Abstract:
A simple, two piece slide-on electrical device cover assembly can be adapted for either horizontal or vertical mounting on the same base. Removable rail members that are coupled to the cover through thinned or partially broken or grooved sections enable the rail members to be snapped off under reasonable force. A manufacturer can package and ship a product in a generic configuration and allow an installer to select whether a horizontal or vertical configuration is desired, and quickly adapt and assembly the product for either configuration.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application is a continuation of the earlier patent application entitled, “Horizontal and Vertical Slide Mountable Electrical Device Cover,” Ser. No. 11/380,611, filed Apr. 27, 2006, which application claims priority to United States provisional patent application entitled “Horizontal and Vertical Slide-Mountable Electrical Device Cover,” Ser. No. 60/676,239, filed Apr. 28, 2005, the disclosures of which are all hereby incorporated herein by reference. 

   BACKGROUND 
   1. Technical Field 
   Aspects of this document relate generally to slide-mountable small electrical device covers, such as for use with electrical outlets and switches. More specific implementations involve flat or while-in-use covers with removable rail members or angled rail members for configuration as either horizontal or vertical use orientation covers using the same assembly. 
   2. Background Art 
   Horizontal and vertical mountable electrical device cover assemblies using hinges are known in the art. Some examples of these assemblies are shown and described in U.S. Pat. Nos. 5,763,831 to Shotey et al. (issued Jun. 9, 1998) titled “Universal Cover Plate, Cover Plate Assembly, and Related Methods,” 6,133,531 to Hayduke et al. (issued Oct. 17, 2000) titled “Weatherproof Outlet Cover,” 6,441,307 to Shotey et al. (issued Aug. 27, 2002) titled “Universal Cover Plate,” 6,476,321 to Shotey et al. (issued Nov. 5, 2002) titled “Horizontal and Vertical Mountable Weatherproof Cover Plate,” and 6,979,777 to Marcou et al. (issued Dec. 27, 2005) titled “Weatherproof Electrical Enclosure Having an Adjustable-Position Cover,” and U.S. patent application Ser. No. 11/056,835 to Shotey et al. (filed Feb. 11, 2005) titled “Weatherproof Receptacle Cover with Adapter Plate,” the disclosures of each of which are hereby incorporated herein by reference for their general relevance to the formation and manufacture of cover assemblies. Such assemblies are conventionally made of plastic or metal, may be converted for use with removable portions to adapt the electrical device openings of the base for use with many different types of electrical devices using the same components, and may incorporate spring biased hinge members to enable use in both horizontal and vertical orientations using the same assemblies. Each of these assemblies, however, uses hinge members on the respective cover and base to allow for hinged coupling of the cover to the base. 
   Other references disclose single orientation sliding covers. For situations where a sliding cover is desirable, the ability to have a single assembly that could be adapted to horizontal and vertical use would be advantageous and reduce the inventory required by stores and installers. 
   SUMMARY 
   In one aspect, this document features a slide-on cover assembly for an electrical device that allows the device to be mounted horizontally or vertically with the same assembly. Various implementations include implementations dedicated for either horizontal or vertical orientation use, implementations having removable rail member portions that can be configured by an installer for either horizontal or vertical orientation use, flat cover implementations, while-in-use (or bubble) cover implementations, implementations with cord releases, and implementations with sliding rail members angled diagonally across the assembly. With only a two-part cover assembly, a horizontal and vertical slide-mountable may be formed from plastic or metal using conventional plastic and metal fabrication methods. 
   Specifically, each of the cover assemblies includes a cover and a base. It should be clear from the disclosure herein that although the specific implementations show the base configured for use with a duplex electrical outlet, it may alternatively be configured, directly or through the use of removable tabs or adapter plates, for use with a different electrical device such as, and without limitation, an electrical switch, a GFCI outlet, a round outlet, an electrical cable, multiple electrical devices, and the like. Covers and bases configured according to the implementations disclosed may be formed of metal or non-metal, such as plastic or resin depending upon the use for the particular cover assembly. 
   For particular implementations, a base includes two pairs of parallel rail members on opposing sides of a generally rectangular base and cover for the assembly so that each side of the assembly includes a rail member. Rail members along two adjacent sides of the assembly are made removable through grooves such that removal of a rail member along one side of the cover or base adapts the assembly for horizontal use orientation and removal of the rail member along another side adapts the assembly for vertical use orientation. Slidable engagement of the remaining cover and base rail members couples the cover to the base in the desired orientation. The rail members may be parallel to the plane of the base, or angled in relation to the plane of the base. 
   For other particular implementations, a horizontal and vertical mountable electrical device cover assembly includes a base and a cover with an opposing pair of parallel rail members extending across the assembly (across each of the base and the cover) at an angle of between about 40 and about 50 degrees relative to its mounting orientation. By engaging the rail members of the base with the rail members of the cover, the cover slides diagonally across the surface of the base to open and close the assembly in either the horizontal or vertical use orientation. A spring-biased bubble cover implementation provides additional assurance that the lid will close. 
   The foregoing and other aspects, features, and advantages will be apparent to those artisans of ordinary skill in the art from the DESCRIPTION and DRAWINGS, and from the CLAIMS. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention will hereinafter be described in conjunction with the appended drawings, where like designations denote like elements, and: 
       FIG. 1  is a perspective view of an electrical device cover assembly including a base and a cover; 
       FIG. 2  is perspective view of a front side of an electrical device cover; 
       FIG. 3  is a perspective view of an electrical device cover assembly in an open position configured for horizontal orientation use; 
       FIG. 4  is a perspective view of a back side of an electrical device cover assembly in a closed position configured for horizontal orientation use; 
       FIG. 5  is a perspective view of a front side of an electrical device cover assembly in a closed position configured for horizontal orientation use; 
       FIG. 6  is a perspective view of an electrical device cover assembly in an open position configured for vertical orientation use; 
       FIG. 7  is a perspective view of an electrical device cover assembly in a closed position configured for vertical orientation use; 
       FIG. 8  is a perspective view of a while-in-use electrical device cover assembly in a closed position configured for horizontal orientation use; 
       FIG. 9  is a perspective view of a while-in-use electrical device cover assembly in an open position configured for horizontal orientation use; 
       FIG. 10  is a perspective view of a second implementation of a while-in-use electrical device cover assembly in a closed position configured for horizontal orientation use; 
       FIG. 11  is a perspective view of a second implementation of a while-in-use electrical device cover assembly in an open position configured for horizontal orientation use; 
       FIG. 12  is perspective view of an electrical device cover with angled rail members; 
       FIG. 13  is perspective view of the electrical device cover of  FIG. 12  with angled rail members removed for vertical orientation use; 
       FIG. 14  is a perspective view of an electrical device cover assembly base with angled rails; 
       FIG. 15  is a side view of an electrical device cover assembly including the cover of  FIG. 13  and the base of  FIG. 14  assembled in an open position for vertical orientation use; 
       FIG. 16  is a rear perspective view of an electrical device cover assembly including the cover of  FIG. 13  and the base of  FIG. 14  assembled in a closed position for vertical orientation use; 
       FIG. 17  is a front perspective view of an electrical device cover assembly including the cover of  FIG. 13  and the base of  FIG. 14  assembled in a closed position for vertical orientation use; 
       FIG. 18  is perspective view of the electrical device cover of  FIG. 12  with angled rail members removed for horizontal orientation use; 
       FIG. 19  is a front perspective view of an electrical device cover assembly including the cover of  FIG. 18  and the base of  FIG. 14  assembled in an open position for horizontal orientation use; 
       FIG. 20  is a rear perspective view of an electrical device cover assembly including the cover of  FIG. 18  and the base of  FIG. 14  assembled in a closed position for horizontal orientation use; 
       FIG. 21  is a front perspective view of the electrical device cover assembly of  FIG. 20 ; 
       FIGS. 22   a  and  22   b  are, respectively, front and rear perspective views of an electrical device cover assembly base with angled rail members; 
       FIGS. 23   a  and  23   b  are, respectively, front and rear perspective views of an electrical device cover assembly cover with angled rail members; 
       FIGS. 24   a  and  24   b  are, respectively, plan and perspective views of the cover assembly illustrated in  FIGS. 22   a  and  23   a  in a vertical use orientation; 
       FIGS. 25   a  and  25   b  are, respectively, plan and perspective views of the cover assembly illustrated in  FIGS. 22   a  and  23   a  in a horizontal use orientation; and 
       FIGS. 26   a  and  26   b  are perspective views of an alternate implementation of an electrical device cover assembly having removable rail members. 
   

   DESCRIPTION 
   This disclosure, its aspects and implementations are not limited to the specific components or assembly procedures disclosed herein. Many additional components and assembly procedures known in the art consistent with the intended cover assembly and/or assembly procedures for a cover assembly will become apparent for use with implementations of horizontal and vertical electrical device cover assemblies from this disclosure. Accordingly, for example, although particular hardware is disclosed, such hardware and implementing components may comprise any shape, size, style, type, model, version, measurement, concentration, material, quantity, and/or the like as is known in the art for such hardware and implementing components, consistent with the intended operation of a horizontal and vertical electrical device cover assembly. 
     FIG. 1  is a perspective view of an electrical device cover assembly  2  including a base  4  and a cover  6 . The base of this particular implementation includes, in the form of ridges, rail members  8  extending along two of its sides, and rail members  10  extending along its other two sides. These rail members  8  and  10  act in concert with rail members  12 - 15  of the cover  6  to cause the cover  6  to slide in relation to the base  4  in a direction substantially planar to both the plane of the cover  6  and the front of the base  4 . 
   The base  4  includes mounting screw openings  16  and  18  and electrical device openings  20 . As explained above, and examples of which were incorporated by reference, the electrical device openings may be configured in many different configurations including, but not limited to, differently shaped openings, openings with removable tabs for adapting the openings to a variety of electrical device shapes and sizes, and/or adapter plates. 
   The cover  6  of this implementation (also illustrated in  FIG. 2 ) includes a generally planar surface  22  and four walls  24 - 27  extending outwardly therefrom. At least two of the walls on adjacent sides, in this implementation walls  24  and  26 , are configured having grooves  28  and  30 , and  32  and  34 . The grooves  28 ,  30 ,  32  and  34  enable the walls  24  or  26  to be selectively removed from the cover  6  through prying. Groves used for attaching removable components, such as removable tabs for varied electrical device styles, are known in the art. It is contemplated that the groove will have a depth of 40%-60% of the total wall depth, though greater and lesser depths are also contemplated up to 80% of the wall depth with greater and lesser ease in breaking the walls  24  or  26  from the cover  6 . Through removal of the walls  24  or  26 , the corresponding rail members  12  or  14  are also removed. 
   In particular implementations, it is contemplated that rather than a particular wall being removed, the rail members themselves may be removed through grooved attachments. In other particular implementations, the walls  24  or  26  may be selectively coupled to the cover  6  (or the base  4  if the implementation involves the removable rail members on the base  4 ) for either horizontal or vertical orientation use. In such an implementation, two of the cover walls  25  and  27  could be permanently attached to the cover  6  and an installer could select whether to attach wall  24  or  26  through a connector, such as a pronged connector into an opening in the cover surface  22 . Although the rail members of the various implementations may be implemented as a particular style of rail, for example a ridge rail members and slot rail members as in  FIG. 1 , other rail member designs are also contemplated and equivalent to the presently disclosed designs and may be equivalently interchanged for the designs shown and described herein. Additional optional cover slide stops may be included to restrict movement of the cover beyond a certain point in the vertical and/or the horizontal direction. Any of the methods and designs disclosed herein may be readily implemented in the various implementations illustrated throughout this disclosure. 
     FIGS. 3 ,  4  and  5  illustrate an implementation of an electrical device cover assembly  2  illustrating the base  4  and cover  6  of  FIG. 1  where the base  4  and cover  6  have been elongated slightly. Other than the slightly longer base, and cover to match, the design implemented is the same as that in  FIG. 1 . For the illustration in  FIG. 3 , the rail members  14  from  FIG. 1  have been removed through removal of wall  26  from  FIG. 1  by breaking the wall  26  from the cover  6  along grooves  32  and  34  of  FIG. 1 . With the wall removed, and the remaining walls  24  and  25  with their respective remaining rail members  12  and  13  acting as a rail system in conjunction with base rail members  8 , the cover can now slidably engage the base for use in the horizontal orientation. In other words, when the rail members  14  are removed, the cover  6  may slide vertically on the base  4  when the base  4  is mounted with its electrical device openings  20  oriented horizontally. Vertical use orientation would involve the base  4  being mounted with the electrical device openings  20  oriented vertically. Horizontal and vertical orientation terminology for electrical device covers is conventional and well known in the industry. 
   The manufacture of metal and plastic components that slide in relation to each other is known in the art. For the purposes of the present disclosure, particular implementations are required by the electrical code to include a cover that closes against the base on its own. In such cases, less friction is desirable between the cover rail members and the base rail members so that the cover can close on its own under the force of gravity. Those of ordinary skill in the art will readily be able to design rail member components that cooperate to this end without excessive experimentation using general knowledge of components having sliding relationships. 
     FIGS. 6 and 7  illustrate an implementation of an electrical device cover assembly  2 , like the one in  FIG. 3 , illustrating the base  4  and cover  6  of  FIG. 1  where the base  4  and cover  6  have been elongated slightly, but with the rail members  12  from  FIG. 1  removed through removal of wall  24  from  FIG. 1 . Wall  24  was removed from  FIG. 1  by breaking the wall  24  from the cover  6  along grooves  28  and  30  of  FIG. 1 . With the wall  24  removed, and the remaining walls  26  and  27  with their respective remaining rail members  14  and  15  acting as a rail system in conjunction with base rail members  10 , the cover can now slidably engage the base for use in the vertical orientation. 
   It should be clear from the present disclosure that although the removable rail members are implemented on the cover walls, they may just as easily be interchanged with the base so that the removable portions are associated with the base rather than the cover, or one of the removable portions could be implemented on the base and another portion could be implemented on the cover. From a review of the various implementations, configurations including these alternatives will become readily apparent. 
     FIGS. 8 and 9  illustrate an implementation of a vertical and horizontal slide-mountable cover assembly including a while-in-use or “bubble” cover  40 . The base  4  of this implementation is the same as the base  4  used in  FIG. 1 . The rail system of  FIGS. 8 and 9  works the same as the rail system of  FIG. 1 .  FIGS. 8 and 9  include removable rail members  44  and  46 , removable along appropriately configured grooves. Selective removal of rail member  44  adapts the assembly for use in the vertical orientation and removal of rail member  46  adapts the assembly for use in the horizontal orientation. Distinct from the implementation of  FIG. 1 , the bubble cover  40  of  FIGS. 8 and 9  includes removable cord escape tab  48  for horizontal orientation and another cord escape tab (not shown) for vertical orientation. The tab corresponding to the selected orientation would be removed and the cord could escape from the cover assembly when in a closed position. 
     FIGS. 10 and 11  illustrate another implementation using a bubble cover. This implementation includes a cord escape  50  in the base  52 , along a first side, and a cord escape  54  in the cover  56 . Cord escapes  58  along a second side of the cover  56 , and corresponding cord escapes  60  along the second side of the base  52  are included in this design. Like the design of each of the implementations discussed thus far, the rail members may be removed by selective removal of the corresponding wall for use in either a vertical or a horizontal orientation. 
   As mentioned briefly elsewhere in this disclosure, the rail members do not need to extend parallel to the plane of the top of the base.  FIGS. 12-21  illustrate an implementation of a horizontal and vertical slide-mountable electrical device cover assembly where the rail members are at an angle with respect to the base and cover so that the movement of the cover is from an open position farther away from the base, to a closed position adjacent the base. 
     FIG. 12  is a perspective view of a cover  70  having a first pair of opposing rail members  72  and  73 , and a second pair of opposing rail members  74  and  75 . For this implementation, all four of the rail members  72 ,  73 ,  74  and  75  are removable from the base through grooves similar to the implementation shown in  FIG. 1 . For the rail members of this implementation, however, the rail members  72 ,  73 ,  74  and  75  include a track at an angle to the plane parallel to the top of the cover and to the plane parallel to the bottom of the base. Although the implementations shown in  FIGS. 12-21  include a constant angle (i.e. the rail member track is a straight line), an arcuate angle (track that travels in a changing angle to form an arc) or other angle is also contemplated within the meaning of “angle.”  FIG. 13  illustrates the cover of  FIG. 12  with opposing rail member pair  74  and  75  removed by breaking the rail members  74  and  75  from the cover along grooved connectors  77 , leaving opposing rail member pair  72  and  73 , for configuration of the cover  70  for use in a vertical orientation. 
     FIG. 14  illustrates a base  76  having angled rail member pair  78  extending along opposing long sides of the rectangular base  76  and angled rail member pair  79  extending along opposing short sides of the rectangular base  76 . Cord escape tabs  80  and  81  are included near a bottom corner of the base  76  so that the base  76  may be further adapted for use in either its vertical or horizontal orientation and still include an appropriately configured cord escape opening. 
     FIGS. 15 ,  16  and  17  illustrate the cover  70  and remaining rail pair  72  and  73  of  FIG. 13 , configured for use in the vertical orientation, slidably mounted to rail members  78  of the base  76  of  FIG. 14 . By including the rail members of both the cover and the base at matching angles relative to the plane defined by the back surface of the base  76 , the cover  70  closes on the base  76  while remaining consistently parallel to the base. By slidably moving the cover  70  vertically away from the base  76 , the cover assembly is able to be opened to access the electrical device within the assembly. By slidably moving the cover  70  vertically toward the base  76  and back toward the base  76  at an angle, the cover  70  seats against the base at the end of the sliding movement rather than sliding along the base  76  surface. In particular implementations of an electrical device cover assembly, a gasket is included around the lip of the base to enhance the weatherproofing characteristics of the assembly when it is in its closed position. By causing the cover  70  to slide toward the base  76  at an angle, it is possible to use a gasket in a slidably mounted cover assembly without prematurely wearing out the gasket from constant vertical wear against it. 
     FIG. 18  illustrates the cover  70  of  FIG. 12  with opposing rail member pair  72  and  73  removed by breaking the rail members  72  and  73  from the cover along grooved connectors  71 , leaving opposing rail member pair  74  and  75 , for configuration of the cover  70  for use in a horizontal orientation.  FIGS. 19 ,  20  and  21  illustrate the cover  70  and remaining rail pair  74  and  75  of  FIG. 13 , configured for use in the horizontal orientation, slidably mounted to rail members  79  of the base  76  of  FIG. 14 . 
     FIGS. 22   a  and  22   b  illustrate front and back perspective views of a base  84  of an electrical device cover assembly having angled rail members  86  extending across the face of the base  84 . Cord escape tab  88  (or “knockout”) is included between the rails on a wall of the base  84 . The rail members  86  of this implementation are substantially parallel to the plane defined by the back surface of the base  84 . This is also parallel to the plane of the support structure to which the base  84  will be mounted for use of the assembly. However, as shown in the implementation shown in  FIGS. 12-21 , there is no requirement that the rail members  86  be parallel to the base plane, and there are some advantages for particular implementations in having the rail members extend at an angle down toward the base plane because the cover may be able to seat more tightly against the base (wedged against it) and a gasket seal for the sliding cover may now be practical. Although protruding rail members  86  are shown on the base and recessed rail members  92  are shown on the cover ( FIGS. 23   a  and  23   b ), these two structure types may equivalently be switched or interchanged so long as the corresponding rail member parts can slidably engage with each other. 
     FIGS. 23   a  and  23   b  illustrate, respectively, front and back views of a cover  90  to match the base  84  shown in  FIGS. 22   a  and  22   b . Rail members  92  slidably receive the corresponding rail members  86  on the base  84 . Ridge  91  is included along the trailing two sides of the cover  90  to act as a stop and provide additional weatherproofing once the cover  90  is seated against the base  84 . The angle of the cover  90  rail members  92  matches the angle of the base  84  rail members  86 . For implementations where the electrical device cover assembly is desirable for both horizontal and vertical use orientations, the angle of the rails is between about 40 degrees and about 50 degrees relative to the parallel rectangular sides of the base, which are parallel to the horizontal and vertical mounting orientations. By selecting an angle between about 40 degrees and about 50 degrees, and preferably about 45 degrees, the cover  90  slidably mounted on the base  84  will be most likely to be able to slide closed through the force of gravity on the weight of the cover  84  in both the vertical and horizontal use orientations. 
     FIGS. 24   a  and  24   b  and  26  illustrate, respectively, a plan view and a perspective front view of the electrical device cover assembly shown in  FIGS. 22 and 23  with the cover  90  and its rail members  92  slidably mounted to the base  84  and its rail members  86 , and oriented for use in the vertical orientation. The cord escape tab  88 , attached to the base  84  by a grooved connector, is included on the deep base. Alternatively, the cord escape tab  88  could be included on the cover  90  along the corresponding side of the cover  90 . In such implementations, the base may be made shallower. 
   For each of the implementations shown herein, cord escape tabs may be included within the base if a deeper base is used. For bubble cover implementations, one or more cord escape tabs may be included in the cover if the base is not deep enough. Alternatively, as shown in  FIGS. 10 and 11 , cord escapes, or cord escapes covered by cord escape tabs, may be included in both the cover and the base. As another less preferred option, it is also contemplated that a spring-biased door be included in the side of a bubble cover implementation to allow for a plug cap or switch extending beyond the plane of the base and pass through the side of the cover when the door opens or closes without leaving a constant opening in the side like that caused by a knockout tab. This design, however, requires additional pieces and production costs and is, therefore, not the most preferred option. 
     FIGS. 25   a  and  25   b  illustrate, respectively, a plan view and a perspective front view of the electrical device cover assembly shown in  FIGS. 22 and 23  with the cover  90  and its rail members  92  slidably mounted to the base  84  and its rail members  86 , and oriented for use in the horizontal orientation. 
   An electrical device cover assembly, identical to that shown and described with reference to  FIGS. 22-25 , may be adapted with a spring bias to cause the cover to be biased closed against the base. Sliding rail members of the base and sliding rail members of the cover would guide the cover closed against the base under the bias of spring members coupled to the respective cover and base through spring pins. Although with the angled rail members the spring bias is not required in most cases, having a spring bias may assist in holding the cover more tightly against the base, and to close more quickly against the base than without the spring members. 
     FIGS. 26   a  and  26   b  illustrate an alternate implementation for establishing removable rail members  113  and  122  by removing the wall  112  or  116  to which they are attached from its position to a different position. The electrical device cover assembly of  FIGS. 26   a  and  26   b  each include a base  102 , of similar construction to that shown in  FIG. 1 , and a cover  104 . Although two of the walls  112  and  116  of the cover  104  include removable rail members, the walls  112  and  116  remain coupled to the cover  104 . Walls  112  and  116  are coupled, respectively, to the cover  104  along their top edges through a “living hinge” material  111  and  118 , such as a polypropylene, rubber, or a thin plastic material, that allows the walls  112  and  116  to flex once initially broken free. The sides of the walls  112  and  116  of this implementation are initially attached by grooved connectors to the adjacent wall sides, though other reattachable implementations are also contemplated. 
   Once an installer selects an intended use orientation, the installer simply snaps off the sides of the appropriate wall  112  or  116  to disconnect it from adjacent walls, and bends the respective living hinge  111  or  118  until the selected wall  112  or  116 , and its corresponding receiver  114  or  120 , couples with the corresponding pin  108  or  110  to hold the wall out of the way. Accordingly, the rail members  113  or  122  are removed from their interference with the base  102  as it slides into the remaining rail members for either the vertical ( FIG. 26   a ) or horizontal ( FIG. 26   b ) use orientation. 
   It will be understood that implementations are not limited to the specific components disclosed herein, as virtually any components consistent with the intended operation of a method and/or system implementation for an electrical outlet cover may be utilized. Accordingly, for example, although particular shapes and sizes of electrical outlet cover assembly components may be disclosed, such components may comprise any shape, size, style, type, model, version, class, grade, measurement, concentration, material, weight, quantity, and/or the like consistent with the intended operation of a method and/or system implementation for an electrical outlet cover may be used. 
   In places where the description above refers to particular implementations of electrical device cover assemblies, it should be readily apparent that a number of modifications may be made without departing from the spirit thereof and that these implementations may be applied to other cover assembly types. The accompanying claims are intended to cover such modifications as would fall within the true spirit and scope of the disclosure set forth in this document. The presently disclosed implementations are, therefore, to be considered in all respects as illustrative and not restrictive, the scope of the disclosure being indicated by the appended claims rather than the foregoing description. All changes that come within the meaning of and range of equivalency of the claims are intended to be embraced therein.