METER SWITCH GUARD

A method of insulating an electrical switch includes forming a switch cover having a front wall, a first side wall, a second side wall, a top wall, and an open bottom opposite the top wall by folding a sheet of electrically insulating material. The method includes placing the switch cover over a component of the electrical switch, the component extending into the switch cover through the open bottom.

BACKGROUND

Buildings and other structures are typically electrically connected to an electrical grid that delivers power from a utility power source to the building. The utility power source may be, for example, a coal plant, a nuclear plant, a hydro-electric dam, a solar farm, a wind farm, etc. An electrical meter is installed at an electrical connection of the building to the electrical grid. The electrical meter, also known as a watthour meter, measures an amount electrical power consumed at the build and supplied via the electrical grid. The amount of electrical power measured electrical power may be used to determine how much a consumer should be billed by an operator of the utility power source.

A switch block having a plurality of switches moveable between open and closed positions that provide open and closed electrical circuits may be connected to the electrical grid, the meter, and/or electrical loads of the building. Various switches of the switch block may be placed in the open position and other switches of the switch block may be placed in the closed position, e.g., to open a circuit connected to the electrical grid and to close one or more circuits connected to the meter and the electrical loads. Such configuration may inhibit power from the electrical grid from flowing to the meter and electrical loads, while permitting testing of the meter and/or any electrical device such as a current transformer or voltage transformer that is connected, to ensure proper measure of electrical power consumed by the electrical loads.

DETAILED DESCRIPTION

An assembly includes a switch block assembly having a plurality of switches. The assembly includes a switch cover formed from a folded sheet of electrically insulating material and supported by the switch block assembly, the switch cover enclosing a component of one of the switches.

The one of the switches may include jaws and the switch cover may include an extension wall disposed within the jaws.

The switch cover may define a cavity, the component of one of the switches may include a toggle arm within the cavity, and the extension wall may be disposed within the jaws outside the cavity.

A method of insulating an electrical switch includes forming a switch cover having a front wall, a first side wall, a second side wall, a top wall, and an open bottom opposite the top wall by folding a sheet of electrically insulating material. The method includes placing the switch cover over a component of the electrical switch, the component extending into the switch cover through the open bottom.

The folding the sheet of electrically insulating material into the switch cover may include folding the sheet along a plurality of pre-formed fold lines.

The plurality of pre-formed fold lines may each include one of a perforated line, a scored line, or a crimped line.

The switch cover formed by folding the sheet of electrically insulating material may include an extension wall extending from the front wall.

The extension wall may extend inwardly from the front wall.

The extension wall may extend outwardly from the front wall.

The method may include placing the extension wall between jaws of the electrical switch.

The extension wall may extend upward beyond the top wall.

The extension wall may include a bottom edge and the front wall may include a bottom edge vertically spaced from the bottom edge of the extension wall.

The top wall may include a first panel extending from the first side wall toward the second wall and a second panel extending from the second side wall toward the first side wall.

The first panel may include a first engagement feature and the second panel may include a second engagement feature.

The forming the switch cover may include engaging the first engagement feature with the second engagement feature.

The first engagement feature may include a tab and the second engagement feature may include a slot.

Forming the switch cover may include disposing the tab of the first engagement feature into the slot of the second engagement feature.

The sheet of electrically insulating material may include a top edge, a bottom edge, a first pre-formed fold line extending from the top edge to the bottom edge and a second pre-formed fold line extending from the top edge to the bottom edge.

The sheet of electrically insulating material may include a right edge, a left edge, a third pre-formed fold line extending from the left edge to the first pre-formed fold line, and a fourth pre-formed fold line extending from the right edge to the second pre-formed fold line.

The sheet of electrically insulating material may include a fifth pre-formed fold line, a sixth pre-formed fold line, and a seventh pre-formed fold line, all extending from the top edge to the bottom edge and between the first pre-formed fold line and the second pre-formed fold line.

With reference toFIGS.1,2,10and11, wherein like numerals indicate like elements thought the several view, a switch block assembly20having a plurality of switches22is shown. The switch block assembly20may be connected to one or more power sources (e.g., an electrical utility grid, a solar panel, a power wall, a generator, etc.), one or more electrical meters, one or more load centers, etc. (not shown). The switches22may open and close one or more electrical circuits that include the various elements connected to the switch block assembly20. Each of the switches22is moveable from an open position to a closed position, and vice versa. The switch22in the open position inhibits flow of electricity, e.g., from one electrical connection of the switch22to another. The switch22in the closed position permits flow of electricity. For example, the switch22may include a toggle arm24connected to one electrical connection of the switch22and jaws26connected another electrical connection. The toggle arm24and the jaws26include an electrically conductive material. The toggle arm24may rotate about a pivot from the open position to the closed position, and vice versa. The toggle arm24in the open position may be spaced from, and not in physical contact with, the jaws26. The toggle arm24in the closed position may be disposed between, and in physical contact with, the jaws26. The switch22may include any other suitable structure, i.e., to open and closed the various electrical circuits connected to the switch block assembly20. The switch22may include a connection post25to enable connection of electrical equipment to the switch22. The connection post25may be in electrical communication with the jaws26and/or the toggle arm24, i.e., such that electrical power can flow therebetween.

A switch cover28, shown inFIGS.1-18, electrically insulates components, such as the toggle arm24, the connection post25, and/or the jaws26, of at least one of the electrical switches22. For example, the switch cover28may prevent physical contact between components of the switch22and an operator actuating the switches22. As another example, the switch cover28may inhibit moment of the switch22to the closed position. The switch cover28formed from a folded sheet64of electrically insulating material, e.g., as described below.

The switch cover28may include a front wall30, a first side wall32, a second side wall34, and a top wall36. The front wall30, the first side wall32, and the second side wall34may extend downward from the top wall36. The top wall36, the first side wall32and the second side wall34may extend rearward from the front wall30. The switch cover28defines a cavity38, e.g., between the first side wall32and the second side wall34. The front wall30and the top wall36enclose a front and a top of the cavity38. The switch cover28may include an open bottom40opposite the top wall36. The switch cover28may include an open rear42opposite the front wall30. The open bottom40and the open rear42may be between the first side wall32and the second side wall34. Components of the switch22may be placed within the cavity38via the open bottom40and the open rear42.

The front wall30may include a first panel44extending from the first side wall32toward the second side wall34. The first panel44may extend generally halfway to the second side wall34. The front wall30may include a second panel46extending from the second side wall34toward the first side wall32. The second panel46may extend generally halfway to the first side wall32. Distal ends of the first panel44and the second panel46may abut each other. The first panel44and the second panel46of the front wall30may be free from overlapping each other.

The top wall36may include a first panel48extending from the first side wall32toward the second side wall34. The first panel48may extend over halfway to the second side wall34. The first panel48may extend to the second side wall34. The top wall36may include a second panel50extending from the second side wall34toward the first side wall32. The second panel50may extend not all the way, e.g., halfway, to the first side wall32. The first panel48and the second panel50may engage, e.g., couple, each other to collectively provide the top wall36. For example, the first panel48may include a first engagement feature52and the second panel50may include a second engagement feature54. The first engagement feature52and the second engagement feature54are engageable with each other. The first engagement feature52may include a tab56and the second engagement feature54may include a slot58. The tab56may be disposed with the slot58to engage the first engagement feature52with the second engagement feature54. The first engagement feature52and the second engagement feature54may include any suitable structure for coupling the first panel48and the second panel50together.

The switch cover28may include an extension wall60extending from the front wall30. The extension wall60may extend from the distal ends of the first panel44and the second panel46of the front wall30. The extension wall60may extend transversely, e.g., perpendicular, from the front wall30. The extension wall60may extend upward from a bottom edge62beyond the top wall36. In other words, the extension wall60may extend above the top wall36. The bottom edge62at the extension wall60may be vertically spaced from the bottom edge62at the front wall30and/or at the first side wall32and the second side wall34. For example, the bottom edge62at the extension wall60may be above the bottom edge62at the front wall30and the first side wall32and the second side wall34. The extension wall60may extend outwardly from the front wall30, as shown inFIGS.1-9. For example, the extension wall60may extend from the front wall30and away from the cavity38. The extension wall60may extend inwardly from the front wall30, as shown inFIGS.10-18. For example, the extension wall60may extend from the front wall30and into the cavity38.

The switch cover28may be supported by the switch block assembly20, insulating at least one of the switches22. The switch cover28may enclose a component of one of the switches22, such as the toggle arm24, the connection post25, and/or the jaws26within the cavity38. The component of the switch22, e.g., the toggle arm24and/or the jaws26, may extend into the cavity38of the switch cover28through the open bottom40and/or open rear42. In other words, the component of the switch22may extend from below and/or behind the first side wall32and the second side wall34upward and/or forward to between the first side wall32and the second side wall34. The extension wall60may be disposed between jaws26of the electrical switch22. Force applied to opposite sides of the extension wall60by the jaws26may secure the switch cover28to the switch22. With reference toFIGS.1and2, the extension wall60disposed within the jaws26may be outside the cavity38. With reference toFIGS.10and11, the extension wall60disposed within the jaws26may be inside the cavity38.

With refence toFIG.19, an exemplary sheet64of electrically insulating material for forming the switch cover28is shown. The sheet64may be formed into the switch cover28by folding the sheet64, e.g., along a plurality of pre-formed fold lines66,68,70,72,74,76,78and as further described below. The electrically insulating material does not conduct electricity. For example, the sheet64may be plastic, foam board, paper, or any other suitable material. The sheet64may include multiple layers of material. The fold lines66,68,70,72,74,76,78promote deformation there along, e.g., such that a bending force applied to the sheet64folds the sheet64along the fold lines66,68,70,72,74,76,78. The sheet64at the fold lines66,68,70,72,74,76,78may be less ridged than adjacent the fold lines66,68,70,72,74,76,78. For example, the pre-formed fold lines66,68,70,72,74,76,78may include at least one of a perforated line, a scored line, or a crimped line extending along the sheet64. The perforated line may include plurality of holes extending part way, or all the way, through the sheet64, and the holes may be spaced from each other along the fold line. The score line may extend part way, but not all the way through the sheet64, the score line may be continuous along the fold line. The crimped line may be compressed continuously along the fold line, e.g., via folding the sheet64with or pressing the sheet64with a stamp.

The sheet64of electrically insulating material includes a top edge80and the bottom edge62spaced from the top edge80. The sheet64of electrically insulating material includes a right edge82and a left edge84spaced from the right edge82. The top edge80and the bottom edge62may both extend from the right edge82to the left edge84. The right edge82and the left edge84may both extend from the top edge80to the bottom edge62. The top edge80and the bottom edge62may include various curves, cusps, and various angled and linear portions. The right edge82and the left edge84may extend laterally from the top edge80to the bottom edge62, e.g., without and various curves, cusps, and various angled and linear portions therebetween.

The sheet64may include a first pre-formed fold line66extending from the top edge80to the bottom edge62. A portion88of the sheet64that provides the first side wall32may be between the left edge84and the first pre-formed fold line66. The sheet64may include a second pre-formed fold line68extending from the top edge80to the bottom edge62. A portion90of the sheet64that provides the second side wall34may be between the right edge82and the second pre-formed fold line68.

The sheet64may include a third pre-formed fold line70extending from the left edge84to the first pre-formed fold line66. The third pre-formed fold line70may be perpendicular to the first pre-formed fold line66. The portion of the sheet64that provides the first side wall32may be between the third pre-formed fold line70and the bottom edge62. A portion92of the sheet64that provides the first panel48of the top wall36may be between the third pre-fold line and the top edge80. The sheet64may include a fourth pre-formed fold line72extending from the right edge82to the second pre-formed fold line68. The fourth pre-formed fold line72may be perpendicular to the second pre-formed fold line68. The portion of the sheet64that provides the second side wall34may be between the fourth pre-formed fold line72and the bottom edge62. A portion94of the sheet64that provides the second panel50of the top wall36may be between the fourth pre-fold line and the top edge80.

The sheet64of electrically insulating material may include a fifth pre-formed fold line74, a sixth pre-formed fold line76, and a seventh pre-formed fold line78, all extending from the top edge80to the bottom edge62and between the first pre-formed fold line66and the second pre-formed fold line68. The fifth pre-formed fold line74may be between the first pre-formed fold line66and the seventh pre-formed fold line78. The sixth pre-formed fold line76may be between the second pre-formed fold line68and the seventh pre-formed fold line78. The first pre-formed fold line66, the second pre-formed fold line68, the fifth pre-formed fold line74, the sixth pre-formed fold line76, and the seven pre-formed fold line may be parallel with each other.

A portion96of the sheet64that provides the first panel44of the front wall30may be between the first pre-formed fold line66and the fifth pre-formed fold line74. A portion98of the sheet64that provides the second panel46of the front wall30may be between the second pre-formed fold line68and the sixth pre-formed fold line76. A portion100of the sheet64that provides the extension wall60may be between the fifth pre-formed fold line74and the sixth pre-formed fold line76. A distal edge of the extension wall60may be provided by the seventh pre-formed fold line78.

The top edge80of the sheet64between the fifth pre-formed fold line74and the sixth pre-formed fold line76may be spaced from the top edge80between the first pre-formed fold line66and the fifth pre-formed fold line74and the top edge80between the second pre-formed fold line68and the sixth pre-formed fold line76. For example, the sheet64between the fifth pre-formed fold line74and the sixth pre-formed fold line76may extend away from the bottom edge62beyond the top edge80between the first pre-formed fold line66and the fifth pre-formed fold line74and the top edge80between the second pre-formed fold line68and the sixth pre-formed fold line76.

The top edge80of the sheet64between the left edge84and the first pre-formed fold line66and between the right edge82and the second pre-formed fold line68may be spaced from the top edge80between the first pre-formed fold line66and the fifth pre-formed fold line74and the top edge80between the second pre-formed fold line68and the sixth pre-formed fold line76. For example, the sheet64between the left edge84and the first pre-formed fold line66and between the right edge82and the second pre-formed fold line68may extend away from the bottom edge62beyond the top edge80between the first pre-formed fold line66and the fifth pre-formed fold line74and the top edge80between the second pre-formed fold line68and the sixth pre-formed fold line76.

The bottom edge62between the left edge84and the fifth pre-formed fold line74and between the right edge82and the sixth pre-formed fold line76may be spaced from the bottom edge62between the fifth and the sixth pre-formed fold line76. For example, the sheet64between the left edge84and the fifth pre-formed fold line74and between the right edge82and the sixth pre-formed fold line76may extend away from the top edge80beyond the bottom edge62between the fifth and the sixth pre-formed fold line76.

The sheet64of electrically insulating material may include a first tear line77and a second tear line79extending from the top edge80to the bottom edge62. The first tear line77may be between the first pre-formed fold line66and the left edge84. The second tear line79may be between the second pre-formed fold line68and the right edge82. The first tear line77and the second tear line79promote separation (e.g., tearing) there along, e.g., such that a force applied to the sheet64separates the sheet64along first tear line77and the second tear line79. The sheet64at the first tear line77and the second tear line79may be weaker than adjacent the first tear line77and the second tear line79. For example, the first tear line77and the second tear line79may include at least one of a perforated line, a scored line, or a crimped line extending along the sheet64. Tearing along the first tear line77and the second tear line79may removed a portion81and a portion83of the sheet64, e.g., to decrease the length of the switch cover28formed from the sheet64.

With reference toFIG.20, a method200of insulating at least one electrical switch22of the switch block assembly20is shown. The method200begins at a block210where the sheet64of electrically insulating material is procured. The sheet64may be as described herein, e.g., including the various pre-formed fold lines66,68,70,72,74,76,78and the first tear line77and the second tear line79. The sheet64may be procured from among a plurality of sheets64. The sheets64may be, for example, stored in a common packaging and in a stacked arrangement.

Next, at a block220the sheet64formed into the switch cover28by folding the sheet64along the various pre-formed fold lines66,68,70,72,74,76,78. For example, the sheet may be physically manipulated to bend the sheet64along the various pre-formed fold lines66,68,70,72,74,76,78. The sheet64may first be folded along the seventh pre-formed fold line78to provide the extension wall60of the switch cover28. The sheet64may then be folded along the fifth pre-formed fold line74and the sixth pre-formed fold line76to provide the front wall30. The sheet64at the fifth pre-formed fold line74and the at the sixth pre-formed fold line76may be folded in opposite directions, e.g., with the first panel44of the front wall30extending from the extension wall60away from the second panel46of the front wall30and the second panel46of the front wall30extending from the extension wall60away from the first panel44of the front wall30. The sheet64may also be folded along the first pre-formed fold line66and the second pre-formed fold line68to form the first side wall32and the second side wall34of the switch cover28. The first pre-formed fold line66may be folded in a same direction as the fifth pre-formed fold line74, and the second pre-formed fold line68may be folded in a same direction as the sixth pre-formed fold line76to form the switch cover28with the extension wall60within the cavity38. The first pre-formed fold line66may be folded in an opposite direction as the fifth pre-formed fold line74, and the second pre-formed fold line68may be folded in an opposite direction as the sixth pre-formed fold line76to form the switch cover28with the extension wall60outside the cavity38. The sheet64may be folded along the third pre-formed fold line70to form the first panel48of the top wall36and may be folded along the fourth pre-formed fold line72to form the second panel50of the top wall36. Formation of the switch cover28may be completed by engaging the first engagement feature52of the first panel48of the top wall36with the second engagement feature54of the second panel50of the top wall36. For example, the tab56may be inserted into and disposed within the slot58. Once the switch22is formed, spacing between the bottom edge62between to left edge84and the first pre-formed fold line66and the bottom edge62between the right edge82and the second pre-formed fold line68may provide the open bottom40of the switch cover28. Spacing between the left edge84and the right edge82may provide the open rear42end. The switch cover28may be formed by folding the sheet64in an order other than as described. Additionally at the block230the sheet64may be torn along the first tear line77and the second tear line79to remove the portion81and the portion83from the sheet64to decrease the length of the switch cover28.

At a block230, after the switch cover28is formed from the sheet64, the switch cover28is placed over a component of the switch22, the component may extend in into the switch cover28through the open bottom40. For example, as shown inFIGS.1and2, the toggle arm24may extend into of the cavity38via the open bottom40and out of the cavity38via the open rear42. As another example, as shown inFIGS.10and11, the connection post25and the jaws26may extend into the cavity38via the open bottom40. Additionally, the extension wall60may be placed between jaws26of the electrical switch22, e.g., securing the switch cover28to the switch22.

The adjectives first, second, etc., are used throughout this document as identifiers and are not intended to signify importance, order, or quantity.