Patent Publication Number: US-2022238286-A1

Title: Weatherproof decorator cover with positive indicator

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of co-pending application Ser. No. 17/164,243, filed Feb. 1, 2021, which is a continuation of application Ser. No. 16/508,672, filed Jul. 11, 2019 (now U.S. Pat. No. 10,943,750), which is a continuation of application Ser. No. 15/340,086, filed Nov. 1, 2016 (now U.S. Pat. No. 10,354,818), which claims priority to U.S. Provisional Application Ser. No. 62/249,994 filed Nov. 3, 2015 each of which are incorporated herein by reference in their entirety. 
    
    
     BACKGROUND 
     Field 
     The present disclosure relates to switch covers and, more particularly, to weatherproof decorator switch covers with positive indicators. 
     Description of the Related Art 
     Weatherproof toggle switches are often used in damp or wet environments. Various ways exist for providing a weatherproof toggle switch. One way is to provide a switch designed and manufactured to include a sealed configuration for preventing condensation or water from entering the switch. Another way is to provide a weatherproof switch plate cover which includes a sealed membrane that covers the forwardly projecting toggle lever. When used in conjunction with the weatherproof switch plate cover, a standard interior toggle switch can be used in damp or wet environments. 
     Interior wall switches have evolved from simple on/off toggle switches to more attractive decor type switches. Decor type switches include decorator rocker style switches. 
     Weatherproof switch plate covers exist for use with rocker style switches. However, these covers generally consist of a flat rubber membrane that covers the entire switch. One downside of these covers is that it is not possible to visually determine whether the switch is in the on or off position. 
     SUMMARY 
     A weatherproof cover includes a base plate, a rocker arm provided in the base plate and movable between a first position and a second position and a membrane provided below the rocker arm, the membrane providing a weatherproof seal. 
     A weatherproof cover kit includes a rocker switch adapted for switching electrical power on and off, a weatherproof electrical box in which the rocker switch is to be mounted and a weatherproof switch cover adapted for covering the rocker switch and mountable to the weatherproof electrical box. The weatherproof switch cover includes a base plate, a rocker arm provided in the base plate and movable between a first position and a second position, and a membrane provided below the rocker arm, the membrane providing a weatherproof seal. 
     A multi-gang weatherproof cover includes a base plate, at least two rocker arms provided in the base plate, each rocker arm movable between a first position and a second position and a membrane provided below the at least two rocker arms, the membrane providing a weatherproof seal. 
     A multi-gang weatherproof cover includes a base plate, a rocker arm provided in the base plate and movable between a first position and a second position, a flip cover pivotally mounted to the base plate and providing a weatherproof seal and a membrane provided below the rocker arm, the membrane providing a weatherproof seal. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A more complete appreciation of the present disclosure and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein: 
         FIG. 1  is a top perspective view of a representative weatherproof switch cover according to an illustrative embodiment of the present disclosure; 
         FIG. 2  is a bottom perspective view of the representative weatherproof switch cover according to an illustrative embodiment of the present disclosure; 
         FIG. 3  is side perspective view of a representative weatherproof switch cover according to an illustrative embodiment of the present disclosure and a utility box housing a decorator type rocker style switch; 
         FIG. 4  is an exploded view of a weatherproof switch cover according to an illustrative embodiment of the present disclosure; 
         FIGS. 5A and 5B  are cross-sectional side views showing how the weatherproof switch cover interacts with a decorator type rocker style switch according to an illustrative embodiment of the present disclosure; 
         FIG. 6  is a perspective view of a multi-gang weatherproof switch cover for covering two decorator type rocker style switches according to an illustrative embodiment of the present disclosure; 
         FIG. 7  is a perspective view of a multi-gang weatherproof switch cover for covering a decorator type rocker style switch and a duplex outlet according to an illustrative embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Illustrative embodiments of the present disclosure may be provided as improvements to weatherproof switch covers. For example, a weatherproof switch cover according to an embodiment of the present disclosure allows an decorator type rocker switch to be used in wet or damp environments. 
     Illustrative embodiments of the present disclosure provide multi-gang weatherproof covers for covering two or more decorator type rocker switches and/or a decorator type rocket switch and a duplex outlet. 
     According to an embodiment of the present disclosure, a weatherproof switch cover includes a rocker switch mechanism that provides positive tactile feedback to a user when the user moves the switch between the on and off positions. 
     In certain illustrative embodiments described herein, one or more components of the weatherproof switch cover may be constructed from metal (e.g., stamped steel, spring steel), plastic (e.g., polycarbonate or nylon) or a combination of such materials. Alternatively, steel, galvanized steel, brass, aluminum or other appropriate alloy may be used for the appropriate components. Of course, other types of materials such as other types of plastics, composites, etc. may be used as desired and where appropriate. 
     In certain embodiments of the present disclosure, a weatherproof switch cover as disclosed herein is mounted to a weatherproof electrical box in which a decorator type rocker switch is provided. The weatherproof electrical box may be a multi-gang box for housing one or more decorator type rocker switches and/or one or more duplex outlets. The weatherproof switch cover as disclosed herein may include one or more rocker arm assemblies for covering one or more decorator type rocker switches and/or one or more weatherproof flip covers for covering one or more standard or decorator type duplex outlets. 
     A representative weatherproof switch cover according to an embodiment of the present disclosure is shown in  FIGS. 1 and 2  and is referred to generally as switch cover  100 . According to this embodiment of the present disclosure, switch cover  100  includes a weatherproof rocker arm assembly including a rocker arm  30  mounted to a base plate  10 . 
     The base plate  10  includes a top wall  10   a , a bottom wall  10   b , a pair of side walls  10   c  and  10   d  and an exterior surface  10   e  secured to or integrally molded into the walls. The space within the walls  10   a - 10   d  and the exterior surface  10   e  is an open interior area  10   f . A gasket  90  may be removably provided on a back surface of the exterior surface  10   e  of base plate  10  as will be described later below. Screws  24  extend through holes  12  provided in spacers  14  formed along the upper and lower ends of the base plate  10  such that the screws  24  align with screw holes in a yoke  130  of an electrical device, such as a decorator type rocker style switch  120 , as will be described later below. A retainer  80  is secured to base plate  10  using fasteners  15 . Retainer  80  holds components of the rocker arm assembly in place. A sealing membrane  70  which includes recessed nubs  72 A,  72 B provides a weatherproof seal as will be described later below. 
       FIG. 3  depicts a single gang weatherproof electrical box  20  which may be made of metal, plastic, etc. A decorator type rocker style switch  120  is positioned in weatherproof electrical box  20  as shown. Electrical wiring (not shown) is run into electrical box  20  via one or more knockouts  121  and is connected to decorator type rocker style switch  120  in the usual manner. Decorator type rocker style switch  120  includes a rocker arm  122 . Generally, switch  120  is arranged such that rocker arm  122  is movable between an “ON” position and an “OFF” position, where the position shown is the “OFF” position. Rocker arm  122  would normally be pressed in area A in order to move rocker arm  122  to the “ON” position. Baseplate  10  of a weatherproof switch cover  100  according to an embodiment of the present disclosure, is positioned over rocker style switch  120  and is secured to weatherproof electrical box  20  such that gasket  90  provides a weatherproof seal between baseplate  10  and an outer edge of weatherproof electrical box  20 . Screws  24  which extend through holes  12  in base plate  10  are aligned with screw holes  132  in the yoke  130  of the decorator type rocker style switch  120  for securing base plate  10  to weatherproof electrical box  20 . As will be described in more detail below, when weatherproof switch cover  100  is mounted to electrical box  20 , pressing rocker arm  30  in area A′ will cause switch  120  to move to the “ON” position. 
     An exploded view of switch cover  100  is shown in  FIG. 4 . A weatherproof rocker arm assembly according to an embodiment of the present disclosure includes rocker arm  30 , plunger assembly  40 , flipper  50 , chassis  60 , sealing membrane  70  and retainer  80 . The rocker arm assembly is mounted to baseplate  10 . As will be described later below with respect to  FIG. 5 , flipper element  50  cooperates with the plunger assembly  40  for providing a snap like action so that the user can feel the switch switching thus providing tactile feedback to the user. Retainer  80  is secured to the back of base plate  10  to keep the rocker arm assembly together as described above. Sealing membrane  70  and gasket  90  may be made of any suitable weatherproof sealing material including, for example, rubber, neoprene, etc. The spring  42 , finger  44 , seen in  FIG. 5A , and flipper  50  may be made of suitable material such as steel including, for example, spring steel, etc. The other elements of switch cover  100  may be made from metal (e.g., stamped steel), plastic (e.g., polycarbonate or nylon) or a combination of such materials. If the base plate  10  and/or retainer  80  are made of metal, the retainer  80  may be secured to the base plate  10  with fasteners  15 , seen in  FIG. 2 , which may include rivets, screws, a press fit, etc. If the base plate  10  and/or retainer  80  are made of plastic, fasteners  15  may include sonic welds, screws, rivets, etc. Rubber o-rings  22  slip onto screws  24  and provide a weatherproof seal around orifices  12  in base plate  10 . 
     A weatherproof switch cover  100  according to an embodiment of the present disclosure is shown in cross-section in  FIGS. 5A and 5B  mounted to a utility box  20 . Rocker arm  122  is representative of a rocker arm of a decorator type rocker style switch  120  that is mounted to box  20  below weatherproof switch cover  100 . For ease of description, the other portions of switch  120  are not shown. Rocker arm  30  includes fingers  32 A,  32 B located adjacent sealing membrane  70 . Sealing membrane  70  includes recessed nubs  72 A,  72 B. When rocker arm  30  is pressed along section B, rocker arm  30  moves into the position shown in  FIG. 5A . In this position, finger  32 B urges nub  72 B into the rocker switch  122  below such that the rocker switch below will be in, for example, the “OFF” position. When rocker arm  30  is pressed along section A, finger  32 A urges nub  72 A into the rocker switch  122  below such that the rocker switch  122  moves into, for example, the “ON” position shown in  FIG. 5B . 
     Sealing membrane  70  includes a multi-tiered edge  74 . Sealing membrane  70  is sandwiched between carriage chassis  60  and retainer  80  such that retainer  80  presses multi-tiered edge  74  into a correspondingly shaped edge of carriage chassis  60 , thus providing a weatherproof seal. 
     Flipper  50  rests on rocker nub  62  provided on carriage chassis  60 . Spring  42  and finger  44  are movably provided in a recess  35  formed on the back of rocker arm  30 . Spring  42  urges finger  44  against flipper  50  just above nub  62 . As shown in  FIG. 5A , flipper  50  is in a first position. When rocker arm  30  is pressed along section A, finger  44  moves such that flipper  50  cams over in the opposite direction into the second position as shown in  FIG. 5B . This arrangement provides a positive tactile feel when rocker arm  30  is moved between the “ON” and “OFF” positions. 
       FIG. 6  depicts a duplex weatherproof switch cover  200  according to an embodiment of the present disclosure. According to this embodiment, base plate  202  is dimensioned to cover a  2  gang box  204  housing two decorator type rocker switches  206 ,  208  as shown. The base plate  202  includes a top wall  202   a , a bottom wall  202   b , a pair of side walls  202   c  and  202   d  and an exterior surface  202   e  secured to or integrally molded into the walls. The space within the walls  202   a - 202   d  and the exterior surface  202   e  is an open interior area  202   f . A gasket  214  is provided between base plate  202  and box  204 . One or more weatherproof rocker arm assemblies including rocker arms  210  and  212  are mounted to base plate  202 . According to an embodiment of the present disclosure, the rocker arm assemblies are similar to the rocker arm assembly (e.g., single switch) described above with respect to  FIG. 4 . Of course, instead of providing separate rocker arm assemblies, the components of the rocker arm assembly may be designed and dimensioned for use with the 2 gang weatherproof switch cover  200 . Screws  220  align with corresponding holes  232  in the yoke  230  of the decorator type rocker style switches  206 ,  208 . 
       FIG. 7  depicts a duplex weatherproof switch/outlet cover  300  according to an embodiment of the present disclosure. According to this embodiment, base plate  302  is dimensioned to cover a  2  gang box  304  housing a decorator type rocker switch  306  and a duplex outlet  308 , e.g., a decorator type duplex outlet, as shown. The base plate  302  includes a top wall  302   a , a bottom wall  302   b , a pair of side walls  302   c  and  302   d  and an exterior surface  302   e  secured to or integrally molded into the walls. The space within the walls  302   a - 302   d  and the exterior surface  302   e  is an open interior area  302   f . A gasket  314  is provided between base plate  302  and box  304 . A weatherproof rocker arm assembly including rocker arm  310  is mounted to base plate  302 . The rocker arm assembly is similar to that described above with respect to  FIG. 4 . According to this embodiment, a flip cover  312  is pivotally mounted to base plate  302  via a spring biased hinge  332  and provides access to duplex outlet  308 . Flip cover  312  includes a gasket  330  providing a weatherproof seal. Screws  320  align with corresponding holes  332  in the yoke  330  of the decorator type rocker style switches  306  and the duplex outlet  308 . 
     As shown throughout the drawings, like reference numerals designate like or corresponding parts. While illustrative embodiments of the present disclosure have been described and illustrated above, it should be understood that these are exemplary of the disclosure and are not to be considered as limiting. Additions, deletions, substitutions, and other modifications can be made without departing from the spirit or scope of the present disclosure. Accordingly, the present disclosure is not to be considered as limited by the foregoing description.