Patent Document

FIELD OF THE INVENTION 
   The present invention pertains to electrical boxes also know as junction boxes. More particularly, the present invention relates to a method and apparatus for an electrical box repair cover. 
   BACKGROUND OF THE INVENTION 
   Electrical boxes, also known as junction boxes or boxes, are the predominant method for making and terminating electrical connections to other devices, such as, but not limited to switches, outlets, etc. 
   Often when connecting an electrical device to electrical wiring a cover of some type is used to protect the wiring and/or the device from environmental elements, such as, but not limited to rain, nesting insects, etc. 
   Sometimes the fastening means for securing the covers to the electrical boxes become inoperative. For example, screws used to fasten a cover to an electrical box may be over tightened resulting in stripped threads or stripping the “boss” into which the screw is treaded. Replacing an electrical box because of stripping is problem. 
   Weather and age may also corrode these boxes and covers over time. When screws become corroded and rusted, the heads may break off and as a result there is no way to reattach a cover to a box. If you have multiple conduits and electrical wire running through these boxes, it makes replacing the electrical boxes a very hard and time consuming job. These boxes may still be safe, however, there is no way to attach a cover to them and as a result the box may need to be replaced. This presents a problem. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention is illustrated by way of example and not limitation in the figures of the accompanying drawings in which: 
       FIG. 1A ,  FIG. 1B ,  FIG. 1C , and  FIG. 1D  illustrates various embodiments of the invention; 
       FIG. 2A ,  FIG. 2B ,  FIG. 2C , and  FIG. 2D  illustate one embodiment of the invention also showing use of an unmodified face plate; 
       FIG. 3A ,  FIG. 3B , and  FIG. 3C  illustrate one embodiment of the invention also showing straps around the back of an electrical box; 
       FIG. 4A ,  FIG. 4B , and  FIG. 4C  illustrate one embodiment of the invention also showing strap clamps around the electrical box and a cover; 
       FIG. 5A ,  FIG. 5B , and  FIG. 5C  illustrate various embodiments of the invention also showing some various cover variations; and 
       FIG. 6A ,  FIG. 6B , and  FIG. 6C  illustrate one embodiment of the invention also showing a cover with securing legs. 
   

   DETAILED DESCRIPTION 
   The invention, as exemplified in various embodiments, illustrates a method and apparatus for attaching a cover to an electrical box. 
   In one embodiment of the invention, an external fastening electrical cover is attached to a damaged electrical box. 
   In another embodiment of the invention, when original (internal) screws used for securing a cover to an electrical box can no longer be used, external fastening screws and brackets will allow a cover to be safely attached preventing water penetration and/or electrical shock. 
     FIG. 1A  illustrates a clamp mechanism  100  having two rectangular U-shaped sections  102  and  122 . Section  102  has legs  104 ,  106 , and  108  that form the U-shape.  102  also has tabs  112  and  116 , as well as tabs or ears  110  and  114 . Section  122  has legs  124 ,  126 , and  128  that form the U-shape.  122  also has tabs  132  and  136 , as well as tabs or ears  130  and  134 . Electrical box  139  is shown housing an electrical outlet  137 . Clamp  100  sections  102  and  122  may be placed on the outside of electrical box  139 . Screw  117  and  119  may then secure sections  102  and  122  via pressure to the outside of the electrical box  139  by the threaded section of screw  117  passing through a hole in tab  112  and being threaded into the tapped hole in tab  132 , and by the threaded section of screw  119  passing through a hole in tab  116  and being threaded into the tapped hole in tab  136 . 
     FIG. 1B  illustrates clamp  140  secured around electrical box  149  housing an electrical outlet  147 . 
     FIG. 1C  illustrates a face plate or cover assembly. Cover  152  has four tabs  154 ,  156 ,  158 , and  160 . In this embodiment, the tabs  154 ,  156 ,  158 , and  160  have holes that allow the threaded portion of screws  155 ,  157 ,  159 , and  161  to pass through the respective tabs. In this embodiment, cover  152  also has lids  163  and  165  that may be closed (as shown) to keep environmental elements from entering the electrical box (such as  149 ). To form a seal against environmental elements a gasket, seal, or pad  168  may be situated between the cover  152  and an electrical box (such as  149 ). 
     FIG. 1D  illustrates clamp  170  secured to electrical box  189 . A gasket  178  is situated between cover  172  and electrical box  189 . Cover  172  is drawn tight against electrical box  189  by tightening screws  175 ,  177 ,  179 , and  181 . 
     FIG. 1A ,  FIG. 1B ,  FIG. 1C , and  FIG. 1D  illustrate how this embodiment of the invention cover and bracket design allows an exterior power box to be sealed safely in the event of screw or tap damage that prevents securing the cover. This arrangement gives an electrician a quick way to seal a damaged receptacle and continue without having to rewire the receptacle or junction box. 
     FIG. 2A  shows clamp  200  having two U-shaped sections that may be fitted over the outside of an electrical box  239 . 
     FIG. 2B  shows claim  240  tightened around electrical box  249 . 
     FIG. 2C  illustrates a face plate or cover  252  with lids  263  and  265  that may have been originally used on an electrical box (such as  249 ) but which now no longer may be attached because of, for example, stripped screw inserts in the electrical box (such as  249 ). Frame  253  has four tabs or ears  254 ,  256 ,  258 , and  260  as shown in this embodiment with holes allowing the threaded portions of screws  255 ,  257 ,  259 , and  261  to pass thorough the respective tabs. 
     FIG. 2D  illustrates clamp  270  secured to electrical box  289 . Original faceplate or cover  272  is situated between frame cover  273  and electrical box  289 . Cover  272  is drawn tight against electrical box  289  by tightening the frame  273  against the cover  272  via screws  275 ,  277 ,  279 , and  281 . 
     FIG. 2A ,  FIG. 2B ,  FIG. 2C , and  FIG. 2D  illustrate how this embodiment of the invention cover and bracket design allows an exterior power box to be sealed safely in the event of screw or tap damage. This arrangement gives an electrician a quick way to seal a damaged receptacle reusing the original face plate and continue without having to rewire the receptacle or junction box. 
     FIG. 3A  shows an electrical box  339  housing an electrical outlet  337 . 
     FIG. 3B  shows two straps  302  and  322 . Shown for strap  302  are tabs  312 , and  316 . Strap  322  has two tabs, only one of which is shown (not labeled). Cover  352  has four tabs  354 ,  356 ,  358 , and  360 . In this embodiment, the tabs  354 ,  356 ,  358 , and  360  have holes that allow the threaded portion of screws  355 ,  357 ,  359 , and  361  to pass through the respective tabs. In this embodiment, cover  352  also has lids  363  and  365  that may be closed (as shown) to keep environmental elements from entering the electrical box (such as  339 ). To form a seal against environmental elements a gasket, seal, or pad  368  may be situated between the cover  352  and an electrical box (such as  339 ). 
     FIG. 3C  illustrates straps  392  and  393  secured around electrical box  389 . A gasket  378  is situated between cover  372  and electrical box  389 . Cover  372  is drawn tight against electrical box  389  by tightening screws  375 ,  377 ,  379 , and  381 . 
     FIG. 3A ,  FIG. 3B , and  FIG. 3C  illustrate how this embodiment of the invention cover and bracket design allows an exterior power box to be sealed safely in the event of screw or tap damage that prevents securing the cover. This arrangement gives an electrician a quick way to seal a damaged receptacle and continue without having to rewire the receptacle or junction box. 
     FIG. 4A  shows an electrical box  409  housing into which an electrical outlet  407  is mounted. 
     FIG. 4B  shows clamps and face plates. Shown are strap clamps  432  and  434 . Face plate  422  has lids  433  and  435 , and four strap clamp guides  424 ,  426 ,  428 , and  430 . Faceplate  442  has four strap clamp guides  444 ,  446 ,  448 , and  450 . 
     FIG. 4C  shows electrical box  469  with strap clamps  462  and  464  engaged with faceplate  482  (via  472 ,  478 , and  474 ,  476  for straps  462  and  464  respectively). Face plate  482  may be tightened against electrical box  469  by tightening the strap clamps  462  and  464 . 
     FIG. 4A ,  FIG. 4B , and  FIG. 4C  illustrate how this embodiment of the invention cover and bracket design allows an exterior power box to be sealed safely in the event of screw or tap damage that prevents securing the cover. This arrangement gives an electrician a quick way to seal a damaged receptacle using a band fastener and specially made slotted face plate. 
     FIG. 5A  illustrates one embodiment of the invention showing brackets  504  and  506 , an optional seal  508 , and a multiple gang faceplate  502 . 
     FIG. 5B  illustrates one embodiment of the invention showing brackets  524  and  526 , an optional sealing gasket  528 , and a cover faceplate  522  having two lids  523  and  525  which may cover, for example, electrical outlets. 
     FIG. 5C  illustrates one embodiment of the invention showing brackets  544  and  546 , an optional seal  548 , and a single gang faceplate  542 . 
     FIG. 6A  shows an electrical box  609  into which an electrical outlet  607  is mounted. 
     FIG. 6B  illustrates various embodiments of the invention.  620  illustrates a 2 lid cover faceplate having 4 legs (only 2 shown due to perspective view).  632  illustrates a water tight pad insert. In this illustration pad  632  has cutouts for a two receptacle outlet. Cover  640  has no openings for electrical devices and also has 4 legs (only 2 shown). 
   Cover  622  has two lids  623  and  625 , and 4 legs  624 ,  626  as shown and two others located at positions shown by arrows  628  and  630  but not shown because of the perspective view. Legs  624 ,  626 , and those at positions  628  and  630 , accept screws  625 ,  627 ,  629 , and  631  respectively. 
     FIG. 6C  illustrates an electrical box  649  with a cover  642  secured to the box  649  by screws  645  (leg  644 ),  647  (leg  646 ), and two screws at locations indicated by arrows  648  and  650 . 
   While the invention has been illustrated with respect to electrical or junction boxes, the invention is not so limited. The techniques of the invention may be used to secure a cover to a receptacle. 
   One of skill in the art will appreciate that the present invention has many variations only a small sample of which are illustrated in the Figures. For example, referring to  FIG. 1 , a variation on clamp  100  may be a rectangular clamp requiring only a single screw for closing, for example, in this variation, legs  104  and  124  may be one contiguous leg and screw  117  and tabs  112  and  132  may be the means of tightening variation on clamp  100  to an electrical box. 
   Other variations may include, but are not limited to, a rectangular frame that may be slid over an electrical box and secured with a cam-like screw mechanism. Another variation is a push-over frame with one-way gripping prongs which when a face plate is secured to it will “dig” into the electrical box. Other variations may include crisscrossing straps around the electrical box, raised bumps for gripping on the straps and/or clamps, straps that go over the top and/or bottom of an electrical box, etc. 
   While the Figures have illustrated a “free standing” electrical box, the invention is not so limited and my be used on other electrical boxes as well, for example, back mounted, side stud mounted, etc. 
   Thus a method and apparatus for an electrical box repair cover have been described. 
   For purposes of discussing and understanding the invention, it is to be understood that various terms are used by those knowledgeable in the art to describe techniques and approaches. Furthermore, in the description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be evident, however, to one of skill in the art that the present invention may be practiced without these specific details. In some instances, well-known structures and devices are shown in block diagram form, rather than in detail, in order to avoid obscuring the present invention. These embodiments are described in sufficient detail to enable those of skill in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that logical, mechanical, electrical, and other changes may be made without departing from the scope of the present invention. 
   As used in this description, “one embodiment” or “an embodiment” or similar phrases means that the feature(s) being described are included in at least one embodiment of the invention. References to “one embodiment” in this description do not necessarily refer to the same embodiment; however, neither are such embodiments mutually exclusive. Nor does “one embodiment” imply that there is but a single embodiment of the invention. For example, a feature, structure, act, etc. described in “one embodiment” may also be included in other embodiments. Thus, the invention may include a variety of combinations and/or integrations of the embodiments described herein. 
   Thus a method and apparatus for an electrical box repair cover have been described.

Technology Category: 5