Abstract:
A cover assembly for a floor box including an access door for covering at least a portion of the floor box. The access door includes an opening for passage of at least one cord therethrough. The cover assembly further includes a cord door positioned to cover the opening in the access door. The cord door is removeably securable to the access door in at least two mounting orientations.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/690,368 filed on Jun. 14, 2005. 

   BACKGROUND OF THE INVENTION 
   This invention pertains to floor boxes which house power and communication wires for termination and, more particularly, to a cover assembly having a smaller cord door that can be re-positioned as needed. 
   It is well-known to run electrical wires and telecommunications wires underneath the surface of a floor. These cables and electrical systems may be placed under the floor surface so as to be more efficient in supplying power and data/telecommunication signals in commercial buildings. The electrical cables or wires beneath the floor may be accessed through a hole in the surface of the floor. In order to provide convenient access to the wires or cables as well as the termination devices which terminate the wires, a floor box is typically placed in the hole through the floor. 
   Floor boxes are typically made of metallic material so that they are resistant to the outside elements, such as moisture, and are also strong enough to maintain the structural integrity of the floor. The cover used on these floor boxes oftentimes varies depending on the type of flooring to be employed, i.e. wood, tile, exposed concrete, and the like. Such covers oftentimes incorporate a smaller cord door that is used after the building is completed in order to allow wires to extend from the floor box through the cord door and to the device being powered or communicated with. 
   However, during construction, the exact placement of such devices is not known. Thus, it is common to find the cord door in an inconvenient/improper orientation following the installation process. Also, once the building is completed, it is quite common for the building layout to change over time and thus these powered or communicated devices will be moved to yet another location. Thus, the cover on these floor boxes will need to be adjusted once again to take into account the new location of these devices. Further, it is common for the building layout to require a new or different type of cover to be employed, such as one requiring connection to a flexible conduit. Hence the floor box and/or its cover may need to be altered accordingly. 
   In the past, when such a situation was encountered, it became necessary for the entire cover of the embedded floor box to be separated from the box. The cover would then be rotated (if possible) so as to properly position the smaller cord door to open in the desired direction. This required the removal of the flooring material surrounding the floor box (and oftentimes beyond) so that the fasteners securing the cover to the box could be accessed. In some cases, concrete had to be removed if the pour extended over these fasteners. Also, removal and replacement of this flooring material is costly and hence, in many situations, the cost and effort of re-positioning the cover was not deemed worth the effort. 
   Also, even if worth the effort of re-positioning the cover, some boxes may not permit this because the cover may only be secured to the box in one orientation. Alternatively, the box may not be square and hence the cover may only be able to be rotated 180 degrees and not 90 degrees which may be the desired cord door opening direction. Furthermore, even if the box is of some other shape that can accommodate a rotatable cover, the fastener locations may not be in alignment so that even if the box can accommodate a re-positioned cover, the fasteners cannot. 
   Regardless of the need required of the floor box and its cover, the design must also be adequate enough to support the weight and loading that a typical floor box is subject to and the floor box assembly must still comply with all local and national codes and or specifications pertaining to floor boxes. 
   It is thus an object of this invention to provide a floor box cover that incorporates a smaller cord door therein. Another object of this invention is to provide a floor box that complies with all local and national codes and specifications. A further object of this invention is to provide a floor box with a cord door such that the cord door can be adjusted so as to open in the desired direction without having to re-position or re-orient the entire cover. Still another object of this invention is to provide a cord door that can be removed and re-positioned as needed and further that can be replaced with another different cover plate if the need to do so arises. These and other objects and advantages of this invention will become evident upon further review. 
   SUMMARY OF THE INVENTION 
   The present invention, which addresses the needs for the prior art, relates to a cover assembly for a floor box. The cover assembly includes an access door for covering at least a portion of the floor box. The access door includes an opening for passage of at least one cord therethrough. The cover assembly further includes a cord door positioned to cover the opening in the access door. The cord door is removeably securable to the access door in at least two mounting orientations. 
   Additionally, the cord door can be pivotally secured to said access door, as well as including a locking mechanism for securing the cord door in an open position. The locking mechanism can include a biasing element to resist pivoting the cord door when the cord door is in the open position. Also, the cover assembly can further include an cord door frame secured to the perimeter of the opening in the access door and supporting the cord door. This cord door frame can include a plurality of fastening openings that align with respective openings on the access door for securing the cord door frame in at least one of the mounting orientations. Alternatively, the cord door itself can include a plurality of fastening openings that align with respective openings on the access door for securing the cord door in at least one of the mounting orientations. Further still, the cover assembly can include a frame secured to at least a portion of the floor box, with the access door supported by this frame. The access door can be pivotally secured to the floor box. 
   The present invention further relates to that portion of a cover assembly for a floor box that includes a cord door positioned over at least a portion of the floor box. The cord door pivotally mounts to rotate between a closed position and a first open position. The cover assembly also includes a locking mechanism secured to the cord door. The locking mechanism selectively retains the cord door in a second open position. 
   Additionally, the locking mechanism can include a biasing element to resist pivoting of the cord door when the cord door is in the second open position. Also, the locking mechanism can include a button engaged with the biasing element. Movement of the button causes movement of the biasing element to counter the resistance of the biasing element to allow pivoting of the cord door. 
   These and other objectives, features, and advantages of this invention will become apparent from the following detailed description of illustrative embodiments thereof, which is to be read in connection with the accompanying drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view showing the door assembly of the present invention exploded away from a floor box and with both the cover and cover door in a fully closed position. 
       FIG. 2  is a view similar to  FIG. 1  with both the cover and cord door shown in an open position and with cords extending therefrom. 
       FIG. 3  is a perspective view of the cover assembly of the present invention shown with cords extending therefrom. 
       FIG. 4  is a side view of the cover assembly of  FIG. 3  without the cords. 
       FIG. 5  is a bottom view of the cord door of  FIG. 3  without the cords. 
       FIG. 6  is an exploded perspective view of the cord door components. 
       FIG. 7  is a bottom perspective view of the cord door of the present invention in an open position. 
       FIG. 8  is an exploded perspective view of the present invention showing the cord door component separate from the cover component. 
       FIG. 9  is an exploded perspective view of an alternate cord door of the present invention. 
       FIG. 10  is an exploded perspective view of another alternative cord door of the present invention. 
       FIG. 11  is an exploded perspective view of still another alternative cord door. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
   Referring initially to the drawings,  FIGS. 1 and 2  show a floor box assembly  10  including a floor box  12  and a cover  14 . Floor box  12  may be of standard or typical construction or floor box  12  may be constructed as shown in  FIGS. 1 and 2  which is described in more detail in co-pending patent application, entitled “Floor Box with Voltage Divider,” commonly assigned to Thomas &amp; Betts International, Inc., which is incorporated herein by reference. 
   As should be noted, floor box  12 , no matter what its construction, is designed to be mounted in a floor of a building so as to provide access to power or communication wires extending through duct or conduit or the like extending within the floor. Such wiring is, in the normal fashion, mounted to receptacles, fixtures, terminals, jacks or the like that are in turn supported via plates  18  within floor box  12 . 
   Cover  14  has a substantially planar surface or appearance  20  when in the fully closed position as shown in  FIG. 1 . Cover  14  is shown in an open position in  FIG. 2 . Cover  14  would preferably include an exterior flange  22  that is sized and configured to mate with floor box  12 , hence the shape of flange  22  is likely to vary depending on the floor box  12  used. Typically, one side region of flange  22  is configured with a hinge assembly  24  while another opposite side region of flange  22  is configured with an opening assembly  26 . Both hinge assembly  24  and opening assembly  26  can be of typical construction, such as a pin and socket arrangement for hinge assembly  24  and detents or recesses  28  for the opening assembly  26 . 
   Within flange  22  of cover  14  is access door  30 . This access door  30  pivots on hinge assembly  24  and it is opened via opening assembly  26 ,  28 . Hence, a user may operate access door  30  such as by placing a tool within detents or recesses  28  and prying upwardly. It may also be desirable for access door  30  to incorporate some type of retention mechanism  32 , such as a ball and spring assembly, so as to retain access door  30  in the closed position. 
   As shown in  FIG. 1 , when access door  30  is in the closed position, it is ideally flush with flange  22 . However, as shown in  FIG. 2 , when access door  30  is in the open position, access to the interior  34  of floor box  12  is provided. Thus, access door  30  enables a user to plug and un-plug a wire  38  from its associated terminal mounted in plates  18 . Also, depending on the configuration of floor box  12 , access door  30  may also enable a user to re-configure or re-wire the interior  34  of floor box  12  to add or subtract power or communication fixtures. However, such reconfiguration is preferably accomplished when floor box  12  is initially being constructed and wired. 
   Also shown in the drawings is cord door  40  that is located within the interior of frame  62  which is itself located within the interior of access door  30 . Cord door  40  may be centrally located therein or it may be positioned off center, depending on the style preferred. In any event, access door  30  is configured with an opening  43  therein that accommodates cord door  40 . Hence, cord door  40  provides separate and independent access to the interior  34  of floor box  12 . 
   Cord door  40 , when pivoted open as shown in  FIGS. 2 and 3 , permits wires  38  to extend from or into floor box  12 . Locking mechanism  44  is employed to keep cord door  40  from collapsing upon or crimping wires  38  when they pass through opening  43 . Locking mechanism  44  preferably incorporates a brace  46 , as shown in  FIG. 6 , having detents or notches  48  at its distal end regions that fit around the perimeter of opening  43 . Alternatively, the perimeter of opening  43  may include latches  50  that mate with notches  48  when cord door  40  is opened. 
   It should be understood that different configurations are equally likely for locking mechanism  44 . As shown herein, brace  46  is biased by spring  52  to always pivot outwardly or to encourage notches  48  to enter into the engaged position with the perimeter of opening  43  or with latches  50 . This can only occur when cord door  40  is opened. Once engaged, however, brace  46  can be disengaged by overcoming the bias of spring  52 . Such disengagement is achieved by pivoting the button region  54  of brace  46  against the bias of spring  52 . A tool can be inserted to overcome the bias of spring  52  or a user can reach one or more fingers underneath cord door  40  and push against spring  52 . As shown in this embodiment, brace  46  pivots on hinge  56  so it is readily apparent how brace  46  can become automatically engaged and how it can be manually disengaged. 
   Now, such disengagement of cord door  40  may be desired to either cause it to close and be generally flush with access door  30  or it may be desirable to disengage cord door  40  completely so that it can be more fully opened as shown in  FIG. 2 . This latter position is useful when passing wires  38  through opening  42  in access door  30 . The normal operating or locked open position of cord door  40  however is shown in  FIG. 3 , wherein brace  46  is employed to keep cord door  40  partially open and locked in place thereby permitting wires  38  to pass. 
   Referring once again to  FIG. 6 , preferably cord door  40  pivots about hinge pin  60  that is retained within frame  62  via cover plate  64 . Cover plate  64  is secured to frame  62  via screws  66  and cover plate  64  contains a recessed area running along hinge pin  60 . In fact, if desired, a central extent of hinge pin  60  may engage a central extent of the recessed area  65  of the cover plate  64  so that cord door  40  may be moved just enough for it to clear catch  68  on an opposite side thereof. By clearing catch  68 , cord door  40  may be pivoted open. Such upward movement of cord door  40  will continue until locking mechanism  44 , and particularly brace  46 , impedes further rotation. Once engaged or locked, however, brace  46  will prevent cord door  40  from closing so that wires  38  can pass through opening  43  as needed without being pinched. 
   As shown in  FIG. 8 , frame  62  is configured with corner fastening holes  70 . These holes  70  align with similar openings in access door  30  such that if cord door  40  and particularly frame  62  needs to be rotated, it can be without the need to also rotate access door  30  or cover  14 . To accomplish such rotation of frame  62 , the user need only remove the fasteners  71  from holes  70 , rotate both cord door  40  and frame  62 , and then re-insert the fasteners  71  into holes  70 . This operation is shown in  FIG. 8 . Thus, regardless of the orientation of access door  30 , cord door  40  can be adjusted so that it opens in the right direction. This will prevent wires  38  from being bent or kinked, it will also prevent these wires from extending up over cord door  40  thereby possibly creating a tripping hazard. 
   For sealing purposes, as shown in  FIGS. 8 and 9 , a gasket  58  that seals out moisture or ‘scrub water’ can be incorporated between access door  30  and cord door  40 . In this way, little to no water migration from outside floor box  12  will makes its way to the interior region  34 . 
     FIG. 9  shows a variation in that cord door  40  and frame  62  are replaced with a furniture feed plate  72  that can accommodate conduit and fittings  74 . Such an arrangement may be needed if the building plans call for a furniture feed plate  72  rather than a cord door  40  for use with conduit or flexible cabling. 
   Hence, whether a frame  62  is employed or whether furniture feed plate  72  is employed, it is a simple matter to now re-position such coverings in one of four different directions as may be needed. Of course, altering the shape of frame  62  or feed plate  72  (i.e. triangle, circle, hexagon, etc.) may mean that there are more or fewer such orientations. As shown in  FIGS. 10 and 11 , a circular version of frame  62  or feed plate  72  mates with a corresponding recess in access door  30 . The embodiment shown in  FIGS. 10 and 11  allow re-positioning at 45 degree intervals, or eight orientations. Thus, in the preferred embodiments prior to separation, cord door  40  and/or feed plate  72  would have a first orientation with respect to access door  30 . However, upon removal and re-attachment of these covers  62 ,  72  facing in a different direction, there would now be a second orientation or opening direction of access door  30 . It should be further understood that the shape of the cord door  40  and the associated plate  62 , gasket  58  or opening  42  could additionally have their shapes altered. For example, the embodiment shown in  FIG. 10  could maintain a relatively square shape for cord door  40 , while providing a circular opening  42 , as shown in  FIG. 11 . 
   While select preferred embodiments of this invention have been illustrated, many modifications may occur to those skilled in the art and therefore it is to be understood that these modifications are incorporated within these embodiments as fully as if they were fully illustrated and described herein.