Electrical Outlet Cover with Keyhole Inserts for Moisture Sealing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional electrical outlet covers do not effectively prevent moisture from entering the electrical box, potentially causing electrical shorts, especially in outdoor applications where water exposure is a concern.
Innovation Solution
The design incorporates a base with keyhole inserts that allow for secure mounting and adjustment of the cover, using a mounting screw aperture with a unique configuration that prevents the screw head from passing through, and a keyhole cover that can be removably secured to prevent unauthorized access and moisture ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a traditional cover plate is used that covers only part of the receptacle, then the socket faces remain accessible for plug insertion, but moisture can enter the electrical box through openings in the cover plate
Solution Approach 1:
The cover plate is segmented into multiple functional zones: a weatherproof cover portion that seals the electrical box, and a receptacle access portion that provides controlled access to socket faces. The cover plate includes a front surface with a receptacle opening and a weatherproof cover that extends to seal against the electrical box, creating distinct sealed and accessible areas.
Solution Approach 2:
A weatherproof cover acts as an intermediary element between the electrical box and the external environment. This cover includes a seal that interfaces with the electrical box to prevent moisture ingress, while still allowing controlled access to the receptacle through the front opening.
2Object-affected harmful factors
If a weatherproof cover is used to seal the electrical box, then moisture ingress is prevented, but the cover becomes difficult to install and adjust
Solution Approach 1:
Mounting screw apertures are pre-formed in the base of the cover plate during manufacturing, with keyhole-shaped openings that facilitate easy installation. The apertures include a first portion and a second portion that guide the mounting screw into proper position and orientation before final tightening, eliminating the need for complex alignment procedures during installation.
Solution Approach 2:
The mounting screw aperture transitions from a static hole to a dynamic keyhole shape that changes its effective opening during the installation process. The aperture allows the mounting screw to pass through at an angle during insertion, then provides a restricted path for final positioning, enabling both easy installation and secure mounting.
3Strength
If mounting screw apertures are provided in the cover base for secure attachment, then the cover is firmly mounted, but the screw heads can pass through and become inaccessible for adjustment
Solution Approach 1:
The mounting screw aperture is designed as a nested structure with a first portion and a second portion. The first portion has a larger opening that receives the mounting screw head during installation, while the second portion extends into the first portion with a smaller opening that prevents the screw head from passing through to the exterior, effectively nesting one functional zone within another.
4Ease of manufacture
If the cover is designed as a single molded piece, then manufacturing is simplified, but flexibility for adjustment and removal is reduced
Solution Approach 1:
The cover plate is segmented into a base and a removable keyhole cover. The base includes the mounting screw apertures and structural support, while the keyhole cover is a separate component that can be removed and reinstalled. This segmentation allows the base to be manufactured as a single piece for simplicity, while the removable cover provides the necessary adaptability for adjustment and maintenance.
Data Source
AI summary
An electrical outlet cover including a base and an opening extending through the base, the opening configured to allow access to a socket face through the base. The electrical outlet cover further including a mounting screw aperture extending through the base, and a keyhole cover slidably connected to the base to at least partially cover the mounting screw aperture.