Electrical Box Replacement Cover Method And Apparatus

Abstract

The present invention is an electrical box cover system and method of installation that covers and protects existing electrical boxes and their electrical components. This invention prevents corrosion and the resulting damage to the mechanical and electrical components of the electrical box while ensuring the electrical box is safe to open and allowing access to the inside of the electrical box. The electrical box cover system includes a cover, fasteners, and a gasket. Generally, to install the cover, the fasteners are drilled through the cover and onto the sides of the damaged electrical box with the gasket, which is placed in the cover.

Description

CROSS-REFERENCES TO RELATED APPLICATIONS[0001]The present application is a continuation of U.S. application Ser. No. 14 / 445,053 filed on Jul. 28, 2014 which issues on Mar. 28, 2017 as U.S. Pat. No. 9,608,422 (Docket No. BUTI-003), which is a continuation-in-part of U.S. application Ser. No. 13 / 858,942 filed on Apr. 8, 2013 (Docket No. BUTI-002). Each of the aforementioned patent applications, and any applications related thereto, is herein incorporated by reference in their entirety.TECHNICAL FIELD[0002]The present invention, in some embodiments thereof, relates to devices and methods for covering electrical boxes, and, more particularly, related to devices associated with watertight methods for attaching such devices to electrical boxes.BACKGROUND OF THE INVENTION[0003]In the field of outdoor electrical fixture maintenance, protection from environmental elements, particularly rain, landscape sprinklers, bubblers, and water is critical to the function and use of the electrical compo...

AI Technical Summary

Benefits of technology

The present invention relates to an electrical box cover system that can replace existing covers. The system utilizes a rectangular replacement cover with unique side panels, fasteners, or phillips pan head machine screws, and a gasket. The cover is secured to the electrical box with fasteners or screws inserted through the side panels. The cover creates a watertight seal with the existing box and is easily installed and removed. The cover can be made from plastic or poured aluminum to minimize production costs and weight. The method of installation involves removing the damaged front plate and internal bosses, placing the cover over the open end of the box, and exerting firm pressure on the cover while driving screws through the side panels and into the box. The cover can also be replaced by removing the existing front plate and internal bosses, placing the cover over the open end of the box, and refastening it with the screws. This method creates a complete seal and eliminates the need to replace the entire electrical box and rewire it. The cover system helps prevent water exposure and corrosion, reduces required time and money to repair damaged electrical boxes, and prevents damage to the cover plates and screws.

Problems solved by technology

Specifically, this is an issue with outdoor electrical boxes with removable covers, which typically house electrical connections, cords, and receptacles above ground for electricians to easily access.

It is often not a viable option to store the electrical box or electrical components underground for protection from the weather.

As a result, the structural integrity of the electrical boxes is often compromised by weather and water damage from landscape watering, resulting not only in a damaged or unusable electrical box, but also a risk of electrocution to the electrician or homeowner.

This current system, however, does not adequately protect the inside of the electrical box, putting the electrical components at risk, particularly to water damage and corrosion.

As a result of the water damage, the front plate, screws, and internal bosses are subject to corrosion and rust.

With enough moisture inside of the electrical box, a small current will flow, resulting in electrolysis and augmenting the corrosion.

Furthermore, if the screws are rusted in place, the electrician may be completely prevented from accessing the internal electrical components.

Any attempt to remove rusted screws, now rusted in place, will damage the boss strip and render it nonfunctional for new screws.

Once corroded, the threaded holes in the internal boss are no longer usable (due to old screws being rusted in place or stripped screw holes) and a new front plate cannot be installed on the damaged electrical box due.

Instead, the entire electrical box must be replaced, a time consuming and costly repair due to the wires running through the electrical box.

Currently, a large amount of time and money is devoted to regularly repairing or replacing these electrical boxes.

Cheap alternatives to repair the electrical box and damaged cover, such as duct tape or plastic ties, are not weather resistant or safe and are unsightly.

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