Weatherproof Electrical Box Cover With Tortuous Cord Entry
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Solution Overview
Problem
Existing weatherproof electrical box covers lack effective solutions for preventing insects and water ingress while allowing cord access in multiple orientations, with existing designs often relying on gravity or springs and not providing a comprehensive tortuous path for cords.
Innovation Solution
A weatherproof cover assembly with a hinged base and outer guard that forms a tortuous path for cords, featuring a movable closure to prevent water and insects, and a cord hook to secure the cord in place, allowing the cover to close completely over the cord access opening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a simple cord access opening is provided in the base, then cord access is simple and direct, but insects and water can easily enter the cover assembly
Solution Approach 1:
The patent introduces an outer guard that extends laterally from the base, creating a three-dimensional tortuous path structure. The cord access opening is offset from the outer surface, requiring cords to navigate through multiple spatial dimensions rather than a direct linear path, thereby blocking insects and water while maintaining cord accessibility.
Solution Approach 2:
The patent employs curved surfaces and rounded contours in the outer guard and base structure to create a smooth tortuous path for cords. The curved geometry naturally guides cords through a winding route rather than sharp angles, making it difficult for insects and water to penetrate while allowing cord passage.
2Object-affected harmful factors
If the cord access opening is offset from the outer surface to create a tortuous path, then weatherproofing is improved, but cord installation and access becomes more difficult
Solution Approach 1:
The patent incorporates a pre-formed cord access opening with specific dimensions and orientation during manufacturing. This preliminary preparation allows installers to easily route cords through the offset opening without requiring complex field modifications, maintaining ease of installation while achieving weatherproofing through the tortuous path geometry.
3Adaptability or versatility
If a removable face plate is used to accommodate different electrical devices, then adaptability is improved, but the number of parts and assembly complexity increases
Solution Approach 1:
The patent designs the base and outer guard structure with universal features that can accommodate multiple electrical device types. The offset cord access opening and tortuous path geometry work with various device configurations, eliminating the need for multiple specialized face plates while maintaining adaptability across different applications.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a comprehensive weatherproofing mechanism that prevents insects and water ingress while allowing cord access in both horizontal and vertical orientations, ensuring the electrical device remains protected.
Implementation Method 1
a hinge assembly for pivotally coupling the cover to the base
Implementation Method 2
a cord hook to secure the cord in place
Data Source
AI summary
A weatherproof cover assembly for an electrical device such as an electrical outlet has a base and hinged cover that encloses the base when a cord or plug is connected to the electrical outlet. The base has a cord access opening to allow the cord to pass between the base and the cover when the cover is closed. An outer guard partially encloses the access opening in the base to inhibit water, dirt and insects from entering the internal cavity of the base. The outer guard has an open portion with a center axis that is misaligned with the axis of the access opening to form a diverging path through the open portion of the guard and the access opening in the base. The open portion in the guard has a closure member that can move between a closed position when not in use and an open position to allow a cord to pass through the guard to the access opening in the base.