuration. In the expanded configuration, the cover assembly provides two cord openings that are accessible with the cover plate closed. In the collapsed configuration, the cord openings are completely closed to seal all openings and thereby protect the electrical device from rain, dirt, insects and other hazards. 
   OBJECTS AND ADVANTAGES 
   Several advantages are achieved with the cover assembly of the present invention, including:
         (1) The cover assembly can be retrofitted to an existing field service electrical box to upgrade its operation or appearance.   (2) The cover assembly provides additional functionality over existing field service boxes including a compressed configuration and an expanded configuration.   (3) The cover assembly provides a compressed configuration for completely sealing the interior of the field service box and its contents from rain, dirt, insects, and other hazards.   (4) The cover assembly provides an expanded configuration for protecting the interior of the field service box while also providing dual cord openings for accessing an installed electrical receptacle.   (5) The cover assembly can be easily converted from an expanded to a compressed configuration as desired by the homeowner.       

   These and other objects and advantages of the present invention will be better understood by reading the following description along with reference to the drawings. 

   
     DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a rear perspective view of a cover assembly for an electrical box according to the present invention. 
       FIG. 2  is a front view of a inner frame member that forms a portion of the cover assembly of  FIG. 1 . 
       FIG. 3  is a side view of the inner frame member of  FIG. 2 . 
       FIG. 4  is an end view of the inner frame member of  FIG. 2 . 
       FIG. 5  is a front view of a outer frame member that forms a portion of the cover assembly of  FIG. 1 . 
       FIG. 6  is a sectional view of the outer frame member taken along line  6 - 6  of  FIG. 5 . 
       FIG. 7  is an end view of the outer frame member of  FIG. 5 . 
       FIG. 8  is a plan view of an adapter plate that forms a portion of the cover assembly of  FIG. 1 . 
       FIG. 9  is a side view of the adapter plate of  FIG. 8 . 
       FIG. 9A  is a sectional view of the adapter plate taken along line  9 A- 9 A of  FIG. 9 . 
       FIG. 10  is an end view of the adapter plate of  FIG. 8 . 
       FIG. 10A  is a sectional view of the adapter plate taken along line  10 A- 10 A of  FIG. 10 . 
       FIG. 11  is a perspective view of a cover member that forms a portion of the cover assembly of the present invention. 
       FIG. 11A  is a front view of the cover member of  FIG. 11 . 
       FIG. 11B  is a side view of the cover member of  FIG. 11 . 
       FIG. 11C  is a bottom view of the cover member taken from line  11 C- 11 C of  FIG. 11A . 
       FIG. 12  is a sectional view of the top and inner frame members of the cover assembly of the present invention in a compressed configuration to form a one-tier cover for an electrical box. 
       FIG. 13  is a sectional view of the top and inner frame members of the cover assembly of the present invention in an expanded configuration to form a two-tier cover for an electrical box. 
       FIG. 14  is a side view of the cover assembly of the present invention in an expanded configuration thereby forming a two-tier cover for an electrical box. 
       FIG. 15  is a side view of the cover assembly of the present invention in a compressed configuration thereby forming a two-tier cover for an electrical box. 
       FIG. 16  is an exploded perspective view of the cover assembly of the present invention and a duplex receptacle in position to be retrofitted to a field service electrical box. 
       FIG. 17  is a bottom view of the cover assembly of the present invention in an expanded configuration. 
       FIG. 18  is a bottom view of the cover assembly of the present invention in a compressed configuration. 
     
       
         
               
             
               
               
               
             
           
               
                   
               
               
                 INDEX TO REFERENCE NUMERALS IN DRAWINGS 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                   
                  20 
                 adjustable cover assembly 
               
               
                   
                  22 
                 inner frame member 
               
               
                   
                  24 
                 outer frame member 
               
               
                   
                  26 
                 peripheral wall of inner frame member 
               
               
                   
                  28 
                 inner surface of peripheral wall of inner frame member 
               
               
                   
                  30 
                 outer surface of peripheral wall of inner frame member 
               
               
                   
                  32 
                 front edge of inner frame member 
               
               
                   
                  34 
                 rear edge of inner frame member 
               
               
                   
                  36 
                 outward extending lip 
               
               
                   
                  38 
                 rear panel of inner frame member 
               
               
                   
                  40 
                 opening in rear panel 
               
               
                   
                  42 
                 electrical device mounting aperture 
               
               
                   
                  44 
                 slot in rear panel 
               
               
                   
                  46 
                 outward-extending ramp 
               
               
                   
                  48 
                 outward extending ledge 
               
               
                   
                  50 
                 outer edge of outward-extending ramp 
               
               
                   
                  51 
                 inner edge of outward-extending ramp 
               
               
                   
                  52 
                 side ramp 
               
               
                   
                  53 
                 outward extending projections 
               
               
                   
                  54 
                 peripheral wall of outer frame member 
               
               
                   
                  56 
                 inner surface of peripheral wall of outer frame member 
               
               
                   
                  58 
                 outer surface of peripheral wall of outer frame member 
               
               
                   
                  60 
                 front edge of outer frame member 
               
               
                   
                  62 
                 rear edge of outer frame member 
               
               
                   
                  64 
                 inward extending lip of outer frame member 
               
               
                   
                  66 
                 inward-extending ramp of outer frame member 
               
               
                   
                  68 
                 post 
               
               
                   
                  70 
                 outer edge of inward-extending ramp 
               
               
                   
                  72 
                 inner edge of inward-extending ramp 
               
               
                   
                  74 
                 tab on outer frame member 
               
               
                   
                  76 
                 U-shaped slot in outer frame member 
               
               
                   
                  78 
                 adapter plate 
               
               
                   
                  80 
                 front surface of adapter plate 
               
               
                   
                  82 
                 rear surface of adapter plate 
               
               
                   
                  84 
                 tab 
               
               
                   
                  86 
                 hook 
               
               
                   
                  88 
                 top of hook 
               
               
                   
                  90 
                 sloping front surface 
               
               
                   
                  92 
                 central opening in adapter plate 
               
               
                   
                  94 
                 aperture in adapter plate 
               
               
                   
                  96 
                 cover member 
               
               
                   
                  98 
                 peripheral wall of cover member 
               
               
                   
                 100 
                 ear 
               
               
                   
                 102 
                 aperture 
               
               
                   
                 104 
                 U-shaped slot in cover member 
               
               
                   
                 106 
                 latch member 
               
               
                   
                 108 
                 opening in latch member 
               
               
                   
                 113 
                 locking arrangement 
               
               
                   
                 115 
                 minor ramp 
               
               
                   
                 116 
                 directional arrow 
               
               
                   
                 118 
                 limiting arrangement 
               
               
                   
                 119 
                 attachment arrangement for securing adapter plate 
               
               
                   
                 120 
                 gasket 
               
               
                   
                 122 
                 electrical box 
               
               
                   
                 124 
                 circular cord opening 
               
               
                   
                 126 
                 electrical cord 
               
               
                   
                 128 
                 duplex receptacle 
               
               
                   
                 130 
                 fastener 
               
               
                   
                   
               
             
          
         
       
     
   

   DETAILED DESCRIPTION OF THE INVENTION 
   With reference to  FIG. 1  there is shown a preferred embodiment of the present invention, an adjustable cover assembly  20  for use in covering an existing electrical box (not shown). The adjustable cover assembly  20  includes an inner frame member  22  that nests within and is slideable with respect to an outer frame member  24 . 
   Referring to  FIGS. 2-4 , the inner frame member  22  includes a peripheral wall  26  having an inner surface  28 , an outer surface  30 , a front edge  32  and a rear edge  34 . An outward extending lip  36  extends from the outer surface  30  of the peripheral wall  26  at the front edge  32  of the inner frame member  22 . The inner frame member  22  further includes a rear panel  38  having an opening  40  centered therein, electrical device mounting apertures  42  surrounding the opening  40 , and slots  44  between the mounting apertures  42  and the peripheral wall  26 . An outward-extending ramp  46  extends from the outer surface  30  of the peripheral wall  26  of the inner frame member  22 . The inner frame member  22  also includes an outward extending ledge  48  near the rear edge  34 . The outward-extending ramp  46  on the inner frame member  22  includes an outer edge  50  and an inner edge  51  and the outward-extending ramp  46  slopes outward from the inner edge  51  to the outer edge  50 . Side ramps  52  and outward extending projections  53  are further provided on the outer surface  30  of the peripheral wall  26  of the inner frame member  22 . 
   With reference to  FIGS. 5-7 , the outer frame member  24  includes a peripheral wall  54  having an inner surface  56 , an outer surface  58 , a front edge  60 , and a rear edge  62 . The rear edge  62  of the outer frame member  24  is provided with an inward extending lip  64  and an inward-extending ramp  66  extends from the inner surface  56  of the peripheral wall  54 . Posts  68  extend from the outer surface  58  of the outer frame member  24 . The inward-extending ramp  66  on the outer frame member  24  includes an outer edge  70  and an inner edge  72  with the inward-extending ramp  66  sloping inward from the outer edge  72  to the inner edge  70 . The outer frame member  24  further includes a tab  74  extending from the front edge  60  and U-shaped slots  76  in the peripheral wall  54  extending inwards from the front edge  60 . 
   Referring to  FIGS. 8-10A  there is shown an adapter plate  78  that may form a portion of the adjustable cover assembly of the present invention. The adapter plate  78  includes a front surface  80 , a rear surface  82 , and tabs  84  extending from the front surface  80 . The tabs  84  include one or more hooks  86  extending substantially laterally therefrom (see  FIG. 10A ). The hooks  86  include a top  88  and a sloping front surface  90  that slopes downward from the top  88  of the hook. A central opening  92  and apertures  94  are provided in the adapter plate  78 . 
   With reference to  FIGS. 11-11C , there is shown a cover member  96  that forms a portion of the adjustable cover assembly of the present invention. The cover member  96  includes a peripheral wall  98 , ears  100  extending from the peripheral wall  98 , apertures  102  in the ears  100 , and U-shaped slots  104  in the peripheral wall  98 . The cover member  96  further includes a latch member  106  and an opening  108  in the latch member  106 . 
   With reference to  FIGS. 12-13 , by sliding the inner frame member  22  with respect to the outer frame member  24 , the adjustable cover assembly of the present invention can be placed in either of two configurations, including a compressed configuration as shown in  FIG. 12  and an expanded configuration as shown in  FIG. 13 . As shown in  FIG. 12 , the outward extending lip  36  on the front edge  32  of the inner frame member  22 , the outward-extending ramp  46  extending from the outer surface  30  of the peripheral wall  26  of the inner frame member  22 , the inward extending lip  64  on the rear edge  62  of the outer frame member  24 , the inward-extending ramp  66  extending from the inner surface  56  of the peripheral wall  54  of the outer frame member  24 , and the outward extending ledge  48  of the inner frame member  22  form a locking arrangement  113  for locking the adjustable cover assembly  20  in either the compressed configuration (see  FIG. 12 ) or expanded configuration (see  FIG. 13 ) as desired by the user. 
   In the compressed configuration, as shown in  FIG. 12 , the outer frame member  24  is slid over the inner frame member  22  until the inward-extending ramp  66  of the outer frame member  24  engages the outward extending ledge  48  of the inner frame member  22 . Outward extending projections  53  on the inner frame member  22  engage the minor ramps  115  of the outer frame member  24  causing a frictional fit between the inner  22  and outer  24  frame members in the compressed configuration and thereby eliminating any rattling or vibration, caused by wind or other environmental factors, of the inner frame member  22  within the outer frame member  24 . 
   In the expanded configuration, as shown in  FIG. 13 , the outer frame member  24  is slid outward, in the direction of the arrows  116 , with respect to the inner frame member  22  until the outer edge  50  of the outward-extending ramp  46  of the inner frame member  22  engages the inner edge  72  of the inward-extending ramp  66  of the outer frame member  24 . In the expanded configuration, the outward-extending ramps  46  of the inner frame member  22  also engage the rear edge  62  of the outer frame member  24 . In the expanded configuration, the inner frame member  22  is therefore locked with respect to the outer frame member  24 . 
   As shown in  FIG. 13 , the adjustable cover assembly of the present invention furthermore includes a limiting arrangement  118  for limiting the forward travel of the outer frame member  24  with respect to the inner frame member  22 . The limiting arrangement  118  for limiting the forward travel of the outer frame member  24  with respect to the inner frame member  22  includes the outward extending lip  36  on the front edge  32  of the inner frame member  22  and the inward extending lip  64  on the rear edge  62  of the outer frame member  24 . As both the inward extending lip  64  and outward extending lip  36  extend around a considerable portion of the inner periphery of the outer frame member  24  and the outer periphery of the inner frame member  22  respectively, further movement of the outer frame member  24  in the direction of arrows  116  is limited by lip  36  engaging lip  64 . 
   With reference to  FIG. 14 , the adjustable cover assembly  20  is depicted in the expanded configuration including the cover member  96  and the adapter plate  78 . The adapter plate  78  can be snapped onto the rear panel  38  of the inner frame member  22  by aligning the tabs  84  with the slots  44  in the rear panel  38  and pressing the tabs  84  and hooks  86  through the slots  44  in the rear panel  38 . The tabs  84  and hooks  86  of the adapter plate  78  and the slots  44  within the rear panel  38  comprise an attachment arrangement  119  for securing the adapter plate  78  to the inner frame member  22 . The sloping front surface  90  biasing the tabs  84  inwards when the adapter plate  78  is aligned with the slots  44  in the rear panel  38  of the inner frame member  22  and pushed thereon. An optional gasket  120  can be inserted between the adapter plate  78  and an existing electrical box  122  (dashed lines) and also, if desired, a gasket (not shown) can be inserted between the inner frame member  22  and the adapter plate  78 . The cover member  96  is rotatably attached or hinged to the outer frame member  24 , with the posts  68  of the outer frame member  24  extending through the apertures  102  in the ears  100  of the cover member  96 . The cover member  96  is shown closed upon the outer frame member  24  with the tab  74  of the outer frame member  24  engaging the latch member  106  of the cover  96 . The tab  74  of the outer frame member  24  is received in the opening  108  of the latch member  106  when the cover member  96  is closed upon the outer frame member  24 . 
   When the adjustable cover assembly is in the expanded configuration, as shown in  FIG. 17 , and cover member  96  is closed upon the outer frame member  24 , circular cord openings  124  are formed by the joining of the U-shaped slots  104  in the cover member  96  and the U-shaped slots  76  in the outer frame member  24 . With the adjustable cover assembly  20  in the expanded configuration, the circular cord openings  124  are open as the outer frame member  24  is expanded outwards and the cord openings  124  are open and not obscured by the peripheral wall  26  of the inner frame member  22 . Thus, the adjustable cover assembly  20  of the present invention can be placed in the expanded configuration at those times when an electrical cord  126  (see  FIG. 14 ) is plugged into a receptacle  128  within the cover assembly  20 . The cord openings  124  will be open when the adjustable cover assembly  20  is in the expanded configuration. 
     FIG. 18  depicts a bottom view of the adjustable cover assembly  20  in the compressed configuration. With the adjustable cover assembly  20  in the compressed configuration, the circular cord openings  124  are closed as the outer frame member  24  is compressed inwards and the cord openings  124  are closed or obscured by the peripheral wall  26  of the inner frame member  22 . Thus, in those times when the electrical receptacle  128  is not in use (see  FIG. 15 ), the adjustable cover assembly  20  can be placed in the compressed configuration to close the cord openings and therefore seal all the openings on the cover assembly and thereby protect the interior of the cover assembly from dust, rain, infiltration by insects, etc. A side view of the adjustable cover assembly in a compressed configuration, shown in  FIG. 15 , depicts the cover member  26  closed on the outer frame member  24 . 
   With reference to  FIG. 16 , there is shown an exploded perspective view of the adjustable cover assembly  20  of the present invention and a duplex receptacle  128  in position to be retrofitted to a field service electrical box  122  or FS box. The adapter plate  78  is optional. Two fasteners  130  are used to secure the adjustable cover assembly  20  to the FS box  122 . Optional gaskets (not shown) can be inserted on each side of the adapter plate  78 , if desired, to provide an air tight seal between the adapter plate  78  and FS box  122  and between the adapter plate  78  and inner frame member  22 . 
   For an understanding of the operation of the adjustable cover assembly  20  of the present invention, the reader is referred to  FIG. 16 . The adjustable cover assembly  20  is typically used to cover an existing electrical box  122 . The adjustable cover assembly  20  is provided assembled as a unit, with the inner  22  and outer  24  frame members secured together and the cover member  96  hinged to the outer frame member  24 . The cover assembly  20  can also include the optional adapter plate  78  secured to the inner frame member  22 . The adapter plate  78  is useful in those instances in which the inner frame member  22  is smaller than the electrical box  122 . The adapter plate  78  is typically provided as a portion of the adjustable cover assembly  20 , with the adapter plate  78  snapped onto the inner frame member  22 . The adapter plate  78  can be easily removed if not required for a particular installation. 
   For a typical installation on an existing FS box  122 , the existing conventional cover plate (not shown) and the electrical device, such as duplex receptacle  128  shown in  FIG. 16 , are removed from the existing FS box  122 . The adjustable cover assembly  20  is then aligned with the existing FS box  122 . Fasteners  130  are then secured through the electrical device mounting apertures  42  and into the device mounting apertures (not shown) within the FS box  122 . Tightening the fasteners  130  secures the adjustable cover assembly  20  to the existing FS box  122 . With gaskets (not shown) on each side of the adapter plate  78 , an air tight fit is obtained between the adjustable cover assembly  20  and the existing FS box  122 . In the expanded configuration the circular cord openings  124  will be open and electrical cords  126  (see  FIG. 14 ) can be connected to the receptacle  128  within the adjustable cover assembly  20 . 
   After being installed to the FS box  122 , the adjustable cover assembly  20  is easily converted from the expanded configuration, shown in  FIG. 16 , to the compressed configuration, shown in  FIG. 15 , by grasping both sides of the peripheral wall  54  of the outer frame member  24 , pulling the walls  54  on each side out slightly until the peripheral wall  54  clears the outward-extending ramp  46  of the inner frame member  22 , and then applying slight pressure on the outer frame member  24  to push it over the inner frame member  22 . The adjustable cover assembly  20  is in the fully compressed configuration (see  FIG. 15 ) when the rear edge  62  of the outer frame member  24  is in contact with the adapter plate  78  or the wall surrounding the FS box  122 . In the compressed configuration the circular cord openings will be closed and the adjustable cover assembly  20  sealed against the external environment. 
   The adjustable cover assembly  20  of the present invention therefore provides an attractive electrical box cover that can be adjusted to an expanded configuration for those times when electrical cords are in use or, alternatively, adjusted to a compressed configuration for those times when the plugs within the cover assembly are not in use and the user desires to minimize the profile of the cover assembly and also seal the interior of the cover assembly against the outside environment. 
   The inner frame member  22 , outer frame member  24 , adapter plate  78 , and cover member  96  of the adjustable cover assembly  20  of the present invention may be constructed of metal or plastic but is most preferably each of these portions of the cover assembly are molded in one piece of plastic. The inner frame member  22 , outer frame member  24 , adapter plate  78 , and cover member  96  can be molded of any suitable plastic including polycarbonate, polyvinylchloride, acrylonitrilebutadienestyrene, or a polyolefin. 
   Although the description above contains many specific descriptions, materials, and dimensions, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. Thus the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given.