Patent Publication Number: US-RE48192-E

Title: Receptacle-mounted cover plate to hide electrical socket face

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is continuation-in-part of patent application by Shotey, et al. entitled “RECEPTACLE-MOUNTED COVER PLATE TO HIDE ELECTRICAL SOCKET FACE,” Ser. No. 10/853,925, filed on May 25, 2004, which is a continuation of patent application by Shotey, et al. entitled “RECEPTACLE-MOUNTED COVER PLATE TO HIDE ELECTRICAL SOCKET FACE”, Ser. No. 10/283,586, filed Oct. 29, 2002 and issued on Jul. 13, 2004 as U.S. Pat. No. 6,761,582, which is a continuation of patent application by Shotey et al. entitled “RECEPTACLE-MOUNTED COVER PLATE TO HIDE ELECTRICAL SOCKET FACE”, Ser. No. 09/351,761, filed Jul. 12, 1999 and issued on Jan. 28, 2003 as U.S. Pat. No. 6,511,343, which is a continuation of patent application by Shotey, et al. entitled “RECEPTACLE-MOUNTED COVER PLATE TO HIDE ELECTRICAL SOCKET FACE,” Ser. No. 08/775,382, filed Dec. 30, 1996 and issued on Oct. 12, 1999 as U.S. Pat. No. 5,965,846, the disclosures of which are hereby incorporated herein by reference. 
     BACKGROUND OF THE INVENTION 
     1. Technical Field 
     This invention relates generally to cover plates for electrical outlets and more particularly to a simplified means to cover the face of unattractive electrical sockets and thereby make the outlet more aesthetically pleasing while maintaining proper functionality. 
     2. Background Art 
     Conventional electrical outlets are made of several components, including a wall box and a receptacle, which is typically composed of pairs of sockets and a yoke. The receptacle is typically attached to the wall box that is typically attached to a framing member inside the wall, and is accessible through a hole cut in the wall. A cover plate having apertures to allow the sockets to protrude is installed over these components, typically with one or two screws. Electrical devices are plugged in by inserting the plug blades through aligned apertures in the cover plate and socket. 
     A cover plate is installed after construction. It is common practice to remove the cover plate during remodeling or redecorating so that it does not become damaged or defaced with paint drips and splatters, wallpaper paste, or other decorating materials. The conventional cover plate is easily removed by unscrewing the screw or screws that attach it directly to the receptacle. However, the receptacle is not usually removed during remodeling or redecorating because it is hard-wired into the building&#39;s electrical system. Consequently, the receptacle and sockets are left exposed and the face of the sockets become covered with paint splatters and the like. If not cleaned immediately, the face becomes permanently defaced, thereby making the electrical outlet more unsightly and conspicuous. Repeated paintings only make the problem worse. Reinstalling the cover plate then emphasize the paint-splattered surface of the outlet, as the defaced socket surface is compared to the pristine surface of the cover plate. 
     Cover plates are available in a variety of colors, decorator textures and even covered with wallpaper to match the wall. However, the underlying receptacles and cover plates are made in standard colors, usually beige and dark brown, and unfortunately do not match many decorative cover plates. Because most cover plates allow the face of the sockets to be exposed, such mismatched sockets and cover plates cause the outlets to be more conspicuous. It is desirable, then, to provide a cover plate that can be installed over existing receptacles that covers not only the wall box assembly, but the face of the sockets, too, in order to make the outlet less conspicuous and more attractive. 
     Decorative cover plates known in the art attempt to make outlets more attractive by attaching a new cover plate to existing cover plates. For example, in U.S. Pat. No. 1,784,277 Darlington describes an ornamental cover for a light switch manufacturable in many colors. The cover is a multilayer pad of adhesively-backed sheets which is adhesively attached to the existing cover plate. When desired, a decorative sheet may be removed, exposing a new sheet. In U.S. Pat. No. 4,312,458, Stewart describes a fabric slipcover for an existing cover plate. In U.S. Pat. No. 3,840,692 Wells describes an outsized cover plate that is screwed over an existing cover plate. Because these decorative cover plates overlay the existing cover plate, these inventions result in a cover that projects farther from the wall than the original cover plate, thereby making the outlet even more noticeable. 
     More complex devices have been invented to achieve an aesthetically pleasing electrical outlet. For example, U.S. Pat. No. 5,180,886 issued to Dierenbach describes an entire wall box assembly to provide an attractive designer-style appearance. The decorative appearance is achieved with the use of a multi-component cover plate requiring a plurality of attachment means to secure the components in place. 
     The prior art also describes removable paint shields to protect the sockets and cover plates during painting. In U.S. Pat. No. 5,003,128 Grondin describes a cover that removably adheres to an existing cover plate of an electrical outlet so that the electrical elements are protected during painting. The device completely covers the receptacles such that a plug may not be inserted. Gilchrist describes a paint shield in U.S. Pat. No. 5,285,014 that also covers all exposed surfaces of an electrical outlet. The shield is temporarily attached using suction of adhesives, or with prongs that fit snugly in the socket apertures. While these devices do protect the outlets if installed before painting, they do not remedy the situation where the sockets are already defaced. Similarly, these covers do not provide a means for making the outlets more attractive. 
     Other patents describe inventions that replace existing cover plates to improve safety of the outlet. In U.S. Pat. No. 5,165,042 Klinger describes a decorative safety cover plate that replaces the existing plate. This invention comprises a base plate and a decorative face plate that slides between a closed position where the sockets are occluded, and an open position where the sockets are exposed. Barla describes a safety cover plate in U.S. Pat. No. 5,240,426 that replaces the existing cover plate. The plate has manually positionable shutters to occlude the entire socket so that plugs may not be inserted. While improving safety, these devices are multi-component parts that are relatively expensive, more difficult to install than a conventional cover plate, and prone to breaking. They also suffer the same problem as the known decorative cover plates: they project farther from the wall than the original cover plate, thereby making the outlet even more noticeable. 
     In U.S. Pat. No. 5,965,846 to Shotey et al., from which this patent is a continuation-in-part, a cover plate is disclosed having a thickness of 0.080 inches or greater. Cover plates according to this invention with thicknesses of 0.080 inches or greater have been sold. However, it does not teach the use of a cover plate with a thickness less than 0.080 inches. 
     Accordingly what is needed is a cover plate to cover the socket face of unattractive electrical receptacles and thereby make the receptacle less noticeable while maintaining proper functionality of electrical devices plugged into the covered socket. 
     BRIEF SUMMARY OF THE INVENTION 
     This invention provides a simple, easily-installed cover plate that hides the face of sockets by covering an electrical outlet, including the face of the sockets. In particular embodiments, the cover plate may comprise a plurality of plug blade apertures, a front surface, one or more thinned regions on the front surface, and a back surface region that contacts the socket face. 
     The back surface region may be substantially flat to seat against the insulative socket face. In particular embodiments, the cover plate also comprises an alignment structure to align the plurality of plug blade apertures on the cover plate with the plug blade apertures on the socket face. The alignment is particularly useful in obtaining proper seating of the back surface region against the insulative socket face. 
     In other embodiments of the present invention, the thinned areas may be of various shapes, including, but not limited to a duplex shape and a decora shape and may be formed using protrusions from the front surface or grooves in the front surface. 
     The foregoing and other features and advantages of the present invention will be apparent from the following more detailed description of the particular embodiments of the invention, as illustrated in the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front view of a cover plate with one securing aperture; 
         FIG. 2  is a front view of a decora cover plate with one securing aperture; 
         FIG. 3  is a front view of a duplex cover plate with one securing aperture; 
         FIG. 4  is a front view of a cover plate with two securing apertures; 
         FIG. 5  is a front view of a decora cover plate with two securing apertures; 
         FIG. 6  is a front view of a duplex cover plate with two securing apertures; 
         FIG. 7  is a back view of a cover plate with two truncated circle recesses and one securing aperture; 
         FIG. 8  is a back view of a cover plate with two rectangular recesses and one securing aperture; 
         FIG. 9  is a back view of a cover plate with one rectangular recess and two securing apertures; 
         FIG. 10  is a back view of a cover plate with two securing apertures; 
         FIG. 11  is a section view of a cover plate taken along line  11 - 11  of  FIG. 1 ; 
         FIG. 12  is a section view of a decora cover plate taken along line  12 - 12  of  FIG. 2 ; 
         FIG. 13  is a section view of a duplex cover plate taken along line  13 - 13  of  FIG. 3 ; 
         FIG. 14  is a section view of a cover plate with two securing apertures taken along line  14 - 14  of  FIG. 4 ; 
         FIG. 15  is a section view of a decora cover plate with two securing apertures taken along line  15 - 15  of  FIG. 5 ; 
         FIG. 16  is a section view of a duplex cover plate with two securing apertures taken along line  16 - 16  of  FIG. 6 ; and 
         FIG. 17  is a section view of a cover plate taken along line  17 - 17  of  FIG. 1 . 
     
    
    
     DESCRIPTION OF THE SEVERAL EMBODIMENTS 
     Referring to  FIGS. 1-6 , embodiments of the invention are illustrated.  FIG. 1  shows cover plate  20  having a flat face with a set of apertures  22  for plug blades and a securing aperture  24 .  FIG. 2  shows cover plate  30  having a decora face  32  with a set of apertures  22  for plug blades and a securing aperture  24 .  FIG. 3  shows cover plate  40  having a face with a duplex shape  42  with a set of apertures  22  for plug blades and a securing aperture  24 .  FIG. 4  shows cover plate  50  having a flat face with a set of apertures  22  for plug blades and top and bottom securing apertures  52  and  54 .  FIG. 5  shows cover plate  60  having a face with a decora groove  62  with a set of apertures  22  for plug blades and top and bottom securing apertures  52  and  54 .  FIG. 6  shows cover plate  70  having a face with duplex shaped grooves  72  with a set of apertures  22  for plug blades and top and bottom securing apertures  52  and  54 . It will be understood by those of ordinary skill in the art that a duplex face or duplex socket face are those typically used wherein there are two sets of plug blade apertures located on two truncated circle shaped insulative socket faces. Also, the securing apertures may be adaptable such that each of the cover plates,  20 ,  30 ,  40 ,  50 ,  60 , and  70  may have one or two securing apertures depending on the type of electrical outlet to be covered. The shape placed on the front surface of the cover plate, either by using grooves or protrusions, aids in the visual quality of the cover plate. 
     In embodiments of the present invention, the cover plate is specifically designed to cover the socket faces of the receptacle so there are no socket face apertures in the cover plate. For example and referring to  FIGS. 7-10 , the cover plate is adapted to receive the face of the socket against the reverse side or the back of the cover plate. In  FIG. 7 , a set of truncated circle shaped recesses  80  may receive a duplex socket face, while maintaining proper alignment of the apertures  22  for plug blades and the securing aperture  24 .  FIG. 8  shows the use of rectangular recesses  82  for receiving the socket face and aligning apertures  22  for plug blades and securing aperture  24 .  FIG. 9  uses a rectangular shaped recess  84  for receiving decora shaped socket faces and creating proper alignment of the apertures  22  for plug blades and securing apertures  52  and  54 . Finally, as seen in  FIG. 10  a flat surface back  86  may be used to cover any type of socket with alignment of the apertures  22  obtained by use of securing apertures  52  and  54 . The various front cover types  20 ,  30 ,  40 ,  50 ,  60  and  70 , as seen in  FIGS. 1-6 , may be used in conjunction with each type of reverse side configuration as shown in  FIGS. 7-10  in order to obtain the look for the type of front surface desired while maintaining the ability to fit the socket face being covered. It will be understood that the specific embodiments illustrated in the figures are for exemplary purposes only and the present invention may be formed to have many various shapes, looks and textures on the front surface while altering the reverse side to fit any type of outlet socket face. 
     While the shape of the recessed, thinned areas need not coincide with the shape of the socket, the recessed, thinned areas can be manufactured to match the shape of the socket face. The cover plate is stronger and more durable with smaller thinned areas, however. With the more durable embodiment of the cover plate, the cover plate can also protect the receptacle from damage due to rough handling. For example, if a plug inserted into an outlet with a conventional cover plate is yanked out of the wall sideways, that is, substantially parallel to the wall, the forces applied to the sockets can cause the receptacle to be jarred loose or to crack. A cover plate of the present invention can help protect the receptacle because as the plug is pulled sideways from an outlet having the present cover plate, the applied forces in part act on the cover plate, reducing or eliminating the forces on the receptacle. Additionally, as areas of the cover plate are thinned, there is a visible slight variation in the cover plate at the thinned areas. Separating the thinned area by use of grooves or protrusions separates the visible distinction of the thinned area from the rest of the cover plate, rendering the differentiation more inconspicuous. 
     Referring now to  FIGS. 11-16 , section views of the preferred embodiment cover plates  20 ,  30 ,  40 ,  50 ,  60  and  70  respectively are shown. In  FIG. 11 , the cover plate  20  has a flat face and a back with truncated circle shaped recesses  80  and a securing aperture  24  to match the shape of a conventional duplex socket face. Flanges  26  surround the securing aperture  24  and are used for alignment of the apertures for plug blades located through the truncated circle shaped recesses  80 .  FIG. 12  shows a cover plate  30  with a decora protrusion face  32  and rectangular recesses  82  on the back of the cover plate  30 . Flanges  26  surround the securing aperture  24  and are used for alignment of the apertures for plug blades located through the rectangular recesses  82 . Looking at  FIG. 13 , a cover plate  40  with a duplex face  42  has square recesses  82  on the back of the cover plate  40 . Flanges  26  surround the securing aperture  24  and are used for alignment of the apertures for plug blades located through the square recesses  82 . In  FIG. 14 , the cover plate  50  with a flat face has a flat surface back  86 . The securing apertures  52  and  54  are used for alignment of the apertures for plug blades located through the cover plate  50 .  FIG. 15  shows a cover plate  60  with a decora groove  62  of the face and decora recesses  84  on the back of the cover plate  60 . The securing apertures  52  and  54  are used for alignment of the apertures for plug blades located through the cover plate  60 . Looking at  FIG. 16 , a cover plate  70  with duplex grooves  72  on the face has a set of truncated circle shaped recesses  80  on the back of the cover plate  70 . The securing apertures  52  and  54  are used for alignment of the apertures for plug blades located through the cover plate  50 . It will be understood that any combination of faces, reverse sides (with the various recesses or a flat surface) and securing apertures may be utilized to form a cover plate with the desired design and proper functionality. 
     Also shown in  FIGS. 11-16  is a thickness  88 . For the exemplary purposes of this disclosure, the thickness  88  of the cover plates in the portions covering the socket faces are not more than 0.075 inches. The thickness  88  is located at the apertures  22  for the plug blades as seen in  FIGS. 1-10 . The thickness  88  may be of various shapes and sizes, so long as the thickness  88  does not exceed a maximum thickness of 0.075 inches. This area is the area through which plug blades are inserted and provides the point of electrical contact for a corded plug in the receptacle. This small thickness allows the plug blades to be inserted deeper into the plug blade apertures of the receptacle despite the insulative plug cover layer extending over the socket face. Additionally, a plane defined in part by one or more regions of the front surface with thickness  88 , whereby the plane extends parallel to the cover plate, may serve as a boundary through which no portion of the front surface of the cover plate may extend beyond. 
     Exemplary embodiments of the present invention have the thickness  88  within the range of not more than 0.075 inches. It has been found that the conventional thickness of 0.080 inches and larger causes concern among some that sufficient contact will not be made by the plug prongs into the socket. Reduction of the thickness  88  to less than 0.075 inches, and more particularly to a range of 0.020-0.075 inches, permits the plug prongs to extend more fully into the socket, relieving many of those concerns. In particular embodiments of the present invention, a thickness of 0.020 inches may be achieved by use of particular materials, such as, but not limited to, polypropylene and polyethylene. In other particular embodiments, the thickness of 0.020 inches may also be accomplished by use of a vacuum used during the material flow process. As the vacuum evacuates the air within a mold used to form a cover plate, the material forming the cover plate may more easily be drawn into all cavities of the mold. To maximize the strength of the covering surface while minimizing the thickness  88 , it has been found that a thickness between 0.030 inches and 0.055 inches reduces the likelihood of structural failure while maintaining the ability to achieve sufficient contact of the plug prongs within the socket. To maximize the contact made by the plug prongs into the socket, it has been found that a thickness within the range of 0.035-0.045 inches provides a substantially maximum contact between the plug prongs and the socket for a covered socket face while providing adequate strength of the covering surface. It will be understood by those of ordinary skill in the art that the ranges of thickness disclosed are for the exemplary purposes of this disclosure and that the present invention is not limited to these ranges. 
     In particular embodiments of the present invention, the thickness  88  may be accomplished by recessing or reducing the thickness from the back surface of the cover plate. This enables the front surface of the cover plate to not extend beyond the plane defined in part by the one or more thinned regions of the front surface that extends parallel to the cover plate. This vertical plane sets the boundary for which portions of the cover plate should not extend past, allowing for unobstructed insertion of plug blades into the receptacle through the cover plate. While portions of the front face may not extend beyond the vertical plane, they may extend backward. For example, a protrusion may extend from the back surface of the cover plate at the plug blade apertures corresponding to particular recesses on the socket face. This protrusion thereby provides proper alignment of the apertures, allowing the back surface of the cover plate to seat properly against the socket face, while maintaining the vertical plane boundary at the thinned front surface regions of the cover plate. Protrusions extending from the back surface may be used so long as the thickness  88  remains less than 0.075 inches from the front surface of the cover plate to the foremost portion of the socket face seated against the back surface of the cover plate at the plug blade apertures of the cover plate. 
     Referring to  FIG. 17 , a section view of the truncated circle shaped recess  80  is shown with thickness  88 . In particular embodiments of the present invention radii  90  may used instead of a right angles to achieve a small thickness  88  and still maintain the structural and aesthetic integrity of the cover plate. Conventional recesses are formed using right angle edges, which is harder to manufacture due to insufficient material flow. Additionally, recessed or thinned areas with thicknesses less than 0.075 inches formed using right angle recesses often form a wavy or inconsistent surface affecting the aesthetics and structure of the cover plate. The use of radii  90  at the corners in particular embodiments of the present invention improves material flow and enables the cover plate to have improved structural and aesthetics integrity by substantially reducing or eliminating wavy surfaces. The greater the radius of curvature, the better the material flow, but at some point the radius wall will interfere with the socket face. Those of ordinary skill in the art will readily be able to select a radius of curvature appropriate for matching a back surface of a cover plate with a particular socket face to optimize material flow without significantly impeding the socket face from resting against the back surface of the cover plate. 
     Cover plates of the present invention may be installed in various manners. Conventional outlets have a threaded receiving aperture centered between the sockets for receiving a screw while other outlets have a pair of receiving apertures placed at opposite ends of the receptacle in the yoke. The present invention may be made to accommodate any underlying receptacle. If necessary to strengthen the cover plate&#39;s securing aperture, a protrusion such as the flange  26 , shown surrounding the securing aperture  24  in  FIG. 11 , may project outwardly from the reverse side of the cover plate. 
     The number of apertures in the cover plate for receiving plug blades is dependent on the number of blades on the plug. Typically, the number and position of apertures on the cover plate will match the number and position of apertures on the receptacles, although fewer apertures may be used on the cover plate to exclude particular apertures in the socket faces, if desired. Conventional dual receptacle outlets have two sets of apertures, one set for each socket face. In addition to outlets having different numbers of apertures, outlets may have varying numbers of socket faces. For example, conventional outlets have two socket faces and are known as single-gang outlets. Double-gang outlets are also common. The cover plate of the present invention can be made with corresponding number and placement of apertures to match and align with the number of underlying socket faces. Alternatively, cover plates comprising selected aspects of the present invention may be manufactured to include one or more openings for switches or other electrical devices, without limitation, in addition to including one or more thinned front surface regions for hiding socket faces. 
     The cover plates of the present invention typically have outside dimensions that substantially match a conventional or existing cover plate, but the cover plates herein described may be designed in any desired size and shape to enhance the appearance of the electrical outlet. 
     The embodiments and examples set forth herein were presented in order to best explain the present invention and its practical application and to thereby enable those of ordinary skill in the art to make and use the invention. However, those of ordinary skill in the art will recognize that the foregoing description and examples have been presented for the purposes of illustration and example only. The description as set forth is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the teachings above without departing from the spirit and scope of the forthcoming claims.