BACKGROUND
1 Field of the Invention
The present disclosure is related to a cover plate for electrical boxes. In particular, the present disclosure is related to a hinged adjustable mount cover plate for electrical boxes.
2. Description of Related Art
The traditional mounting process of a cover plate is to attach the cover plate to an electrical box, which also is called an outlet box, place the assembly of the cover plate and electrical box over the stud, align the assembly of the cover plate and electrical box, and screw attach the assembly of the cover plate and electrical box while holding it. A regular cover plate undesirably cannot be mounted on each side of the stud. A different depth for the cover plate is also needed depending on the wall thickness. Even further, these stud mount cover plates will not usually work with pre-fab installations. Additionally, once the cover plate has been installed, the working space opening in the electrical box has been undesirably reduced drastically.
Accordingly, it has been determined by the present disclosure that there is a continuing need for a device that overcomes, alleviates, and/or mitigates one or more of the aforementioned and other deleterious effects of prior devices.
SUMMARY
A cover plate that is connectable to an electrical box is provided that includes a body configured to mount to a stud, a brace assembly, in a gang application, or, when the cover plate is a first cover plate and the body is a first body that is mounted to a first side of the stud, a second body of a second cover plate can overlap a portion of the first body to be mounted to a second side of the stud at the same time that the first body of the first cover plate is mounted to the first side of the stud.
In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the body is connectable to a mud ring to form a hinged connection between the body and the mud ring.
In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the electrical box is a plurality of electrical boxes each having a different size, and the body is connectable to each of the plurality of electrical boxes.
In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the body has a box flange, and the body has a plurality of fastener holes and and/or grooves through the box flange to connect to electrical boxes of various sizes.
In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the body has a tab and a projection that extend on opposite sides of the stud to connect the cover plate to the stud.
In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the tab has a bent portion to apply tension to maintain a connection between the cover plate to the stud.
In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the body has a hole to receive a fastener to connect the cover plate to the stud.
In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the cover plate is a first cover plate and further comprising a second cover plate, and the body of the first cover plate has a first opening to receive a tab of the second cover plate to connect the first cover plate and the second cover plate in a gang application.
In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, a pair of tabs is on opposite sides of the body that are connectable to a brace.
In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the body has a hole to receive a fastener to connect the cover plate to the brace.
In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the body has a receptacle to receive a hinge projection of a mud ring.
In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the mud ring has a hinge tab that is bendable to connect the mud ring to the body.
In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the mud ring has a sleeve, and the sleeve has a depth that is adjustable.
In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the mud ring has a connection portion that has a fixed depth that is not adjustable that is connectable to an electrical device.
In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the body is connectable to a side support.
In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the body is connectable to a mud ring to form a fixed connection between the body and the mud ring.
In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the body has a first side member on a first side of the body and a second side member on a second side of the body opposite the first side, and the body has a first frame member between the first side member and the second side member on a third side and a second frame member between the first side member and the second side member on a fourth side that is opposite the third side.
In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the body has a plurality of slots through the first frame member and a ridge that is bent along two of the plurality of slots.
In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the ridge forms a plurality of tabs that are connectable to the brace.
In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the first side member has a tab and the second side member has a tab, and wherein the tab of the first side member and the tab of the second side member are each connectable to the stud.
The above-described and other features and advantages of the present disclosure will be appreciated and understood by those skilled in the art from the following detailed description, drawings, and appended claims.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front perspective view of a cover plate connected to a first mud ring in a closed position.
FIG. 2 is a front perspective view of the cover plate of FIG. 1 connected to a second mud ring in a closed position.
FIG. 3 is a front perspective view of the cover plate of FIG. 1 connected to a third mud ring in a closed position.
FIG. 4 is a front perspective view of the cover plate connected to the first mud ring of FIG. 1 in an opened position.
FIG. 5 is a front perspective view of the cover plate connected to the second mud ring of FIG. 2 in an opened position.
FIG. 6 is a front perspective view of the cover plate connected to the third mud ring of FIG. 3 in an opened position.
FIG. 7 is a front perspective view of the cover plate of FIG. 1.
FIG. 8 is a top view of the cover plate of FIG. 1.
FIG. 9 is a front perspective view of a fourth mud ring.
FIG. 10 is a front perspective view of a fifth mud ring prior to connection with the cover plate of FIG. 7.
FIG. 11 is a partial front perspective view of the fifth mud ring having a configuration after connection with the cover plate.
FIG. 12 is a front perspective view of the cover plate connected to the first mud ring of FIG. 1 in the opened position and the cover plate connected to a first electrical box.
FIG. 13 is a partial front perspective view of the cover plate connected to the first electrical box of FIG. 12.
FIG. 14 is a front perspective view of the cover plate connected to the first mud ring of FIG. 1 in the opened position and the cover plate connected to a second electrical box.
FIG. 15 is a partial front perspective view of the first mud ring.
FIG. 16 is a partial front perspective view of the cover plate connected to the second electrical box of FIG. 14.
FIG. 17 is a front perspective view of a first cover plate connected to the first mud ring and the first electrical box of FIG. 12 having the first mud ring in the closed position and a second cover plate connected to the second mud ring and another first electrical box having the second mud ring in the closed position both the first cover plate and the second cover plate connected to a brace and with the brace connected to two studs.
FIG. 18 is a rear perspective view of FIG. 17.
FIG. 19 is a partial enlarged rear perspective view of FIG. 18.
FIG. 20 is a bottom perspective view a first cover plate connected to the first mud ring and the first electrical box of FIG. 12 having the first mud ring in the closed position connected to a first stud and a second cover plate connected to the second mud ring and another first electrical box having the second mud ring in the closed position connected to a second stud.
FIG. 21 is a front perspective view of a first cover plate connected to the first mud ring and the first electrical box of FIG. 12 having the first mud ring in the closed position and a second cover plate connected to the second mud ring and another first electrical box having the second mud ring in the closed position with both the first cover plate and the second cover plate connected to a stud and a third cover plate connected to another first mud ring and still another first electrical box of FIG. 12 connected in a gangable configuration to the first cover plate.
FIG. 22 is a front perspective view of the cover plate of FIG. 1 connected to a sixth mud ring and a third electrical box.
FIG. 23 is a front perspective view of the cover plate of FIG. 1 connected to a seventh mud ring and the third electrical box.
FIG. 24 is a front perspective view of a side support.
FIG. 25 is a front perspective view of an outer member of the side support of FIG. 24.
FIG. 26 is a front perspective view of an inner member of the side support of FIG. 24.
FIG. 27 is a front perspective view of a side support.
FIG. 28 is a front perspective view of an outer member of the side support of FIG. 27.
FIG. 29 is an enlarged front perspective view of a portion of the outer member of FIG. 28.
FIG. 30 is a front perspective view of an inner member of the side support of FIG. 27.
FIG. 31 is an enlarged front perspective view of a portion of the inner member of FIG. 30.
DETAILED DESCRIPTION
Referring to the drawings and in particular to FIG. 1, an exemplary embodiment of a cover plate according to the present disclosure is shown and is generally referred to by reference numeral 10. Advantageously, cover plate 10 is a “hinged adjustable mount cover plate” that can be snapped-on over a stud 100, as shown in FIG. 20, freeing a user's hands for an easier installation. Cover plate 10 is gangable, for example, as shown in FIG. 21, allowing cover plate 10 to be mounted on each side of stud 100. The depth of cover plate 10 is fully adjustable from ½ inch to 1⅜ inch so the wall thickness is not an issue anymore. The adjustability of mud rings, for example, mud ring 12, that are connectable to cover plate 10 can be done without detaching an electrical box that is connected to cover plate 10. The hinged feature of cover plate 10 and mud rings, for example, mud ring 12, allows the mud rings to fully open when attached to cover plate 10, and mud rings when attached to cover plate 10 can open over ninety degrees relative to cover plate 10, maximizing working space. Cover plate 10 can also be used for pre-fab applications, where the “hinged adjustable cover plate” can be snapped-on a brace 200 as shown in FIGS. 17-18 that is an adjustable brace for a hands free mounting. The hinged feature of cover plate 10 and mud rings, for example, mud ring 12, can be open without the removal of an electrical box that that is connected to cover plate 10. Another advantage is this universal design of cover plate 10 eliminates the need of many SKU's.
Referring still to FIG. 1, cover plate 10 is connectable to different types of mud rings by a hinged connection or a fixed connection. Examples of the mud rings having a hinged connection with cover plate 10 are shown in FIGS. 1-3, namely, cover plate 10 can be connected by hinges 9 to a first mud ring 12, a second mud ring 14 as shown in FIG. 2, and a third mud ring 16 as shown in FIG. 3. First mud ring 12, second mud ring 14 and third mud ring 16 are movable between a closed position as shown in FIGS. 1-3, respectively, to an open position as shown in FIGS. 4-6, respectively. First mud ring 12 has a first mud ring body 112. First mud ring 12 has an opening 111 through first mud ring body 112. A sleeve 13 is positioned through opening 111 through first mud ring body 112. Sleeve 13 is slidable in opening 111 through first mud ring body 112 to increase or decrease a depth D1. Depth D1 is a distance between an outer ridge 113 of sleeve 13 and first mud ring body 112. Depth D1 is increased or decreased by screws 13a, 13b that attached sleeve 13 to first mud ring body 112. Screws 13a, 13b are inserted through holes in sleeve 13 and holes in first mud ring body 112 that align with holes in sleeve 13. Rotation of screws 13a, 13b in a first direction decreases a size of depth D1 and rotation of screws 13a, 13b in a second direction that is opposite the first direction increases the size of depth D1. Similarly, second mud ring 14 has a second mud ring body 114. Second mud ring 14 has an opening 115 through second mud ring body 114. A sleeve 15 is positioned through opening 115 through second mud ring body 115. Sleeve 15 is slidable in opening 115 through second mud ring body 114 to increase or decrease a depth D2. Depth D2 is a distance between an outer ridge 125 of sleeve 15 and second mud ring body 115. Depth D2 is increased or decreased by screws 15a, 15b that attached sleeve 15 to second mud ring body 115. Screws 15a, 15b are inserted through holes in sleeve 15 and holes in second mud ring body 115 that align with holes in sleeve 15. Rotation of screws 15a, 15b in a first direction decreases a size of depth D2 and rotation of screws 15a, 15b in a second direction that is opposite the first direction increases the size of depth D2. Third mud ring 16 has a third mud ring body 116. Third mud ring 16 has an opening 117 through third mud ring body 116. A sleeve 17 is positioned through opening 117 through third mud ring body 116. Sleeve 17 is slidable in opening 117 through third mud ring body 116 to increase or decrease a depth D3. Depth D3 is a distance between an outer ridge 135 of sleeve 17 and third mud ring body 116. Depth D3 is increased or decreased by screws 17a, 17b that attached sleeve 17 to third mud ring body 116. Screws 17a, 17b are inserted through holes in sleeve 17 and holes in third mud ring body 116 that align with holes in sleeve 17. Rotation of screws 17a, 17b in a first direction decreases a size of depth D3 and rotation of screws 17a, 17b in a second direction that is opposite the first direction increases the size of depth D3.
Referring to FIG. 7, cover plate 10 has a body 700. Body 700 has a first side member 702 on a first side of body 700 and a second side member 704 on a second side of body 700 opposite the first side. First side member 702 has a first hole 706, a first horizontal oblong hole 708, a second hole 710, a first vertical oblong hole 712, a first opening 714, a first gap 716, a third hole 718, a fourth hole 719 adjacent a diamond shaped hole 720, a fifth hole 722, a second gap 724, a second vertical oblong hole 726, a sixth hole 728, a second horizontal oblong hole 730, a seventh hole 732, and a second opening 734 through first side member 702. First side member 702 has a first projection 733 that extends through first gap 716 and a second projection 735 that extends through second gap 724. Body 700 has a tab 736 that extends from first side member 702 adjacent first vertical oblong hole 712 and a tab 738 that extends from first side member 702 adjacent second vertical oblong hole 726. Tabs 736, 738 are each bent in a first direction A to be perpendicular to first side member 702 to form intermediate portions 740, 742, respectively. Tabs 736, 738 are each bent in a second direction B inward to form end portions 744, 746, respectively. End portions 744, 746 extend in opposite directions. First side member 702 also has hinge receptacles 745, 747.
Similarly, second side member 704 has a first hole 748, a first horizontal oblong hole 750, a second hole 752, a first vertical oblong hole 754, a first opening 756, a first gap 758, a third hole 760, a fourth hole 762 adjacent a diamond shaped hole 764, a fifth hole 766, a second gap 768, a second vertical oblong hole 770, a sixth hole 772, a second horizontal oblong hole 774, a seventh hole 776, and a second opening 778 through second side member 704. Second side member 704 has a first projection 782 that extends through first gap 758 and a second projection 784 that extends through second gap 768. Body 700 has a tab 786 that extends from second side member 704 adjacent first vertical oblong hole 754 and a tab 788 that extends from second side member 704 adjacent second vertical oblong hole 770. Tabs 786, 788 are each bent in first direction A to be perpendicular to second side member 704 to form intermediate portions 790, 792, respectively. Tabs 786, 788 are each bent in a third direction C inward to form end portions 794, 796, respectively. End portions 794, 796 extend in opposite directions. Second side member 704 also has a fastener hole 797.
Body 700 has a first frame member 798 between first side member 702 and second side member 704 on a third side and a second frame member 800 between first side member 702 and second side member 704 on a fourth side that is opposite the third side. Body 700 has three slots 802, 804, 806 and two ridge slots 808, 810 through first frame member 798. First frame member 798 has a ridge 812 that is bent along two ridge slots 808, 810. Ridge 812 forms tabs 814, 816. Each of tabs 814, 816 are bent to form a bent portion 818, 820, respectively. Similarly, body 700 has three slots 822, 824, 826 and two ridge slots 828, 830 through second frame member 800. As shown in FIG. 12, second frame member 800 has a ridge 832 that is bent along two ridge slots 828, 830. Ridge 832 forms tabs 834, 836. Each of tabs 834, 836 are bent to form a bent portion 838, 840, respectively. Referring back to FIG. 7, body 700 also has a box flange 842. Body 700 has fastener holes 844, 846, 848, 850 and grooves 849, 851 through box flange 842 to connect to electrical boxes of various sizes. Cover plate 10 can be metal or plastic.
Referring to FIG. 9, cover plate 10 is connectable to different types of mud rings by a hinged connection. For example, mud rings can be of 4 inches, 4 11/16 inches, single device, and/or double device. For example, mud ring 901 is connectable to cover plate 10 by a hinged connection. Mud ring 901 has a ring body 900. Ring body 900 forms a connection portion 902 that is connectable to an electrical device, for example, a light switch or electrical outlet. Connection portion 902 has a fixed depth 903 that is not adjustable. Ring body 900 also forms a fastener opening 904. Two hinge projections 906, 908 and a hinge tab 910 extend from ring body 900. Referring to FIG. 10, a mud ring 1000 is shown that is the same as mud ring 900 except has a connection portion 1002 that is different, and, accordingly the same reference numerals with be used. To connect a mud ring, for example, mud ring 1000 to cover plate 10, hinge tab 910 is bent so that hinge tab 910 forms a less than 180 angle with ring body 900 and is not adjacent hinge projection 908, as shown in FIG. 10, allowing hinge projection 906 to be positioned in hinge receptacle 745 and hinge projection 908 to be positioned in hinge receptacle 747, and, then, hinge tab 910 is bent to be adjacent hinge projection 908, as shown in FIG. 11, to maintain hinge projection 906 in hinge receptacle 745 and hinge projection 908 in hinge receptacle 747 forming a hinged connection and hinges 9 so that mud ring 1000 is rotatable relative to cover plate 10. Mud rings 12, 14, 16 are connected to cover plate 10 the same as mud rings 901 and 1000.
Referring to FIGS. 12-16, cover plate 10 is connectable to different electrical boxes of different sizes. For example, cover plate 10 is connectable to an electrical box 1212 as shown in FIG. 12 and an electrical box 1412 as shown in FIG. 14. Referring to FIGS. 12 and 13, a fastener 1200 is inserted through groove 849 in cover plate 10 and an aperture 1204 through electrical box 1212 to connect cover plate 10 and electrical box 1212. Referring to FIGS. 14-16, a fastener 1400 is inserted through groove 851 in cover plate 10 and an aperture 1404 through electrical box 1412 and another fastener 1406 is inserted through hole 846 in cover plate 10 and an aperture 1408 through electrical box 1412 to connect cover plate 10 and electrical box 1412. Fastener holes 844, 846, 848, 850 and grooves 849, 851 through box flange 842 allows cover plate 10 to connect to electrical boxes of various sizes. Referring to FIG. 15, mud ring 12 has a plate 1502 that fits in fastener opening 904. Plate 1502 has an opening forming four flaps 1504 surrounding a fastener 1506, for example, a screw. Plate 1502 holds fastener 1506 so fastener 1506 does not become disconnected and lost prior to or during installation. Fastener 1506 passes through fastener opening 904, plate 1502 and fastener hole 797 when mud ring 12 is in the closed position to maintain mud ring 12 in the closed position. Accordingly, only one screw is needed to connect cover plate 10 with mud ring 12.
Referring to FIGS. 17-18, cover plate 10 is connectable to a brace 200. Brace 200 allows one or more electrical boxes to connect by one or more cover plates 10 between two studs 100, 102. Brace assembly 200 has an inner brace member 202 and an outer brace member 204. Outer brace member 204 has an outer end support 206 and a first outer rail 208 and a second outer rail 210 extending from outer end support 206. Outer end support 206 has two holes to receive fasteners 280. First outer rail 208 and a second outer rail 210 have holes 211. Inner brace member 202 has an inner end support 212 and a first inner rail 214 and a second inner rail 216 extending from inner end support 212. Inner end support 212 has two holes to receive fasteners 282. First inner rail 214 and second inner rail 216 have holes 217. First outer rail 208, second outer rail 210, first inner rail 214 and second inner rail 216 each have a C-shaped cross-section. The C-shaped cross-section of first inner rail 214 is sized smaller than the C-shaped cross-section of first outer rail 208 so that first outer rail 208 fits over first inner rail 214 and the C-shaped cross-section of second inner rail 216 is sized smaller than the C-shaped cross-section of second outer rail 210 so that second outer rail 210 fits over second inner rail 216 allowing first outer rail 208 and second outer rail 210 to slide on first inner rail 214 and second inner rail 216, respectively, to move outer end support 206 and inner end support 212 toward and away from one another adjusting a size of brace assembly 200. A stop structure such depressions in each of first outer rail 208 and second outer rail 210 that each fit in one of depressions in first inner rail 214 and second inner rail 216 at a maximum distance outer end support 206 and inner end support 212 can be apart is included so that inner brace member 202 and outer brace member 204 are prevented from separating. Outer end support 206 connects to a first stud 100 by fasteners 280 passing through the two holes therein and inner end support 212 connects to a second stud 102 by fasteners 282 passing through holes therein.
Two cover plates 10a and 10b are connected to brace 200. Cover plates 10a and 10b are the same as cover plates 10. Cover plate 10a is connected to mud ring 12 and electrical box 1412. Cover plate 10a is positioned between first outer rail 208 and second outer rail 210 positioning tabs 814, 816 around first outer rail 208 so that bent portions 818, 820 are positioned behind first outer rail 208 and tabs 834, 836 around second outer rail 210 so that bent portion 838, 840 are positioned behind second outer rail 210. Bent portions 818, 820 of tabs 814, 816 and bent portion 838, 840 of tabs 834, 836 temporarily hold cover plate 10a in place on brace 200 by a snap connection allowing for hands free mounting. To secure cover plate 10a on brace assembly 200, fasteners 1700 are each positioned in one or more of three slots 802, 804, 806 and one or more of three slots 822, 824, 826. As shown, a fastener 1700 is positioned in slot 802 and one of holes 211 of upper outer rail 208 and a fastener 1700 is positioned in slot 826 and one of holes 211 of lower outer rail 210. Fasteners 1700 are, for example, screws. If a user would like to position cover plate 10a closer to outer end support 206 of outer brace member 204, then first side member 702 can overlap outer end support 206 so that each of fasteners 280 can each be positioned through one of first horizontal oblong hole 708 and second horizontal oblong hole 730, respectively. Cover plate 10a can be connected to inner brace member 202 and/or outer brace member 204 the same as connecting to outer brace member 204 as described herein. In addition, first vertical oblong hole 712 makes it easier to break tab 736 off cover plate 10a and second vertical oblong hole 726 makes it easier to break tab 738 off cover plate 10a to allow for more variability in positioning cover plate 10a on brace 200. Further, first vertical oblong hole 754 makes it easier to break tab 786 off cover plate 10a and second vertical oblong hole 770 makes it easier to break tab 788 off of cover plate 10a to allow for more variability in positioning cover plate 10a on brace 200.
Similarly, cover plate 10b is connected to mud ring 14 and electrical box 1702 that is the same as electrical box 1412. Cover plate 10b is positioned between first outer rail 208 and second outer rail 210, first inner rail 214 and second inner rail 216 positioning tab 814 around first outer rail 208 and tab 816 around first inner rail 214 so that bent portions 818, 820 are positioned behind first outer rail 208 and first inner rail 214, respectively, and tabs 834, 836 around second outer rail 210 and second inner rail 216, respectively, so that bent portion 838, 840 are positioned behind second outer rail 210 and second inner rail 216, respectively. Bent portions 818, 820 of tabs 814, 816 and bent portion 838, 840 of tabs 834, 836 temporarily hold cover plate 10b in place on brace 200 by a snap connection allowing for hands free mounting. To secure cover plate 10b on brace assembly 200, fasteners 1700 are each positioned in one or more of three slots 802, 804, 806 and one or more of three slots 822, 824, 866. As shown, a fastener 1700 is positioned in slot 806 and one of holes 211 of upper inner rail 214 and a fastener 1700 is positioned in slot 822 and one of holes 211 of lower outer rail 210. If a user would like to position cover plate 10b closer to inner end support 212 of inner brace member 202, then second side member 704 can overlap inner end support 212 so that each of fasteners 282 can each be positioned through one of first horizontal oblong hole 750 and second horizontal oblong hole 774, respectively. Cover plate 10b can be connected to inner brace member 202 and/or outer brace member 204 the same as connecting to outer brace member 204 and inner brace member 202 as described herein. In addition, first vertical oblong hole 712 makes it easier to break tab 736 off of cover plate 10b and second vertical oblong hole 726 makes it easier to break tab 738 off of cover plate 10b to allow for more variability in positioning cover plate 10b on brace 200. Further, first vertical oblong hole 754 makes it easier to break tab 786 off of cover plate 10b and second vertical oblong hole 770 makes it easier to break tab 788 off of cover plate 10b to allow for more variability in positioning cover plate 10b on brace 200.
To allow cover plate 10a to be positioned closer to cover plate 10b, second side member 704 of cover plate 10a overlaps first side member 702 of cover plate 10b. Tab 786 of cover plate 10a extends through first opening 714 of cover plate 10b so that a portion of first side member 702 of cover plate 10b is between tab 786 and first projection 782. Tab 788 of cover plate 10a extends through second opening 734 of cover plate 10b so that a portion of first side member 702 of cover plate 10b is between tab 788 and second projection 784. Alternatively, first side member 702 of cover plate 10b overlaps second side member 704 of cover plate 10a. Tab 736 of cover plate 10b extends through first opening 756 of cover plate 10a so that a portion of second side member 704 of cover plate 10a is between tab 736 and first projection 733. Tab 738 of cover plate 10b extends through second opening 778 of cover plate 10a so that a portion of second side member 704 of cover plate 10a is between tab 738 and second projection 735. First side member 702 and second side member 704 of either or both of cover plate 10a and/or cover plate 10b can overlap one or more other cover plates 10 on brace 200 as desired by the user the same as second side member 704 of cover plate 10a overlapping first side member 702 of cover plate 10b described herein.
Referring to FIG. 20, cover plate 10a is connectable directly to stud 100. Cover plate 10a is connected to mud ring 12 and electrical box 1412. First side member 702 of cover plate 10a is placed over stud 100 so that tabs 736, 738 are on a first side of stud 100 and first projection 733 and second projection 735 are on a second opposite side of stud 100 to temporarily hold cover plate 10a in place on stud 100 by a snap connection. End portions 744, 746 apply tension on tabs 736, 738, respectively, to temporarily hold cover plate 10a in place on stud 100 for hands free mounting. A fastener 2000 can be inserted through first hole 706 and stud 100 and a fastener 2002 can be inserted through seventh hole 732 and stud 100 to connect cover plate 10a to stud 100. Alternatively, or in addition to fasteners 2000 and 2002, a fastener can be inserted through second hole 710 and stud 100 and/or a fastener can be inserted through sixth hole 728 and stud 100 to connect cover plate 10a to stud 100. Second side member 704 is connected to a side support 2400. A fastener 2005 can be inserted through fourth hole 762 of second side member 704 and a hole 2402 through side support 2400 connecting second side member 704 and side support 2400. Side support 2400 also has protuberances 2404, 2406. Protuberance 2404 of side support 2400 is inserted through third hole 760 of second side member 704 and protuberance 2406 of side support 2400 is inserted through fifth hole 766 of second side member 704 when second side member 704 and side support 2400 are connected. Side support 2400 abuts a wall on a side opposite the side having hole 2402 to support cover plate 10a that is connected to mud ring 12 and electrical box 1412.
Referring to FIG. 20, cover plate 10b is connected to mud ring 14 and electrical box 1702 that is the same as electrical box 1412. Cover plate 10b is connectable to stud 100 on the opposite side of stud 100 by second side member 704 of cover plate 10b being placed over stud 100 so that tabs 786, 788 are on the second side of stud 100 and first projection 782 and second projection 784 are on the first side opposite the second side of stud 100 to temporarily hold cover plate 10b in place on stud 100 by a snap connection. End portions 794, 796 apply tension on tabs 786, 788, respectively, to temporarily hold cover plate 10a in place on stud 100 for hands free mounting. A fastener 2004 can be inserted through first hole 748 and stud 100 and a fastener 2006 can be inserted through seventh hole 776 and stud 100 to connect cover plate 10b to stud 100. Alternatively, or in addition to fasteners 2004 and 2006, a fastener can be inserted through second hole 752 and stud 100 and/or a fastener can be inserted through sixth hole 772 and stud 100 to connect cover plate 10a to stud 100. First side member 702 is connected to a side support 2401 that is the same as side support 2400 so the same reference numerals are used. A fastener 2007 can be inserted through fourth hole 719 of first side member 702 and hole 2402 through side support 2401 connecting first side member 702 and side support 2401. Side support 2401 also has protuberances 2404, 2406. Protuberance 2404 of side support 2401 is inserted through third hole 722 of first side member 702 and protuberance 2406 of side support 2401 is inserted through fifth hole 718 of first side member 702 when first side member 702 and side support 2401 are connected. Side support 2401 abuts a wall on a side opposite the side having hole 2402 to support cover plate 10b that is connected to mud ring 14 and electrical box 1702. Accordingly, cover plates 10a and 10b can connect to either side of stud 100.
Referring to FIG. 21, cover plate 10a and cover plate 10b can connect to the same to stud 100. Cover plate 10a is connected to mud ring 12 and electrical box 1412. Cover plate 10a connects to stud 100 the same as shown in FIG. 20, and, prior to inserting fasteners 2000, 2002 through first side member 702 of cover plate 10a, second side member 704 of cover plate 10b overlaps first side member 702 of cover plate 10a so that tab 786 of second side member 704 of cover plate 10b is through first opening 714 of first side member 702 of cover plate 10a and tab 788 of second side member 704 of cover plate 10b is through second opening 734 of first side member 702 of cover plate 10a so that a portion of first side member 702 of cover plate 10a is between tab 786 and first projection 782 and a portion of first side member 702 of cover plate 10a is between tab 788 and second projection 784 connecting first side member 702 of cover plate 10a and second side member 704 of cover plate 10b. First projection 782 and second projection 784 of second side member 704 of cover plate 10b also are adjacent the first side of stud 100. When first side member 702 of cover plate 10a and second side member 704 of cover plate 10b are connected, cover plates 10a, 10b are temporarily held in place on stud 100 by snap connection so that fastener 2000 can be inserted through first hole 748 of second side member 704 of cover plate 10b, first hole 706 of first side member 702 of cover plate 10a and stud 100 and fastener 2002 can be inserted through seventh hole 776 of second side member 704 of cover plate 10b, seventh hole 732 of first side member 702 of cover plate 10a and stud 100 to connect cover plate 10a and cover plate 10b to stud 100. Alternatively, cover plate 10b connects to stud 100 the same as shown in FIG. 20, and, prior to inserting fasteners 2004, 2006 through second side member 704 of cover plate 10b, first side member 702 of cover plate 10a overlaps second side member 704 of cover plate 10b so that tab 736 of first side member 702 of cover plate 10a is through first opening 756 of second side member 704 of cover plate 10b and tab 738 of first side member 702 of cover plate 10a is through second opening 778 of second side member 704 of cover plate 10b so that a portion of second side member 704 of cover plate 10b is between tab 736 and first projection 733 and a portion of second side member 704 of cover plate 10b is between tab 738 and second projection 735 connecting first side member 702 of cover plate 10a and second side member 704 of cover plate 10b. First projection 733 and second projection 735 of first side member 702 of cover plate 10a also are adjacent the second side of stud 100. When first side member 702 of cover plate 10a and second side member 704 of cover plate 10b are connected, cover plates 10a, 10b are temporarily held in place on stud 100 by snap connection so that fastener 2000 can be inserted through first hole 748 of second side member 704 of cover plate 10b, first hole 706 of first side member 702 of cover plate 10a and stud 100 and fastener 2002 can be inserted through seventh hole 776 of second side member 704 of cover plate 10b, seventh hole 732 of first side member 702 of cover plate 10a and stud 100 to connect cover plate 10a and cover plate 10b to stud 100. First side member 702 of cover plate 10b is connected to side support 2401 the same as in FIG. 20.
Cover plates 10 can be placed side-by-side, or, in other words, ganged, with one another as shown by cover plate 10a being connected to a cover plate 10c in FIG. 21. Cover plate 10c is the same as cover plate 10 and is connected to a mud ring 2100 that is the same as mud ring 12 and an electrical box 2102 that is the same as electrical box 1412. Second side member 704 of cover plate 10a overlaps first side member 702 of cover plate 10c. Tab 786 of cover plate 10a extends through first opening 714 of cover plate 10c so that a portion of first side member 702 of cover plate 10c is between tab 786 and first projection 782 of cover plate 10a. Tab 788 of cover plate 10a extends through second opening 734 of cover plate 10c so that a portion of first side member 702 of cover plate 10c is between tab 788 and second projection 784 of cover plate 10a. When cover plates 10a, 10c are connected, cover plates 10a, 10c are temporarily held in place together in a snap connection so that fastener 2110 can be inserted through first hole 748 of second side member 704 of cover plate 10a and first hole 706 of first side member 702 of cover plate 10c and another fastener 2112 can be inserted through seventh hole 776 of second side member 704 of cover plate 10a and seventh hole 732 of first side member 702 of cover plate 10c to connect cover plates 10a, 10c. Fasteners 2110, 2112 are, for example, screws. Alternatively, first side member 702 of cover plate 10c overlaps second side member 704 of cover plate 10a. Tab 736 of cover plate 10c extends through first opening 756 of cover plate 10a so that a portion of second side member 704 of cover plate 10a is between tab 736 and first projection 733. Tab 738 of cover plate 10c extends through second opening 778 of cover plate 10a so that a portion of second side member 704 of cover plate 10a is between tab 738 and second projection 735. When cover plates 10a, 10c are connected, cover plates 10a, 10c are temporarily held in place together in a snap connection so that fastener 2110 can be inserted through first hole 748 of second side member 704 of cover plate 10a and first hole 706 of first side member 702 of cover plate 10c and another fastener 2112 can be inserted through seventh hole 776 of second side member 704 of cover plate 10a and seventh hole 732 of first side member 702 of cover plate 10c to connect cover plates 10a, 10c. Second side member 704 of cover plate 10c is connected to a side support 2403 that is the same as side support 2400 is connected to cover plate 10a in FIG. 21 by a fastener 2405, for example, a screw. First side member 702 and second side member 704 of either or all of cover plate 10a and/or cover plate 10b and/or cover plate 10c can overlap and connect to one or more other cover plates 10 as described herein.
Referring to FIGS. 22 and 23, cover plate 10 is connectable to mud rings 2200, 2300 by a fixed connection by fasteners 2202, for example, screws. Cover plate 10 is connectable to different electrical boxes, for example, electrical box 2204.
Referring to FIG. 24, side support 2400 is shown that is connectable to cover plate 10 as described herein. Side support 2400 has an outer member 2408 and an inner member 2410. Outer member 2408 has an outer body 2412. Outer body 2412 has an outer middle wall 2414 and outer side walls 2416, 2418 extending from opposite sides of outer middle wall 2414. Outer side walls 2416, 2418 each form an angle that is greater than 90 degrees with outer middle wall 2414. Outer side walls 2416, 2418 each has an outer bent portion 2420, 2422, respectively, that bend inward toward one another. Outer member 2408 forms a space between outer bent portions 2420, 2422 that is wider than an outer width W1 of outer middle wall 2414 allowing a punch to form outer member 2408 that can punch material to form outer member 2408 around the punch and then, the punch can be withdrawn from outer member 2408 between outer bent portions 2420, 2422. Outer middle wall 2414 has a first row of three openings 2424, a second row of two openings 2426, a third row of three openings 2428, a middle opening 2430, a fourth row of three openings 2431, and a fifth row of three openings 2432. Each of first row of three openings 2424, second row of two openings 2426, third row of three openings 2428, middle opening 2430, fourth row of three openings 2431, and fifth row of three openings 2432 is at a different position on outer middle wall 2414. An outer exterior wall 2434 extends from one end of outer middle wall 2414. Outer exterior wall 2434 is bent to extend over outer side walls 2416, 2418. Outer member 2408 has hole 2402 through outer exterior wall 2434 and protuberances 2404, 2406 are formed in outer exterior wall 2434.
Inner member 2410 has an inner body 2436. Inner body 2436 has an inner middle wall 2438 and inner side walls 2440, 2442 extending from opposite sides of inner middle wall 2438. Side walls 2440, 2442 each form an angle that is greater than 90 degrees with inner middle wall 2438. Inner side walls 2440, 2442 each has an inner bent portion 2444, 2446, respectively, that bend inward toward one another. Inner member 2410 forms a space between inner bent portion 2444, 2446 that is wider than an inner width W2 of inner middle wall 2438 allowing a punch to form inner member 2410 that can punch material to form inner member 2410 around the punch and then, the punch can be withdrawn from inner member 2410 between inner bent portion 2444, 2446. Inner middle wall 2438 has an opening 2448 between two protuberances 2450, 2452 and an opening 2454. Protuberance 2450 is sized to fit the first opening of each of first row of three openings 2424, second row of two openings 2426, third row of three openings 2428, fourth row of three openings 2431, and fifth row of three openings 2432. Protuberance 2452 is sized to fit the third opening of each of first row of three openings 2424, third row of three openings 2428, fourth row of three openings 2431, fifth row of three openings 2432 and the second opening of second row of two openings 2426. Opening 2454 is sized and positioned to overlap middle opening 2430. An inner exterior wall 2456 extends from one end of inner middle wall 2438. Inner exterior wall 2456 is bent to extend over inner side walls 2440, 2442 at a first end that is opposite a second end that is adjacent opening 2448 and two protuberances 2450, 2452.
Inner width W2 of inner middle wall 2438 and sizes of inner side walls 2440, 2442 are sized to slidably fit in outer middle wall 2414 and outer side walls 2416, 2418. Inner member 2410 is slidable in outer member 2408. When protuberance 2450 is inserted into the first opening of first row of three openings 2424, protuberance 2452 is inserted into the third opening of first row of three openings 2424, and opening 2448 overlaps the second opening of first row of three openings 2424 a fastener, for example, a screw, can be inserted into opening 2448 and the second opening of first row of three openings 2424 to maintain this position of outer member 2408 relative to inner member 2410 so that side support 2400 has a first length, for example, 3½ inches. When protuberance 2450 is inserted into the first opening of second row of two openings 2426, protuberance 2452 is inserted into the second opening of second row of two openings 2426, and opening 2454 overlaps middle opening 2430, a fastener, for example, a screw, can be inserted into opening 2454 and middle opening 2430 to maintain this position of outer member 2408 relative to inner member 2410 so that side support 2400 has a second length, for example, 3⅝ inches. When protuberance 2450 is inserted into the first opening of third row of three openings 2428, protuberance 2452 is inserted into the third opening of third row of three openings 2428, and opening 2448 overlaps the second opening of third row of three openings 2428 a fastener, for example, a screw, can be inserted into opening 2448 and the second opening of third row of three openings 2428 to maintain this position of outer member 2408 relative to inner member 2410 so that side support 2400 has a third length, for example, 4 inches. When protuberance 2450 is inserted into the first opening of fourth row of three openings 2431, protuberance 2452 is inserted into the third opening of fourth row of three openings 2431, and opening 2448 overlaps the second opening of fourth row of three openings 2431 a fastener, for example, a screw, can be inserted into opening 2448 and the second opening of fourth row of three openings 2431 to maintain this position of outer member 2408 relative to inner member 2410 so that side support 2400 has a fourth length, for example, 5½ inches. When protuberance 2450 is inserted into the first opening of fifth row of three openings 2432, protuberance 2452 is inserted into the third opening of fifth row of three openings 2432, and opening 2448 overlaps the second opening of fifth row of three openings 2432 a fastener, for example, a screw, can be inserted into opening 2448 and the second opening of fifth row of three openings 2432 to maintain this position of outer member 2408 relative to inner member 2410 so that side support 2400 has a fifth length, for example, 6 inches. Outer middle wall 2414 has indicia 2433 that indicates a length of side support 2400 when protuberances 2450, 2452 are inserted in each of first row of three openings 2424, second row of two openings 2426, third row of three openings 2428, fourth row of three openings 2431, and fifth row of three openings 2432 is at a different position on outer middle wall 2414. Side support 2400 advantageously can support cover plate 10 connected to an electrical box to comply with Underwriters Laboratories (“UL”) Standards.
Referring to FIGS. 27-30, side support 2700 is the same as side support 2400 except outer member 2408 is modified to outer member 2408a that has two protrusions 2702, 2704 on opposite sides of an opening 2706 instead of first row of three openings 2424, two protrusions 2708, 2710 instead of second row of two openings 2426, two protrusions 2712, 2714 on opposite sides of an opening 2716 instead of third row of three openings 2428, two protrusions 2718, 2720 on opposite sides of an opening 2722 instead of fourth row of three openings 2431, two protrusions 2724, 2726 on opposite sides of an opening 2728 instead of fifth row of three openings 2432, and inner member 2410 is modified to inner member 2410a so that inner side walls 2440, 2442 are modified to inner side walls 2440a, 2442a that omit inner bent portion 2444, 2446. Protrusions 2702, 2704, 2708, 2710, 2712, 2714, 2718, 2720, 2724 and 2726 do not have sharp edges that can be formed by openings so that protuberances 2450, 2452 of inner member 2410a do not catch on sharp edges and are more easily insertable and removable from protrusions 2702, 2704, 2708, 2710, 2712, 2714, 2718, 2720, 2724 and 2726. Side support 2700 advantageously can support cover plate 10 connected to an electrical box the same as side support 2400.
Accordingly, cover plate 10 advantageously is configured to (1) mount on a stud; (2) mount on a brace; and (3) connect in gangable applications. Cover plate 10 advantageously allows first mud ring 12, second mud ring 14, and third mud ring 16 or other mud ring having a hinged connection to cover plate 10 to be moved between the closed position and the opened position while cover plate 10 maintains a connection to one or more of stud 100, brace assembly 200, another assembly 10 or structure, and any combination thereof, without an electrical box that is connected to cover plate 10 dropping therefrom. In addition, cover plate 10 being the “hinged adjustable cover plate” has snap-on tabs on the right and left side of it for hands free mounting. This cover plate allows for side by side stud mounting. Adjustability of the mud rings compensate for different wall thicknesses. Cover plate 10 has snap on tabs for hands-free pre-fab applications. The hinged feature opens up the working space and can be opened or closed with the electrical box attached allowing for wiring while cover plate 10 is (1) mounted on a stud; (2) mounted on a brace; and (3) connect in gangable applications. Cover plate 10 can be installed on any electrical box with any depth.
It should also be noted that the terms “first”, “second”, “third”, “upper”, “lower”, and the like may be used herein to modify various elements. These modifiers do not imply a spatial, sequential, or hierarchical order to the modified elements unless specifically stated.
While the present disclosure has been described with reference to one or more exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiment(s) disclosed as the best mode contemplated, but that the disclosure will include all embodiments falling within the scope of the appended claims.
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PARTS LIST
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hinges 9
first gap 716
intermediate portions 790, 792
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cover plate 10
third hole 718
end portions 794, 796
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cover plates 10a, 10b, 10c
fourth hole 719
fastener hole 797
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first mud ring 12
diamond shaped hole 720
first frame member 798
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sleeve 13
fifth hole 722
second frame member 800
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screws 13a, 13b
second gap 724
slots 802, 804, 806
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second mud ring 14
second vertical oblong hole 726
ridge slots 808, 810
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sleeve 15
sixth hole 728
ridge 812
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screws 15a, 15b
second horizontal oblong hole 730
tabs 814, 816
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third mud ring 16
seventh hole 732
bent portion 818, 820
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sleeve 17
second opening 734
slots 822, 824, 826
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screws 17a, 17b
first projection 733
ridge slots 828, 830
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stud 100
second projection 735
ridge 832
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brace 200
tab 736
tabs 834, 836
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opening 111
tab 738
bent portion 838, 840
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first mud ring body 112
intermediate portions 740, 742
box flange 842
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ridge 113
end portions 744, 746
fastener holes 844, 846, 848,
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second mud ring body 114
hinge receptacles 745, 747.
850 and grooves 849, 851
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opening 115
first hole 748
mud ring 901
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third mud ring body 116
first horizontal oblong hole 750
ring body 900
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opening 117
second hole 752
connection portion 902
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outer ridge 125
first vertical oblong hole 754
fastener opening 904
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outer ridge 135
first opening 756
fixed depth 903
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inner brace member 202
first gap 758
hinge projections 906, 908
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outer brace member 204
third hole 760
hinge tab 910
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outer end support 206
fourth hole 762
mud ring 1000
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first outer rail 208
diamond shaped hole 764
connection portion 1002
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second outer rail 210
fifth hole 766
fastener 1200
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holes 211
second gap 768
aperture 1204
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inner end support 212
second vertical oblong hole 770
electrical box 1212
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first inner rail 214
sixth hole 772
fastener 1400
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second inner rail 216
second horizontal oblong hole 774
fastener 1406
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holes 217
seventh hole 776
aperture 1408
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fasteners 280
second opening 778
electrical box 1412
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fasteners 282
first projection 782
plate 1502
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body 700
second projection 784
flaps 1504
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first side member 702
tab 786
fastener 1506
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second side member 704
tab 788
fasteners 1700
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first hole 706
side support 2700
electrical box 1702
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first horizontal oblong hole 708
outer member 2408a
fastener 2000
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second hole 710
protrusions 2702, 2704
fastener 2002
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first vertical oblong hole 712
opening 2706
fastener 2005
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first opening 714
protrusions 2708, 2710
fastener 2006
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fastener 2110, 2112
protrusions 2712, 2714
fastener 2007
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mud ring 2100
opening 2716
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electrical box 2102
protrusions 2718, 2720
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side support 2400
opening 2722
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side support 2401
protrusions 2724, 2726
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hole 2402
opening 2728
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side support 2403
inner member 2410a
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protuberances 2404, 2406
inner side walls 2440a, 2442a
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outer member 2408
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inner member 2410
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outer body 2412
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outer middle wall 2414
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outer side walls 2416, 2418
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outer bent portion 2420, 2422
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first row of three openings 2424
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second row of two openings 2426
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third row of three openings 2428
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middle opening 2430
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fourth row of three openings 2431
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fifth row of three openings 2432
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outer exterior wall 2434
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inner body 2436
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inner middle wall 2438
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inner side walls 2440, 2442
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inner bent portion 2444, 2446
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opening 2448
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protuberances 2450, 2452
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opening 2454
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inner exterior wall 2456
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Patent Application
20230261453
