Note: Descriptions are shown in the official language in which they were submitted.
CA 02581557 2010-05-17
ADJUSTABLE DEVICE COVER
FIELD OF THE INVENTION:
[0002] This invention pertains to a cover of an electrical outlet box and more
particularly
to a cover having an adjustable extension sleeve attached thereto.
BACKGROUND OF THE INVENTION:
[0003] During construction, electrical outlet boxes are affixed to their
support or stud
prior to the wall covering (i.e. dry wall) being installed. It is generally
known what thickness of
dry wall is going to be installed and hence electrical outlet boxes are
installed off-set from the
front of the stud by that amount so as to be flush with the wall. However, if
the dry wall
thickness is not known or if it changes or if additional wall material (i.e.
tile, sound insulation,
double-layer dry wall) is subsequently added, then the box opening will no
longer be flush with
the wall and hence it will be difficult, if not impossible, to properly
install an electrical device
within the box.
CA 02581557 2007-03-14
[0004] Solutions to this problem are varied. U.S. 5,253,831 discloses a
bracket that is
rigidly affixed to the stud. A box is then adjustably secured to the bracket.
Thus, if the wall
material is greater or less than expected, the entire box can be adjusted
accordingly.
Unfortunately, if the code specifies that all wiring to/from the box be
contained in conduit, this
would mean that the conduit would also have to move along with the box which
is not always
possible.
[0005] U.S. 4,927,039 discloses a removable attachment that abuts the open
perimeter of
the box. A first (cut-out) wall covering is applied over the box before the
attachment is secured
against the open front face of the box. Then a second wall covering is
installed. Thus, this
attachment is configured to accommodate both wall thicknesses, but such
thicknesses must be
known beforehand so that the proper sized attachment can be ordered. If there
is any subsequent
change, this attachment cannot be subsequently altered.
[0006] A further variation is shown in U.S. 2,378,861 and U.S. 4,634,015. In
both of
these cases, an extension sleeve is mounted to either the box itself or to the
box's cover. The
extension sleeve is threadably mounted such that it can be adjusted as needed
even after the wall
material is installed. In both cases, however, the user must make the
adjustments from inside the
box which exposes the installer to the oftentimes live wires contained
therein. Also, in both
cases, long screws are needed as they must be at least as long as the
adjustment range of the
extension sleeve. Such screws also project well into the box and can interfere
with the box's
wiring. Further, in both cases, the ground path from the electric device to
the box passes through
2
CA 02581557 2007-03-14
the screw; hence if the screw is loose or the mating threads are not properly
sized, grounding
issues can surface. Finally, in both cases, the screw is used to position the
extension sleeve and
hence the extension sleeve can never be rigidly locked into any one position.
[0007] It is thus an object of this invention to provide a cover that is
inexpensive to
manufacture and yet is infinitely adjustable. A further object of this
invention is to provide a
cover whose adjustable extension sleeve provides a solid ground path for the
electric device and
which can be easily locked or fixed at a selected position as desired. Still a
further object of this
invention is to eliminate the need for long screws that can interfere with the
box's wiring and to
also eliminate the need for the installer to make adjustments from within the
box. Yet another
object of this invention is to provide a means where adjustments to the box
can be made without
adjusting the position of the box itself. It is a further object of this
invention to provide a means
of making adjustments even if the wall thickness varies or if later a new wall
covering is applied.
These and other objects and advantages of this invention will be come apparent
upon further
investigation and review.
SUMMARY OF THE INVENTION:
[0008] This invention pertains to an adjustable cover that is mounted to an
electrical
outlet box. The cover incorporates a mounting plate that extends over a
portion of the electrical
outlet box. This cover includes a collar that surrounds an opening with this
collar having a distal
end spaced from the mounting plate. An extension sleeve fits within this
collar and moves with
respect thereto. Adjacent the opening is at least one fastener, this fastener
being movable
3
CA 02581557 2007-03-14
between a locking position and an unlocking position. The fastener operates a
locking device to
selectively cause such device to engage or disengage the extension sleeve in
order to selectively
lock or unlock the extension sleeve with respect to the mounting plate.
[0009] The adjustable cover for an electrical outlet box of the present
invention includes
a mounting plate, an extension sleeve, at least one fastener, and a locking
device. The mounting
plate has a collar surrounding an opening. The collar has a distal end region
remote from the
mounting plate. The extension sleeve is sized to move within the opening
adjacent the distal end
of the collar. The fastener is secured adjacent the opening and movable
between a locking and an
unlocking position. The a locking device is operable by the fastener, and the
locking device is
configured to selectively engage and disengage the extension sleeve so as to
selectively lock and
unlock the extension sleeve with respect to the mounting plate.
[0010] The present invention includes an adjustable cover for an electrical
outlet box
including a mounting plate having a collar. The collar has an inner rim and a
planar portion
extending from the inner rim. An extension sleeve extends adjacent to the
inner rim and
perpendicular to the mounting plate. The extension sleeve freely moves
perpendicularly within
the inner rim and includes at least one stop extending from both edges of the
extension sleeve to
prevent the extension sleeve from sliding out from the mounting sleeve. At
least one fastener is
secured between the extension sleeve and the inner rim and movable between a
locking position
and an unlocking position. A locking device is operable by the fastener. The
locking device is
4
CA 02581557 2007-03-14
configured to selectively engage and disengage the extension sleeve so as to
selectively lock and
unlock the extension sleeve with respect to the mounting plate.
BRIEF DESCRIPTION OF THE DRAWINGS:
[00111 Fig. 1 is a top perspective view of the present invention.
[0012] Fig. 2 is a bottom perspective view of Figure 1.
[0013] Fig. 3 is a top perspective view of Figure 1 partially disassembled.
[0014] Fig. 4 is a top perspective view of another embodiment of the present
invention.
[0015] Fig. 5 is a bottom perspective view of the embodiment of Figure 4.
[0016] Fig. 6 is a top perspective view of the embodiment of Figure 4
partially
disassembled.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT:
[0017] Referring to Figures 1-3, there is shown one embodiment of adjustable
device
cover 10. This assembly includes a generally rectangular base or mounting
plate 12 that is used
to secure device cover 10 to an electrical outlet box (not shown). A series of
slots or apertures 14
are spaced along the perimeter of plate 12 through which one or more fasteners
would extend so
as to mount cover 10 to the outlet box in the convention fashion. These slots
14 are preferably
arranged so that mounting plate 12 can be secured to the box in a variety of
different orientations.
[0018] The center of cover 10 contains a large opening 16 that permits access
through
cover 10 to the interior of the electrical outlet box. Surrounding and perhaps
defining opening 16
5
CA 02581557 2007-03-14
is collar 18 which projects away from and generally perpendicular to mounting
plate 12. The
upper distal end 20 of collar 18 is generally rounded, being curved towards
opening 16.
[0019] Slidably positioned within collar 18 and oftentimes abutting distal end
20 is
extension sleeve 22. Extension sleeve 22 is generally an open box-like
structure having
sidewalls 24 corresponding with opening 16. The depth of sidewalls 24 is
approximately the
amount of adjustment provided by cover 10, hence such depth can be varied by
the manufacturer
as needed. Extension sleeve 22 contains device mounting tabs 26 which are used
to secure an
electric device (not shown) to cover 10. Also, if desired, extension sleeve 22
can be configured
with upper and lower stops 28 that prevent extension sleeve 22 from sliding
out of mounting
plate 12. Such stops 28 can consist primarily of small projections that engage
distal end 20 but
cannot pass through opening 16.
[0020] The opposite corners 30 of extension sleeve 22 are beveled. While this
bevel is
shown as being flat, other configurations are possible if desired. It is also
possible that the four
corners 30 of extension sleeve 22 are regular 90 degree corners. In some
cases, protruding stops
32 are located at one or more such corners 30 which help prevent extension
sleeve 22 from
sliding out of collar 18. However, these stops 32 are not required for the
operation of cover 10.
[0021] As shown, just outside opposite corners 30 is a short fastener 34 that
threads into
collar 18 and, in this embodiment, the distal end 20 thereof. These fasteners
34 are adjustable
between a locking position and an unlocking position. Loosely contained by
fastener 34 when in
6
CA 02581557 2007-03-14
the unlocked position is a wedge 36. This wedge 36 is configured with an
upturned edge 38 that
ideally matches the shape of its adjacent corner 30 of extension sleeve 22.
Wedge 36 is shown in
this embodiment as being triangular with upturned edge 38 being configured so
as to engage as
fully as possible the bevel of corner 30.
[0022] Wedge 36 is sized so that while it is loosely restrained by fastener 34
(such as via
wedge aperture 40), extension sleeve 22 can move freely with respect to
mounting plate 12.
However, once extension sleeve 22 is positioned where desired, the subsequent
tightening of
fastener 34 will force upturned edge 38 against beveled corner 30. Such force
as applied by
wedge 36 will bind or lock extension sleeve 22 within collar 18, and
especially when multiple
such fasteners 34 are tightened. Thus extension sleeve 22 will be locked in
place within cover 10
via a short fastener 34 located outside central opening 16. Further, because
the surface of
upturned edge 38 engages a similarly shaped (i.e. straight) surface on beveled
corner 30, there is
much greater contact between mounting plate 12 and extension sleeve 22. This
provides for a
more reliable ground connection between the two.
[0023] Another embodiment is shown in Figures 4-6, there is shown an
adjustable device
cover 110. This assembly includes a generally rectangular base or mounting
plate 112 that is
used to secure device cover 110 to an electrical outlet box (not shown). A
series of slots or
apertures 114 are spaced along the perimeter of plate 112 through which one or
more fasteners
would extend so as to mount cover 110 to the outlet box in the conventional
fashion. These slots
7
CA 02581557 2007-03-14
114 are preferably arranged so that mounting plate 112 can be secured to the
box in a variety of
different orientations.
[0024] The center of cover 110 contains a large opening 116 that permits
access through
cover 110 to the interior of the electrical outlet box. Surrounding and
perhaps defining opening
116 is collar 118 which projects away from and generally perpendicular to
mounting plate 112.
The upper distal end, or inner rim, 120 of collar 118 is generally rounded,
being curved towards
opening 116. Up to this point, cover 110 is similar to a typical mud or dry-
wall ring.
[0025] Slidably positioned within collar 118 and oftentimes abutting distal
end 120 is
extension sleeve 122. Extension sleeve 122 is generally an open box-like
structure having
sidewalls 124 corresponding with opening 116. The depth of sidewalls 124 is
approximately the
amount of adjustment provided by cover 110; hence such depth can be varied as
needed.
Extension sleeve 122 contains device mounting tabs 126 which are used to
secure an electric
device (not shown) to cover 110. Also, if desired, extension sleeve 122 can be
configured with
stops 128 that prevent extension sleeve 122 from sliding out of mounting plate
112. Such stops
128 can consist primarily of small projections that engage distal end 120 but
cannot pass through
opening 116. Each corner of the extension sleeve 122 is roughened which
provides for frictional
engagement between the extension sleeve 122, and wedge 136 and/or mounting
plate 112.
[0026] In the preferred embodiment, two opposite corners 130 of extension
sleeve 122
are beveled. While this bevel is shown as being flat, other configurations are
possible if desired.
8
CA 02581557 2007-03-14
Protruding stops 132 are located along extension sleeve 122 which also help
prevent extension
sleeve 122 from sliding out of collar 118. As shown in Figures 4 -6 protruding
stops 132 extend
from the bottom edge of the extension sleeve 122. The stops 132 can be located
anywhere along
the length of extension sleeve 122, including flush with the bottom edge of
the extension sleeve
122. As can be seen, the adjacent corners of collar 118 are configured to
conform to or
accommodate the shape of these corners 130 on extension sleeve 122.
[0027] As shown in Figures 4-6, just outside opposite corners 130 of extension
sleeve
122 is a short fastener 134 that freely passes through aperture 140 in the
adjacent corners of
collar 118. In this embodiment, such open apertures 140 are located at the
distal end 120 of
collar 118. These fasteners 134 thread into wedge 136 which is adjustable
between a locking
position and an unlocking position.
[0028] When fastener 134 is rotated into the locking position, the threaded
wedge 136 is
moved along fastener 134 so as to bias tightly against corner 130 of extension
sleeve 122. This is
accomplished by forcing wedge 136 to ride along the inner surface of collar
118 whenever
fastener 134 is rotated. Because the distal end of this inner surface bends or
is curved towards
extension sleeve 122, wedge 136 is thus forced in this direction and against
its respective corner
130. This will lock extension sleeve 122 in place. When fastener 134 is
rotated into the
unlocking position, the threaded wedge 136 is moved in the opposite direction
so as to be
loosened or unbiased from corner 130 of extension sleeve 122 thereby allowing
extension sleeve
122 to move freely.
9
CA 02581557 2007-03-14
[00291 In the present embodiment, wedge 136 is sized to abut both the beveled
corner
130 of extension sleeve 122 as well as abut the underneath side of collar 118.
Thus, when in the
locked position, wedge 136 is rigidly biased against both extension sleeve 122
and the underside
of collar 118 thereby creating an electrical ground path between the two.
Fastener 134 also
serves as a ground path between the two.
[00301 As indicated above, in the locked position the mounting plate 112 is
sandwiched
between the wedge 136 and fastener 134 and further the wedge 136 seats under
and within the
rounded distal end 120 of the collar 118. This positioning of the wedge 136
allows for flush
mounting of mounting plate 112 without the wedge 136 interfering with the
installation of the
device 110. The wedge 136 is generally planar with a triangular shape to match
the shape and
angle of its adjacent corner 130 of extension sleeve 122 at the hypotenuse 142
of the wedge 136.
The remaining sides 144 and 146 of the wedge are configured to match the shape
of the
underside of the distal end 120 of the collar 118 to allow for placement
therein when the wedge
136 is in the locked positioned, as shown in Figure 4. The hypotenuse 142 of
wedge 136 may be
slightly bowed or convexed outwardly toward the extension sleeve 122 such that
the center
portion 142a of the hypotenuse 142 engages with the bevel of corner 130, and
the two edge
portions 142b of the hypotenuse 142 are not engaged with the corner 130. Thus,
there is a slight
gap 148 between the edges portions 142b and the corner 130. This allows for
easier
repositioning of the extension sleeve 122 because less turns of the fastener
134 is required to
unlock the wedge 136. The wedge 136 is able to shift about the hypotenuse 142
and use the gap
CA 02581557 2007-03-14
148 between the edge portions 142b and the beveled corner 130 to create enough
slack to move
the extension sleeve 122 with respect to collar 118.
[0031] Referring to Figure 4, wedge 136 is sized so that while it is
threadably connected
to fastener 134 but spaced from extension sleeve 122 and while fastener 134
passes through open
aperture 140, extension sleeve 122 can move freely with respect to mounting
plate 112.
However, once extension sleeve 122 is positioned where desired, the subsequent
tightening of
fastener 134 will force the center portion 142a of the wedge 136 against
beveled corner 130 of
extension sleeve 122. Such force as applied by wedge 136 will bind or lock
extension sleeve 122
within collar 118, and especially when multiple such fasteners 134 are
tightened. Thus extension
sleeve 122 will be locked in place within cover 110 via a short fastener 134
located outside
central opening 116. Further, because the hypotenuse 142 is slightly bowed
outwardly toward
the corner 130, there is specific contact between the center portion 142a and
extension sleeve
122, thereby providing a ground path between the two. Other ground paths also
arise such as
where extension sleeve 122 is forced against collar 118 due to this locking
action.
[0032] Further, the extension sleeve 122 may include markings 150 to identify
the proper
placement of the mounting plate thereabout for the specified wall thickness.
11
CA 02581557 2007-03-14
Having described the preferred embodiments herein, it should now be
appreciated that variations
may be made thereto without departing from the contemplated scope of the
invention.
Accordingly, the preferred embodiments described herein are deemed
illustrative rather than
limiting, the true scope of the invention being set forth in the claims
appended hereto.
12
