Patent Document

BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to mechanisms for mounting electrical outlets. 
     2. Description of the Related Art 
     Techniques for mounting and covering standard electrical outlets are innumerable. Most variations concern one of three themes, (i) safety for small children, (ii) aesthetics or (iii) recession for electrical cord management. Despite the abundance of related art in this sector, practically all indoor electrical outlet boxes and covers sold in the United States are of traditional design, with little of the patented derivatives finding any level of commercial appeal. The failure of current designs to penetrate the commercial market results from the following:
         i) In terms of safety: obtrusive aesthetic design, excessive manufacturing cost or difficulty in installation. Electrical outlet installation is generally permanent in nature, while children&#39;s safety is required only periodically and temporarily. Safety features impede normal access to outlets in such a manner as to deter the housing developers from incorporating permanent inconveniences to a majority of customers on behalf of a minority of customers. Also, the construction necessary to retrofit an outlet for this temporary purpose is cost prohibitive and impractical. Therefore add-on temporary products such as plastic electrical outlet safety caps dominate the marketplace.   ii) In terms of aesthetics, most designs, (a) amount to a derivative of a cap that protrudes from the wall, clearly visible and therefore creating limited appreciable aesthetic benefit, (b) incorporate covers that either require storage elsewhere when the outlet is in use or that are more obtrusive when the outlets are in use than cover-free outlets, (c) require excessive manufacturing cost, (d) require additional labor for the home and office contractors.   iii) In terms of recessed outlet design, (a) too many electrical devices utilize low voltage transformers or other plugs that a recessed outlet will not accommodate, thereby preventing prevalent installation, (b) a recessed design that fails to incorporate aesthetic closures and easy closing mechanisms offers limited benefit outside of special applications. As a result, installations of such designs are relegated to specialty uses such as wall-mounted audio visual equipment.       

     Home builders recognize the aesthetic detraction of standard outlets, as evidenced by the increasing practice of obscuring kitchen outlets through under-cabinet mounting, despite more difficult access for consumers. Such mounting preserves the clean, uninterrupted visual appearance of a kitchen wall. However, no other room in a home or office building offers such a means of obscuring the electrical outlets in a manner that would preserve the aesthetics of an un-breached wall. The lack of commercial penetration by electrical boxes other than of standard design is evidence that no current design has incorporated the four necessary elements: 
     (i) aesthetically appealing design, 
     (ii) user-friendly mechanical operation that provides easy access to the outlet, 
     (iii) competitive manufacturing cost, and/or 
     (iv) the same field installation steps as used for standard boxes and covers, 
     In terms of aesthetic improvement referenced in (i) above, the outlet, when not in use should closely resemble the surrounding wall. Features that can improve the aesthetic appearance so include (a) minimal profile such that difference in depth is difficult to perceive, (b) no exposed screws or hinges, (c) limited gaps around the cover closure and (d) paintable material to be painted the same color as the drywall. 
     Proper mechanical operation referenced in (ii) above, requires that the outlet not be particularly more difficult to access than are standard exposed outlets, can be accessed with one hand while holding an electrical plug and/or must not require the removal and storage of a detachable cover. 
     As referenced in (iii) above, the parts used for mechanical operation and the general design as a whole cannot be significantly more expensive to manufacture than standard boxes and cover plates. 
     Installation of the box, flange and cover in new construction must be consistent with current practice as referenced in (iv) above, requiring no additional labor, time, or skills to install. 
     A design that sufficiently incorporates any of the individual elements would be unique. A design that incorporates all elements in combination would be additionally unique. However, no prior art has produced designs of any one of these elements sufficient to penetrate the current marketplace with these individual attributes and particularly in combination with one another. 
     SUMMARY OF THE INVENTION 
     The present invention is a multi-configured electrical box, integrated flange and various cover mechanisms. Each feature of the multi-configured electrical box, flange and cover represent a separate embodiment and each design can be independent of, and freely combinable with, the others. An object of the present invention is to obscure electrical outlets in new construction and remodeling such that when not in use, they are generally indistinguishable from the surrounding wall and when in use are no more, or are less prominent than standard uncovered outlets. Also, by obscuring and covering outlets, the invention provides a level of safety for children and provides energy savings. Although the information herein, including the Detailed Description, concerns the concealment of electrical outlets, the present invention could be readily adapted to cover any type of outlet including a phone jack, cable outlet, or other outlet as understood by one of ordinary skill in the art. Furthermore, while such electrical outlets are generally described as adjoined by a drywall surface, the invention is not so limited and may be installed, for example, on floors, ceilings and at other desirable locations having a variety of surface materials. 
     The electrical box integrates and incorporates various cover mechanisms such that covers are unseen when the outlet is in use and certain mechanisms obscure the connection between the electrical plugs and outlets when outlets are in use. One embodiment of the box is configured to allow the electrical outlet to be mounted in a recessed and un-recessed position interchangeably before and after original outlet installation. The box is vertically reversible and therefore capable of mounting on either side of a 2×4 frame. The technique for installing the box, cover and flange are virtually identical to those required for standard outlets. 
     The integrated design of the electrical box, flange and cover obscure the outlet when not in use. Other embodiments can obscure one outlet when the other is in use, can obscure both outlets when in use, and/or can be recessed inside the electrical box, undetectable when the outlet is in use. 
     Different embodiments incorporate various closure mechanisms, including: spring loaded counterweight, gravity, flat magnet, spring-loaded magnet, detent, or track mounted sectional doors, each closure mechanism accommodating the low-profile design of the cover and flange and is undetectable when the outlet is in use. 
     In the below embodiments of the present invention, the integrated flange covers the drywall cutout for the electrical box, protects from exposed wires in the outlet, seals the gap between electrical box and drywall from which energy is lost, and aligns with the cover when the cover is closed. In further embodiments, an interior compartment or wall further protects from exposed wires in the outlet. The configuration and fastening mechanism allows no screws or hinges to be exposed and for the flange to protrude from the wall by only the width of the material from which it is constructed. The alignment with the closed cover and the low profile design provide the illusion of no-profile cover flush with the wall. 
     The invention overcomes limitations of related art as follows: 
     1. Aesthetics: The protrusion of covered outlets when viewed from the front and particularly from the side has significant affect on perceived aesthetics. Second to color, depth of an object compared with its immediate surroundings most heavily influences its relative prominence. Depth is a perceptual process function involving three-dimensional organization of stimuli. Contributors to the perception of objects include shadows, which indicate distance, linear perspective, the convergence of parallel tracks or lines as they recede into the distance and among others, retinal disparity—the differences among images on the retinas of the two eyes. In order to accommodate the effect that depth perception has on the prominence or obscurity of an object, the design of the invented item incorporates the lowest profile possible and alignment of all components via the relationship between the door, flange and wall. For example, specific embodiments may achieve a profile of 1 mm-2 mm (depending on the material used); however, the invention is not limited to such a range. This depth to the wall averages approximately 900% less than that of related art. This is accomplished by the integrated design of box, flange and cover as more thoroughly described under Detailed Description. 
     Unlike prior art, the invention does not include exposed screws or other fasteners, hinges, or the profile associated with these mechanisms. 
     When the outlet is in use, the cover remains attached to the unit. Through the hinge system of the box, the cover opens to one side and inside the box, obscured from view. This differs from prior art that, when the outlet is in use, includes (i) plates that slide over the wall, substantially increasing the prominence of the unit by increasing the area covered by the outlet and its components, (ii) hinge systems that protrude out from the wall, causing the cover to rest partly over the electrical plugs and therefore more prominent than are uncovered outlets when engaged and (iii) removable covers that require storage. 
     2. Ease of access: Related art uses covers that impede access, removable covers and other mechanisms that require two hands or two steps in order to engage an electrical device with an outlet. The lack of market penetration by related art partly reflects that the marketplace will not sacrifice functionality for aesthetics, in addition to limited aesthetic benefits having been introduced. The cover of the invented item can be opened with one hand while holding the electrical cord. Once opened, the cover does not interfere with the effort to engage the electrical cord in the outlet and is then easily recessed into the wall with the same hand. The hinge and pocket for cover and closing systems are more thoroughly described under Detailed Description. 
     3. Child Safety. The lack of market penetration by related art that is primarily designed for child safety reflects the inconvenience of use by other than children, the manufacturing cost to construct the units, and in some cases, difficult and time consuming installation. Conversely, the camouflage nature of the invented item reduces interest of children and the closing mechanisms can provide child safety without impeding use by others or adding cost. 
     4. Energy Savings. According to the U.S. Department of Energy&#39;s ‘Energy Savers Tips on Saving Energy and Money at Home’, two percent of air escapes through electrical outlets/switches. This occurs due to the space between the drywall cut and the electrical box and through the outlet sockets. The flange of the invented device seals the area between the drywall and the electrical box. The cover of the invented device creates a barrier between the outlet sockets and the room. Together the flange and cover virtually eliminate this type of energy loss and do so whether none, one, or both outlets are in use. 
     Other objects and features of the present invention will become apparent from the following detailed description considered in conjunction with the accompanying drawings. It is to be understood, however, that the drawings are designed solely for purposes of illustration and not as a definition of the limits of the invention. It should be further understood that the drawings are not necessarily drawn to scale and that, unless otherwise indicated, they are merely intended to conceptually illustrate the structures and procedures described herein. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  is a front view showing a flange and cover of the present invention. 
         FIG. 2  is a side view showing an electrical box, flange and cover of the present invention. 
         FIG. 3  is a front view showing an electrical box of the present invention. 
         FIG. 4  is a front view showing an electrical box of the present invention. 
         FIG. 5  is front view showing an installed flange with open cover. 
         FIG. 6  is a cutaway view of a flange of the present invention. 
         FIG. 7  is a view showing a closure mechanism and a cover of the present invention in a closed position. 
         FIG. 8  is a view showing an electrical box and a cover of the present invention at a midpoint between fully open and fully closed. 
         FIG. 9  is a view showing a cover of the present invention in an open position. 
         FIG. 10  is a view showing an integrated hinge and cover of the present invention. 
         FIG. 11  is a front view showing an electrical box of the present invention. 
         FIG. 12  is a cutaway side view of an electrical box and track of the present invention. 
         FIG. 13  is a view showing a cover of the present invention. 
         FIG. 14  is a back view showing a cover of the present invention. 
         FIG. 15  is a view showing a cover of the present invention. 
         FIG. 16  is a view of a split side-by-side cover of the present invention. 
         FIG. 17  is a view showing a cover of the present invention. 
         FIG. 18  is a view showing a split over/under cover of the present invention. 
         FIG. 19  is a view showing a closure mechanism of the present invention. 
         FIG. 20  is a view showing a single cover. 
         FIG. 21  is a view showing cover attachment points of the present invention. 
         FIG. 22  is a view showing cover hinge nodules. 
         FIG. 23  is a view showing a hollow receptor of the present invention. 
         FIG. 24  is a view showing a receptor affixed to a flange and abutting a cover of the present invention. 
         FIG. 25  is a view through a cover showing a receptor mount of the present invention. 
         FIG. 26  is a view showing a detent closure mechanism of the present invention. 
         FIGS. 27 and 28  are views showing an electrical box of the present invention. 
         FIG. 29  is a schematic showing a front view, side view and a rear view of an electrical box of the present invention. 
         FIGS. 30 and 31  are views showing a flange of the present invention. 
         FIG. 32  is a schematic showing a front view, side views and a rear view of a flange of the present invention. 
         FIG. 33  is a view showing a door of the present invention. 
         FIG. 34  is a schematic showing side views and a rear view of a door of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Embodiment modes of the present invention are explained below with respect to the drawings. However, implementation of the present invention can be achieved in various different modes and with modifications readily understood by those of ordinary skill in the art. Therefore, the present invention should not be construed to be limited to specific embodiments of the present invention, including universal box configurations or other integrated designs. 
     Embodiment 1 
       FIGS. 1 and 2  show the fully assembled unit, front and side view, installed with cover closed. The flange  1  surrounds and integrates the unit into the surrounding drywall  2 . Cover  3  is closed with only the outline  4  of the intersection of the flange and cover being visible. The electrical box  5  shown in  FIG. 2 , which is an integral component of the present invention, is obscured in  FIG. 1  and the electrical outlet is obscured in  FIGS. 1 and 2 . 
       FIG. 3  shows the electrical box  5  having a height of 4.25″. The single cover is retracted into the open box and only the leading edge  6  of the cover is exposed. 
     Top mounting plates  7  and  9  and bottom mounting plates  8  and  10  include electric outlet stabilizing tabs  11 . On standard electrical boxes, the stabilizing tabs of the outlet rest on the outside edge of the box and extend beyond the top and bottom of the box. 
     According to one example of this embodiment, top mounting plate  7  and bottom mounting plate  8  may be formed, for example, recessed 1.75″ in electrical box  5  to allow outlet  12  to be installed such that the face of outlet  12  is recessed approximately 1.5″ from the front edge of electrical box  5 . 
     According another example of this embodiment, top mounting plate  9  and bottom mounting plate  10  may be formed, for example, recessed ¼″ in electrical box  5  to allow outlet  12  to be installed such that the face of outlet  12  is recessed approximately ⅙″ from the front edge of electrical box  5 . Furthermore, electrical box  5  is formed having a width sufficient to accommodate side by side outlets. 
     The dual mounting configuration of electrical box  5  allows outlet  12  to be mounted in electrical box  5  over top mounting plate  7  and bottom mounting plate  8  in order to be fully recessed, or over top mounting plate  9  and bottom mounting plate  10  in order to be slightly recessed and is interchangeable during initial home or of installation, or even after initial installation. 
     By recessing outlet  12  inside the electrical box such that face of outlet  12  is recessed in accordance with this first embodiment, single vertical cover when closed, will align flush with flange  1 , which is flush with the wall on which electrical box  5  is installed and separated only by the thickness of the material from which flange  1  is constructed. For the purpose of simplicity, all electrical boxes subsequently shown in this application are “single gang boxes” with only one set of mounting brackets. 
       FIG. 4  shows a front view of electrical box  5  without the outlet  12  installed. The invention&#39;s second interior wall  13  attaches to the back wall of the electrical box  5  and continues toward the front edge of the electrical box to the approximate depth of the bottom of the electrical outlet when installed. This creates a channel into which the cover in embodiments 2 and 3 may recede into the box without interference by electrical wire entering and/or exiting the electrical box. It also serves to separate the electrical connections from the flange opening, in accordance with Underwriters Laboratories safety specifications. Interior wall  13  would be included on any one or all four walls of the electrical box, depending on the intended cover configuration. The proximity of each interior wall  13  to the knockout tabs  14  for entry and exit of electrical wires into and out of the electrical box is shown. Guide tabs  5 A are recessed from the leading edge of the electrical box by a depth determined by the thickness of the drywall. It extends for approximately 1.5″ perpendicular to the box, which is the approximate width of a 2×4 wooden stud. This provides for more consistent mounting of the box on a wooden stud than do the small notches on standard boxes which can be affected by the rounding of the corners of many 2×4s. The depth of the box in relation to the drywall is significantly more acute in this integrated design than with standard boxes and covers. Consistent mounting of the box in relation to the drywall is required in order for the cover, when closed, to align flush with the flange which is almost flush with the drywall, in keeping with the objective of the integrated design, to obscure the outlet. Guide tabs  5 A may be incorporated into each of Embodiments 1-4. 
       FIG. 5  shows the flange  1  to be used with the electrical box (not shown). Outlet  12  is in either mounting position  7 / 8  or  9 / 10  as previously outlined in  FIG. 3 . 
     The flange  1  rests flush on the drywall  2  protruding from the wall only by the width of the material from which it is constructed. The flange  1  crosses the plane defined by the front of the electrical box (not shown) and immediately recesses into the electrical box at point  15  to a depth that is relative to the positioning of the outlet,  7 / 8  or  8 / 10  as indicated in  FIG. 3 . The flange  1  continues from both ends toward the center of the electrical box and is attached at the center screw  16  of outlet  12 . In this manner, the flange protects the electrical wires and screws on each side of the receptacle. The connection mechanism of the flange at the center screw  16  in either outlet position  7 / 8  or  9 / 10  is obscured when the cover is closed. The flange is therefore one continuous unit, except that the portion of the flange on the hinge side of the electrical box stops as it crosses the plane of the electrical box (not shown) at position  17 , providing a channel for the cover in embodiments 2 and 3. Only the leading edge  6  of the open cover is exposed. When the cover is closed, the flange  1  at position  17  abuts and is flush with the trailing edge of the cover (not shown).  FIG. 5  shows a flange configuration for a single cover, hinged on the left side of electrical box. However the cover and flange could be configured similarly for hinging at the right, bottom, or top of electrical box, or any combination. Ground Fault Interrupter (“GFI” plugs) are configured in the same manner except that the attachment points of the flange would be at the top and bottom of the stabilizer mounts on the GFI plug  7 / 8 ,  9 / 10  respectively, as shown on  FIG. 3 , because center screws are not incorporated into GFI outlets. 
       FIG. 6  shows a cutaway view of the flange  1 , extending approximately ½ inch over the drywall  2  cutout for the electrical box  5 , on all four sides. The flange  1  enters the electrical box  5  on one to three walls of the electrical box depending on cover configuration. It would not extend into the electrical box on the hinge side(s) of the electrical box, as shown in  FIG. 5 . On all sides, the flange  1  extends toward the outlet  12 , protecting the electric wiring. 
       FIG. 7  shows the first embodiment of the closure mechanism of the electrical box  5 . The electrical box is viewed from the bottom, with cover  3  in the closed position. The hinge  18  and cover  3  are formed as one molded or injected piece and are attached to electrical box  5  at  19  and on the opposing side of electrical box  5 . Note that the hinge can be attached to the interior or exterior of the electrical box. The wire spring  20  is attached to hinge  18  at  21  and to electrical box  5  at  22 . The expanded view of wire spring  20  shows its shape, which includes a portion  20 A, a minimal offset  20 B and opposing 180 degree bends at  20 C and  20 D. This spring holds the cover closed when cover is closed and holds the cover open when cover is open and it prevents cover from being left partially open where it could be damaged by people or animals walking by the outlet. The hinge and spring act as a counterweight, allowing the cover to be opened by pressing the cover  3  at  23 , eliminating the need for a handle or finger hole to open cover, supporting the purpose of the design which is to provide the appearance of an uninterrupted wall and obscuring the outlet. The electrical box  5  is angled at  24  to allow the cover to rotate down as further shown in  FIGS. 8 and 9 . 
       FIG. 8  shows the electrical box  5 , viewed from the bottom with cover  3  at the midpoint between opened and closed. The tab  25 , extends from the leading edge  6  of cover  3 , allowing cover, when open and recessed, to be lifted, and it is obscured when cover is closed, further supporting the intention of the design to provide the appearance of an uninterrupted wall. 
       FIG. 9  shows the cover  3  in the fully open position. In this position, the hinge  18  is attached to the outside of electrical box  5  at  19  and the cover rests outside the electrical box  5 . If the hinge  18  is attached inside of the electrical box  5  at  19 , the cover rests inside the electrical box  5 . Whether the hinge is mounted outside or inside electrical box  5 , only leading edge  6  is exposed when cover is open, as also shown at  6  of  FIG. 5 . The box is angled at  24 , as also shown in  FIG. 7 . 
       FIG. 10  shows the construction of integrated hinge and cover such that the hinge attached to an electrical box at connection point  19 , angles approximately 90% at  25 , then angles approximately 90% at  26 . 
     Embodiment 2 
       FIG. 11  shows an electrical box according to a second embodiment of the present invention. The electrical box  5  in Embodiment 2 is substantially similar to the electrical box in Embodiment 1; however, the closure mechanism differs. The closure mechanism in Embodiment 2 is formed as dual tracks  27  and  28  built into the electrical box, in which a sectional door, attached to a roller, shall be inserted, much like a vertically operated garage door and track. This door (or cover) retracts into the electrical box, which is designed to accept the door due to the box width, internal hinge tracks, and interior box wall (not shown) that prevents interference from electrical wires inside the box, each more fully described under  FIG. 4 . When combined with the cover configuration shown in  FIG. 13 , the electrical outlet is obscured when not in use. Tracks  29  and  30  would support a horizontal (close across) closure utilizing the closures shown in  FIG. 15  or  FIG. 16 . Screw holes  31  and  32  for outlet attachment to electrical box  5  would be attached to box  5  behind tracks  29  and  30  so not to interfere with cover movement. 
     When tracks  29  and  30  are used and when combined with outlet positioning  7 / 8  in  FIG. 2 , and when combined with a split side-by-side cover as shown in  FIG. 17 , the connection point between the electrical wire and the electrical outlet is obscured, even when an electrical plug is engaged, providing the visual effect of electrical wires entering a wall. 
     Tracks  27  and  28 , when utilized in conjunction with cover shown in  FIG. 18  and with outlet position  7 / 8  or  9 / 10  in  FIG. 3 , a single outlet connector may be covered while the other outlet connector is in use. 
     In each configuration, covers are stored in the electrical box when the outlet is in use, obscuring them from view. 
       FIG. 12  shows a cutaway side view of electrical box  5  and track  28  supporting a vertical closure. An opening  33  in track  28  allows for the insertion of the rollers attached to the cover. A similarly styled insertion point would be utilized for tracks  27 ,  29  and  30  shown in  FIG. 11 . 
       FIG. 13  shows a single vertically closing cover  34  constructed in various sections  35  and attached to rollers  36  that would mount into the hinge tracks  27  and  28  in  FIG. 11 . 
       FIG. 14  shows the back of cover  34  shown in  FIG. 13  with hinges  37  at each section  35 , holding the sections together allowing the cover to follow a curved track  28  of  FIG. 12 , 
       FIGS. 15-18  show various cover configurations that would integrate with various cover track configurations in the second embodiment of the electrical box. 
       FIG. 15  shows a single cover that would mount into the hinge tracks  29  and  30  shown in  FIG. 11 . The door, built in panels or sections  35 , allow it to follow in the curved tracks  29  and  30  in  FIG. 11 . Each cover in  FIGS. 15-18  incorporate the same sectional design, though not shown. 
       FIG. 16  shows a split side-by-side cover that would mount into the hinge tracks  29  and  30  shown in  FIG. 11 . This configuration would be incorporated with recessed outlet positioning  7 / 8  in  FIG. 3 , obscuring the electrical plugs and outlet, even when in use. 
       FIG. 17  illustrates a close up view of the cover illustrated in  FIG. 16 , incorporating cutouts  38  for electrical cords engaged in the outlet. Spring-loaded sliding plates on the back side of each cover would obscure cutouts  38  when the outlet is not in use. 
       FIG. 18  illustrates a split over/under cover for use in hinge tracks  27  and  28  in  FIG. 11 , allowing one outlet to be covered while the other is in use. 
     Embodiment 3 
       FIG. 19  shows Embodiment 3 of the closure mechanism incorporated into the electrical box  5 . The electrical box  5  in Embodiment 3 is substantially similar to the electrical box in Embodiments 1 and 2; however, the closure mechanism differs. The top mounted hinge tracks  39  and bottom mounted hinge tracks  40  are built into the electrical box  5 , can receive cover hinges shown in  FIGS. 20 and 21 , and are formed on only one side of the electrical box  5 , rather than three sides in Embodiment 2. 
     Tracks  41 / 42 , when combined with  39 / 40 , can receive split side-by-side covers. Tracks  43 / 44  provide a single vertical (close down) cover configuration and when utilized with tracks  45 / 46  and a split vertical cover, a single outlet may be obscured while other outlet is in use. 
     The invented electrical box could accommodate all or any one of the above configurations. 
       FIGS. 20 and 21  show that Embodiment 3 is configured to integrate solid (non-sectional) covers attaching only at cover hinge nodules  47  and  48  on the trailing edge  49  of the cover  3 . The attachment points could be positioned at the bottom or top, or the left or right of all sides of cover  3 , depending on the intended track configuration of electrical box as described in  FIG. 19 . The leading edge  6  of cover  3  is unattached to hinge tracks and therefore requires a separate closing mechanism including magnets or detents to hold it in place when closed. Conversely, Embodiment 2 includes a sectional cover attaching at four points to a curved track and therefore does not need a separate closure mechanism to hold it in place when closed. 
       FIG. 22  illustrates the shape of the cover hinge nodules  47  and  48 . As shown in details A and B, the hinge is positioned on the inside of the cover such that the profile of the hinge would not exceed that of the cover and would not protrude from the drywall or electrical box when cover is closed. 
       FIG. 23  shows hollow receptor  51  that will accept a flat magnet mount or a touch latch magnet mount. 
       FIG. 24  shows the position of the receptor  51  affixed to flange  1  and abutting cover  3 . 
       FIG. 25  shows a see-through view through cover  3  to receptor  51  as described in  FIGS. 23 and 24  positioned at either  52  or  53 , depending on the cover configuration. 
       FIG. 26  shows a detent closing mechanism  54  built into cover  3  with an opposing detent  55  in flange  1 . 
     Embodiment 4 
       FIGS. 27-34  show a further embodiment of the present invention. In  FIGS. 27 and 28 , electrical box  60  is shown, which has been provided with mounting tabs  61  to allow the box to be installed or attached to a structure with minimized installation error (e.g., ensuring proper mounting depth). Furthermore, electrical box  60  is optimally shaped having dimensions to comply with code specifications requiring specific cubic volume, while concurrently limiting or minimizing the size of any drywall cut required to install the electrical box  60 . 
     An electrical outlet may be mounted to screw holes tabs  62  such that the outlet is attached within electrical box  60 . Specifically, screw hole tabs  62  are provided at a depth allowing an electrical outlet mounted such that an attached flange  65  (shown in  FIGS. 30 and 31 ) intersects with electrical box  60  in a manner that avoids displacement of the flange  65  by such screws. For example, when an electrical outlet is mounted to screw hole tabs  62  with dome screws, the depth of screw hole tabs  62  is sufficient to allow intersection of the flange  65  and the electrical box  60  having a finished fit and avoids rocking of the flange  65 . 
     Specifically, this embodiment as illustrated particularly in  FIGS. 30-34  provides an electrical outlet cover configured to be mounted and attached to an electrical outlet. The electrical outlet cover comprises a main body  56  that includes front faceplate flange  65  defining a generally planar top cover surface peripherally extending around a central opening  57  therein and mounting plate  58  recessed inward from the generally planar top cover surface and located within the central opening. Mounting plate  58  includes a mounting mechanism (screw hole  66 ) configured to mount the mounting plate  58  to the electrical outlet. A first opening  59  is configured to expose at least a portion of the electrical outlet when mounted thereto and an elongated second opening  67  is offset from or adjacent to the first opening  59  as shown. 
     A door pivot support mechanism defines a pivot axis located inward of mounting plate  58  and includes a hinge receptor  68  and hinge portions  69 . A door or cover  70  ( FIGS. 33 and 34 ) is pivotally attachable to the door pivot support mechanism ( 68 / 69 ) to move through the elongated second opening  67  with rotational motion about the pivot axis defined by hinge receptor  68  between an open position and a closed position. In the open position, the first opening  59  is exposed and the door is located substantially inward of the top cover surface of the main body  56 . In the closed position, the door covers the central opening  57  and a top surface of the door is substantially flush with the top cover surface of the main body  56 . 
     Referring back to  FIG. 28 , electrical box  60  includes a first box cavity  73  capable of receiving the electrical outlet therein and a second box cavity  74  offset from and separated from the first cavity box  73  by a divider wall  63 . Mounting structure (screw hole tabs  62 ) is configured to fixedly mount the electrical outlet in the first box cavity  73 . 
     Electrical box  60  (shown in  FIGS. 27-28 ) also includes internal wall  63  (shown in  FIGS. 27-29 ), provided to separate wires connected to an outlet terminal from interfering with the movement of door  70  (shown in  FIG. 33 ). When an outlet is installed within electrical box  60 , wiring connected to the outlet is constrained to an inner portion of internal wall  63 . Accordingly, even when door  70  (shown in  FIGS. 33 and 34 ) or flange  65  (shown in  FIGS. 30 and 31 ) is removed from electrical box  60 , a connected wiring would remain partitioned by inner wall  63 , to avoid unintended contact with the connected wiring. For example, if a child were to remove either door  70  or flange  65  from electrical box  60 , access to electrical connections would still be impeded by internal wall  63 , according to this embodiment of the present invention. 
     With an electrical outlet attached to electrical box  60  at screw hole tabs  62 , flange  65  is provided such that it can be attached the electrical outlet through screw hole  66 . Door  70  can be attached to flange  65  by coupling hinge nodule  72  of door  70  to hinge receptor  68  of flange  65 . When attached to flange  65 , door  70  can traverse door opening  67 , such that door  70  can be closed flush with flange  65  or alternatively retracted inside electrical box  60 . Hence, both the flange  65  and door  70  are adapted to, yet removable from, electrical box  60 . As such, the attachment mechanism of each part is configured to ensure a consistent relationship and finished fit, while also allowing easy maintenance or replacement of the individual parts, such as the flange  65  and the door  70 . 
     Furthermore, by coupling the flange  65  with the door  70  at hinge portions  69  and  71 , respectively, instead of edge portions, the interface of flange  65  and door  70  can be hidden within electrical box  60  by the bevel and reverse bevel of flange  65  and door  70 , so as to create a satisfying aesthetic appearance. In addition, the hinge mechanism including hinge portions  69  and  71  is provided having a shape that allows the hinge to rotate, yet intersect the flange at a relatively flat angle (that is, less than 90°). Accordingly, door  70  may be opened and closed with minimal required clearance, such that an electrical outlet installed within electrical box  60  may be safely and easily accessed, for example, behind furniture and other objects that are situated in front of the outlet, which embodiments 2 and 3 do not provide. 
     A flange  65  according to this embodiment can be manufactured using “Finite Element Analysis” manufacturing techniques, which are known in the art and not described herein, to allow production of flange  65  with extremely thin, yet durable, material. A flange  65  produced in this manner will allow extreme tapering of the flange&#39;s intersection with surrounding drywall (or other adjoining surface). 
     Furthermore, a flange  65  and/or a door  70  of this embodiment can be provided with opening/closing mechanisms including, for example, a kinematic push/pull opening mechanism or a spring assisted door, that facilitate the operation of the door. Such opening/closing mechanism allows the user access by pushing lightly on the hinge side of the door and have it open fully, allowing one-handed access by a user with an electrical chord in hand, which embodiments 2 and 3 do not provide. It also can enhance the safety features of the present invention, for example, by mechanically shutting a door  70  that is only partially opened and reducing the risk that door  70  is inadvertently opened or left open. 
     This embodiment of the present invention therefore achieves additional safety and aesthetic advantages by integrating an electrical box, flange and door, such that the door is easily accepted into the flange and inside the electrical box with minimal interference from within the electrical box or by the attachment mechanism and minimal clearance required outside of the electrical box. 
     Each embodiment of the present invention described above can be further adapted and implemented in a variety of different combinations with modifications readily understood by those of ordinary skill in the art. Therefore, the scope of the present invention is intended to be comprehended in accordance with the general knowledge of the art and should not be construed to be limited solely to the above described embodiments.

Technology Category: h