Note: Descriptions are shown in the official language in which they were submitted.
31L2~35~1
~IR:ING DE~I:OE CA3?AB3:E OF ~UTOMA~IC ASS~ LY
T~e present invention relates generally to electrical
receptacles mounted in walls and more particularly to
receptacles that can be automatically assembled.
Electrical wall receptacles adapted to accept the
prongs of plugs generally have a cover and a back held
together by a wrap-around metal strap and ~y metal drive
pins. Also, mounting flanges at each end of the receptacle
have a pair of snap-off "ears," or washers, connected to each
~lange.
Such standard wall receptacles are capable of limited
automatic assembly. Drive pins are knocked through apertures
in the flanges of the receptacle. Then a wrap-around metal
strap is positioned around the length of the receptacle.
If either drive pin is not well-placed, the back of the
receptacle assembly can become loose or actually separate
from the cover. Also, a certain safety hazard exists because
of the metals present, nameIy the wrap-around strap, the
drive pins, and the metal washers. Finally, a number of
separate entities are present that must be manufactured
separately and then assembled in addition to the internal
connectors, namely, the two drive pins, the strap, and the
metal ears. These limitations and disadvantages of the
prior art are well-known to people associated with the industry.
The present invention contemplates the elimination of
most of the above limitations and disadvantages of the prior
art.
Accordingly, it is an object of an aspect of this
invention to provide an electrical wall receptacle that is
capable of automatic assembly.
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It is an object of an aspect of this invention to
pxovide an electrical receptacle-capabIe of receiving the
pronys and the ground of at least one plug that is capable
of fully automatic assem~ly.
It i~ an object of an aspect of this invention to
provide an el:ectrical receptacle made of non-conductive
material that has a cover capable of being snap-mounted onto
a back.
It is an object of an aspect of the present invention
to provide a plastic receptacle having a cover and a rear
compartment made of modified polyvinyl chloride.
It is an object of an aspect of the invention to
provide a receptacle that is capable of receiving the prongs
and grounds of two plugs and that can be snap-mounted during
assembly.
It is an object of an aspect of this invention to
provide an electrical receptacle capable of being snap-
assembled and that has a cover and a rear compartment made of
electrîcally non-conductive material.
It is an object of an aspect of the present invention
~o provide a non-metal receptacle capable of being snap-
assembled that also has a pair of non-metal washers at either
side of the housing that are capable of being snapped off for
use as washers.
It is an object of an aspect of the present invention
to provide a snap-mounted receptacle of non-conductive
material that is capable of receiving a pair of connecting
members for connecting the prongs of a pair of plugs to the
leads of conductors of cable in a wall box to which the
receptacle is mounted and of receiving a ground connecting
member that is locked into the receptacle and that is capable
of electrically connecting the ground contacts. of a pair of
plugs to a grounding conductor at the wall ~ox~
An aspect of the invention is as follows:
~n electrical receptacle device, in combination
comprising:
a housing including a base membèr and a cover member,
securing means for snap-mcunting said cover member
to said base member,.
said base member h.aving a rear wall, a pair of opposed
end walls, and a pair of opposed side walls secured to the
edge portions of said rear wall, said walls defining a
compartment,
said cover member forming at least one pair:of!recesses
capable of passing the first and second contacts of at least
one plug and forming at least one aperture capable of passing
a grounding contact ~or said at least one plug,
first connecting means mounted in said compartment
for electrically connecting said first contact with the lead
of a first conductor,
second connecting means mounted in said compartment
spaced from said first connecting means for electrically
connecting said second contact with the lead of a second
conductor,
grounding connecting means mounted in said compartment
spaced from and positioned between said first and second
connecting means, said grounding connecting means being for
electrically connecting said grounding contact with. the lead
of a grounding conductor,
said base member forming passage means for passing said
leads for said first and second conductors and said grounding
conductor to said first and second connecting means and said
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grounding connecting means reæpectively,
engaging means for removably connecting said first,
second,- and grounding contacts with said first, second, and
grounding connecting means respectively,
means for fastening said leads of said first, second,
and grounding conductors with said fîrst, second, and
grounding connecting means respectively, and
means for attaching said housing to a mounting member.
By way of added explanation, the present invention
fulfills the above objects and overcomes the limitations
and disadvantages of the prior art by providing a novel
receptacle device that includes a housing having a base
forming a compartment and a cover secured to the base by a
securing mechanism adapted to snap-mount the cover to the
base. The cover and ~ase are made of a moldable, electrically
non-conductive material, preferably a modified polyvinyl
chloride tPVC~. The cover forms recesses for passing at
least one pair of first and second contacts for at least one
plug and preferably two pair of first and second contacts
for two plugs. The cover also forms at least one aperture
for passing at least one grounding contact for at least one
plug and preferably two apertures for passing grounding
contacts for two plugs. The base compartment includes
passages for passing leads from at least one pair of first
and second conductors and preferably leads rom two pair of
irst and second conductors from a wall box into the housing.
A first connecting member and a secona connecting member
capable of electrically connecting the respective first and
second contacts with the leads of the respective first and
second conductors are positioned along the opposing side
walls of the compartment. Each connecting member is provided
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with alternate mechanisms for fastening leads for the fir~t
and second conductors. One mechanism i~ a conventional
screw locking, or holding, mechanisms that fixes a wire lead
between a screw head and a plate, and a push-in wiring type
mechanism that loc~s the lead between a bîased clip and a
plate. Each connecting member is further provi.ded with.
receptacles for removabLy connecting the ~irst and second
contacts.
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A grounding contact member is located in the base compartment
between the first and second connecting members. Each
connecting member is positioned in a separate ch~mber defined
in the base compartment by side and end walls, intermediate
walls, and a short side wall. The grounding connecting
member is locked into the middle chamber; the connecting
member includes a bend or crimp that is disposed at right
angles to the main longitudinal portion of the grounding
member. The bend is set in a side chamber formed in part
by the short wall. The side chamber also holds a screw
and nut fastening mechanism for fastening the lead of the
grounding conductor from the wall box. A hole formed by the
rear wall of the base compartment is capable of passing the
lead of the grounding conductor to the side chamber for
connection to the lead fastening mechanism. A pair of
flanges extend from the ends of the base compartment with
bolt holes for connecting to the wall box or wall plate. A
pair of plastic washers made of the same material as the
housing are connected to each of the flanges; breaking
indentations are formed between the washers and the main
body of each flange to allow easy breaking off of the washers.
The invention will be more clearly understood from
the following description of a specific embodiment of the
invention together with the accompanying drawings, wherein
reference characters denote similar elements through the
several views, and in which:
Fig. 1 is a top view of the device according to the
present invention;
Fig. 2 is a side cross-sectional view of the device
taken through line 2-2 in Fig. l;
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Fig. 3 is a top view of the base taken through line
3-3 of Fig. 2;
Fig. 4 is a fragmentary sectional view of a locking
tab taken through line 4-4 of Fig. 3;
Fig. 5 is a sectional view taken through line 5-5 in
Fig. 3;
Fig. 6 is a sectional view taken through line 6-6 in
Fig. 3;
Fiq,~7 is a fragmentary sectional view taken along line
7-7 in Fig. 3; and
Fig. 8 is a fragmentary sectional view taken along line
8-8 in Fig. 3.
Fig. 9 is a view of the rear wall of the base member in
isolation.
Fig. 10 is a perspective view of the grounding connecting
member.
Fig. 11 is a perspective view of the electrical connecting
members.
Reference is now made in detail to the drawings.
Fig. 1 illustrates a top view of electrical device 10
and Fig. 2 shows device 10 in side sectional elevation. As
best seen in Fig. 2, device 10 includes a housing 12 which
comprises a base member 14 and forming a compartment 29 and
a cover member 16 which in turn is snap-mounted to base
member 14 in a manner to be described. Housing 12 is set
into electrical wall box 17 which is flush mounted to wall
19. A cover mounting plate 21 is set over cover 16 of the
present invention and is secured to cover 16 b~ center
mounting screw 23(shown in section in Fig.l). A pair of side
mounting screws 11 through opposed mounting tabs 13 extending
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from the opposed ends of base 14 via screw holes 15.
Screws 147 pass through tabs 145 of base 14 into wall 19
in a conventional manner with wall cover plate 21 set over
screws 147 again in a conventional manner leaving the
receptacles of cover 16 exposed for electrical connection.
Device 10 is arranged and constructed in the preferred
embodiment as illustrated in the accompanying drawings
described as being capable of receiving the prong contacts
and gr~unding contacts of two plugs. It is understood that
the present invention as described herein can apply equally
to a devicé arranged and constructed to receove the contacts
of a single plug within the spiri-t of the invention.
Cover member 16 and base member 14 are made of a non-
conductive material that also has a resilient ~uality for
snap-mounting and that furthermore is moldable. The material
preferred is a modified polyvinyl chloride(PVC).
Fig. 1 illustrates cover 16 forming two first recesses
18 and 18' capable of receiving two first prongs, or male
contacts 22 and 22' respectively and two second recesses
20 and 20' capable of receiving two second prongs, or male
contacts, 24 and 24' respectively. The plugs holding contacts
22 and 22' and 24 and 24' are not illustrated. The first
plug would have first prong contact 22 and second prong
contact 2~; and the second plug would have first prong contact
72' and second prong contact 24'. Cover 16 further forms first
and second passages 26 and 26' capable of receiving first
and second ~rounding contacts 28 and 28' of the first and
second plugs.
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As shown in Fig. 3, first and second elongated connecting
members 30 and 31 respectively are mounted in compartment 29
in a manner to be described. Members 30 and 31 are electrically
conductive and made of metal. First member 30 is for
electrically connecting first contacts 22 and 22' with first
leads 32 and 32' respectively of the two first conductors that
extend from a connecting box 17 mounted in a wall or the
like into base compartment 14 in a manner to be described.
Likewise, second member 31 is for electrically connecting
,. . . .
second contacts 24 and 24' with second leads 36 and 36'
respectively of two of the second conductors that extend from
the connecting box mentioned above into compartment 29 in
a manner to be described. Alternate positions for leads 32
and 32' and leads 36 and 36' are shown in phantom lines as
leads 32a and 32'a and leads 36a and 36'a. Also, elongated
electrically conductive grounding connecting member 40 is
likewise mounted in compartment 29 in a manner to be described
positioned between the f~rst and second connecting members
30 and 31. Grounding connecting member 40 is for electrically
connecting first and second grounding contacts 28 and 28'
for the first and second plugs with lead 42 of grounding
conductor(not shown) from the connecting box mentioned above that
extends into compartment 29 in a manner to be described.
As best seen in Figs. 2,3, and 9, base 14 includes a rear
wall 44 and an opposed open side 46. Rear wall 44 is to be
set into wall box 17 while open side 46 is set facing outward
from the box. Open side 46 is overlaid by cover 16 when
cover 16 is snap-mounted to base 14. Opposed first and second
end walls 48 and 49 intersect rear wall 44. First and second
substantially parallel side walls 51 and 52 also intersect
rear wall 44 and in addition intersect end walls 48 and 49.
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Rear wall 44, end walls 48 and 49, and side walls 51 and 52
form compartment 29. End walls 48 and 49 include three
angled wall portions 54 which meet side walls 51 and 52.
End walls 48 and 49 include three angled wall portions 53 disposed
below projecting members 56 that extend from base compartment
14 at the intersections of side walls 48 and 49 with second
side wall 52 and the intersection of first side wall with
first end wall 48 in a manner that will be discussed in detail
.... ., .~ .. .
below. Side walls 51 and 52 are preferably longer than end
walls 48 and 49 are wide. First and secind walls 51 and 52
forms first and second wall openings 54 and 55 respectively
approximately midway between end walls 4 8 and 49.
- A first intermediate wall 57 extends inwardly inwardly
into compartment 14 from rear wall 44 to open side 46 between
end walls 48 and 49 substantially parallel to and spaced
from first side wall 54. A spaced portion 58 of first intermediate
wall 57 is located between open side 46 and spaced from second
end 49 so that first intermediate wall 57 extends inwardly a
short distance from rear wall 44. Likewise, as seen in side
view in Fig, 2 and in top view in Fig. 1, wall 57 is spaced
from open side 46 at center portion 59 in order to receive
transverse ceriter brace portion 61 of cover 16. As seen in
Fig. 3, a short structural wall 60 extends at right angles
from wall 57 spaced from second end wall 49 to first side
wall 51.
A second intermediate wall 63 generally extends inwardly
into compartment 14 from rear wall 44 to open side 46 between
first end wall 48 to a position spaced from said second
end wall 49. Second intermediate wall 63 is substantially
parallel to and spaced from both second side wall 52 and first
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intermediate wall 57. Wall portion 64 extends at approximately
right angles at the mated spaced position from second
intermediate wall 63 to second side wall 52. Wall portion
64 is preferably spaced from second end wall 49 as is
structural wall 60. In the same arrangement as the first
intermediate wall, second intermediate wall 63 is spaced from
open side 46 at a center portion amalagous to center portion
59 of forst intermediate wall 57 in order to receive center
,
brace portion 61 of cover 16. .
Rear wall 44, first end wall 48, first side wall 51, second
end wall 49, and first intermediate wall 57 define a first
chamber 66, which is open at open side 46. First chamber
66 can also be defined by short structural wall 60 rather
than second end wall 49. Likewise, rear wall 44, first
end wall 51, second side wall 52, and second intermediate
wall 63 define a second chamber 67. Also, rear wall 44, first
end wall 48, first intermediate wall 57, second intermediate
wall 63, second end wall 55, second side wall 52, and wall
portion 64 define a middle chamber 68. Middle chamber 68
includes elongated middle chamber portion 60 formed between
first and second end walls 48 and 49 and a side chamber 70
of middle chamber 68 formed between second end wall 49,
wall portion 64, and second side wall 52.
First connecting member 30 is positioned in first chamber
66, which is adapted to receive member 30. Second connecting
member 31 is positioned in second chamber 67, which is
adapted to receive member 31. Grounding connecting member
40 is positioned in middle chamber 68, which is adapted to
receive member 40. Grounding member 40 includes elongated
portion 72 and bend portion 73, which extends~at approximately
right angles to portion 72. Elongated portion 72 is positioned in
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elongated middle chamber portion 69 and bend portion 73 is
positioned in side chamber portion 70. Thus, grounding
connecting member 40 is prevented from being moved relative
to end walls 48 and 49 and to side walls 51 and 52 by the
bent, or crimped, positioning.
First connecting member 30 includes two contact receptacles
76 and 76' for removably engaging first contacts 22 and 22'
respectively; receptacles 76 and 76' are connected to
opposite ends of elongated first member 30. Second connecting
. ~.
member 31 includes two receptacles 78 and 78' for removably
engaging second contacts 24 and 24' respectively; receptacles
78 and 78' are connected to opposite ends of elongated
second member 31. Each receptacle includes conventional
oppositely positioned arms forming a recess oriented for
receiving the particular contact intended for it. Each
receptacle has a base en~ disposed proximate to rear wall
44 which is in turn connected to each respective connecting
member by an arm 82, whi-ch is resilient to a limited extent
as an aid in positioning the contact in the receptacle
during insertion. First receptacles 76 and 76' are disposed
in association with first recesses 18 and 18' and second
receptacles 78 and 78' are disposed in association with
second recesses 20 and 20' for convenient reception of each
receptive contact.
As best seen in isolation in Fig, 10, grounding connecting
member 40 includes two grounding receptacles 84 and 84' for
removably engaging first and second grounding contacts 28a
and 28' respectively; receptacles 84 and 14' are connected to
opposlte ends of elongated portion 72 of grounding member
40. Grounding member 40 includes a plate that disposed across
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middle chamber 68 with a pair of locking flanges 88 positioned
approximately at the center area between end walls 48 and 49
and having a pair of tabs 89(Fig. 9) set into tab recesses
formed in cavity 91 in rear wall 44. A plate hole 90 is
formed in grounding member 40 approximately midway between
end walls 48 and 49 for the purpose of receiving a center
mounting screw 23 set into the wall cover plate 21 through
cover screw hole 92 and finally into the grounding connecting
member screw hole 90 thus acting to fasten cover plate 21,
device 10, and grounding member 40 together. Receptacles
84 and 84' are conventional receptacles with paired arms
extending toward first and second passages 26 and 26'
respectively in cover 16; the arms are positioned around
respective plate recesses 85, 85' which accept the ends of
grounding contacts 28 and 28'.
First and second connecting members 30 and 31 are further
adapted to fasten the first and second leads of the conductors
extending from wall box 12. Each connecting member has
alternate types of mechanisms for fastening the leads, one
type being a conventional screw locking mechanism and the
other type being a push-in wiring mechanism.
As seen in isolation in Fig. 11, first connecting member
30 includes paired first screw holding, or locking, mechanisms
100 and 100' for fastening the bare wire leads(not shown) of
the two first conductors(not shown) from wall box 17.
Screw locking mechanisms 100 and 100' are positioned at
first wall opening 54(Fig.3) of first side wall 51 and
face outward from base compartment 14. The screw locking
mechanisms are conventional and each includes a screw base
wall 101 fox each screw 99 to press the particular conductor
lead wire against. A screw-receiving recess 106(Fig. 3) is
formed behind each base wall 101. Recesses 106 are defined
in part by first and second intermediate walls 57 and 63.
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Preferably a slot 102 between each screw mechanism is formed
an~ which opens toward rear wall 44 and which settles around
a mounting tab 103 (Fig. 2) positioned in side walls 51 and
52. The tab 103 in turn being connected to a tab flange 104
(Fig. 2) extending from the adjoining intermediate walls
57 and 63 and rear wall 44.
In the same manner as for member 30, connecting member
31 likewise includes similar paired second screw locking
mechanisms 107 and 107l for fastening the wire leads of the
two second conductors(not shown) of the two second conductors
(not shown) from wall box 17. Screw locking mechanisms 107
and 107' are positioned at second wall opening 55(Fig. 3) at
second side wall 52 and face outward from base compartment 14.
Each includes a base wall 101 for each screw 99 to screw
press the conductor wire lead against. Preferably each member
31 forms a slot 102 between each screw mechanism that opens
toward wall 44 and that settles around a mounting tab 103
pos~tioned in side wall 52, similar to the tab 103 in side
wall 51, the tab in turn being connected to tab flange 104
extending from the adjoining intermediate second wall 63 and
rear wall 44.
Fig. 1 shows only one first paired screw locking mechanism
100 and one second paired screw locking mechanism 107, each
located nearest first end wall 48 since there is a shift of
the mechanisms towards second end wall 49 to compensate
for the preferable off~center positioning grounding passages
26 and 26' towards second end wall 49 relative to first and
second recesses 18 and 20 for the contacts of first plug and
first and second recesses 18' and 20' for the contacts of the
second plug. It is noted that the first passage 26 could be
positioned towards first end wall 48 within the spirit of the
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invention thus centering the contacts of the first andsecond plugs, but, of course, the arrangement of the elements
would differ.
As best seen in Figs. 9 and 11, the wiring for each of
the leads for each first conductor lead 32 and 32' and each
second conductor lead 36 and 3Ç' passes through pairs of
grooves formed in rear wall 44. In particular, a pair of
open-sided grooves 109 and 109' formed in rear wall 44 at the
edge of first side wall 51 for passing leads of first
conductors 32a and 32a' respectively from wall box 17 to
first screw locking mechanisms 100 and 100' respectively.
One of the grooves of each groove pair is adapted to pass
the conductor to the screw mechanism and the other to receive
the loose end of the base wire after passing around the threaded
portion of each screw 99. Similarly, an open-sided groove
pair 110 and open-sided groove pair 110' are formed in rear
wall 44 at the edge of second side wall 52 for passing leads
36a and 36a' of the second conductors to second screw locking
mechanisms 107 and 107' respectively.
The alternate type of mechanism available for fastening
the conductor leads to the first and second connecting members
30 and 31 is the push-in wiring type mechanism which is
mounted with the screw locking mechanism described previously
and seen in Fig. 11. One biased clamp mechanism 113 is
positioned in proximity to each first and second screw
locking mechanism 100,101' and 107, 107' connected to
connecting members 30 and 31 respectively. A clamp mechanism
113 is positioned between receptacle 76 and screw locking
mechanism 100; between receptacle 76' and screw locking
mechanism 100'; between receptacle 28 and screw locking
mechanism 107; and between receptacle 28' and screw locking
mechanism 107'. Each clamp mechanism includes a resilient,
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biasable clamp arm 116 positioned in proximity to each arm82. As described previously, an arm 82 extends from each
receptacle 76,7~', 78 and 78' outwardly to base walls
101 of each screw locking mechanism. Likewise, biasable
clamp axms 116 are connected to base walls 101 via flanges
105. Each clamp arm 116 is spaced from each arm 82 so as
to define apertures 118 that are adapted to fasten, or secure,
push-in leads for conductors 34,34', 38, and 38' to the
clamp~mecnanisms 113. The leads must, of.course, be of the ty~e --
adapted to be pushed into the clamp mechanisms 113, which
then pin each lead.and prevent it from being withdrawn by
way of a conventional arrangement of each clamp arm 116 being
angled against the return route of travel of each lead.
Rear wall 44 forms first holes 122 and 122' for passing
leads 32 and 3Z' respectively for the first conductors
and second holes 123 and 123' for passing leads 36 and 36'
respectively for the second conductors to the first and
second clamp mechanisms 113.
As seen in Fig. 3 and in isolation in Fig. 10, grounding
connecting member 40 includes as previously described a bend
portion 73 that is connected to elongated portion 72 and
is disposed across side chamber 70 of middle chamber 68. As
further seen in Figs. 5 and 6, a pair of tabs 126 extend
from the end of elongated portion 73 proximate to side wall
51 to rear wall 44 forming inner passage 127 coextensive with
outer passage 128 formed in side wall 51 spaced from rear wall 44.
A screw-and-nut fastening mechanism 129 is positioned in
side chamber 70 with screw head 130 disposed in outer passage
128 and threaded portion 130 through tab passage 127 and
outer.passage, or aperture, 128 into side chamber 70 where a
nut 132 is mounted to threaded portion 131. Nut 132 is spaced
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from outer passage 128 and adjacent tabs 126. Rear wall44 forms a hole 133 that leads into one side of side chamber
70 between both screw head 131 and tabs 126 and preferably
curved nut 132. Hole 133(Fig. 9) is adapted to pass lead
42 of the grounding conductor from wall box 17 into side
chamber 70 where the lead can be fastened to mechanism 129.
Nut 132 and screw head 130 are drawn together upon screwing
of head 130 thus fastening lead 42 between them. Nut 132 is
also drawn into electrical contact with tab 126 during the
fastening process, thus creating an electrical connection
between grounding lead 42 and grounding connector 40.
Receptacle 10 is capable is capable of being automatically
assembled by way of having snap-mounting connections extending
from both cover 16 and base 14. In particular, cover 16 is
adapted to be laid over open side 16 of compartment 29 and
be snap-mounted to base ~4 by means of four snap-mounting
connections in accordance with the present invention and as
illustrated in the preferred embodiment in Figs. 1 and 3 and
in detail in Fig.4, the latter applicable to both members
136 and 136'. Three snap-mounting members 136 each includes
a cover tab 139 extending into a slot 140, preferably tapered
as illustrated, ~ormed three projecting members 56 that
extends from each angled wall portion 53 described previously
at the areas of intersection of first and second end walls
48 and 49 with second side wall 52 and first side wall 51
with first end wall 48. Projecting member 56 extend outwardly
from base 14 at open side 46, in proximity to cover 16.
Each tab 139 is provided with an outwardly projecting lip
141 at the end of each tab, lip 141 fitting over a ridge
142 extending transversely across the outer wall, or track, of
each slot 140. Each tab 139 is resiliently biased in
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accordance with the resilient material of the device asdescribed, a mosified polyvinyl chloride(PVC). A fourth
snap-mounting member 136l is positioned on housing 12
between outer passage 128, that is, side chamber 70, and first
connecting member 30. Here, in the same manner as snap-
mounting members 136, cover tab 139 extends into slot 140
formed in fourth projecting member 56' that extends from
first side wall Sl at open side 46 located as described.
Again, tab 139 has lip 141 that clips over ridge 142 on the
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outside track of slot 140.
Extending from each mounting tab 13 are a pair of washer
ears 149. A breaking line 150 formed between each of the
four ears and their mounting tabs 13 allows easy breaking off
of the washers for general use.
The embodiments of the invention particularly disclosed
here are presented merely as examples of the invention. Other
embodiments, forms, and modifications of the invention coming
within the proper scope of the invention will, of course,
readily suggest themselves to those skilled in the art;
