Abstract:
A removable plug for closing an unused cord opening on an electrical box. The cord opening is typically a U-shaped slot extending from the side of an electrical box or side of the cover member. The plug includes a main body, inner arms and outer arms that define a channel therebetween. The channel has a width slightly greater than the walls of an electrical box that it will be used in conjunction with. The plug may be used to plug any unused cord openings to prevent the entry of insects into the electrical box. The plug can be removed or reinserted as desired to protect any unused cord openings.

Description:
FIELD OF THE INVENTION 
   This invention relates to electrical boxes and specifically to a removable plug for closing the unused cord openings on an electrical box or an electrical box cover in order to protect the box from unwanted entry by insects. 
   BACKGROUND OF THE INVENTION 
   Electrical boxes are commonly mounted on the exterior walls of buildings to provide electrical devices such as duplex receptacles or outlets to service various electrical equipment. One of the more popular electrical boxes for exterior applications includes what is termed as “in-use cover”. An in-use cover is one that can be kept closed on the electrical box even while the electrical outlets mounted therein are in use, or have electrical cords plugged into them. This is typically accomplished by providing cord openings within either the box or the cover member of the electrical box. 
   Although in-use covers adequately protect the electrical device within the box from rain, snow, and other falling items, they do not adequately protect the device from other hazards, such as insects. When a cord opening is not occupied by an electrical cord, the cord opening becomes an open pathway to allow entry of various insects into the electrical box. Insects can compromise any electrical box, as wasps and other stinging insects tend to build nests in enclosed spaces and spiders typically spin webs. All of these can make it hazardous or simply unpleasant for the homeowner when he wishes to access an electrical box that has been occupied by insects. 
   What is needed therefore is a device for preventing insects from infiltrating the unused cord openings on an in-use electrical box. 
   SUMMARY OF THE INVENTION 
   The invention is a removable plug for closing the cord opening of an electrical box. The cord opening is typically a substantially U-shaped slot extending from the side of an electrical box or from the side of a cover member. The plug includes a main body, inner arms, and outer arms that define a channel therebetween. The channel has a width slightly greater than the walls of an electrical box that it will be used in conjunction with. The plug may be used to plug any unused cord openings to prevent the entry of insects into the electrical box. The plug can be removed or reinserted as desired to protect any unused cord openings. 
   OBJECTS AND ADVANTAGES 
   A first advantage of the removable plug of the present invention is that it seals any unused cord openings on an in-use electrical box. 
   Another advantage of the removable plug of the present invention is that it provides protection against insects to the electrical box and any electrical device installed therein. 
   A further advantage of the removable plug of the present invention is that it is easily removable. Any plug that has been previously installed can be easily removed by simple hand pressure. 
   A further advantage of the removable plug of the present invention is that it is easily manufactured in one piece. 
   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 front view of a preferred embodiment of a removable plug for an electrical box according to the present invention. 
       FIG. 2  is side view of the removable plug taken along line  2 – 2  of  FIG. 1 . 
       FIG. 3  is a section view of the removable plug taken along line  3 – 3  of  FIG. 1 . 
       FIG. 4  is a top view of the removable plug of  FIG. 1 . 
       FIG. 5  is a perspective view of the removable plug of  FIG. 1 . 
       FIG. 6  is a perspective view of a second embodiment of a removable plug for an electrical box according to the present invention. 
       FIG. 7  is a side view of the removable plug of  FIG. 7 . 
       FIG. 8  is a perspective view of a portion of an electrical box with a bottom corner of the cover cut away and with two of the removable plugs of  FIG. 1  exploded away and in alignment to be inserted in cord openings in the cover member. 
       FIG. 9  is a perspective view of the electrical box of  FIG. 8  with the two removable plugs installed in cord openings in the cover. 
       FIG. 10  is an exploded perspective view of a two-way electrical box cover assembly, an electrical box, an electrical device, a faceplate and two of the removable plugs of  FIG. 6  shown exploded away and in alignment to be inserted in cord openings in the cover member. 
       FIG. 11  is a perspective view of a portion of a recessed electrical box shown with the cover open and with two of the removable plugs of  FIG. 1  exploded away and in alignment to be inserted in cord openings in the electrical box. 
     TABLE OF NOMENCLATURE 
     The following is a listing of part numbers used in the drawings along with a brief description: 
     
       
         
               
               
             
           
               
                   
               
               
                 Part Number 
                 Description 
               
               
                   
               
             
             
               
                 20 
                 removable plug, preferred embodiment 
               
               
                 22 
                 opening in cover 
               
               
                 24 
                 cover 
               
               
                 26 
                 electrical box 
               
               
                 28 
                 opening in electrical box 
               
               
                 30 
                 sidewall 
               
               
                 32 
                 electrical box 
               
               
                 34 
                 central body 
               
               
                 36 
                 inner side 
               
               
                 38 
                 outer side 
               
               
                 40 
                 top periphery 
               
               
                 42 
                 outer arm 
               
               
                 44 
                 inner arm 
               
               
                 46 
                 channel 
               
               
                 48 
                 side of channel 
               
               
                 50 
                 top of channel 
               
               
                 52 
                 bottom of channel 
               
               
                 53 
                 recessed electrical box 
               
               
                 54 
                 electrical outlet 
               
               
                 56 
                 removable plug, second embodiment 
               
               
                 58 
                 outer arm 
               
               
                 60 
                 inner arm 
               
               
                 62 
                 channel 
               
               
                 64 
                 top of channel 
               
               
                 66 
                 bottom of channel 
               
               
                 68 
                 tab 
               
               
                 70 
                 sidewall of cover 
               
               
                 72 
                 two-way opening electrical box cover assembly 
               
               
                 74 
                 outer cover member 
               
               
                 76 
                 middle member 
               
               
                 78 
                 base member 
               
               
                 82 
                 gasket 
               
               
                 84 
                 electrical box 
               
               
                 86 
                 face plate 
               
               
                 88 
                 duplex outlet 
               
               
                 90 
                 flat bottom end 
               
               
                 92 
                 edge of cover 
               
               
                 W1 
                 width of channel at bottom 
               
               
                 W2 
                 width of channel at top 
               
               
                 W3 
                 width of channel at tab 
               
               
                 W4 
                 width of channel away from tab 
               
               
                   
               
             
          
         
       
     
   

   DETAILED DESCRIPTION OF THE INVENTION 
   The present invention comprises a removable plug for closing an opening on an electrical box. The removable plug is especially useful for closing the cord openings on an in-use electrical box to keep insects out while the cord opening is does not have a cord running there through. 
   With reference to  FIG. 8 , there is shown the preferred embodiment of a removable plug  20  for closing an opening on an electrical box cover.  FIG. 8  depicts the removable plugs  20  in alignment to be inserted in openings  22  in the cover  24  of an electrical box  26 .  FIG. 11  depicts the removable plugs  20  in alignment to be inserted in openings  28  in the sidewall  30  of a recessed electrical box  53 . 
   Referring to  FIGS. 1–5 , the removable plug  20  includes a central body  34  with an inner side  36 , an outer side  38 , and a top periphery  40 . An outer arm  42  extends from the top periphery  40  at the outer side  38  and two inner arms  44  extend from the top periphery  40  at the inner side  36 . As shown in  FIGS. 3 and 4 , a channel  46  extends along the top periphery  40  and is defined by the inner arm  44  and the outer arm  42 . The top periphery  40  of the central body  34 , as shown in  FIGS. 1 and 5 , is substantially U-shaped, with the top periphery  40  an inverted U shape with the removable plug  20  oriented as shown in  FIGS. 1 and 5   
   With reference to  FIG. 3 , the channel  46  of the removable plug  20  includes two sides  48 , a top  50 , and a bottom  52 . The top  50  of the channel  46  is slightly wider than the bottom  52  of the channel  46  and the channel  46  slopes evenly on each side  48  from the top  50  to the bottom  52  thereby gradually narrowing the channel from the top  50  to the bottom  52 . Preferably, the width W 1  of the bottom  52  of the channel  46  is between 0.010 and 0.030 inch narrower than the width W 2  of the top  50  of the channel  46 . 
   With reference to the recessed electrical box in  FIG. 11 , the removable plug  20  may be installed in a cord opening  28  on a sidewall  30  of the recessed electrical box  53  to close off the cord opening  28  when it is not in use. The recessed electrical box  53  includes cord openings  22  in the cover  24  and cord openings  28  in the electrical box  53 , which overlap when the cover  24  is closed upon the electrical box  53 . When the removable plug  20  is inserted in the cord opening  28  and the cover  24  is closed upon the electrical box  53 , the any plugs  20  that are installed will block the entire cord opening  28 . There will be no open space between the closed cover  24  and the cord opening thus sealed by the inserted plug  20 . The cord opening  28  is in use when an electrical cord (not shown) extends through the opening  28 , such as when the electrical cord is plugged into one of the electrical outlets  54  of the electrical box  53 . Sliding the removable plugs  20  into the openings  28  in the sidewall  30  in the direction of the arrows enables a friction fit of the removable plug  20  in the opening  28  with the inner arm  44  and the outer arm  42  holding frictionally thereon onto the sidewall  30 . The opening  28  in the sidewall  30  is preferably U-shaped. The top periphery  40  of the central body  34  is U-shaped to match the shape of the opening  28  in the sidewall  30  of the electrical box  53  and thereby provide a close fit within the opening  28  with no gaps or holes when the plug  20  is fully installed therein. Details of the recessed electrical box can be found in U.S. Pat. No. 6,921,861, which is incorporated herein in its entirety by reference. 
   Referring to the electrical box in  FIG. 8 , the removable plug  20  may also be installed in a cord opening  22  on the cover  24  of an electrical box  26  to close off the cord opening  22  when it is not in use. With reference to  FIG. 9 , after being installed in the cord openings  22  on the cover  24 , the removable plugs  20  protect the interior of the electrical box  26  and the electrical outlet  54  therein from insects and the like which typically could enter and build nests or otherwise compromise the interior of the box. When one or more electrical cords (not shown) are connected to the electrical outlet  54 , one or both of the plugs  20  may be removed by simply pulling them out of the openings  22 . Since they are held by a frictional fit as a result of the narrowing channel  46  gripping the sidewalls  70  of the cover  24 , the plugs  20  can be easily removed by grasping them and pulling them out. If the electrical cord is again removed from the electrical outlet  54 , the plugs  20  can be reinstalled by simply aligning them with the openings  22  and pushing them in. 
   With reference to  FIGS. 6 and 7 , a second embodiment of a removable plug  56  is depicted. The removable plug  56  includes an outer arm  58  and inner arms  60  defining, as shown in  FIG. 7 , a channel  62  there between. The channel  62  includes a top  64  and a bottom  66 . A tab  68  extends into the channel  62  and narrows the channel  62  at the tab  68 . Preferably, the width W 3  of the of the channel  62  at the tab  68  is between 0.010 and 0.030 inch narrower than the width W 4  of the channel  62  away from the tab  68 . 
   Operation of the second embodiment of the removable plug is analogous to that of the first embodiment. With reference to  FIG. 10 , a two-way opening electrical box cover assembly  72  is depicted with two removable plugs  56  aligned and ready to be inserted in the cover  74  of the electrical box  72 . The two-way opening cover assembly  72  includes an outer cover member  74 , a middle member  76 , a base member  78 , and, if required, a gasket  82 . The two-way opening cover assembly  72  works in conjunction with a standard electrical box  84  and a standard face plate  86  to house an electrical device therein, such as the duplex outlet  88  shown. One or both of the plugs  56  can be installed in the openings  22  in the cover  74  to close off the cord openings  22  when they are not in use. If a cord opening  22  is placed in use, the removable plugs  56  can be easily removed by grasping each plug  56  and pulling it out of the opening  22 . Details of the two-way electrical box cover assembly can be found in U.S. Pat. No. 6,921,861, which is incorporated herein in its entirety by reference. 
   With reference to  FIGS. 5 and 6 , the removable plugs  20  and  56  disclosed herein are preferably molded in one piece from plastic. Thus, with reference to the first and preferred embodiment as shown in  FIG. 5 , the central body  34 , outer arm  42 , and inner arm  44  are molded from plastic as a unit. 
   The removable plugs as disclosed herein may be used to plug a cord opening on either a cover member or on an electrical box, as the cord opening may be formed on one or the other. As disclosed herein and shown in  FIGS. 5 and 6 , the top peripheries  40  of removable plugs  20  and  56  are preferably U-shaped to fit the U-shaped cord opening  28  in an electrical box or the U-shaped cord opening  22  in its cover  24  (see  FIG. 8 ). Although the particular embodiment shown here depicts U-shaped cord openings, it should be understood that other shaped openings, such as rectangular or square, can easily be accommodated by varying the shape of the top periphery  40  of the removable plugs to match the shape of the openings in the cover or in the electrical box. With reference to  FIGS. 5 and 6 , removable plugs  20  and  56  further include a flat bottom end  90  to allow the bottom end to line up essentially even with the edge  92  (see  FIG. 8 ) of the cover  24  or electrical box having the openings  28  therein. 
   The removable plugs disclosed herein provide a method of closing an opening on an electrical box. With reference to  FIG. 5 , the method involves providing a removable plug  20  including a central body  34 , an inner side  36 , an outer side  38 , a top periphery  40 , an outer arm  42  extending from the top periphery  40  along the outer side  38 , an inner arm  44  extending from the top periphery  40  along the inner side  36 , and a channel  46  along the top periphery  40  defined by the inner arm  44  and the outer arm  42 . The removable plug  20  is used to close the cord opening  22  (see  FIG. 8 ) in a cover  24  or the cord opening  28  in an electrical box  53  (see  FIG. 11 ). The method includes inserting the removable plug  20  into the opening  22  until the top periphery  40  of the plug contacts the sidewall  70 . 
   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.