[0001] The present disclosure is directed to wiring devices and, more particularly, to a liquid resistant cover plate incorporating an integrated, molded sealing member for protecting electrical wiring devices and electrical connections from harsh elements such as, for example, liquids, dust, cleaning materials, etc.

BACKGROUND

[0002] Wiring devices are well known. Wiring devices provide a convenient mechanism for supplying, routing, controlling, etc. electrical power. To route, install and otherwise use AC electrical power, manufacturers produce many varieties of wiring devices. Examples of wiring devices include switches, electrical receptacles, dimmers, occupancy sensors, ground/arc fault circuit interrupters, and the like.

[0003] In a typical wiring device installation, a wiring device is connected to AC electrical power via electrical conductors and then the wiring device may be inserted into an electrical junction box and covered by a cover plate. Exposure of the electrical conductors and connections to, for example, liquid, moisture, dust, etc. may deteriorate these conductors and connections over time.

[0004] Wiring devices may be used in various locations. Some wiring devices may be used in harsh environments where they are likely to encounter increased amounts of liquid, dust, cleaning materials, etc. For example, wiring devices and cover plates used in hospitals or manufacturing facilitates such as food processing plants, etc. are more likely to encounter liquid, dust, and be subjected to higher levels of cleaning. However, introducing liquids (e.g., water, cleaning materials, etc.) and dust to electrical wiring devices and cover plates is disadvantageous because these elements could damage the wiring device and electrical connections and/or create unsafe conditions.

[0005] As a result, wiring devices and electrical connections, especially those in harsh environments (e.g., hospitals, manufacturing facilitates, etc.), should be protected from liquids, dust, etc. One approach for protecting wiring devices and electrical connections from liquids, dust, etc. is to utilize a gasket. In use, the gasket may be installed behind the cover plate between the wall surface and the cover plate. For example, some existing products utilize a rigid cover plate and separate flat sheet gasket with a cut-out for the face of the wiring device.

[0006] One disadvantage of such conventional designs is that the gasket must be manually installed and thus subject to variations in placement, thus limiting their abilities to provide effective seals. In addition, such conventional designs are not arranged and configured to effectively seal the cover plate against variations in wall surfaces against which the cover plate is mounted and/or to effectively seal the device opening formed in the cover plate against variations in different wiring devices.

[0007] Thus there remains a need for an improved cover plate. It is with this in mind that the present disclosure is provided. SUMMARY

[0008] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended as an aid in determining the scope of the claimed subject matter.

[0009] Disclosed herein is a cover plate with an integrated sealing member. In accordance with one or more features of the present disclosure, in use, when used in combination with a wiring device, the cover plate prevents, or at least minimizes, liquids, dust, etc. from entering between a wall surface and a plate perimeter and between the wiring device and the device opening. In addition, the cover plate with integrated sealing member is arranged and configured to provide a seal against the cover plate mounting screws to resist liquid and airflow from entering through the mounting screw openings formed in the cover plate. Thus arranged, the cover plate with integrated sealing member is particularly well suited for use in areas subjected to regular cleaning (e.g., areas regularly sprayed with liquids such as, for example, hospitals, food processing plants, etc.). In addition, the cover plate with integrated sealing member is arranged and configured to resist airflow, which has particular benefits in hospital “clean” rooms or labs where a pressure differential may be maintained.

[0010] In accordance with one or more features of the present disclosure, in use, the integrated sealing member is arranged and configured to seal against variations in wall surface and against variations in face sizes of the wiring device. [0011] In one embodiment, the cover plate comprises a front surface, a rear surface, and an outer perimeter, the front and rear surfaces having an opening therethrough, the opening defining an edge that is arranged and configured to receive a corresponding outer perimeter of a wiring device face. The cover plate further comprising a sealing member integrally molded to the cover plate. The sealing member is arranged and configured to extend beyond the outer perimeter of the cover plate so that the cover plate is substantially sealed to a wall or ceiling surface and the sealing member is further arranged and configured to overlie the edge of the cover plate so that the edge is substantially sealed against the corresponding outer perimeter of the wiring device face.

[0012] In one embodiment, the sealing member is permanently attached to the cover plate.

[0013] In one embodiment, the sealing member is overmolded to the cover plate.

[0014] In one embodiment, the sealing member includes a lip arranged and configured to protrude through the opening formed in the cover plate.

[0015] In one embodiment, the lip includes a groove formed therein for receiving the edge of the cover plate.

[0016] In one embodiment, the sealing member comprises a groove formed adjacent to an outer perimeter of the sealing member, the groove arranged and configured to receive the outer perimeter of the cover plate. [0017] In one embodiment, the sealing member includes an inner segment and an outer segment, the inner segment including the lip and an opening arranged and configured to correspond with the opening formed in the cover plate, the outer segment arranged and configure to surround the outer perimeter of the cover plate.

[0018] In one embodiment, the inner segment is coupled to the outer segment via one or more bridge members.

[0019] In one embodiment, the sealing member includes an opening arranged and configured to correspond with the opening formed in the cover plate, the opening formed in the sealing member being dimensioned such that the opening formed in the sealing member is smaller than the opening formed in the cover plate.

[0020] In one embodiment, the opening formed in the cover plate is sized and configured to be slightly larger than the outer perimeter of the wiring device face and the opening formed in the sealing member is sized and configured to be slightly smaller than the outer perimeter of the wiring device face.

[0021] In one embodiment, the sealing member is arranged and configured to produce a liquid-tight interference fit against the outer perimeter of the wiring device face.

[0022] In one embodiment, the lip includes a tapered surface.

[0023] In one embodiment, the tapered surface tapers from a front surface of the lip to a rear surface of the lip. [0024] In one embodiment, the sealing member is arranged and configured to accommodate variations in wall surfaces and variations in wiring devices.

[0025] In one embodiment, the cover plate is manufactured from one of a plastic or a metal, and the sealing member is manufactured from an elastomer. In one embodiment, the cover plate is manufactured from a stainless steel and the sealing member is manufactured from thermoplastic vulcanizate.

[0026] In one embodiment, the sealing member includes one or more screw holes aligned with one or more screw holes formed in the cover plate to seal against one or more cover plate mounting screws to inhibit liquid from entering through the screw holes formed in the cover plate.

[0027] In one embodiment, the sealing member is arranged and configured to inhibit airflow.

BRIEF DESCRIPTION OF THE DRAWINGS

[0028] By way of example, a specific embodiment of the disclosed device will now be described, with reference to the accompanying drawings, in which:

[0029] FIG. 1 illustrates a front view of an embodiment of a cover plate with integrated sealing member in accordance with one or more features of the present disclosure, the cover plate illustrated in combination with an embodiment of a wiring device (e.g., a Decora-style switch); [0030] FIG. 2 illustrates a front view of the cover plate with integrated sealing member shown in FIG. 1;

[0031] FIG. 3 illustrates a rear view of the cover plate with integrated sealing member shown in FIG. 1;

[0032] FIG. 4 illustrates a rear perspective view of an embodiment of a sealing member that may be used in the cover plate with integrated sealing member shown in

FIG. 2;

[0033] FIG. 5 illustrates a cross-sectional view of the cover plate with integrated sealing member shown in FIG. 2, taken along line V-V in FIG. 2; and

[0034] FIG. 6 illustrates a cross-sectional view of the cover plate with integrated sealing member shown in FIG. 2, taken along line VI- VI in FIG. 2.

[0035] It should be understood that the drawings are not necessarily to scale and that the disclosed embodiments are sometimes illustrated diagrammatically and in partial views. In certain instances, details which are not necessary for an understanding of the disclosed methods and devices or which render other details difficult to perceive may have been omitted. It should be further understood that this disclosure is not limited to the particular embodiments illustrated herein. In the drawings, like numbers refer to like elements throughout unless otherwise noted. DETAILED DESCRIPTION

[0036] Various features or the like of a cover plate or wallplate (terms used interchangeably herein without the intent to limit or distinguish) incorporating an integral, integrated, molded, or otherwise permanently attached sealing member (termed integrated sealing member herein) will now be described more fully hereinafter with reference to the accompanying drawings, in which one or more features of the cover plate with integrated sealing member will be shown and described. It should be appreciated that the various features may be used independently of, or in combination, with each other. It will be appreciated that the various cover plates with integrated sealing member as disclosed herein may be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will convey certain features of the cover plate with integrated sealing member to those skilled in the art.

[0037] In accordance with one or more features of the present disclosure, the cover plate with integrated sealing member is arranged and configured to protect a wiring device and electrical connections from liquid, dust, etc. In particular, the cover plate with integrated sealing member is arranged and configured for use in harsh embodiments subjected to increased cleaning such as, for example, hospitals, manufacturing facilitates, food processing plants, etc. where electrical wiring devices are subject to regular cleaning or spraying with liquids. In addition, the cover plate with integrated sealing member is arranged and configured to resist airflow, which has particular benefits in hospital “clean” rooms or labs where a pressure differential may be maintained [0038] As will be described herein, in one embodiment, the cover plate with integrated sealing member may be in the form of a stainless steel cover plate with an integrated flexible gasket that is arranged and configured to accommodate variations in wall surfaces and variations in dimensions of the wiring device face. As such, in one embodiment, the integrated sealing member or gasket is arranged and configured to surround an outer circumference, perimeter, edge, etc. (terms used interchangeably herein without the intent to limit or distinguish) of the cover plate to seal the cover plate against the wall surface to which the wiring device and cover plate are mounted and to surround the circumference, perimeter, edge, etc. (terms used interchangeably herein without the intent to limit or distinguish) of the device opening formed in the cover plate to seal against the received wiring device.

[0039] In accordance with one or more features of the present disclosure, the cover plate with integrated sealing member is arranged and configured for use with one or more electrical wiring devices. While the present disclosure will show the cover plate with integrated sealing member in connection with an electrical switch such as, for example, a Decora style electrical switch having a large rectangular switch or paddle for turning ON and OFF an associated electrical load such as, for example, a lighting load, it should be appreciated that the cover plate with integrated sealing member may be used with any suitable wiring device now known or hereafter developed such as, for example, an electrical receptacle, a toggle switch, a dimmer switch, an occupancy sensor, a ground/arc fault circuit interrupter, a fan speed control, an energy management device, a surge suppressor, a communication device, and the like. As such, it should be understood that the term “wiring device” is intended to include any now known or hereafter developed electrical device. As such, the present disclosure should not be limited to any particular wiring device unless explicitly claimed.

[0040] In addition, while the cover plate with integrated sealing member will be shown and described as a single gang cover plate (e.g., a cover plate arranged and configured with a single opening for receiving a single wiring device), the present disclosure is not so limited and the cover plate may be provided in other configurations including, for example, dual gang, three gang, four gang, etc.

[0041] Moreover, the cover plate may be manufactured from any suitable material now known or hereafter developed such as, for example, a metal, a plastic, etc. In a preferred embodiment, the cover plate may be manufactured from stainless steel. Similarly, the integrated sealing member may also be manufactured from any suitable material now known or hereafter developed such as, for example, an elastomer. In a preferred embodiment, the integrated sealing member may be manufactured from a thermoplastic elastomer or thermoplastic vulcanizate such as, for example, Santoprene™ such as, grade 8211-45.

[0042] Referring to FIGS. 1-6, an example embodiment of a cover plate 100 with integrated sealing member 200 is shown. As illustrated in FIG. 1, the cover plate 100 is arranged and configured to receive a wiring device 50 such as, for example, a Decora- style electrical switch. Specifically, as illustrated, the cover plate 100 includes a front surface 102, a rear surface 104, and an opening 106. In use, the opening 106 is arranged and configured to enable the wiring device 50 to be accessible therethrough. As will be appreciated, wiring devices 50 are normally fastened to electrical boxes in walls and ceilings of buildings or in other suitable locations. For example, the wiring device 50 may include a housing sized and configured as a single gang wall box mounted device.

In various embodiments, the wiring device 50 may include a strap arranged and configured to couple the wiring device 50 to the electrical box via, for example, one or more fasteners or screws. Thereafter, in use, the cover plate 100 may be coupled to the wiring device 50 via, for example, one or more fasteners or screws 110. Thus arranged, the cover plate 100 covers the wiring device 50 providing, for example, an aesthetically pleasing appearance.

[0043] In addition, as will be described in greater detail herein, in accordance with one or more features of the present disclosure, the cover plate 100 provides a seal between the rear surface 104 of the cover plate 100 and the wall surface to which the wiring device 50 and the cover plate 100 are mounted and/or between the cover plate 100 and the wiring device 50 thereby protecting the wiring device 50 from unwanted environmental conditions (e.g., cover plate 100 is arranged and configured to prevent, or at least inhibit, environmental conditions such as, liquids, dust, etc. from reaching the wiring device 50 either through a space created between the rear surface 104 of the cover plate 100 and the wall surface and/or through a spaced created between the wiring device 50 and the opening 106 formed in the cover plate 100). [0044] That is, in accordance with one or more features of the present disclosure, the cover plate 100 includes an outer perimeter 112 and an inner edge 114 defining the opening 106 formed in the cover plate 100. The integrated sealing member 200 is arranged and configured to surround the outer perimeter 112 of the cover plate 100 to provide a seal between the cover plate 100 and the wall surface on which the cover plate 100 is mounted. In addition, as illustrated, the integrated sealing member 200 is arranged and configured to surround the inner edge 114 defining the opening 106 formed in the cover plate 100 to provide a seal between the wiring device 50 and the opening 106 formed in the cover plate 100.

[0045] In use, the sealing member 200 may be coupled to the cover plate 100 by any suitable mechanism now known or hereafter developed. In a preferred embodiment, the sealing member 200 may be permanently attached to the cover plate 100. For example, in one embodiment, the integrated sealing member 200 may be overmolded to the cover plate 100. In one embodiment, as illustrated, the sealing member 200 may include an inner lip 210 arranged and configured to protrude through the opening 106 formed in the cover plate 100. As best illustrated in FIGS. 5 and 6, the lip 210 may include a groove 212 formed therein for receiving the inner edge 114 of the cover plate 100. Similarly, the sealing member 200 may include an outer perimeter 220 having a groove 222, the groove 222 being arranged and configured to receive the outer perimeter 112 of the cover plate 100. Thus arranged, the sealing member 200 may be fixedly integrated to the cover plate 100 thereby providing a cover plate with an integrated sealing member. [0046] Referring to FIG. 4, in one embodiment, the integrated sealing member 200 may include one or more screw holes or openings 202. In use, the screw holes or openings 202 are aligned with the one or more screw holes or openings formed in the cover plate 100. Thus arranged, fasteners or screws 110 may be inserted through the cover plate 100, through the integrated sealing member 200, and into the strap of the wiring device 50 to couple the cover plate with integrated sealing member 100 to the wiring device 50. Thus arranged, the cover plate with integrated sealing member 100 is arranged and configured to provide a seal against the cover plate mounting screws 110 to resist liquid and airflow from entering through the mounting screw openings formed in the cover plate.

[0047] In one embodiment, the integrated sealing member 200 may also include an inner segment or portion 230 and an outer segment or portion 240. In use, the inner segment 230 includes an opening 232 arranged and configured to substantially correspond with the opening 106 formed in the cover plate 100. In addition, the inner segment 230 includes the lip 210 arranged and configured to surround the inner edge 114 of the device opening 106 formed in the cover plate 100 to seal against the received wiring device 50. The outer segment 240 is arranged and configure to surround the outer perimeter 112 of the cover plate 100 to provide a seal between the cover plate 100 and the wall surface on which the wiring device 50 and the cover plate 100 are illustrated.

[0048] As illustrated, in one embodiment, the inner segment 230 may be coupled to the outer segment 240 via, for example, a bridge member 250 so that the integrated sealing member 200 may be monolithically formed. Alternatively however it is envisioned that the integrated sealing member 200 may be provided in different forms. For example, in one embodiment, the inner and outer segments 230, 240 may be separately formed. In one embodiment, the inner and outer segments 230, 240 may then be coupled together by any suitable mechanism such as, for example, an adhesive. Alternatively, it is envisioned that the inner and outer segment 230, 240 may remain separate from each other and be independently coupled to the cover plate 100. Moreover, in one embodiment, the integrated sealing member 200 may be formed as a single segment or portion that is arranged and configured to seal the outer perimeter 112 of the cover plate 100 and the inner edge 114 of the device opening 106 formed in the cover plate 100.

[0049] In accordance with one or more features of the present disclosure and as previously mentioned, the integrated sealing member 200 is arranged and configured to accommodate variations. For example, the integrated sealing member 200 is manufactured from materials and geometry arranged and configured to accommodate differences in wall surfaces such as, for example, uneven wall surfaces, and/or variations in wiring device dimensions.

[0050] For example, in one embodiment, the protruding lip 210 of the sealing member 200 may be dimensioned such that the opening 232 defined by the sealing member 200 is slightly smaller than the opening 106 formed in the cover plate 100. Thus arranged, the sealing member 200 (e.g., lip) may be arranged and configured to compress against the outer surface of the wiring device 50 to create an enhanced seal against the wiring device 50. In one embodiment, the seal may be a liquid-tight interference fit.

That is, in one embodiment, the opening 106 formed in the cover plate 100 may be sized and configured to be slightly larger than an outer perimeter of a wiring device face 50 (e.g., the opening 106 formed in the cover plate 100 may be slightly larger than a standard NEMA sized wiring device so that the wiring device 50 may protrude through the opening 106 formed in the cover plate 100). The opening 232 formed in the sealing member 200 may be sized and configured to be slightly smaller than the outer perimeter of the wiring device face (e.g., the opening 232 formed in the sealing member 200 may be slightly smaller than a standard NEMA sized wiring device to produce a water-tight interference fit).

[0051] In addition, in one embodiment, the lip 210 may include a tapered surface to compress against the outer surface of the wiring device 50. For example, in one embodiment, the lip 210 may include a taper from the front surface to the rear surface, although it is envisioned that the lip 210 may include a reverse taper (e.g., a taper surface from back to front) or may be non-tapered. In one embodiment, the tapered surface may include a 1 to 2 percent taper. Thus arranged, the lip 210 forms a wiping seal with the outer surface of the wiring device 50 to prevent unwanted outside environmental conditions (e.g., liquids, dust, etc.) from entering.

[0052] The foregoing description has broad application. While the present disclosure refers to certain embodiments, numerous modifications, alterations, and changes to the described embodiments are possible without departing from the sphere and scope of the present disclosure, as defined in the appended claim(s). Accordingly, it is intended that the present disclosure not be limited to the described embodiments. Rather these embodiments should be considered as illustrative and not restrictive in character. All changes and modifications that come within the spirit of the invention are to be considered within the scope of the disclosure. The present disclosure should be given the full scope defined by the language of the following claims, and equivalents thereof. The discussion of any embodiment is meant only to be explanatory and is not intended to suggest that the scope of the disclosure, including the claims, is limited to these embodiments. In other words, while illustrative embodiments of the disclosure have been described in detail herein, it is to be understood that the inventive concepts may be otherwise variously embodied and employed, and that the appended claims are intended to be construed to include such variations, except as limited by the prior art. Unless otherwise defined, all technical terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the disclosure belongs.

[0053] Directional terms such as top, bottom, superior, inferior, medial, lateral, anterior, posterior, proximal, distal, upper, lower, upward, downward, left, right, longitudinal, front, back, above, below, vertical, horizontal, radial, axial, clockwise, and counterclockwise) and the like may have been used herein. Such directional references are only used for identification purposes to aid the reader’s understanding of the present disclosure. For example, the term “distal” may refer to the end farthest away from the medical professional/operator when introducing a device into a patient, while the term “proximal” may refer to the end closest to the medical professional when introducing a device into a patient. Such directional references do not necessarily create limitations, particularly as to the position, orientation, or use of this disclosure. As such, directional references should not be limited to specific coordinate orientations, distances, or sizes, but are used to describe relative positions referencing particular embodiments. Such terms are not generally limiting to the scope of the claims made herein. Any embodiment or feature of any section, portion, or any other component shown or particularly described in relation to various embodiments of similar sections, portions, or components herein may be interchangeably applied to any other similar embodiment or feature shown or described herein.

[0054] It should be understood that, as described herein, an "embodiment" (such as illustrated in the accompanying Figures) may refer to an illustrative representation of an environment or article or component in which a disclosed concept or feature may be provided or embodied, or to the representation of a manner in which just the concept or feature may be provided or embodied. However, such illustrated embodiments are to be understood as examples (unless otherwise stated), and other manners of embodying the described concepts or features, such as may be understood by one of ordinary skill in the art upon learning the concepts or features from the present disclosure, are within the scope of the disclosure. Furthermore, references to “one embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. [0055] In addition, it will be appreciated that while the Figures may show one or more embodiments of concepts or features together in a single embodiment of an environment, article, or component incorporating such concepts or features, such concepts or features are to be understood (unless otherwise specified) as independent of and separate from one another and are shown together for the sake of convenience and without intent to limit to being present or used together. For instance, features illustrated or described as part of one embodiment can be used separately, or with another embodiment to yield a still further embodiment. Thus, it is intended that the present subject matter covers such modifications and variations as come within the scope of the appended claims and their equivalents.

[0056] As used herein, an element or step recited in the singular and proceeded with the word “a” or “an” should be understood as not excluding plural elements or steps, unless such exclusion is explicitly recited. It will be further understood that the terms “comprises” and/or “comprising,” or “includes” and/or “including” when used herein, specify the presence of stated features, regions, steps, elements and/or components, but do not preclude the presence or addition of one or more other features, regions, integers, steps, operations, elements, components and/or groups thereof.

[0057] The phrases “at least one”, “one or more”, and “and/or”, as used herein, are open-ended expressions that are both conjunctive and disjunctive in operation. The terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein.

[0058] Connection references (e.g., engaged, attached, coupled, connected, and joined) are to be construed broadly and may include intermediate members between a collection of elements and relative to movement between elements unless otherwise indicated. As such, connection references do not necessarily infer that two elements are directly connected and in fixed relation to each other. Identification references (e.g., primary, secondary, first, second, third, fourth, etc.) are not intended to connote importance or priority, but are used to distinguish one feature from another. The drawings are for purposes of illustration only and the dimensions, positions, order and relative to sizes reflected in the drawings attached hereto may vary.

[0059] The foregoing discussion has been presented for purposes of illustration and description and is not intended to limit the disclosure to the form or forms disclosed herein. For example, various features of the disclosure are grouped together in one or more embodiments or configurations for the purpose of streamlining the disclosure. However, it should be understood that various features of the certain embodiments or configurations of the disclosure may be combined in alternate embodiments or configurations. Moreover, the following claims are hereby incorporated into this Detailed Description by this reference, with each claim standing on its own as a separate embodiment of the present disclosure.