Patent Publication Number: US-2021175690-A1

Title: Prefabricated electrical circuit breaker panel cover extension used in a flush mount application

Description:
FIELD OF INVENTION 
     The present invention relates to a cover for a wall, and more particularly, the present invention relates to a prefabricated electrical circuit breaker panel cover extension for hiding imperfections or openings in a section of a wall. 
     BACKGROUND 
     An electrical circuit breaker panel, also known as a distribution board, is the main distribution point for electrical circuits in a home. A typical breaker panel in a united states&#39; home includes a cabinet or enclosure that is mounted inside a 16 inch on center, 2×4 stud wall. The cabinet is usually made of sheet metal. The cabinet which includes the wiring and electrical devices is covered by a panel cover. The panel cover is installed flush with the drywall or other wall coverings, hiding the cabinet and its immediate surrounding. The panel cover may also include a door for gaining access into the cabinet. 
     Later, after installation, it is common to have modifications in the wiring of the breaker panel. The modification can be adding new wires or replacing the old ones. Wires are usually added into the panel from above or below, into the wall and travel to different electrical points in a building. Adding or removing a wire in a breaker panel is difficult, time consuming, and generally requires cutting off a section of the drywall above or below the breaker panel. First, the panel cover is removed and then a section of the drywall is cut-off for gaining access to the wires. After completion of the job, the section of the drywall can be repaired. 
     However, the repairing of the drywall is both a laborious and time-consuming job. Moreover, the pathing of the drywall is not always perfect and can look odd and imperfections may be there. Since later modifications in wiring after installations are common and may be frequent, a long-standing need is there for a cover that can hide the cutouts, patches, or imperfections in drywall immediately above or below a breaker panel. 
     SUMMARY OF THE INVENTION 
     The following presents a simplified summary of one or more embodiments of the present invention in order to provide a basic understanding of such embodiments. This summary is not an extensive overview of all contemplated embodiments and is intended to neither identify key or critical elements of all embodiments nor delineate the scope of any or all embodiments. Its sole purpose is to present some concepts of one or more embodiments in a simplified form as a prelude to the more detailed description that is presented later. 
     The principal object of the present invention is therefore directed to a breaker panel cover extension that can hide imperfections or openings in drywall immediately above or below the breaker panel. 
     It is an additional object of the present invention that the cover extension is prefabricated and quick to install. 
     It is a further object of the present invention that the cover extension can have an aesthetic appearance. 
     It is another object of the present invention that the cover extension can be easily installed and removed. 
     It is yet another object of the present invention that the cover extension is economical to manufacture and install. 
     In one aspect, disclosed is a breaker panel cover extension that can be installed above or below a breaker panel and can hide imperfections or openings in drywall immediately above or below the breaker panel. The disclosed cover extension can include a panel member having a proximal end and a distal end. The panel member can have a top edge, a bottom edge, a left edge, and a right edge defining an area of the panel member. The panel member having a front face and a rear face. A thin and narrow downward flange extends downwards from the bottom edge and away from the panel member. The thin and narrow flange can extend along the length of the bottom edge. In one case, the thin and narrow flange is slightly offset rearwardly which can tuck behind the panel cover of the breaker panel. In one case, the thin and narrow flange is continuous with the rear face of the panel member. The distal end of the panel member, near the top edge, can have two or more brackets wings or zip-mount retainers integrated on its rear face. The bracket wings hold the cover extension tight to the wall. 
     In one aspect, the panel member can have a curved flange that extends along the periphery of the panel member and curves rearwardly. The thin and narrow bottom flange extends downwards from the lower end periphery of the curved flange. The brim of the curved flange and the rear face of the bottom flange can be coplanar. 
     In one aspect, the bracket can be an L-shaped bracket having two protruding legs i.e., an upper leg and a side leg, on the rear face of the panel member. At the intersection of the two legs of the bracket, between the two legs, can be a hole in the panel member. A flip tab can be coupled to the panel member through a fastener that runs through the hole in the panel member. The head of the fastener is on the front face of the panel member while the shank of the fastener freely passes through the hole. The shank having threads along its length. The flip tab can be of a narrow and elongated geometry its one end configured as a screw, wherein the inner surface of the screw is having threads configured to threadedly engage with the threads of the shank. Clockwise rotation of the fastener can turn the flip tab clockwise, while the upper leg of the bracket restricts the clockwise rotation of the flip tab, wherein the upper leg points towards the upper edge of the panel member. The anticlockwise rotation of the fastener can rotate the flip tab anticlockwise while the side leg of the bracket limits the anticlockwise rotation of the flip tab. Thus, the flip tab can rotate 90 degrees between the two legs of the bracket. 
     These and other objects and advantages of the embodiments herein will become readily apparent from the following detailed description taken in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying figures, which are incorporated herein, form part of the specification and illustrate embodiments of the present invention. Together with the description, the figures further explain the principles of the present invention and to enable a person skilled in the relevant arts to make and use the invention. 
         FIG. 1  is a perspective view of a breaker panel cover extension, according to an exemplary embodiment of the present invention. 
         FIG. 2  shows a front face of the cover extension, according to an exemplary embodiment of the present invention. 
         FIG. 3  is a side view of the cover extension, according to an exemplary embodiment of the present invention. 
         FIG. 4  is showing an integrated bracket on a rear face of a panel member of the cover extension, according to an exemplary embodiment of the present invention. 
         FIG. 5  shows a rear face of the cover extension, according to an exemplary embodiment of the present invention. 
         FIG. 6  is showing the brackets and flip tabs fastened using a threaded fastener, according to an exemplary embodiment of the present invention. 
         FIG. 7  shows the flip tabs with the threaded fastener, according to an exemplary embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     Subject matter will now be described more fully hereinafter with reference to the accompanying drawings, which form a part hereof, and which show, by way of illustration, specific exemplary embodiments. Subject matter may, however, be embodied in a variety of different forms and, therefore, covered or claimed subject matter is intended to be construed as not being limited to any exemplary embodiments set forth herein; exemplary embodiments are provided merely to be illustrative. Likewise, a reasonably broad scope for claimed or covered subject matter is intended. Among other things, for example, the subject matter may be embodied as methods, devices, components, or systems. The following detailed description is, therefore, not intended to be taken in a limiting sense. 
     The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments. Likewise, the term “embodiments of the present invention” does not require that all embodiments of the invention include the discussed feature, advantage, or mode of operation. 
     The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of embodiments of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises”, “comprising,”, “includes” and/or “including”, when used herein, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. 
     The following detailed description includes the best currently contemplated mode or modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention will be best defined by the allowed claims of any resulting patent. 
     Disclosed is a breaker panel cover extension that can be installed above or below a breaker panel. The cover extension can be used to hide cut-outs imperfections in drywall immediately above or below the breaker panel. Such cut-outs in the drywall can be made to add wires into the panel. Additionally, during the replacement of a circuit breaker panel box that is flush mounted into a wall, the section of the wall along the circuit breaker panel box may get chipped or broken. The disclosed breaker panel cover extension can hide such damages in the wall around the circuit breaker panel box. The cover extension can have an aesthetic appearance that can blend-in with the existing cover of the breaker panel or the surrounding wall. 
     Referring to  FIG. 1 , which shows an exemplary embodiment of the cover extension  100 . The cover extension includes a panel member  105  that can be of planar geometry. The panel member can also have a slightly curved geometry. The length of the panel member can be proportional to the width of a panel cover of a breaker panel. The panel member can be made from a sheet of a rigid material, such as plastics or metal. For example, the panel member can be molded from plastic material or metal sheets. The front face of the panel member can be provided with an aesthetic appearance, such as a color shade or pattern. For example, the color shade of the panel member can match with the existing panel cover of the breaker panel.  FIG. 1  also shows a curved flange  110  that extends rearwardly from the periphery of the panel member  105 . Such a curved flange can be optional, but if present can have a front face continuous with the front face of the panel member  105 . The curved flange can be coupled to the periphery of the panel member or the curved flange  110  and the panel member  105  can be integral. The curvature of the flange  110  can be a quarter circle. Two screw heads  115  can also be seen on the front face of panel member  105 . 
     The panel member can have a top edge, a bottom edge, a left edge, and a right edge defining an area of the panel member. The panel member having a front face shown in  FIG. 2  and a rear face shown in  FIG. 5 . The two screw heads  115  are near the top edge of the panel member  105 . At the bottom edge of the panel member  105  can be seen a thin and narrow bottom flange  120  that extends downwards from the bottom edge and away from panel member  105 . The thin and narrow bottom flange  120  can extend along the length of the bottom edge. The thickness of the bottom flange can be more clearly seen in  FIG. 3 , which shows the side view of the cover extension  100 . The bottom flange  120  and the panel member  105  can be integral. While installing the disclosed cover extension  100  over drywall and above or below a breaker panel, the bottom flange  120  can be sandwiched between a panel cover of the breaker panel and the surface of the drywall for supporting the cover extension  100  over the drywall.  FIG. 3  shows the bottom flange  120  continuous with the brim of the curved flange  110 . The curved flange  110  and the bottom flange  120  can be integral. As described above, the curved flange  110  can be optional and in absence of the curved flange  110 , the bottom flange  120  can be continuous with the rear face of the panel member but thinner than the panel member. Alternatively, the bottom flange can be slightly offset rearwardly. The length of the bottom flange can be the same or lesser than the width of the panel cover of the breaker panel. 
     Referring to  FIG. 4  which shows a close-up view of a bracket  120  coupled on a rear face of the panel member  105 . Bracket  120  can be of an L-shaped profile having two legs, an upper leg and a side leg. The upper leg points towards the top edge of the panel member while the side leg points towards the right edge of the panel member. The two legs of bracket  120  shown in  FIG. 4  is curved and continues, but a sharp intersection of the two legs can also be possible, without departing from the scope of the present invention. The bracket  120  can be protruding perpendicularly from the rear face of the panel member. The bracket  120  can be coupled to a surface of the panel member  105  or the bracket and the panel member can be integral. Two or more of such brackets can be provided on the rear face and near the top edge of the panel member  105 .  FIGS. 5 and 6  show two spaced brackets below the top edge of the panel member on its rear surface. Referring to  FIG. 4 , between the two legs of bracket  120  and adjacent the intersection of the two legs can be a hole in the panel member. A threaded fastener can freely pass through this hole.  FIG. 1  shows the head  115  of the fastener retained on the front face of the panel member  105 .  FIG. 3  shows a threaded shank  130  of the fastener. Also, as can be seen in  FIG. 4  is an annular elevated sleeve  135 . Such a sleeve  135  can be used to increase the distance between the surface of the panel member and the flip tab  125 . In case, the panel member is having the curved flange  110 , the sleeve  135  may be needed, wherein the height of the sleeve  135  can be proportional to the height of the curved flange  110 . 
     Referring to  FIG. 6  which shows two spaced coupling members on the rear face of the panel member  105 . The coupling member can be a flip tab of an elongated, thin, and narrow profile. The flip tabs can be turned 90 degrees between an engaged position and a disengaged position. The flip tabs can be turned upwards to engage with drywall for securing the cover extension  100  to the drywall.  FIG. 5  shows the flip tab  140  extended sidewards against the side leg of the bracket in a disengaged position. The flip tab  145 , in the same  FIG. 5 , is shown extended upwards against, the upwards leg of the bracket, in an engaged position. It is to be understood that drawings show the two flip tabs in upward and sideward position for illustration only, but to mount the cover extension, both the flip tabs can be switched to the engaged portion. Also, the cover extension can have one or more of such brackets and the flip tabs, without departing from the scope of the present invention. 
     Referring to  FIG. 6  which shows the flip tabs  125  with the fasteners. One end of the flip tab  125  can be of a screw profile having inner threads. The inner threads of the flip tab  125  can threadedly engage with the threads of the fastener. Clockwise rotation of the fastener brings the flip tab closer towards the surface of the planer member i.e., the flip tab is moved towards the head of the fastener. Opposite, the anticlockwise rotation of the fastener moves the flip tab away from the planer member  105 . When the flip tabs can freely rotate, the torque from the rotation of the fastener causes the rotation of the flip tabs. In case, the flip tabs are free to rotate 360 degrees, the fastener can rotate freely with the flip tabs. The brackets are positioned to limit the rotation of flip tabs up to 90 degrees i.e., between the upper leg and side leg of the bracket. When the flip-tab is in a sideward position ( 140  in  FIG. 5 ), the clockwise rotation of the fastener causes the flip tab to move upwards ( 145  in  FIG. 5 ) against the upper leg of the bracket. Once, the rotation of the flip-tab is restricted by the upper leg, the further clockwise rotation of the head  115  of the fastener results in vertical movement of the flip tab towards the panel member. While installing, such a movement of the flip-tab clamps the flip tab to drywall for securing the cover extension over the drywall. Rotating the fastener anti-clockwise loosens the flip tabs which then rotates laterally, and the cover extension can then be removed from the drywall. 
     In practice, a user wishing to add a new wire to the breaker panel first removes the panel cover. Thereafter, a section of the drywall above or below the breaker panel can be cut-off to gain access to the wires behind the drywall. Once the job is completed, the size of the section cut out from the drywall can be leveled to match the size of the cover extension, such as the brackets on the rear face just slide-in along the edge of the drywall. Thereafter, the cover extension can be positioned above or below the breaker panel, and the panel cover is attached such as the bottom flange of the cover extension is sandwiched between the panel cover and the drywall. Thereafter, the screw head on the front wall can be screwed in the clockwise direction for clamping the flip tabs to the drywall. 
     While the foregoing written description of the invention enables one of ordinary skill to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiment, method, and examples herein. The invention should therefore not be limited by the above-described embodiment, method, and examples, but by all embodiments and methods within the scope and spirit of the invention as claimed.