GB1562152A - Cover assembly for an electrical outlet box - Google Patents

Description

(54) COVER ASSEMBLY FOR AN ELECTRICAL OUTLET BOX (71) We, CROUSE-HINDS COM PANY, a corporation organised and exsting under the laws of the State of New York, United States of America, of Syracuse, New York, United States of America, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement:- The present invention - is directed to a cover assembly for use with an electrical outlet box and incorporating a multiple function one-piece gasket.

Gaskets for sealing electrical sockets against moisture are well known and old in the art. Generally, such electrical sockets are disposed in an outlet box provided with a cover plate having an aperture for the electrical socket and a cover door which is pivoted on the cover plate to close the aperture when a plug is not fitted with the socket.

A typical gasket arrangement is shown in United States Patent Specification 1,366,246, which discloses the use of three separate gaskets to perform three separate sealing functions. One gasket is disposed between the cover plate and the outlet box, a second gasket is mounted in the pivoted door to seal the aperture in the cover plate when the door is closed in the absence of a plug, and a third gasket is disposed about the aperture in the cover plate for sealing the plug member when it is disposed in mating engagement with the electrical outlet in the junction box. Even with the use of three separate gaskets, which are expensive and time consuming to install, there is still no sealing function provided between the electrical receptacle and the cover body.

Other prior art devices might achieve two of the sealing functions with a single gasket but there are no prior are devices which provide for all four sealing functions much less provide for all four sealing functions with a single one-piece gasket.

In accordance with the present invention there is provided a cover assembly for an electrical outlet box, comprising a cover plate having an aperture to provide access to at least one electrical socket in the box, a cover door normally spring biased into a closed position overlying the aperture, and a one-piece gasket of elastomeric material having a respective aperture aligned in use with the or each of the said sockets, the gasket being provided with an outwardly facing groove engaging the edge of the plate defining the plate aperture, and the or each aperture in the gasket having a first sealing portion for engaging the socket, a second sealing portion adapted to engage a plug inserted in the socket when the cover door is moved against its spring bias to an open position, and a third sealing portion underlying the cover plate to provide a seal between the cover plate nad the outlet box and means on the cover door for engaging the gasket to seal the aperture in the cover plate when the door is closed in the absence of a plug.

By way of example only, two embodiments of the invention will now be described with reference to the accompanying drawings in which: Figure 1 is a perspective view of a cover plate assembly and gasket according to one embodiment of the present invention.

Figure 2 is a longitudinal sectional view of the assembly shown in Figure 1 with the door closed.

Figure 3 is a cross-sectional view similar to Figure 2 showing the door open and a plug and socket coupled together.

Figure 4 is a perspective view of a modified cover plate and gasket assembly embodying the invention for a duplex outlet.

Figure 5 is a transverse sectional view through the assembly of Figure 4 showing one of the doors closed and the other door opened with a plug and socket coupled together.

In the embodiment shown in Figures 1-3, a cover plate assembly for a single socket is illustrated. The cover plate 10 comprises a rectangular plate having a flange 12 extending about the entire periphery and is further provided with a circular aperture 14 through which access may be had to a socket 16 which is mounted in the conventional manner in an outlet box 18 (Fig. 3). The cover plate 10 is secured to the outlet box 18 by a plurality of screws 20.

The plate 10 is provided with a pair of integral upstanding lugs 22 and 24 and a cover door 26 is pivoted between the lugs by means of a pivot pin 28. A spring 30 is wrapped about the pivot pin 28 with one end secured in an anchor block 32 which is secured to the cover plate 10 while the opposite end 34 of the spring bears against the cover 26 to normally bias the cover into the closed position shown in Figure 2. The cover 26 is provided with a peripheral flange 36 which extends substantially about the entire circumference of the cover with the exception of the point where the pivot pin and spring are located and a point diametrically opposite thereof where a finger recess 38 is provided to assist in lifting the cover door. The flange 36 will be spaced from the upper surface of the cover plate 10 and a shorter circular flange 39 depends from the under surface of the cover door 26 for engagement with the gasket to be described hereinafter.

The gasket 40 is formed in onepiece from any suitable elastomeric material such as rubber, plastics or the like by conventional molding techniques. The gasket comprises an annular rib portion 42 having an external groove 44 formed about the entire circumference thereof and adapted to receive the peripheral edge of the aperture in the cover plate 10. A first annular flange 46 extends radially inwardly from the rib 42 and terminates in an annular rib 48 which is adapted to engage the receptacle 16 in the outlet box 18. The rib 42 is provided with a second annular flange 50 which is parallel to the flange 46 but spaced - outwardly therefrom away from the outlet box 18. The diameters of the apertures defined by the flanges 46 and 50 are substantially equal so' that the outermost flange 50 will sealingly engage a plug 52 which is brought into mating engagement with the socket 16. The flange 50 also serves to sealingly engage the circular flange 39 on the cover when the cover is closed in the absence of a plug to prevent the entry of moisture into the vicinity of the socket 16.

Finally, the rib 42 is provided with a radially outwardly extending flange 54 which has an overall configuration substantially coincident with that of the cover plate so as to fit within the recess on the underside of the cover plate defined by the flange 12 of the cover plate. The flange 54 is provided with apertures for the screws 20 and is secured to the underside of the cover plate 10 by means of strap 55 which is secured by screws 56. Thus, when the cover plate and cover door assembly is secured to the outlet box, the flange 54 will sealingly engage the edge of the outlet box to prevent the entry of moisture into the box. Thus, the single one-piece gasket 40 provides four separate sealing functions namely that of sealing the cover plate- to the outlet box, the socket to the cover plate, the spring door to the cover plate when the door is closed and the interface between the outlet socket and mating inserted plug when the door is open.

-In the embodiment of Figures 4 and 5, a gasket suitable for use with a dual socket assembly is disclosed. The two sockets 60 and 62 are mounted in an outlet box 64. The cover 66 having- a peripheral flange 68 and a central elongated aperture 70 is secured to the outlet box 64 by screws 72.

The cover plate 66 is provided with a pair of upstanding lugs 74 and 76 which support pivot pin 78. A pair of doors 80 and 82 are pivoted on the pivot pin 78 and a pair of coil springs 84, only one of which is shown in each figure, are disposed about the pivot pin 78 for normally biasing the covers to the closed position. The doors 80 and 82 are provided with peripheral flanges 86 and 88, respectively, which are adapted to extend about three sides of the cover plate in spaced relation when the doors are in the closed position. Projections 90 and 92 are formed on each flange, respectively, to provide a finger grip to raise the cover plate when it is desired to have access to the socket covered by the respective door. Each door is also provided with a pair of concentric inner flanges 94 and 96 as well as a side flange 98 which are shorter in length than the flanges 96 and 88 and which are adapted to be disposed in sealing engagement with the gasket 100 when the doors are closed.

The gasket -100 which is adapted to dispose in elongated recess 70 formed in the cover plate 66 is a one-piece construction and may be molded from any suitable elastomeric material such as rubber, plastic or the like. The gasket 100 is substantially of a Figure 8 configuration with two apertures adapted to be aligned with the socket 60 and 62 and an outer periphery which substantially follows the outline of the aperture 70 in the cover plate 66. The portion of the gasket following the periphery of the elongated aperture 70 has a substantially S-shaped cross section having three flat parallel portions 102, 104 and 106 which are joined together by two connecting portions 108 and 110. The flat portions 104 and 106 are disposed on opposite surfaces of the cover plate with the connecting portion 110 engaging the periphery of the aperture 70 in the cover plate. The gasket 100 is provided with a central transverse portion 112 which separates the two sockets 60 and 62 from.

each other and provides an upper sealing surface 114 which is coextensive with the upper surface of the flat peripheral portion 102. The transverse portion 112 is also provided with a pair of flanges 116 which are coextensive with the connecting portion 110 to define an annular sealing surface.

In use, the portion 106 of the gasket will provided a seal between the cover plate 66 and the outlet box 64. The annular sealing surface defined by the connecting portion 110 and flange 116 is disposed in sealing engagement with the sockets 60 and 62 and the flat composite sealing surface defined by the portions 102 and 114 provide sealing engagement with the flanges 94, 96 and 98 on the doors 80 and 82 when they are closed to prevent moisture from reaching the sockets 60 and 62.

When the door is open and a plug similar to the plug 52 is inserted into the socket 60 as shown in Figure 5, the edge of the gasket portion 102 and the lip on the central portion 112 sealingly engage the plug to prevent moisture from reaching the interface between the plug and receptacle.

Thus, in both the single and duplex receptacle arrangements a single one-piece molded gasket performs a plurality of sealing functions. Therefore, it is not necessary to mold a plurality of separate individual gaskets for each assembly and laboriously assemble the gaskets in a plurality of individual time consuming steps.

The single gasket according to the present invention can quickly and easily be attached by a single operation which is far more efficient. An additional sealing function is provided where the screws 20 and 72 penetrate the gaskets in both embodiments.

The holes provided for the screws are of a smaller diameter than the screws to provide a tight sealing engagement.

WHAT WE CLAIM IS: 1. A cover assembly for an electrical outlet box, comprising a cover plate having an aperture to provide access to at least one electrical socket in the box, a cover door normally spring biased into a closed position overlying the aperture, and a one-piece gasket of elastomeric material having a respective aperture aligned in use with the or each of the said sockets, the gasket being provided with an outwardly facing groove engaging the edge of the plate defining the plate aperture, and the or each aperture in the gasket having a first sealing portion for engaging the socket, a second sealing portion adapted to engage a plug inserted in the socket when the cover door is moved against its spring bias to an open position, and a third sealing portion underlying the cover plate to provide a seal between the cover plate and the outlet box and means on the cover door for engaging the gasket to seal the aperture in the cover plate when the door is closed in the absence of a plug.

2. A cover assembly according to Claim 1 in which the gasket comprises a substantially annular rib, the first sealing portion comprising a first radially inwardly extending flange for engaging the socket, the second sealing portion comprising a second radially inwardly extending flange disposed parallel to and spaced from the flange to engage the said plug, and the third sealing portion comprising a radially outwardly extending flange: 3. A cover assembly according to Claim 1 in which the cover plate aperture is an elongate aperture for providing access to two of the said sockets, and the gasket comprises an annular rim. portion of outwardly-opening U-shaped cross-section extending around the entire periphery of the aperture, a flat annular flange portion disposed parallel to the two arms of the rim portion m spaced relation thereto, the flange portion being connected to one of the said arms by a connecting portion remote from the bight between the two arms of the U-shaped cross-section, and a transverse portion connected between the elongate sides of the rim portion to divide the gasket in two halves, each half forming an aperture for alignment with a respective one of the two sockets.

4. A cover assembly for an electrical outlet box substantially as herein described with reference to either Figs. 1-3 of Figs. 4 and 5 of the accompanying drawings.

**WARNING** end of DESC field may overlap start of CLMS **.

Claims (4)

**WARNING** start of CLMS field may overlap end of DESC **. periphery of the aperture 70 in the cover plate. The gasket 100 is provided with a central transverse portion 112 which separates the two sockets 60 and 62 from. each other and provides an upper sealing surface 114 which is coextensive with the upper surface of the flat peripheral portion 102. The transverse portion 112 is also provided with a pair of flanges 116 which are coextensive with the connecting portion 110 to define an annular sealing surface. In use, the portion 106 of the gasket will provided a seal between the cover plate 66 and the outlet box 64. The annular sealing surface defined by the connecting portion 110 and flange 116 is disposed in sealing engagement with the sockets 60 and 62 and the flat composite sealing surface defined by the portions 102 and 114 provide sealing engagement with the flanges 94, 96 and 98 on the doors 80 and 82 when they are closed to prevent moisture from reaching the sockets 60 and 62. When the door is open and a plug similar to the plug 52 is inserted into the socket 60 as shown in Figure 5, the edge of the gasket portion 102 and the lip on the central portion 112 sealingly engage the plug to prevent moisture from reaching the interface between the plug and receptacle. Thus, in both the single and duplex receptacle arrangements a single one-piece molded gasket performs a plurality of sealing functions. Therefore, it is not necessary to mold a plurality of separate individual gaskets for each assembly and laboriously assemble the gaskets in a plurality of individual time consuming steps. The single gasket according to the present invention can quickly and easily be attached by a single operation which is far more efficient. An additional sealing function is provided where the screws 20 and 72 penetrate the gaskets in both embodiments. The holes provided for the screws are of a smaller diameter than the screws to provide a tight sealing engagement. WHAT WE CLAIM IS:

1. A cover assembly for an electrical outlet box, comprising a cover plate having an aperture to provide access to at least one electrical socket in the box, a cover door normally spring biased into a closed position overlying the aperture, and a one-piece gasket of elastomeric material having a respective aperture aligned in use with the or each of the said sockets, the gasket being provided with an outwardly facing groove engaging the edge of the plate defining the plate aperture, and the or each aperture in the gasket having a first sealing portion for engaging the socket, a second sealing portion adapted to engage a plug inserted in the socket when the cover door is moved against its spring bias to an open position, and a third sealing portion underlying the cover plate to provide a seal between the cover plate and the outlet box and means on the cover door for engaging the gasket to seal the aperture in the cover plate when the door is closed in the absence of a plug.

2. A cover assembly according to Claim 1 in which the gasket comprises a substantially annular rib, the first sealing portion comprising a first radially inwardly extending flange for engaging the socket, the second sealing portion comprising a second radially inwardly extending flange disposed parallel to and spaced from the flange to engage the said plug, and the third sealing portion comprising a radially outwardly extending flange:

3. A cover assembly according to Claim 1 in which the cover plate aperture is an elongate aperture for providing access to two of the said sockets, and the gasket comprises an annular rim. portion of outwardly-opening U-shaped cross-section extending around the entire periphery of the aperture, a flat annular flange portion disposed parallel to the two arms of the rim portion m spaced relation thereto, the flange portion being connected to one of the said arms by a connecting portion remote from the bight between the two arms of the U-shaped cross-section, and a transverse portion connected between the elongate sides of the rim portion to divide the gasket in two halves, each half forming an aperture for alignment with a respective one of the two sockets.

4. A cover assembly for an electrical outlet box substantially as herein described with reference to either Figs. 1-3 of Figs. 4 and 5 of the accompanying drawings.