Electrical enclosure cooling structure assembly and method

1. An electrical enclosure assembly comprising: an enclosure having walls defining an interior space for housing electrical components and having a front flange surrounding a front opening; a cover hingedly mounted to the enclosure for selectively closing the front opening, the cover comprising a front wall larger than the front opening and a rearwardly extending peripheral rim and cooling structure integrally formed on an interior surface of said cover proximate said peripheral rim, said cooling structure comprising a partition wall and a plurality of spaced apart cooling ribs between the partition wall and the peripheral rim, the cooling ribs each having a shoulder engaging the enclosure front flange when the cover is in a closed position to provide an air flow path between said interior space and outside of the enclosure through spaces between the cooling ribs.

2. The electrical enclosure assembly of claim 1 , wherein said cooling structure prohibits direct access to said electrical components.

3. The electrical enclosure assembly of claim 1 , wherein said cooling ribs extend along opposite sides of the cover.

4. The electrical enclosure assembly of claim 3 , wherein said cooling ribs are L shaped to define said shoulder and said peripheral rim extends rearwardly of the front flange.

5. The electrical enclosure assembly of claim 1 , wherein said peripheral rim extends around a top edge of the front wall to define a top rim and wherein said electrical enclosure assembly further comprises a protective ledge formed below said top rim.

6. The electrical enclosure assembly of claim 5 , further comprising vertical support ribs disposed between said protective ledge and said top rim.

7. The electrical enclosure assembly of claim 1 wherein said cover comprises a unitary structure formed of polymer material.

8. The electrical enclosure assembly of claim 7 , wherein said polymer material is a polycarbonate-acrylonitrile butadiene styrene blend.

9. A method for manufacturing an electrical enclosure assembly comprising the steps of: providing an enclosure having walls defining an interior space for housing electrical components and having a front flange surrounding a front opening; forming a cover comprising a front wall larger than the front opening and a rearwardly extending peripheral rim including a top rim and opposite side rims; forming a cooling structure on the interior surface of said cover, said cooling structure comprising a partition wall and a plurality of spaced apart cooling ribs between the partition wall and the peripheral rim, the cooling ribs each having a shoulder; and mounting said cover to said enclosure with said cooling rib shoulders engaging the enclosure front flange when the cover is in a closed position to provide an air flow path between said interior space and outside of the enclosure through spaces between the cooling ribs.

10. The method of claim 9 , wherein said cooling structure defines prohibits direct access to said electrical components.

11. The method of claim 9 , wherein said cooling ribs extend along opposite sides of the cover.

12. The method of claim 11 , wherein said cooling ribs are L shaped to define said shoulder and said peripheral rim extends rearwardly of the front flange.

13. The method of claim 9 , further comprising a step of forming a protective ledge below said top rim.

14. The method of claim 13 , further comprising a step of forming vertical support ribs disposed between said protective ledge and said top rim.

15. The method of claim 9 , further comprising a step of forming said cover from a polycarbonate-acrylonitrile butadiene styrene blend.