Caps and methods

Abstract

A power outlet cover is provided, comprising a frame configured for attachment to an electrical fitting, and an outer cover configured to substantially cover the frame. The cover is removably connected to the frame. The frame comprises a substantially planar body having a first planar surface with at least four elastically deformable tabs and at least two fixed receiving apertures. The four elastically deformable tabs are located at spaced apart locations on at least two edges of the substantially planar body. The outer cover has a planar portion with an outer surface and an inner surface, the outer cover further comprising a rim extending around the perimeter of the inner surface, wherein the depth of the rim is at least equal to the depth of the frame. The rim includes tab receiving slots configured to receive the elastically deformable tabs of the frame, and the inner surface of the cover has a receiving indentation. A method of manufacturing a power outlet cover for an electrical fitting is also provided.

Description

Technical Field

[0001] This invention relates to power socket covers, such as covers for power sockets or light switches, and a method for manufacturing external power socket covers. Background Technology

[0002] Various types of electrical fittings, such as switch and socket assemblies, are typically installed within the walls of a building. The components of electrical fittings are usually contained within a back box or junction box located within the wall. Traditional electrical fittings have a back panel to cover the back box. An external panel is attached to the back panel to provide an aesthetically pleasing cover for the electrical fitting. Traditionally, the panel is located on the upper part of the wall and can be attached to the back panel and / or back box via fasteners.

[0003] To remove visible fasteners, some covers have tabs on their rear surface that connect to a backplate to secure the cover in place with electrical fittings. Furthermore, reducing the thickness of the cover and the degree to which it protrudes from the wall surface provides improved aesthetics. However, reducing the cover's thickness and any required cover machining also reduces structural integrity. This is especially important when a more ductile metal / alloy (such as brass) is the choice of housing material. Therefore, balancing the need for a thin cover with the need to avoid cover deformation is crucial during manufacturing and / or installation.

[0004] Therefore, the object of the present invention is to provide an improved power socket cover and a method for manufacturing the same, while mitigating one or more of the aforementioned disadvantages associated with conventional electrical accessories. Summary of the Invention

[0005] According to a first aspect of the invention, a power outlet cover is provided, comprising: a frame configured for attachment to an electrical accessory; and an outer cover configured to substantially cover the frame, wherein the cover is detachably connected to the frame, and wherein the frame includes a substantially flat body having a first flat surface having at least four resiliently deformable tabs and at least two retaining receiving holes, the four resiliently deformable tabs being located at spaced-apart positions on at least two edges of the substantially flat body, and wherein the outer cover has a planar portion having an outer surface and an inner surface, the outer cover further including an edge extending around the periphery of the inner surface, wherein the depth of the edge is at least equal to the depth of the frame, wherein the edge includes tab receiving grooves configured to receive the resiliently deformable tabs of the frame, and wherein the inner surface of the cover has receiving recesses such that, in an assembled configuration, the flat surface of the frame is parallel to and contacts the inner surface of the planar portion of the cover, and the resiliently deformable tabs of the frame are located in the tab receiving grooves of the outer cover to securely hold the frame and the outer cover in the assembled configuration.

[0006] A frame can be a single, integral component. Therefore, a frame can be formed as a single component.

[0007] The thickness of the planar body of the frame can be less than 3.5 mm.

[0008] Elastically deformable tabs formed along at least two edges of the planar body can be configured as part of a frame, giving them inherent elasticity. Therefore, tabs can be formed as part of a frame, allowing them to inherently deform elastically.

[0009] The elastically deformable tabs can be formed with selected dimensions to facilitate repeated elastic deformation and attachment to the outer cover. The tabs can extend beyond the frame edge by approximately 1.1 mm to 1.6 mm. The tabs can extend beyond the frame edge by approximately 1.3 mm to 1.4 mm.

[0010] The frame can have six elastically deformable tabs. The frame can have four elastically deformable tabs. The frame can have two pairs of corresponding elastically deformable tabs.

[0011] The elastically deformable tabs can be arranged in pairs on opposite edges of the frame. The power socket cover can have two pairs of opposing elastically deformable tabs on two identical opposite edges of the frame. Alternatively, the power socket cover can have two pairs of opposing elastically deformable tabs on different edges of the frame.

[0012] Elastically deformable tabs may include tabs that are thicker than the material of the surrounding frame.

[0013] An elastically deformable tab may include elongated protrusions. An elastically deformable tab may be a generally elongated protrusion with a rounded outer edge. A tab may have a square cross-section. A tab may have a square cross-section and rounded protrusions on its outer edge.

[0014] The dimensions of the elastically deformable protrusions can be between 1.5 mm and 3 mm x 5 mm and 20 mm. The dimensions of the elastically deformable protrusions can be between 2.1 mm and 2.9 mm x 6 mm and 17 mm. The radius of the circular protrusions can be between 0.4 mm and 0.8 mm.

[0015] Each elastically deformable tab may have adjacent elongated slots. These elongated slots may be positioned parallel to the edge of the frame within the region of the elastically deformable tab. The elastically deformable tab may be centered relative to the elongated slot on the edge of the frame. The elongated slots allow the tab to elastically deform.

[0016] The elongated groove can be adjacent to and parallel to the tab. The elongated groove can be 1.4 to 3 times the length of the tab. The longest dimension of the tab can be between 38% and 73% of the longest dimension of the elongated groove. The elongated groove can have a width of 1.5 mm to 3 mm and a length of 15 mm to 32 mm.

[0017] The planar body of the frame can have an outer surface of a first basic plane and a second inner surface. Therefore, the outward-facing portion of the frame can be flat, so that the frame has no components that extend or protrude beyond the outer front surface.

[0018] The second inner surface of the frame may be configured to correspond to an electrical box, rear box, or junction box, to which the electrical socket cover is intended to be attached during use. The second inner surface of the frame may include a shaped surface. Alternatively, the second inner surface of the frame may be substantially flat.

[0019] The frame can be mounted to electrical fittings, such as rear boxes or junction boxes located within cavities or recessed into walls. At least two mounting holes can receive fasteners such as screws to attach the frame to the rear box or junction box during use. The frame may include multiple spaced mounting holes extending through a planar portion to securely fasten the frame to the rear box or junction box during use.

[0020] The power outlet cover may further include a washer. The washer may include a substantially flat component.

[0021] The gasket can be configured to engage with a second inner surface of the frame, allowing the frame's height / depth to be adjusted and providing additional strength to the frame when electrical fittings are mounted flush with or below a flat surface of the wall. In an assembled configuration, the gasket can be configured to increase the depth of the frame. Therefore, the gasket allows the power outlet cover to be selectively adjusted for connection to the desired electrical fittings during use.

[0022] The contour of the second inner surface of the frame can securely accommodate the washer. The size of the washer can be adapted to the external dimensions of the frame. The molded inner surface of the frame can form a washer receiving recess. The depth of the washer receiving recess can substantially correspond to the thickness of the washer.

[0023] The thickness of the gasket can be less than approximately 2.5 mm. The gasket can be approximately 1.2 mm thick.

[0024] The second inner surface of the frame may have inwardly overhanging corners. Washers may be shaped to be received within washer receiving recesses between the four inwardly overhanging corners of the frame.

[0025] The molded inner surfaces of the frame and gasket may each include mating features to allow the frame and gasket to be joined in an assembly configuration without additional fasteners. The gasket may include a retaining hole aligned with a retaining hole in the frame. Therefore, in use, the joined gasket and frame can be secured to a rear box or junction box by fasteners inserted into the retaining holes.

[0026] The flat body of the frame may include holes to allow electrical fittings to extend through. For example, these holes may allow electrical fittings—such as switches or sockets embedded in junction boxes—to be accessed through the frame.

[0027] The frame may be provided with one or more pre-installed punching components, which can be selectively removed from the frame to form holes of the desired size. The pre-installed components may be removable to form the desired holes during installation. The pre-installed components may be located in one or more segments to enable the formation of holes of different sizes as needed.

[0028] The second internal formed surface of the frame may have a vertical portion supported by ribs surrounding the holes and / or pre-stamped blanks. The vertical portion and the adjacent ribs may be removable to allow the frame to be configured for connection to a particular type of back box or junction box.

[0029] The frame can be configured to couple to a standard EU-style back box. Alternatively, the frame can be configured to couple to a standard US-style back box.

[0030] The frame and / or gasket may include plastic materials. The frame and / or gasket may contain up to 70% recycled plastic.

[0031] The frame and / or gaskets can be manufactured by molding.

[0032] The outer cover can be made of brass. The outer cover may include die-cast brass.

[0033] The flat portion of the outer cover can have a thickness of less than 3.8 mm. The flat portion of the outer cover can have a thickness of approximately 1.5 mm.

[0034] The depth of the outer cover edge can be approximately 3.5 mm.

[0035] The total thickness of the outer cover can be between 2.7 mm and 5.5 mm. The thickness of the outer cover can be approximately 5 mm.

[0036] The tab receiving groove can be provided along the inner edge of the edge, where the edge meets the inner surface of the planar portion. The cross-section of the tab receiving groove can be triangular.

[0037] The tab receiving groove can have a right-angled triangular cross-section. Specifically, the tab receiving groove can have a right-angled triangular cross-section with an interior angle of 75 degrees and a height between 1.6 mm and 2 mm.

[0038] The tab receiving slot of the elastic tab forming the receiving frame may be misaligned relative to the positioning tabs on the frame edge in the assembly configuration. The elastically deformable tab may be geometrically offset relative to the tab receiving slot. Therefore, the tab receiving slot may require elastic deformation of the frame so that the tab is securely received within the cover. In the elastically deformed state, the frame can be accommodated within the outer cover in the assembly configuration.

[0039] The elastically deformable tabs and tab receiving slots can be offset by a distance between approximately 0.05 mm and 0.4 mm. In the assembled configuration, there can be an offset of approximately 0.19 mm between the tabs of the frame and the tab receiving slots of the outer cover. This offset can be such that the tabs of the frame extend beyond the tab receiving slots of the outer cover to provide constant pressure on the cover in the direction of the wall.

[0040] The inner surface of the planar portion of the outer cover may include at least two fixing and receiving recesses. Each recess may be located on the inner surface of the outer cover to correspond to the position of a fixing hole in the frame.

[0041] The size and shape of each fastener receiving notch are such that they at least partially receive the head of the fastener extending through a fastener receiving hole in the frame, for securing the frame to the electrical fittings in use. The electrical fittings may be at least partially embedded in the wall.

[0042] The depth of each fixed receiving notch can be less than 0.5 mm. The thickness of each fixed receiving notch can be less than 35% of the thickness of the outer cover's flat portion.

[0043] The outer surface of the planar portion can be formed with the desired surface finish, such as brushing, grinding, aging, polishing or antiquing.

[0044] According to a second aspect of the invention, a method of manufacturing an outer cover for an electrical accessory is provided, the method comprising the steps of: (i) die-casting an outer cover having a substantially flat body having an outer surface and an inner surface, and including an edge extending around a periphery of the inner surface; and (ii) machining at least four grooves along the inner edge of the edge, wherein the edge is in contact with the inner surface of the planar body.

[0045] The method may include forming a planar portion of an outer cover with a thickness of less than about 2 mm. The method may include forming an edge with a depth of about 3.5 mm. The method may include forming an outer cover with a total thickness of less than about 5.5 mm.

[0046] The method may include machining a tab receiving groove along the inner edge of the edge where the edge meets the inner surface of the planar portion. The method may also include machining a tab receiving groove with a triangular cross-section.

[0047] The method may also include machining a receiving notch on the inner surface of the cap. The method may include machining the receiving notch by removing up to 0.5 mm of material from the outer surface of the cap to a depth of 1 mm.

[0048] This method may include machining the cover using pre-programmed computer software, such as using computer numerical control (CNC) machining processes.

[0049] The method may also include trimming the outer surface of the planar portion as needed. The method may include selectively trimming the outer surface of the planar portion by at least one of brushing, grinding, aging, or polishing.

[0050] The method may include making the outer cover from brass.

[0051] The method may include a die-cast outer cover to include any single feature or any combination of features of the cover mentioned in the first aspect of the invention, or any embodiment of the invention referred to below.

[0052] According to a third aspect of the invention, a method for manufacturing a power socket cover for electrical accessories according to a first aspect of the invention is provided, the method comprising the steps of: (i) manufacturing a power socket cover according to a second aspect of the invention; and (ii) molding a frame with plastic.

[0053] This method may include molding a frame using recycled plastic material. The method may also include molding a frame using plastic material containing up to 70% recycled plastic material.

[0054] The above aspects of the invention may be combined with any other aspects, features or embodiments described in the specification and / or shown in the drawings. Attached Figure Description

[0055] Embodiments of the invention will now be described by way of example only, with reference to the accompanying drawings, in which: Figure 1 This is a front perspective exploded view of the power socket cover according to the first embodiment of the present invention. Figures 1a to 1c It shows Figure 1 Detailed views of each component; Figure 2 yes Figures 1a to 1c A cross-sectional view of the power socket cover under the assembled configuration; Figure 3 It is in the assembly configuration Figures 1a to 1c A detailed sectional view of the corner portion of the assembled power socket cover; Figure 4a and Figure 4b yes Figure 1c Cross-section and rear perspective view of the corner portion of the outer cover; Figure 5a and Figure 5b They are Figure 1a and Figure 1b Side and rear views of the gaskets and frame in the assembly configuration; Figure 6 yes Figure 1b A rear-view perspective of the frame; Figure 7 yes Figure 1a Rear view of the washer; Figure 8 This is a front perspective exploded view of the power socket cover according to the second embodiment of the present invention. Figure 8a and Figure 8b It shows Figure 8 Detailed views of each component; Figure 9a and Figure 9b yes Figure 8b The cross-section and rear perspective view of the outer cover; Figures 10a to 10c They are Figure 8a The front perspective, side view, and front view of the frame; and Figure 11 According to the second embodiment of the present invention Figure 8a and Figure 8b An exploded front perspective view of a power outlet cover in a pre-assembled configuration for attachment to a wall. Detailed Implementation

[0056] The power socket cover according to the first embodiment of the present invention is shown in the exploded view. Figures 1a to 1c The central part is generally indicated by the reference numeral "10" in the attached drawing. The power outlet cover 10 is designed to be mounted against a wall to provide an outer cover for a switching power outlet (not shown).

[0057] The power outlet cover 10 includes a washer 11, a frame 20, and an outer cover 30. The washer 11 and the frame 20 can be connected together and can both be installed into a backbox or patchress box (not shown) located in a cavity on the outer surface of a wall. Figure 2 The power outlet cover 10 is shown in an assembled configuration. The power outlet cover 10 is provided as an external feature of an electrical accessory with a decorative or attractive appearance. The outer cover 30 is attached to the frame 20 and extends through the frame 20 to cover and conceal it.

[0058] Frame 20 in Figure 6 As shown in the figure. Frame 20 is formed of molded plastic as a single component, such that all the features of frame 20 described below are formed within a single mold and customized into a shape defined by the mold.

[0059] Frame 20 has a generally square body portion with rounded corners and a flat front surface 25 (as shown). Figure 1 As shown), the front surface 25 is arranged parallel to and flat against the inner surface 33 of the cover 30. The frame body is approximately 10.4 mm thick. Therefore, the flat front surface 25 of the frame 20 lies flat, so that the frame 20 has no components extending or protruding outward from the outer front surface 25.

[0060] The body portion of the frame 20 has a centrally located square hole 24 to allow electrical fittings to extend through. In this embodiment, the hole 24 allows access, during use, to electrical fittings, such as switches or sockets, embedded in a junction box via the frame 20. Two elongated fixing receiving holes 29 pass through the body portion and are located opposite the central hole 24. The holes 29 are configured to receive fasteners, such as screws, to attach the frame to a rear box or junction box during use.

[0061] The body portion of frame 20 has a profiled inner surface 23 (e.g., Figure 6 (As shown). The molded surface 23 of the frame 20 has four straight vertical portions 27 that overhang inward from each inner edge of the hole 24. Each vertical portion 27 is supported by four ribs 28. Adjacent ribs 28 can be selectively removed using suitable tools to allow the frame 20 to be properly configured around a desired back box or junction box (not shown), thereby achieving versatility for connection to a variety of back boxes or junction boxes.

[0062] The molded inner surface 23 of the frame 20 has inwardly overhanging corners 26, and is formed such that a washer receiving recess is formed between the four inwardly overhanging corners 26 of the frame 20. The depth of the washer receiving recess substantially corresponds to the thickness of the washer 11. The shape of the washer 11 is such that it is received within the washer receiving recess.

[0063] Figure 7Washer 11 is shown. Washer 11 is a substantially flat square member with four strips 15 centered along each edge, allowing washer 11 to be received in washer receiving recesses of frame 20, located within four inwardly overhanging corners 26. Washer 11 also has a centered square hole 14 to allow the socket / switch to protrude through the hole when used in wall mounting. The thickness of the washer is approximately 1.2 mm. Washer 11 includes a retaining receiving hole 19 aligned with a retaining receiving hole 29 of frame 20. The rear surface of washer 11 is configured to abut the outer surface of the back box and / or wall to which the washer will be mounted in use.

[0064] The washer 11 is configured to couple to the molded inner surface 23 of the frame 20 so that the height / depth of the frame 20 can be adjusted. In the assembly configuration, the washer 11 increases the depth and strength of the frame 20 so that the frame can be used with a rear box or junction box, which is mounted flush with or recessed below a flat surface of the wall.

[0065] The molded inner surface 23 of the frame 20 and the washer 11 each include mutually mating features, such as rib receiving grooves 18 and center strips 15, so that the frame 20 and the washer 11 can be connected into an assembly configuration without additional fasteners.

[0066] The frame 20 has two pairs of elastically deformable tabs 21 spaced apart at their opposite edges. The tabs 21 are formed as elongated tabs with a substantially square cross-section, having spherical or circular tabs extending from their edges. The tabs 21 extend beyond the outer edge of the frame 20 by 1.35 mm. The dimensions of the tabs 21 are between approximately 2.35 mm and 2.85 mm x 8 mm and 14 mm. The frame 20 has elongated slots 22 disposed adjacent to and parallel to the edge of the frame 20 in the region of each elastically deformable tab 21, with the tabs 21 centered relative to each slot 22 at the edge of the frame. The width of the elongated slots is approximately 2 mm, and the length is approximately 19 mm to 27 mm. Thus, the tabs 21 are formed as part of the frame 20, allowing them to inherently deform elastically.

[0067] Figure 5a and Figure 5bA frame 20 and a washer 11 in a coupled configuration are shown. Frame 20 and washer 11 have aligned, centrally located holes 24, 14, allowing access to the socket and / or switch during use. Additionally, frame 20 and washer 11 have upper and lower aligned retaining holes 19, 29, respectively, to allow insertion of fasteners such as screws (not shown) and threaded engagement with a rear housing or junction box during use, which houses the electronic components of the switch and / or socket. Frame 20 and / or washer 11 comprise up to 70% recycled plastic.

[0068] The cover 30 is configured to substantially cover the frame 20 and the washer 11, and is detachably attached to the frame 20 and the washer 11. Although not shown in the figures, the cover 30 is manufactured to include one or more holes or openings sized to allow access to the socket and / or switch through the cover 30.

[0069] like Figure 1 , Figure 4a and Figure 4b As shown, the outer cover 30 has a planar portion with an outer surface 35 and an inner surface 33. In the assembled configuration, the inner surface 33 is close to and faces the frame 20. The thickness of the planar portion is 1.5 mm. An inwardly overhanging rim 36 extends around the periphery of the inner surface 33. The depth of the rim is 3.2 mm. Therefore, the thickness of the outer cover is 4.7 mm.

[0070] In this embodiment, the outer cover 30 is made of die-cast brass. Molten brass is pressed under high pressure into a steel mold with the desired characteristics to form the cover 30 as described above. The brass solidifies into the shape of the mold, forming a brass cover 30 having an outer surface 35 and an inner surface 33.

[0071] The additional features of the outer cover 30 described below are formed by computer numerical control (CNC) machining. Therefore, pre-programmed computer software instructs the movement of factory tools and machines to precisely form the tab receiving groove 31 and the notch 39 through a subtractive manufacturing process, thereby removing material with high precision from the inner surface 33 and edge 36 of the cover 30. Thus, this embodiment of the invention utilizes digital manufacturing technology, where computer-aided design (CAD) is translated into G-code, which instructs the machine to operate the cutting tools in the desired manner to complete the cover's structure.

[0072] Therefore, two pairs of opposing, spaced-apart tab receiving slots 31 are machined along the opposing inner edges of the edge 36, wherein the edge 36 is in contact with the inner surface 33 of the planar portion of the cover 30. The tab receiving slots 31 are configured to securely receive the elastic tabs 21 of the frame 20. The cross-section of the tab receiving slot is a right-angled triangle with an interior angle of 75 degrees and a height of approximately 1.6 mm.

[0073] In the assembly configuration, the tab receiving groove 31 is slightly offset by 0.19 mm in the direction of the groove 22 relative to the position of the tab 21 on the edge of the frame 20. Therefore, the tab receiving groove 31 requires elastic deformation of the frame 20 so that the tab 21 is securely received within the cover 30. The offset is chosen to ensure that the frame 20 and the gasket 11 are in an elastically deformed state in the assembly configuration when received within the outer cover 30, ensuring that the outer cover does not easily detach from the frame 20 after installation. This is achieved thanks to the different profiles of the tab 21 and the receiving groove 31. The rounded edge portion of the tab 21 is received in the triangular groove 31, and not in a perfectly matched fit, to further place the frame 20 under the required degree of elastic deformation, such as... Figure 3 As shown.

[0074] Two retaining recesses 39 are machined on the inner surface 33 of the outer cover 30. When the power socket 10 is in the assembled configuration, the retaining recesses 39 are positioned to correspond to the positions of the retaining holes 19, 29 in the gasket 11 and the frame 20. Each retaining recess 39 has a depth of 0.5 mm, thus allowing at least a portion of the protruding head of the retainer to be accommodated. In the assembled configuration, the head of the retainer is received in the recess, such that the cover 30 rests substantially flat against the outer surface of the wall. The size and shape of each recess 39 can be configured such that the head of the retainer loosely fits in its corresponding recess 39. Therefore, in addition to the depth of the recess 39, the size of the recess 39 can be wider to allow the inner surface 33 of the cover 30 to accommodate various retainers with different head sizes.

[0075] The machining of the tab receiving groove 31 in the edge 36 of the cover 30 and the minimal material removal to accommodate the head of the fastener reduce the internal stress generated by heat in the cover 30. Therefore, the structural integrity of the cover 30 is improved, and the likelihood of the cover 30 bending in response to machining and / or pressure applied by the user is reduced.

[0076] This embodiment includes a final processing step, the results of which are not shown in the figures. The outer surface 35 of the cover 30 can be processed to have the desired finish. Typically, various finishes can be applied in the final processing step, and the finish provides the desired aesthetics for the power socket cover 10.

[0077] Before installation, washer 11 and frame 20 are joined together. One or more ribs 28 are removed as needed to fit and engage with the geometry of the rear housing. To install the power socket cover 10, fasteners such as screws are inserted into aligned mounting holes 19, 29 in washer 11 and frame 20, with their ends received in the rear housing to securely attach frame 20 and washer 11 thereto.

[0078] The cover 30 is configured such that when the cover 30 is attached to the frame 20, the plane 33 contacts the outer surface of the frame 20. The cover 30 is detachably mounted to the frame 20 by aligning the cover 30 and the frame 20 and applying slight pressure. Resiliently deformable tabs 21 are configured to engage or snap into recesses 31 in the cover 30 to detachably attach the cover 30 to the frame 20 when the tabs 21 are received in their respective recesses 31. The different shapes of the recesses 31 and the tabs 21 allow the cover 30 to be securely received in the desired position, a result of the required elastic deformation of the frame 20 due to a degree of geometric overlap.

[0079] The described power outlet cover 10 provides an aesthetically pleasing cover for electrical accessories because, when fully assembled, the cover 30 lies substantially flat on the outer surface of the wall surrounding the cavity, in which the frame 20, electrical components, and switches / sockets are housed.

[0080] The power socket cover 10 of the first embodiment of the present invention is applicable to various typical EU back boxes and junction boxes manufactured and sold by various different companies under different brands.

[0081] Figures 8a to 11 A second embodiment of the invention is illustrated. Similar but not identical components with similar functions have been described using the same two-digit reference numerals prefixed with "1". The power outlet cover 110 of the second embodiment of the invention uses the same key features but can be used in conjunction with various typical back boxes used and installed in the United States. Therefore, the power outlet covers 10, 110 can be adapted into standard electrical accessories in the European Union or the United States, as well as in other countries using similar back boxes.

[0082] The power socket cover 110 of the second embodiment of the present invention is rectangular instead of square, and includes a frame 120 and an outer cover 130. No gasket 11 is used in conjunction with these components.

[0083] like Figure 8b , Figure 9a and Figure 9bAs shown, the outer cover 130 has similar features to those described in the first embodiment of the invention, and these features are manufactured using a similar process. A key difference from the first embodiment is that the four tab receiving slots 31 are located in pairs on adjacent opposing edges of the edge 136, such that each inner edge of the edge 136 includes a centrally located tab receiving slot 131. Another difference is that both the inner and outer surfaces 125 of the frame 120 are substantially flat.

[0084] Figure 11 An exploded view of the installation of the power outlet cover 110 within a wall is shown. The rear housing 112 is embedded within the wall 113. Electronic components (not shown for clarity) are housed within the rear housing 112. A frame 120 covers the rear housing 112. Another component 116 is placed on the frame 120 to provide electrical grounding for the cover 130, as required by U.S. regulations. A screw 117 passes through mounting holes in the grounding component 116 and the frame 120 and is received in a threaded hole 119 in the rear housing 112. The outer cover 130 can then be secured in place on the frame 120 by applying slight pressure, such that the tab 121 is positioned within the receiving slot 131 due to elastic deformation caused by the limited thickness of the frame 120 and the presence of the elongated slot 122 of the adjacent tab 121.

[0085] Within the scope of this invention, other embodiments not described above are conceivable. The invention is not limited to the specific examples or structures shown. These embodiments are not exhaustive and / or exclusive; other embodiments may be utilized and modifications may be made without departing from the scope of the appended claims.

[0086] For example, although the invention is depicted in the accompanying drawings and described with reference to a single wall switch or socket, those skilled in the art will understand that key aspects of the invention can also be applied to dual or triple switch sockets or multiple switch groups. The invention is also applicable to, for example, many different types and styles of electrical fittings, sockets, and switches incorporating removable covers.

[0087] In the first embodiment, the presence of the gasket 11 allows the power outlet cover 10 to be selectively adjusted for connection with desired electrical fittings during use. According to another embodiment, the gasket 11 can be discarded when the periphery of the rear box rests against the outer surface of the wall, and the frame 20 can be directly attached to the rear box to minimize the gap between the power outlet cover and the outer surface of the wall.

[0088] According to another embodiment, the frame is provided with one or more pre-stamped blanks that can be selectively removed from the frame to allow for the formation of holes 24, 124 of the desired size. This is particularly useful because universal frames can be manufactured in a variety of sizes, and these universal frames can be customized according to the type of electrical fittings that the socket is intended to cover. The pre-stamped blanks can be removed during installation to form the desired holes. The pre-stamped blanks can be provided in one or more sections to allow for the formation of holes of different sizes as needed.

[0089] According to an alternative embodiment, the tabs on the frame have different shapes or lengths while still performing the same function as the elastic tabs, which are arranged to engage with the grooves on the inside of the cover.

[0090] The above embodiment describes four tabs because this is considered the optimal number for the power socket cover 10. However, different numbers of tabs may be provided according to other embodiments and other sizes of electrical fittings.

[0091] According to an alternative embodiment, each retaining head may be a tight fit or an interference fit in its respective groove. This may be advantageous when it is necessary to remove as little material as possible from the inner surfaces 33, 133 of the cover 30 and the dimensions of the retainers are standard or known.

[0092] Modifications and improvements may be made without departing from the scope of the invention. Relative terms such as “outer,” “exterior,” “inner,” “edge,” “front,” and / or “center” are used for illustrative purposes only and are not intended to limit the scope of the invention.

Claims

1. A power socket cover, comprising: A frame configured for attachment to electrical fittings and an outer cover configured to substantially cover the frame, wherein the cover is detachably connected to the frame, and wherein the frame includes a substantially flat body having a first flat surface having at least four resiliently deformable tabs and at least two retaining receiving holes, the four resiliently deformable tabs being located at spaced-apart positions on at least two edges of the substantially flat body, and wherein the outer cover has a planar portion having an outer surface and an inner surface, the outer cover further including an edge extending around the periphery of the inner surface, wherein the depth of the edge is at least equal to the depth of the frame, wherein the edge includes tab receiving grooves configured to receive the resiliently deformable tabs of the frame, and wherein the inner surface of the cover has receiving recesses such that, in an assembled configuration, the flat surface of the frame is parallel to and contacts the inner surface of the planar portion of the cover, and the resiliently deformable tabs of the frame are located in the tab receiving grooves of the outer cover to securely hold the frame and the outer cover in the assembled configuration.

2. The power socket cover according to claim 1, wherein, The frame is formed as a single component with a thickness of less than 3.5 mm.

3. The power socket cover according to claim 1 or 2, wherein, The elastically deformable tabs formed along at least two edges of the flat body are configured as part of the frame, such that they have inherent elasticity and extend beyond the edges of the frame by about 1.1 mm to 1.6 mm.

4. The power socket cover according to claim 1 or 2, wherein, The elastically deformable tabs are arranged in pairs on opposite edges of the frame, and the elastically deformable tabs include tab portions that are thicker than the material of the surrounding frame.

5. The power socket cover according to claim 1 or 2, wherein, The shape of the tab receiving groove does not match the shape of the elastic tab of the frame, so that the frame is received in the outer cover in the assembly configuration when it is in an elastically deformed state.

6. The power socket cover according to claim 1 or 2, wherein, The elastically deformable tab includes elongated protrusions having a square cross-section and circular portions on their outer edges.

7. The power socket cover according to claim 1 or 2, wherein, Each of the elastically deformable tabs has an adjacent elongated groove parallel to the edge of the frame and extending in length 1.4 to 3 times the length of the tab, wherein the elastically deformable tab is centrally located on the edge of the frame relative to the elongated groove, the elongated groove enabling the tab to elastically deform.

8. The power socket cover according to claim 1 or 2, wherein, The flat body of the frame has a first substantially flat outer surface and a second inner surface, such that the frame has no components that extend or protrude beyond the outer front surface.

9. The power socket cover according to claim 8, wherein, The second inner surface of the frame is configured to correspond to an electrical box, rear box, or junction box, and the electrical socket cover is intended to be attached to the electrical box, rear box, or junction box during use.

10. The power socket cover of claim 8, further comprising a washer configured to couple to the second inner surface of the frame so that the height / depth of the frame can be adjusted.

11. The power socket cover of claim 10, wherein the thickness of the gasket is less than about 2.5 mm, and wherein the inner surface of the frame has inwardly overhanging corners, and wherein the gasket is shaped such that it is received in a gasket receiving recess defined between the four inwardly overhanging corners of the frame.

12. The power socket cover according to any one of claims 9-11, wherein, The frame is provided with one or more pre-installed shielding components that can be selectively removed from the frame to allow for the formation of holes of the desired size, thereby enabling electrical fittings to extend through the holes.

13. The power socket cover according to claim 12, wherein, The second inner shaped surface of the frame has a vertical portion supported by ribs surrounding the hole and / or pre-stamped blanking, wherein adjacent ribs are removable so that the frame can be configured to connect to a particular type of back box or junction box.

14. The power socket cover according to any one of claims 1-2, 9-11, and 13, wherein, The tab receiving groove is positioned along the inner edge of the edge, where the edge is in contact with the inner surface of the planar portion.

15. The power socket cover according to any one of claims 1-2, 9-11, and 13, wherein, The cross-section of the convex receiving groove is triangular.

16. The power socket cover according to any one of the preceding claims 1-2, 9-11, and 13, wherein, In the assembly configuration, the tab receiving slot is geometrically offset relative to the position of the elastically deformable tab on the edge of the frame, such that the frame is received within the outer cover in an elastically deformable state.

17. The power socket cover according to any one of claims 1-2, 9-11, and 13, wherein, The inner surface of the planar portion of the outer cover includes at least two fixing receiving recesses located on the inner surface of the outer cover to correspond to the positions of fixing holes in the frame, and wherein the depth of each fixing receiving recess is less than 0.5 mm.

18. A method for manufacturing an outer cover for electrical components, the method comprising the following steps: (i) a die-cast outer cover having a substantially flat body having an outer surface and an inner surface and including an edge extending around the periphery of the inner surface; and (ii) at least four grooves machined along the inner edge of the edge, wherein the edge is in contact with the inner surface of the flat body.

19. The method of claim 18, the method comprising forming the outer cover with a total thickness of less than about 5.5 mm.

20. The method of claim 18 or 19, the method comprising machining a tab receiving groove having a triangular cross-section along an inner edge of a side edge, wherein the side edge is in contact with an inner surface of the planar portion.

21. The method according to any one of claims 18 to 19, the method further comprising machining a receiving notch in the inner surface of the cap by removing up to 0.5 mm of material.

22. The method according to any one of claims 18 to 19, the method comprising manufacturing the outer cover with brass.

23. A method for manufacturing a power socket cover as claimed in any one of claims 1 to 17, the method comprising the following steps: (i) Manufacturing a power socket cover according to any one of claims 18 to 22; (ii) Using plastic molded frames.

24. The method of claim 23, wherein the method comprises molding the frame using plastic containing up to 70% recycled plastic material.

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