Patent Publication Number: US-2007107631-A1

Title: Covers including a shaped surface

Description:
CROSS-REFERENCE TO RELATED APPLICATION  
      The present invention claims the benefit of U.S. Provisional Application No. 60/731,815 filed Oct. 31, 2005, the entire disclosure which is herein incorporated by reference. 
    
    
     FIELD OF THE INVENTION  
      The present invention relates to covers, and more particular to covers including a shaped surface for facing away from an interior area of a container.  
     BACKGROUND OF THE INVENTION  
      Conventional housings are known to include a cover. The housing typically forms an interior area and the cover is configured to cooperate with another structure of the housing to close the interior area. Such covers are known to include an outer surface with a substantially flat upper surface. Such flat surfaces may not be designed to encourage fluid flow in a particular direction. Still further, a certain amount of fluid may pool on the upper flat surface of the cover.  
     SUMMARY OF THE INVENTION  
      Accordingly, it is an aspect of the present invention to obviate problems and shortcomings of conventional covers.  
      In accordance with one aspect, a cover for a container including an interior area is provided. The cover includes a shaped surface for facing away from an interior area of a container. The shaped surface includes a substantially planar surface, a substantially concave surface, and a smooth transition from the substantially planar surface to the substantially concave surface.  
      In accordance with another aspect, a cover for a container including an interior area is provided. The cover includes a shaped surface for facing away from an interior area of a container. The shaped surface includes a first substantially convex surface, a second substantially convex surface, and a substantially concave surface. A portion of the substantially concave surface extends from a portion of the first convex surface to a portion of the second convex surface.  
      In accordance with still another aspect, a cover for a container including an interior area is provided. The cover includes a shaped surface for facing away from an interior area of a container. The shaped surface includes a first substantially convex surface, a second substantially convex surface, a substantially planar surface, a substantially concave surface, and a transition from the substantially planar surface to the substantially concave surface. The cover further includes a second surface for facing towards an interior area of a container. The second surface includes a transition that substantially follows the transition of the shaped surface. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      The foregoing and other aspects of the present invention will become apparent to those skilled in the art to which the present invention relates upon reading the following description with reference to the accompanying drawings, in which:  
       FIG. 1  is a perspective view of a junction box incorporating aspects of the present invention;  
       FIG. 2  is a top view of the junction box of  FIG. 1 ;  
       FIG. 3  is a top view of the junction box of  FIG. 1  with the cover in an open orientation;  
       FIG. 4  is a sectional view of the junction box along line  4 - 4  of  FIG. 2 ;  
       FIG. 5  is a front elevational view of the junction box of  FIG. 1 ;  
       FIG. 6  is a front elevational view of the junction box of  FIG. 1  with the cover in an open orientation;  
       FIG. 7  is a right side elevational view of the junction box of  FIG. 1 ;  
       FIG. 8  is a right side elevational view of the junction box of  FIG. 1  with the cover in an open orientation; and  
       FIG. 9  is a bottom view of the junction box of  FIG. 1 . 
    
    
     DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS  
      Certain terminology is used herein for convenience only and is not to be taken as a limitation on the present invention. Further, in the drawings, the same reference numerals are employed for designating the same elements.  
      Aspects of the present invention comprise covers for use with a container including an interior area for receiving electrical wire from a conduit.  FIGS. 1-8  depict a cover  60  in accordance with one example of the present invention. The example cover may be incorporated as part of a housing.  FIGS. 1-9  depict one example of a housing  10  including a container  40  defining an interior area  42  of the housing  10 . The container  40  can include a peripheral edge  44  defining an opening  43  providing access into the interior area  42 . The cover  60  of the housing is configured to close the opening  43  into the interior area  42 .  
      The container  40  can comprise various structural configurations to define the interior area  42 . For example, as shown, the container  40  can include a base wall  54  and a peripheral wall  56  including the peripheral edge  44 . The base wall  54  is illustrated as substantially planar but may comprise, at least partially or entirely, a curved or other nonplanar shape. The peripheral wall  56  can be disposed to extend from the base wall  54  at a wide range of angles. For example, as shown in  FIG. 4 , the peripheral wall  56  can extend at an angle of slightly greater than 90° from the base wall to simplify injection molding techniques. In further examples, the base wall can extend at 90° from the base wall  54  or at various angles greater or less than 90° from the base wall  54 . As further illustrated, the peripheral wall  56  can at least partially circumscribe the interior area  42 . In the illustrated example, the peripheral wall  56  entirely circumscribes the interior area  42  of the container  40 .  
      The peripheral wall  56  can have a single wall portion or a plurality of wall portions. For example, the peripheral wall can comprise a single wall portion having a circular, oval, or other shape. In further examples, the peripheral wall can comprise a plurality of wall portions defining a generally polygonal shape having three or more sides. For instance, the peripheral wall can comprise three or more wall portions connected with respect to one another to form a peripheral wall including a substantially triangular, rectangular, square, or other polygonal shape. Moreover, each wall portion can include one or more different types of segments. For instance one or more wall portions can be formed with a substantially straight segment defining a substantially planar surface. In further examples, one or more wall portions can be formed with a substantially curved segment having a substantially curved surface. For example, as shown in  FIGS. 3 and 7 , the illustrated peripheral wall  56  comprises four wall portions defining a generally rectangular shape. The illustrated generally rectangular peripheral wall  56  includes a first wall portion  56   a , a second wall portion  56   b , a third wall portion  56   c  and a fourth wall portion  56   d . Although not required, the first wall portion  56   a  comprises a substantially straight segment (see  FIG. 7 ) while the second, third and fourth wall portions  56   b ,  56   c ,  56   d  comprise substantially curved segments (see  FIG. 3 ).  
      Each wall portion can extend at various heights with respect to the base wall. For example, each wall portion can extend from the base wall with substantially the same height profile. In further examples, at least one wall portion can extend from the base wall with a height profile that is substantially different than a height profile of another wall portion. One or more of the wall portions may have a height profile comprising a substantially straight line that is substantially parallel to the base wall wherein the height of the wall portion is substantially constant along a length of the wall portion. For instance, as shown in  FIG. 6 , the first wall portion  56   a  has a height profile comprising a substantially straight line that is substantially parallel to the base wall  54  wherein the first wall portion  56   a  extends from the base  54  at a substantially constant first height “H 1 ” along the entire length “L 1 ” of the first wall portion  56   a . Providing the first wall portion  56   a  with a height profile comprising a substantially straight line can accommodate a linear hinge as described below.  
      In further examples, one or more of the wall portions may have a height profile comprising a substantially straight line that extends at an angle with respect to the base wall wherein the height of the wall portion changes along a length of the wall portion. In still further examples, one or more wall portions may have a height profile comprising a curved line wherein the height of the wall portion changes along a length of the wall portion. For example, as shown in  FIG. 6 , the second wall portion  56   b  includes a height profile comprising a curved line that extends from the base  54  at a height that changes along the entire length “L 2 ” of the second wall portion  56   b  between a second height “H 2 ” to a third height “H 3 ”. As shown in  FIGS. 3 and 6 , the third and fourth wall portions  56   c ,  56   d  can be substantially identical mirror images of one another. Moreover, as shown in  FIG. 8 , the third and fourth wall portions  56   c ,  56   d  each have a height profile comprising a curved line that extends from the base  54  at a height that changes along the entire length “L 3 ” of the third and fourth wall portions  56   c ,  56   d  between the first height “H 1 ” to the third height “H 3 ”. The height profiles of the wall portions permit the peripheral edge  44  of the peripheral wall  56  to conform to the shape of corresponding portions of the cover  60 . Morever, as shown in  FIG. 7 , the height profiles of the wall portions further permit the cover  60  to generally extend at an angle with respect to the base wall  54  in the closed position by extending from the first wall portion  56   a  to the second wall portion  56   b.    
      As shown, housings can comprise at least one coupling although further examples of the invention may be employed without couplings. Each coupling, if provided, includes an internal passage configured for communicating with an interior area of the housing. The internal passage permits wires from a conduit to be inserted through the internal passage and into the interior area of the housing. For example, as shown in  FIG. 9 , one example of the at least one coupling comprises a six sockets  20  although more or less than six sockets may be employed in further examples. Each socket  20  includes an internal passage  26  configured to communicate with an interior area  42  of the housing  10 . Each socket  20  can also include an optional knock-out wall  24  adapted to initially inhibit a communication between the interior area  42  of the housing  10  and the internal passage  26  of the socket  20 .  
      As shown in  FIG. 4 , each socket  20  can comprise three reception areas  20   a ,  20   b ,  20   c  that successively increase in size along the internal passage  26  to form a stepped configuration to alternatively receive conduits having three different sizes. The stepped configuration of the attachment areas of the coupling can be formed with a wide range of sizes and configurations to accommodate alternative conduit sizes and/or shapes. For example, the first reception area  20   a  may be dimensioned to receive a 0.5 inch conduit, the second reception area  20   b  may be dimensioned to receive a 0.75 inch conduit, and the third reception area  20   c  may be configured to receive a 1 inch conduit. In alternative embodiments, the sockets may be able to receive conduits having other dimensions. Accordingly, a single socket may be provided with reception areas arranged in a stepped configuration to accommodate one of various standard and/or customized conduit sizes. An optional chamfered surface  22  may be provided between adjacent reception areas to help the end of a smaller conduit travel from a larger sized reception area to a smaller sized reception area when inserting a conduit into the socket.  
      The reception areas can also include a wide variety of shapes to accommodate various applications. As shown in the illustrated example, the reception areas  20   a ,  20   b ,  20   c  can comprise a substantially circular cylindrical cross sectional shape. In such an embodiment, the plurality of reception areas include successively larger inner diameters along the internal passage such that the socket forms a stepped configuration to receive and attach to an outer cylindrical area of different sized conduits.  
      Aspects of the present invention may include a single coupling although a plurality of couplings may be provided in further examples. For instance, as shown in  FIG. 9 , six sockets  20  are provided although more or less sockets may be provided in further examples. If a plurality of sockets are provided, they may be independently supported with respect to a portion of the container. Alternatively, a plurality of the sockets may be linked together. For instance, as illustrated, a plurality of the sockets may be linked together with walls  21  as one or more clusters  19  to increase the overall structural integrity of the sockets  20 .  
      Housings in accordance with the present invention may be constructed in a wide variety of ways and from a wide range of materials, such as weather resistant materials. For instance, components of the housings may be constructed from metal, plastic, composites, resins, and/or other materials. In one example, components of the housing are formed with an injection molding process although other fabrication techniques may be employed. As shown, the container and the couplings may be integrally molded, such as injection molded, as a one piece design to simplify the manufacturing process and to enhance the structural integrity of the couplings. For example, as shown in  FIG. 4 , each coupling  20  can be integrally molded with the base wall  54 .  
      As mentioned previously, housings in accordance with the present invention include a cover to close the opening into the interior area defined by the container. Aspects of the present invention may be used with various cover types and configurations. In one example, the cover can be designed to selectively close the container although it is contemplated that the cover may also be designed to permanently close the interior area of the housing. A variety of cover configurations may be provided to allow the cover to selectively close a container. For example, the cover may be designed for complete disengagement from the housing to open the interior area of the container. In such an embodiment, the cover may snap into place to discourage inadvertent removal of the cover from the container.  
      In further examples, the cover can be pivotally connected to the container wherein the cover can pivot between closed and open orientations. For instance, as shown in the illustrated example, the cover  60  can be pivotally attached to the container  40  by way of a hinge structure  65 . As shown in  FIGS. 1, 2 ,  5  and  7 , the cover may be pivoted to a closed orientation wherein the cover closes the opening  43  of the container  40 . Alternatively, as shown in  FIGS. 3, 6  and  8 , the cover  60  can also be pivoted to an open orientation wherein the cover does not close the opening  43  of the container  40 .  
      Various structures may be provided to pivotally connect the cover to the container. For example, a living hinge may be provided between the cover and the container. In further examples, the cover and container can include hinge portions that cooperate to define the hinge structure. As shown, portions of the cover  60  and the container  40  cooperate to form a hinge structure  65  to pivotally attach the cover  60  to the container  40 . As shown, the hinge structure  65  comprises a linear hinge structure although nonlinear hinge structures may be provided in further examples of the present invention.  
      The cover can include a wide variety of shapes and sizes. Covers in accordance with the present invention comprise a shaped surface  62  for facing away from the interior area  42  of the container  40 . In one example, the shaped surface  62  can include a substantially planar surface  64 . Providing the substantially planar surface  64  can be beneficial to accommodate a linear hinge structure. Indeed, as shown in  FIGS. 1 and 2 , the substantially planar surface  64  provides a linear area configured to accommodate a linear hinge structure  65 . In further examples, it is also contemplated that a nonplanar surface may be provided that can accommodate a linear hinge structure. However, the illustrated planar surface  64  may be provided to minimize the thickness of the cover  60  while providing sufficient mounting for the linear hinge structure. In still further examples, it is contemplated that a nonlinear hinge structure may be incorporated with a nonplanar or substantially planar surface.  
      As further illustrated, the shaped surface  62  of the cover can also include a substantially concave surface  66  to help direct a liquid flowing on the shaped surface  62 . The substantially concave surface  66  can be located at various positions of the shaped surface  62 . In the illustrated example, the substantially concave surface  66  is opposed to the substantially planar surface  64  at the front portion of the cover  60 . Providing the substantially concave surface  66  at the front portion of the cover  60  can help direct a liquid flow stream in a direction from the rear portion to the front portion of the cover  60 . Moreover, providing the substantially concave surface  66  at the front of the cover  60  can be used with a second wall portion  56   b  having a reduced height “H 2 ”. As shown in  FIG. 6 , providing the second wall portion  56   b  with a reduced height “H 2 ” can provide enhanced access into the interior area  42  by an individual accessing the interior area  42  of the container  40  from the front side of the container.  
      If the concave surface  66  is provided at the front portion of the cover  60 , the substantially concave surface may be located at a right, left, or central area of the front portion of the cover  60 . For example, as shown, the substantially concave surface  66  is located at a central area of the front portion of the cover  60 . Thus as shown, a liquid flow on the shaped surface  62  may be encouraged to flow from the rear portion of the cover  60  toward the central area of the front portion of the cover  60 . Moreover, providing the substantially concave surface  66  at the central area of the front cover  60  can be used with a second wall portion  56   b  having a reduced height “H 2 ” located at a central portion of the second wall portion  56   b . As shown in  FIG. 6 , providing the reduced height “H 2 ” at the central portion of the second wall portion  56   b  can allow enhanced access to central portions of the interior area  42  while still allowing sufficient access to the right and left areas of the interior area  42  of the container  40 .  
      As further illustrated, examples of the shaped surface  62  can also include a smooth transition  63  from the substantially planar surface  64  to the substantially concave surface  66 . Providing a smooth transition  63  can be beneficial to help prevent pooling of liquid on the cover. Rather than pooling, a liquid stream can be directed along the cover  60  to gradually transition between areas of the shaped surface  62 .  
      Examples of the shaped surface may include at least one convex surface. For example, as shown, the shaped surface  62  can comprise a first substantially convex surface  68  and a second substantially convex surface  70 . As shown in  FIG. 5 , the convex surfaces  68  and  70  can comprise substantial mirror images of one another. The convex surfaces can further enhance drainage of liquid from the cover. For example, as shown in profile in  FIG. 7 , the convex surface  68  can extend downward from a rear of the shaped surface  62  towards a front of the shaped surface  62 . Moreover, providing the substantially convex surfaces  68  and  70  at the right and left portions of the cover  60  can be used with third and fourth wall portions  56   c ,  56   d  of a container  40  having an increased height “H 1 ” at the rear of the container that gradually reduces to the maximum height “H 3 ” of the second wall portion  56   b  in a direction towards the front of the container. Therefore, the height of the third and fourth wall portion  56   c ,  56   d  can be increased to provide a larger interior area  42  for the container  40  while still providing convex surfaces  68  and  70  to enhance drainage of liquid from the cover  60 .  
      As shown in  FIGS. 1 and 3 , a portion of the substantially concave surface  66  extends from a portion of the first convex surface  68  to a portion of the second convex surface  70 . Indeed, the illustrated shaped surface  62  gradually transitions from the substantially planar surface  64  to the substantially concave surface  66 . As the concave surface  66  begins to form in a direction from the rear portion to the front portion of the cover  60 , portions of the concave surface  66  extend between portions of the first and second convex surfaces  68 . Furthermore, as shown in  FIG. 2 , portions of the concave surface  66  farthest away from the substantially planar surface  64  extend beyond surface areas located between the convex surfaces  68 ,  70 . Although not shown, in further examples, the concave surface may be located entirely between the convex surfaces.  
      Accordingly, covers herein can shield the interior area of the container from contaminants such as liquids. For example, the cover can be configured to shield the interior area from water originating from a body of water, such as a swimming pool, hot tub, or the like. The cover is can also shield the interior area from water originating from a garden hose, rain, or other condensation. Moreover, providing the cover with the illustrated and described shaped surface  62  can accommodate a linear hinge structure while encouraging drainage of fluid introduced to the surface of the cover. Indeed, the substantially planar surface  64  is configured to accommodate the illustrated linear hinge structure  65 . Moreover, the substantially concave surface  66  and the substantially convex surfaces  68 ,  70  can help direct a drainage flow of liquid introduced to the shaped surface  62 . Indeed, the concave surface  66  and convex surfaces  68 ,  70  can generally encourage liquid to drain in a direction from the substantially planar surface  64  at the rear of the housing towards the substantially concave surface  66  at the front of the housing.  
      As shown in  FIGS. 4 and 6 , the cover  60  can also include a second surface  72  for facing towards the interior area  42  of the container  40 , wherein the second surface includes a transition that substantially follows the transition  63  of the shaped surface  62 . Providing the second surface  72  that substantially follows the transition  63  of the shaped surface  62  can provide a substantially constant or desired thickness of material to enhance the structural integrity of the cover without excess material. As shown, the second surface  72  can be provided with a plurality of ribs  74  adapted to increase the rigidity of the cover  60 .  
      The peripheral edge  44  of the container  40  can also be designed to follow the shape of the cover. For example, as shown in  FIGS. 3 and 6 , the peripheral edge  44  can include a substantially straight portion  46  configured to extend with respect to the substantially planar surface  64  of the cover  60  and a substantially curved portion  48  configured to extend with respect to the substantially concave surface  66  of the cover  60 . The peripheral edge  44  can also include a substantially curved portion  50  configured to extend with respect to the first substantially convex surface  68  and another substantially curved portion  52  configured to extend with respect to the second substantially convex surface  70 . The cover  60  can be designed to conform to the peripheral edge  44  of the peripheral wall  56  to encourage a fluid seal between the cover  60  and the housing  40 . For instance, as shown in  FIG. 4 , the cover  60  can include a groove provided with a seal  76 , such as a resilient gasket. When closing the housing  40  with the cover  60 , the peripheral edge  44  may enter the groove of the cover  60  and engage the seal  76  to provide a fluid seal between the cover  60  and the container  40 .  
      The housing  10  may be supported in a wide variety of ways. For example, the housing may be supported entirely by one or more conduits. Thus, the one or more sockets  20  may have sufficient structural integrity to allow the housing  10  to be entirely supported by the one or more conduits attached to the corresponding one or more sockets  20 . In addition or alternatively, one or more mounting tabs may be provided to allow the housing to be mounted to a support surface. For instance, as shown in  FIG. 1 , a pair of mounting tabs  14   a ,  14   b  are provided to allow the housing  10  to be mounted to a vertical wall or other surface. Although not shown, a separate mounting adapter may also be provided to permit connection between the housing and a post having a circular cross section.  
      From the above description of the invention, those skilled in the art will perceive improvements, changes and modifications. Such improvements, changes and modifications within the skill of the art are intended to be covered by the appended claims.