Abstract:
An expandable while-in-use electrical outlet cover assembly comprising a lid operatively coupled to a base, the lid comprising flexible clips each comprising a first end, a mid-position and a second end. The collapsible lid may be held in an expanded position by the first end of the flexible clips and collapsed to a collapsed position by applying force to the lid such that a box-like cap slides with respect to a support ring such that the cap seats at the mid-portion of the flexible clip. Particularly useful for rigid lids, like metal lids, the collapsible cover protects the outlet beneath the cover while an electrical cord is plugged in, but still collapses to a smaller profile.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This document is a continuation-in-part application of U.S. pending patent application Ser. No. 12/169,058, filed Jul. 8, 2008 to Shotey et al., entitled “Expandable In-Use Outlet Cover,” which is a continuation of issued U.S. Pat. No. 7,396,996, filed Jun. 6, 2006 to Shotey et al., entitled “Expandable In-Use Outlet Cover,” which claims priority to provisional patent application No. 60/688,089, filed Jun. 6, 2005 to Shotey et al., entitled “Expandable In-Use Outlet Cover,” the disclosures of each of which is hereby incorporated herein by reference. 
     This document also claims the benefit of the filing dates of U.S. Provisional Patent Application Ser. No. 61/014,153 to Shotey, et al., entitled “Collapsible Metal While-in-Use Cover,” filed Dec. 17, 2007, the disclosure of which is hereby incorporated herein by reference. 
    
    
     BACKGROUND 
     1. Technical Field 
     Aspects of this document relate generally to collapsible while-in-use electrical outlet covers. 
     2. Background Art 
     In-use outlet covers are those outlet covers that are configured to allow an electrical plug to be plugged into the outlet while a protective cover is closed. Having the cover closed while being used allows the cover to protect the outlet from the elements, such as rain, moisture and dust. Metal covers are generally used in areas where there is a risk of damage to the cover from heavy machinery crushing the cover. 
     Conventionally, to enable an electrical outlet cover to close while the outlet is in use, the base or lid of the cover unit needs to be adapted to be deep enough to allow for the lid to close without significant interference with the plug when the plug is inserted into the outlet. Some of the conventional approaches to accomplishing this deeper base are shown and described in U.S. Pat. No. 6,723,922 to Shotey et al. (Issued Apr. 20, 2004) titled “Universal cover plate”, U.S. Pat. No. 6,133,531 to Hayduke (Issued Oct. 17, 2000) titled “Weatherproof outlet cover”, U.S. Pat. No. 4,988,832 to Shotey et al. (Issued Jan. 29, 1991) titled “Recessed electrical outlet with cover”, U.S. Pat. No. 4,803,307 to Shotey et al. (Issued Feb. 7, 1989) titled “Weatherproof outlet cover”, the disclosures of each of which are hereby incorporated herein by reference for their general relevance to the formation and manufacture of cover assemblies. 
     Each of these designs involves a cover unit having a fixed dimension using what is typically called a bubble cover lid that bulges to allow room for the plug and cord within the cover when it is closed. One of the common complaints associated with conventional in-use cover designs is that the cover units protrude three or more inches from the exterior of the home, may be damaged or dislodged by passers-by, and are often unattractive on the home due to the size. 
     Typical base configurations for electrical devices include, but are not limited to, blank, duplex, decora, ground fault circuit interrupt (GFCI), round and switch. Examples of structures that may be used to enable a base member to be configured for conversion between various other configurations are shown and described in U.S. Pat. Nos. 6,723,922 to Shotey et al. (issued Apr. 20, 2004) titled “Universal cover plate”, 6,987,225 to Shotey et al. (issued Jan. 17, 2006) titled “Convertible electrical device cover and method for installing same”, 6,441,307 to Shotey et al. (issued Aug. 27, 2002) titled “Universal Cover Plate,” and 6,770,816 to Shotey et al. (issued Aug. 3, 2004) titled “Convertible electrical device cover and method for installing same”, the relevant disclosures of which are hereby incorporated herein by reference. Alternatively, as suggested in U.S. Pat. No. 6,770,816, the base member may be configured with an opening and attachment members and replaceable adapter plates may be used to enable the installer to select the desired base configuration. These references also include examples of removable cord escape tabs for vertical or horizontal orientations. 
     SUMMARY 
     Aspects of this document relate to while-in-use electrical outlet covers. 
     In one aspect, a while-in-use electrical outlet cover assembly comprises a collapsible lid operatively coupled to a base, the lid comprising a rigid cap having an internal volume and rigid sides and a rear opening defined by a rear edge, wherein the rear edge comprises an outwardly extending lip, the lid further comprising a support ring comprising four support sides each having an inner surface and a front edge comprising an inwardly extending lip. The lid may further comprise at least one flexible support clip coupled to the inner surface each of at least two of the support sides. The electrical device cover assembly collapses from a second depth to a first depth smaller than the second depth by the rigid cap sliding inside the support ring from the second depth where the outward extending lip of the rigid cap rests near an end of the flexible support clips to a first depth where the outwardly extending lip of the rigid cap rests at a mid-section of the flexible support clips. 
     Particular implementations may include one or more of the following. The base and/or lid may be formed primarily of metal or plastic. The flexible support clips may be formed primarily of metal and may even be spring steel support clips. The flexible support clips may be coupled to the inner surface of the at least two support sides by metal or plastic rivets. The lid may comprise at least one flexible support clip coupled to the inner surface each of at least three or four of the support sides, or even two flexible support clips coupled to the inner surfaces of each of the at least two support sides. The base may comprise at least one removable tab adapted such that removal of the at least one removable tab adapts the base from a base configured for a first electrical outlet style to a base configured for a second electrical outlet style different from the first style. The support ring may comprise a cord port extending through at least one of the support sides. The lid may be hingedly coupled to the base. 
     In another aspect, a while-in-use electrical outlet cover assembly comprises a metal base configured for attachment to an electrical outlet box and a lid hingedly coupled to the base. The lid may comprise a box-like metal cap nested inside a metal support ring, the metal support ring comprising a plurality of flexible metal clips coupled to an inner surface of the metal support ring at a first end of the metal clips. The flexible metal clips may each comprise a mid-section and a second end, wherein the lid comprises an expanded position where the metal cap is supported by the second end of each of the metal clips and a collapsed position where the metal cap contacts and is retained in the collapsed position at the mid-section of the metal clips. 
     Particular implementations may include one or more of the following. The base and/or lid may be formed primarily of metal or plastic. The flexible support clips may be formed primarily of metal and may even be spring steel support clips. The flexible support clips may be coupled to the inner surface of the at least two support sides by metal or plastic rivets. The lid may comprise at least one flexible support clip coupled to the inner surface each of at least three or four of the support sides, or even two flexible support clips coupled to the inner surfaces of each of the at least two support sides. The base may comprise at least one removable tab adapted such that removal of the at least one removable tab adapts the base from a base configured for a first electrical outlet style to a base configured for a second electrical outlet style different from the first style. The support ring may comprise a cord port extending through at least one of the support sides. The lid may be hingedly coupled to the base. 
     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 
       An electrical device mounting box assembly will hereinafter be described in conjunction with the appended drawings, where like designations denote like elements, and: 
         FIG. 1  is a front perspective view of one particular implementation of a while-in-use cover assembly for an electrical outlet in an open configuration; 
         FIG. 2  is a rear perspective view of the lid of the particular implementation of  FIG. 1  in an expanded position; 
         FIG. 3  is a rear perspective view of the lid of the particular implementation of  FIG. 1  in a collapsed position; 
         FIG. 4  is front view of the particular implementation of the while-in-use cover assembly of  FIG. 1  in a collapsed position; and 
         FIG. 5  is side sectional view of the particular implementation of the while-in-use cover assembly of  FIG. 4  taken along section lines A-A. 
     
    
    
     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 electrical outlet cover assembly and/or methods for using an electrical outlet cover assembly will become apparent for use with implementations of electrical devices from this disclosure. Accordingly, for example, although particular electrical outlet cover assemblies, lids, bases, removable tabs, adapters, bias clips, attachment mechanisms, hinges, and cord ports are disclosed, such implementing components are not limited to those particular embodiments disclosed herein and 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 electrical outlet cover assemblies and implementing components consistent with the intended operation of an electrical outlet cover assembly. 
     There are a variety of implementations of the electrical outlet cover assembly possible from the present disclosure.  FIGS. 1-5  illustrate non-limiting example implementations of an electrical outlet cover assembly, but those of ordinary skill in the art will readily comprehend other particular implementations and variations from the disclosure provided in relation to this particular implementation. In this implementation the electrical outlet cover assembly is a while-in-use cover assembly. Although implementations may be made primarily of plastic or metal, the particular implementations shown in  FIGS. 1-5  are particularly beneficial for use with a cover assembly formed primarily of metal. 
     Manufacture of metal while-in-use electrical device covers differ from that of plastic while-in-use electrical device covers for many reasons. One of those reasons is that metal is not pliable like plastic and, therefore, the parts made of metal that need to work together, need to be able to work together without having a pliable characteristic. Another reason metal manufacture is different from plastic is that metal is heavier than plastic. This affects the working relationships between the parts made of metal in much different ways than the parts made of plastic. 
     There are many aspects of a while in-use electrical outlet cover assembly  2  disclosed herein, of which one, a plurality, or all aspects may be used in any particular implementation. 
     The particular implementation shown includes a base  4  configured for attachment to an electrical outlet box mounted in a wall. A lid  6  is operably coupled to the base. The lid  6  comprises a box-like cap  8  that is rigid, formed of either plastic or metal, the lid  6  comprising an internal volume  10  and rigid sides  12  with a rear opening defined by a rear edge  14 . An outwardly extending lip  16  extends outwardly from the rear edge  14  of the rigid cap  8 . The lid further comprises a support ring  20  comprising support sides  22  each having an inner surface  24  and a front edge  26  with an inwardly extending lip  28 . The rigid cap  8  is nested inside the support ring  20 . A plurality of flexible support clips  30  is each coupled to an inner surface  24  of a support side  22 . The lid  6  is hingedly coupled to the base through the support ring  20 . In the particular implementation of  FIG. 1 , the base comprises a pair of pins  44  extending from opposing sides of the base  4  that mate with corresponding sockets  46  on or through the support ring  20 . Although a particular hinge configuration is used in this particular implementations shown in  FIGS. 1-5 , the particular hinge configuration is not crucial to the operation of the cover assembly and other hinge configurations are contemplated and anticipated for use to couple the base  6  to the support ring  20 . 
     Although this particular implementation includes only three pieces (the base  4 , the support ring  20  and the cap  6 ), additional pieces may be included within particular implementations to allow for greater expansion/collapsing capabilities. For example, additional support rings may be included between the primary support ring  20  and the cap  6  to allow for the same distance of expansion with a smaller collapsible size, or for a greater distance of expansion. 
     During the use of a typical while-in-use cover, for example when a user plugs an electrical cord cap into a receptacle on to which the cover assembly  2  is installed, it is desirable for the lid  6  to be able to close on the base  4  with the plug plugged into the receptacle to keep water from the receptacle. However, it is also desirable for the cord to not be bent at too tight of an angle to avoid damaging the cord. In contrast, it is also desirable to make the while-in-use cover  2  less visible when the receptacle is not in use. For plastic covers, this problem has been overcome with differently structured solutions. However, for metal covers, prior to this disclosure no known solution has been found to enable a low profile metal cover. 
     To maintain the weatherproof nature of a collapsible weatherproof cover, such as that shown in  FIGS. 1-5 , it is desirable to keep the cap  8  fully extended while the cover  2  is in use. The additional weight and non-flexibility of a metal cover makes the earlier solutions used for plastic collapsible covers less effective or unavailable. 
     For the particular implementation shown in  FIGS. 1-5 , the cap  8  comprises an outwardly extending lip  16  around its periphery at its open end that contacts a corresponding inwardly extending lip  28  around the periphery of the support ring  20  when the cap  8  is moved to its expanded position. The plurality of flexible support clips  30  (made from a resilient material such as spring steel or a durable plastic) coupled to an inside surface  24  of the support ring  20  maintain the cap  8  in its expanded position. The flexible support clips  30  in the particular implementation shown each include a first end  32 , a mid-section  34  and a second end  36 . The flexible support clips are each coupled to the inner surface  24  of the support sides  22  by at least one attachment mechanism  38 . The attachment mechanism  38  may comprise a metal or plastic rivet, or an adhesive or may even be welded to the support sides  22  depending upon the particular materials being used and the forces to which the flexible support clips  30  will be exposed. When the cap  8  is in its expanded position, the outwardly extending lip  16  of the cap is supported by the second end  36  of the flexible support clips  30 . 
     When force is applied to the cap  8  to collapse the cap  8 , the outwardly extending lip  16  presses against the curved second ends  36  of the flexible support clips  30  and they collapse out of the way toward the inner surface  24  of the support sides  22 , allowing the outwardly extending lip  16  to move to and snap into position at the respective mid-sections  34  of the flexible support clips  30 . When it reaches the mid-sections  34  of the flexible support clips  30 , the outwardly extending lip  16  of the cap  8  rests in this collapsed position until a force acts on the cap  8  to expand it to its expanded position, where the flexible support clips  30  collapse toward the support sides  22  to again allow the outwardly extending lip  16  of the cap  8  to pass and snap into the expanded position and be supported by the respective second ends  36  of the flexible support clips  30 . One particular advantage from using spring steel spring elements is that the surface of the flexible support clip comprises a bearing surface that will not prematurely wear out. Nevertheless, other components such as cast parts-on-cast parts sliding relative to each other may also accomplish the same function intended here. 
     The particular implementations shown in  FIGS. 1-5  illustrate two flexible support clips  30  on each side of the support ring  20 . However as few as only two flexible support clips  30  on opposing sides of the support ring  20  may be used. In another particular implementation, three flexible support clips  30 , one on each of three adjacent sides, may be used. In yet another particular implementation, four flexible support clips  30 , one on each side of the support ring  20 , are used. In still yet other implementations, two or more flexible support clips are used on each side of the support ring  20  on which flexible support clips are used. 
     Although no latch element is shown in  FIGS. 1-5 , it is contemplated that a latch element as is known in the art of metal or plastic while-in-use covers may be included in the present implementations of a while-in-use cover. Those of ordinary skill in the art will readily understand how to adapt the particular designs discussed to include an appropriate latch element. 
     In particular implementations of the base  4 , the base may comprise at least one removable tab  40  adapted such that the electrical outlet aperture  41  in the base  4  may be converted from being configured for a first electrical outlet type, such as a decora or ground fault current interrupter (GFCI) type, to being configured for a second electrical outlet type, such as a round type. Alternatively, the base may be configured for conversion from a duplex to a decora, GFCI or round type as well. Additional adapters may be added as well to further enable the base to be reconfigured for other outlet types. The base  4  is adapted for mounting to an electrical outlet box in a wall through box mounting screw apertures  50  positioned to align with the electrical outlet box mounting screws when mounted. 
     The particular implementation illustrated in  FIGS. 1-5  also includes a cord port  42  extending through at least one of the support sides  22  of the support ring  20 . Alternatively, the cord port  42  may be arranged to extend through more than one support side  22  by including multiple cord ports  42  on adjacent sides or one cord port  42  on a corner of the support ring  20 . 
     A while in-use cover assembly with a lid may additionally include supplemental weatherproofing (not shown) which can also protect an electrical device from weather while collapsed, extended, and partially extended. For example, one or more additional gaskets in locations such as on the back of the base and on the support ring lip  28  and/or the cap lip  16  may also assist in reducing the likelihood that water will pass to inside the collapsible while-in-use cover assembly  2  in any significant amount. It is specifically contemplated that a while in-use electrical outlet cover assembly may encompass a cover and/or base of any size, shape, profile, configuration or dimension. 
     The concepts disclosed herein are not limited to the specific implementations shown herein. For example, it is specifically contemplated that the components included in a particular implementation of an electrical outlet cover assembly may be formed of any of many different types of materials or combinations that can readily be formed into shaped objects and that are consistent with the intended operation of an electrical outlet cover assembly. For example, the components may be formed of: rubbers (synthetic and/or natural) and/or other like materials; polymers and/or other like materials; plastics, and/or other like materials; composites and/or other like materials; metals and/or other like materials; alloys and/or other like materials; and/or any combination of the foregoing. 
     Furthermore, the electrical outlet cover assemblies, lids, bases, removable tabs, adapters, bias clips, attachment mechanisms, hinges, cord ports, and electrical devices, and any other components forming a particular implementation of an electrical outlet cover assembly may be manufactured separately and then assembled together, or any or all of the components may be manufactured simultaneously and integrally joined with one another. Manufacture of these components separately or simultaneously may involve extrusion, pultrusion, vacuum forming, injection molding, blow molding, resin transfer molding, casting, forging, cold rolling, milling, drilling, reaming, turning, grinding, stamping, cutting, bending, welding, soldering, hardening, riveting, punching, plating, and/or the like. If any of the components are manufactured separately, they may then be coupled or removably coupled with one another in any manner, such as with adhesive, a weld, a fastener, any combination thereof, and/or the like for example, depending on, among other considerations, the particular material(s) forming the components. 
     In places where the description above refers to particular implementations of an electrical outlet cover assembly, 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 electrical outlet cover assemblies. 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.