Abstract:
The present invention is directed to a “while-in-use” electrical device cover that shuts the power off to the device when the cover is open. The power is re-activated when the cover is closed using a cam device.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority to U.S. Provisional Application No. 61/070,079, filed on Mar. 20, 2008, which is in incorporated herein. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to a box for housing electrical termination devices such as jacks and receptacles. More particularly, the present invention relates to an integral hingable box and cover to allow users easy access and an automatic power safety switch on/off which is connected thereto. 
     BACKGROUND OF THE INVENTION 
     Electrical boxes and housings are typically used to house electrical termination devices such as electrical receptacles and data/communication jacks which terminate wires running thereinto. These termination devices are provided so as to permit connection of electrical wires and cables terminated by complimentary termination devices such as plugs and the like. 
     With many electrical boxes, especially those which are used to house termination devices positioned within a floor or wall, it is desirable to construct the box to provide easy access for inserting the plug yet is not interfering. 
     A typical exterior electrical box has a cover which is pivoted to an open position to reveal the various power and signal components which are terminated therein. 
     In a typical electrical box power is continually supplied to the receptacle within the box. If covered, the user must open the cover, pull the plug into the box, locate the receptacle, and properly align and connect the plug to the receptacle in the confined space of the box. All this occurs with minimal viewing ability to assist in confirming the connection without damage or injury. There is no provision to shut the power off using the action of the cover. 
     It is, therefore, desirable to provide an electrical box which allows for easy access and viewability of the receptacle and connections therein, and provide a safety mechanism which will cut the power when the cover is open and provide power when the cover is closed. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a “while-in-use” electrical device cover that shuts the power off to the device when the cover is open. The power is re-activated when the cover is closed using a cam device. 
     In one embodiment of the invention, the electrical device is a flush mount device with the box recessed and the receptacle pivots along with the cover. The electrical interlock provides power to the receptacle when the cover/receptacle is in the closed position and the power is terminated when the cover/receptacle is in the open position. 
     In another embodiment of the invention, the electrical device provides for a receptacle fixed inside the box with only the cover pivotable open. Power is terminated when the cover is in the open position. Power is restored upon closure of the cover. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective showing of the electrical box assembly of the present invention. 
         FIG. 2  is a perspective showing of the electrical box with the cover in the closed position of  FIG. 1 . 
         FIG. 3  is a front side exploded view of the electrical box of  FIG. 1 . 
         FIG. 4  is a rear side exploded view of the electrical box of  FIG. 1 . 
         FIG. 5  is a side sectional view of the box of  FIG. 2  showing the cam operated micro switch power-on. 
         FIG. 6  is a side sectional view of the box of  FIG. 1  showing the cam operated micro switch power-off. 
         FIG. 7  is a side sectional view of the box of  FIG. 1  showing the cam operated micro switch power-off. 
         FIG. 8  is a side sectional view of the box of  FIG. 7  showing the GFCI device therein. 
         FIG. 9  is a front perspective view of the interior of the base of the box assembly of  FIG. 1 . 
         FIG. 10  is a rear perspective view of the interior of the cover of the box assembly of  FIG. 1 . 
         FIG. 11  is a perspective showing of  FIG. 2  including a power cord plugged into the assembly. 
         FIG. 12  is a perspective showing of  FIG. 1  including a power cord plugged into the assembly and exiting therefrom. 
         FIG. 13  is a perspective showing of the rearview of a portion of the box assembly of  FIG. 1 . 
         FIG. 34  is a perspective showing of an electrical box assembly of the present invention. 
         FIG. 15  is a perspective showing of an electrical box assembly of  FIG. 14  with the cover open and power supply off. 
         FIG. 16  is a top perspective showing of an electrical box assembly of  FIG. 15 . 
         FIG. 16A  is a sectional view showing of an electrical box assembly of  FIG. 16 . 
         FIG. 17  is an exploded perspective showing of an electrical box assembly of  FIG. 14 . 
         FIG. 18  is an exploded perspective showing of the cam switch and receptacle of  FIG. 17 . 
         FIG. 19  is a perspective showing of the cover connector of  FIG. 17 . 
         FIG. 20  is a perspective showing of the cam switch of  FIG. 17 . 
         FIG. 21  is a perspective showing of the electrical switch of  FIG. 17 . 
         FIG. 22  is a perspective showing of the electrical box assembly of  FIG. 14 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The present invention is directed to an outdoor electrical box assembly which provides an electrical interlock such that power to the receptacle is terminated when the cover is in the opened position. The receptacle can be attached to the cover or attached to the box interior. The box can be a flush mount box assembly or exterior box mount. 
     Referring now to  FIGS. 1-13 , the box assembly  10  of the present invention is shown. Box assembly  10  includes an exterior box housing  20 , an interior box housing  30 , a cover  40 , and locking flange  50  which secures the cover  40  to box housings  20  and  30 . Exterior housing  20  is a generally rectangular box-like member having a removable back wall  60 , a pair of sidewalls  24 , upper sidewall  26 , lower sidewall  28 , and an open front  12  which cover  40  is positioned therein. The open front  12  is defined by sidewalls  24 , upper sidewall  26 , and lower sidewall  28 . The open front  12  is lined about the perimeter by inner flange  52 . As is well known, exterior box housing  20  and interior box housing  30  may be formed of a variety of materials including plastic or metal. 
     As shown in  FIGS. 3-4 , exterior box housing  20  is generally square with a pair of mirror image sidewalls  24  which are rectangular with a back corner of the rectangle cut-off. One edge of the sidewalls  24  is attached to a substantially planar inner flange  52  which extends perpendicular from the sidewalls  24 . The pair of sidewalls  24  are attached to an upper sidewall  26 . The sidewalls  24  extend above the upper sidewall  26  such that the upper sidewall  26  is inset from a free edge of each sidewall  24 . The upper sidewall  26  is generally rectangular in shape and has four edges. Each edge is attached to perpendicularly extending members, such as sidewalls  24 , flange  52  or back wall  60 . The attachment point between the sidewalls  24  and the upper sidewall  26  includes channels  74  with holes  75 . The channels  74  provides for attachment of the removable back wall  60  to the remaining exterior box housing  20 . Lower sidewall  28  is generally rectangular and is attached on two opposing edges by the sidewalls  24 . At the joint where the lower sidewall  28  edge and each sidewall  24  edge meets is a channel  72  including a hole  73 . This channel  72  provides a means of attaching the removable back wail  60  to the remaining box housing  20 . The lower sidewall  28  is also attached to the flange  52  which extends perpendicular to the lower sidewall  28 . In this embodiment, the lower sidewall  28  is shorter than the upper sidewall  26 . Additionally, the channel  72  is shorter than the channels  74 . 
       FIGS. 3 ,  4  and  8  show removable back wall  60  including a rectangular portion  62  and a lower lip or ridge portion  64  extending perpendicular to the rectangular portion  62 . Lower ridge portion  64  is attached to angular portion  66  at an angle less than 90. The rectangular portion  62  includes a rim  68  which is rectangular in shape and protrudes perpendicularly outward from the back wall  60 . Rim  68  is inset from the edges of the rectangular portion  62 . A leveling bar  70  protrudes outwardly from the angled portion  66 . The rim  68  and bar  70  assist with proper positioning and securement of the back wall  60  to the sidewalls  24 ,  26  and  28 . The rectangular portion  62  includes holes  76  which align with holes  75  to provide securement of the back wall  60  to the sidewalls  24  with fasteners. Additionally, holes  77  extends through the angled portion  66  and aligns with holes  73  of the sidewalls  24  to provide securement therewith fasteners. Angular portion  66  also includes knock-outs  71  for power supply lines to extend from the floor or wall through to the box assembly  10 . 
       FIGS. 4 and 5  show exterior box housing  20  encompassing interior box housing  30 . Interior box housing  30  includes a pair of interior sidewalls  32  and an interior back wall  36 . One edge of each interior sidewall  32  and one edge of interior back wall  36  is attached to upper wall  26  on the lower surface. Interior box is generally a rectangular box like member with a curved back wall  36  which is continuous to form both the back wall and the bottom wall of the interior box  30 . 
     As shown in  FIGS. 3 ,  4 ,  8  and  9  interior back wall  36  is curved at an obtused angle. Interior back, wall  36  is attached to the upper sidewall  26  the interior sidewalls  32 , and either to flange  52  as shown in  FIG. 5 , or lower wall  28  as shown in  FIG. 8 . The interior sidewalls  32 , upper sidewall  26  and interior wall  30  define the box interior  38 . The box interior  38  is defined by the interior back wall  36 , two interior sidewalls  32  attached to the interior back wall  36  and a portion of upper sidewall  26 . One side of each interior sidewalls  32  has a curved portion to mirror the curvature of the interior back wall  36 . The interior sidewalls  32  are set a distance in from the sidewalls  24  to provide a space  23  between the interior sidewall  22  and sidewalls  24  for a switch  56  to be placed therein. This space  23  provides room for the switch  56  and electrical wires to extend through to supply to the interior  38  of the box assembly  10 . 
       FIG. 9  shows flange  52  extends the perimeter about open front  12 . Flange  52  is substantially planar with two opposing cam receiving slots  54  for attachment of the cover  40 , access to electrical wire and micro switch. Flange  52  also includes divot  58  for the wires of a plug to extend therethrough when the cover  40  is in the closed position, see  FIG. 12 . 
     As shown in  FIGS. 3-5  cover  40  is generally a rectangular shaped geometry and designed to seat inside box interior  38 ,  FIG. 10  shows cover  40  including a pair of cover sidewalls  42 , a cover top wall  44  and a cover face plate  46 . The cover sidewalls  42 , top wall  44  and face plate  46  define a cover interior  45  of which a receptacle is attached and placed therein as shown in  FIG. 11 . The cover side walls  42  are generally rectangular having an angled bottom edge  41 . Additionally, the bottom edge  41  is attached to an adjacent side edge in a curved manner. Additionally, one side edge includes a protruding notch  43  to provide attachment of the receptacle  81 . Sidewalls  42  includes a hole  47  near the corner where the top wall  44  and face plate  46  connect. The hole  47  is for electrical wires to extend therethrough. On the opposite side of the hole  47  is cam  48 . Cam  48  seats in cam receiving slot  54  of the exterior box housing  20  to attach cover  40  to exterior box housing  20 . Cam  48  is generally a cylindrical shape protruding perpendicular from the exterior surface of the sidewalls  42 . Cam  48  includes two cam divots  49  which controls the status of switch  56 ,  FIG. 13  shows the wheel  56   a  of the switch  56  which is inserted into rectangular hole  82  in the receiving slot  54  of the frame  52 .  FIG. 5  shows the wheel  56   a  of the switch inserted into rectangular hole  82  and in contact with cam  48 . When the wheel  56   a  of switch  56  extends into cam divot  49 , the switch  56  is in the on-position and this allows power to be supplied to receptacle  81  ( FIG. 5 ). When the wheel  56   a  of switch  56  is not in cam divot  49  and is on the exterior cylindrical surface of cam  48  the switch is in the off-position and this prevents power from being supplied to the receptacle  81  ( FIG. 6 ). 
     The receptacle  81  is placed within the cover  40  at an angle, as shown in  FIGS. 1 ,  8  and  11 . The angled placement of the receptacle  81  provides for easier access to the receptacle  81  when the cover  40  is in the open position. A receptacle mounting bracket  83  engages with notch  43  of the cover  40  to seat the receptacle  83  within the cover  40 . A faceplate  84  is placed over the receptacle mounting bracket  83  and secured to the mounting bracket  83  to secure the receptacle  81  within the cover  40 . 
     Box assembly  10  is assembled by attaching the cover  40  to the exterior box housing  20  and interior box housing  30 . The cam  48  of the cover  40  is placed into the cam receiving slot  54 . Then locking flange  50  is placed over cover flange  52  and fasteners are used to secure locking flange  50  to flange  52 . Flange  50  covers the cam receiving slot  54  to prevent cam  48  from exiting the slot. Locking flange  50  is a rectangular strip of planar material which covers the entire inner flange  52 . Locking flange  50  includes two inner extending semi-circular prongs  51  for aligning and engaging with cam  48  to secure cover  40  in place. Locking flange  50  is removable and can be replaced if the user wants a different color, texture or material. Additionally, gasket  53  may be placed between flange  52  and locking flange  50 . Locking flange  50  includes cut-out  59  which corresponds with divot  58  of the inner flange  52  to allow for egress of wires  80  when the cover  40  is in the closed position. 
       FIG. 5  shows the box assembly  10  completely assembled and the switch  56  engaged with, cam  48 . The switch  56  is in the power-on position, supplying power to the receptacle when the cover  40  is closed.  FIG. 6  shows the cover  40  in an opened position, and the switch  56  is in the power-off position.  FIG. 7  shows the switch  56  in one of the cam divots  49  allowing the switch to provide power to the receptacles.  FIG. 7  shows the cam in power-on position to allow the user to test GFCI circuit. In this position the cover  40  must be forced up against a spring load  14  but cover  40  cannot remain in this position absent a force overcoming spring load  14 . 
     While in the preferred embodiment, cam  48  rotates along with cover  40  while switch  56  remains relatively stationary, the opposite is also likely. In other words, switch  56  (or a component thereof) can be configured to rotate along with cover  40  while cam  48  remains substantially, if not wholly, stationary. 
     Having described the components of the box of the present invention, its operation may now be described. The box assembly  10 , as described in  FIG. 1 , may be inserted into a floor or wall through which wires and cables (not shown) are typically run. Wires and cables are extended through the knockouts  71  of the back wall  60 . The wires are then attached to the switch  56  and receptacle. The back wall  60  is secured to exterior box  20 . The box  10  assembly may be inserted into the floor or wall with or without the cover assembly attached thereto. If the housing  10  is inserted first, the cover  40  may be positioned subsequently. Once the cover  40  is attached, by inserting cam  48  into cam slot  54 , the flange  50 , or gasket  53  and flange  50  are attached to the flange  52  and secured thereto. The flange  50  provides a smooth transition to a wall, carpet or other flooring placed over the floor or wall. 
     Referring now to  FIGS. 1 ,  2 ,  11  and  12 , in order to connect a terminated electrical wire  80  to the receptacles  81  and jacks supported within box assembly  10 , the cover  40  is pivotally moved to an open position as shown in  FIG. 11 . Connections can now be made in the conventional fashion to the receptacles  81  and jacks located within the cover  40 . The power supply is in the off position when the cover  40  is open. After the connections are made, the cover  40  can be pivotally closed to lie flush with the floor or wall as shown in  FIG. 12 . When the cover  40  is closed, the power supply is in the power-on position. Divot  58  and cut-out  59  accommodates the egress of the terminated wires  80  from the box assembly  10 . 
     Additionally the cover  40  can be removed and replaced. The cover can be replaced with a cover of a different color, different texture or different material. Further, if the cover is damaged it may be replaced. Similarly the locking flange  50  may be removed and replaced to match the cover  40  and floor or wall material of which it is installed in. 
     An alternative embodiment is box  100  which is similar to box  10  but instead of having the receptacle attached to the cover and moving with the cover, the receptacle is located in the box and the cover moves freely. The power supply is still provided to the receptacle by the cam and controlled by the position of the cover, as in box  10 . Additionally, box  100  provides a light  201  which is a sensor activated light that can be activated by motion, light, or a combination. 
     Specifically, referring now to  FIGS. 14-22 , the box assembly  100  of the present invention is shown. Box assembly  100  includes a box housing  200 , and a cover  400 , and face plate  500  which encloses the receptacle within the box housing  200 . Face plate  500  is planar with cut outs to access the receptacle and the light. Box housing  200  is a generally rectangular box-like member having a back wall  600 , a pair of sidewalls  240 , upper sidewall  260 , lower sidewall  280 , and an open front  120 . The upper sidewall  260  has a stepped geometry having a top portion  260   a , a riser  260   b  and a lower portion  260   c . This allows the cover  400  to open and slide over the top portion  260   a  and riser  260   b  without interference. The cover  400  is attached to the pair of sidewalls  240 . The open front  120  is defined by sidewalls  240 , upper sidewall  260  and lower sidewall  280 . The open front  120  has an inner flange  520  extending parallel to the open front  120  and perpendicular from the lower sidewall  280 . The inner flange  520  includes a locking hole which aligns with a locking hole of the cover  400  to provide a means of locking the cover to the box. The lower sidewall  280  includes holes for the wires to exit therethrough. The back wall  600  includes holes for a fastener to attach the box to a wall or other support member. The back wall  600  also includes an electrical wire entrance for wires to supply power to the receptacle. As is well known, box housing  200  may be formed of a variety of materials including plastic or metal. 
     As shown in  FIGS. 14 ,  15  and  23  cover  400  is generally a rectangular shaped geometry and designed to attach to box  200  by sidewalls  240 . Cover  400  includes a pair of triangular cover sidewalls  420 , a cover front wall  440 , a top wall  450  and a bottom wall  460 . The sidewalls  420  include a hinged attachment member  421  which attach to the sidewall  240  attachment member  241 . The cam control member  481  extends through the hinged attachment member  421  and sidewall attachment member  241 . The cam control member  481  includes a fastening members  482 , cap  483 , cam  480 , cover connector  484  and o-ring  485  as shown in  FIG. 17 . The cover bottom wall  460  includes a flange  461  which extends downward and aligns with flange  520  when the cover  400  is in the closed position. The flanges  520  and  461  provide a hole for a lock to extend therethrough and lock the box and cover in the closed position. The front wall  440  is molded to provide additional room within the box cavity for wire plugs to extend into. 
     As shown in  FIGS. 17-21 , the box  200  holds the receptacle  830 , switch  560  and light  201  therein. The switch  560  is controlled by the cam control member  483 . The switch  560  includes a wheel  561 . The wheel  561  engages with cam  480 . Cam  480  includes a shaft  480   c  with a D-shaped hole, a cam wheel  480   a  and a divot  480   b  in the cam wheel  480   a . The wheel  563  of the switch  560  rides on the cam wheel  480   a  and when the switch wheel  561  enters the divot  480   b  the switch is in the power-on mode and power is supplied by the switch to the receptacle. This power-on mode is accomplished when the cover is in the closed position. When the switch wheel  563  is engaged with the remaining cam wheel  480   a , not divot  480   b , the switch is in the power-off mode and the switch prevents power supply to the receptacles. The power-off mode is accomplished when the cover is in the open position. 
     Cam  480  is attached to cover connector  484 . Cover connector shaft  484   a  extends into cam shaft  480   c . Cover connector  484  has a corresponding D-shaped geometry to mate with the internal D-shaped geometry of the cam shaft  480   c . Fastener  482  extends into cover connector shaft  484   a  and through cam shaft  480   c  to secure the two components together. O-ring  485  is placed on the exterior of cover connector shaft  484   a . On the opposite end of the cam shaft  480   c  fastener  482  extends therethrough to secure opposite end.  FIG. 17  shows the sequence of assembling the cam  481 . The cam  480  is located within the box  200  while the cover connector  484  is located external to the box and the cover. The o-ring  485  is located between the sidewall  240  and the cover sidewall  420 . The cover connector  484  extends through the cover sidewall  420 , the o-ring  485  and into the cam  480 . The fastener  482  extends into the cover connector  484  and a cap  483  is secured over the cover connector  484 . On the other side of the box, a fastener  484  is inserted through the cover  420  and the sidewall  240  of the box. The cap  483  is placed over the fastener  482  and the cover hinge  421 . As the cover  420  is rotated the cover connector  484  is rotated. The cover connector includes pins  484   c  which align and mate with the pin holes  421   c  of the cover, such that the pins  484   c  and pin holes  421   c  corroboratively rotate the cover connector  484 . The cover connector  484  rotates the cam  480 . 
       FIGS. 14 and 15  show the box assembly  100  completely assembled.  FIG. 14  shows the switch  560  in the power-on position supplying power to the receptacle when the cover  400  is closed.  FIG. 35  shows the cover  400  in an opened position, and the switch  560  is in the power-off position.  FIGS. 16-16   a  show the switch  560  in the cam divot  480   b  allowing the switch to provide power to the receptacles. 
     Having described the components of the box of the present invention, its operation may now be described. The box assembly  100  may be attached to wall through which wires and cables (not shown) are typically run. Wires and cables extend through the knockouts in the back wall  600  to supply power to the receptacle. The wires are then attached to the switch  560  and receptacle. 
     To connect a terminated electrical wire (not shown) to the receptacles  810  and jacks supported within box assembly  100 , the cover  200  is pivotally moved to an open position as shown in  FIG. 15 . Connections can now be made in the conventional fashion to the receptacles  810  and jacks located within the cover  400 . The power supply is in the off position when the cover  400  is open. After the connections are made, the wires are run through the openings at the lower sidewall  280  to accommodate the egress of the terminated wires  80  from the box assembly  10 . The cover  400  is pivotally closed and may be locked to the box housing  200 . When the cover  400  is closed, the power supply is in the power-on position. 
     It will be appreciated that the present invention has been described herein with reference to certain preferred or exemplary embodiments. The preferred or exemplar embodiments described herein may be modified, changed, added to or deviated from without departing from the intent, spirit and scope of the present invention. It is intended that all such additions, modifications, amendments and/or deviations be included within the scope of the claims appended hereto.