Abstract:
An outlet cover assembly includes a base member configured to be mounted to a surface and a cover member pivotally connected to the base member via a pair of tabs with openings configured to engage a complementary pair of pins on the base member. The cover member and base member are configured to facilitate attachment of the cover member to the base member without substantial deformation of the pair of tabs when an angle formed between a major axis of the cover member and a major axis of the base member is greater than about 90 degrees. The cover member is secured to the base member when the angle formed between the cover member and base member is less than 90 degrees.

Description:
FIELD 
       [0001]    This application relates to outlet covers. Specifically, this application relates to a weatherproof outlet cover assembly with a user attachable cover member. 
       BACKGROUND 
       [0002]    An outlet cover assembly is a housing that enclose a wiring devices, such as AC voltage terminals, switches, etc. The outlet cover assembly helps protect against short circuits, electrical shock, and/or unwanted use of the wiring device. The outlet cover assembly usually includes a base member that mounts to a surface and a cover member. The base member defines one or more center openings through which the device is accessed and fastener openings through which fasteners are inserted and threaded to secure the base member to a surface. 
         [0003]    The cover member is configured to be opened to facilitate access to the device, or closed to prevent access to the device and protect the device from the elements. Typical cover members are fixed to the base in the factory. 
         [0004]    To mount the outlet cover assembly, an installer positions the assembly over a pre-installed electrical terminal, holds the cover member in the open position, inserts fasteners through the fastener openings, and then tightens the fasteners. However, holding the cover member while fastening can tend to be a cumbersome process. The process is exacerbated when the wiring device is close to the ground as the cover member tends to block the view of the inside of the outlet cover assembly, making it difficult to thread the fasteners. 
         [0005]    Another problem with existing outlet covers assemblies relates to extra-duty requirement UL 514D in the National Electric Code (NEC) that requires cover members of outlet cover assemblies to withstand a force of 40 pounds without breaking off. Some hinges used on outlet cover assemblies may tend to permanently deform or break under such a force. 
       SUMMARY 
       [0006]    In one aspect, an outlet cover assembly includes a base member configured to be mounted to a surface and a cover member pivotally connected to the base member via a pair of tabs with openings configured to engage a complementary pair of pins on the base member. The cover member and the base member are configured to facilitate attachment of the cover member to the base member without substantial deformation of the pair of tabs when an angle formed between a major axis of the cover member and a major axis of the base member is greater than about 90 degrees. The cover member is secured to the base member when the angle formed between the cover member and the base member is less than 90 degrees. 
         [0007]    In a second aspect, an outlet cover assembly includes a base member and a cover member. The base member includes a pair of opposing sidewalls, top and bottom opposing sidewalls extending therebetween, and a rear wall. First and second pins extend from respective outside surfaces of the pair of sidewalls. The cover member is configured to be attached to the base member. The cover member includes first and second tabs positioned at a top end of the cover member that extend, respectively, from opposing edges of the cover member. Each tab defines an opening configured to slide over and to engage one of the first and second pins of the base member. A thickness of the cover member is configured so that during attachment of the cover member to the base member, the second tab flexes by an amount less than about 0.05 inches, as measured by a change in distance between the first and second tabs. 
         [0008]    Yet another aspect is to provide a method of assembling an outlet cover assembly that includes providing a base member. The base member includes a pair of opposing sidewalls, top and bottom opposing sidewalls extending therebetween, and a rear wall. First and second pins extend from respective outside surfaces of the pair of sidewalls. A cover member is also provided. The cover member includes first and second tabs positioned at a top end of the cover member that extend, respectively, from opposing edges of the cover member. Each tab defines an opening configured to slide over and to engage one of the first and second pins of the base member. The cover member is rotated in a first direction relative to the base member to facilitate sliding of the first pad over the first pin to secure the first pad to the first pin. The cover is then rotated in an opposite direction while the first pad is secured to the first pin to secure the second pad to the second pin. While securing the second pad to the second pin, the second tab flexes by an amount less than about 0.05 inches, as measured by a change in distance between the first and second tabs. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    The accompanying drawings are included to provide a further understanding of the claims and are incorporated in and constitute a part of this specification. 
           [0010]      FIGS. 1A and 1B  are front and back perspective views, respectively, of an exemplary outlet cover assembly in a closed configuration; 
           [0011]      FIGS. 2A and 2B  are front and back perspective views, respectively, of the outlet cover assembly in an open configuration; 
           [0012]      FIG. 3  illustrates the outlet cover assembly fixed to a surface; 
           [0013]      FIG. 4  illustrates a pin of a base member of the outlet cover assembly; 
           [0014]      FIG. 5  illustrates a tab of a cover member of the outlet cover assembly; 
           [0015]      FIG. 6  is a top view of the outlet cover assembly; 
           [0016]      FIG. 7  illustrates a space between the tab of the cover member and the base member; and 
           [0017]      FIGS. 8A and 8B  illustrate attachment of the cover member to the base member. 
       
    
    
     DETAILED DESCRIPTION 
       [0018]    Embodiments below describe an outlet cover assembly with a cover member pivotally attached to a base member. The base member is configured to be mounted over a wiring device and secured to a surface. The cover member rotates between open and closed positions. In the open position, the cover member is attachable to the base member. In the closed position, the cover member is secured to the base member. 
         [0019]      FIGS. 1A and 1B  are front and back perspective views, respectively, of an exemplary outlet cover assembly  100  in a close configuration. The outlet cover assembly  100  includes a base member  105  and a cover member  110 . The cover member  110  is configured to pivotally rotate to an open configuration, as illustrated in  FIGS. 2A and 2B . The base member  105  and cover member  110  may be formed of a rigid material, such as aluminum or steel. The gauge/thickness of the material may be about 0.10 inch. In some implementations, the base member  105  and cover member  110  may be formed from different materials and/or have different gauges/thicknesses. 
         [0020]    The base member  105  is a generally open box-shaped structure that includes a pair of opposing sidewalls ( 120   a,    120   b ). Top and bottom ( 130   a ,  130   b ) opposing sidewalls extend between the top edges and bottom edges, respectively, of the sidewalls ( 120   a , 120   b ). A rear wall  125  extends between the edges of the respective sidewalls ( 120   a,    120   b,    130   a,    130   b ). The rear wall  125  may define an opening through which a wiring device may be accessed. While a single rectangular opening is shown, it is understood that the number opening and/or shape may be different depending on the type of outlet terminal being covered. 
         [0021]    First and second pins ( 115 ,  117 ) extend from outside surfaces of the pair of sidewalls ( 120   a,    120   b ), respectively. In some implementations the first and second pins ( 115 ,  117 ) are integrally formed with the base member  105  and have a generally cylindrical shape with a diameter D 1  of about 0.5 inches. The position of the longitudinal centers of the pins ( 115 ,  117 ) may be offset from the top sidewall  130   a  and rear wall  125  by about 1 inch and 0.6 inches, respectively. In some implementations, the pins ( 115 ,  117 ) are centered between front and back edges of the respective sidewalls ( 120   a,    120   b ). 
         [0022]    The diameter of the pins ( 115 ,  117 ) and relative positioning of the pins ( 115 ,  117 ) along the sidewalls allows the pins ( 115 ,  117 ) to withstand the forces associated with the extra-duty requirement, described earlier. For example, as illustrated in  FIG. 3 , when mounted to a surface  305 , the pins ( 115 ,  117 ) are configured to stay intact when the cover member  110  is pulled in an upward direction with a force F of up to about 40 pounds. Smaller diameter pins may shear under such a force. And positioning of the pins ( 115 ,  117 ) closer to the edges of the sidewalls ( 120   a,    120   b ) may cause the sidewalls ( 120   a,    120   b ) to crack under such a force. 
         [0023]    In addition, in the open configuration, the top edge  147  of the cover member  110  is configured to contact the top edge  107  of the rear wall  125 . Thus, the upward force F is translated to the rear wall  125 , which secured to the surface and, therefore, able to withstand the force. Contact of the top edge  107  of the cover member  110  with the rear wall  125  also limits the amount by which the cover member  110  may be opened. In one implementation, contact occurs when the cover member  110  forms an angle of about  110  degrees with the base member  105 . This places the center of gravity of the cover member  110  beyond the front of the base member  105  so that that cover member  110  will automatically close under the force of gravity. 
         [0024]    In  FIG. 4 , a first pin  115  may have a beveled outside face  405 . The angle A formed between the surface of the outside face  405  and the longitudinal axis of the first pin  115  may be about  83  degrees. The angle of the bevel is configured so that during attachment of the cover member  110  to the base member  105 , the surface of the outside face of the first pin  115  is substantially parallel to the surface of the first tab  122  when an edge of the first tab  112  reaches an edge of the outside face  405  of the first pin  117 , as illustrated in  FIG. 6C . 
         [0025]    Referring back to  FIGS. 1A and 1B , the cover member  110  is a generally box-shaped structure that includes a pair of opposing sidewalls  140   a  and  140   b,  and a front surface that includes upper, lower, and center surfaces ( 145   a,    145   b,    145   c ) that extend between forward facing edges of the sidewalls ( 140   a,    140   b ). 
         [0026]    A first tab and a second tab ( 122 ,  124 ) extend from rear edges of the pair of sidewalls ( 140   a,    140   b ), respectively, and are positioned near the upper surface  145   a  of the cover member  110 . Each tab ( 122 ,  124 ) defines an opening  505  ( FIG. 3 ) configured to slide over and to engage one of the first and second pins ( 115 ,  117 ) of the base member  105 . The opening  505  is more clearly illustrated in  FIG. 5   
         [0027]    In  FIG. 5 , the first tab  122  defines a channel  510  sized to receive the first pin  115 . The width W of the channel  510  may be slightly larger than the diameter D 1  of the pin  115 . The channel  510  extends from an edge of the first tab  122  to the opening  505  of the first tab  122 . The depth of the channel  510  decreases gradually from a depth D 2  of about 0.035 inches at the edge of the first tab  122  to a depth of about zero inches at the opening in the first tab  122 . 
         [0028]    In  FIG. 6 , the distance D 3  between the first and second tabs ( 122 ,  124 ) is about 0.375″ inches larger than the distance between the forward edges ( 121   a,    121   b ) of the pair of opposing sidewalls ( 120   a,    120   b ) of the base member  105 . This small difference facilitates rotation of the cover member  110  about the pins ( 115 ,  117 ). Maintaining a small difference also prevents removal of the cover member  110  from the base member  105  when the outlet cover assembly  100  is in a closed configuration because the first and second tabs ( 122 ,  124 ) will interfere with the forward edges ( 121   a ,  121   b ) of the pair of opposing sidewalls ( 120   a,    120   b ) if removal is attempted. 
         [0029]    The distance D 4  between the opposing sidewalls ( 120   a,    120   b ) in a region nearest the first and second pins ( 115 ,  117 ) is about 0.375 inches smaller than the distance between the first and second tabs ( 122 ,  124 ). Referring to  FIG. 7 , this difference in distances results in a space with a width D 5  of about 0.10 inches between the first tab  122  and the sidewall  120   a  when the outlet cover assembly  100  is in the open configuration. This space allows the first tab  122  to clear the sidewall  120   a  without interference, which facilitates attachment of the cover member  110  to the base member  105 . 
         [0030]      FIGS. 8A and 8B  illustrate attachment of the cover member  110  to the base member  105 . In  FIG. 8A , the second tab  124  of the cover member  110  is slid over the second pin  117  of the base member  105  and rotated in a direction R. As illustrated in  FIG. 8B , rotation of the cover member  110  brings the first tab  122  in proximity of the first pin  115 . Just before contact, the outside face of the pin  115  is substantially parallel to the surface of the tab  122  and acts as a ramp that allows the tab  122  to easily slide over the outside face of the pin  115 . As rotation continues, the pin  115  is guided into the opening in the first tab  122  by the channel  510 . The gradual change in the depth of the channel  510  causes the first pin  115  to press against the first tab  122 , which in turn cause the first tab  115  to resiliently flex by a small amount during rotation. The amount of flex may be specified in terms of the change in the distance D 3  ( FIG. 6 ) between the first and second tabs ( 122 , 124 ). In this case, the flex is about 0.05 inches. The gradual change in depth of the channel and the substantially parallel surfaces facilitates flexing of the relatively rigid material. 
         [0031]    While the outlet cover assembly has been described with reference to certain dimensions, materials and configurations, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the claims. For example, the various dimensions above may be scaled up or down as needed to accommodate a wiring devices of different sizes. The pins may be provided on the cover and the tabs may be provided on the base member. The pins may be positioned on inside surfaces of the base member rather than on outside surfaces and the tabs on the cover member may be configured to engage the inward facing pins. Either pin or both pins may be beveled. Either tab or both tabs may have channels. Many other modifications may be made to adapt a particular situation or material to the teachings without departing from its scope. Therefore, it is intended that the outlet cover assembly defined by the claims not be limited to the particular embodiment disclosed, but rather any outlet cover assembly that falls within the scope of the claims.